SRVO-116

Check Current Axis Positions

From the teach pendant, press MENU → SYSTEM → Variables. Review $POSJNT to identify which axis exceeded limits. Compare current joint angles against $JOGLIMIT to see how far out of range the axis traveled.

The alarm detail screen (ALARM → F1 DETAIL) will show the specific axis number that violated the limit, saving time in diagnosis.

Recover Robot Position

While alarm is active, press and hold SHIFT + RESET to clear the alarm temporarily. Immediately switch to JOINT mode and carefully jog the offending axis back within soft limits using reduced override (25% or less). Monitor position in $POSJNT until all axes show within range.

Ensure no obstacles or tooling interference exists in the jog direction before moving. The robot may be in an unusual configuration.

Review SOFFLOAT Application Forces

Analyze the process where SOFFLOAT is used. Check if external forces (material insertion, operator push forces, fixturing contact) are excessive. Use I/O signals or program flow to limit the distance the robot can be moved during floating operations.

Consider implementing FINE or CNT0 positioning before SOFFLOAT to ensure the robot starts from a known safe position away from soft limits.

Add Programmatic Position Monitoring

Insert position checking logic in your TP program after SOFFLOAT operations. Use IF $POSJNT[axis]>limit THEN JMP safety_recovery to detect approaching limits before they trigger alarms. This allows graceful handling rather than fault conditions.

Set warning thresholds at 90-95% of soft limit values to give advance notice before hitting hard limits.

Review Current Soft Limit Settings

Navigate to MENU → SYSTEM → Variables and review $JOGLIMIT[GP1,axis,1] for lower limits and $JOGLIMIT[GP1,axis,2] for upper limits. Record these values for all six axes. Compare against mechanical limits documented in the robot mechanical unit manual.

Never modify soft limits to exceed mechanical hard limits or reduce safety clearances without proper risk assessment.

Check Mastering and Calibration Data

Verify robot mastering is correct by checking MENU → SYSTEM → Master/Cal. Poor mastering can cause position offsets that make soft limits appear more restrictive. If mastering is suspect, re-master affected axes following standard procedures.

After any mastering change, always verify positions with a known calibration fixture or reference points before running production.

Adjust Soft Limits If Appropriate

If workspace analysis confirms more range is needed, modify $JOGLIMIT values: MENU → SYSTEM → Variables → $JOGLIMIT. Increase limits incrementally (5-10 degrees at a time for rotational axes) and test SOFFLOAT operation. Ensure minimum 5-degree safety margin from mechanical hard limits remains.

Soft limit changes require safety review and may need risk assessment documentation per ISO 10218. Coordinate with safety personnel before implementation.

Validate Application Workspace Requirements

Run the SOFFLOAT application in T1 mode at 10% override while monitoring $POSJNT in real-time. Note the maximum and minimum values reached for each axis under normal operation. Set soft limits to provide 10-15% margin beyond these observed extremes.

Use the position register snapshot feature (MENU → DATA → Position Reg) to capture min/max positions during test runs for documentation purposes.

Identify SOFFLOAT Program Location

Review the TP program where SRVO-116 occurred (check alarm history for program name and line number: MENU → ALARM → F5 HIST). Locate all instances of SOFFLOAT or Soft Float instructions. Note the position registers or taught points immediately preceding these instructions.

Search across all programs using MENU → DATA → Program → F5 FIND to locate all SOFFLOAT usage if multiple programs share similar operations.

Analyze Pre-Float Positions

Touch up and record the robot positions immediately before SOFFLOAT activation. Calculate distance-to-limit for each axis: check $POSJNT values vs $JOGLIMIT. Axes within 10 degrees (rotational) or 50mm (linear) of limits are at high risk during floating operations.

Always operate in T1 mode at reduced speed when testing position modifications near axis limits.

Modify Approach Positions

Re-teach positions before SOFFLOAT to move the robot further from soft limits. Focus on the offending axis identified in the alarm. Use JOINT motion type for repeatable positioning. Test with manual external force application in T1 mode to verify adequate margin.

Create home or safe positions as PR[safe_float] and call them before SOFFLOAT operations for consistent starting configuration across programs.

Implement Motion Termination Logic

Add program logic to automatically exit SOFFLOAT when axis approaches limits. Use IF $POSJNT[axis]>($JOGLIMIT[GP1,axis,2]-threshold) THEN to disable SOFFLOAT and execute controlled motion away from limit. This prevents alarm conditions during normal operation.

Combine position checking with timer limits (e.g., WAIT 5.00(sec)) to ensure SOFFLOAT doesn't remain active indefinitely if process conditions change.