This is the most common fault in long-term used rotary tables. The main symptoms include inconsistent dimensional tolerance of batch workpieces and obvious angle deviation after indexing. Core causes: gear wear, increased transmission backlash, loose locking mechanism, insufficient lubrication leading to mechanical clearance, or slight deformation of the table surface caused by long-term heavy load. Solutions: Calibrate the positioning accuracy with professional instruments; adjust the gear backlash and locking tension; supplement lubricating oil; trim the table surface flatness if necessary; replace severely worn gears and bearings.

If the rotary table makes friction noise, impact noise or buzzing noise during idle running or processing, the causes vary by noise type. Friction noise is mostly caused by insufficient lubrication and foreign matter in the rotating gap; impact noise comes from loose internal transmission parts and gear gap abnormality; buzzing noise is usually a circuit or servo motor parameter mismatch problem. Solutions: Clean internal sundries and fully lubricate transmission components; fasten loose internal parts and adjust gear clearance; reset servo motor parameters and check circuit connection.

The rotary table has delayed rotation response, slow indexing cycle, or even jamming during operation. For hydraulic models, it is mainly caused by insufficient hydraulic pressure, blocked oil circuit or deteriorated hydraulic oil; for servo models, it is due to servo motor aging, parameter setting errors or excessive load beyond the equipment rated range. Solutions: Check hydraulic station pressure and clean oil circuit filter elements; replace aging hydraulic oil; reset servo operating parameters; avoid long-term overload processing; overhaul the motor if the response is severely delayed.

The rotary table cannot be locked firmly after indexing, or the locking force is insufficient, resulting in slight rotation during cutting and workpiece processing errors. Hydraulic rotary tables are mostly caused by insufficient hydraulic pressure, damaged sealing rings or blocked locking oil circuit; servo models are caused by brake wear and loose brake parameters. Solutions: Adjust hydraulic system pressure, replace aging sealing parts and clean oil circuit; overhaul servo brake components, adjust brake tension parameters, and replace worn brake pads.

The machine tool system pops up servo alarm, encoder signal loss or communication failure. The main causes include loose encoder wiring, aging signal lines, motor overheating, and system parameter confusion. Solutions: Reconnect and fix encoder signal lines; replace aging wires; stop the machine for heat dissipation when the motor is overheated; restore and calibrate system original parameters, and match the rotary table model parameters again.

Oil leakage often occurs at the hydraulic cylinder, pipe joint and shaft seal position, which not only pollutes the processing environment but also leads to insufficient hydraulic pressure and reduced locking force. Core causes: aging and failure of rubber sealing rings, loose pipe joints, and damaged oil pipe surfaces. Solutions: Replace all aging sealing accessories; fasten and reinforce pipe joints; repair or replace damaged oil pipes, and test the hydraulic system tightness after maintenance.

The servo motor or hydraulic station overheats rapidly during operation, triggering overheating protection and shutdown. The reasons include long-term high-speed continuous operation, blocked heat dissipation system, excessive processing load, and internal mechanical friction resistance increase. Solutions: Clean heat dissipation holes and heat dissipation fans; reasonably arrange processing cycles to avoid long-term continuous high-load operation; overhaul internal mechanical transmission structures to reduce friction resistance.

The rotary table vibrates obviously during cutting, resulting in workpiece surface roughness failure and tool wear acceleration. Causes: uneven table stress, loose mounting base, insufficient equipment rigidity, and unreasonable cutting parameters matching. Solutions: Fasten the rotary table mounting base and calibrate horizontal level; adjust cutting speed and feed parameters to avoid violent cutting; enhance equipment rigidity and eliminate mechanical clearance.