rapidly repeated ERROR 50055 JOINT LOAD TO HIGH

I believe you would have a service routine called LoadID. I would recommend running this and follow the instructions. This would set the tool and/or load with the proper center of gravity (based on the robots calculations) and should run better following this. See if you have it by going to the service routines in the program editor screen. Keep in mind you will have to run this in manual mode and then auto mode. I always check in manual first (as it gives you the option to just do it in auto) as It will follow the same path in manual/auto. If you need to cancel and restart, you will need to cancel call routine, bring it back to the main and then try the service routine again. I recommend placing the robot in a safe place with a good amount of room before trying this. Good luck!

AJ,

Yes, you should check those motor connection cables as it can either affect the brake release or the resolver feedback which would both cause these types of issues.

You said there was oil coming out of the motor? If this is the case then oil may have pushed through the motors seals and got into the motor causing the brake to over-speed and fail. This would require a motor rebuild.

When you press the manual brake release for the motor do you hear a clicking noise and it moves easily?

When you manually push the robot around axis 1 while holding the break release do you hear any noise or is there excessive resistance?

Open the oil drain plug for Axis 1 (This is in the product manual) If you don't have we can provide and assist. Check to see if there are any metal shavings in the oil.

I suspect the motor brake is likely starting to fail and causing this error. We see this all the time.

We have all of these parts in stock and every other part for the IRB1600. We have 2 year warranty on all parts, and also have full repair shops and labs around the work and can quickly repair any servo motor, wrist units, power supplies, drives, or controls.

Let us know how we can best support.

Thanks,

Robotics Tech Support Team
FSD Robotics - Radwell

Brake connections are in the motor connector that appears undamaged. Agree with Viperacebb, need to fix obvious resolver connector/cable issue. Broken cable shielding in the resolver cable allows motor noise in the resolver signal and commonly gives collision, overload, and other errors.

FSD has good advice for checking the brake as brake failures are also common with joint overload errors.

Isolate where the oil is coming from, that's very important before putting the robot into production.

Since the robot is inverted, the drain plug is next to axis 1 motor, straight up from axis 1 motor connectors. It's visible in 2nd picture of post #3 above.

The plug circled in the 1st picture in post 7 is a blind hole used by the ABB's Calibration Pendulum for setting axis 1. There is no oil in the robot base, only cables & SMB.

There should not be oil in the motor. It will need to be replaced or repaired by a reputable motor shop. Oil in the motor usually requires multiple wash & bake cycles to remove all oil residue.

You can check to see if axis 1 brake is getting voltage by:

Disconnect axis 1 motor cable, measure for 22-24VDC between pin 4 (+) and pin 5 (-) when someone pushes axis 1 brake release button.

Yes - the arrow is pointing to the drain.

Oil enters the motor thru its worn front seal.

Oil can also enter past a slightly worn front seal that would normally not pass oil if the robot is subject to temperature variations.

Example would be a robot stored in an unheated area or shipped during cold temps then brought to room temperature. As the air in the oil/grease chamber expands, the increased pressure can cause some oil to force past a slightly worn seal.

Cable seals and other seals keep external debris and liquid out of motors and the internal portions of the robot.

Please re-read post #8 by Skooter.

Taking the motor apart may have made it harder for a motor shop to align it unless they're familiar with this type. I recommend replacing.

If you have the ABB part #, that should be all you need. Axis 2 motor is the same.

ABB had multiple vendors for the gearboxes with different motor pinions. Double check the pinion is the same on the replacement before you install it.

Quote from Alan Justice

Hello guys, recently I installed ABB 1600 (2013) version (it was second-hand) for laser cutting. It's give very often error 50055 "joint load to high" on axis 1 in manual mode, i tried to decrease the speed up to V50, looks like it's working but this speed is too small for robot working in auto mode, moreover, this error repeating often, even when I move it manually by joystick it give this error

Can you guide me on how can i fix this issue, please

I've checked troubleshooting manual, here what is writen in the book:

Description 50055:

Actual torque on joint arg too high. Might be caused by incorrect load data, too high acceleration, high external process forces,low temperature or hardware error.

Recommended actions

Check load data. Reduce acceleration or speed. Check

hardware

P.S. Please consider that I have installed new laser head (tool) and new height controller and new laser source.

I really appreciate any help you can provide.

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There may be a weight definition, the tool weight may be incorrectly defined. The robot may have been loaded with more load than it can handle.