Comau robots, born of Turin's automotive automation DNA — the full range

The product detail page on the official website indicates that the current model comes with a C5G controller and TP5 teach pendant (Works with C5G TP5 section on the page). Older NJ/Racer batches may be paired with first-generation control cabinets. After the second-hand equipment arrives, first verify the control cabinet nameplate and teach pendant model before determining the spare parts and software versions; The program for cross-generation controllers is not compatible with the driver board; upgrades and modifications require evaluation of the compatibility between the main encoder and motor power, with specific on-site diagnostics as the final reference.

Comau's official website emphasizes hollow wrist wiring for models like the NJ4, with welding torch/tool cables running through the arm to reduce external friction and the risk of production discontinuation. Maintenance focus includes: regularly checking the cable sheath wear and bending fatigue through the wrist inspection holes, especially for high-current welding bars used in spot welding; When replacing internal wiring harnesses, remove the wrist cover in the order of the manual and record the zero point/travel. After reassembly, perform TCP calibration verification. Abnormal vibrations or alarms must be confirmed together with on-site diagnosis.

The Racer series (such as Racer-3/5/7, with a load capacity of 3-7kg and repeatability of 0.02-0.05mm) focuses on collaborative scenarios and supports direct human-machine mixing; NJ/NJ4 is a six-axis with a medium-to-high load capacity of 16-650kg, mostly used for spot welding, handling, machine loading and unloading, and usually requires safety fencing. Maintenance differences: Collaborative models are more sensitive to zero drift after collisions, so repeatability should be checked after collision events; NJ high-load models focus on checking the condition of the reducer and balancing mechanism.

The official NJ high-load models (such as NJ-420-3.0) have technical specifications indicating protection ratings of IP65/IP67, capable of handling dust and water mist environments in foundry workshops. On-site recommendations include: regularly inspect the main body seals and cable inlet sheaths, and ensure the air source is dry when using the optional air curtain positive pressure device; IP rating only applies to factory condition; protection decreases after seal aging, and if oil backflow or water ingress occurs, the machine must be stopped immediately for drying and insulation testing.

The Comau official website does not uniformly disclose grease injection intervals for each series; please refer to the included maintenance manual for actual use. The general rules are consistent with similar six-axis robots: J1-J3 large gear reducers should replenish or replace grease according to operating hours or years; wrist reducers and bearings should be inspected according to manual intervals; new machines should be inspected after about 1000-2000 hours of operation. High temperature, dust, or flip loading conditions should shorten the cycle; Excessive grease injection causing oil seals to bulge and leak oil is also a common fault and should be confirmed together with on-site diagnosis.

Like most industrial robots, Comau robots use absolute encoders for multi-axis use and retain position data with batteries after power is cut off. A typical sign of battery depletion is the telegraph encoder/position loss alarm, which requires full-axis zeroing and recalibration. Battery replacement should be performed while the control cabinet is powered on or within the time limit specified in the manual, to avoid loss of origin data during power outages; After replacement, zero reset and accuracy verification must be performed. For frequent power-off alarms, check the battery holder contact and the cabinet's internal holding circuit.

Common causes include aging industrial computers/hard drives inside the cabinet, poor contact with screen cables, UPS battery bulging and power supply damage. In public maintenance practice, most old control cabinets can undergo board-level repairs or be retrofitted with a new controller + preserved body, but it is necessary to first confirm that the body's reducer, motor, and encoder are in good condition, and the program can be rebuilt on-site. Whether there is value should be evaluated based on the remaining precision of the equipment and process complexity, and conclusions should be made after on-site inspection.