Servo Motor Alignment Matters: Here’s Why

Servo motors are often the core drivers behind automated production lines, CNC machines, and robotic systems. And while they’re powerful tools driving production forward, their effectiveness hinges on proper alignment.

Achieving and maintaining correct alignment isn’t just a matter of good practice — it’s a critical factor in the performance and longevity of your manufacturing equipment. Misalignment, even by fractions of a millimeter, can lead to a cascade of issues that impact your bottom line.

Signs of misalignment — and their consequences

When servo motors are misaligned, the repercussions can be severe and far-reaching. The most immediate impact is a reduction in efficiency and performance. Misalignment forces the motor to work harder to overcome the additional friction and resistance, leading to increased energy consumption and decreased output. Over time, the consequences become more pronounced:

• Accelerated wear and tear on bearings, seals, and couplings
• Premature failure of motor components
• Increased vibration and stress on connected machinery
• Higher energy costs due to inefficient operation

Recognizing the signs of misalignment can prevent excessive downtime. Symptoms might be subtle at first, but they can quickly worsen if not addressed promptly. Here’s what to look for:

• Unusual vibrations or noise during operation
• Excessive heat generation around the motor or coupling
• Inconsistent performance or unexpected positioning errors
• Increased power consumption without a corresponding increase in output

Proper alignment: Techniques and best practices

Achieving proper servo motor alignment requires precision and the right tools. There are two common methods — both of which GES offers to customers with misaligned servo motors:

1. Laser alignment: This technique uses lasers to measure misalignment with extreme accuracy. It’s fast, precise, and can detect even minute discrepancies in both angular and parallel misalignment.
2. Dial indicator method: While more traditional, this method can still be effective when performed correctly. It involves using dial indicators to measure the displacement of the shaft as it rotates.

Maintaining alignment is also an ongoing process. Establish regular inspection and maintenance schedules, and make sure to provide comprehensive training for technicians on alignment techniques. Keep detailed documentation of alignment procedures and measurements for each servo motor and try to regularly analyze performance data to spot potential alignment issues before they become critical.

Servo motor alignment: The benefits

Because servo motors play such an integral role in factory automation, it pays to invest the time and resources in proper alignment. The benefits are manifold:

1. Improved efficiency and accuracy: Correctly aligned motors operate at peak efficiency, delivering precise movements and consistent performance.
2. Extended equipment lifespan: Reduced stress on components means less wear and tear, extending the operational life of both the motor and connected machinery.
3. Lower maintenance costs: Properly aligned systems require less frequent repairs and replacements, reducing both direct maintenance costs and costly downtime.
4. Enhanced system performance: When all components work in harmony, the entire manufacturing process benefits from improved reliability and output quality.

Keep your servo motors aligned

The importance of servo motor alignment cannot be overstated. It’s a critical factor that impacts everything from day-to-day operational efficiency to long-term equipment reliability and cost management. Well-maintained servo motors lay the foundation for improved productivity, reduced costs, and enhanced competitiveness in the long run.

Now’s the perfect time to have your servo motors serviced, including alignment. Throughout the month of September, GES is running our Servo Motor Special: 15% off three or more servo motor repairs — or 10% off any single repair. Let us restore perfect alignment to your servo motors, so you can reap the benefits of precision automation in your factory!