ABB robot troubleshooting guide

1. The robot alarm is "20252", the temperature is high, and DRV1 fault handling

Solution: Check whether the motor is overheated. If the motor temperature is normal, check whether the connection is normal (it may be that the aviation plug at the control cabinet is not properly plugged in. If no problem is found and the robot is in a hurry to use, the alarm signal can be temporarily short-circuited. However, please note that at this time, the motor will not alarm even if it is really overheated, which may cause the motor to burn out.

Specific operation method: Find the A43 board in the lower left corner of the control cabinet, find the 5 plugs on the board, there are 4 wires on it, of which the two wires with wire numbers 439 and 440 are the motor overheat alarms. Disconnect the two wires from the middle and short-circuit the two wires on this side of the board. (As shown below)

2. ABB robot board short circuit fault handling

Human factors: Hot plugging is very dangerous. Many faults are caused by hot plugging. Improper force when plugging and unplugging boards and plugs under power can cause damage to the chips, etc., which can lead to damage to the robot board. As the robot is used for a longer time, the circuit boards on the robot will naturally age, which can lead to failure of the robot circuit boards.

Environmental factors: Due to improper maintenance by the operator, the robot circuit board is covered with dust, which can cause signal short circuit.

3. Under what circumstances is it necessary to back up industrial robots

1. After the new machine is powered on for the first time.

2. Before making any changes.

3. After completing the modification.

4. If the industrial robot is important, check it regularly once a week.

5. It is best to back up the data on a USB drive.

6. Delete old backups regularly to free up hard disk space.

4. When the robot is turned on, the teaching pendant keeps displaying the following interface. How to deal with it?

The above situation is that there is no communication connection between the teach pendant and the robot main controller. The reasons for not establishing the connection include:

1. The robot host is faulty.

2. The CF card (SD card) built into the robot host is faulty.

3. Looseness between the teach pendant and the host computer, etc.

Solution: 1. Check whether the host is normal and whether the SD card in the host is normal.

2. Check whether the network cable from the teach pendant to the host is connected properly.

5. What does it mean when the robot displays the alarm message 10106 Maintenance Time Reminder?

This situation is the ABB robot's intelligent periodic maintenance reminder.

6. What should I do if the robot enters a system failure state when it is turned on?

1. Restart the robot once.

2. If it doesn’t work, check the teach pendant for more detailed alarm prompts and handle them.

3. Reboot.

4. If the problem still cannot be solved, try booting with B.

5. If that doesn't work, try P-boot.

6. If it still doesn't work, try I-boot (this will return the robot to 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, and cannot be used for robots B or C, because this will cause system failure.

8. What files can be shared in the robot backup?

If two robots are of the same model and configuration, they can share RAD programs and EIO files, but they must be verified before they can be used normally.

9. What is the mechanical origin of the robot? Where is the mechanical origin?

The robot's six servo motors all have a unique fixed mechanical origin. Incorrectly setting the robot's mechanical origin will cause the robot to have restricted or malfunctioning movements, be unable to move in a straight line, and even seriously damage the robot.

10. How to cancel the robot 50204 motion alarm?

1. Modify the robot motion monitoring parameters (Control Panel - Motion Monitoring Menu) to match the actual situation.

2. Use the AccSet command to reduce the robot acceleration.

3. Reduce the v_rot option in the velocity data.

11. How to deal with the alarm "50296, SMB memory data difference" when the robot is powered on for the first time?

1. Select Calibration in the ABB main menu.

2. Click ROB_1 to enter the calibration screen and select SMB memory.

3. Select "Advanced", and then click "Clear control cabinet memory".

4. Click "Close" when finished, then click "Update".

5. Select "The control cabinet or robot has been exchanged, use SMB memory data to update the control cabinet".

12. How to customize the speed of robot trajectory movement in RAPID program?

1. Select Program Data in the teach pendant main menu.

2. After finding the data type Speeddata, click New.

3. Click Initial Value. The four variables of Speeddata have the following meanings: v_tcp represents the linear running speed of the robot, v_rot represents the rotational running speed of the robot, v_leax represents the linear running speed of the external axis, and v_reax represents the rotational running speed of the external axis. If there is no external axis, the latter two do not need to be modified.

4. The customized data can be called in the RAPID program.

13. Six common faults in ABB robot servo motor repair

1. What should I do if the motor error counter overflows during high-speed rotation?

A motor error counter overflow error occurs during high-speed rotation.

Countermeasure 1: Check whether the wiring of the motor power cable and the cable is correct and whether the cable is

A motor error counter overflow error occurs when a longer command pulse is input.

A motor error counter overflow error occurred during operation.

Countermeasure 2: Increase the error counter overflow level setting value; slow down the rotation speed; extend the acceleration and deceleration time; the load is too heavy, it is necessary to reselect a larger capacity motor or reduce the load, and add a transmission mechanism to increase the load capacity.

2. What to do if the device does not work when there is pulse output?

Monitor the current value of the controller's pulse output and whether the pulse output light is flashing, confirming that the command pulse has been executed and the pulse is being output normally;

Check whether the control cable, power cable and encoder cable from the controller to the drive are wired incorrectly, damaged or have poor contact;

Check whether the brake of the servo motor with brake is open;

Monitor whether the servo drive panel recognizes the input of pulse instructions;

Run command is normal;

The control mode must select the position control mode;

Whether the input pulse type set by the servo drive and the command pulse setting are the same;

Ensure that the forward side drive stop, the rotary side drive stop signal and the error counter reset signal are not input, disconnect the load and the no-load operation is normal, and check the mechanical system.

3. How to deal with the overload report without load?

If the servo Run signal is connected and no pulse is sent:

Check the servo motor power cable wiring to see if there is poor contact or cable damage; if it is a servo motor with a brake, the brake must be turned on; whether the speed loop gain is set too large; whether the integral time constant of the speed loop is set too small.

If the servo is only operating:

Is the orientation loop gain set too large? Is the positioning completion amplitude set too small? Check whether the servo motor shaft is blocked and readjust the machine.

4. What should I do if abnormal sound or vibration occurs during operation?

Servo wiring:

Use standard power cables, encoder cables, and control cables to check whether the cables are damaged; check whether there are interference sources near the control cables, and whether they are parallel to or too close to nearby high-current power cables; check whether the potential of the grounding terminal changes to ensure good grounding.

Servo parameters:

The servo gain setting is too large. It is recommended to readjust the servo parameters manually or automatically. Confirm the setting of the speed response time constant. The initial value is 0. You can try to increase the setting value. The gear ratio setting is too large. It is recommended to restore it to the factory setting. For the resonance of the servo system and the mechanical system, try to adjust the notch filter frequency and amplitude.

Mechanical system:

The coupling connecting the motor shaft and the equipment system is offset and the mounting screws are not tightened. Poor engagement of the pulley or gear will also cause changes in the load torque. Test no-load operation. If it is normal, check whether there are any abnormalities in the joints of the mechanical system. Confirm whether the load inertia, torque and speed are too large, test no-load operation. If it is normal, reduce the load or replace the drive and motor with larger capacity.

5. What should I do if the ABB robot servo motor is not positioned accurately during position control when repairing it?

First, check whether the actual pulse value issued by the controller is consistent with the expected value. If not, check and modify the program.

Monitor whether the number of pulse commands received by the servo driver is consistent with that issued by the controller. If not, check the control cable; check whether the setting of the servo command pulse mode is consistent with that of the controller, such as CW/CCW or pulse+direction;

The servo gain is set too large. Try to adjust the servo gain manually or automatically. The servo motor is prone to cumulative errors when performing reciprocating motion. It is recommended to set a mechanical origin signal under process conditions and perform an origin search before the error exceeds the allowed range. The mechanical system itself is not accurate or the transmission mechanism is abnormal (such as offset of the coupling between the servo motor and the equipment system).