At my plant, we have a Kawaskai cell that was build and programmed by a pretty amateur team.
That's quite a bold statement to make, saying you are coming from a Fanuc world and not Kawasaki.
When the robot has a fault, I noticed the in the PLC program there's a bit coming from the Kawasaki robot that is labeled " Un-resetable fault" Does any know of a fault from Kawasaki that is un-resetable?
Yes, there are lots of un-resettable faults that exist and I assume all robots will have faults which cannot be reset too - hardware failures, encoder signal loss, low voltages, cpu failures etc.
In the troubleshooting manual, you will find the listing of errors, resettable status and action upon error codes produced.
As for the term used in the PLC.......there's only one line of enquiry there and that is to ask the 'team' whom programmed the PLC, but I would choose my words more selectively if you want to get a positive response from them.....You never know members of that team could be members here on the forum.
The Kawasaki can be configured and programmed to send a dedicated error signal, or by a programmatical route where a PC Task is evaluating the error code produced and setting bespoke signal(s) relative to specific error code returns.
You would need to look at the Kawasaki file save in order to see how this is being done though as opposed to just looking at the PLC side.
There is also the other alternative, what they have written may in fact be 100% correct, but the only real way of knowing is to look at the Kawasaki code.
Hi,
In the Kawasaki manuals, errors will have code that is started with a letter and 4 digits. With each being classified as acceptable, or non-acceptable (read resetable or not-resetable) with non-acceptable errors with issues that cannot be reset without the issue being addressed and isn't likely to be a temporary state. Will usually require at least a power cycle, but might be indicative of serious issues. An example might be like this header (can't post the full page for obvious reasons).
Check your logs on the controller for errors and verify in your manuals. I'm wondering if you have some mislabeled tag on the PLC based on a dedicated signal from the robot if it's not a serious issue.
That's quite a bold statement to make, saying you are coming from a Fanuc world and not Kawasaki.
Yes, there are lots of un-resettable faults that exist and I assume all robots will have faults which cannot be reset too - hardware failures, encoder signal loss, low voltages, cpu failures etc.
In the troubleshooting manual, you will find the listing of errors, resettable status and action upon error codes produced.
As for the term used in the PLC.......there's only one line of enquiry there and that is to ask the 'team' whom programmed the PLC, but I would choose my words more selectively if you want to get a positive response from them.....You never know members of that team could be members here on the forum.The Kawasaki can be configured and programmed to send a dedicated error signal, or by a programmatical route where a PC Task is evaluating the error code produced and setting bespoke signal(s) relative to specific error code returns.
You would need to look at the Kawasaki file save in order to see how this is being done though as opposed to just looking at the PLC side.There is also the other alternative, what they have written may in fact be 100% correct, but the only real way of knowing is to look at the Kawasaki code.
I meant no offense. I am a Fanuc integrator, but I have also set up Denso, ABBs, and Kukas for over a decade. As the saying goes, "Truth has no agenda". When I called them an amateur team, I meant to report the situation factually. Its this teams first Kawasaki robot cell the have ever set up, and first PLC project.
There's a lot of "standard" things Ive always programed on my cells, that this cell is missing. Like an automatic homing routine and sequence reset.
I'll take a look at the robot logs and see if I can see what the error code is. I have noticed you can reset the error code on the pendant, and not the PLC. So that tells me the fault at least doesn't need a power down.
I have also notice that they are resting the faults by latching on a bit, instead of oneshoting it. The Kawasaki manual seems to spell out a OFF-ON-OFF sequence. Almost like it needs to see a falling edge.
Thoughts?
Remember not all integrators are the same.
Some integrators know the product very well and then employ advanced techniques relative to the specific product in order to handle some very basic tasks.
Some do not have specific product knowledge and use templates from a previous installation using different OEM supplied kit and then fudge the templates to suit.
Coupled with the assumption that all robots are the same and therefore consider reading manuals or undertaking product training beneath them.
Dedicated signal descriptions and handling them are explained in the external IO manual.
Error codes, actions, results and descriptions are explained in the troubleshooting manual.
Kawasaki errors will generate an error window on the teach pendant, set the dedicated error output signal (if used) and activate the error output relay on the power sequence board.
Then require some form of reset action.
Resetting the error can either be via:
- Pressing reset on the error window screen. on the teach pendant.
- Pressing reset on the minimised window screen on the teach pendant.
- Pressing the 'R' key twice on the teach pendant.
- Setting the external error reset input using a pulse duration of 0.3 - 0.5s
- Sending ERESET command to the controller.
ERESET and Error resets can be handled in many unconventional ways using advanced techniques within the Kawasaki or via a simple error reset dedicated input pulse for the required duration stipulated in the manual.
So you really need to ascertain:
- What an 'error' is when it is produced by the Kawasaki, and the consequence of the error.
- How the error output is configured and handled in the Kawasaki.
- How the error reset input is configured and handled in the Kawasaki.
You cannot learn how this is from the PLC side or use the forum as a substitute for product training.
Ah ok....
FYI - ERESET is a command in the Kawasaki to reset the error in the Kawasaki which can either:
- Be typed directly using the built in keyboard.
- Be used directly in a PC Task within the Kawasaki.
- Be executed by way of external error reset signal, or via teach pendant.
Do you know where this 'output bit' is coming from on the Kawasaki then?
- Hardwired from the power sequence board.
- Hardwired from the digital IO board.
- Fieldbus signal.
Can you provide a Kawasaki file save at all for me to look at?
- you can send via 'conversation' if you do not wish to make public.
This sounds like a possible overall reset/restart sequence to me.
