1. Reducer (highest failure rate, 35%) Common Problems

Strange noise/vibration: gear wear or insufficient lubrication

Positioning deviation: Harmonic reducer flexible wheel fatigue

Oil leakage: aging seals

Maintenance program

Preventive maintenance: replace special grease every 4000 hours Replacement of special grease

Lifetime assessment Wear monitoring via vibration sensors

Upgrade options: Reduce torque loss with hollow structure gearboxes. Upgrade Options: Reduce torque loss by adopting a hollow structure reducer

2. Servomotors (25% failure rate)

Typical faults

Overheating alarm: cooling fan is not working. Overheating alarm: blocked cooling fan or short-circuited winding

Encoder abnormality: signal Interference or contamination of encoder

Stuck bearing: dust intrusion

Solution

Quarterly maintenance: use 

Quarterly maintenance: use compressed air to clean the heat dissipation channel

Anti-interference measures: add magnetic ring, shielded cable grounding

Replacement criteria: Recommended to replace bearings when current fluctuates >15%.

Technical Tips: Fanuc servo motor disassembly requires special tools, avoid violent disassembly!

KUKA robot

3. Controller (failure rate 20%)

High-frequency problems

Main board burned: poor heat dissipation or voltage instability

Software crash : Insufficient memory or virus attack

Communication interruption: oxidized Ethernet port

Professional Maintenance Recommendations

Environmental control: maintain a Temperature 0-45°C, Humidity 20-80%

Data backup: Export system image monthly

Hardware upgrade : Replacement of Solid State Disk (SSD) to enhance the operation speed

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4. robotic arm cable (15% failure rate)

Damage performance

Signal intermittent: internal core broken

Insulation failure : short circuit due to cracked outer jacket

Life extension tips

Bend radius: move the cable to keep it ≥8x diameter bends

Alternative: choose a Highly flexible cables

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