Maintenance and repair

For every day a robot is shut down, the production line loses output by one day. We prioritize repair response speed and technical transparency: inspect first, quote later, and repair afterward—every step is recorded.

What faults can we handle?

When an industrial robot shuts down, it's usually not the whole machine being scrapped, but rather a component failing. We categorize faults into four main categories: electrical, mechanical, control, and communication, each item checked: electrical includes servo motor abnormal noises or overheating, encoder alarms, driver overcurrent or overvoltage, main body cable wear and breakage, grounding and leakage; Mechanical issues include reducer oil leaks or excessive clearance, bearing wear on each shaft, abnormal gearbox noises, air leakage or pressure degradation in the balancing cylinder, and dust ingress due to aging seals of the body; Control types include controllers failing to power on, persistent alarm codes that cannot be cleared, black screens or button failures of the teach pendant, and system battery depletion leading to loss of zero position; Communication includes signal interruptions with PLCs, vision systems, and host computers, unresponsive I/O points, and bus communication errors. Whether it's FANUC, ABB, Yaskawa, Kawasaki, KUKA, or Inovance, Estun, Epson, Stäubli, and Universal, we can independently handle common faults from mainstream brands.

Electrical and drive system failures

Servo systems are the part of the robot with the highest failure rate. Common symptoms include: abnormal noise or abnormal temperature rise during motor operation (mostly bearing wear or brake pad wear), encoder alarms (encoder body or feedback cable faults), driver overcurrent or overload (mechanical jamming causing sudden load increase or power module aging), severe overheating of brake resistors (brake unit failure or parameter drift). We bring servo motors, encoders, and feedback lines of the same specifications to the site for replacement verification, quickly distinguishing whether the issue is with the motor body, driver, or mechanical load, and to avoid mistaken replacement errors. Common faults on the controller side include: fan shutdown causing alarms of excessive cabinet temperature, low mainboard battery voltage causing loss of program or zero point, power module damage causing power-on failure, and I/O board channel burnout. For board-level repairs, we replace components and conduct functional tests, avoiding blind replacement of entire boards.

Mechanical and drivetrain system failures

Mechanical failures are often progressive, initially manifesting as reduced accuracy, trajectory shifts, or end shaking. The reducer is a core component: RV reducers (Nabtesco RV-E, RV-C and other series) are commonly found on heavy-load shafts, with faults such as oil leakage, excessive backlash, and low-speed crawling; Harmonic reducers (Harmonic Drive SHF, CSF series, etc.) are mostly used for low-load shafts and SCARA, with faults manifesting as flexible pulley fatigue fracture and output shaking. Wear of bearings on each shaft can cause axial movement and abnormal noises, so it is necessary to disassemble and inspect them before measuring the clearance. The balancing cylinder (spring cylinder or pneumatic-hydraulic cylinder) is used to offset the weight of the boom. When leakage or insufficient pressure occurs, the robot will slide down or operate under significantly higher motor load. Additionally, aging of the main sealing ring can lead to the intrusion of cutting fluid, dust, and moisture, which over time can progressively damage the reducer and wiring harness. In such cases, we handle both sealing and internal cleaning, rather than just replacing the parts.

Typical alarm codes and preliminary judgments

Different brands have different alarm systems, but there are common patterns. FANUC's SRVO-series alarms point to servo and encoder faults (such as SRVO-038 pulse encoder data anomaly, SRVO-062 BZAL loss of zero position), SYST-series alarms relate to the system and safety circuits; ABB's 38xxx series is often associated with serial measurement board SMBs and their batteries, while the 10xxx series is often associated with motion monitoring and safety chains; YASKAWA's 4xxx type alarms mostly point to servo drivers and encoders, accompanied by detailed subcodes on the teach pendant; KUKA (KUKA) KR C4/KR C5 controllers provide textual information prompts, commonly including acceleration monitoring, soft limit triggering, and safety circuit disconnection. Our approach is: first check the alarm code to lock the direction, then check historical alarm records and operation logs to determine whether the fault is sudden or cumulative, and finally use the replacement method or instruments to measure and locate the specific component, rather than replacing the most expensive part on the strength of a code alone. It should be emphasized that the same code may have completely different causes under different operating conditions; the final conclusion should be based on on-site inspection.

Covering brands and models

We have handled over a thousand models from ten major mainstream brands, including FANUC's LR Mate series, M-710iC/M-900iB series, R-2000iC series, and ARC Mate and CR collaboration series; ABB's IRB 1200, IRB 1600, IRB 4600, IRB 6700, and YuMi collaboration series; Yaskawa's GP series, MH series, and Motoman models; Kawasaki's RS, BX, CX series; KUKA's KR AGILUS, KR QUANTEC, KR FORTEC series; as well as series from Inovance, Estun, Epson, Stäubli, and Universal Robots. The controller platform covers mainstream generations such as FANUC R-30iB/R-30iB Mate Plus/R-50iA, ABB IRC5/OmniCore, Yaskawa DX200/YRC1000, and KUKA KR C4/KR C5. For discontinued older models, we ensure repairability through three paths: disassembling parts, compatible parts, and board-level repairs, rather than simply telling customers "the manufacturer is no longer supplying."