What is the effect of excessive robot payload on servo motor lifespan?

Excessive robot payload significantly reduces servo motor lifespan by increasing the mechanical stress and thermal load on the motors and related components. Servo motors are responsible for providing the torque needed to move and position the robot's joints. When the robot operates with a payload that exceeds its rated capacity, the servo motors must work harder to overcome the increased inertia and gravitational forces. This increased workload leads to higher motor currents, which in turn generate more heat. Excessive heat accelerates the degradation of the motor's insulation, bearings, and other critical components. The increased stress also causes premature wear and tear on the motor's gears and bearings, leading to increased backlash and reduced accuracy. Over time, this can result in motor failure, requiring costly repairs or replacements. For example, if a robot designed to handle a 10 kg payload is consistently used to lift 15 kg, its servo motors will experience significantly higher stress and heat, leading to a shortened lifespan compared to a robot operating within its specified payload range. Operating beyond the payload limit can also cause the servo amplifiers to repeatedly trip due to overcurrent, further stressing the system. Regular monitoring of motor temperatures and currents can help detect and prevent payload-related stress.