Repairing the UR10 Collaborative Robot without restarting

With the continuous development of industrial robots, UR robot (Universal Robots), as an advanced industrial automation equipment, has been widely used in various industries. However, the UR robot control system as a precision integrated equipment system, it is inevitable that some failure problems will occur, bringing a lot of trouble to the user.

I. A Case Study on Common Control Cabinet Failures

The control section of UR collaborative robots mainly includes the main board, safety control board, teach pendant, 48V power supply, 12V power supply, power distributor, and so on. Common failure phenomena of the control cabinet are:

1. Power Supply Issues: No Electricity to the Control Cabinet

Fault Phenomenon: The control cabinet does not power on

Solution:

Check the Main Power Supply: Ensure that the power supply to the control cabinet is switched on and that there are no blown fuses or tripped circuit breakers in the supply line.

Inspect Power Cables: Look for any visible damage or disconnections in the power cables.

Verify Power Settings: Confirm that the power supply settings match the robot's specifications (e.g., voltage, frequency).

2. Communication Interruptions: Loss of Connection

Fault Phenomenon: The robot loses connection with the control cabinet or other networked devices.

Solution:

Check Network Cables: Inspect Ethernet cables for damage or loose connections.

Verify Network Configuration: Ensure that the robot's IP address and network settings are correctly configured and consistent with the network requirements.

Restart Network Devices: Power cycle the robot and any affected network devices to re-establish the connection.

3. Robot Failure to Start

Fault Phenomenon: The robot does not initiate movement or operation.

Solution:

Review Error Codes: Check the control panel for any error codes that provide insight into the cause of the malfunction.

Inspect Emergency Stop: Ensure that the emergency stop button has not been activated and that all safety interlocks are clear.

Check Control Cabinet Status: Verify that the control cabinet is fully powered and that all components are operational.

4. Inability to Access the System

Fault Phenomenon: The user interface or teach pendant does not respond or allow system access.

Solution:

Hard Reset: Perform a hard reset of the teach pendant and control cabinet to clear any temporary software glitches.

Update Firmware: Ensure that the robot's firmware is up to date, as outdated software can cause access issues.

Inspect Connectivity: Confirm that the teach pendant is properly connected to the control cabinet.

5. Startup Detection Errors

Fault Phenomenon: The robot detects an error upon startup that prevents operation.

Solution:

Review Error Messages: Carefully read any error messages and refer to the UR10 manual for troubleshooting steps specific to the error code.

Check Mechanical Components: Inspect for any mechanical obstructions, misalignments, or damaged components that could trigger a startup error.

Run Diagnostics: Utilize the robot's built-in diagnostics to identify and isolate the issue.

6. Control I/O Failures

Fault Phenomenon: Input/output (I/O) modules in the control cabinet are not functioning correctly.

Solution:

Inspect I/O Modules: Check for any visible signs of damage or loose connections on the I/O modules.

Test I/O Signals: Use a multimeter to test the continuity and signal strength of the I/O connections.

Replace Faulty Modules: If a module is found to be defective, replace it with a new one.

7. Voltage Anomalies

Fault Phenomenon: Abnormal voltage readings within the control cabinet.

Solution:

Check Power Supplies: Inspect the power supply units for any signs of failure or malfunction.

Monitor Voltage Levels: Use a voltmeter to monitor the voltage levels across the control cabinet to identify any inconsistencies.

Regulate Power: If necessary, install voltage regulators or stabilizers to maintain consistent power levels.

8. Safety Relay Malfunctions

Fault Phenomenon: The robot's safety relay is triggering unexpectedly, causing the system to shut down.

Solution:

Inspect Safety Circuits: Check all safety-related circuits and interlock mechanisms for proper operation and integrity.

Test Relay Function: Perform a test of the safety relay to ensure it is responding correctly to safety signals.

Reset Safety System: If the safety relay is faulty, reset or replace it as needed.

9. Damaged Cables

Fault Phenomenon: Damaged or frayed cables are affecting the robot's operation.

Solution:

Inspect Cable Condition: Visually inspect all cables for cuts, fraying, or other damage.

Replace Damaged Cables: Replace any cables that show signs of wear or damage to ensure reliable connectivity.

Secure Cabling: Ensure that cables are properly secured and routed to prevent future damage.

II. Cleaning Instructions

Note: Always disconnect the power supply before cleaning the robot!

The UR Robot does not require excessive maintenance while in use, but depending on the environment and use, moderate cleaning and maintenance may be required.

1. To clean the UR Robot Teach Pendant, avoid strong solvents such as acetone, although the paint is resistant to most solvents; if possible, disassemble the Teach Pendant and store it in a clean location when not in use.

2. Clean the inside of the UR Robot controller cabinet. The inside of the controller should be cleaned at appropriate intervals depending on the environmental conditions, e.g. once a year;

When maintaining the robot, pay special attention to cleaning the cooling fans and air intakes/outlets. Use a dust brush for cleaning and a vacuum cleaner to remove dust under the brush. Robot maintenance Do not use a vacuum cleaner to clean the parts directly, as this may cause static discharge and subsequent damage to the parts.

3. Cleaning and Replacing Filters

• The controller has 2 filters, one on each side of the controller.
• Remove the filter holder from the controller and replace it with a new one.
• In addition to replacing the filters, cleaning the filters is also an option for robot maintenance.
• The details are as follows:

Wash the filter cloth 3-4 times in 30-40°C water with detergent. The filter cloth must not be wrung out, but can be placed on a flat surface to dry. The filter can also be blown clean with clean compressed air.

Conclusion

The UR10 collaborative robot is a powerful tool in industrial automation, but it requires regular maintenance and prompt attention to control cabinet issues. By following these troubleshooting steps, technicians can quickly identify and resolve common faults, ensuring minimal downtime and maintaining the robot's optimal performance.

When facing a non-starting UR10 robot, methodical troubleshooting is key. Always refer to the official Universal Robots service manuals and work with certified technicians to ensure the safety and integrity of your robotic systems.