Hello we have a large cell that welds locomotive frames with a cycle time that ranges from 8 hours to 11 hours using 2 HP-20-D arms. Each robot has its own DX100 controller and the cell has a large 360 degree rotational positioner. We are having problems with both robots holding taught positions and they are not consistently off in any direction they are all over the place. we are using touchsense and comarc. On one robot we do know we have a bad encoder as we have had several alarms with the L axis including Alarm 1325 communication Error Encoder robot 1 L axis, Alarm 1326 defective encoder absolute data robot 1 L axis, Alarm 9127 collision detect must be enabled, and Alarm 4107 out of range absolute data robot 1 L axis. but would this cause the other robot to lose postion or is this something else. We have had serveral communication issues but think we have solved that problem as we have replaced the ycpo1 board but the issues of the robots not keeping taught position has been on going for sometime in both robots we basically cannot run in auto and have to continually reteach everything. Any help on this would be greatly appreciated as we are replacing the encoder motor in the L axis this week.
Robots losing taught positions
- BAlexander
- Thread is marked as Resolved.
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Have you change the batteries ?
Sometimes it could be as simple as changing the batteries -
Yes I assume you mean the controller batteries? We have changed the batteries on the controller and all the servo encoder batteries.
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You should call Yaskawa to get an onsite Audit to see if they can find a problem with a drive, motor or servo system.
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Yes I think that is what we are going to have to do because even after replacing the encoder motor on the L axis the problem still exists in both robots.
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Are your positions stored as position variables? If so, make sure that you are not using the same ones in more than one job.
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NO, the only position we have stored as a variable is the home position and it is only used in a job to send the robot back to the home position.
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NO, the only position we have stored as a variable is the home position and it is only used in a job to send the robot back to the home position.
Sounds like the NuTech cell, I know this job....I’m guessing a comarc and or touch sensing issue. Did you change wire manufacturers? When was the last time comarc was calibrated? Try running without comarc and see. Maybe weld grounding causing intf in comarc readings.
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When you reteach. Try to see if any one axis in joint mode will get you back to where you were. If it's B or T, they run on pullies. The bolt may need to be tightened.
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Yes that is a good Idea I will give that a try Thanks
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is there a chance the wire is getting bent? we ran into an issue like this and it was caused by the operator not emptying the cut containers on the reamers. it was so full it would bend or move the wire so when it went to touch sense it was off location.
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There's a very good chance that could be the issue if you're not using a wire cutter before doing your touch sensing. Also, new torches are now equipped with a wire brake to make sure that the wire does not move during air moves.
So check that
- you're calling the WIRECUT job before you touch sense
- you're turning on the wire brake before you touch sense
- you're turning off the wire brake once your touch sensing is done -
So we changed the encoder and recalibrated TCP and home positions but found out the problem was someone was jogging the wire with the wire brake on and caused the inside of the torch to get filled up with small slivers of wire being shaved off from the wire brake being on while jogging the wire and not letting the wire brake fully engage so the wire was moving while touching. we use benzel water cooled torches but anyway problem is solved and seems to be running normal now thanks for all your input and ideas
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