I. Mechanical System Condition Assessment
1. Positioning Accuracy Test
Use a laser tracker to measure repeatability. If the positioning error is consistently >0.1mm and cannot be restored through calibration, it indicates severe wear on the tabletop or guide rails.
If there is noticeable looseness at the module joints (manual movement >0.5mm), consider replacing the positioning pins or modules.
2. Structural Integrity Check
If the tabletop deformation exceeds 1mm/m (check with a spirit level) or cracks appear in the cast iron (confirm with magnetic particle inspection),
II. Electrical and Control System Diagnosis
1. Motion Stability Test
If the robot exhibits periodic jitter (vibration >11.2mm/s) during operation, after ruling out bearing problems, it may be a gear or encoder failure.
If the servo motor current fluctuation is >15% and accompanied by unusual noise (such as clicking), it indicates wear on the transmission components.
2. Safety Function Verification Emergency stop button response delay > 0.5 seconds, or oxidation of the safety door switch contacts leading to false triggering.
III. Welding Quality Correlation Analysis
1. Weld Seam Consistency Comparison
Under the same parameters, weld seam profile variations > 20% (e.g., increased fish-scale fracture rate) may be due to tabletop vibration or positioning failure.
Unstable shielding gas flow (fluctuation > 10%) requires checking the air line seal and solenoid valve status.
2. Decreased Equipment Efficiency
Productivity per unit time has decreased by more than 30%, and after eliminating process parameter issues, increased auxiliary time may be due to tabletop aging.
IV. Economic Decision Reference
1. Repair Cost Threshold
The cost of a single repair exceeds 50% of the equipment's residual value, or the annual maintenance cost exceeds 15% of the new machine price.
2. Technology Upgrade Needs
The existing workbench is incompatible with new welding guns (e.g., laser hybrid welding heads), and the cost of retrofitting is prohibitive.
