1600 IRB Wire Harness

[King_Kingston]

I have had 3 IRB 1600 robots throw resolver errors for either axis 4,5,6 or a combination of them.  What I've found on the three robots is all the same issue or failure.  It seems that the upper cover (inside) for axis 3-6 motors has a bolt boss that is either rubbing/pinching the set of resolver cables.  I've attached a picture of the resolver cable "bundle" and the corresponding bolt boss that is rubbing the bundle.  I am more than likely going to inspect all of the 1600 robots that we have in service.  Is this a known issue or is this something that is just a fluke?  Has anybody else come upon this?  Any feedback would be appreciated.  Thanks.

[prnuk2003]

I would advise getting ABB involved so they can take a look at what you have found and also all your remaining 1600 robots. Usually the local ABB will then report their finding to ABB in Vasteras.  If it is seen as a build problem then the process is that they will issue instructions to the local service centres to correct the problem for all their units in the field.
You tend to get some issues like this with new mechanical units so the earlier it is reported the quicker they can act.

[King_Kingston]

At this point, I have checked 21 of the 37 1600's that are in service, and 17 of them had the aforementioned "pinch."  We are compiling pictures of each robot.  When all 37 of them have been checked and documented, the information will be passed to our engineer that purchases the robots and he will take it from there. 

I did find that the majority of the robots that had the issue were manufactured between '05 and '06.  Anything after '06 did not seem to have the issue.  Thanks for replying prnunk.