Fanuc "Robot Position is Out of Stop Tolerance"

  • I receive this alert on the majority of my cells upon restart, especially when we have to move the robot in T1 prior to restart. If this issue occurs, it normally happens if we have to go into the cell to fix any type of issue and then button everything back up and restart it in AUTO. We will hit the cycle start button and the message of "The robot position is out of stop tolerance. Please select action. Choosing CONTINUE will require cycle restart." We always select continue and have to hit the cycle start button again. Again, some times this pops up and then some times it doesn't.


    This isn't prohibiting any type of operation, it is more of a nuisance.
    Is this something that can be rid of or is it an occurrence that everyone has and has to deal with?


    Any input would be greatly appreciated!

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  • I had a robot that would occasionally display that same message. It was infrequent enough that I never pursued it. You might check actual position versus program point - especially if the point you step to has a large tolerance zone.

    Edited once, last by Iowan ().

  • From what i remember, this occurs when the robot drops more than it is allowed between the servo power being cut and the brakes engaging. I do not remember how to fix that issue. Are they old robots, such that the brakes could simply be wearing out?

  • This occurrence is happening on all of our cells. They range from being installed in 2004 and all the way up to this summer. I found that if you disable the resume tolerance feature under MENU/SETUP/RESUME TOL will get rid of the popup window. I haven't done this yet but I was wondering if I disable this, I will run into any other issues???

  • I am kind of curious why this is happening. I am pretty new to my position, so i don't have the years of experience to draw on yet. Do your robots stop in a position that is extended away from the base horizontally, or do they have heavy EOAT or payloads?

  • We run welding robots with less than a 7kg payload.


    From what I've gathered looking this up, the points of your program must match the axis's physical position within the system. Example, if you open up a door while the robot is moving, the brakes will engage and all motion will stop. While all of this is happening, the robot may "float" or "settle" and put you outside the measured tolerance of a specific position. And on your older cells, if there is "slop" in your brakes, your position may move and put you outside the measured tolerance. All of this happening will be miniscule to the point that you will not see any movement but the controller will, thus showing you the window.


    I'm not sure if this is correct or not. I plan on disabling the measured tolerance feature next week and see how that turns out.

  • The message is a warning, I wouldn't disable it.


    Is there to remind you that you are attempting to re-start at a different position, far from were the robot was last time it stopped (in AUTO).


    As you explained, sometimes cell stops for any reason, you move the robot in teach beyond the (resume) tolerance, if you attempt to re-start then you´ll get that warning message.


    It could be a nuisance, but it can prevent costly mistakes!

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