Have checked for the robot mounting? Whether the bolts are torque tight? I had similar issue with Repeatability in pick and place and found one of the mounting bolt was loose as the robot was installed at shop floor for testing purpose and not at End-Customer.
Also check for Payload calibration of the tool. If its not done properly or entered approx. values then also you might face this issue.
Display MoreRegular usage and exacerbated with collisions can result in 'loosening of bolts, fixtures' and is always top of my list before diving into code.
By reducing the speed of the robot, if this was the case could result in the total displacement changing also.
But, it appears not to be the case in this instance.
Seems a little 'sledgehammer to crack a nut' in order to rectify it, as there doesn't seem to be an answer to the problem.....
What have Fanuc actually done, have they explained - ie version upgrade, software revision etc
Yes your are right!!!!
No updates from FANUC what exactly did they do with the Image backup. But yes some software package they mentioned about which they installed.
Now i yet dont have exactly what software package have they installed or any particular updates. But yes they said they tried running it on a robot at their warehouse, tested and then sent back for us to test here. Today whole day we didn't had any crash or deviation.
But yes, tomorrow we would be trying full fledge continuous run of the machine and robot just to make sure that issue has been resolved. Once confirmed will update what exactly did they have done in the Image backup.
Thanks for you valuable inputs.
Display MoreAny deviation of that scale, before investigating code, I would always check physical mountings.
Go around all physical mounting points and make sure they are all tight and secure.
- Robot mounting points
- EOAT mounting points
- External fixtures
Can you slow the 'repeat speed' down, if so does this effect the distance of shifting.
Thanks for that, and its very important.
Yes, definitely there was loosening of bolts of pedestal where robot was mounted. Secured them back with torque tool but still that issue persisted.
After tightening the deviation was reduced however, we still had that random deviation in positive x or y direction or negative x & y direction.
No reducing the speed didn't change the scale of deviation or changed the distance of shifting.
But yes, I had sent image backup and All of above backup to FANUC and they sent an updated image file.
Loaded that and restored the All of above and took trials. Its didn't crash or loose its path now for around 30-40 cycles that we did today.
Could you post the program before line 75 ?
Is it possible that the PLC sends you a 1 and right after a 2 or even both at the same time ?
Have you tried the program always using the same option from the PLC ? Somehow block place 2 on the PLC and work only with place 1
Hey, yes definitely find the attached LS file of the whole program.
Yes monitored for PLC sending place position and its sending 1 & 2 respectively every time.
No haven't tried with only 1 position.
But yes, I had sent image backup and All of above backup to FANUC and they sent an updated image file.
Loaded that and restored the All of above and took trials. Its didn't crash or loose its oath now for around 30-40 cycles that we did today.
When you say "placing randomly" , Is the robot getting coord from a PLC ? Could it be possible that the values of the PR are changinf while the robot is moving from A to any one of the other two points
When is the value of R[32] update ?
Yes, the place has 2 positions which is decided by the PLC. If position 1 is selected then PR[R(32)] has a value stored in PR[10] & if position 2 is selected the PR[25]. These 2 PR has fixed location. depending on location 1 or 2 received from PLC it chooses PR[10] or PR[25] which has fixed coordinates.
DB means distance before. On your first point, it is saying to call VAC_OFF 20mm before you arrive.
Also, indirectly addressed PRs? ew.
What is the magnitude of your repeatability error? I am not aware of this ve nomenclature.
Yes, the place has 2 positions which is decided by the PLC. If position 1 is selected then PR[R(32)] has a value stored in PR[10] & if position 2 is selected the PR[25]. These 2 PR has fixed location.
+ve & -ve, I mean to say positive & negative offset. The repeatability error varies from 10 - 35 mm.
Hi,
I am facing issue with Fanuc M10iA ID/16S manipulator and R30iB Plus controller. Its used for handling application (Pick and Place). The payload of the tool is 1 kg and product weight is around 150gms. The robot picks part from Point A & drops at Point B or Point C. There is no issue while picking part from Point A but while placing randomly sometimes the robot shifts its place position in X and Y both directions. The offset is sometime +ve & sometimes -ve and this offset is random. Out of 6-7 cycles, we get this repeatability error, collides with fixtures and stops with collision error.
Kindly assist me in resolving the error. I also noticed new parameter as shown in the image highlighted with yellow. Please help me with understanding DB 20.00mm & 10.00mm parameter also.
What I have observed is, when there is change in acceleration and approximation, robot tends to stop at that point and continue. If you want to have smooth motion without stopping but want to vary approximation or acceleration then you should always keep both acceleration and approximations in the ratio of 1:1. You will have smooth motion without stoppage.
Exactly right.. The root cause for this error was due to empty counterbalance. The robot was already installed and covered with fire jacket due to which we missed out to check for it... Thank you so much for your assistance.
Well I guess,
On the right side of the IO mapping screen, You must select the fieldbuses and select the already assigned field device from which the communication is gonna happen.
Set the field bus to the HMI from which you gonna send and receive inputs and outputs. IO map with respective robot IO's and download.
You must be able to control from your HMI then.
Hello,
Yes you are right. There is overload problem in the old robot too. Only thing is we don't get that pop message and robot dosn't stop. But we can see the sagging effect and after every 3-4 days the robot has to be re-teached for the production to go on.
We are in contact with the KUKA person and he says that there is no issue with the overload, but it might be some current or mechanical issue. The KUKA service engineer is suppose to be here, but not yet.
We have sent the KRCDIAG of both the robots, Mechanical zero posn pics and Latest archive to the KUKA team, But no response from them yet.
We have also sent the robot controller and robot manipulator's serial number to the KUKA team.
Hello,
Thank you so much for your valuable advise. I got the software and put in the values. I appreciate your help Panic Mode.
KUKA.Load says that the robot is Statistically Overloaded. Please find the attached screen shot.
But the thing is exactly the same robot and same design and same weighing tool is been used at the site. we find no errors or robot stop due to Current Overload error.
Kindly advise.
Hello,
Thank you for the suggestion. But i am not able to find the KUKA.Load file in the http://www.kuka.au or http://www.kuka.com
Tried increasing the load, but no change. Error still pops up. KUKA service engineer shall be visiting over here and check for the solution.
I am also getting a new error KSS26014 "General Power Supply Error".
Hello,
Please find the attached load data for the tool[11] which is for slag tool.
The attachments are as old robot load configuration for old robot data and tool load data for slag for new robot.
Let me know if you need any further information.
Hello,
I am working on KUKA KRC4 robot controller and KR500R2830 C4 FLR robot. Its a handling robot with 5 different tools for it. One tool is used by the robot each time. Robot gripper weighs : 81.19Kgs
1. Temperature tool which weighs : 100Kgs
2. Ground tool which weighs : 083 Kgs
3. Lance tool which weighs : 083Kgs
4. Spoon tool which weighs : 100Kgs
5. Slag tool which weighs : 282Kgs
When I run the program for first 4 tools i.e. Temperature, Gorund, Lance, Spoon, The robot seems to be perfect and fine in all modes(T1,T2, Auto & Auto Ext) and for all speeds.
But when I try to run the Slag tool, I get this error "Current Overload after 60.0 s (A2)(Holding Current)" for few couple of seconds and it goes off. Then pops up the error acknowledge "Ackn. Cyrrent Overload after 60.0 s (A2)(holding Current)". when I acknowledge this message, then i am able to continue my program.
This error we get when we run the program in T1, T2 or Auto Ext mode randomly at any motion point (not particular to any fixed points). We don’t get this error when we are jogging the robot with the tool in T1 mode from 1% to 100% speed. and this is only for particularly the fifth slag tool.
Astonishingly, we have same setup with same configuration robot (100% identical) running in the same plant with same tools(weight and design) and it works completely fine. with no errors or issues of current overload.
I tried finding the remedy for error code but no solution for error code: KSS26011 and acknowledgement error code: KSS26010.
Kindly find the error pic I have uploaded.
Any resolution, please let me know.
Thanks & Regards,
Niks 
