Troubleshooting Common Issues Related to Robot Grease: How to Diagnose and Fix Leaks, Hardening, and Breakdown in Robot Lubrication

Amid the complex technology associated with robotics and industrial automation, it might sound simple that robot grease is critical to maintaining equipment efficiency, reducing friction, and ensuring exceptional performance that lasts for many years of operation. Proper robot lubrication is essential for minimizing wear, preventing robot grease failures, and avoiding costly robot repairs. However, when lubrication issues arise, they can cause significant downtime and impact productivity.

Industrial robots operate under extreme conditions, performing repetitive, high-speed movements while handling heavy loads. Over time, their lubrication systems face wear and tear, leading to problems such as grease leaks, hardening, and breakdown. Regular maintenance and robot grease troubleshooting are crucial to ensure peak performance and avoid costly interruptions in production.

For maintenance professionals, understanding how to diagnose and fix grease-related issues is a necessary skill, and a proactive approach to lubrication management can extend the lifespan of robotic systems and improve operational efficiency.

Let’s explore common robot grease failures, their root causes, and the best troubleshooting techniques to restore proper lubrication. By implementing these solutions, manufacturers and industrial maintenance teams can reduce downtime, minimize repair costs, and keep their robotic systems operating at their best.

Diagnosing Robot Grease Issues: Key Inspection Steps

A thorough visual inspection is the first step in identifying robot grease issues. Look for:

• Visible grease leaks around robotic joints, seals, and lubrication points. Leaks indicate over-lubrication or potential seal failure.
• Dried or hardened grease, indicating it no longer provides proper lubrication. Grease that has turned crusty, flaky, or solidified is ineffective and may contribute to increased friction and wear on moving parts.
• Grease contamination, such as dust, dirt, or moisture mixing with the lubricant, can often appear discolored or have a gritty texture, reducing its effectiveness and potentially accelerating wear on robotic components.

Uneven grease distribution could mean lubrication points are clogged or improperly maintained. Inconsistent grease application can lead to premature wear in some joints while causing excess grease buildup in others.

Grease Consistency and Breakdown Check

Checking grease consistency helps determine if it is still functioning effectively. Signs of robot grease failures include:

• Grease becoming too thin or too thick.
• Grease separating into oil and solid material.
• Increased resistance when moving robotic joints, indicating insufficient lubrication.

Troubleshooting Common Grease Problems in Robots

A. Grease Leaks: Causes and Fixes

Why is grease leaking?

• Over-lubrication: Applying too much grease can cause pressure buildup, leading to leaks.
• Damaged seals: Worn-out or defective seals allow grease to escape.
• Clogged grease fittings: If grease can’t reach lubrication points, pressure forces it out elsewhere.

Solutions:

• Inspect and replace worn seals to prevent further leakage.
• Follow manufacturer guidelines for proper grease application amounts.
• Clean or replace grease fittings to ensure proper flow and prevent blockages.

B. Hardening of Grease: Why It Happens and What to Do

Why does grease harden?

• Incompatible grease mixing: Different formulations react negatively, causing thickening.
• Exposure to high temperatures: Heat can dry out grease, reducing its effectiveness.
• Aging grease: Grease left in robotic joints too long without reapplication can solidify.

Solutions:

• Flush out old grease and replace it with a compatible, manufacturer-recommended lubricant.
• Use high-temperature-resistant grease in environments with extreme heat exposure.
• Standardize grease types across all robots in a facility to prevent mixing greases.

C. Grease Breakdown: What Causes It and How to Prevent It

Why does grease break down?

• Incorrect grease type: Using non-recommended grease can cause early degradation.
• Contamination: Dust, metal shavings, and moisture accelerate grease breakdown.
• Excessive robot workload: High speeds and heavy loads increase lubrication stress.

Solutions:

• Always use OEM-recommended grease, such as FANUC’s Vigo Grease (P/N: A98L-0040-0174#16KG).
• Check for environmental contamination and improve sealing or filtration if necessary.
• Adjust lubrication schedules to match the robot’s working conditions and stress levels.

Decisions! Decisions!: Cleaning vs. Replacing Grease

When to Take Action

• If grease shows minor contamination but retains proper viscosity.
• If lubrication is needed due to gradual depletion.
• If scheduled maintenance calls for replenishment.

Steps:

• Wipe off old grease from joints and fittings.
• Apply the correct amount of recommended grease.
• Ensure all lubrication points are covered evenly.

When to Fully Replace Grease

• If grease has hardened or separated into components.
• If there is significant contamination (dust, moisture, or metal particles).
• If seals have failed, allowing excess grease loss.

Steps:

1. Remove all old grease using compressed air or manufacturer-approved cleaning solvents.
2. Flush and replace seals if necessary.
3. Apply fresh grease at recommended intervals.

Key Preventative Maintenance Steps

• Follow a detailed robot maintenance checklist for scheduled lubrication. Document each maintenance activity to track lubrication performance over time.
• Use grease guns properly to avoid over- or under-application. Over-greasing can lead to leaks and wasted lubricant, while under-greasing can cause excessive friction and wear.
• Store grease correctly to prevent degradation before use. Keep grease containers sealed, away from direct sunlight, and at optimal temperatures to maintain consistency.
• Train technicians to recognize early lubrication issues. Educate maintenance teams on identifying signs of grease failure, such as excessive noise, increased friction, or irregular robot movement.
• Monitor robot performance for early signs of lubrication failure. Implement predictive maintenance tools, such as vibration analysis and thermal imaging, to detect lubrication issues before they cause significant damage.
• Standardize grease types across all robots in a facility to avoid incompatibility issues and simplify inventory management.

Keep Your Robots Running with the Right Grease Strategy

Proper robot lubrication is crucial for robot maintenance, preventing robot grease failures such as leaks, hardening, and breakdown. By following troubleshooting best practices, maintenance teams can reduce robot repairs and minimize downtime.

At T.I.E. Industrial, we provide an extensive inventory of refurbished robotic systems and replacement parts to keep your operations running smoothly. Whether you need robot repairs, maintenance support, or high-quality grease-compatible replacement parts, we’ve got you covered.

Contact T.I.E. Industrial today for expert solutions for all your robots’ grease-related questions.