What causes fault code PAL-ROBOT1 (Robotic Palletizer — Axis Fault / Reach Limit)?

Pallet position shifted — robot trying to place at a location outside its work envelope. Servo motor overloaded — load too heavy or acceleration too aggressive. Collision detected — robot arm hit an obstacle or safety fence. Encoder feedback error on one axis — motor encoder cable or encoder failure. Robot program position taught incorrectly — waypoint is in a collision zone

How do I fix fault code PAL-ROBOT1?

Check robot teach pendant for specific fault code and faulted axis. If collision detection, visually inspect for physical contact — check gripper, product, and surrounding structure. Clear the fault on the teach pendant — do NOT blindly resume, check the robot position first. Jog the robot to a safe home position at slow speed before restarting the program. If axis fault, check motor and encoder cables on the faulted axis joint. Verify pallet and product positions — re-teach waypoints if pallets or products have shifted

Robotic Palletizer — Axis Fault / Reach Limit

PAL-ROBOT1

Robotic palletizer arm has faulted on an axis limit, collision detection, or servo error. Robot has stopped mid-cycle.

high palletizer

palletizer robot axis servo collision fanuc abb

Probable Causes (ranked)

Pallet position shifted — robot trying to place at a location outside its work envelope
Servo motor overloaded — load too heavy or acceleration too aggressive
Collision detected — robot arm hit an obstacle or safety fence
Encoder feedback error on one axis — motor encoder cable or encoder failure
Robot program position taught incorrectly — waypoint is in a collision zone

Fix Steps

1 Check robot teach pendant for specific fault code and faulted axis
2 If collision detection, visually inspect for physical contact — check gripper, product, and surrounding structure
3 Clear the fault on the teach pendant — do NOT blindly resume, check the robot position first
4 Jog the robot to a safe home position at slow speed before restarting the program
5 If axis fault, check motor and encoder cables on the faulted axis joint
6 Verify pallet and product positions — re-teach waypoints if pallets or products have shifted

Field Trick

When a robot palletizer faults on collision detection but nothing is obviously wrong, check the product weight. Collision detection works by measuring motor torque — a heavier-than-expected product registers as a collision. If product weight changed, update the payload parameter in the robot program.

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