Troubleshooting and Repairing Industrial Robots: A Comprehensive Guide

Have you ever encountered perplexing malfunctions in your industrial robot?

Well, I've got some good news for you! I specialize in resolving the most challenging issues that even seasoned robot repair technicians find puzzling. Let's dive into the world of industrial robot repair together!

When it comes to fixing industrial robots, we're dealing with a complex interplay of various systems, including servo systems, control cabinet circuit boards, mechanical structures, power systems, and software. These issues can be quite intricate, but fear not! I'm here to unravel the mysteries behind these common malfunctions and provide you with effective solutions.

Servo System Failures:

• Potential Causes: Motor driver failures, encoder anomalies, loose cables, etc.
• Solutions: Recalibration, replacing motor drivers, inspecting cable connections.

Example: KUKA Robot Error Message

• KSS0021: Second motor cable not connected or incorrectly connected.
  • Solution: Check the second motor cable and the return signal at KPS X114, pin7
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• KSS0102: Detection signal line failure.
  • Solution: Inspect encoder signal lines, KUKA robot motor, and rotary transformer. Replace the RDW if necessary.

Control Cabinet Circuit Board Failures:

• Solutions: Replacing damaged circuit boards or repairing individual components.

Example: FANUC Robot Error Message

• SRVO-044: High abnormal DC voltage in the main circuit power supply.
  • Solution: Check the three-phase input voltage supplied to the FANUC robot servo amplifier
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Mechanical Structure Failures:

• Potential Causes: Wear and tear on components like gearboxes and balance cylinders.
• Solutions: Replacing worn-out parts or tightening loose components.

Example: ABB Robot Error Message

• 32530: No communication with safety system.
  • Solution: Ensure the cable between the ABB robot communication card and the safety system is functioning correctly.

Power System Failures:

• Potential Causes: Insufficient or unstable power supply.
• Solutions: Addressing power supply issues.

Example: ABB Robot Error Message

• 38101: SMB communication failure.
  • Solution: Ensure the serial measurement circuit board and the axis computer are functioning correctly.

Software Failures:

• Potential Causes: Programming errors or software incompatibilities.
• Solutions: Reinstalling software, fixing programming errors, or updating the system.

Tips:

• Stay patient and meticulous when troubleshooting industrial robots.
• Don't hesitate to reach out for assistance if you encounter any difficulties.

Common Industrial Robot Brands: ABB, Yaskawa, KUKA, FANUC, Panasonic, Kawasaki, Stäubli, etc.

Note: This is a general guide, and specific solutions may vary depending on the make and model of your robot. Always consult the manufacturer's documentation for detailed troubleshooting procedures.