Industrial Robotics Troubleshooting - 70 Q&A

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Industrial Robotics Troubleshooting — real-world interview & field troubleshooting questions with clear, practical answers. Tap any question to open its answer.

Showing the first 70 questions free. The complete 150-question set is available as a PDF below.

Robot Power, Controller & Startup

Q1The main power supply has a problem: the robot controller does not power ON. How will you troubleshoot it?
AnswerFirst check incoming voltage, main isolator, MCB/fuses, control power and loose terminals. Then restore the correct supply, replace the correct-rated fuse if required, tighten connections and verify stable control voltage. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q2The emergency-stop circuit has a problem: the controller powers up but the robot cannot be enabled. How will you troubleshoot it?
AnswerFirst check all E-stop buttons, safety relay status, gate signals and reset feedback. Then release the active stop, correct the open safety channel and reset the safety circuit only after the cause is cleared. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q3The controller boot sequence has a problem: the controller starts but remains stuck during boot. How will you troubleshoot it?
AnswerFirst check controller alarms, cooling fan, storage/backup status and power quality. Then record the alarm, verify cooling and supply stability, then follow the controller recovery procedure instead of repeatedly cycling power. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q4The teach pendant connection has a problem: the teach pendant is not detected. How will you troubleshoot it?
AnswerFirst check pendant cable, connector pins, communication status and pendant power. Then reseat or replace the damaged cable/connector and confirm the pendant is recognized before operation. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q5The teach pendant display has a problem: the pendant is powered but the screen is blank. How will you troubleshoot it?
AnswerFirst check display backlight/power, cable connection, brightness settings and hardware alarms. Then verify power and cable condition, correct display settings and replace the faulty display assembly if necessary. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q6The mode selector has a problem: the robot runs in manual mode but will not enter AUTO. How will you troubleshoot it?
AnswerFirst check mode selector input, safety permissives, remote/local selection and PLC command. Then correct the mode input and satisfy every AUTO permissive before starting the automatic cycle. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q7The remote start has a problem: the robot is ready but a PLC remote-start command does nothing. How will you troubleshoot it?
AnswerFirst check remote-enable setting, PLC output, robot input, interlocks and program selection. Then trace the start signal from PLC to robot input, correct the first missing permissive and verify the selected program. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q8The controller cooling fan has a problem: the controller reports high temperature during normal operation. How will you troubleshoot it?
AnswerFirst check fan operation, air filters, cabinet airflow and ambient temperature. Then clean filters, restore airflow or replace the failed fan and confirm temperature returns to the normal range. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q9The backup battery has a problem: a controller memory or encoder battery alarm appears. How will you troubleshoot it?
AnswerFirst check battery status, alarm history, backup procedure and battery connection. Then replace the battery using the approved procedure, back up data where required and clear the alarm after confirming the backup is healthy. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q10The power interruption has a problem: the robot loses power intermittently during a shift. How will you troubleshoot it?
AnswerFirst check incoming supply, terminals, contactor, power-quality events and controller logs. Then identify the intermittent supply point, repair the connection or supply issue and verify stable voltage under operating load. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.

Servo Axes & Motion

Q11The servo enable has a problem: the robot controller is ON but servo motors will not enable. How will you troubleshoot it?
AnswerFirst check servo alarm code, safety chain, motor power and enable status. Then clear the actual alarm cause, restore the safety/enable chain and verify servo-ready status before motion. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q12The axis overload has a problem: one axis shows an overload alarm during motion. How will you troubleshoot it?
AnswerFirst check payload, mechanical resistance, brake release, gearbox condition and acceleration settings. Then remove excessive load, check for mechanical drag and brake release, then correct motion settings if they are outside the approved range. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q13The axis following error has a problem: an axis moves but reports position deviation. How will you troubleshoot it?
AnswerFirst check encoder feedback, motor cable, mechanical jam, backlash and servo tuning. Then inspect feedback and cables, remove mechanical resistance and correct tuning or mechanical looseness based on the alarm evidence. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q14The jerky robot motion has a problem: robot motion is not smooth at low speed. How will you troubleshoot it?
AnswerFirst check payload data, servo tuning, gear condition, lubrication and mechanical looseness. Then verify payload and tuning data, inspect the mechanical transmission and correct lubrication or looseness before retesting. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q15The axis overshoot has a problem: the robot passes the taught position during fast movement. How will you troubleshoot it?
AnswerFirst check acceleration/deceleration, servo tuning, payload data and encoder feedback. Then verify the payload and feedback first, then correct approved motion parameters or servo tuning and validate with a slow test. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q16The axis does not move has a problem: one axis remains stationary while other axes operate. How will you troubleshoot it?
AnswerFirst check axis servo status, brake release, drive alarm, motor cable and mechanical obstruction. Then identify whether the fault is electrical or mechanical, restore brake/drive operation and remove any obstruction before re-enabling motion. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q17The axis moves in wrong direction has a problem: a jog command produces unexpected direction. How will you troubleshoot it?
AnswerFirst check jog configuration, coordinate mode, axis assignment and program command. Then confirm the active coordinate/jog mode and axis mapping, then correct the configuration rather than changing wiring blindly. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q18The robot stops near a point has a problem: the robot repeatedly stops before reaching one taught position. How will you troubleshoot it?
AnswerFirst check position data, collision detection, interference zone and mechanical obstruction. Then inspect the exact stop point, check collision/interference settings and physical clearance, then correct the offending condition. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q19The motor temperature has a problem: one robot axis motor becomes hotter than the others. How will you troubleshoot it?
AnswerFirst check motor load, brake condition, gearbox friction, cooling and duty cycle. Then compare load and temperature trends, inspect brake/gear friction and reduce abnormal mechanical load before continued production. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q20The servo alarm after restart has a problem: a servo alarm returns immediately after reset. How will you troubleshoot it?
AnswerFirst check alarm history, encoder status, motor cable and mechanical load. Then read the alarm code before resetting again, inspect the related feedback/power path and correct the root cause before restart. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.

Teach Pendant, Programming & Jobs

Q21The program selection has a problem: the robot starts the wrong job after a product change. How will you troubleshoot it?
AnswerFirst check job number, recipe selection, PLC handshake and operator selection. Then verify the product ID-to-job mapping and correct the selection logic before allowing production. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q22The program start has a problem: the selected program will not start. How will you troubleshoot it?
AnswerFirst check program mode, cursor/start position, safety conditions, inputs and program status. Then place the cursor/start point correctly, satisfy safety and input conditions and check the program status for an inhibit. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q23The program stops at one line has a problem: a program always stops at the same instruction. How will you troubleshoot it?
AnswerFirst check instruction syntax, missing input, motion condition, I/O wait and alarm history. Then identify the exact stopped instruction, verify its required condition and correct the input, motion or program logic causing the stop. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q24The unexpected robot path has a problem: the robot follows a path different from the approved path. How will you troubleshoot it?
AnswerFirst check tool frame, user/base frame, position data, payload and modified points. Then compare the active frames and point data with the approved backup, then restore or reteach only the incorrect data. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q25The program loop has a problem: the robot repeats one sequence continuously. How will you troubleshoot it?
AnswerFirst check loop logic, jump instructions, completion flag and PLC handshake. Then trace the loop condition and completion signal, then correct the missing exit condition or handshake. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q26The I/O wait has a problem: the robot remains waiting for an input that never arrives. How will you troubleshoot it?
AnswerFirst check input monitor, sensor signal, PLC output, wiring and handshake logic. Then monitor the expected input at the controller, trace it back to the field device and repair the first missing signal. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q27The program backup restore has a problem: restored jobs run differently from the original. How will you troubleshoot it?
AnswerFirst check software/version compatibility, frame data, mastering/calibration and I/O mapping. Then confirm compatible backups and restore dependent data such as frames and I/O mapping before testing the job. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q28The speed override has a problem: the robot runs much slower than the programmed speed. How will you troubleshoot it?
AnswerFirst check speed override setting, safety mode, program speed and payload limitations. Then check the active override and operating mode, then restore the approved speed after confirming safety and payload conditions. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q29The instruction error has a problem: the controller reports an invalid or incomplete instruction. How will you troubleshoot it?
AnswerFirst check program syntax, required parameters, option availability and edited lines. Then read the exact instruction error, compare with a known-good program and correct the missing or invalid parameter. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q30The cycle does not complete has a problem: the robot reaches the final motion but cycle-complete is not sent. How will you troubleshoot it?
AnswerFirst check completion output, final-position condition, PLC handshake and program end logic. Then verify the final condition and output instruction, then correct the handshake so the next station receives a valid completion signal. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.

End Effectors, Grippers & Tooling

Q31The pneumatic gripper has a problem: the gripper does not open when commanded. How will you troubleshoot it?
AnswerFirst check air pressure, solenoid output, tubing, flow control and gripper mechanism. Then restore air supply, verify the valve output and remove mechanical sticking or leakage before retesting. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q32The gripper drops part has a problem: the gripper closes but the part falls during transfer. How will you troubleshoot it?
AnswerFirst check gripping pressure, jaw wear, part size, sensor feedback and acceleration. Then restore gripping force, replace worn jaws and reduce motion stress if necessary after confirming the part is correctly positioned. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q33The electric gripper has a problem: an electric gripper reports a fault and will not move. How will you troubleshoot it?
AnswerFirst check power supply, communication, overload, jaw obstruction and gripper settings. Then remove the obstruction, verify supply and communication and clear the fault only after the mechanical cause is corrected. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q34The tool changer has a problem: the robot cannot complete an automatic tool change. How will you troubleshoot it?
AnswerFirst check tool-changer sensors, pneumatic/hydraulic pressure, locking mechanism and PLC/robot handshake. Then verify tool presence and lock feedback, restore required pressure and repair the first failed handshake condition. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q35The tool not detected has a problem: the controller says the wrong tool is mounted. How will you troubleshoot it?
AnswerFirst check tool ID sensor, connector, tool-change data and mounting condition. Then check the physical tool ID and sensor feedback, then correct the tool data or faulty detection circuit. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q36The vacuum gripper has a problem: vacuum is present but the part is not held securely. How will you troubleshoot it?
AnswerFirst check vacuum level, cup condition, leakage, surface contamination and vacuum switch. Then clean or replace cups, remove leaks and verify the vacuum switch reaches its required threshold before motion. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q37The welding torch has a problem: the torch tip is not positioned correctly on the joint. How will you troubleshoot it?
AnswerFirst check tool center point, torch mounting, calibration and fixture position. Then inspect mounting and TCP calibration, correct the fixture or torch alignment and validate with a test point. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q38The screwdriving tool has a problem: fastening torque is inconsistent between cycles. How will you troubleshoot it?
AnswerFirst check tool calibration, bit condition, screw supply, rundown speed and joint condition. Then calibrate the tool, replace worn bits, stabilize screw feeding and verify approved torque parameters. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q39The tool cable has a problem: the end-effector cable causes intermittent faults during robot movement. How will you troubleshoot it?
AnswerFirst check cable routing, bend radius, connector strain and continuity. Then reroute the cable with the specified bend radius, secure strain relief and replace damaged conductors or connectors. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q40The tool interference has a problem: the tool occasionally contacts the fixture. How will you troubleshoot it?
AnswerFirst check tool dimensions, taught points, frames, clearance and collision settings. Then verify the tool geometry and active frames, correct the affected points and validate the path in reduced-speed test mode. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.

Safety Systems & Interlocks

Q41The safety fence has a problem: robot reports a safety fault even though the gate appears closed. How will you troubleshoot it?
AnswerFirst check gate switch alignment, safety relay inputs, dual-channel wiring and reset feedback. Then inspect both safety channels and switch alignment, repair the open circuit and verify the safety function before reset. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q42The light curtain has a problem: robot stops when the light curtain is clear. How will you troubleshoot it?
AnswerFirst check alignment, receiver/transmitter status, wiring and safety controller diagnostics. Then check alignment and diagnostic indicators, repair wiring or sensor faults and validate the protective function. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q43The safety door has a problem: door closes mechanically but the safety input remains OFF. How will you troubleshoot it?
AnswerFirst check actuator alignment, switch damage, connector and input status. Then realign or replace the switch/actuator and verify both safety channels change state correctly. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q44The external emergency stop has a problem: an external E-stop remains active after release. How will you troubleshoot it?
AnswerFirst check E-stop contact, wiring, safety PLC input and reset circuit. Then trace the safety circuit to the first open contact, repair it and complete the required reset sequence. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q45The enabling switch has a problem: robot motion is unavailable with the enabling switch held. How will you troubleshoot it?
AnswerFirst check three-position switch status, pendant connection, safety input and configuration. Then check switch operation and safety input status, replace the faulty switch if needed and confirm the correct enable configuration. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q46The safety reset has a problem: safety reset button does not restore robot operation. How will you troubleshoot it?
AnswerFirst check reset input, feedback loop, active safety fault and PLC permissive. Then find the still-open safety condition first, then repair it and perform the approved reset sequence. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q47The protective stop has a problem: robot enters protective stop during normal production. How will you troubleshoot it?
AnswerFirst check collision detection, external safety signals, load, path clearance and sensor noise. Then identify whether the stop is collision-based or safety-signal based, correct the physical or signal cause and test at reduced speed. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q48The safety circuit intermittency has a problem: safety faults appear only when the robot cable moves. How will you troubleshoot it?
AnswerFirst check cable flexing, connector strain, terminal tightness and safety input monitoring. Then inspect the cable while monitoring the safety channels, repair the damaged section and secure routing to prevent repeat flexing. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q49The guard monitoring has a problem: guard status is correct but the controller shows a guard alarm. How will you troubleshoot it?
AnswerFirst check PLC/safety controller diagnostics, input mapping and switch feedback. Then compare field status with controller inputs and correct the first mismatch in the safety chain. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q50The safety bypass concern has a problem: production only runs when an interlock is bypassed. How will you troubleshoot it?
AnswerFirst check failed switch, wiring fault, alignment problem and safety logic. Then stop production and repair the interlock or safety circuit; do not use bypassing as a permanent troubleshooting solution. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.

PLC, I/O & Communication

Q51The digital input has a problem: a robot input remains OFF even though the field sensor is ON. How will you troubleshoot it?
AnswerFirst check sensor supply, output voltage, common, wiring and robot input terminal. Then measure the signal at the robot input and trace it back to the sensor, repairing the first open or incorrect connection. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q52The digital output has a problem: the robot output shows ON but the external device does not operate. How will you troubleshoot it?
AnswerFirst check output voltage, relay/interposing module, fuse, wiring and device power. Then measure the output at the terminal and load, then repair the failed interface or field circuit. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q53The PLC handshake has a problem: robot and PLC wait for each other indefinitely. How will you troubleshoot it?
AnswerFirst check ready/start/complete signals, signal timing, I/O mapping and sequence logic. Then monitor both sides of the handshake and identify which expected signal is missing, then correct that signal or logic. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q54The Ethernet communication has a problem: robot communication with PLC drops intermittently. How will you troubleshoot it?
AnswerFirst check network cable, switch port, connector, IP settings and electrical noise. Then check physical links and diagnostics, correct addressing or damaged cabling and reduce noise exposure where applicable. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q55The remote I/O has a problem: one remote I/O station disappears from the controller. How will you troubleshoot it?
AnswerFirst check station power, network connection, node/address and communication diagnostics. Then restore station power and network integrity, verify addressing and confirm the station returns without repeated faults. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q56The analog signal has a problem: robot receives an unstable analog value from a sensor. How will you troubleshoot it?
AnswerFirst check sensor supply, shield/grounding, signal cable, scaling and electrical noise. Then verify supply and scaling, improve shielding/grounding and replace a damaged signal cable or sensor if confirmed. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q57The I/O mapping has a problem: the robot reacts to the wrong physical sensor. How will you troubleshoot it?
AnswerFirst check I/O mapping table, PLC tag assignment and program reference. Then compare the physical point with the configured address and correct the mapping or program reference. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q58The communication timeout has a problem: a robot task fails because a response does not arrive in time. How will you troubleshoot it?
AnswerFirst check network status, PLC scan/logic, timeout value and device response. Then find why the response is late or missing, correct the communication path or sequence and adjust timeout only within the approved design. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q59The PLC output chatter has a problem: a robot-related output turns ON and OFF rapidly. How will you troubleshoot it?
AnswerFirst check PLC logic, input noise, interlocks and scan-dependent conditions. Then monitor the controlling logic and input, remove the unstable condition and confirm the output becomes stable. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q60The lost communication after restart has a problem: communication works until the controller is restarted. How will you troubleshoot it?
AnswerFirst check network initialization, IP settings, device configuration and startup sequence. Then verify retained communication settings and startup order, then correct configuration so the link initializes consistently. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.

Vision Systems & Sensors

Q61The vision camera has a problem: the camera no longer detects the part. How will you troubleshoot it?
AnswerFirst check camera power, trigger, lens condition, lighting and job/recipe. Then restore power and trigger, clean the lens, verify lighting and load the correct inspection job. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q62The vision false reject has a problem: good parts are rejected by the vision system. How will you troubleshoot it?
AnswerFirst check lighting stability, focus, threshold settings, part position and recipe. Then compare good and bad images, stabilize lighting and positioning and correct inspection parameters using approved limits. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q63The photoelectric sensor has a problem: the robot misses parts intermittently. How will you troubleshoot it?
AnswerFirst check sensor alignment, sensing distance, contamination, wiring and background reflection. Then clean and align the sensor, verify the sensing range and repair unstable wiring or mounting. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q64The proximity sensor has a problem: the robot reports a part-present signal when no part is there. How will you troubleshoot it?
AnswerFirst check sensor gap, mounting, target material, cable and input logic. Then set the correct sensing gap, secure the sensor and verify the input changes only for the intended target. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q65The encoder feedback has a problem: sensor feedback becomes inconsistent during robot motion. How will you troubleshoot it?
AnswerFirst check encoder cable, connector, grounding, encoder condition and mechanical coupling. Then inspect the feedback cable and coupling, correct grounding or replace the damaged feedback component if confirmed. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q66The laser measurement has a problem: measured dimensions drift during the shift. How will you troubleshoot it?
AnswerFirst check sensor calibration, temperature, mounting, surface condition and reference target. Then verify calibration and thermal effects, secure the sensor and recalibrate against a known reference. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q67The part-present sensor has a problem: cycle stops because the part-present sensor is not satisfied. How will you troubleshoot it?
AnswerFirst check sensor position, target distance, bracket rigidity and PLC/robot input. Then realign and secure the sensor, confirm the target is within range and verify the input at the controller. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q68The camera trigger has a problem: vision inspection sometimes starts late. How will you troubleshoot it?
AnswerFirst check trigger signal, PLC timing, camera exposure and communication delay. Then monitor the trigger timing, correct the signal sequence and stabilize exposure/communication settings. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q69The barcode reader has a problem: robot cannot read a product code consistently. How will you troubleshoot it?
AnswerFirst check reader focus, lighting, code position, communication and decoding settings. Then clean and focus the reader, stabilize code presentation and verify communication and decoding parameters. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
Q70The sensor cable has a problem: a sensor works when stationary but fails when the robot moves. How will you troubleshoot it?
AnswerFirst check cable flexing, connector strain and continuity. Then inspect the cable during motion, repair or replace the damaged section and improve routing/strain relief. Confirm the fault is cleared and run a controlled test before returning the robot to normal production.
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