Troubleshooting Common Industrial Robot Issues
The core significance of industrial robot fault troubleshooting is to ensure continuous production line operation, reduce downtime losses, and extend equipment service life.
Fault troubleshooting principles should follow:
Safety first, then operation;
Safety first, then operation;
Simplicity first, then complexity;
Externals first, then internals;
Software first, then hardware.
Industry Overview
In industrial automation production, the stable operation of industrial robots is directly related to production line efficiency and capacity benefits.
According to robot industry research data, more than 65% of production line downtime losses are caused by sudden robot faults, and efficient fault troubleshooting can reduce downtime by more than 50%.
As a manufacturer in the robot industry, RBTC has provided services to hundreds of enterprises, quickly solved problems, sorted out the core faults most frequently encountered by users and directly implementable solutions, and provided users with long-term operation and maintenance guarantees.
I. Core Principles of Industrial Robot Fault Troubleshooting
Safety and efficiency are the core principles of industrial robot fault troubleshooting.
Regardless of the type of fault, it is necessary to adhere to "Safety first, then operation; Simplicity first, then complexity; Externals first, then internals; Software first, then hardware" before troubleshooting to avoid expanding the fault scope or causing safety accidents.
Necessary tools and preparations: Teach pendant, multimeter, insulating gloves, wrenches, screwdrivers, equipment manual, program backup，etc.
Following safe and reasonable operations can minimize the risk of fault handling.
II. Common Robot Problems and Solutions
Combined with years of front-line experience of RBTC's after-sales team, the following are the 4 most common types of industrial robot faults and targeted solutions, covering mainstream application scenarios such as welding, handling, and injection molding:
1. Common Mechanical System Faults
1.1 Joint Module Faults
Fault Phenomena: Joint abnormal noise, jamming, unsmooth rotation, overload alarm
Troubleshooting Methods:
- Visual Inspection: Check if the joint seal is damaged, if there is foreign matter intrusion, and if the cables are tangled or stuck
- Parameter Verification: Check the joint load rate and temperature data through the teach pendant to determine if the rated load is exceeded
- Mechanical Inspection: Remove the joint end cover, check the grease condition (whether it is deteriorated or insufficient), and the bearing wear
Troubleshooting Measures: Replenish/replace grease, clean foreign matter, replace worn bearings, adjust load parameters
1.2 End Effector Faults (Welding Torch/Fixture/Gripper)
Fault Phenomena: Welding torch nozzle clogging/leakage, fixture failure to close/insufficient clamping force, gripper slow response
Troubleshooting Methods:
- Air Supply/Hydraulic Inspection: For pneumatic fixtures/grippers, verify if the air pressure meets the standard and if the air pipes are leaking/clogged; For hydraulic systems, check oil pressure and pipeline tightness
- Mechanical Inspection: Check if the end effector has mechanical jamming or loose connectors, and if there is welding slag accumulation at the welding torch nozzle
- Sensor Inspection: Check if the clamping in-place sensor and pressure sensor are malfunctioning and if the signal is transmitted normally
Troubleshooting Measures: Clean nozzles/pipelines, replace seals, replenish air supply/hydraulic oil, calibrate/replace sensors
1.3 Transmission Mechanism Faults
Fault Phenomena: Reducer oil leakage, gear wear abnormal noise, belt slipping/breakage
Troubleshooting Methods:
- Visual Inspection: Check if the reducer has oil leakage, if the belt tension is appropriate, and if there are cracks
- Operation Inspection: During no-load/load operation, monitor the source of abnormal noise in the transmission mechanism and judge the wear degree through a vibration detector
- Oil Inspection: Check the reducer oil level and oil quality
Troubleshooting Measures: Replace seals, replenish/replace oil, adjust belt tension, replace worn gears/belts
2. Common Electrical System Faults
2.1 Servo System Faults
Fault Phenomena: Servo motor overheating alarm, encoder abnormality, servo driver error (overvoltage/overcurrent/undervoltage)
Troubleshooting Methods:
- Power Supply Inspection: Check if the input voltage is stable and if the power module is working normally
- Encoder Inspection: Check if the encoder wiring is loose or damaged, and if the encoder signal is normal (detected with an oscilloscope)
- Driver Inspection: Check if the driver cooling fan is working normally, if there are signs of burnout on internal components, and interpret the error code against the manual
Troubleshooting Measures: Repair/replace the encoder, check power lines, clean the driver cooling channel, replace the faulty driver
2.2 Power System Faults
Fault Phenomena: Robot failure to start, frequent power outages, power indicator not on
Troubleshooting Methods:
- External Power Supply Inspection: Check the workshop main power voltage, if the air switch is tripped, and if the power line is in poor contact
- Internal Power Supply Inspection: Check if the output voltage of the robot power module meets the standard and if the fuse is blown
- Safety Circuit Inspection: Check if the emergency stop button is reset, if the safety door switch is abnormal, and if the safety circuit is disconnected
Troubleshooting Measures: Reset the emergency stop/safety door, replace the fuse, repair power lines, replace the faulty power module
2.3 Line and Connection Faults
Fault Phenomena: Signal transmission interruption, partial function failure, intermittent errors
Troubleshooting Methods:
- Visual Inspection: Check if the cable is worn, aged, or broken, and if the connector is loose or oxidized
- Continuity Test: Use a multimeter to detect the continuity of the line and troubleshoot short circuit/open circuit problems
- Shielding Inspection: Check if the shielding layer of the signal cable is well grounded to avoid electromagnetic interference
Troubleshooting Measures: Replace damaged cables, re-tighten connectors, repair grounding lines, handle oxidized connectors
3. Common Software and Control System Faults
3.1 Program Faults
Fault Phenomena: Program failure to run, errors during operation, collisions caused by incorrect path planning
Troubleshooting Methods:
- Program Verification: Check if there are logical errors in the program (such as abnormal jump instructions, undefined variables) and if the path points exceed the robot's working range
- Teach Pendant Debugging: Run the program step by step to locate the error statement and check if the variable values are normal
- Backup and Recovery: If the program has run normally before, restore the historical backup program to troubleshoot the problem
Troubleshooting Measures: Modify program logic, re-calibrate path points, delete error instructions, restore backup programs
3.2 System Faults
Fault Phenomena: Teach pendant screen not on/touch failure, system crash, parameter loss
Troubleshooting Methods:
- each Pendant Inspection: Check if the teach pendant power is connected, if the data cable is connected normally, and if the screen has physical damage
- System Verification: Check the system log to determine the cause of the fault (such as software conflict, virus infection)
- Parameter Inspection: Check if key parameters (such as zero point parameters, load parameters) are lost or tampered with
Troubleshooting Measures: Restart the system, re-connect the teach pendant, restore the system to factory settings, restore parameter backups
3.3 Communication Faults
Fault Phenomena: Robot failure to communicate with PLC, vision system, welding machine, data
Troubleshooting Methods:
- Network Inspection: Check if the network cable is loose or damaged, if the switch is working normally, and if there is an IP address conflict
- Protocol Inspection: Check if the communication protocols (such as Profinet, EtherNet/IP) are consistent and if the parameters match
- Signal Inspection: Use an oscilloscope to detect communication signals and judge if there is signal interference
Troubleshooting Measures: Re-plug the network cable, configure correct IP address/protocol parameters, repair interference sources, replace faulty communication modules
4. Common Safety System Faults
4.1 Safety Alarm Faults
Fault Phenomena: Safety zone intrusion alarm, safety speed excess alarm, safety circuit abnormal alarm
Troubleshooting Methods:
- Safety Device Inspection: Check if the safety light curtain and laser scanner are blocked or damaged, and if the safety door interlock is normal
- Parameter Verification: Check if the safety zone range and safety speed threshold settings are reasonable
- Circuit Inspection: Check if the safety circuit wiring is loose and if the safety relay is working normally
Troubleshooting Measures: Remove obstacles, repair/replace safety devices, reconfigure safety parameters, tighten safety circuit wiring
4.2 Emergency Stop Faults
Fault Phenomena: Emergency stop button cannot be reset after being pressed, frequent emergency stop alarms without pressing the emergency stop button
Troubleshooting Methods:
- - Emergency Stop Button Inspection: Check if the mechanical structure of the button is stuck and if the contacts are oxidized or in poor contact
- Circuit Inspection: Check if the emergency stop circuit is open and if the emergency stop relay is faulty
Troubleshooting Measures: Repair/replace the emergency stop button, repair the emergency stop circuit, replace the faulty relay
Fault Troubleshooting Process Skills
First, judge the fault type (mechanical/electrical/software) → Narrow down the fault scope (which module/axis/component) → Troubleshoot step by step (start with simple operations) → Record fault information (facilitate subsequent analysis).
RBTC (www.iroboticplus.com) recommends prioritizing reference to the equipment manual to quickly locate the cause of the fault and summarize common error codes.
III. RBTC Service Advantages: More Than Fault Resolution, Focus on Long-Term Guarantee
For manufacturing enterprises, the core of fault troubleshooting is "quick resolution + reducing recurrence".
Relying on its own advantages as a manufacturer, RBTC provides customers with full-cycle operation and maintenance services:
- 24/7 Response: The after-sales team is online 24 hours a day, providing remote guidance for emergency faults and supporting international on-site services;
- Customized Training: Can provide basic fault troubleshooting training for operators, combined with practical operation verification to improve independent problem-solving capabilities;
- Original Factory Guarantee: All accessories are original genuine products, and quality assurance is provided after maintenance to ensure operation and maintenance quality.
IV. Summary
Industrial robot fault troubleshooting relies on industry experience and scientific methods. The high-frequency fault solutions sorted out in this article can guide front-line operations.
For enterprises, choosing a manufacturer with a complete service system can significantly reduce operation and maintenance costs — RBTC not only provides users with high-performance robots, but also builds a full-link operation and maintenance service with more than 10 years of industry experience, comprehensively guaranteeing efficient operation of the production line from fault resolution to after-sales maintenance.
Choose RBTC. If you encounter unresolved faults when using our product, you can contact our after-sales team at any time for professional support.
