Motion Supervision Error

  • i am working on IRB 6700 with Robotware 6.12 and mounted on a flex track. it was working absolutely fine without any error. today when i tried to jog, it shows some errors regarding:

    Motion Supervision 50204,

    Collison Triggered 10024 ,

    Collision retraction 10026,

    Joint Collision 50056.


    Following steps are taken for remedy: robot never collide anything, no visible cable damage (Motor), also cross checked the flexibility of cables and found no such stress on the cables.

    Tool Data, Mass was properly defined using Loadidentify system routine, no other system parameters are changed. i also tried moving robot in small increments and take it away from so called collision point but motion supervision gets active.

    changed sensitivity of motion supervision from default upto 200 and give it a try but error persists.

    Using brake release button on the manipulator i checked all axis , they move smoothly without any noise in both + and -ive direction.

    one thing that confused me that its not about a specific joint or axis, after restarting the system which ever axis i select to jog robot in that axis direction using joy stick, motion supervision and joint collision errors comes with that axis name. which means its not related to some specific axis (mechanical or electrical), even if i try to move the flex track it stops movement after few mm move and generate motion supervision error.

    Any help in this regard will be highly appreciated.

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  • Lots of good details in this document. Unfortunately I don't have a copy available currently, and I can't find it on ABB Library. But someone on here may be able to pull it up, or ABB support should be willing to email it to you.


    Operating manual - Troubleshooting IRC5 3HAC020738-001


    On to your issue... Have you verified that all your motor connectors are securely connected (at the motors, as well as robot base, and inside the cabinet). Also check for damaged floor cables. Number one source of this issue in my experience has been a loose connector or damaged cable. Sometimes they're not very obvious either. There are a few model years where the Motors ON Indicator at the top of the robot is tied into the Brake Circuit in such a way that a damaged cable or shorted LED can affect the entire motor harness. Worth a check!


    If you can't find a wiring or connector issue, try swapping drive modules from another controller if you have one available.

  • "There are a few model years where the Motors ON Indicator at the top of the robot is tied into the Brake Circuit in such a way that a damaged cable or shorted LED can affect the entire motor harness. Worth a check!"

    i don't think that is available for irb 6700. i ll cross check all the connections of motors and connectors at robot base.

    what about this point "one thing that confused me that its not about a specific joint or axis, after restarting the system which ever axis i select to jog robot in that axis direction using joy stick, motion supervision and joint collision errors comes with that axis name. which means its not related to some specific axis (mechanical or electrical), even if i try to move the flex track it stops movement after few mm move and generate motion supervision error." does this make any sense?

  • which ever axis i select to jog robot in that axis direction using joy stick, motion supervision and joint collision errors comes with that axis name. which means its not related to some specific axis (mechanical or electrical), even if i try to move the flex track it stops movement after few mm move and generate motion supervision error.


    Damaged cable can still cause this, if the right conductor is shorted/broken. I would disconnect motor power and resolver cables at base of robot. Then check PIN-to-GND for everything on the Robot and Controller side. Double check anything that is grounded against the wiring diagram.


    If cables check out, my next step would be drive module swap.

  • Seen a low phase cause this. I would verify proper voltage to the servo amps, check phase-to-phase at X1 at the top right corner of the drive module. Use a low impedance meter or 'wiggy' as high impedance DMMs can be fooled by induced voltage.

    Also seen bad drive cause this, check wiring then swap drive module as suggested above by ColoradoTaco.

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