Sluggish robot motion may be caused by:
Low hydraulic pressure (for hydraulic robots)
Correct motor voltage
Balanced payload
Fresh lubrication
If arc starting is difficult, check:
Wire stick-out and contact tip condition
Paint quality
Torch color
Gas cylinder label
Noise from gearbox may indicate:
Worn gears or lack of lubrication
Perfectly working bearings
Balanced torque
Correct speed
If weld bead has porosity, possible cause is:
Low gas flow or contaminated base metal
Correct shielding gas
Clean surface
Dry wire
In troubleshooting, the first step is to:
Identify and define the problem clearly
Replace all parts randomly
Ignore alarms
Increase production speed
Safety sensors in robots are used to:
Detect unsafe conditions and stop the robot
Paint parts
Reduce maintenance needs
A light curtain is used to:
Stop robot movement if an object enters a protected area
Measure light intensity
Increase arc brightness
Detect weld quality
Emergency stop buttons must be:
Easily accessible and clearly marked
Hidden from operators
Placed far away
Painted in any random color
Proximity sensors are used to:
Detect objects without physical contact
Cut welding wire
Measure torque
Increase speed
If a safety sensor fails, the robot:
Should be stopped immediately and repaired
Can continue operation
Can bypass safety
Can increase speed
Limit switches in robots are used to:
Stop motion at preset travel limits
Increase motor torque
Reduce gas flow
Measure wire speed
Regular verification of safety sensors ensures:
Proper robot shutdown during hazards
Increased machine weight
More painting work
Higher current usage
Which test is used to check safety sensor operation?
Functional test
Paint test
Load test only
Vibration test only
Safety mats work by:
Stopping the robot when pressure is detected on the mat
Cleaning floor
Increasing grip
Measuring temperature
Safety interlocks ensure:
Robot cannot run when guards are open
Robot runs faster
Robot bypasses safety
Robot ignores alarms
A dual-channel safety circuit means:
Two independent circuits check safety function
Two robots are connected
Two operators run the robot
Two gas cylinders are used
When checking safety sensors, also verify:
Wiring connections and signal output
Robot color
Wire spool label
Photoelectric sensors in robots detect:
Objects using a beam of light
Gas leaks
Wire rust
Arc voltage
Safety PLCs are designed to:
Control and monitor safety-related functions
Paint surfaces
Store welding programs
During preventive maintenance, test safety sensors:
At regular scheduled intervals
Only after breakdown
Never
Randomly without record
Safety barriers around robots are intended to:
Prevent unauthorized access to hazardous zones
Reduce robot height
Lower voltage
Store spare parts
If a safety light curtain is misaligned:
Robot may not detect entry into hazardous area
Robot becomes faster
Weld quality improves
Gas flow increases
Safety sensor calibration ensures:
Accurate detection and response
More paint use
Higher current
Increased gas consumption
Robot will not restart after an emergency stop until:
Fault is cleared and reset is pressed
Paint is applied
Gas cylinder is replaced
Wire is changed
Testing safety devices without proper training:
Is dangerous and should be avoided
Is safe for anyone
Improves weld quality
Reduces downtime automatically
