Summary of Communication Issues with Kawasaki Robots

This post summarizes all the issues encountered in communication with Kawasaki robots through master control and standard interface, along with their solutions.**

Troubleshooting master control connection failure


Inconsistent configurations of robot IP port and the port in use

  • Explanation: The CPU motherboard has two ports, corresponding to Port 1 and Port 2. Usually, Port 1 (the upper port on the CPU board) is connected to the front panel. If the IP of Port 1 cannot be pinged but Port 2’s IP can be pinged, it indicates that the front panel is connected to Port 2.
  • Solution: It is necessary to open the control cabinet and confirm which port on the motherboard the front panel cable is connected to.

Inconsistent configuration of IPC IP and the used network port

  • Explanation: IPCs have multiple network ports. Ensure that the port used for connection with the robot matches the one set in the configuration.
  • Solution: On the IPC side, plug and unplug the network cable, and check the network adapter panel to see which port’s connection status is changing.

IPC and robot are not in the same network segment

  • Explanation: The IP addresses of the IPC and the robot need to be set in the same network segment; otherwise, they cannot connect.
  • Solution: Check the IPC IP and the robot’s IP, ensuring both IP addresses are in the same network segment. For example, both are in (xxx: 1-255).

Mech-Viz robot address discrepancy with actual robot IP

  • Explanation: The IP address entered in the robot interface in Mech-Viz does not match the actual IP address of the robot.
  • Solution: Ensure the entered IP address matches the real IP address of the robot.

IPC firewall not disabled

  • Solution: In Control Panel/System and Security/Windows Defender Firewall, disable all firewalls.

Router configuration issue

  • Solution: Remove the router initially and test the communication directly. Ensure a stable connection without the router, then test with the router in place.

Program burning

Incorrect file selection for burning, should burn master control program

  • Explanation: mm_control is the file for burning the master control program. mm_module is the file for interface communication. Do not confuse these two burning files.
  • Solution: When burning the master control program, ensure that the file being burned is mm_control. On the front end, select the main program. On the PC backend, run AUTOSTART.PC and AUTOSTART2.PC.

Errors displayed on the teach pendant after burning completion

  • Solution: Better cancel any running programs on both the robot front end and back end during burning. Avoid writing failures due to programs with the same name being in use.

Robot operation

Two PC programs did not start running. There is no running flag displayed in front of the names of the two PC programs *

  • Explanation: After burning the program, it is necessary to open two system switches, AUTOSTART.PC and AUTOSTART2.PC, and then restart the controller to let the background PC programs start running.
  • Solution: On the teach pendant, select the keyboard, then input the following commands:
    autostart.pc ON
    autostart2.pc ON

Afterward, restart the controller.