ABB Robot Common Fault Handling Collection!——YOUNGYOU

1. Robot alarm "20252", motor temperature high, DRV1 fault handling
Treatment method: check whether the motor is overheated. If the motor temperature is normal, check whether the connecting cable is normal (it may be that the aviation plug at the control cabinet is not plugged properly λ If there is no problem found and the robot is urgently needed, the alarm signal can be temporarily short circuited. However, be careful that the motor will not alarm even if it overheats, which may cause the motor to burn out.
Specific operation method: Find the A43 board in the bottom left corner of the control cabinet, find the 5 plugs on the board, and there are 4 wires on the top. The two wires with wire numbers 439 and 440 are the motor overheat alarm signal wires. Disconnect the two wires from the middle and short the two wires on this side of the board. (As shown in the figure below)

2. Handling the Short Circuit Fault of ABB Robot Power Module Short Circuit Board
Human factors: Hot swapping hardware is very dangerous, and many circuit board failures are caused by hot swapping. Improper use of force when inserting cards and plugs with power can cause damage to interfaces, chips, etc., leading to damage to the robot circuit board; As the time of using robots increases, the components on the robot circuit board will naturally age, leading to robot circuit board failures.
Environmental factors: Due to improper maintenance by the operator, the robot circuit board is covered with dust, which can cause signal short circuits.

3. When is it necessary to backup industrial robots
1. After the first power on of the new machine.
2. Before making any modifications.
3. After completing the modifications.
4. If industrial robots are important, they should be done once a week on a regular basis.
5. It is best to make a backup on the USB drive as well.
6. Regularly delete old backups to free up hard drive space.

4. How to handle the situation where the robot is turned on and the teaching pendant keeps displaying the following interface

The above situation is that there is no communication connection established between the teaching pendant and the main controller of the robot, and the reasons for not establishing the connection include:
1. The robot host is faulty.
2. The built-in CF card (SD card) of the robot host is faulty.
3. The network cable between the teaching pendant and the host is loose, etc.
Handling method:
1. Check whether the host is normal and whether the sd card in the host is normal.
2. Check if the connection between the teaching pendant and the host network cable is normal

5. What is the meaning of the 10106 maintenance time reminder when the robot displays an alarm message?
This situation is an ABB robot intelligent periodic maintenance reminder.

6. How to handle a system malfunction when the robot enters a power on state?
1. Restart the robot once.
2. If not, check the teaching pendant for more detailed alarm prompts and take action.
3. Restart.
4. If it still cannot be released, try B startup.
5. If it still doesn't work, please try P startup.
6. If it still doesn't work, please try I startup (this will return the robot to its factory settings, be careful).

7. Can robot backup be shared by multiple robots?

No. For example, the backup of robot A can only be used for robot A, not for robot B or C, as this can cause system failures.

8. What files can be shared in robot backup?

If two robots are of the same model and configuration. You can share the RAPID program and EIO file, but after sharing, it also needs to be verified before it can be used normally.

9. What is the mechanical origin of robots? Where is the mechanical origin?
Each of the six servo motors of the robot has a unique fixed mechanical origin. Incorrect setting of the robot's mechanical origin will cause problems such as limited or incorrect movement of the robot, inability to walk in a straight line, and serious damage to the robot.

10. How to clear the action monitoring alarm of robot 50204?

1. Modify the robot action monitoring parameters (in the control panel action monitoring menu) to match the actual situation.
2. Use the AccSet command to reduce the robot's acceleration.

3. Reduce v in speed data_ The rot option.

11. How to handle the alarm "50296, SMB memory data difference" when the robot is powered on for the first time?
1. Select Calibration from the ABB main menu.
2. Click on ROB_ 1. Enter the calibration screen and select SMB memory.
3. Select "Advanced", enter and click "Clear Control Cabinet Memory".
4. After completing, click "Close" and then click "Update".
5. Select 'Swapped control cabinet or robotic arm, updating control cabinet with SMB memory data'.

12. How to customize the speed of robot trajectory motion in the RAPID program?
1. Select Program Data from the main menu of the teaching pendant.
2. After finding the data type Speeddata, click New.
3. Click on the initial value, and the meanings of the four variables Speeddata are: v_ TCP represents the linear running speed of the robot, v_ Rot represents the rotational speed of the robot, v_ Leax represents the linear operating speed of the external axis, v_ Reax represents the rotational speed of the external axis. If there is no external axis, the last two do not need to be modified.
4. The customized data can be called in the RAPID program.

13. Troubleshooting of 6 Common Faults in ABB Robot Servo Motor Repair
1. How to handle the motor error counter overflow error during high-speed rotation?
Motor error counter overflow fault occurs during high-speed rotation.
Countermeasure 1: Check if the wiring of the motor power cable and encoder cable is correct and if the cable is damaged.
Motor error counter overflow fault occurs when inputting a long command pulse.
Motor error counter overflow fault occurred during operation.
Countermeasure 2: Increase the overflow level setting value of the error counter; Slow down the rotation speed; Extend the acceleration and deceleration time; The load is too heavy, and it is necessary to select a larger capacity motor from scratch or reduce the load, and install transmission organizations such as reducers to increase the load.
2. What should be done if it does not work when there is pulse output?
Supervise the current value of the pulse output of the controller and whether the pulse output light is flashing, acknowledge that the command pulse has been fulfilled and is now outputting normally;
Check if the control cable, power cable, and encoder cable from the controller to the driver are wired incorrectly, damaged, or in poor contact;
Check if the brake of the servo motor with brake has now been opened;
Supervise whether the panel of the servo driver acknowledges the input of pulse commands;
The Run operation command is normal;
The control form must choose the directional control form;
Is the input pulse type set by the servo driver consistent with the setting of the command pulse;
Ensure that the positive rotation side drive is stopped, the rotation side drive stop signal, and the error counter reset signal are not inputted, the load is disconnected, and the no-load operation is normal. Check the mechanical system.
3. What should I do if there is no overload report with load?
If it occurs when the servo Run signal is connected and no pulse is emitted:
Check the power cable wiring of the servo motor to see if there is any poor contact or cable damage; If it is a servo motor with a brake, the brake must be turned on; Is the gain of the speed loop set too high; Is the integral time constant of the speed loop set too small.
If the servo only malfunctions during operation:
Is the gain of the azimuth circuit set too high; Is the amplitude of positioning completion set too small; Check if there is no locked rotor on the servo motor shaft and adjust the machinery from scratch.
4. How to deal with abnormal sounds or vibrations during operation?
Servo wiring:
Use standardized power cables, encoder cables, control cables, and cables to check for damage; Check if there are interference sources near the control line, and if they are parallel or too close to the nearby high current power cables; Check if there is any change in the potential of the grounding terminal to ensure excellent grounding.
Servo parameters:
The servo gain setting is too large, and it is recommended to manually or actively adjust the servo parameters from scratch; Acknowledging the setting of the time constant of the speed response filter, with an initial value of 0, it is possible to increase the set value by testing; The electronic gear ratio setting is too large, advocating to restore to the factory settings; Resonance between servo system and mechanical system, testing and adjusting notch filter frequency and amplitude.
Mechanical system:
The coupling connecting the motor shaft and the equipment system deviated, and the installation screws were not tightened; Poor engagement of pulleys or gears can also lead to changes in load torque. Test no-load operation. If no-load operation is normal, check if there is any abnormality in the bonding part of the mechanical system; Admit whether the load inertia, torque, and speed are too large, test the no-load operation, and if the no-load operation is normal, reduce the load or replace the driver and motor with a larger capacity.
5. How to handle the inaccurate orientation control and positioning during ABB robot servo motor repair?
Firstly, acknowledge whether the actual declared pulse value of the controller is consistent with the expected value, and if not, check and correct the program;
Supervise whether the number of pulse commands received by the servo driver matches the one announced by the controller. If not, check the control cable; Check if the setting of servo command pulse form is consistent with the controller setting, such as CW/CCW or pulse+direction;
The servo gain setting is too large, please manually or actively adjust the servo gain from scratch; The servo motor is prone to accumulated errors during reciprocating motion. It is recommended to set a mechanical origin signal under the conditions allowed by the process, and perform the origin search operation before the error exceeds the allowed scale; The mechanical system itself has low accuracy or abnormal transmission organization (such as deviation of the coupling between the servo motor and the equipment system).
6. ABB robot servo motor repair, directional control operation, overspeed fault reported. How to handle it?
As soon as the servo Run signal is connected, it will trigger: check if the wiring of the servo motor power cable and encoder cable is correct and undamaged.

14. How do ABB industrial robots undergo routine maintenance?
Before normal operation of the "brake inspection", it is necessary to check the motor brake of each axis. The inspection method for the motor brake is as follows:
1. Run the axis of each robotic arm to its maximum load position.
2. Turn the motor mode selection switch on the robot controller to the MOTORS OFF position.
3. Check if the shaft is in its original position. If the mechanical arm still maintains its position after the motor is turned off, it indicates that the brake is in good condition.
Danger of losing deceleration operation (250mm/s) function
Do not change the gear ratio or other motion parameters from the computer or teaching pendant. This will affect the deceleration operation (250mm/s) function.

15. Several points to pay attention to when using teaching aids safely:
The enabling device button installed on the teaching pendant, when pressed halfway, changes the system to MOTORS ON mode. When the button is released or fully pressed, the system changes to MOTORS OFF mode.

16. In order to use teaching aids safely, the following principles must be followed:
When the Enabling device button cannot lose its function during programming or debugging, and the robot does not need to move, immediately release the Enabling device button.
2. When programming personnel enter a safe area, they must always carry the teaching pendant on their body to prevent others from moving the robot.

17. When working within the working range of the robotic arm, the following points must be observed:
1. The mode selection switch on the controller must be turned to the manual position in order to operate the enabling device to disconnect the computer or remotely operate;
2. When the mode selection switch is on
3. Pay attention to the rotation axis of the robotic arm, be careful when hair or clothing gets mixed up. Also, pay attention to other selected components or equipment on the robotic arm;
4. Check the motor brake of each axis.

18. Touch deviation
Phenomenon 1: The position touched by the fingers does not coincide with the mouse arrow.
Reason: After installing the driver program, the teaching pendant did not vertically touch the center of the bull's eye position during calibration.
Solution: Recalibrate the position.
Phenomenon 2: Some areas have accurate touch, while others have deviation in touch.
Cause: A large amount of dust or scale accumulates on the acoustic reflection stripes around the Surface acoustic wave touch screen, which affects the transmission of acoustic signals.
Solution: Clean the touch screen, paying special attention to cleaning the sound wave reflection stripes on all sides of the touch screen. When cleaning, disconnect the power supply of the touch screen control card.

19. Teaching pendant touch no response
Phenomenon: When touching the screen, the mouse arrows do not move and there is no change in position.
Reason: There are many reasons for this phenomenon, as follows:
1. The dust or scale accumulated on the acoustic reflection stripes around the Surface acoustic wave touch screen is very serious, causing the touch screen to fail to work;
2. Touch screen malfunction;
3. The touch screen control card has malfunctioned;
4. The touch screen signal line has malfunctioned;
5. The serial port of the host malfunctions;
6. The operating system of the teaching pendant has malfunctioned;
7. Touch screen driver installation error.
Solution: Observe the touch screen signal indicator light, which flashes regularly under normal circumstances, approximately once per second.
When touching the screen, the teaching pendant goes black, which is a complex problem. If backlight energy-saving is set, black screen is normal; If the second word in the system control area is accidentally operated, the screen will also go black. If the first two points are excluded, update to the latest firmware for review.