In many cases, servo damage or abnormal behavior is not due to product quality or signal problems but because environmental and load conditions exceed tolerances. This article analyzes malfunction causes and testing methods from the use scenario perspective, particularly focusing on how to diagnose issues with GXServo servos in field, industrial, and high-load applications.
1. Environmental Factors Affecting Servos
GXServo offers industrial-grade servo models with IP66 to IP67 waterproof/dustproof ratings. Nevertheless, extreme environments can still degrade performance:
- Temperature Variations
Cold temperatures cause lubricants to freeze and increase gear resistance; high temperatures accelerate circuit aging and insulation breakdown. Testing Method: Operate the servo at different temperatures (e.g., 0°C to 50°C) and compare results. Use an infrared thermometer to check for abnormal heating. - Humidity and Salt Mist
In coastal or rainforest environments, even waterproof housings may be compromised by corroded signal or power terminals. Testing Method: Power off, disassemble terminals and connectors, and look for corrosion, salt buildup, or condensation. - Dust and Vibration
In mines or deserts, dust may clog vents, and vibration can loosen solder joints. Testing Method: Clean the servo with a vacuum, then test again to check for restored function.
2. Mismatched Load Causing Chronic Damage
Torque ratings are critical; GXServo offers models ranging from 1.5kg.cm to 60kg.cm. Failure to calculate inertial loads can cause:
- Motor overloading, resulting in coil overheating;
- Accelerated gear wear due to uneven engagement;
- Weak holding torque, leading to shaft oscillation.
Testing Methods:
- Temporary Unload Test: Remove the load and retest the servo. If it works fine unloaded, the issue is likely load-related.
- Load Simulator Test: Use a spring or adjustable resistance to simulate different torque loads and observe angle deviation and heating.
3. Identifying Long-Term Fatigue Damage
In long-term applications, servos may operate for months, and malfunctions accumulate gradually. GXServo high-end models support “runtime counters” and “operation hour logs,” which help identify end-of-life conditions.
Symptoms include:
- Inaccurate positioning;
- High idle current;
- Delayed responses;
- Increased surface heat.
Such signs indicate it may be time for replacement or maintenance.
