IRB 6700 Motor Replacement

• Keep the replacement motor in its protective packaging until the moment of installation to prevent contamination or accidental damage.
• Handle it carefully, using the designated lifting points. Avoid impacts, especially to the shaft/pinion.
• Verify the motor's article number against your robot's specifications before installation.
• Inspect for shipping damage before accepting delivery.

• Safety: Handle the removed motor with care; it may still be hot or have sharp edges if damaged.
• Inspection: If possible and safe, a brief visual inspection of the old motor's pinion, seals, and connectors might offer clues about the failure mode.
• Identification: Record the motor's serial number and any visible damage or unusual conditions before disposal.
• Disposal: Dispose of the old motor according to local environmental regulations, considering it contains metals, potentially magnets, and electronic components.

After replacing a motor, performing the correct level of calibration (Standard minimum, AbsAcc if originally equipped and required for the safety function's integrity) is essential. An uncalibrated or poorly calibrated robot can lead to the safety system having an incorrect understanding of the robot's true position, potentially rendering safety zones or limits ineffective.

Depending on the specific safety configuration and local regulations/risk assessments, revalidating the safety functions related to the affected axis or the entire SafeMove configuration might be necessary after a motor replacement and recalibration.

• Immediately cover the opening with a clean, lint-free cloth or temporary plastic cap to prevent dust, debris, or dropped items from entering.
• Avoid using compressed air to clean around an open gearbox, as this can blow contaminants inside. Use vacuum cleaners or wiping instead.

• Use clean tools (spatulas, grease guns) for applying grease.
• Keep lubricant containers sealed when not in use to prevent contamination.
• Wipe up any oil or grease spills immediately to prevent slip hazards and contamination spread.

• Keep the immediate work area around the robot as clean as possible throughout the repair process.
• Use a dedicated clean workspace for handling sensitive components like O-rings and seals.
• Maintain organization of fasteners and small parts to prevent loss and contamination.

Double-check the robot's serial number and configuration against the ABB spare parts catalog (or use ABB support/tools like Business Online) to order the exact replacement motor.

Store spare motors in a clean, dry environment, preferably in their original protective packaging. Avoid areas with high vibration or potential for physical damage.

• Control humidity and temperature (follow ABB guidelines)
• Protect from dust and environmental contaminants
• Secure from accidental impact during storage

If multiple spares are kept, rotate stock to use the oldest compatible spare first. This helps ensure that no spare parts exceed their shelf life or storage recommendations.

Between the revolution counter update and a full calibration (Standard or AbsAcc), the robot may exhibit slight deviations from its previously programmed path.

This is because the new motor's zero position, even after synchronization, might be fractionally different from the old one relative to the axis linkage. For non-critical tasks, this might be negligible, but for high-precision paths (welding seams, precise insertions), these deviations could cause issues.

Even after correct calibration, a brand-new motor might have slightly different dynamic characteristics compared to the aged motor it replaced.

In highly optimized, high-speed applications, minor motion tuning adjustments (via system parameters, often requiring expert input) might be needed to fully replicate the exact previous cycle time and motion smoothness. This is less common but possible in demanding scenarios.

Re-emphasizing this: If incorrect Load Data is used, the new motor will be subjected to suboptimal control, potentially leading to rougher motion, increased vibration, longer settling times, and ultimately, reduced lifespan.

Always verify or re-run LoadID if the payload has changed or if overload was a suspected cause of the previous failure. This allows the controller to optimize motion profiles for the specific mass and inertia characteristics of the current tool and payload.

Personnel performing these repairs must have completed relevant ABB-certified maintenance training courses that cover mechanical repairs, electrical safety, LOTO procedures, and system software (including calibration).

Trainees must demonstrate a thorough understanding of the specific hazards involved: stored energy (electrical and mechanical), gravitational forces, heavy lifting, hot surfaces, ESD, and the critical importance of correct reassembly and calibration.

Facilities must foster a strong safety culture where procedures are strictly followed, shortcuts are discouraged, and personnel feel empowered to stop work if they encounter an unsafe condition or are unsure about a step.

Never hesitate to contact official ABB Service support if unsure about any aspect of the procedure, diagnostics, or safety precautions. Rushing a motor replacement can lead to severe consequences.

Are motors on a specific axis failing more frequently than others across the fleet? Is there a correlation with specific applications, payloads, or operating environments?

This data can highlight potential systemic issues (e.g., underrated application, programming causing excessive stress, environmental factors). Create a database of motor failures that records:

• Which axis motors fail most frequently
• Average operational hours before failure
• Correlation with application type
• Environmental factors (temperature, contaminants)
• Indications of root cause when identifiable

While true sensor-based prediction might require additional hardware, tracking operational hours, fault logs, and observed early warning signs (noise, heat) for each motor can help build a profile to anticipate when a motor might be nearing the end of its typical life.

This approach allows for proactive replacement during scheduled downtime rather than emergency repairs during production. Consider implementing:

• Regular motor performance audits (current draw, temperature, vibration)
• Hour meters for each robot/axis to track utilization
• Statistical models based on historical failure data
• Scheduled inspections focused on known early warning signs
• Integration with production planning for optimal maintenance scheduling

Understanding failure rates and trends helps optimize the number of spare motors kept in inventory, balancing cost against potential downtime risk.

Maintain an optimal inventory by:

• Analyzing mean time between failures (MTBF) for each axis/model
• Considering lead times for new part orders
• Calculating the cost of downtime vs. inventory carrying costs
• Identifying which motors are most critical to operations
• Implementing just-in-time ordering where appropriate

Ensure information from repairs (especially root cause findings) is fed back into the maintenance planning and potentially engineering/operations teams to address underlying issues that might be causing premature failures.

Implement a structured feedback system that:

• Documents and categorizes each failure
• Analyzes potential programmatic solutions (trajectory adjustments, speed modifications)
• Evaluates environmental controls or improvements
• Shares findings across multiple facilities or production lines
• Creates actionable improvement plans based on failure patterns

After recalibration, verify the robot's TCP accuracy. Use a physical pointer or a dedicated calibration tool/jig. Jog the robot to a known reference point using the calibrated tool definition.

Any significant deviation indicates a potential issue with the calibration or underlying robot geometry. Run an automated TCP check program if available.

If your facility has standard path accuracy test programs (e.g., moving along defined straight lines or circles while monitoring deviation), run these after the repair and calibration.

This provides a quantitative measure of the robot's restored performance compared to its baseline. Deviations exceeding application tolerances may require more precise calibration.

For the first few shifts or days after the repair, monitor the specific axis motor temperature (if possible with a thermal camera) and listen for any developing noises.

Early detection of issues related to the repair (e.g., incorrect assembly, faulty new motor) is crucial. Compare thermal patterns with other motors on the robot for reference.

How to Verify Genuine ABB Parts

• Purchase from ABB directly or authorized distributors only
• Check for official ABB packaging and documentation
• Verify the ABB logo and part number are properly marked
• Confirm serial numbers match documentation
• If uncertain, contact ABB to verify part authenticity

Long-Term Protection Strategy

• Develop relationship with authorized ABB parts suppliers
• Maintain accurate inventory of robot types and required spares
• Consider ABB service contracts for critical applications
• Document all part replacements with genuine part serial numbers
• Train purchasing staff on the importance of genuine parts