How To Keep Your Industrial Robots in Prime Condition

Industrial robots transform manufacturing operations. You know this. But, like all sophisticated machinery, it won’t run forever, certainly not if you neglect it. Robots require systematic care in order to deliver optimal performance, minimize downtime, and extend their operational lifespan. In fact, the difference between a robot that runs for decades and one that fails prematurely often comes down to how well you maintain it.

When you think maintenance, you might think dusting and lubrication. Though those are certainly important tasks, good upkeep entails more. It encompasses preventive measures, predictive analytics, and strategic component replacement as well.

Here, we provide the lowdown on how to keep your industrial robots in prime condition. By adopting these practices, you can boost production efficiency, product quality, and workplace safety.

Essential Daily Maintenance Tasks

Daily maintenance is the most important and easiest part of a robot care program. These routine checks take very little time and compensate you generously by preventing major preventable issues from developing.

Visual Inspection Protocol

Start each shift with a comprehensive visual inspection of your robotic systems. Look for obvious signs of wear, damage, or contamination on external surfaces. Check for loose bolts, frayed cables, unusual accumulation of debris around joints and moving parts, and other such issues. If it looks off, inspect it further.

Pay particular attention to the robot’s teach pendant and control cabinet. These components house sensitive electronics that can fail if contaminated with dust, moisture, or chemicals. Any visible damage to protective covers or seals should be addressed immediately.

Operational Parameter Monitoring

Monitor key performance indicators during normal operation. Listen for unusual sounds such as grinding, clicking, or excessive motor noise. These audio cues often provide early warning of mechanical problems before they cause catastrophic failure.

Check that all programmed movements execute smoothly without jerking or hesitation. Erratic motion patterns frequently indicate issues with servo motors, encoders, or mechanical components that require immediate attention.

Weekly Maintenance Requirements

Weekly maintenance activities build upon daily inspections to address components that don’t require constant attention but need regular monitoring.

Lubrication System Management

Most industrial robots use automatic lubrication systems that require periodic monitoring and refilling. Check lubricant levels in all reservoirs and top off as needed using manufacturer-specified lubricants only.

Using incorrect lubricants can damage seals, contaminate internal components, and void warranty coverage. Always verify part numbers and specifications before adding any fluids to your robotic systems.

Cable and Harness Inspection

Robot cables endure constant flexing and can develop internal breaks that aren’t immediately visible. That’s why you should inspect all power and signal cables for signs of wear, kinking, or damage to outer jackets. Pay special attention to areas where cables enter and exit the robot housing.

Test cable continuity using appropriate diagnostic equipment when visual inspection reveals potential issues. Replace damaged cables immediately rather than waiting for complete failure, which could be catastrophic for your operations.

Monthly Comprehensive Maintenance

Monthly maintenance procedures require more time and technical expertise but provide opportunities to identify developing problems before they impact production.

Mechanical Component Assessment

Inspect all mechanical joints, gears, and bearings for signs of wear or damage. Look for metal particles in the lubricant, which indicate accelerated wear of internal components. Check belt tension on belt-driven axes and adjust according to manufacturer specifications.

Measure backlash in gear-driven joints using dial indicators or other precision measuring tools. Excessive backlash reduces positioning accuracy and indicates gear wear that may require replacement.

Electrical System Testing

Perform comprehensive electrical testing, including insulation resistance checks on all motor windings. Test emergency stop circuits to verify proper operation and response times. Also, check all safety interlocks and light curtains to confirm they function correctly.

Battery backup systems in robot controllers require regular testing and eventual replacement. Most backup batteries last three to five years but should be tested annually to avoid unexpected program loss.

Advanced Diagnostic Procedures

Modern industrial robots feature sophisticated diagnostic capabilities that provide detailed information about system health and performance trends. Every so often at scheduled intervals, you should be accessing and analyzing these diagnostics to optimize your robots accordingly.

Predictive Analytics Implementation

Implement predictive maintenance programs using data from robot controllers and external sensors. Monitor motor current signatures, vibration patterns, and temperature trends to identify developing problems before they cause failures.

Many robot manufacturers provide software tools that analyze operational data and recommend maintenance actions based on actual usage patterns rather than arbitrary time intervals.

Calibration and Accuracy Verification

Regularly verify robot positioning accuracy using precision measurement tools. Robots can lose accuracy due to mechanical wear, thermal effects, or electronic drift without showing obvious symptoms during normal operation.

Recalibrate robots according to manufacturer procedures when accuracy falls outside acceptable tolerances. This process typically requires specialized tools and training but is essential for maintaining product quality.

Creating Maintenance Documentation

Proper documentation provides the foundation for effective maintenance programs and helps identify patterns that might otherwise go unnoticed.

Maintenance Record Systems

Maintain detailed records of all maintenance activities, including routine inspections, repairs, and component replacements. Include dates, personnel involved, parts used, and any observations about robot condition or performance.

Digital maintenance management systems can automate scheduling, track costs, and provide analytics that help optimize maintenance intervals based on actual equipment performance rather than generic recommendations.

Spare Parts Inventory Management

Maintain appropriate spare parts inventory based on robot age, usage patterns, and manufacturer recommendations. Focus on components with long lead times or those critical to production continuity.

Review spare parts usage annually to identify components that fail more frequently than expected, which may indicate design issues or operating conditions that exceed manufacturer specifications.

Maximizing Robot Performance Through Proactive Care

To keep your industrial robots in prime condition, you must commit to systematic procedures and continuous improvement. Once you establish and stick to a maintenance program, you should notice reduced breakdowns and optimized robot performance. Both of these perks benefit your bottom line by driving well-oiled operations that bring in more money than they cost you.

If you’re looking for an industry expert to partner with for all your robotics needs, turn to Jaeckels Industrial. We do everything, from selling machine tending robots to providing the maintenance for such robots. Reach out today to discuss your facility’s needs and learn how Jaeckels Industrial can fill technological and operational gaps.