Posts by M.Ozkan

Yes, we mostly use similar logic to troubleshoot failures, and I wouldn’t consider myself inexperienced in such situations. However, the actions taken so far are not leading to a solution.

By the way, the motors are not attached to the mechanics; I am testing them separately. This is because when they are connected to the mechanics, the exact situation cannot be fully understood.

The strange thing is that there are no issues with the large motors at all. This makes me think that the difference in dynamics and response between the small and large motors might be the cause. However, I would still expect a sensitive component like a servo motor to respond similarly with vibrations.

I ran the motor idle for about an hour, and it didn’t even heat up at all.

Quote from panic mode

Since it does not squeal when larger motors are used, it must be wrong MADA or wrong motor data. Delete robot from wov project then add It again from correct catalog

Hi panic mode and SkyeFire:

I know that the motor data is incorrect. However, I only installed a different motor for the cable test, and interestingly these motors are working while the original ones are vibrating. We tested with motors of the original code but the result did not change they are also vibrating.

The robot has a history of continuously operating in mass production, performing simple transportation tasks. I did the installation myself 3 years ago and until now there have been no issues. The customer reported that there was noise coming from the motor and that they encountered high current faults on the A4 axis. Based on this we intervened but due to the limited space we had to remove it and it is currently in our workshop.

There is no untested component left in the cabinet that could be related, except for the Mains Filter which we haven't tested. However, logically I don't think this could be the cause.

The situation has evolved into a rather strange point. The KPP and KSP have been replaced in the control panel. The RDW has also been replaced. However, the whistling sound and vibration still persist.

What's odd is that I'm only experiencing issues with the 4th and 5th axes. When I replace the 4th and 5th axis motors with larger motors, all problems disappear. Specifically, when I replace the original 1FK7032 motors with the 4th and 5th axis motors from a KR210, the vibrations stop. The motors rotate normally.

This could lead to the conclusion that the original motors are faulty, but those same motors work perfectly fine on other axes. I also replaced the cables between the control panel and the robot, but the issue remains unresolved for some reason. Of course I measure normal values on PE and phase lines.

Logically, there are no other components left to replace. The ballast resistors show normal values. The MADA is in its original state, and I have tried several different software versions. However, there is still no solution.

SkyeFire, thank you so much for reasoning through the issue and trying to help. The problem has become a bit more complex. I've already disengaged all the motors, and they have no mechanical connections between them. I tested the motors on another robot, and they run smoothly. I'm also testing the other components separately. Right now, the only thing left is the internal cable bundle, which I will remove tomorrow, but I can't evaluate this within a logical framework.

Hello panic mode

Thanks for clarification.

The robot is not newly installed; it has been operating on the production line for about three years. So, there is no software issue. What makes the situation interesting is that three motors are vibrating at a similar rate, and the issue is not caused by the KSP or RDW

Hello,

I am experiencing a very strange issue with a robot I have. The robot is a KR5 with a KRC4 controller running KSS 8.5.7.

When I command movement on the 4th axis, it rotates but then starts making a whistling sound. After rotating for a certain period, the motor stops with a "Gear torque" error. Along with the sound, there is a high-frequency vibration. Even when the motor is not rotating, this vibration persists as soon as power is applied.

At first, I suspected a mechanical issue, but when I removed the wrist, I realized that the same situation occurs on axes 4, 5, and 6. However, the whistling sound is only present on the 4th axis motor, while the others only exhibit high-frequency vibration.

All motor brakes function correctly, and the measured cable values appear normal.

The KSP module for these axes works fine in other robots.

I checked the connectors, motor cables, and encoder cables one by one but not found abnormality.

Motors have been tested and are in good condition.

The RDW is fine.

The wrist is fine, yet the motors vibrate when idle.

Despite all values appearing normal, I suspect internal cables, but honestly, I'm stuck at this point. The probability of all three motor cables failing at the same time doesn’t seem make sense.

Does anyone have any ideas?

Under normal circumstances, Siemens is not a PLC designed for Ethernet/IP and optimal performance. However, you can check your RPI settings. A value of 32ms is recommended for both communication and stability. If you still encounter latency issues, unfortunately, there is not much that can be done. In such cases, you may need to choose a PLC specifically developed for this purpose, such as Allen-Bradley, Omron, or Beckhoff.

Post

RE: Fanuc RTL-R538-HT Ethernet IP communication to Siemens s71500 PLC

[…]

I don't know what the code 'RTL-R538-HT' refers to, but you can communicate with Siemens PLCs between Fanuc using Ethernet/IP Adapter or-and Scanner option packages. However, it's important to note that Siemens PLCs are not natively designed for the Ethernet/IP protocol. They have certain limitations in this regard. If you want to use a genuine Ethernet/IP device, Rockwell PLC (Allen Bradley) or Omron would be excellent choices for this purpose. With Siemens PLCs, you should avoid using low…

M.Ozkan

July 27, 2024 at 12:20 AM

Send your e mail address to pm

I used Advintec with a Fanuc robot, but I did not find it very successful. The scripting and commissioning process was quite troublesome, and I did not receive adequate technical support. Even though I managed to get it working somehow, it is not a product I would prefer again. If you need the latest manual, I can help you.

Quote from panic mode

unfortunately, i don't think he visited forum in a while (months).

No, I am usually here but due to some copyright concerns, I didn't find it very appropriate to release.

Quote from Aqprox

Hello, I have a strange problem. After power shut down the CR4 motherboard Fujitsu-D3445-K1 (Skylake) can't start/boot from internal PSU. 27V is ok at connector. Appear the HW MON Fault red, but Green led is ok close to cmos 3V battery. And 3.3V on LDO is ok Close to CMOS battery. CMOS battery changed. When Main power switch is on, spin up the CPU cooler 0.5sec (power from mainboard) and stop, but thats all. Anyway other parts(Robot control etc) looks like works well.

If try external PSU (ATX connector) That is start booting normally ..Bios windows etc...looks like good.

Where find Motherboard manual PDF?(details)
Anyway How is start the Mainboard? Like Wake on lan?
And found an jumper close to lan ports, what is that? Where is the Bios/cmos reset?

What should be check or set in bios?
Where can I find Bios update file?(fujitsu hompage just D3445-S)

Thanks

Probably the motherboard is faulty. Under normal conditions, when you turn on the power, the motherboard should automatically start.

"Where can I find the Motherboard manual PDF? (details)"

You cannot find the exact manual because the motherboard is custom-made by Fujitsu for KUKA. You can found similar models.

"Anyway, how do you start the Mainboard? Like Wake on LAN?"

If the BIOS battery is dead, the default BIOS settings will be lost. In an emergency, you can use the PW_ON pins on the motherboard. You can achieve the same result by connecting the purple wire and the black wire on the ATX power supply.

"What should be checked or set in BIOS?"

Generally, you cannot enter or change the BIOS settings because it is protected by an unknown password set by KUKA.

"Where can I find the BIOS update file? (Fujitsu homepage only shows D3445-S)"

Do not try this, as the motherboard is equipped with a special firmware customized by KUKA and optimized for the correct operation of the system. Even if you manage to update the BIOS somehow, your motherboard will be useless. KSS reads the motherboard versions and HW codes and decides whether to start the system. Do not try this!

Quote from silverF4NG

Hello Guys

I have a simple material handling application where I need to share bits, integers and perhaps strings values to a s7-1500 PLC, I'm starting with Fanuc robots so perhaps my question is very basic but I still want to know before moving an used robot in a warehouse to site, my question is the next:

Can I communicate a Fanuc R-2000iB /controller R-30iA with RTL-R538-HT (Ethernet IP) option to a Siemens s7-1500 PLC using the LCCF_EnetScanner function ?? , I just want to be sure that this was done before and I can share bits/integers and perhaps strings, I found this information in Siemens website regarding the LCCF_EnetScanner function, link below

https://support.industry.siemens.com/cs/document/10…?dti=0&lc=en-US

Regards,,

I don't know what the code 'RTL-R538-HT' refers to, but you can communicate with Siemens PLCs between Fanuc using Ethernet/IP Adapter or-and Scanner option packages. However, it's important to note that Siemens PLCs are not natively designed for the Ethernet/IP protocol. They have certain limitations in this regard. If you want to use a genuine Ethernet/IP device, Rockwell PLC (Allen Bradley) or Omron would be excellent choices for this purpose. With Siemens PLCs, you should avoid using low (low=fast) RPI (Requested Packet Interval) values. Additionally, you cannot run different protocols on the same port simultaneously (e.g., sharing Profinet and Ethernet/IP). If you are not handling highly critical timing tasks, Siemens will successfully perform the job. Additionally, you cannot send a string structure as a whole to the robot. This is only possible by encoding it byte by byte and transferring it in the form of characters. This process takes up a lot of space, and string conversions due to ASCII encoding are quite difficult.

Asking a question requires as much knowledge as answering it. A question that lacks information or is superficial is generally not worth answering for someone with experience.

Quote from RoboMan3000

M.Ozkan Thanks for the advice! I figured the devices from ebay would probably arrive without the memory card inside... lol. Regional Beckhoff hasn't called me back for 3 days now!

Do you configure the EL6910 as a master in Twincat3 or Workvisual? I've never done a mastering/slaving process before.

We're interested in the most cost-effective solution for now, so that would be great.

The additional hardware components needed for safety over EtherCAT are a CX---- IPC from Beckhoff?

Beckhoff CF or Cfast card is required and usually destroyed by the seller due to copyright issues. You can obtain the factory image of the card with its article code from Beckhoff, but this is entirely at their discretion and may not be available. In terms of licensing, Beckhoff generally prefers to sell hardware along with the license rather than just the license itself. This means that, for example, if you purchase a product without a PLC license and later want to buy a PLC license for it, it might be more expensive than purchasing a product that already comes with a PLC license from the factory.

EL6910 will be configured on the TwinCAT side and programmed within TwinSafe Logic. You will configure the settings of the robot, which is a Profisafe Slave within Workvisual, and this is usually quite simple.

For EtherCAT (FSOE), you must purchase a special EtherCAT bridge from KUKA, not Beckhoff as far as I know (brand is Beckhoff but only can buy from KUKA). This is because the KRC4 does not work by default in EtherCAT slave mode and needs to be run as EtherCAT Master<->Bridge<->EtherCAT Master. In my opinion, this method may not be preferable in terms of ease of implementation and cost. Additionally, in any case, you should purchase TwinSafe Logic, which will incur additional costs. If Beckhoff is not mandatory, I recommend considering Siemens 1214FC or 1500F series for less than half the price.

Devices purchased from internet probably do not include the necessary licenses. In this case, providing these licenses for the respective device will be more expensive than buying a new device. Regional Beckhoff will provide you with the best assistance in this regard. While KRC4 supports Safety protocol via EtherCAT, additional hardware and components are required. Instead, if you use Beckhoff's TwinSAFE Logic modules like EL6910 as Profisafe master, your costs will be lower than ethercat.

Quote from jokababb

Long time since you wrote this but do you have all Boot discs? I'm searching for 3hab2312

I don't have it. ABB setup disks are usually not compatible with each other. There are often issues with options and licenses. Therefore, the safest way is to contact the local ABB office and obtain the original key disks with your serial number. It is not free. Or if you have old backup you can generate with RobInstall software (for S4C and S4C+)

RPI for PLC side. Use "packetinterval" parameter of Function block. You can found parameter in instance DB of FB. If you using RPI less than 32 connection problems occured randomly. Because Siemens PLC is not powerfull CPU for Ethernet/IP

Quote

I have spoken with fanuc and they have said that its probably a problem with the LCCF block of Tia Portal. It seems that they have had more problems with this library of Tia Portal.

Tia libraries of Ethernet/IP working very well. You should make settings correctly in TIA program. Call program in Cyclic Interrupt OB. Use RPI >= 32 ms.

This problem has numerous causes. For example, if SmartHMI.exe stops working, it disconnects the KCP connection. If the PC restarts, the connection is disconnected. In case there is an issue on the Ethercat line, the connection is lost. If the PC cannot catch up with the vxwin cycle time, the connection is lost. The easiest method to identify is to take and examine the logs with KRCdiag.

Seeing a gap can have many reasons. Among these reasons, it can be related to the gearbox, RDW card, driver package, motherboard, parameters, or even cable problems. Based on my previous experiences, even though we replaced the gearbox, the gap persisted due to an issue with the RDW card. If you are confident about the mechanical condition, you should systematically check the other components.