1. Damage to the motor and electrical system
Motor overheating and burnout: Continuous overload will cause the motor current to exceed the rated value by more than 1.1 times, leading to a rapid rise in winding temperature. For Class B insulated motors, prolonged exposure to temperatures exceeding 130℃ will cause insulation aging, short circuits, and even burnout.
Driver alarm shutdown: The servo system will detect an overload and trigger OL1/OL2 fault codes, automatically shutting down for protection, affecting production continuity.
Damage to electrical components: Contactors and thermal relays age faster due to prolonged exposure to high current, and terminals may oxidize and loosen, increasing the risk of short circuits.
2. Increased Wear in Mechanical Systems
Bearing and Gear Damage: Overload causes abnormal stress on the transmission system, leading to bearing overheating and seizing, poor gear meshing, and resulting in a piercing whistling sound or periodic impact noise.
Chain Tooth Skipping or Breakage: Excessive tension accelerates wear on the transmission chain, causing tooth skipping or breakage in severe cases, requiring machine shutdown and replacement.
Gear Reducer Damage: Oil temperature exceeding 85℃ causes lubricating oil failure, resulting in internal gear wear and shortening equipment lifespan.
3. Abnormal Temperature Control and Circulation Systems
Inaccurate Temperature Control: Overheating of the motor affects the accuracy of the temperature control sensor, resulting in slow heating or large temperature fluctuations, affecting dyeing uniformity.
Increased Load on Circulation Pump: If the main pump experiences a decrease in flow rate due to overload, the dye liquor circulation is impaired, easily leading to quality problems such as "color unevenness" and "poor pipe quality."
4. Decreased Dyeing Quality
Uneven Dyeing: Due to obstructed dye liquor circulation or distorted heating curves, the dyeing rate on fibers is inconsistent, resulting in streaks and patches.
Reduced First-Pass Dyeing Rate: Frequent batch-to-batch and color differences lead to increased rework rates and higher consumption of water, electricity, and dyes.
5. Increased Safety Hazards
Leakage Risk: Overload causes increased vibration, leading to loose pipe joints, damaged seals, and leakage of dye liquor or vapor.
Fire Hazard: Damaged motor insulation may cause smoke and fire, especially in high-temperature and high-humidity environments.
