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How Can Servo Off Control Reduce Standby Energy Use During Production Interruptions?

2026/11/06 By le zhan

How Can Servo Off Control Reduce Standby Energy Use During Production Interruptions

During injection molding, robots are not always operating; they may remain idle while waiting for the next molding cycle, material supply, or downstream equipment to become ready. However, even when the robotic arm is not moving, its servo drives may continue to consume power to maintain their operational state. To reduce this unnecessary standby energy consumption, Topstar has incorporated a Servo Off control function—when the robot is not required to operate, operators can cut power to the drive circuit directly via the teach pendant. Additionally, the company uses a 5-in-1 integrated servo drive that shares a single discharge braking resistor, improving energy efficiency by about 10% compared to standalone servo drive configurations. This design reduces overall energy consumption during both robot operation and production downtime.

Servo Off Control and the 5-in-1 Drive

Injection molding robots may still consume power even when not moving. To address this, we have adopted two approaches to reduce energy consumption:

First, optimizing power sharing and management among multiple servo axes;

Second, cutting off power to unnecessary servo motors during production downtime.

The combination of the 5-in-1 integrated servo drive and the Servo Off Control function effectively resolves this issue.

How Does the 5-in-1 Driver Improve Energy Efficiency?

Traditional injection molding robots typically equip each motor with a separate servo driver. Topstar’s 5-in-1 architecture integrates the control functions of five servo motors into a single drive system, thereby reducing the need for multiple independent drive units.

This integrated configuration requires only one braking resistor (used to dissipate regenerative energy), eliminating the need to configure a separate braking resistor for each driver. This not only simplifies the electrical layout but also reduces redundant hardware configurations. Data comparisons show this configuration achieves energy efficiency about 10% higher than traditional independent servo drive setups. Its advantages extend beyond simply reducing the number of drive components; the integrated architecture enables multi-axis coordination, supporting more precise synchronized motion and more efficient power management.

How Does Servo Off Control Reduce Energy Consumption?

When a Cartesian robot stops moving, its energy consumption does not necessarily drop to zero. If the servo system remains enabled, the servo drive’s electronic components may continue to consume standby power. Depending on the mechanical load and control mode, the servo motor may also require current to maintain its position or hold torque.

In addition, the robot controller, PLC, communication interfaces, and safety circuits may still receive power.

Servo Off control eliminates unnecessary energy consumption that occurs when operators keep the servo drive and motor systems powered on without requiring motion. Of course, operators do not need to shut down the entire robot. This way, the equipment can reduce unnecessary servo energy consumption without treating every production interruption as a full machine shutdown.

How Does Servo Off Control Reduce Energy Consumption

When Should the Drive Power Be Disconnected and Restored?

Disconnecting the servo drive power reduces unnecessary energy consumption, but operators must first ensure that the robot is in an appropriate standby state. Operators must securely clamp the workpiece, move the robot away from the mold area, and ensure that all axes can safely maintain or return to their positions. After restoring power, operators should also verify the robot’s position and operating status before resuming automated production.

When Should the Drive Power Be Disconnected and Restored

When Is It Safe to Disconnect the Servo Drive Power Supply?

The Servo Off control is best suited for planned production interruptions, i.e., when the robot is stationary and will not need to perform any actions for a short period.

Before disconnecting the drive power supply, operators should confirm the following three conditions:

  • – Robot Position: All axes have completed their movements and returned to their designated safe standby positions.
  • – Workpiece and Fixture Status: The robot does not grip a workpiece while it hangs unsupported, nor does it rely on real-time torque from the servo drive to maintain a load.
  • – Equipment Coordination: The robot has exited the mold area, and the injection molding machine and peripheral equipment are all in a safe operating state.

If the interruption is brief and the robot needs to resume motion immediately or remain in a specific position, it may be more appropriate to keep the servo drive powered on.

For extended downtime, using the Servo Off function can reduce unnecessary motor power consumption and energy waste.

Note that Servo Off is an energy-saving standby feature and cannot replace complete electrical isolation. Before performing maintenance on the robot, maintenance personnel must still strictly adhere to the factory’s power isolation and “Lockout/Tagout” procedures.

When Is It Safe to Disconnect the Servo Drive Power Supply

Which axes should be checked after a restart?

After restoring power to the servo drive, operators should verify each robot axis’s position and operational status before resuming automated production.

Pay special attention to the vertical axis, as gravity may cause it to move when the servo drive loses power. Operators should confirm that the mechanical holding device is secure and reliable, and that the position feedback signal is valid. Other axes also require verification:

– Vertical axes: Check height, hold status, and reference positions.

– Lateral axes: Confirm that the robotic arm is in the expected horizontal position.

– Longitudinal axes: Verify pick-up and transfer positions.

– Rotational or attitude axes: For five-axis configurations, check the workpiece orientation and rotational reference points.

Note: Never assume the axes retain valid reference positions just because servo power has been restored.

Cut Off Unnecessary Power Supply to Reduce Standby Energy Consumption

The Servo Off control function cuts off unnecessary power to the servo drives and motors when the robot is not moving, reducing standby energy consumption. Combined with 5-in-1 integrated drive technology and simplified braking resistor configuration, this solution offers a more energy-efficient option for injection molding automation.

For production facilities, the key is to use this feature during appropriate production downtime and ensure that the robot can safely maintain or return to its operating position when production resumes. This approach reduces standby power consumption while balancing equipment safety and production continuity, achieving an ideal equilibrium.

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