Month: May 2025

Servo Amplifier Innovations in 2025

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In 2025, the landscape of industrial automation and precision motion control is being redefined by innovations in servo amplifier technology. As smart manufacturing, servo amplifiers have undergone a significant transformation to meet the rising demands for speed, efficiency, and intelligence.

Read more: Servo Amplifier Innovations in 2025

How Servo Amplifiers Have Changed

Past Servo Amplifiers

Older servo amplifiers, commonly used in mid-to-late 20th century industrial and military applications, were primarily analog devices. These devices relied on operational amplifiers (op-amps), transistors, and thyristors (SCRs) to control motor position, speed, or torque. These amplifiers used feedback signals from resolvers, tachometers, or potentiometers to compare the actual motor performance with the commanded input. The error signal was amplified and used to adjust the motor’s power supply. This was done typically via pulse-width modulation (PWM) or linear amplification in high-precision systems.

Power regulation in these systems was often achieved using linear amplifiers for low-power applications or phase-controlled rectifiers (SCR-based) for higher-power motors. Linear amplifiers provided smooth, low-noise output but were inefficient due to significant heat dissipation. SCR-based amplifiers improved efficiency by switching high currents at precise phases of the AC input waveform, though they introduced more electrical noise and required careful tuning to avoid instability in the servo loop.

No Digitalization

Older servo amplifiers lacked modern digital processing, meaning tuning and compensation (such as PID control) had to be manually adjusted using potentiometers and RC networks. This made them sensitive to temperature drift and component aging. Despite their limitations, these systems were robust and provided sufficient performance for many early CNC machines, radar systems, and industrial automation tasks before digital signal processors (DSPs) and microcontrollers revolutionized servo control in the 1980s and beyond.

Servo Amplifiers of 2025

Today’s servo amplifiers have come a long way since their 20th century counterparts. These new servo amplifiers leave smaller environment footprints and built more energy efficient.


Smaller Footprints

One of the most notable trends in 2025 is the drastic reduction in the size of servo amplifiers without compromising performance. Thanks to advancements in power electronics, including the widespread adoption of silicon carbide (SiC) and gallium nitride (GaN) semiconductors, modern servo amplifiers offer higher switching frequencies, reduced heat generation, and more compact form factors. This makes them ideal for tight spaces in collaborative robots (cobots), mobile platforms, and micro-automation environments.

AI

Servo amplifiers have grown smarter. Many new models now feature embedded AI and machine learning algorithms that allow for auto-tuning, adaptive control, and predictive maintenance. These amplifiers can analyze motor performance in real time, detect anomalies, and even predict component failure before it happens. This leads to lower downtime, longer equipment life, and significantly improved OEE (Overall Equipment Effectiveness).


Cloud and Edge Connectivity

Modern servo amplifiers are increasingly designed with native Ethernet-based protocols (like EtherCAT, PROFINET, and Ethernet/IP) and support for edge computing. Some amplifiers even feature built-in web servers for remote access, configuration, and monitoring. This level of connectivity enables seamless integration into industrial IoT (IIoT) ecosystems and real-time data sharing with MES and ERP systems.


Energy Efficiency and Regenerative Capabilities

As sustainability continues to drive industrial innovation, energy-efficient servo amplifiers have become a priority. New-generation amplifiers support dynamic energy regeneration, capturing kinetic energy during deceleration and feeding it back into the power supply or shared bus systems. Coupled with high-efficiency motor control algorithms, these amplifiers contribute to reduced energy costs and a smaller carbon footprint.

Universal Compatibility and Modular Designs

Many new models are motor-agnostic, capable of driving brushless DC (BLDC), stepper, and synchronous/asynchronous AC motors from a single unit. Modular designs allow engineers to scale systems up or down with minimal reconfiguration, speeding up development time and reducing inventory complexity for OEMs.

Integrated Cybersecurity

With increasing connectivity comes greater vulnerability. Recognizing this, manufacturers now embed cybersecurity features directly into servo amplifiers, including secure boot, encrypted firmware updates, and real-time network monitoring to guard against cyber threats. This is especially critical in sectors like aerospace, defense, and medical automation.

Conclusion

The evolution of servo amplifiers in 2025 is emblematic of the broader shift toward smarter, more connected, and sustainable automation technologies. As these amplifiers become more compact, intelligent, and energy-conscious, they will play an even greater role in shaping the next generation of high-performance machinery and robotics.

Whether you’re an automation engineer, OEM, or system integrator, staying abreast of these innovations will be key to building future-ready solutions.

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Updated on May 21, 2025 by Ken Cheng

Servo Amplifiers: Diagnosing and Fixing Ground Faults

Ken Cheng Leave a comment

Ground faults in a servo amplifier system can lead to erratic behavior, unexpected shutdowns, or even permanent damage to equipment. A ground fault occurs when an unintended electrical connection exists between a live conductor and ground, causing leakage currents that disrupt normal operation. Diagnosing and fixing these faults promptly is essential for maintaining system reliability and safety.

This article provides a step-by-step guide to identifying and resolving ground faults in servo amplifier systems.

Read more: Servo Amplifiers: Diagnosing and Fixing Ground Faults

Recognizing the Symptoms of a Ground Fault

The quintessential step to repairing a ground fault is being able to recognize and identify symptoms. After all, you can’t fix a problem if you don’t know what the problem looks like. When looking for symptoms of a ground fault keep an eye out for:

Unexpected shutdowns or fault alarms (e.g., “Ground Fault” error on the drive)

Erratic motor behavior (jittering, unexpected movements, or loss of torque)

Burning smells or overheating components

Electrical noise affecting feedback devices (encoders/resolvers)

Tripped circuit breakers or ground fault protection devices

Safety Precautions

Once you’ve recognized the symptoms of a ground fault, you may have that impulse of wanting to go straight into poking around and tinkering with the drive. However, before you do that, you need to take precautionary steps to ensure your safety. Exercising the following precautions will prevent the chances of a hazard occurring, increasing your safety.

  1. Make sure the power is disconnected and verify with a multi-meter.
  2. Ensure the capacitors are discharged.
  3. Use insulated tools and wear personal protective equipment (PPE)
    – Companies like RefrigiWear offer a selection of insulated foot wear that protects against high voltage.
  4. Follow lockout/tagout procedures if working in an industrial environment.

Isolating the Fault

Once you are confident that all safety precautions have been taken and that the system is completely off and all power fully dispersed, then you can proceed forwards with isolating the fault. Here are a few ways you can isolate a fault.

Checking the Power Supply

Using a multi-meter, you can check the power supply to see if you get a low resistance rating that would indicate a short in the ground.

Checking the Motor Windings

You can test the motor windings by disconnecting the motor cables from the power supply. Next, measure the resistance between each motor phase and the ground. There should be high resistance (>1MΩ). A low resistance is an indicator of a short in the motor frame.

Check Encoders and Resolver Connections

Another way is to check encoders and resolvers for any exposed or damaged wires. You can check do this by checking for continuity between signal lines and ground. There should be no direct connection.

Inspecting the Servo Amplifier

If you need to check the servo amplifier, look for obvious visual signs like burnt components, blown fuses, or discolored PCBs. Using a multi-meter test the DC bus capacitors for leakage or short circuits. Double check proper grounding of the amplifier chassis.

Repairing the Ground Fault

While diagnosing and isolating faults are lightly challenging but doable for most people, it is advised that if you are not most versed in servo amplifiers then reach out to a professional for repairs.

Repair/Replace Damaged Wiring

If the issue is with the cables then replace any damaged or frayed cables. Also, check for strain relief on connection points to the devices. Good strain relief prevents future wear of cables. Make sure you use shielded cables for motor and feedback connections.

Address Motor Issues

Check your motor bearings as mechanical wear can cause internal shorts. If your motor windings are shorted, replace the motor.

Replacing Components

Replace blown out PCB and capacitors. Double check the amplifier is properly grounded. Be sure to check the specs before doing so.

Verify Grounding Scheme

When verifying the grounding scheme, make sure the system has a single-point ground to avoid ground loops. Also, make sure wires are properly sized and securely connected

After Repair Testing

After repairs are done, before you restore power, make sure to give another test. Use a multimeter to test resistance on motor windings and cables. After that, gradually power up the system and monitor for fault messages. Finally, run the servo motor at low speed and check for any odd sounds or for overheating.

Conclusion

Ground faults in servo amplifier systems can cause significant downtime if not addressed properly. By following a structured diagnostic approach—checking power supplies, motor windings, feedback cables, and amplifier components—you can efficiently locate and resolve the issue. Always prioritize safety, use proper testing equipment, and ensure correct grounding practices to prevent future faults.

Regular preventive maintenance, including insulation resistance checks and visual inspections, can help detect ground faults early and extend the lifespan of your servo system.

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Updated on May 1, 2025 by Ken Cheng