How to Troubleshoot Robot External Axis Desynchronization? Coordinated Inspection of Positioners, Rails, and the Main Robot

When a robot performs coordinated motion with a positioner, floor rail, or rotary table, even slight deviations in the external axis can cause weld seam offset, trajectory deformation, or misjudgment of safety zones. The issue should not be masked by merely adjusting program points.

1. Key Inspection Points
2. Verify the external axis mechanical zero point, encoder value, revolution counter, and axis definition in the controller.
3. Check couplings, reducers, rack and pinion, timing belts, and brakes for looseness or backlash.
4. Verify motor, drive, reduction ratio, motion direction, load, and inertia parameters.
5. Inspect external axis communication, feedback cables, as well as coordinated motion and workpiece coordinate configurations.
6. Implementation Steps
7. Conduct separate tests: run the external axis at low speed alone and in coordinated operation with the robot.
8. Measure repeat positioning at multiple angles and compare errors when approaching from the same direction versus the reverse direction.
9. After mechanical repairs, recalibrate the external axis zero point and associated workpiece coordinates.
10. Before resuming production, verify software limits, safety zones, complete trajectories, and actual process quality.
11. Common Misconceptions
12. Only modifying welding or gripping program points without addressing zero points and mechanical backlash.
13. Using old zero point data directly after replacing a motor or reducer.
14. Neglecting the impact of changes in external axis load and inertia on following error.
15. Summary

External axis desynchronization may stem from zero points, transmission backlash, load parameters, encoder feedback, communication configuration, or coordinated motion programs, requiring troubleshooting along both mechanical and control paths.

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Contact Repair Engineer: +86 18122009539