Position confirmation alarm, especially when it comes to the problem of origin loss, is one of the common problems in robot operation. Origin calibration is the process of comparing and confirming the “robot position” with the “encoder position”. If the robot suddenly loses power during operation or the control cabinet battery is out of power, the origin of the body may be lost.
Yaskawa robots are widely used in industrial automation. However, position confirmation alarms can occur during their operation, which may disrupt the production process. Understanding these alarms and their solutions is crucial.
One common cause of position confirmation alarms is mechanical issues. For example, problems with the robot’s joints, such as worn – out bearings or loose connections, can lead to inaccurate position feedback. If this is the case, technicians should visually inspect the joints for any signs of damage or looseness. Worn – out parts need to be replaced, and loose connections should be tightened.
Another reason could be encoder malfunctions. Encoders are responsible for providing precise position information to the robot’s control system. A faulty encoder may send incorrect data, triggering the alarm. In such situations, the encoder should be tested using specialized diagnostic tools. If it is found to be defective, it must be replaced with a new one.
Software – related problems can also cause position confirmation alarms. Incorrect calibration data or programming errors can make the robot misinterpret its position. Technicians need to check and, if necessary, recalibrate the robot’s position settings. Reviewing and debugging the program to ensure proper position – related commands are also essential steps.
In addition, external factors like interference from nearby electrical equipment can affect the robot’s position sensors. Shielding cables and ensuring proper grounding can help mitigate this issue. By promptly addressing these position confirmation alarms through appropriate handling methods, the reliable operation of Yaskawa robots can be maintained, minimizing production downtime.
1 Position confirmation alarm
Position confirmation alarm mainly involves the error of position information. 4107 alarm is a typical type of this type of alarm. 4107 alarm is “absolute data exceeds the allowable range abnormality”. This alarm usually occurs when the difference between the power on and off positions exceeds the allowable range.
The so-called “absolute data” refers to the position information of each axis of the robot, which is recorded by the encoder. When the robot suddenly loses power during high-speed operation, or the origin position is lost due to the bumps of the truck during transportation, the robot will try to restore to the state before the power failure after powering on again, but if the detected position is too different from the expected position recorded by the encoder, it will trigger the 4107 alarm.
2 Handling methods
To handle this type of alarm, you need to set the second origin position (confirmation point). The second origin position is different from the inherent origin position of the robot. It is set as a check point for the absolute origin data. When a control cabinet controls several robots and tooling axes, each robot or each tooling axis must set the second origin position. Set the second origin position in the following order.
Step ①: Select the second origin in the robot menu, and the screen showing the position and the second origin position will be displayed. Step ②: After selecting the appropriate axis group, press and hold the servo power on on the teach pendant keyboard, and then press and hold forward to advance to the second origin position. Step ③: Finally, click the data menu, and click again when the position confirmation appears to eliminate the corresponding 4107 alarm. In addition, it should be noted that if an AL1325 communication error (encoder) or an AL1692 PG power fuse is broken (servo) occurs at the same time, it is necessary to refer to the corresponding alarm code for processing. Because these faults may affect the robot’s position data at the same time, solving the 4107 alarm alone may not completely restore the system status.
In general, although the 4107 alarm is common, it is relatively straightforward to deal with. Through correct reset operation and position confirmation, the problem can generally be effectively solved. However, in order to avoid the recurrence of similar problems, it is recommended to perform regular maintenance and inspections on the robot and ensure that the operators receive appropriate training to enhance their ability to deal with such problems. This will not only extend the service life of the robot, but also ensure the stable operation of the production line.