Robots Aborting Mid-Program

[JDLemar]

We have some of our robots that are aborting their programs mid-cycle, when E-stops etc are pressed.. The robots are stationary at the time, and our production department do a check of every Emergency Stop button on the line. This seems to make two of our RJ-2 S-420iF robots abort their programs..

The only alarms in the error log are the ones below, that are to be expected. All of these are of severity "SERVO" and should only cause the program to be paused. However they are aborting..

Other robots on the same production line are fine, although most of these are RJ-3iB robots and/or they're at home/aborted anyway.

SRVO-004  Fence Open
SRVO-037  IMSTP input (Group 1)
SRVO-002  Teach Pendant E-Stop
SRVO-007  External Emerg. Stops.

Any ideas?

[Monsterke]

Do you have running a shell program??
Grtz,

Monsterke

[JDLemar]

Not sure what you mean by shell program but I don't think so.. The robots just run normal TP programs. Robot software is SpotTool..

[Vlad]

Prof,

if you have IMSTP, it seems you have a PLC which turn off the UI signals. Is it possible that the same PLC gives the CSTOPI input to the robot?

Regards,

Vlad

[JDLemar]

The configuration setting in the robot "CTSTOPI For Abort" is set to FALSE.. The PLC does control the CSTOPI Signal but it doesn't come on in this case, even if it did, with the above setting set to FALSE, the robot ignores it..

[Monsterke]

Not sure what you mean by shell program but I don't think so.. The robots just run normal TP programs. Robot software is SpotTool..

I mean, that you maybe run a background program that is writin in "Karl" and that you can activate trough your variable $shell_cfg.$shell_name

[edbanks]

Sounds like you have a electrical problem in your safety circuit. Last time I ran into issues such as you describe, it was a bad pendant.

[Vlad]

Did you try with a good init start? you know, just to see if it is a sw problem or electrical problem.....
regards,
Vlad

[RJ3iBnR30iA]

I also think that it might be a SW problem. If you are sure that the Line PLC is not aborting the programs via UI signals.
Please check whether MENU-SYSTEM-CONFIG- RESTORE SELECTED PROGRAM is set to TRUE.

[cja7928]

I am having a similar issue with one of our robots.  when the safety fence is broken it aborts the program, when the operator  closes the fence and tries to restart it run the first program on the select screen and smashes into a fixture.
what is "SW problem" stand for?  also I noticed the system variable $ERSEVERITY has a value of 131072 on the robot that has the issue.  all the other robots that dont have this issue this variable has a value of 0.  I didnt want to change its value before knowing what it is - can anyone shed some light on this variable??

Thanks,
Chris

[Mtech]

When the robots fault are they in a exact position or close each time? CJA**** if your robot is crashing on a restart you may want to consider programming a code to check position at that first program in the select. Just have the robot record its position then apply register math to position into a safer move home or to restart.

[cja7928]

Yea, it goes to an inspection position.  The operator has to open the fence and check the part. then close the fence and restart the robot.  We have 5 other robots that are setup the same way.  The only difference I can find is in the $erseverity variable which I cant find any info on in the books.  At first I thought the PLC had to be kicking out a cstop on UI4 but I cant spot it doing that.  Thats a good idea on the position check. thx.