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Welding robot continuously resetting—what could cause frequent resets?

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  • #1 21668851
    Abdurahman Ahmed
    Anonymous  
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  • #2 21668852
    NIHKIL GUNDAGE
    Anonymous  
  • #3 21668853
    Steve Lawson
    Anonymous  
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  • #4 21668854
    Mark Harrington
    Anonymous  
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  • #5 21668855
    Aditya Muralidhar
    Anonymous  
  • #6 21668856
    bo Indebetou
    Anonymous  
  • #7 21668857
    stephen Van Buskirk
    Anonymous  
  • #8 21668858
    stephen Van Buskirk
    Anonymous  
  • #9 21668859
    Frank Bushnell
    Anonymous  
  • #10 21668860
    Mark Harrington
    Anonymous  
  • #11 21668861
    Mark Harrington
    Anonymous  
  • #12 21668862
    Todd Hayden
    Anonymous  
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  • #13 21668863
    Frank Bushnell
    Anonymous  

Topic summary

✨ The discussion addresses a welding robot experiencing continuous resets. Potential causes include software bugs such as improper code logic, pointer errors, or unintended reset calls; hardware issues like faulty reset switches stuck in the 'on' position; power supply problems including voltage drops ("brown outs"), voltage spikes, or noisy power lines; and environmental factors such as electromagnetic interference or electrical discharges from nearby equipment. Monitoring internal voltages with a multichannel analyzer revealed spikes on +5V and ±12V lines, and using an uninterruptible power supply (UPS) helped reduce resets. Heat-related component failures and watchdog timer behavior were also suggested as possible causes. Recommendations include thorough debugging of the robot's code, checking the reset circuitry and power supply stability, consulting the manufacturer's troubleshooting guide, and providing detailed system information for further diagnosis.
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FAQ

TL;DR: Frequent welding-robot resets often trace to power/ESD issues; one field case saw "a very high voltage (50 kV) got discharged" into the arm, causing resets. Grounding and power conditioning fixed it. [Elektroda, bo Indebetou, post #21668856]

Why it matters: Production stops and quality drops when control electronics brown out, watchdog, or ESD-reset mid-cycle—this FAQ helps you locate and fix the root cause fast.

Quick Facts

How do I quickly triage a welding robot that keeps resetting?

Start with power and noise. 1) Isolate the controller from the welder’s mains or add a UPS/line conditioning. 2) Measure +5 V/±12 V rails with a scope or logger for dips and spikes. 3) Verify grounds and bonding at the tool and arm to shunt ESD. [Elektroda, bo Indebetou, post #21668856]

Could brownout be the cause, and how do I confirm it?

Yes. Load changes from the welder can sag controller voltage and trigger brownout resets. Monitor the supply during arc starts and heavy motion. If resets align with voltage dips, improve supply capacity, separation, or add a UPS. "Voltages that are too low can cause 'brown out' resets." [Elektroda, Steve Lawson, post #21668853]

What’s the fastest electrical fix you’ve seen work on resets?

Provide a solid ground path for the end-effector and ensure the spray gun or torch mount is not isolated. In one case, bonding the gun to the robot arm eliminated resets after ESD discharges were measured around 50 kV. [Elektroda, bo Indebetou, post #21668856]

How do I check if the watchdog timer is causing resets?

Review firmware to see if the watchdog is enabled and where it’s serviced. Add logging or a boot flag to detect watchdog resets. If loops miss servicing due to blocking I/O or timing bugs, the watchdog will reset the controller on schedule. [Elektroda, Steve Lawson, post #21668853]

Can a bad reset button really cause continuous resets?

Yes. A failing or sticking reset switch can remain closed and hold the MCU in reset. Inspect and replace the switch, and confirm pull-up/pull-down integrity on the reset line. This exact fault produced nonstop resets until the button was replaced. [Elektroda, Aditya Muralidhar, post #21668855]

What instrumentation helps find the root cause?

Use a multichannel voltage analyzer or oscilloscope on +5 V and ±12 V rails, with event printout or logging. Look for spikes, dips, and timing relative to motion or arc events. This revealed problematic transients and guided the UPS and grounding fixes. [Elektroda, bo Indebetou, post #21668856]

How can nearby equipment cause random controller resets?

Noisy or failing devices on the same circuit can inject line noise. One case traced intermittent scope failures to a copier power supply a few rooms away. Separate circuits, repair offenders, or add filtering to prevent coupled disturbances. [Elektroda, stephen Van Buskirk, post #21668858]

What symptoms point to heat-related resets?

If the system fails after a fixed runtime and recovers after cooldown, suspect thermal issues. Check component temperatures, airflow, and current draw on outputs. Extra cooling improving behavior supports a heat diagnosis. [Elektroda, stephen Van Buskirk, post #21668857]

What is brownout detection?

Brownout detection is a microcontroller feature that forces a reset when supply voltage falls below a safe threshold. It prevents erratic behavior but will repeatedly reset if the supply keeps dipping under load. Tune thresholds and fix the power path. [Elektroda, Mark Harrington, post #21668854]

What is a watchdog timer?

A watchdog timer is a hardware or firmware timer that resets the controller if software fails to service it in time. It guards against hangs, but misconfigured intervals or long blocking calls can trigger unintended resets. [Elektroda, Steve Lawson, post #21668853]

How should I separate welder and controller power?

Avoid sharing outlets or feeders between the welder and control electronics. Use dedicated circuits and, when needed, a UPS for the controller. This reduces weld-induced sags and noise that produce controller resets. [Elektroda, bo Indebetou, post #21668856]

Could software bugs alone explain frequent resets?

Yes. Null pointers, memory overruns, or logic that deliberately calls reset can loop the system. Review code paths, add assertions, and instrument reset reasons to confirm. "We will need more information"—including code and schematics—before final fixes. [Elektroda, Steve Lawson, post #21668853]

Any real-world frequency stats that hint at electrical noise?

In one shop, resets occurred a few times a day, mapped to a copier’s bad power supply cycles. Correlating reset timestamps with facility equipment use can expose hidden noise sources. [Elektroda, stephen Van Buskirk, post #21668858]

What should I prepare before asking for help or calling the OEM?

Document make, model, controller type, environment, power sources, and attach photos. Include measured rail voltages, noise captures, and when the resets occur. Use the manual’s troubleshooting guide and share your findings with support. [Elektroda, Frank Bushnell, post #21668859]

Three-step how-to: isolate and fix frequent resets

  1. Electrically separate welder and controller; add a UPS to the controller. 2. Scope +5 V/±12 V rails during weld start and motion for dips/spikes. 3. Improve grounds, check cooling, and test with watchdog disabled for diagnostics. [Elektroda, stephen Van Buskirk, post #21668857]
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