During the operation of the OTC DAIHEN Welding Robot, if the system experiences operation and peripheral device faults such as shock sensor collision protection, spraying machine or extension mechanism not connected, or weaving trajectory over limit, the teach pendant will usually display a hardware and control-level alarm in the 4920 to 5008 range. If these faults are not investigated promptly, they may cause serious operational safety hazards or damage to core components such as the reducer.
To help on-site engineers and mechanics quickly locate problems, we have organized the diagnostic terminology from the official maintenance manual to provide you with the following intuitive fault quick reference table. We recommend using the search function, entering the error code (e.g., 4920), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (4920-5008)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 4920 | Shock Sensor Detected Collision | A collision occurred at the front end of the welding gun or robot body, triggering the shock sensor, and the system performed an emergency stop. | Manually move the interfering object away, confirm the hardware is undamaged, release the shock sensor, and perform an exception reset. |
| 4921 | Module Mechanism Interpolation Exception | The calculated motion trajectory makes it impossible for the module mechanism to reach the specified position and posture. | Change the interpolation type to [Joint], or adjust the wrist axis angle of the start and end points, and perform an exception reset. |
| 4930 | No Connecting Mechanism in Spraying Machine | The spraying machine set as the first parameter is not registered, or a physical connection not set exception is detected. | Re-register the spraying machine in the system, correctly set the connecting mechanism parameters, and reset the fault. |
| 4931 | Spraying Machine Does Not Belong to Current Unit | The spraying machine connecting mechanism set as a parameter logically does not belong to the current control unit. | Check and re-record a valid spraying machine number belonging to the current unit, and reset the fault. |
| 4932 | Rotation Axis Information Exception | The extended synchronization control information is not set for the thermal spraying axis, or the calculation error is caused by too small pitch. | Correctly set the rotation axis parameter information again, and reset the fault. |
| 4999 | Alarm Occurred Specified Number of Times Becoming a Fault | The same type of minor alarm occurred frequently and reached the upper limit of retries set by the system. | Review the previous alarm history, completely eliminate the root cause of the alarm, and perform an exception reset. |
| 5005 | Weaving Trajectory Exceeds Specified Speed | The speed limit is exceeded because the taught distance between weaving points is too long, or the set weaving frequency is too high. | Modify the distance between weaving points, reduce the frequency or running speed, and perform an exception reset. |
| 5006 | Weaving Posture Variation Exceeds Limit | The change amplitude of the wrist posture (angle) taught between adjacent weaving points is too large to execute. | Reteach the weaving pattern data, reduce the posture rotation angle between the two points, and perform an exception reset. |
| 5007 | Posture Calculation Error | The posture data specified in the weaving conditions is illogical, causing the system to be unable to calculate the axis angles. | Check the weaving condition settings, correct the conflicting or unreachable posture data, and perform an exception reset. |
| 5008 | Exceeded Allowable Speed | The stop time setting in the weaving conditions of welding time maintenance is too large or the frequency is too high, causing the speed to exceed the limit. | Reduce the stop time, lower the weaving frequency, or cancel the welding time maintenance function, and perform an exception reset. |
II. Get Professional Technical Support and Maintenance Services
When the robot frequently displays the above hardware-level alarms, and routine reset attempts are ineffective, do not forcefully pull the robot arm or repeatedly force restarts, so as not to cause secondary irreversible damage.
Contact Anhui Oujie for Technical Guidance
- System Recovery & Hardware Repair: Manager Fang
- Service Hotline (WhatsApp): 180-9663-1656
- Official Email: ahojotc@gmail.com