1. System Check Before Debugging 
Hardware connection verification 
Power System: 
Three-phase five-wire system (380V ± 5%, 50Hz), measure the voltage difference of each phase with a multimeter, and it should be ≤ 5V. 
Grounding resistance ≤ 1Ω (measured with a grounding resistance tester), PE line cross-sectional area ≥ 10mm². 
Signal line: 
The encoder and sensor signal lines use shielded twisted-pair cables, with the shield layer grounded at one end (near the controller end). 
The distance between the power line and the signal line should be no less than 300mm, and they should be arranged vertically at the crossing point. 
2. Insulation and Voltage Resistance Test 
Measure the insulation resistance of the motor windings with a 500V megohmmeter, and it should be greater than or equal to 10MΩ. 
Control loop withstand voltage test (1500V/1 minute), leakage current ≤ 10mA. 
II. System Segmentation Debugging Process 
Power supply and distribution system 
Power-up sequence: 
Close the main circuit breaker and observe the power indicator light (green). 
Start up the UPS, PLC and HMI in sequence. The self-check time for each module should be no more than 30 seconds. 
Finally, turn on the servo driver and the IO module. 
Voltage Monitoring: 
Monitor the DC24V output ripple with a scope to ensure it is ≤ ±5% (i.e., ≤ 1.2V). 
The DC bus voltage fluctuation of the servo driver is ≤ ±10% (rated value 540V). 
2. PLC and IO System 
Input signal test: 
Short-circuit the limit switch, and the LED light corresponding to the input point of the PLC should be illuminated. 
Simulate the sensor signal (such as 4-20mA) using a signal generator, and the error of the PLC's analog-to-digital conversion value should be ≤ ±0.5%. 
Output signal test: 
Force output of the relay contact, and measure the resistance of the contact closure ≤ 50 mΩ; 
The action response time of the electromagnetic valve shall be ≤ 20ms (monitored by measuring the coil current with an oscilloscope). 
3. Servo drive system 
Parameter initialization: 
Set the electronic gear ratio (for example, if the motor encoder has 20000 pulses per revolution and the lead of the screw rod is 10mm, then the numerator = 10000, and the denominator = 20000). 
The gain of the speed loop is ≥ 1000 rad/s, and the gain of the position loop is ≥ 3000 rad/s (adjusted according to the ratio of load inertia). 
Static debugging: 
In the manual JOG mode, the motor operates smoothly without any vibration (vibration acceleration ≤ 0.5 m/s²). 
Positioning accuracy test: Issue a 10mm command, and the actual displacement error is ≤ ±0.01mm (measured by laser interferometer). 
Dynamic performance: 
The speed step response time is ≤ 50ms (from 0 to rated speed). 
The speed fluctuation caused by load variation (20% of the rated load) is ≤ ±2%. 
4. Visual registration system 
Hardware calibration: 
The perpendicularity between the optical axis of the industrial camera and the workbench is ≤ 0.1° (measured by an angle gauge). 
The uniformity of light source brightness is ≥ 95% (measured by an illuminance meter). 
Software Calibration: 
The distortion correction is carried out using a standard calibration plate (with an accuracy of ±0.002mm), and the distortion rate is ≤ 0.1%. 
Establish the mapping between the visual coordinate system and the mechanical coordinate system, with the conversion error being ≤ ±0.01mm. 
5. Security System 
Emergency stop circuit: 
Press the emergency stop button, and the system will cut off all power supplies within 0.1 seconds. 
After resetting, the original point return operation needs to be performed again to ensure the accuracy of the position. 
Safety Light Curtain: 
If any beam of the light curtain is blocked, the equipment should stop operating within 0.2 seconds. 
Response time test: Use a high-speed camera to record the time from the trigger of the light curtain to the stop of the motor, which should be less than or equal to 150ms. 
III. Interconnected Debugging and Performance Optimization 
Synchronous control 
Multi-axis synchronization: 
The position deviation of the dual-drive shaft is ≤ ±0.005mm (during synchronous operation); 
The speed matching error between the pressure shaft and the feeding shaft is ≤ ±0.5%. 
Shear function: 
The accuracy of the cutting moment is ≤ ±0.1° (corresponding to the mechanical angle); 
The error in the cutting length is ≤ ±0.05mm (calculated based on 100 consecutive cuts). 
2. Dynamic Response Optimization 
Acceleration and deceleration control: 
The acceleration and deceleration time of the S curve should be no less than 150ms (to avoid shock); 
The maximum acceleration limit is ≤ 10000 mm/s³ (adjusted according to the load). 
Vibration Suppression: 
Add a notch filter (with a frequency range of 50-200Hz) to the speed loop; 
When the load inertia ratio is ≥ 3, the automatic tuning function is enabled. 
3. Process Parameter Testing 
Die-cutting pressure control: 
The deviation between the set pressure value and the actual pressure value is ≤ ±2% (pressure sensor calibration); 
Pressure fluctuation ≤ ±1% (during high-speed operation). 
Registration accuracy: 
After 1000 consecutive die-cutting processes, the average deviation of registration accuracy is ≤ ±0.02mm, and the maximum value is ≤ ±0.03mm. 
When the temperature changes by ±5℃, the registration deviation shall be ≤ ±0.01mm (a temperature compensation algorithm is required). 
IV. Compliance Testing and Documentation 
EMC testing 
Radiation interference (RE) ≤ 30 dBμV/m (30 - 1000 MHz, at a distance of 10 meters); 
Conduction interference (CE) ≤ 40 dBμV (150kHz - 30MHz). 
2. Energy Efficiency Assessment 
Standby power consumption ≤ 1kW; 
The full-load energy efficiency ratio is ≥ 0.85 (compliant with IE3 standard). 
3. Acceptance Documentation 
"Electrical System Commissioning Report": Includes parameter setting table, test data, and waveform diagrams; 
"Safety Function Verification Report": Emergency stop response time, light curtain trigger test records; 
"CE Certification Document": Test certificate that complies with EN 60204-1 and EN 55011 standards. 
V. Typical Fault Resolution 
Servo motor overheating: 
Check whether the encoder feedback is normal (observe the A/B phase waveforms using an oscilloscope); 
Reduce the time constant of acceleration and deceleration (for example, increase it from 100ms to 150ms). 
Registration instability: 
Clean the camera lens (using a lint-free cloth and IPA solution); 
Increase the brightness of the light source (to above 1000 lux). 
PLC communication interrupted: 
Check if the Modbus RTU baud rate is matched (default 9600 bps); 
Measure the differential signal voltage of RS485 (normal range: 2 - 6V). 
Recommended debugging tools: 
Laser interferometers (such as Renishaw XL-80) are used for measuring positional accuracy; 
The power quality analyzer (such as Fluke 435) monitors power harmonics. 
The servo debugging software (such as Mitsubishi MR Configurator2) enables real-time observation of the motor's operating status. 
During the debugging process, it is necessary to wear an anti-static wrist strap (with an electrostatic voltage of ≤ 100V) to prevent electrostatic damage to electronic components. For precision die-cutting below 0.1mm, it is recommended to conduct the final accuracy verification in a constant temperature and humidity environment (23 ± 0.5℃, 50 ± 5% RH).