W1016 Faults after software update

    We recently got a software upgrade on all of our Kawasaki controllers and after the update all of our T02H-D041 robot controllers started alarming out with a W1016 (Torque of motor is over limit; Jt#). I turned off the current saturation alarm in zoption_6 for now but we really need this setting to remain on for multiple reasons.

    Is there a function that I can use that will auto calculate and save new nominal torque values for all joints after running it through its normal job? Possibly just a way to change the upper limit torque values on each joint?

    I haven't been able to find anything in the manuals or forums about this issue, so any help is appreciated. Thanks

    Toyota Indiana

    Controller: T02H-D041

    Robot Model: HR050N

  • massula March 17, 2025 at 10:57 PM

    Approved the thread.

    Welcome to the forum..............:beerchug:

    Unfortunately I personally have never come across this style of controller or arm.
    The only advice I can offer is suggest reporting this to Kawasaki (KRI - USA branch) directly so they can investigate it further.

    Upgrading firmware always carries risks and I'm surprised at your situation as from memory, Toyota used to follow strict standards for firmware upgrades and always collaborated with Kawasaki prior to doing so.

    Quote from ToyoKaN

    Is there a function that I can use that will auto calculate and save new nominal torque values for all joints after running it through its normal job? Possibly just a way to change the upper limit torque values on each joint?

    I'm aware of zoption_6 on standard E controllers where you can enable:
    'frecast of inspection'.
    This allows for enabling failure prediction and set new base data.
    May be worth exploring if this function exists.

    It could be these base values need to be refreshed after a firmware upgrade.

    I believe this exists in T controllers too.
    Information on the actual screens is usually available in the operations manual.

    Thank you, I am able to see the frecast of inspection option and I'm currently looking into it.

    Also yes we do collaborate with them prior but I was not involved in that over the weekend. However our engineering team have tried getting someone from Kawasaki to come back out to look into this but it seems our guys dropped the ball which is frustrating to say the least.

    Quote from ToyoKaN

    Also yes we do collaborate with them prior but I was not involved in that over the weekend. However our engineering team have tried getting someone from Kawasaki to come back out to look into this but it seems our guys dropped the ball which is frustrating to say the least.

    My previous experience with Toyota here in the UK, firmware upgrades would have been supplied with specific procedures from Japan and usually would have had an engineer over from Japan in support too.

    The arm wouldn't happen to be similar to the older SR version that ran on S Controller would it?
    If it is, then documentation would be hard to find and restricted to Toyota as I believe those types of arm maybe exclusive to Toyota only.

    Hope you can get it sorted..........:top:

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