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Industrial robot fault and repair methods

2020/7/28      view:

Take Fanuc robot as an example: 1 can not be turned on to check and repair: check 1: kzq circuit breaker is on and does not trip maintenance: close circuit breaker to check 2: check whether the LED indicator (GREEN) on the power board (PSU) is on. Maintenance: If the LED indicator is not on, it may be that the 200V power supply of PSU is not available or the F1 fuse on PSU is damaged: 1 If the 200V power supply is not available, please check the power supply line. 2 If the 200V power supply has been provided to PSU, please cut off the power supply: A F1 fuse is damaged please refer to maintenance 2 B F1 fuse is not damaged please replace the PSU Maintenance 2: Failure causes of fuse damage and countermeasures A Check whether CP2 and CP3 connectors between the PSU and other circuit boards are in good contact. B If surge absorption VS1 short circuit please replace VS1 Order No. : A50L-2001-0122#G431K C two j tube DB1 Short circuit D Backup power module H1 damaged If B or C is faulty please replace the corresponding spare parts... Check 3: Check EXON1, EXON2, EXOFF1, EXOFF2 signal wiring maintenance on the panel board: if no external switch function is used, please short connect signals EXON1 and EXON2, EXOFF1 and EXOFF2; If the external on-off function is used, check the connecting cable. Check 4: The JRS11 cable on the panel board is in good contact. Check 5: Check 1, 2, and 3 above to ensure that the 200V power supply ON CP1 is properly connected and the ON/OFF switch of the machine is normal. Check the PSU as follows: If the LED (ALM: red) on the PSU is on, check whether the external +24V is grounded or connected to 0V. A F4 fuse is destroyed B Replace the PSU F4 fuse Order No. :... 2. Use the LED indicator of the control BOARD to diagnose and rectify the fault 2.1 MAIN BOARD Step 1 After the startup of the MAIN board, all leds light up.1 Replace the CPU card. 2 Replace the MAIN board BOARD Step 3 Complete DRAM initialization and maintenance when the robot system starts. 1 Replace the CPU card. 2 Replace the MAIN BOARD. Step 4 Complete DRAM and SRAM initialization and maintenance when the robot system starts BOARD 3 Replace the FROM/SRAM card Step 5 Communication IC initialization is completed when the robot system starts. 1 Replace the MAIN BOARD. 2 Replace the FROM/SRAM card BOARD BOARD 2 Replace the FROM/SRAM card Step 7 Repair the MAIN BOARD when the robot starts the basic software 1 Replace the MAIN BOARD board 2 Replace the FROM/SRAM card. Step 8 Repair the main board board when the robot kzq communicates with the TP teacher 1 Replace the main board board 2 Replace the FROM/SRAM card Step 9 Replace the MAIN BOARD when the robot loads the option software. 2 Replace the process I/O BOARD. Step 10 Replace the MAIN BOARD when initializing DI/DO. 1 Replace the FROM/SRAM card When replacing the MAIN BOARD and FROM/SRAM cards, the user programs and system Settings stored in the machine will be lost. Make sure to make a backup before replacing the MAIN BOARD and FROM/SRAM cards. In addition, you should also make a backup before installing the robot system software. Step 11 Repair the SRAM. 1 Replace the shaft control card. 2 Replace the MAIN BOARD. 3 Replace the servo amplifier. Step 12 Initialize the shaft control card Repair 1 Replace the shaft control card 2 Replace the MAIN BOARD 3 Replace the servo amplifier Step 14 Repair the power supply of the robot servo system 1 Replace the MAIN BOARD Step 15 Repair 1 Replace the MAIN BOARD when running the program 2 Replace the process I/O BOARD Step 16 Repair the MAIN BOARD when performing I/O operations 1 Replace the MAIN board. Step 17 The initialization is complete. The maintenance is normal The user programs and system Settings stored in the machine will be lost when the BOARD and FROM/SRAM cards are used. Make sure to make a backup before replacing the MAIN BOARD and FROM/SRAM cards. In addition, you should also make a backup before installing the robot system software. 7 digits Fault Description and countermeasures Fault: The RAM parity check fails on the CPU card Measure 1: Replacing the CPU card Measure 2: Replacing the MAIN BOARD Fault: The RAM parity check fails on the FROM/SRAM card Measure 1: Replace the FROM/SRAM card Measure 2: Replace the MAIN BOARD Fault Description and countermeasures Fault: Communication between kzq and PANEL BOARD Fault Measure 1: Check the cable connecting the MAIN BOARD and PANEL BOARD, if damaged, replace the communication cable Measure 2: Replace the MAIN BOARD Measure 3: replace the PANEL BOARD 7 sections of code digital fault description and countermeasures Fault: servo bj Measure 1: replace the servo control card Measure 2: replace the MAIN BOARD 7 sections of code digital fault description and countermeasures Fault: The system stops abruptly bj Measure 1: Replace the servo control card Measure 2: replace the CPU card Measure 3: Replace the MAIN BOARD with seven digits Fault Description and countermeasures Fault: system error Measure 1: Replace the servo control card Measure 2: replace the CPU card Measure 3: Replacing the MAIN BOARD When replacing the MAIN BOARD and FROM/SRAM cards, the user programs and system Settings stored in the machine will be lost. Before replacing the MAIN BOARD and FROM/SRAM cards, make sure to make a backup. In addition, you should also make a backup before installing the robot system software. 2.2 PSU LED indication Fault Description and Countermeasures Fault: ALM LED (red) on PSUbj Measure 1: Check F4 (+24V) fuse on PSU, if damaged, replace Measure 2: Check the +5V, +15V, +24V voltage on the PSU and the related cables and equipment connected therewith. If damaged, replace the measure 3: Replace the PSU Fault: PIL LED (Green) is not bright, the 200V power supply of the PSU is not on Measure 1: Check the F1 fuse on the PSU, if damaged, replace the measure 2: Replace the PSU 2.3 LED indicator on the PANEL BOARD RDY: Fault: The LED (GREEN) is not on, which means that the communication between the PANEL BOARD and the MAIN BOARD is interrupted. Check the communication cable between the MAIN BOARD and the PANEL BOARD. If it is damaged, replace it. Measure 2: Replace the MAIN BOARD. The LED is not bright, that is, the +24V voltage to +5V voltage failure on the PANEL BOARD Measure 1: check the CRM63 connector, +24V input power measure 2: Procedure Replace the LED indicator on the PANEL BOARD 2.4 Process I/O CA/CB/DA: Fault: The communication between the MAIN BOARD and the PROCESS I/O is incorrect. Measure 1: Replace the I/O board Measure 2: Process I/O CA/CB/DA: Fault: The fuse of the I/O BOARD is damaged Measure 1: Replace the fuse Measure 2: Check the peripheral cable Measure 3: Replace the LED indicator on the I/O board 2.5 servo amplifier

以发那科机器人为例: 

1 无法开机 检查及维修:

 检查1:kzq断路器开且没有跳闸 维修: 合上断路器 检查 2:查看电源板(PSU)上的LED指示灯(GREEN)是否亮。 维修: 

如果 LED指示灯没亮可能是PSU的200V供电电源没有或PSU上的F1保险丝毁坏: 1如果200V电源没有请检查供电线路 

2 如果200V电源已提供给PSU请切断电源: A F1保险丝毁坏请参照维修2 B F1保险丝没有毁坏请更换PSU 

维修2:保险丝毁坏故障原因及应对措施 A 查看PSU与其他电路板间的CP2、CP3连接件是否接触良好。 

B 如果浪涌吸收VS1短路请更换VS1定货号:A50L-2001-0122#G431K C 二j管DB1短路 D 后备电源模块H1毁坏 

如果B或C有故障请更换相应备件 … 检查3:查看panel board板上的EXON1、EXON2,EXOFF1、EXOFF2信号接线 维修: 

如果没有使用外部开关机功能请短接信号EXON1与EXON2,EXOFF1与EXOFF2;如果使用了外部开关机功能请查看连接电缆。 

检查 4:panel board板上的JRS11的连接电缆是否接触良好。 检查 5:查看上面的1、2、3确定CP1上的200V电源已接好且机器ON/OFF开关正常请按以下步骤检查PSU: 

如果PSU上的LED (ALM: red)亮请查看外部+24V是否被接地或接0V。 A F4保险丝毁坏 B 更换PSU F4保险丝定货号: … 

2、利用控制板LED指示灯诊断排除故障 2.1 MAIN BOARD 步骤 1 开机后所有的LED都亮 维修 1 更换CPU卡 2 

更换MAIN BOARD板 步骤 2 机器人系统软件启动时 维修 1 更换CPU卡 2 更换MAIN BOARD板 步

骤 3 机器人系统启动时CPU卡 DRAM初始化完成 维修 1 更换CPU卡 2 更换MAIN BOARD板 

步骤 4 机器人系统启动时DRAM、SRAM初始化完成 维修 1 更换CPU卡 2 更换MAIN BOARD板 

3 更换FROM/SRAM卡 步骤 5 机器人系统启动时通信IC初始化完成 维修 1 更换MAIN BOARD板 

2 更换FROM/SRAM卡 步骤 6 机器人系统启动时基本软件载入完成 维修 1 更换MAIN BOARD板 

2 更换FROM/SRAM卡 步骤 7 机器人开机启动基本软件时 维修 1 更换MAIN BOARD板 2 更换FROM/SRAM卡 

步骤 8 机器人kzq与TP示教器通信时 维修 1 更换MAIN BOARD板 2 更换FROM/SRAM卡 步骤 9 机器人载入选项软件时 维修

 1 更换MAIN BOARD板 2 更换process I/O 板 步骤 10 初始化DI/DO时 维修 1 更换FROM/SRAM卡 2 更换MAIN BOARD板 

更换MAIN BOARD和FROM/SRAM卡时机器中存储的用户程序及系统设置都会丢失,在更换MAIN BOARD和FROM/SRAM卡前一定要作好备份;

另外在安装机器人系统软件前也要作好备份。 步骤 11 SRAM准备完成 维修 1 更换轴控制卡 2 更换MAIN BOARD板 3 更换伺服放大器 

步骤 12 轴控制卡初始化完成 维修 1 更换轴控制卡 2 更换MAIN BOARD板 3 更换伺服放大器 步骤 13 校对完成 维修 1 更换轴控制卡 

2 更换MAIN BOARD板 3 更换伺服放大器 步骤 14 机器人伺服系统得电 维修 1 更换MAIN BOARD板 步骤 15 执行程序时 维修

 1 更换MAIN BOARD板 2 更换process I/O 板 步骤 16 执行I/O操作时 维修 1 更换MAIN BOARD板 步骤 17 初始化完成 维修 初始化正常结束

 步骤 18 机器人正常 维修 机器人正常时LED1、LED2会不停闪烁 更换MAIN BOARD和FROM/SRAM卡时机器中存储的用户程序及系统设置都会丢失,

在更换MAIN BOARD和FROM/SRAM卡前一定要作好备份;另外在安装机器人系统软件前也要作好备份。 7段码数字 故障描述及应对措施 

故障:CPU卡上的RAM奇偶校验出错 措施1:更换CPU卡 措施2:更换MAIN BOARD板 故障描述及应对措施 故障:FROM/SRAM卡上的RAM奇偶校验出错 

措施1:更换FROM/SRAM卡 措施2:更换MAIN BOARD板 故障描述及应对措施 故障:kzq与PANEL BOARD板间通信出错 

措施1:查看MAIN BOARD与PANEL BOARD间连接电缆,如损坏就更换该通信电缆 措施2:更换MAIN BOARD板 措施3:

更换PANEL BOARD 7段码数字 故障描述及应对措施 故障:伺服bj 措施1:更换伺服控制卡 措施2:更换MAIN BOARD板

 7段码数字 故障描述及应对措施 故障:系统紧急停止bj 措施1:更换伺服控制卡 措施2:更换CPU卡 措施3:更换MAIN BOARD板 7段码数字 

故障描述及应对措施 故障:系统出错 措施1:更换伺服控制卡 措施2:更换CPU卡 措施3:更换MAIN BOARD板

 更换MAIN BOARD和FROM/SRAM卡时机器中存储的用户程序及系统设置都会丢失,在更换MAIN BOARD和FROM/SRAM卡前一定要作好备份;

另外在安装机器人系统软件前也要作好备份。 2.2 PSU LED指示 故障描述及应对措施 故障:ALM LED (red)亮PSUbj 

措施1:查看PSU上的F4(+24V)保险丝,毁坏则更换 措施2:检查PSU上的+5V、+15V、+24V电压和与其连接的相关电缆、设备,

如有毁坏则更换 措施3:更换PSU 故障:PIL LED (Green)不亮,PSU的200V电源没有 措施1:检查PSU上的F1保险丝,毁坏则更换 

措施2:更换PSU 2.3 PANEL BOARD板上LED指示 RDY: 故障:该LED(GREEN)不亮即PANEL BOARD板与MAIN BOARD板间通信中断 

措施1:检查MAIN BOARD板与PANEL BOARD板间的通信电缆,毁坏则更换 措施2:更换MAIN BOARD板 措施3:

更换PANEL BOARD板 PON: 故障:该LED不亮即PANEL BOARD板上+24V电压转+5V电压失败 

措施1:检查CRM63接头,+24V输入电源 措施2:更换PANEL BOARD 2.4 PROCESS I/O板上的LED指示 Process I/O CA/CB/DA:

 故障:MAIN BOARD与PROCESS I/O板间通信错误 措施1:更换I/O板 措施2:更换MAIN BOARD 措施3:

更换I/O通信电缆 Process I/O CA/CB/DA: 故障:I/O板保险丝毁坏 措施1:更换保险丝 措施2:检查外设电缆

措施3:更换I/O板 2.5 伺服放大器上LED指示