A robot cell does not stop from one day to the next — it gives warning first. These five symptoms typically appear weeks before a failure.
1. Creeping cycle time
If the cycle time degrades by seconds over a few weeks, it is an early sign of a drive or brake problem. The OEE trend shows it automatically.
2. Recurring orientation errors
TCP deviation points to wear of the torch mount or deformation after a collision. A quarterly TCP check catches it.
3. Porosity in the weld
A gas-supply problem, worn wire-feed rollers or a contaminated torch area — all three are maintenance issues, not programming ones.
4. A change in the sound of the drives
An experienced operator's ear is the best sensor. Squeaking or humming means a bearing or lubrication problem.
5. Accumulating minor faults in the log
Faults piling up in the controller's error log that "resolve themselves" signal escalation. Our remote monitoring raises an alarm on these automatically.
With an annual service contract all of this is monitored — 24/7 remote monitoring and a 12-hour nationwide response time turn an unplanned stoppage into planned maintenance.