Manufacturer Repairs: Not Sustainable

09.04.2025 by Viktor Siebert

Manufacturer Repairs: Not Sustainable

A long-standing mechanical engineering customer recently brought us two defective XtraDrive servo amplifiers (XD-02-MN01, XD-02-MSDO). Previously, these had been repaired by the original manufacturer, but these repairs frequently took over four weeks and did not always yield the desired results.

Manufacturer Repairs: Limited Effectiveness

The manufacturer offered repairs at a flat-rate price. Despite the seemingly cost-effective offer, the devices were frequently still faulty after repair. Our examination revealed that usually only individual electrolytic capacitors were replaced, without deeper fault analysis.

Systematic Root-Cause Analysis in Our Workshop

We accepted the challenge systematically and with meticulous care. Our engineers set up a specialized test station to evaluate the amplifiers under realistic conditions. In other words, we simulated the actual operating environment—including full load—to ensure the devices reliably function under stress after repairs. Each XtraDrive amplifier underwent testing at this specialized station after being repaired, ensuring no hidden weaknesses remained.

Prevention Instead of Mere Fault Correction

Our technicians utilize standardized checklists to ensure no assembly is overlooked. In addition to replacing defective parts, we proactively replace components known to deteriorate over time or regularly prone to failure—particularly older Electrolytic capacitors, optoelectronic components, relays, buffer capacitors, transistors.

Sustainable Quality and Consistent Results

Through this structured approach, we have successfully repaired hundreds of XtraDrive amplifiers, ensuring stable, long-term performance.

Conclusion: Thorough root-cause analysis and proactive component replacement allow us to deliver consistent quality and long-term customer satisfaction. The initial savings from a flat-rate manufacturer repair quickly become insignificant when considering the high follow-up costs and production downtime.

This is how the devices leave our repairshop: