At present, industrial robots have been widely used in automobile and auto parts manufacturing, machining industry, electrical and electronic industry, rubber and plastic industry, food industry, wood and furniture manufacturing industry and other fields. In industrial production, industrial robots such as welding robots, assembly robots, spraying robots and handling robots have been widely adopted.
There are more and more robots in the company, worried about robot problems? How can we be prepared? How to simplify the solution? Here are some tips and common failure analysis.
Don't panic when the robot malfunctions during work. If the malfunction is not caused by the controller, the cause of the malfunction must be damage to the machine parts. In order to deal with the fault as quickly as possible in the easiest way, the fault should be analyzed. And need to find out which part caused the failure. Please follow the steps below for simple inspection and maintenance:
Step 1: Which axis has the problem?
First, check which axis caused the fault. If it is difficult to detect the fault, check whether there are the following possible machine abnormalities.
â‘ Are there any parts making noise?
â‘¡Are any parts overheating?
â‘¢Are there any loose parts or recoil?
Step 2: Which part is damaged?
If an abnormal axis is detected, check which part is causing the problem. There are many possible causes for the same phenomenon.
note:
1) Overload-phenomenon occurs when the load exceeds the rated motor load. Specifically, it triggered the thermal relay of the coil protector.
2) There is noise during operation-the phenomenon is vibration during operation.
3) Swing when stopped-the phenomenon is that the robot swings when it stops.
4) Irregular tremor-the phenomenon is sporadic tremor when the robot is not moving.
Step 3: Deal with the faulty parts. After investigating the faulty parts, perform the relevant repair steps according to the "Main Components Fault Diagnosis and Resolution".
Fault diagnosis and resolution of main parts
The main components of industrial robots include reduction gears, braking devices, motors, encoders, etc. Among component failures, reduction gears are frequently used, followed by braking devices, motors, and encoders.
When the reduction gear is damaged, it will vibrate or make an abnormal sound. In this case, it will cause overload and abnormal deviation to disturb normal operation. Sometimes it can cause overheating. The robot may not be able to move at all or a position offset error may occur. These reasons may be caused by damage to the reduction gear main shaft (S, H, V) or the wrist shaft (R2, B, R1). How to diagnose whether the main shaft or the wrist shaft is damaged?
A few detailed diagnoses are required:
(1) When the robot is working, check the reduction gear for vibration, abnormal noise or overheating.
(2) Check whether the reduction gear is loose and worn. Move the brake release switch of the S-axis to the [ON] position, swing the first robotic arm in the forward and backward directions, and then check whether there is any abnormality by hand.
(3) Check whether peripheral equipment has been connected to the robot before the abnormal phenomenon occurs. (The damage of the reduction gear may be caused by the connection.)
(4) Shake the end effector (such as welding torch and hand device, etc.) back and forth to check whether the reduction gear is loose.
(5) Turn off the motor, turn on the brake release switch at the same time, and check whether the shaft can be turned by hand. If not, the reduction gear is in poor condition.
(6) Check whether peripheral equipment has been connected to the robot before the abnormal phenomenon occurs. (The damage of the reduction gear may be caused by the connection.)
After diagnosis according to this step, it can be determined whether the main shaft or the wrist shaft is damaged. After the damage location is determined, corresponding solutions can be made. If the reduction gear of the main shaft needs to be replaced, a crane is required to lift and suspend the robot arm. In addition to replacing the reduction gear, the wrist shaft can also replace the entire mechanical wrist. It is a quick and reliable solution to replace the mechanical wrist of the whole machine, because it takes time and some necessary equipment to replace the reduction gear. If you have any difficulties, please consult our service department.
Compared with the replacement of the reduction gear, the replacement of the brake device and the motor is much simpler. It is worth noting that when diagnosing and replacing the brake device, you need to pay attention to safety. When turning off the motor, check whether the brake sound can be heard during operation by turning on and off the brake release switch. If you cannot hear it, the brake cable is broken. When opening and closing the brake release switch, be careful that the robot arm falls off. The brake release switch is located on the control panel of the controller box door. Check out damage and aging and replace new parts in time.
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