Posts by SHIFT_Lock
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Do you have an idea of where the zero position of the 7th axis should be? If so it's easy to change and only takes a couple minutes or less. I just had to establish a new zero on our linear 7th axis due to a gear failure. Also is your 7th axis in Group 1 or Group 2?
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shift_lock were you able to figure out how to get your TP to stop going to user screen? I'm having same issue with a new Rji3b that was just installed by intergrators.
Unfortunately not long after I made this post those two robots got moved to one of our other buildings and someone else is over them now.
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Instead of calling two separate sub programs you could use a RUN command to start the turntable. Ours is setup in G2 which there should be a few posts in the forums about how to set this up. As far as the RUN job goes though:
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2: ! G2 Spin
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4: RO[8:During spin] = OFF
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6: LBL[111]
7: J P[1] 10% CNT100 CTV80
8: RO[8:During spin] PULSE, 0.2sec
9: IF RO[7 Spin stop req.] = OFF,
JMP LBL[111]
10: RO[8During Spin] = OFF
11:
12 J P[2] 50% FINE
13:
14: END
[END]
At the end of our main job we flag RO[7 Spin Stop Req] to let the run job complete. Ours is setup as a milling chuck so positional data isn't of any concern. And we are setup at about 16,000deg/sec for that axis I believe which is roughly 2600RPM's.
Quote from HawkME
If you don't need position control, then I would set it up as a Process Axis. That gives you speed control only, but it is very simple. You don't have to teach points, you just give it the rpm you want and it goes. Perfect for spindles, conveyors, pumps, etc that need precise speed control but you don't care about stopping at an exact angular position.
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Also can be a problem, if your usb is bigger than 4gb
I usually use a 2GB USB stick myself. But I have talked to people that have used larger ones without issues too.
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Best bet is to have a USB with nothing at all on it as it's a lot easier to do. Otherwise you need to create a folder and select it through the robots file menu. I'm going to PM you with some info on how to do this automatically using a command file that i've found on these forums.
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You can't take an image backup from the USB port on the TP it has to be plugged into the controller USB port for an image. Make sure your USB is properly formatted to FAT(32) you can do this on a PC or on the TP itself. Then plug it into the controller and follow these steps.
MENU>FILE>1.FILE
F5 for Utilities and select 1. Set Device
Select USB Disk (UD1:) which is the controller port.
Then hit F4 [BACKUP] and select IMAGE
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Any chance you could hook up the aux axis and tie it up out of the way just to clear the alarms and move your robot? We have a robot with two motion groups that is now re purposed as a temporary material handler and just made a bracket to hold the servo allowing us to leave it plugged in. I know you said yours was broken off of the gear box but if the cables are undamaged this would work.
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Code
Display MoreSRVO-023 Stop error excess(G:%d A:%d) Cause: When the robot stopped, the servo positional error exceeded a specified value ($PARAM_GROUP.$STOPERLIM). This alarm means that the robot cannot reach a taught point or cannot keep a taught posture. Probable causes: 1. Overload 2. External force to the robot 3. Disconnection or misconnection of the motor power cable or brake cable 4. Incorrect setup for the robot which has 2 axis brake option 5. Insufficient torque by low voltage of power supply 6. Brake failure (includes mis-setting of brake number for auxiliary axis) 7. Aux. brake unit failure for aux. axis 8. Amplifier failure 9. Motor failure 10. Motor power cable or brake cable failure Remedy: 1. Check whether the duty and applied load exceed the rating. If so, reduce the duty or applied load.
If this is indeed a new setup then most of this probably doesn't apply except as pdl stated, your robot is overloaded.
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Like I said earlier I have never had any training or anything on this. But there are 2 groups, we have a table on one side and a rotary on the other. I keep G1(Table side) WORLD active when I do the calibrating.
There's your issue then. you need to also master and calibrate G2. This is why you are receiving the MOTN-049 alarm.
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Can you tell us a little more on your calibration process? As dha stated you need to be sure to calibrate any external axis such as something in group 2. if you open the Master cal screen in G1 and open option 4 for single axis mastering do you have a value of 2 under the (ST) column? I would assume you do or you would also be getting a SRVO-075 Pulse not established alarm.
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As long as power was never turned off to the robot you shouldn't have lost mastering. Be sure that the batteries are indeed good in the base of the robot and installed properly then you need to clear the pulse coder alarms. In order to do so you need to go to MENU>SYSTEM>MASTER/CAL. Once in this menu you will see RES_PCA above the F3 button. Hit F3 and it will ask you if you wish to reset the pulse coder alarms and hit F4 for yes. Next hit FCTN>0>8 and it will ask if you wish to cycle power and select yes. Once booted back up your alarms should be cleared. Again if your batteries are not good and properly installed and you cycle power you will loose mastering for sure. Also if you don't see the MASTER/CAL option under MENU>SYSTEM you will need to go to the MENU>SYSTEM>VARIABLES and find $MASTER_ENB and change the 0 to a 1 and hit ENTER, I usually have to cycle power after changing this variable for the MASTER/CAL option to pop up.
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Are you using Program Select as STYLE and Start as UOP? For style 35 did you have UI 9, 10, and 14 coming on? And then UI 6 to start? You could try checking out $SHELL_WRK.$CUST_NAME and see what is there. Also under System Config are you using local or remote?
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I've been messing around with one of our Robots and changing things in the controller and the PLC to see if I can mimic your error but no luck so far. I've been able to get SYST-069 Program number out of range, SYST-070 No program name in table, and SYST-072 Program not enabled to come up but not SYST-073. I'll keep messing around with it and let you know what I come up with.
I assume when you say that the bits for style selection are coming from the PLC ok you're referring to UI 9-16 coming on accordingly to match the STYLE number?
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There is a standard macro called GET_HOME. This will copy the data from the first reference position, to the first position register. When you re-teach the new home position, also re-teach the reference position.
This is what i was thinking of when asking if he had a reference position setup. I ran into this issue on one of our robots in another department but the Reference position was all 0 so it set PR1 to all 0 and would cause a crash.
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Is there a Reference Position setup with the same position data as your first PR? I've not really messed with BG Logic but couldn't that be used to overwrite PR data? HawkME had some great advice using the robots web browser to see where that PR is used in each program. it would be a lot easier than trying to skim every job for it.
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Please check here for a download link.
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Look in this thread. There is a download link in it.
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I believe our engineer is just as curious as the rest of us (only 4 of us in my department) but another issue we have is overtime has been completely cut for the time being. I'm hoping that here soon the overtime will come back and we will be able to come in on a weekend and pull the other three cables off the robot to start testing. I know the cable from ARP2 to the 7th axis encoder is ok because we've been through at least 9-10 of them probably and chances are slim that they were all bad. We actually kept three of them on the robot and would swap back and forth between them each time the alarm would occur. The cable from ARP1 to the controller should be ok as it just lays in a cable tray but I wouldn't rule it out completely (we ran a new one of these too). I do know that we will be holding a couple of these new one piece cables on hand for future occurrences so that's a plus!
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Thought I would just add a post as this thread has made for a very interesting read, not only in the problem, but also the progression of troubleshooting it to.
It would be very nice to categorically prove the internal harness is at fault and I would offer the advice of using a megger to test it's integrity, should you have the time and availability to do it.
Obviously disconnect both ends and carry out tests across all signal conductors associated with the pulsecoder, with any luck, should yield a result in line with the applied solution.
From what I have read, I think this would give you peace of mind that this fault has indeed been located and resolved.
This has been a great thread to follow (not that I have been able to assist in any way with as I am new to Fanuc).
But has given me some great troubleshooting tips I will pop in my toolbox for future reference.
Thanks for sharing this SHIFT_Lock and all those who contributed.....
I've used meggers before in the electrical field but unfortunately as far as I know we do not have one where i'm at now. Although if given an opportunity I would love to remove this cable and test it to determine for sure it was the problem seeing as how this cable replaced three cables and all connectors on the robot. Kind of makes it hard to narrow it down to what the specific problem was. If we get the chance to do this I will update further but I think for the time being we are just happy to be back to full production with no more nuisance alarms!