Top 6 Reasons for VFD Failure and How to Prevent Them

Are you getting over voltage faults from your VFD? Erratic operation? Hearing strange noises? VFD failure? Chances are you may need to change your use and maintenance routines for your VFD and probably other equipment too.  As a rule, VFDs are reliable as hell. But like most things, they have their critical needs, and sadly, their breaking points.

variable frequency drive (VFD) controls the speed, torque, and direction of an AC motor. It is also referred to as an AC drive or inverter. This sounds pretty basic, but the electronic guts of the operation are actually complicated and need consistent maintenance by qualified operators.

We’ve produced a helpful bullet list of common causes of VFD failures, along with maintenance and repair tips. If there’s ONE takeaway, it’s this – avoid what we call the “Electronic Axis of Evil” like the very costly plague it could become: dirt, heat, and moisture. 

Top Reasons for VFD Failure and Tips to Identify and Prevent Costly Problems:

1) Buildup

Mainly this means “gunk” made up of dust combined with typical plant air which usually contains oil, moisture, and metallic particles. This buildup is probably the number one cause of VFD failure! And it’s not the actual dirt itself. It’s that the dirt/dust buildup attracts moisture and prevents good airflow. This results in excess heat, and the metallic particles can create stray current paths on your circuit boards. A triple play by the bad guys! The result? At a minimum, you will get diminished performance from your drive and at worst, catastrophic failure – bang! 

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Simple Tips for Encoder Repair and Troubleshooting

If motion control is important to your production, then your encoder is one of the keys to your success. Encoders are exposed to shock, contaminants/oil, excess vibration, moisture, and high temperatures that regularly put their toughness to the test.

There are a lot of encoders out there in industry, doing their job 24/7. These little workhorses includ incremental aka quadrature encoders which uses a transparent disk with section equally spaced to determine movement; absolute encoders which use a photodetector and LED light source and a disk with concentric circle patterns; linear repairs for linear encoders which  use a transducer or reading-head linked to a scale; magnetic rotary encoders which use hall effect sensors; and commutation encoders which are similar to incremental encoders but have commutation tracks along the outer edge of the disk.

Choosing Which Encoder to Buy

First, start out right! Two basic rules apply to buying encoders:

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Capacitive vs Resistive Touchscreens

In recent years, touchscreen technology has been evolving rapidly, leading to new and improved technologies that provide consumers and businesses with a wide array of touchscreens to choose from. The capacitive and resistive touchscreens are the likeliest to come across since they dominate the market today. 

When it comes to choosing a touchscreen for your industrial application, it is crucial that you understand the most popular types of touchscreens to find the best solution. Learn more about the differences between capacitive and resistive touchscreens, including the pros and cons, from the experts at ACS Industrial Services. While resistive touchscreens are still available, capacitive touchscreens are the wave of the future.

Resistive Touchscreens

The resistive touchscreen uses a simple technology and comprises two flexible layers separated by an air gap or inert gas. Both layers have a metallic coating, which creates an electric flow when pressure is applied. When someone applies pressure to the screen, the resistance is measured between the two layers indicating where the point of contact is on the panel. 

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Comparing Bearings for Industrial Machinery

Bearings are fundamental to the machine industry as they make up one of the most vital aspects of machinery. Bearings for industrial machinery help to facilitate the rotation of one element relative to minimize friction between the two objects. Ultimately, the ease of moving increases the performance and efficiency of the machine. 

Many industrial techs looking to repair electronic devices want to know how bearings for industrial machinery compare. This blog talks about the different types of bearings and their uses. Keep reading to learn more from the experts at ACS Industrial Services.

What are the Different Types of Bearings and their Uses?

Bearings can be classified into four categories; cylindrical bearings, ball bearings, tapered bearings, and needle bearings. Each type has its strengths and weaknesses, which is why you may want to compare each of these bearings to establish the one that suits your needs.

Let’s take a deep dive into the four different types:

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How Do I Tell If My Electronic is Industrial?

When it comes to electronic devices, it can sometimes be difficult to distinguish between an industrial electronic device or a consumer electronic device. From time to time, we have ACS Industrial customers who will inquire about repairing an electronic device that does not actually fall into the “industrial” category. We thought it would be helpful to create a blog post about what makes an electronic device “industrial” so that our customers have a better understanding of what we are able to repair. Keep reading to learn more!

What is an Industrial Electronic Device?

Industrial Electronics are a subset of electronics that involves electronic equipment in an industrial or sometimes commercial setting. Industrial electronics play a major role in most industries, both light and heavy, like manufacturing, CNC and fabricating, energy, transportation, and agriculture. Industrial electronics are also commonly used in chemical processing plants, power plants, water treatment plants, laboratories, and construction sites.

Examples of Industrial Electronics

Here are some common examples of electronics that fall under the “industrial” category:

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Manufacturing Trends in 2022

At ACS Industrial Services, our job is to complete your industrial repairs fast, so you can get your business back up to speed quickly. That requires our teams of technicians to stay ahead of the curve with the latest trends in the manufacturing industry. Keep reading to learn a bit more about what’s anticipated for the manufacturing industry in 2022 from the experts at ACS Industrial Services. 

Supply Chain Disruptions 

Unfortunately for Americans, supply chain disruptions are here to stay in 2022. The supply chain worldwide will continue to be affected by challenges from the COVID-19 pandemic. Delays and disruptions are expected to continue well into 2022 and possibly beyond. Many manufacturers are faced with difficulty when it comes to supply chain challenges. The supply chain issue has forced organizations to seek resources and manage their supply chains differently to stay in business. 

Talent Shortage

Like all industries, manufacturing is not immune to hiring and retaining top talent. Even in 2022, experts are predicting that recruiting and keeping skilled professionals (like engineers, designers, and technicians) will continue to be a struggle for manufacturing organizations. With demand for manufactured goods growing among consumers, companies have to be prepared to take the necessary steps to recruit and retain skilled professionals. 

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Additive Manufacturing Explained

Additive manufacturing, more commonly known as 3D printing, has transformed the industrial manufacturing industry. Since its initial creation in the 1980s, 3D printing has been on a steady climb to popularity among manufacturers. Utilizing 3D printers has allowed manufacturers to create lighter and stronger manufactured goods, which helps increase their bottom line. Learn more about additive manufacturing, including the benefits and potential repairs, from the experts at ACS Industrial Services. 

What is Additive Manufacturing?

Before we begin, let’s explain what additive manufacturing is first. As the name implies, additive manufacturing occurs when a machine adds material to create an object. Additive manufacturing uses computer-aided design (CAD) software to build materials. This occurs when a machine deposits material in many thin layers to create precise shapes. Additive manufacturing differs from traditional manufacturing, which instead relies on the creation of an object through a more hands-on technique, like milling or carving. 

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Considerations When Hiring an Industrial Electronic Repair Company

There are many considerations to keep in mind when hiring a company to repair your industrial electronic devices. After all, you’ve invested a great deal of money into your industrial electronic equipment, so you want to make sure that the repair company you’ve selected will protect your important investment. The experts at ACS Industrial Services have been in business for over 20 years as a trusted industrial electronic repair company. We’ve compiled a list of important considerations to keep in mind when selecting a repair company to solve your repair needs. Keep reading to learn more!

Evaluation Process

First and foremost, the evaluation process to receive a quote should be simple, fast, and free. Make sure that you hire an industrial electronic repair company that makes the evaluation process as painless as possible. At ACS Industrial Services, we offer an easy, no-obligation repair form here.

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5 Indicators Your Robot’s Electronics Need Repair

Robots are no longer the stuff of science fiction books and movies. They have become integrated into every facet of our lives – from picking and packing boxes in a warehouse to working on space stations.

While they may seem like a huge investment, robots can be found in small to midsize businesses across the country. Unlike humans, robots won’t get tired, require salaries or benefits, and never call in sick – or require training.

Having robots on an automated line or serving another role in an operation can speed up production while reducing error. This application allows industries to use their personnel wisely, by placing them in positions that a robot can’t fill.

Robots aren’t perfect, and over time their electronic components can begin to show signs of malfunction. While internal components and overall design contribute to their durability and dependability, robots still require maintenance and electronic parts replacement over time.

What to Look For:

Accuracy

Robots are machines, so signs that they’re beginning to fail are similar to those you see with other machinery.

Robots are programmed to perform their jobs on a consistent and accurate basis. In some cases internal electronic components that help control sensors and motors can be damaged and affect the machine’s ability to properly do its job. If you or your team are seeing inaccurate results from a unit, there could be an internal electronic component that’s become damaged. 

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Asset Managers

The life and duties of an asset manager are never dull – and a seemingly endless list of chores and tasks can be overwhelming.

As an asset manager, you have to pay attention to multiple assets, and they come in many forms, shapes, and sizes. 

Whether you’re taking care of your labor force, or reviewing the performance of machinery and production, you need to get maximum output and pay attention to the bottom line.

When it comes to asset management of physical items, you have to pay attention to the entire life cycle of the process, including:

  • Design
  • Construction
  • Commissioning
  • Operating
  • Maintaining
  • Repairing

Facilities Asset Management

Taking care of an operation that produces equipment and machinery requires deep experience, and a working knowledge of production and how your personnel perform their duties. You may need to keep track of factors that include maintenance, safety, and even code compliance.

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