Hi! Now I have really bad new about my irb 2400.
2 days my robot was working OK but today I started to move it and and something cracked in the third axis.
And fatal error appeared!
I turned off it and tried to move the third axis and everything is OK. But today the cracking appeared again.
Who faced this problem? And what could i do to solve this problem?
Thanks!
3 axis Cracking
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PaulSola -
July 22, 2017 at 1:34 PM -
Thread is marked as Resolved.
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What are your error messages?
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Sometimes i hear just cracking and no errors appear.
Yesterday the massage was : Fatal error . unrecoverble error(I cant exactly say what massage was, but something like this).
After this error i turned off the system and after some minutes I turned it on, everythis was OK.
Also after that was the same cracking but the massage was: 3 axis error. -
Have you tried releasing the brake on axis 3 and moving it by hand to feel for any tight spots or jamming?.
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No, Thank you for idea!
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Do you have any ideas what could it be?
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Bearings, "junk" in the joint, trailing arm bearings.
Have you tried releasing the brake on axis 3 and moving it by hand to feel for any tight spots or jamming?.
Moving the joint by hand will let you see from what/where the noise emanates. Is the noise coming from the "elbow", or the base (the motor/gearbox location)? You can uncouple the trailing arm to see if it is causing the noise.There should be some error numbers associated with the messages you're getting.
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Perhaps someone changed the axis 3 motor at one time. Check to see if there is gear oil in the axis 3 gearbox. Should be 60-70mm down from the fill plug, I use a 200mm (8 inch) cable tie as a dipstick. Oil is EP320. Axis 2 should be the same.
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Thank you all for your replies!
I have just checked it and there is 10mm between the plug and oil. I heared that overfilling the oil could prevent the robot from
moving freely.
But could it cause the cracking? Because it sounded like something is going to brake now. -
I would still suggest moving the axis around by hand (it'll take another person to release the brake) to determine from where the noise is coming (or perhaps you already know). You might also get a feel for how much backlash is in the gearbox. A bearing would (probably) have more of a rumble - a crack or pop...???
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Sure, tomorow i will try it! I just wanted to hear all probable causes.
Thank you for your help! -
Might also be a brake sticking - the snap/crack/pop being when it releases.
On older vintage 'bots, KR3 could get dirty contacts and cause problems.
If it's the brake, itself, the motor will need to be replaced - "no user-serviceable parts inside".
A sticky brake/relay might work fine until the robot sits still for awhile. -
How did the oil look? It should have an amber color and be free of any contaminants.
Can you post the error number for the axis 3 error you get?
Is it a single crack sound or does it repeat as the arm goes up or down?
Does it happen in the same position?
Does the speed you jog the robot make a difference?
Does the upper arm jump/drop when it "cracks"?
Can you get a clear recording of the sound and post it. -
Ok. Let's start with the oil. The oil is clear and light and the oil level is 10 millimeters from the plug, so there is a lot of oil inside.
Also I should show how many hours does it work.(16956) The photo below.
Today i turned the system on and started to move the robot. And first 2 seconds of moving, my robot was making strange sounds like it is heavy to do it!
And after those 2 secounds i heard the same "cracking" and it really sounds like the BREAK SOUND!
And I should say that I heard this sound 3 times(for the all time). When I heard it at the first time (5 days ago), it was in a middle part of working ( Maybe, after an hour of working with the robot). And 2 other times the sound appeared at the very beginning (I turn on the system and start to move the robot and I hear a sound in the first seconds during the moving and it stops moving).
And when i hear the sound i see 5 errors(photos below). I turn the system off, than i turn it on and it works perfectly!! No sounds/pops/cracks or other strange sounds.
And I should answer the questions:
1)Is it a single crack sound or does it repeat as the arm goes up or down? | This is a single sound.
2)Does it happen in the same position? | This happens in the position in which I left the robot with the last work with it.
3)Does the speed you jog the robot make a difference? | Perhaps not, but every time I moved the robot slowly.
4)Does the upper arm jump/drop when it "cracks"? | Yes, not too much. Yes a little .
5)Can you get a clear recording of the sound and post it. | OK, i will do it but it sounds like break sound.Today I tried to move 3 axis by hand.
With the brake released and the moving of the third axis by hand , a slight backlash feels in the reducer gears.
I have not heard the "cracking", Movement is easy, BUT there is a slight vibration on the axis.Also i have made a photo of bearing of the 3 axis.(photo below)
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And after those 2 secounds i heard the same "cracking" and it really sounds like the BREAK SOUND!
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5)Can you get a clear recording of the sound and post it. | OK, i will do it but it sounds like break sound.Clarification - is that the sound of the brakes setting, or does it sound like something breaking?
Vibration might be gear mesh (not unusual). The arm dropping would be typical when system faults. Hard to say what came first - that motion fault could be generated when the arm drops. The internal drive fault message might be a clue. I Don't remember if the drive module for axis 3 is the same as another - if so, you might swap drive modules to see if the problem remains with the axis or moves with the module. -
That is the sound of the brakes setting. Yes
I will try to record the sound. -
Last sound : I released the pressed button
But now it moves much more strange
Also hear the sound when i lower the axis.
This is a video. -
I presume you have included the weight of that transformer in your load definition...
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That is the welding torch and wire feeder
All it weights not more than 6 kg.
And it was working with it all time... -
Breaking - Braking. Now I get it. If it's a brake issue then let's try this:
Take the cover off the axis motor and monitor the 24V (usually 21.5-24V) to the axis 3 brake. It's the 2 medium size wires on the larger connector: pin 7 (+) & pin 8 (-). Could be a bad wire between the motor and the brake release board.
If voltage is low, check the brake unit located on the base back cover where the brake release buttons are. Make sure the connectors are seated and inspected to make sure nothing is burnt or damaged. Incoming voltage to the brake release unit is on R2.BU pins 1 & 2 (+) and 3 & 4 (-). Voltage is usually to 22-24V.
Check the motor power connector R1.MP to the robot and make sure none of the pins are pushed in.
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