File size: 120,686 Bytes
5117960 | 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 596 597 598 599 600 601 602 603 604 605 606 607 608 609 610 611 612 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645 646 647 648 649 650 651 652 653 654 655 656 657 658 659 660 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675 676 677 678 679 680 681 682 683 684 685 686 687 688 689 690 691 692 693 694 695 696 697 698 699 700 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 738 739 740 741 742 743 744 745 746 747 748 749 750 751 752 753 754 755 756 757 758 759 760 761 762 763 764 765 766 767 768 769 770 771 772 773 774 775 776 777 778 779 780 781 782 783 784 785 786 787 788 789 790 791 792 793 794 795 796 797 798 799 800 801 802 803 804 805 806 807 808 809 810 811 812 813 814 815 816 817 818 819 820 821 822 823 824 825 826 827 828 829 830 831 832 833 834 835 836 837 838 839 840 841 842 843 844 845 846 847 848 849 850 851 852 853 854 855 856 857 858 859 860 861 862 863 864 865 866 867 868 869 870 871 872 873 874 875 876 877 878 879 880 881 882 883 884 885 886 887 888 889 890 891 892 893 894 895 896 897 898 899 900 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917 918 919 920 921 922 923 924 925 926 927 928 929 930 931 932 933 934 935 936 937 938 939 940 941 942 943 944 945 946 947 948 949 950 951 952 953 954 955 956 957 958 959 960 961 962 963 964 965 966 967 968 969 970 971 972 973 974 975 976 977 978 979 980 981 982 983 984 985 986 987 988 989 990 991 992 993 994 995 996 997 998 999 1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 1050 1051 1052 1053 1054 1055 1056 1057 1058 1059 1060 1061 1062 1063 1064 1065 1066 1067 1068 1069 1070 1071 1072 1073 1074 1075 1076 1077 1078 1079 1080 1081 1082 1083 1084 1085 1086 1087 1088 1089 1090 1091 1092 1093 1094 1095 1096 1097 1098 1099 1100 1101 1102 1103 1104 1105 1106 1107 1108 1109 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119 1120 1121 1122 1123 1124 1125 1126 1127 1128 1129 1130 1131 1132 1133 1134 1135 1136 1137 1138 1139 1140 1141 1142 1143 1144 1145 1146 1147 1148 1149 1150 1151 1152 1153 1154 1155 1156 1157 1158 1159 1160 1161 1162 1163 1164 1165 1166 1167 1168 1169 1170 1171 1172 1173 1174 1175 1176 1177 1178 1179 1180 1181 1182 1183 1184 1185 1186 1187 1188 1189 1190 1191 1192 1193 1194 1195 1196 1197 1198 1199 1200 1201 1202 1203 1204 1205 1206 1207 1208 1209 1210 1211 1212 1213 1214 1215 1216 1217 1218 1219 1220 1221 1222 1223 1224 1225 1226 1227 1228 1229 1230 1231 1232 1233 1234 1235 1236 1237 1238 1239 1240 1241 1242 1243 1244 1245 1246 1247 1248 1249 1250 1251 1252 1253 1254 1255 1256 1257 1258 1259 1260 1261 1262 1263 1264 1265 1266 1267 1268 1269 1270 1271 1272 1273 1274 1275 1276 1277 1278 1279 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 1290 1291 1292 1293 1294 1295 1296 1297 1298 1299 1300 1301 1302 1303 1304 1305 1306 1307 1308 1309 1310 1311 1312 1313 1314 1315 1316 1317 1318 1319 1320 1321 1322 1323 1324 1325 1326 1327 1328 1329 1330 1331 1332 1333 1334 1335 1336 1337 1338 1339 1340 1341 1342 1343 1344 1345 1346 1347 1348 1349 1350 1351 1352 1353 1354 1355 1356 1357 1358 1359 1360 1361 1362 1363 1364 1365 1366 1367 1368 1369 1370 1371 1372 1373 1374 1375 1376 1377 1378 1379 1380 1381 1382 1383 1384 1385 1386 1387 1388 1389 1390 1391 1392 1393 1394 1395 1396 1397 1398 1399 1400 1401 1402 1403 1404 1405 1406 1407 1408 1409 1410 1411 1412 1413 1414 1415 1416 1417 1418 1419 1420 1421 1422 1423 1424 1425 1426 1427 1428 1429 1430 1431 1432 1433 1434 1435 1436 1437 1438 1439 1440 1441 1442 1443 1444 1445 1446 1447 1448 1449 1450 1451 1452 1453 1454 1455 1456 1457 1458 1459 1460 1461 1462 1463 1464 1465 1466 1467 1468 1469 1470 1471 1472 1473 1474 1475 1476 1477 1478 1479 1480 1481 1482 1483 1484 1485 1486 1487 1488 1489 1490 1491 1492 1493 1494 1495 1496 1497 1498 1499 1500 1501 1502 1503 1504 1505 1506 1507 1508 1509 1510 1511 1512 1513 1514 1515 1516 1517 1518 1519 1520 1521 1522 1523 1524 1525 1526 1527 1528 1529 1530 1531 1532 1533 1534 1535 1536 1537 1538 1539 1540 1541 1542 1543 1544 1545 1546 1547 1548 1549 1550 1551 1552 1553 1554 1555 1556 1557 1558 1559 1560 1561 1562 1563 1564 1565 1566 1567 1568 1569 1570 1571 1572 1573 1574 1575 1576 1577 1578 1579 1580 1581 1582 1583 1584 1585 1586 1587 1588 1589 1590 1591 1592 1593 1594 1595 1596 1597 1598 1599 1600 1601 1602 1603 1604 1605 1606 1607 1608 1609 1610 1611 1612 1613 1614 1615 1616 1617 1618 1619 1620 1621 1622 1623 1624 1625 1626 1627 1628 1629 1630 1631 1632 1633 1634 1635 1636 1637 1638 1639 1640 1641 1642 1643 1644 1645 1646 1647 1648 1649 1650 1651 1652 1653 1654 1655 1656 1657 1658 1659 1660 1661 1662 1663 1664 1665 1666 1667 1668 1669 1670 1671 1672 1673 1674 1675 1676 1677 1678 1679 1680 1681 1682 1683 1684 1685 1686 1687 1688 1689 1690 1691 1692 1693 1694 1695 1696 1697 1698 1699 1700 1701 1702 1703 1704 1705 1706 1707 1708 1709 1710 1711 1712 1713 1714 1715 1716 1717 1718 1719 1720 1721 1722 1723 1724 1725 1726 1727 1728 1729 1730 1731 1732 1733 1734 1735 1736 1737 1738 1739 1740 1741 1742 1743 1744 1745 1746 1747 1748 1749 1750 1751 1752 1753 1754 1755 1756 1757 1758 1759 1760 1761 1762 1763 1764 1765 1766 1767 1768 1769 1770 1771 1772 1773 1774 1775 1776 1777 1778 1779 1780 1781 1782 1783 1784 1785 1786 1787 1788 1789 1790 1791 1792 1793 1794 1795 1796 1797 1798 1799 1800 1801 1802 1803 1804 1805 1806 1807 1808 1809 1810 1811 1812 1813 1814 1815 1816 1817 1818 1819 1820 1821 1822 1823 1824 1825 1826 1827 1828 1829 1830 1831 1832 1833 1834 1835 1836 1837 1838 1839 1840 1841 1842 1843 1844 1845 1846 1847 1848 1849 1850 1851 1852 1853 1854 1855 1856 1857 1858 1859 1860 1861 1862 1863 1864 1865 1866 1867 1868 1869 1870 1871 1872 1873 1874 1875 1876 1877 1878 1879 1880 1881 1882 1883 1884 1885 1886 1887 1888 1889 1890 1891 1892 1893 1894 1895 1896 1897 1898 1899 1900 1901 1902 1903 1904 1905 1906 1907 1908 1909 1910 1911 1912 1913 1914 1915 1916 1917 1918 1919 1920 1921 1922 1923 1924 1925 1926 1927 1928 1929 1930 1931 1932 1933 1934 1935 1936 1937 1938 1939 1940 1941 1942 1943 1944 1945 1946 1947 1948 1949 1950 1951 1952 1953 1954 1955 1956 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 2039 2040 2041 2042 2043 2044 2045 2046 2047 2048 2049 2050 2051 2052 2053 2054 2055 2056 2057 2058 2059 2060 2061 2062 2063 2064 2065 2066 2067 2068 2069 2070 2071 2072 2073 2074 2075 2076 2077 2078 2079 2080 2081 2082 2083 2084 2085 2086 2087 2088 2089 2090 2091 2092 2093 2094 2095 2096 2097 2098 2099 2100 2101 2102 2103 2104 2105 2106 2107 2108 2109 2110 2111 2112 2113 2114 2115 2116 2117 2118 2119 2120 2121 2122 2123 2124 2125 2126 2127 2128 2129 2130 2131 2132 2133 2134 2135 2136 2137 2138 2139 2140 2141 2142 2143 2144 2145 2146 2147 2148 2149 2150 2151 2152 2153 2154 2155 2156 2157 2158 2159 2160 2161 2162 2163 2164 2165 2166 2167 2168 2169 2170 2171 2172 2173 2174 2175 2176 2177 2178 2179 2180 2181 2182 2183 2184 2185 2186 2187 2188 2189 2190 2191 2192 2193 2194 2195 2196 2197 2198 2199 2200 2201 2202 2203 2204 2205 2206 2207 2208 2209 2210 2211 2212 2213 2214 2215 2216 2217 2218 2219 2220 2221 2222 2223 2224 2225 2226 2227 2228 2229 2230 2231 2232 2233 2234 2235 2236 2237 2238 2239 2240 2241 2242 2243 2244 2245 2246 2247 2248 2249 2250 2251 2252 2253 2254 2255 2256 2257 2258 2259 2260 2261 2262 2263 2264 2265 2266 2267 2268 2269 2270 2271 2272 2273 2274 2275 2276 2277 2278 2279 2280 2281 2282 2283 2284 2285 2286 2287 2288 2289 2290 2291 2292 2293 2294 2295 2296 2297 2298 2299 2300 2301 2302 2303 2304 2305 2306 2307 2308 2309 2310 2311 2312 2313 2314 2315 2316 2317 2318 2319 2320 2321 2322 2323 2324 2325 2326 2327 2328 2329 2330 2331 2332 2333 2334 2335 2336 2337 2338 2339 2340 2341 2342 2343 2344 2345 2346 2347 2348 2349 2350 2351 2352 2353 2354 2355 2356 2357 2358 2359 2360 2361 2362 2363 2364 2365 2366 2367 2368 2369 2370 2371 2372 2373 2374 2375 2376 2377 2378 2379 2380 2381 2382 2383 2384 2385 2386 2387 2388 2389 2390 2391 2392 2393 2394 2395 2396 2397 2398 2399 2400 2401 2402 2403 2404 2405 2406 2407 2408 2409 2410 2411 2412 2413 2414 2415 2416 2417 2418 2419 2420 2421 2422 2423 2424 2425 2426 2427 2428 2429 2430 2431 2432 2433 2434 2435 2436 2437 2438 2439 2440 2441 2442 2443 2444 2445 2446 2447 2448 2449 2450 2451 2452 2453 2454 2455 2456 2457 2458 2459 2460 2461 2462 2463 2464 2465 2466 2467 2468 2469 2470 2471 2472 2473 2474 2475 2476 2477 2478 2479 2480 2481 2482 2483 2484 2485 2486 2487 2488 2489 2490 2491 2492 2493 2494 2495 2496 2497 2498 2499 2500 2501 2502 2503 2504 2505 2506 2507 2508 2509 2510 2511 2512 2513 2514 2515 2516 2517 2518 2519 2520 2521 2522 2523 2524 2525 2526 2527 2528 2529 2530 2531 2532 2533 2534 2535 2536 2537 2538 2539 2540 2541 2542 2543 2544 2545 2546 2547 2548 2549 2550 2551 2552 2553 2554 2555 2556 2557 2558 2559 2560 2561 2562 2563 2564 2565 2566 2567 2568 2569 2570 2571 2572 2573 2574 2575 2576 2577 2578 2579 2580 2581 2582 2583 2584 2585 2586 2587 2588 2589 2590 2591 2592 2593 2594 2595 2596 2597 2598 2599 2600 2601 2602 2603 2604 2605 2606 2607 2608 2609 2610 2611 2612 2613 2614 2615 2616 2617 2618 2619 2620 2621 2622 2623 2624 2625 2626 2627 2628 2629 2630 2631 2632 2633 2634 2635 2636 2637 2638 2639 2640 2641 2642 2643 2644 2645 2646 2647 2648 2649 2650 2651 2652 2653 2654 2655 2656 2657 2658 2659 2660 2661 2662 2663 2664 2665 2666 2667 2668 2669 2670 2671 2672 2673 2674 2675 2676 2677 2678 2679 2680 2681 2682 2683 2684 2685 2686 2687 2688 2689 2690 2691 2692 2693 2694 2695 2696 2697 2698 2699 2700 2701 2702 2703 2704 2705 2706 2707 2708 2709 2710 2711 2712 2713 2714 2715 2716 2717 2718 2719 2720 2721 2722 2723 2724 2725 2726 2727 2728 2729 2730 2731 2732 2733 2734 2735 2736 2737 2738 2739 2740 2741 2742 2743 2744 2745 2746 2747 2748 2749 2750 2751 2752 2753 2754 2755 2756 2757 2758 2759 2760 2761 2762 2763 2764 2765 2766 2767 2768 2769 2770 2771 2772 2773 2774 2775 2776 2777 2778 2779 2780 2781 2782 2783 2784 2785 2786 2787 2788 2789 2790 2791 2792 2793 2794 2795 2796 2797 2798 2799 2800 2801 2802 2803 2804 2805 2806 2807 2808 2809 2810 2811 2812 2813 2814 2815 2816 2817 2818 2819 2820 2821 2822 2823 2824 2825 2826 2827 2828 2829 2830 2831 2832 2833 2834 2835 2836 2837 2838 2839 2840 2841 2842 2843 2844 2845 2846 2847 2848 2849 2850 2851 2852 2853 2854 2855 2856 2857 2858 2859 2860 2861 2862 2863 2864 2865 2866 2867 2868 2869 2870 2871 2872 2873 2874 2875 2876 2877 2878 2879 2880 2881 2882 2883 2884 2885 2886 2887 2888 2889 2890 2891 2892 2893 2894 2895 2896 2897 2898 2899 2900 2901 2902 2903 2904 2905 2906 2907 2908 2909 2910 2911 2912 2913 2914 2915 2916 2917 2918 2919 2920 2921 2922 2923 2924 2925 2926 2927 2928 2929 2930 2931 2932 2933 2934 2935 2936 2937 2938 2939 2940 2941 2942 2943 2944 2945 2946 2947 2948 2949 2950 2951 2952 2953 2954 2955 2956 2957 2958 2959 2960 2961 2962 2963 2964 2965 2966 2967 2968 2969 2970 2971 2972 2973 | {
"$schema_version": "1.0",
"description": "FactoryBench knowledge graph: machine specs, gripper specs, dataset/task/event definitions, fault root causes, anomaly catalogue, error→protocol mappings, anomaly severity ranking, and the relevance specs that drive fault-aware sub-series sampling. See SCHEMA.md for field-level documentation.",
"machines": [
{
"machine_id": 0,
"machine_model": "UR3e",
"manufacturer": "Universal Robots",
"series": "E-series",
"machine_type": "Collaborative robot (cobot)",
"weight_kg": 11,
"payload_kg": 3,
"degrees_of_freedom": 6,
"joint_rotation": {
"wrist_joints": "360_degree_rotation",
"end_joint": "infinite_rotation"
},
"typical_applications": [
"light assembly tasks",
"automated workbench scenarios"
],
"control_interfaces": [
"UR PolyScope (teach pendant)",
"UrScript",
"TCP/IP socket connection",
"RTDE (Real-Time Data Exchange)"
],
"minimum_polyscope_version_for_screwdriver": "5.4",
"used_in_paper_for": "Automated screwdriving anomaly detection dataset collection (AURSAD)",
"safety_modes": {
"variable": "safety_mode",
"description": "Safety state of the Universal Robots controller as reported via RTDE.",
"enum": [
{
"name": "NORMAL",
"value": 1,
"description": "Robot is operating normally within configured safety limits."
},
{
"name": "REDUCED",
"value": 2,
"description": "Robot is operating in reduced mode with limited speed and/or force due to safety configuration or zone activation."
},
{
"name": "PROTECTIVE_STOP",
"value": 3,
"description": "Protective stop triggered due to collision detection, excessive force, or safety threshold violation. Requires operator reset."
},
{
"name": "RECOVERY",
"value": 4,
"description": "Robot is in recovery mode following a safety event and requires manual intervention."
},
{
"name": "SAFEGUARD_STOP",
"value": 5,
"description": "External safeguard device (e.g., light curtain, safety door, interlock) has triggered a stop."
},
{
"name": "SYSTEM_EMERGENCY_STOP",
"value": 6,
"description": "Emergency stop activated from the robot control box."
},
{
"name": "ROBOT_EMERGENCY_STOP",
"value": 7,
"description": "Emergency stop activated from the teach pendant or robot-mounted E-stop button."
},
{
"name": "VIOLATION",
"value": 8,
"description": "Configured safety limits (speed, position, joint limits, etc.) have been violated."
},
{
"name": "FAULT",
"value": 9,
"description": "Internal safety system fault detected. System requires troubleshooting before operation can resume."
},
{
"name": "AUTOMATIC_MODE_SAFEGUARD_STOP",
"value": 12,
"description": "Safeguard stop triggered while the robot is operating in automatic mode."
},
{
"name": "SYSTEM_THREE_POSITION_ENABLING_STOP",
"value": 13,
"description": "Stop triggered due to incorrect activation of the system three-position enabling device."
},
{
"name": "TP_THREE_POSITION_ENABLING_STOP",
"value": 14,
"description": "Stop triggered due to incorrect activation of the teach pendant three-position enabling device."
},
{
"name": "IMMI_EMERGENCY_STOP",
"value": 15,
"description": "Emergency stop triggered through an IMMI (external machinery interface) safety connection."
},
{
"name": "IMMI_SAFEGUARD_STOP",
"value": 16,
"description": "Safeguard stop triggered through an IMMI (external machinery interface) safety connection."
},
{
"name": "PROFISAFE_WAITING_FOR_PARAMETERS",
"value": 17,
"description": "Robot is waiting for safety parameters via PROFIsafe communication before operation can proceed."
},
{
"name": "PROFISAFE_AUTOMATIC_MODE_SAFEGUARD_STOP",
"value": 18,
"description": "Safeguard stop triggered via PROFIsafe while in automatic mode."
},
{
"name": "PROFISAFE_SAFEGUARD_STOP",
"value": 19,
"description": "Safeguard stop triggered through PROFIsafe safety communication."
},
{
"name": "PROFISAFE_EMERGENCY_STOP",
"value": 20,
"description": "Emergency stop triggered through PROFIsafe safety communication."
},
{
"name": "SAFETY_API_SAFEGUARD_STOP",
"value": 22,
"description": "Safeguard stop triggered via the Safety API interface."
}
]
},
"joint_modes": {
"variable": "joint_mode",
"description": "Per-joint servo control state of each UR robot joint as reported via RTDE. One value is provided for each joint (0–5 on UR3e).",
"enum": [
{
"name": "RESET",
"value": 235,
"description": "Joint is in reset state following a fault or shutdown event."
},
{
"name": "SHUTTING_DOWN",
"value": 236,
"description": "Joint controller is in the process of shutting down."
},
{
"name": "BACKDRIVE",
"value": 238,
"description": "Backdrive mode active; joint can be manually moved with reduced resistance."
},
{
"name": "POWER_OFF",
"value": 239,
"description": "Joint motor power is disabled."
},
{
"name": "READY_FOR_POWER_OFF",
"value": 240,
"description": "Joint is prepared for power-off but not yet fully powered down."
},
{
"name": "NOT_RESPONDING",
"value": 245,
"description": "Joint controller is not responding; communication failure or internal issue."
},
{
"name": "MOTOR_INITIALISATION",
"value": 246,
"description": "Joint motor is undergoing initialization sequence."
},
{
"name": "BOOTING",
"value": 247,
"description": "Joint controller is booting."
},
{
"name": "BOOTLOADER",
"value": 249,
"description": "Joint is in bootloader mode (firmware loading state)."
},
{
"name": "VIOLATION",
"value": 251,
"description": "Joint safety or operational limits have been violated."
},
{
"name": "FAULT",
"value": 252,
"description": "Joint has encountered a fault condition and requires intervention."
},
{
"name": "RUNNING",
"value": 253,
"description": "Joint is operating normally under active control."
},
{
"name": "IDLE",
"value": 255,
"description": "Joint is powered and ready but not actively moving."
}
]
},
"robot_modes": {
"variable": "robot_mode",
"description": "Overall operational state of the Universal Robots controller as reported via RTDE. This reflects the high-level lifecycle state of the robot arm and safety control system.",
"enum": [
{
"name": "DISCONNECTED",
"value": 0,
"description": "Connection with the safety control board is not established."
},
{
"name": "CONFIRM_SAFETY",
"value": 1,
"description": "Robot is validating and updating safety settings before enabling operation."
},
{
"name": "BOOTING",
"value": 2,
"description": "Safety control board is booting and communication with other components is being verified."
},
{
"name": "POWER_OFF",
"value": 3,
"description": "Robot is powered but joints are not energized. Ready to boot up the joints."
},
{
"name": "POWER_ON",
"value": 4,
"description": "Robot joints are in the process of booting up and being energized."
},
{
"name": "IDLE",
"value": 5,
"description": "Robot joints are powered and ready, but not executing motion. Can transition to RUNNING or BACKDRIVE."
},
{
"name": "BACKDRIVE",
"value": 6,
"description": "Robot is in backdrive mode. Brakes are selectively released to allow restricted manual movement."
},
{
"name": "RUNNING",
"value": 7,
"description": "Brakes are fully released and robot is ready to execute or currently executing a program. Safety mode is active and displayed in PolyScope."
},
{
"name": "UPDATING",
"value": 8,
"description": "Controller firmware is being updated."
},
{
"name": "POWERING_OFF",
"value": 9,
"description": "Robot arm is in the process of powering down."
},
{
"name": "ARM_BOOTING",
"value": 10,
"description": "Robot arm hardware is booting up."
},
{
"name": "ARM_UPDATING",
"value": 11,
"description": "Robot arm firmware is being updated."
}
]
},
"runtime_states": {
"variable": "runtime_state",
"enum": [
{
"name": "STOPPING",
"value": 0
},
{
"name": "STOPPED",
"value": 1
},
{
"name": "PLAYING",
"value": 2
},
{
"name": "PAUSING",
"value": 3
},
{
"name": "PAUSED",
"value": 4
},
{
"name": "RESUMING",
"value": 5
}
]
}
},
{
"machine_id": 1,
"machine_type": "CNC milling machine",
"manufacturer": null,
"model": null,
"origin": "University of Michigan Smart Lab experiments",
"machine_category": "Computer Numerical Control (CNC) milling machine",
"axes": [
{
"name": "X-axis",
"sensor_data": "position, velocity, acceleration"
},
{
"name": "Y-axis",
"sensor_data": "position, velocity, acceleration"
},
{
"name": "Z-axis",
"sensor_data": "position, velocity, acceleration"
}
],
"spindle": {
"sensor_data": "motor readings"
},
"workpiece_material": "wax",
"experiment_count": 18,
"purpose": "Tool wear detection data collection for machine learning",
"data_source": "Kaggle dataset (tool-wear-detection-in-cnc-mill)",
"notes": "Exact CNC machine make/model not specified in dataset documentation",
"safety_modes": {},
"joint_modes": {},
"robot_modes": {},
"runtime_states": {}
},
{
"machine_id": 2,
"machine_model": "Yu 5 Industrial",
"manufacturer": "Agile Robots SE",
"series": "Yu",
"machine_type": "Collaborative robot (cobot)",
"weight_kg": 31.5,
"payload_kg": 5,
"payload_kg_at_reduced_reach": 7,
"payload_kg_at_reduced_reach_mm": 850,
"reach_mm": 1000,
"repeatability_mm": 0.05,
"degrees_of_freedom": 6,
"joint_position_limits_deg": {
"joint_1": [
-220,
220
],
"joint_2": [
-310,
130
],
"joint_3": [
-160,
160
],
"joint_4": [
-310,
130
],
"joint_5": [
-220,
220
],
"joint_6": "continuous"
},
"joint_speed_limits_deg_s": {
"joint_1": 141,
"joint_2": 141,
"joint_3": 169,
"joint_4": 180,
"joint_5": 180,
"joint_6": 180
},
"tcp_max_linear_speed_m_s": 2.0,
"tcp_force_control_accuracy_N": 0.5,
"power_supply": "220-230 VAC, 50/60 Hz",
"average_power_consumption_W": 250,
"full_load_current_A": 6.3,
"ip_rating": "IP54",
"operating_temperature_range_C": [
5,
40
],
"integrated_sensors": [
"torque sensors on all 6 axes",
"built-in 2D camera with dual high-power LEDs",
"Neural Processing Unit (NPU) for object recognition"
],
"safety_certifications": [
"ISO 10218-1",
"ISO 13849-1 (Category 3, Performance Level d)",
"ISO/TS 15066",
"IEC 61508",
"TÃœV SÃœD Certificate No. Z10 116233 0004 Rev. 01"
],
"typical_applications": [
"machine tending",
"assembly operations",
"pick-and-place tasks",
"collaborative human-robot interaction"
],
"control_interfaces": [
"Ethernet (browser-based interface via Chrome)",
"Plug-and-play peripheral connectivity"
],
"used_in_paper_for": "Multivariate time-series anomaly detection dataset collection (voraus-AD)",
"safety_modes": {},
"joint_modes": {},
"robot_modes": {}
},
{
"machine_id": 3,
"machine_model": "KR 10 R1100-2",
"manufacturer": "KUKA",
"series": "KR AGILUS-2",
"machine_type": "Industrial 6-axis robot arm",
"weight_kg": 56,
"payload_kg": 5,
"payload_kg_max": 11.1,
"reach_mm": 1101,
"repeatability_mm": 0.02,
"degrees_of_freedom": 6,
"joint_position_limits_deg": {
"joint_1": [
-170,
170
],
"joint_2": [
-190,
45
],
"joint_3": [
-120,
156
],
"joint_4": [
-185,
185
],
"joint_5": [
-120,
120
],
"joint_6": [
-350,
350
]
},
"joint_speed_limits_deg_s": {
"joint_1": 300,
"joint_2": 225,
"joint_3": 330,
"joint_4": 360,
"joint_5": 360,
"joint_6": 433
},
"ip_rating": "IP65",
"operating_temperature_range_C": [
0,
45
],
"typical_applications": [
"high-speed assembly",
"packaging",
"handling",
"machine tending"
],
"control_interfaces": [
"KUKA smartPAD (teach pendant)",
"KRL (KUKA Robot Language)",
"EtherCAT",
"PROFINET",
"EtherNet/IP"
],
"controller": "KR C4 compact / KR C5 micro",
"used_in_paper_for": "Real industrial robot data recording for FactoryBench anomaly detection benchmark",
"safety_modes": {},
"joint_modes": {},
"robot_modes": {},
"runtime_states": {
"variable": "runtime_state",
"source_variable": "kuka_robot_process_state",
"description": "Program execution state of the KUKA KRC4/KRC5 controller ROBOT interpreter as reported via the robot data interface ($PRO_STATE1).",
"enum": [
{
"name": "P_FREE",
"value": 0,
"description": "No program selected; program memory is free."
},
{
"name": "P_RESET",
"value": 1,
"description": "Program is loaded and in reset state; initialised but not yet started."
},
{
"name": "P_ACTIVE",
"value": 2,
"description": "Program is actively running."
},
{
"name": "P_STOP",
"value": 3,
"description": "Program execution is stopped (paused); resumable without reset."
},
{
"name": "P_END",
"value": 4,
"description": "Program execution has reached the end; robot is stationary."
}
]
}
}
],
"grippers": [
{
"gripper_id": 0,
"gripper_model": "2FG14",
"manufacturer": "OnRobot",
"gripper_type": "2-finger electric parallel gripper",
"actuation": "electric",
"finger_count": 2,
"weight_kg": 1.5,
"payload_kg": 14,
"payload_kg_form_fit": 20,
"grip_force_range_N": [
40,
280
],
"max_stroke_mm": 160,
"opening_range_mm": [
5,
117
],
"max_gripping_speed_mm_s": 450,
"repeatability_mm": 0.1,
"ip_rating": "IP67",
"operating_temperature_range_C": [
0,
50
],
"tool_flange": "ISO 9409-1-50-4-M6",
"communication": [
"Ethernet",
"Modbus TCP"
],
"compatible_robots": [
"Universal Robots",
"ABB",
"KUKA",
"Fanuc",
"Yaskawa"
],
"ur_integration": "URCap",
"features": [
"programmable grip force",
"grip detection",
"lost-grip detection",
"customizable finger design"
],
"typical_applications": [
"CNC machine tending",
"heavy component handling",
"assembly tasks",
"pick-and-place"
],
"used_in_paper_for": "Finger gripping for pick-and-place and peg-in-hole tasks on UR3 and KUKA KR10"
},
{
"gripper_id": 1,
"gripper_model": "Screwdriver",
"manufacturer": "OnRobot",
"gripper_type": "Electric screwdriver end-of-arm tool",
"actuation": "electric",
"weight_kg": 2.5,
"dimensions_mm": [
308,
86,
114
],
"torque_range_Nm": [
0.15,
5.0
],
"max_speed_rpm": 340,
"screw_size_range": [
"M1.6",
"M6"
],
"max_screw_length_mm": 50,
"retracted_screw_length_mm": 35,
"bit_types": [
"Philips (PH1-PH3)",
"Slot",
"Torx"
],
"bit_holder": "magnetic (Type A and Type B)",
"bit_extenders_mm": [
50,
100
],
"power_supply": "24 VDC, 0.75 A",
"ip_rating": "IP54",
"esd_certified": true,
"operating_temperature_range_C": [
5,
50
],
"tool_flange": "ISO 9409-1-50-4-M6",
"compatible_robots": [
"Universal Robots",
"ABB",
"KUKA",
"Fanuc",
"Yaskawa",
"Doosan"
],
"ur_integration": "URCap",
"screw_feeder_models": [
"OnRobot Screw Feeder M1.6",
"OnRobot Screw Feeder M2-M6"
],
"features": [
"programmable torque control",
"screw detection",
"screw length verification",
"insertion quality control",
"automatic safety stop on excessive axial force",
"screw retraction during arm motion"
],
"typical_applications": [
"electronics assembly",
"general assembly automation",
"collaborative robot screwdriving",
"multi-variant assembly lines"
],
"used_in_paper_for": "Automated screwdriving task on UR3"
},
{
"gripper_id": 2,
"gripper_model": null,
"manufacturer": "Schmalz",
"gripper_type": "vacuum gripper",
"actuation": "vacuum",
"equipment_note": "Schmalz vacuum generator",
"notes": "Exact gripper model not reported in the voraus-AD dataset documentation; only the Schmalz vacuum generator is specified.",
"used_in_paper_for": "Pick-and-place task on Yu 5 Industrial (voraus-AD)"
}
],
"datasets": [
{
"dataset_id": "aursad",
"name": "AURSAD (interpolated)",
"description": "Automated UR3e Screwdriving Anomaly Dataset, interpolated to uniform timestep. Collected on a UR3e cobot performing automated screwdriving tasks with injected faults.",
"machine_id": 0,
"gripper_id": 1,
"task_id": "screwing",
"source": "https://github.com/AaltoPML/AURSAD",
"license": "MIT"
},
{
"dataset_id": "vorausad",
"name": "voraus-AD (interpolated)",
"description": "Voraus Anomaly Detection dataset, interpolated to uniform timestep. Collected on a UR5 cobot performing pick-and-place tasks with injected faults.",
"machine_id": 2,
"gripper_id": 2,
"task_id": "pick_and_place",
"source": "https://github.com/vorausrobotik/voraus-ad-dataset",
"license": "Apache-2.0"
},
{
"dataset_id": "factorywave",
"name": "FactoryWave",
"description": "Real-robot recordings from a UR3 cobot covering pick-and-place, peg-in-hole, and screwing tasks, with normal, fault, counterfactual, and trajectory-optimization conditions.",
"machine_id": 0,
"gripper_id": null,
"task_id": "mixed",
"source": "https://huggingface.co/datasets/Forgis/FactoryWave",
"license": "Apache-2.0"
}
],
"tasks": [
{
"id": "pick_and_place",
"name": "Pick and Place",
"description": "Robot picks an object from a source location and places it at a target location (bin).",
"phases": [
{
"id": "above_pick",
"label": 0,
"name": "Above Pick",
"description": "EEF moves to a waypoint directly above the object."
},
{
"id": "descend",
"label": 1,
"name": "Descend",
"description": "EEF lowers toward the object."
},
{
"id": "settle",
"label": 2,
"name": "Settle",
"description": "Brief hold to let physics settle before grasping."
},
{
"id": "close",
"label": 3,
"name": "Close",
"description": "Gripper closes around the object."
},
{
"id": "lift",
"label": 4,
"name": "Lift",
"description": "EEF lifts the grasped object off the surface."
},
{
"id": "move_xy",
"label": 5,
"name": "Move XY",
"description": "Lateral transfer toward the bin."
},
{
"id": "lower",
"label": 6,
"name": "Lower",
"description": "EEF lowers into the bin."
},
{
"id": "open",
"label": 7,
"name": "Open",
"description": "Gripper opens, object released."
},
{
"id": "retract",
"label": 8,
"name": "Retract",
"description": "EEF moves away from the bin."
},
{
"id": "return",
"label": 9,
"name": "Return",
"description": "EEF returns to home configuration."
}
]
},
{
"id": "screwing",
"name": "Screwing",
"description": "Robot tightens a pre-gripped screw into a threaded hole, then loosens and retrieves it.",
"phases": [
{
"id": "approach",
"label": 0,
"name": "Approach",
"description": "EEF moves to a pre-contact waypoint above the fastener."
},
{
"id": "descend_to_screw",
"label": 1,
"name": "Descend",
"description": "EEF lowers to engage the fastener."
},
{
"id": "screw",
"label": 2,
"name": "Screw",
"description": "Continuous downward force + wrist rotation to thread."
},
{
"id": "disengage",
"label": 3,
"name": "Disengage",
"description": "Gripper opens / tool lifts off."
},
{
"id": "retract_after_screw",
"label": 4,
"name": "Retract",
"description": "EEF returns to a safe height."
},
{
"id": "descend_to_loosen",
"label": 5,
"name": "Descend",
"description": "EEF lowers to engage the fastener."
},
{
"id": "loosen",
"label": 6,
"name": "Loosen",
"description": "Loosen screw."
},
{
"id": "engage",
"label": 7,
"name": "Engage",
"description": "Gripper closes."
},
{
"id": "retract_home",
"label": 8,
"name": "Retract",
"description": "EEF returns to a home position."
}
]
},
{
"id": "peg_in_hole",
"name": "Peg in Hole",
"description": "Robot inserts a pre-gripped peg into a fixture/slot, releases it, then retrieves it and returns home.",
"phases": [
{
"id": "above_hole_approach",
"label": 0,
"name": "Above Hole",
"description": "EEF moves above the hole and aligns."
},
{
"id": "insert",
"label": 1,
"name": "Insert",
"description": "EEF pushes peg downward into the hole."
},
{
"id": "disengage",
"label": 2,
"name": "Disengage",
"description": "Gripper opens."
},
{
"id": "above_hole_rise",
"label": 3,
"name": "Above Hole",
"description": "EEF rises back to the waypoint above the hole."
},
{
"id": "retract_after_insert",
"label": 4,
"name": "Retract",
"description": "EEF returns to home position."
},
{
"id": "above_object_descend",
"label": 5,
"name": "Above Object",
"description": "EEF moves above the object and aligns with object."
},
{
"id": "engage",
"label": 6,
"name": "Engage",
"description": "Gripper closes."
},
{
"id": "above_object_rise",
"label": 7,
"name": "Above Object",
"description": "EEF rises back to the waypoint above the object."
},
{
"id": "retract_home",
"label": 8,
"name": "Retract",
"description": "EEF returns to home position."
}
]
}
],
"events": [
{
"id": 6,
"name": "Payload Addition",
"description": "an increase of {x} kg to the payload",
"tasks": [
"pick_and_place"
],
"variables": {
"x": "numeric"
}
},
{
"id": 11,
"name": "Friction Decrease Injection",
"description": "a decrease of {reduction_pct}% in the friction coefficient",
"tasks": [
"pick_and_place",
"screwing"
],
"variables": {
"reduction_pct": "numeric"
}
},
{
"id": 12,
"name": "Motor Miscommutation Injection",
"description": "a commutation phase offset of {phase_offset_deg} degrees on {motor}",
"tasks": [
"pick_and_place",
"screwing"
],
"variables": {
"motor": "string",
"phase_offset_deg": "numeric"
}
},
{
"id": 13,
"name": "Gripper Activation Failure Injection",
"description": "activation failure of gripper {gripper}",
"tasks": [
"pick_and_place"
],
"variables": {
"gripper": "string"
}
},
{
"id": 14,
"name": "Gripper Release Injection",
"description": "mid-motion payload release by gripper {gripper}",
"tasks": [
"pick_and_place"
],
"variables": {
"gripper": "string",
"release_time": "numeric"
}
},
{
"id": 16,
"name": "Collision Injection",
"description": "a collision with {object} ({impact_impulse} N-s impact impulse)",
"tasks": [
"pick_and_place"
],
"variables": {
"object": "string",
"impact_impulse": "numeric",
"trajectory_fraction": "numeric"
}
},
{
"id": 17,
"name": "Foam Collision",
"description": "a collision with a foam cube at {trajectory_fraction} of the trajectory",
"tasks": [
"pick_and_place"
],
"variables": {
"trajectory_fraction": "numeric"
}
},
{
"id": 18,
"name": "Cardboard Collision",
"description": "a collision with a cardboard box at {trajectory_fraction} of the trajectory",
"tasks": [
"pick_and_place"
],
"variables": {
"trajectory_fraction": "numeric",
"braced": "boolean"
}
},
{
"id": 19,
"name": "Cable Collision",
"description": "a collision with a hanging cable at {trajectory_fraction} of the trajectory",
"tasks": [
"pick_and_place"
],
"variables": {
"trajectory_fraction": "numeric"
}
},
{
"id": 20,
"name": "Peg Misalignment",
"description": "a {offset_type} offset of {offset_value} in the peg insertion approach",
"tasks": [
"peg_in_hole"
],
"variables": {
"offset_type": "string",
"offset_value": "numeric"
}
}
],
"root_causes": [
{
"fault_id": 1,
"task": [
"screwing"
],
"root_cause": "damaged_screw_thread",
"description": "The screw thread itself is physically damaged, preventing proper engagement during tightening.",
"severity_levels": [
"medium",
"high"
],
"injectable": false,
"possible_anomalies": [
"sustained_contact_force",
"gradual_current_force_temperature_rise",
"high_current_low_motion",
"persistent_tracking_error",
"acoustic_spike_without_force"
],
"simulation_procedure": "Physically damage the screw thread with a file or by cross-threading before placing it in the feeder. Run the tightening cycle and observe torque signature anomaly.",
"datasets": [
"factorywave",
"aursad"
]
},
{
"fault_id": 2,
"task": [
"screwing",
"pick_and_place"
],
"root_cause": "extra_assembly_component",
"description": "An unexpected object such as a washer is present in the assembly location, altering contact geometry.",
"severity_levels": [
"low",
"medium",
"high"
],
"injectable": false,
"possible_anomalies": [
"tcp_force_spike",
"sustained_contact_force",
"persistent_tracking_error",
"speed_drop_with_force_spike",
"protective_stop_event"
],
"simulation_procedure": "Place an additional washer or shim in the assembly location before the tightening cycle. The robot will detect abnormal contact geometry.",
"datasets": [
"factorywave",
"aursad"
]
},
{
"fault_id": 3,
"task": [
"screwing"
],
"root_cause": "missing_screw",
"description": "The robot attempts tightening but no screw is present, often due to pick failure or skipped step.",
"severity_levels": [
"low",
"medium"
],
"injectable": false,
"possible_anomalies": [
"gripper_close_no_force",
"reduced_contact_force",
"persistent_tracking_error",
"unexpected_low_current_during_tightening"
],
"simulation_procedure": "Remove the screw from the feeder or skip the pick step so the robot attempts to tighten an empty hole.",
"datasets": [
"factorywave",
"aursad"
]
},
{
"fault_id": 4,
"task": [
"screwing"
],
"root_cause": "damaged_plate_thread",
"description": "The threaded hole in the plate is damaged, preventing proper screw engagement.",
"severity_levels": [
"medium",
"high",
"critical"
],
"injectable": false,
"possible_anomalies": [
"sustained_contact_force",
"gradual_current_force_temperature_rise",
"high_current_low_motion",
"acoustic_spike_without_force",
"protective_stop_event"
],
"simulation_procedure": "Pre-damage the threaded plate hole with an oversized tap or by cross-threading a screw manually. Confirm thread engagement fails during the tightening cycle.",
"datasets": [
"factorywave",
"aursad"
]
},
{
"fault_id": 5,
"task": [
"screwing"
],
"root_cause": "loosening_phase",
"description": "Robot is performing a screw loosening operation rather than tightening. This is a normal operational phase but may appear anomalous if only tightening behavior is expected.",
"severity_levels": [
"none",
"low"
],
"injectable": false,
"possible_anomalies": [
"reduced_contact_force",
"unexpected_low_current_during_tightening",
"persistent_tracking_error",
"spurious_force_spike",
"spurious_current_spike"
],
"simulation_procedure": "Program the robot to execute a loosening (counterclockwise) rotation instead of tightening. No hardware modification required.",
"datasets": [
"aursad"
]
},
{
"fault_id": 6,
"root_cause": "voraus_ad_class_0_undocumented",
"description": "Voraus-AD dataset anomaly class 0. Semantic description pending curation.",
"severity_levels": [
"unknown"
],
"injectable": false,
"possible_anomalies": [],
"simulation_procedure": "Pending curation.",
"datasets": [
"vorausad"
],
"needs_documentation": true
},
{
"fault_id": 7,
"root_cause": "motor_miscommutation",
"description": "Motor commutation error producing inconsistent torque-forming behaviour on an affected joint, logged as max current deviation failure.",
"severity_levels": [
"medium",
"high"
],
"injectable": false,
"possible_anomalies": [
"broadband_torque_noise",
"persistent_tracking_error",
"joint_current_imbalance"
],
"simulation_procedure": "Power-cycle the controller; re-run a slow diagnostic cycle on the affected joint; inspect motor winding connections if the fault recurs.",
"datasets": [
"vorausad"
]
},
{
"fault_id": 8,
"task": [
"pick_and_place"
],
"root_cause": "gripper_activation_failure",
"description": "The vacuum gripper fails to activate and never picks up the can. The robot completes the motion but carries no payload.",
"severity_levels": [
"medium"
],
"injectable": true,
"event_id": 13,
"possible_anomalies": [
"payload_torque_absence",
"sustained_low_torque",
"torque_deviation_from_nominal"
],
"simulation_procedure": "Disconnect the vacuum line or disable the solenoid valve command in the gripper control I/O, then run a pick-and-place cycle.",
"datasets": [
"factorywave",
"vorausad"
]
},
{
"fault_id": 9,
"task": [
"pick_and_place"
],
"root_cause": "gripper_release_during_motion",
"description": "The vacuum gripper releases the can mid-trajectory at a random point during transport, causing an abrupt loss of payload load on the robot arm.",
"severity_levels": [
"medium"
],
"injectable": true,
"event_id": 14,
"possible_anomalies": [
"abrupt_torque_drop",
"oscillation_around_setpoint",
"sustained_low_torque",
"torque_deviation_from_nominal"
],
"simulation_procedure": "Inject a timed solenoid OFF pulse into the gripper control line mid-trajectory via a programmable relay or script-triggered digital output.",
"datasets": [
"factorywave",
"vorausad"
]
},
{
"fault_id": 10,
"task": [
"pick_and_place"
],
"root_cause": "additional_axis_payload",
"description": "A physical weight is attached to one robot axis, increasing its effective inertia and gravity loading. Affects torque demands on all joints due to the kinematic chain.",
"severity_levels": [
"low",
"medium",
"high"
],
"injectable": true,
"event_id": 6,
"possible_anomalies": [
"torque_sensor_elevation",
"increased_computed_inertia",
"motor_iq_elevation",
"persistent_tracking_error"
],
"related_error_codes": [
"C153A0",
"C153A1",
"C153A2",
"C153A3",
"C153A4",
"C153A5",
"C173A0",
"C173A1",
"C173A2",
"C173A3",
"C173A4",
"C173A5"
],
"primary_error_code": "C153A0",
"simulation_procedure": "Attach a calibrated dead weight (e.g. 0.5-2 kg) directly to one of the robot links using a mechanical fixture, then run the standard program.",
"datasets": [
"factorywave",
"vorausad"
]
},
{
"fault_id": 11,
"task": [
"pick_and_place"
],
"root_cause": "collision_foam_object",
"description": "The robot contacts a soft foam block placed in the workspace. The low stiffness of foam absorbs most of the impact energy, producing a brief TCP force spike and transient torque perturbation without triggering a protective stop.",
"severity_levels": [
"low"
],
"injectable": false,
"possible_anomalies": [
"tcp_force_spike",
"oscillation_around_setpoint"
],
"related_error_codes": [
"C157A"
],
"primary_error_code": "C157A",
"simulation_procedure": "Place a foam cube or foam block directly in the programmed trajectory of the TCP. The robot will push through or deflect it with only a brief force spike recorded.",
"datasets": [
"factorywave",
"vorausad"
]
},
{
"fault_id": 12,
"root_cause": "voraus_ad_class_7_undocumented",
"description": "Voraus-AD dataset anomaly class 7. Semantic description pending curation.",
"severity_levels": [
"unknown"
],
"injectable": false,
"possible_anomalies": [],
"simulation_procedure": "Pending curation.",
"datasets": [
"vorausad"
],
"needs_documentation": true
},
{
"fault_id": 13,
"root_cause": "cable_routed_on_robot",
"description": "A cable or tether is routed along the robot arm, adding asymmetric drag and torque bias on one or more joints throughout motion.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"persistent_tracking_error",
"sustained_contact_force",
"oscillation_around_setpoint"
],
"simulation_procedure": "Reroute the cable off the robot link or add a service loop; run a test cycle and verify joint torques return to nominal.",
"datasets": [
"vorausad"
]
},
{
"fault_id": 14,
"root_cause": "invalid_gripping_position",
"description": "The can is gripped at an unusual or offset position due to a timing error in the pick sequence, causing an asymmetric payload distribution and altered gripper-to-can contact geometry.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"persistent_tracking_error",
"tcp_force_spike",
"speed_drop_with_force_spike"
],
"simulation_procedure": "Introduce a software time delay (e.g. a sleep() call) in the URScript before the gripper activation command, so the gripper closes after the arm has already begun its lift motion, causing it to grip the can at an off-center or tilted position.",
"datasets": [
"factorywave",
"vorausad"
]
},
{
"fault_id": 15,
"task": [
"pick_and_place"
],
"root_cause": "unstable_mounting_platform",
"description": "The robot's mounting platform is unstable due to released wheel brakes or uneven foam placement beneath it, introducing low-frequency vibrations into the arm during motion. Conceptually related to fixture_instability (fault_id 11) but applies to the robot base rather than the workpiece.",
"severity_levels": [
"low",
"medium",
"high"
],
"injectable": true,
"event_id": 15,
"possible_anomalies": [
"broadband_torque_noise",
"oscillation_around_setpoint",
"joint_current_imbalance"
],
"related_error_codes": [
"C157A",
"C173A0",
"C173A1",
"C173A2",
"C173A3",
"C173A4",
"C173A5"
],
"primary_error_code": "C173A0",
"simulation_procedure": "Release the wheel brakes of the robot trolley, or place calibrated foam pads of varying thickness under the base mounting plate.",
"datasets": [
"factorywave",
"vorausad"
]
},
{
"fault_id": 16,
"root_cause": "gearbox_overload",
"description": "A joint gearbox is loaded beyond its rated torque, producing elevated current draw and eventual stall or protective stop.",
"severity_levels": [
"medium",
"high",
"critical"
],
"injectable": false,
"possible_anomalies": [
"high_current_low_motion",
"gradual_current_force_temperature_rise",
"protective_stop_event"
],
"simulation_procedure": "Stop the program; reduce payload or trajectory aggressiveness; inspect the gearbox for damage before resuming.",
"datasets": []
},
{
"fault_id": 17,
"root_cause": "motor_encoder_stall",
"description": "Motor encoder readings stall or drift, leading to position tracking failure on the affected joint.",
"severity_levels": [
"medium",
"high"
],
"injectable": false,
"possible_anomalies": [
"persistent_tracking_error",
"high_current_low_motion",
"protective_stop_event"
],
"simulation_procedure": "Power-cycle the joint; check encoder wiring and seating; replace the joint if the stall persists.",
"datasets": []
},
{
"fault_id": 19,
"root_cause": "joint_position_limit_violation",
"description": "Robot joint moved outside its configured soft or hard position limits, triggering a safety stop.",
"severity_levels": [
"medium",
"high"
],
"injectable": false,
"possible_anomalies": [
"protective_stop_event",
"persistent_tracking_error"
],
"related_error_codes": [
"C1A"
],
"primary_error_code": "C39A3",
"simulation_procedure": "Program a waypoint slightly beyond the configured soft joint limit and execute the move, or manually shift a joint limit in the safety configuration to encroach on the normal trajectory.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 20,
"root_cause": "idle_power_overconsumption",
"description": "The robot draws abnormally high current while nominally idle, indicating a parasitic load or controller fault.",
"severity_levels": [
"low",
"medium"
],
"injectable": false,
"possible_anomalies": [
"sustained_low_torque",
"joint_current_imbalance"
],
"simulation_procedure": "Inspect for stuck brakes, shorted windings, or misconfigured standby modes; clear fault and re-verify idle current draw.",
"datasets": []
},
{
"fault_id": 22,
"root_cause": "tcp_frame_misconfiguration",
"description": "The Tool Center Point (TCP) frame or mounting orientation is configured incorrectly in PolyScope, causing the robot to detect unexpected gravitational torques consistent with wrong mounting.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"protective_stop_event",
"persistent_tracking_error"
],
"related_error_codes": [
"C156A",
"C155A"
],
"primary_error_code": "C156A",
"simulation_procedure": "Enter an incorrect TCP offset (e.g. shift X by 100 mm) or wrong mounting angle in the Installation > TCP configuration in PolyScope, then run the program.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 23,
"root_cause": "payload_misconfiguration",
"description": "The payload mass is left at 0 kg in the robot configuration while a tool or workpiece is physically attached, causing the collision detection model to trigger on normal inertial forces.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"protective_stop_event",
"speed_drop_with_force_spike"
],
"related_error_codes": [
"C158A",
"C162A"
],
"primary_error_code": "C158A",
"simulation_procedure": "Ensure the installation payload is set to 0 kg while a tool (e.g. gripper, 300 g) is physically mounted, then run a standard pick-and-place cycle.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 25,
"root_cause": "external_arm_disturbance",
"description": "An external force continuously pulls or pushes the robot arm during motion, such as a tethered cable, hanging weight, or operator interference, causing persistent torque anomalies.",
"severity_levels": [
"low",
"medium",
"high"
],
"injectable": true,
"possible_anomalies": [
"tcp_force_spike",
"sustained_contact_force",
"protective_stop_event"
],
"related_error_codes": [
"C111A"
],
"primary_error_code": "C111A",
"simulation_procedure": "Anchor a spring or elastic band between a fixed point in the workspace (e.g. the bench frame) and the robot tool flange, with no contact along the arm links. Run the standard trajectory so the arm experiences a continuously varying external pull force at the TCP only. Alternatively, have an operator apply a steady manual push/pull force on the tool flange during motion.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 28,
"root_cause": "payload_cog_misconfiguration",
"description": "The payload center of gravity (CoG) is specified at an incorrect offset from the tool flange, causing the gravity compensation model to apply wrong torques and triggering protective stops during motion.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"protective_stop_event",
"persistent_tracking_error"
],
"related_error_codes": [
"C162A",
"C156A"
],
"primary_error_code": "C162A",
"simulation_procedure": "Set the center of gravity offset in the payload configuration to a position far from the actual tool CoG (e.g. 150 mm offset in Z), then execute a multi-pose trajectory.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 29,
"task": [
"pick_and_place"
],
"root_cause": "collision_hanging_cable",
"description": "A cable or wire hangs across the robot workspace and contacts the arm or tool during motion. The flexible cable wraps around or drags along the arm, producing a sustained asymmetric pull force and persistent torque anomaly rather than a sharp impact.",
"severity_levels": [
"low",
"medium"
],
"injectable": false,
"possible_anomalies": [
"sustained_contact_force",
"persistent_tracking_error",
"oscillation_around_setpoint"
],
"related_error_codes": [
"C157A",
"C111A"
],
"primary_error_code": "C157A",
"simulation_procedure": "Suspend a loose cable or wire across the robot trajectory at arm height so it drags along the robot link or tool flange during the motion cycle.",
"datasets": [
"factorywave",
"vorausad"
]
},
{
"fault_id": 30,
"task": [
"pick_and_place"
],
"root_cause": "collision_cardboard_object",
"description": "The robot strikes a cardboard carton or flat-pack box placed in its path. Cardboard provides moderate resistance — the robot may displace the object or, if the carton is braced, generate enough torque deviation to trigger a protective stop.",
"severity_levels": [
"low",
"medium"
],
"injectable": false,
"possible_anomalies": [
"tcp_force_spike",
"speed_drop_with_force_spike",
"protective_stop_event"
],
"related_error_codes": [
"C157A",
"C283A26"
],
"primary_error_code": "C157A",
"simulation_procedure": "Place a cardboard box (free-standing or lightly braced) in the robot trajectory. A free box will be pushed, recording a moderate spike; brace the box against a wall to increase resistance and provoke a protective stop.",
"datasets": [
"factorywave",
"vorausad"
]
},
{
"fault_id": 31,
"task": [
"pick_and_place"
],
"root_cause": "collision_rigid_object",
"description": "The robot collides with a hard, immovable object such as a metal fixture, tool stand, or structural element. The high contact stiffness produces an immediate large torque deviation and invariably triggers a protective stop.",
"severity_levels": [
"medium",
"high"
],
"injectable": false,
"possible_anomalies": [
"tcp_force_spike",
"protective_stop_event"
],
"related_error_codes": [
"C157A",
"C158A"
],
"primary_error_code": "C157A",
"simulation_procedure": "Place a rigid metal block or clamp a solid fixture at a position that intersects the programmed TCP path. Run the program at normal speed; the collision will trigger an immediate protective stop.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 32,
"task": [
"machine_tending"
],
"root_cause": "peg_insertion_misalignment",
"description": "The peg approaches the hole at an angular or lateral offset, causing the tip to jam against the hole rim rather than enter cleanly, producing elevated contact forces and position tracking errors.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"tcp_force_spike",
"persistent_tracking_error",
"protective_stop_event"
],
"simulation_procedure": "Introduce a small angular offset (e.g. 2-5 degrees) or lateral offset (e.g. 3-8 mm) in the insertion approach waypoint in the robot program, so the peg contacts the hole rim instead of entering cleanly.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 33,
"task": [
"machine_tending"
],
"root_cause": "hole_obstruction",
"description": "A foreign object or debris is lodged inside the insertion hole, preventing full peg insertion and generating an abnormal force buildup as the peg contacts the obstruction.",
"severity_levels": [
"medium",
"high"
],
"injectable": true,
"possible_anomalies": [
"sustained_contact_force",
"tcp_force_spike",
"protective_stop_event"
],
"simulation_procedure": "Place a small object (e.g. a metal chip, rubber disc, or folded paper) inside the hole before the insertion cycle. The peg will contact the obstruction mid-insertion, producing a distinct force anomaly.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 34,
"task": [
"machine_tending"
],
"root_cause": "incorrect_insertion_depth",
"description": "The insertion motion terminates at an incorrect Z depth due to a misconfigured waypoint, leaving the peg partially inserted (too shallow) or causing it to over-push against the hole bottom (too deep).",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"persistent_tracking_error",
"sustained_contact_force"
],
"simulation_procedure": "Modify the insertion endpoint waypoint Z offset in the robot program by +/- 10-20 mm from the nominal value. Too shallow leaves the peg proud; too deep drives it against the fixture bottom.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 35,
"task": [
"machine_tending"
],
"root_cause": "peg_surface_contamination",
"description": "Contamination or increased surface roughness on the peg (e.g. chalk, adhesive residue, or grit) raises insertion friction, producing stick-slip force patterns and higher-than-nominal contact force throughout the insertion stroke.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"sustained_contact_force",
"speed_drop_with_force_spike"
],
"simulation_procedure": "Apply a thin layer of dry chalk powder, fine abrasive paste, or low-tack adhesive to the peg surface before the insertion cycle to increase surface friction.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 36,
"task": [
"machine_tending"
],
"root_cause": "fixture_displacement",
"description": "The insertion fixture has shifted laterally from its nominal position due to vibration, impact, or improper clamping, creating a positional mismatch between the programmed approach and the actual hole location.",
"severity_levels": [
"low",
"medium",
"high"
],
"injectable": true,
"possible_anomalies": [
"tcp_force_spike",
"persistent_tracking_error",
"protective_stop_event"
],
"simulation_procedure": "Deliberately shift the hole fixture by a controlled lateral offset (e.g. 5-15 mm) from its nominal position without updating the robot program waypoints.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 37,
"root_cause": "self_collision_link_interference",
"description": "The robot trajectory passes through a configuration where an arm link collides with the robot's own body or mounting fixture, triggering an immediate protective stop.",
"severity_levels": [
"medium",
"high"
],
"injectable": true,
"possible_anomalies": [
"tcp_force_spike",
"protective_stop_event",
"persistent_tracking_error"
],
"related_error_codes": [
"C157A",
"C158A"
],
"primary_error_code": "C157A",
"simulation_procedure": "Program a waypoint that requires the arm to fold into a self-colliding configuration, or deliberately offset the mounting fixture so the standard trajectory causes a link to contact it.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 38,
"task": [
"pick_and_place"
],
"root_cause": "missing_box",
"description": "The robot executes the full pick-and-place cycle but no box is present at the pick position. The gripper closes on empty air and the arm transports no payload, producing a torque and current profile consistent with an unloaded trajectory.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"payload_torque_absence",
"sustained_low_torque",
"gripper_close_no_force",
"torque_deviation_from_nominal"
],
"simulation_procedure": "Remove the box from the pick position before the episode starts. The robot runs the standard pick-and-place program unmodified.",
"datasets": [
"factorywave"
]
},
{
"fault_id": 39,
"task": [
"peg_in_hole"
],
"root_cause": "missing_peg",
"description": "The robot executes the full peg-in-hole cycle but no peg is gripped. The arm descends into the hole empty-handed and the insertion phase produces no contact force, resulting in an anomalously low force and torque profile during what should be a high-contact phase.",
"severity_levels": [
"low",
"medium"
],
"injectable": true,
"possible_anomalies": [
"reduced_contact_force",
"gripper_close_no_force",
"sustained_low_torque",
"torque_deviation_from_nominal"
],
"simulation_procedure": "Remove the peg from the gripper or skip the peg pick-up step before the episode starts. The robot runs the standard insertion program unmodified.",
"datasets": [
"factorywave"
]
}
],
"anomalies": [
{
"anomaly_name": "tcp_force_spike",
"description": "Abrupt, short-duration spike in TCP wrench (force and or torque).",
"relevant_features_from_schema": [
"true_force_{i}",
"est_contact_force_{i}",
"feedback_speed_{axis}",
"effort_current_{axis}"
]
},
{
"anomaly_name": "speed_drop_with_force_spike",
"description": "Measured joint speeds drop abruptly at the same time as a TCP force spike (typical collision signature).",
"relevant_features_from_schema": [
"feedback_speed_{axis}",
"true_force_{i}",
"est_contact_force_{i}",
"protective_stop_state"
]
},
{
"anomaly_name": "vibration_burst",
"description": "Short transient burst of high acceleration at the tool.",
"relevant_features_from_schema": [
"vibration_0",
"vibration_1",
"vibration_2",
"true_force_{i}",
"est_contact_force_{i}"
]
},
{
"anomaly_name": "acoustic_spike",
"description": "Sudden increase in acoustic emission indicating impact, slip, chatter, or tool interaction.",
"relevant_features_from_schema": [
"acoustic_0",
"true_force_{i}",
"est_contact_force_{i}",
"vibration_0",
"vibration_1",
"vibration_2"
]
},
{
"anomaly_name": "high_current_low_motion",
"description": "Motor current rises while measured joint speed remains low or near zero, indicating resistance or stall-like behavior.",
"relevant_features_from_schema": [
"effort_current_{axis}",
"feedback_speed_{axis}",
"feedback_pos_{axis}",
"setpoint_speed_{axis}",
"setpoint_pos_{axis}"
]
},
{
"anomaly_name": "protective_stop_event",
"description": "Protective stop becomes active, often after contact or safety limit violations.",
"relevant_features_from_schema": [
"protective_stop_state",
"safety_mode",
"feedback_speed_{axis}",
"true_force_{i}",
"est_contact_force_{i}"
]
},
{
"anomaly_name": "persistent_tracking_error",
"description": "Sustained deviation between commanded motion and measured motion (position and or speed).",
"relevant_features_from_schema": [
"setpoint_pos_{axis}",
"feedback_pos_{axis}",
"setpoint_speed_{axis}",
"feedback_speed_{axis}",
"effort_current_{axis}"
]
},
{
"anomaly_name": "reduced_contact_force",
"description": "Measured contact force is abnormally low during a phase where contact is expected (for example, tightening without engaging).",
"relevant_features_from_schema": [
"true_force_{i}",
"est_contact_force_{i}",
"effort_current_{axis}",
"feedback_speed_{axis}"
]
},
{
"anomaly_name": "unexpected_low_current_during_tightening",
"description": "Motor current remains unusually low during a tightening phase where torque demand is expected to rise.",
"relevant_features_from_schema": [
"effort_current_{axis}",
"true_force_{i}",
"est_contact_force_{i}",
"feedback_speed_{axis}",
"setpoint_speed_{axis}"
]
},
{
"anomaly_name": "acoustic_spike_without_force",
"description": "Acoustic emission increases without a corresponding force spike, suggesting slip or chatter rather than hard contact.",
"relevant_features_from_schema": [
"acoustic_0",
"true_force_{i}",
"est_contact_force_{i}",
"vibration_0",
"vibration_1",
"vibration_2"
]
},
{
"anomaly_name": "misalignment_signature",
"description": "Pattern consistent with off-axis insertion, often showing intermittent force pulses, micro-stalls, and small tracking errors.",
"relevant_features_from_schema": [
"true_force_{i}",
"est_contact_force_{i}",
"feedback_speed_{axis}",
"effort_current_{axis}",
"setpoint_pos_{axis}",
"feedback_pos_{axis}",
"vibration_0",
"vibration_1",
"vibration_2"
]
},
{
"anomaly_name": "under_tightening_signature",
"description": "Tightening completes without reaching expected force or torque build-up, indicating insufficient engagement or premature stop.",
"relevant_features_from_schema": [
"true_force_{i}",
"est_contact_force_{i}",
"effort_current_{axis}",
"feedback_speed_{axis}",
"protective_stop_state"
]
},
{
"anomaly_name": "spurious_speed_spike",
"description": "Isolated unrealistic spike in measured joint speed, typically from logging or communication artifacts.",
"relevant_features_from_schema": [
"feedback_speed_{axis}",
"timestamp_ms"
]
},
{
"anomaly_name": "spurious_current_spike",
"description": "Isolated unrealistic spike in motor current not supported by motion or force context.",
"relevant_features_from_schema": [
"effort_current_{axis}",
"feedback_speed_{axis}",
"true_force_{i}",
"est_contact_force_{i}",
"timestamp_ms"
]
},
{
"anomaly_name": "spurious_force_spike",
"description": "Isolated unrealistic spike in force sensor data inconsistent with motion, vibration, or current.",
"relevant_features_from_schema": [
"true_force_{i}",
"est_contact_force_{i}",
"feedback_speed_{axis}",
"vibration_0",
"vibration_1",
"vibration_2",
"timestamp_ms"
]
},
{
"anomaly_name": "unexpected_safety_mode_change",
"description": "Safety mode changes unexpectedly, potentially due to configuration, safety limits, or controller state transitions.",
"relevant_features_from_schema": [
"safety_mode",
"protective_stop_state",
"main_voltage",
"feedback_speed_{axis}",
"true_force_{i}"
]
},
{
"anomaly_name": "sustained_contact_force",
"description": "Contact forces remain elevated for an extended interval, indicating prolonged contact or high process resistance.",
"relevant_features_from_schema": [
"true_force_{i}",
"est_contact_force_{i}",
"effort_current_{axis}",
"feedback_speed_{axis}",
"joint_temp_{axis}"
]
},
{
"anomaly_name": "gradual_current_force_temperature_rise",
"description": "Slow concurrent increase in motor current, TCP force, and joint temperature during continued operation.",
"relevant_features_from_schema": [
"effort_current_{axis}",
"true_force_{i}",
"est_contact_force_{i}",
"joint_temp_{axis}",
"timestamp_ms"
]
},
{
"anomaly_name": "reduced_speed_under_high_setpoint",
"description": "Measured joint speed is significantly lower than commanded speed for a sustained period.",
"relevant_features_from_schema": [
"setpoint_speed_{axis}",
"feedback_speed_{axis}",
"effort_current_{axis}",
"main_voltage",
"joint_temp_{axis}"
]
},
{
"anomaly_name": "oscillation_around_setpoint",
"description": "Feedback position or speed oscillates around the commanded trajectory with periodic behavior.",
"relevant_features_from_schema": [
"setpoint_pos_{axis}",
"feedback_pos_{axis}",
"setpoint_speed_{axis}",
"feedback_speed_{axis}",
"effort_current_{axis}"
]
},
{
"anomaly_name": "position_jump_without_motion",
"description": "Sudden discontinuity in measured joint position without consistent supporting speed or force context.",
"relevant_features_from_schema": [
"feedback_pos_{axis}",
"feedback_speed_{axis}",
"timestamp_ms"
]
},
{
"anomaly_name": "joint_overheating",
"description": "Joint temperature exceeds typical levels or rises abnormally fast, often with elevated current.",
"relevant_features_from_schema": [
"joint_temp_{axis}",
"effort_current_{axis}",
"feedback_speed_{axis}"
]
},
{
"anomaly_name": "voltage_drop",
"description": "Main voltage falls below nominal range or shows abnormal dips correlated with degraded performance.",
"relevant_features_from_schema": [
"main_voltage",
"effort_current_{axis}",
"feedback_speed_{axis}",
"safety_mode"
]
},
{
"anomaly_name": "force_estimation_mismatch",
"description": "Estimated TCP wrench and true measured TCP wrench diverge beyond normal tolerance.",
"relevant_features_from_schema": [
"est_contact_force_{i}",
"true_force_{i}",
"feedback_speed_{axis}",
"effort_current_{axis}"
]
},
{
"anomaly_name": "noisy_force_signal",
"description": "Force sensor readings exhibit abnormal high-frequency noise or jitter relative to expected dynamics.",
"relevant_features_from_schema": [
"true_force_{i}",
"timestamp_ms",
"vibration_0",
"vibration_1",
"vibration_2",
"acoustic_0"
]
},
{
"anomaly_name": "increasing_rms_vibration",
"description": "Vibration energy gradually increases over time, suggesting wear or loosening.",
"relevant_features_from_schema": [
"vibration_0",
"vibration_1",
"vibration_2",
"acoustic_0",
"timestamp_ms"
]
},
{
"anomaly_name": "joint_current_imbalance",
"description": "One joint shows consistently abnormal current relative to other joints for similar commanded motion.",
"relevant_features_from_schema": [
"effort_current_{axis}",
"setpoint_speed_{axis}",
"feedback_speed_{axis}",
"setpoint_pos_{axis}",
"feedback_pos_{axis}"
]
},
{
"anomaly_name": "gripper_close_no_force",
"description": "Gripper is commanded closed but contact force signatures indicate no object engagement.",
"relevant_features_from_schema": [
"gripper_command",
"true_force_{i}",
"est_contact_force_{i}",
"acoustic_0",
"vibration_0",
"vibration_1",
"vibration_2"
]
},
{
"anomaly_name": "torque_sensor_elevation",
"description": "Torque sensor readings at one or more axes are persistently elevated above the expected profile for the commanded motion, indicating increased mechanical resistance or external loading.",
"relevant_features_from_schema": [
"torque_sensor_a_{axis}",
"torque_sensor_b_{axis}",
"motor_torque_{axis}",
"motor_iq_{axis}",
"target_torque_{axis}"
]
},
{
"anomaly_name": "motor_iq_elevation",
"description": "The torque-forming current component Iq at one or more axes is elevated above the expected level for the given commanded motion, indicating increased mechanical load or friction.",
"relevant_features_from_schema": [
"motor_iq_{axis}",
"torque_sensor_a_{axis}",
"target_velocity_{axis}",
"joint_velocity_{axis}",
"power_motor_el_{axis}"
]
},
{
"anomaly_name": "motor_electrical_power_elevation",
"description": "Electrical power consumption at one or more axes is elevated without a proportional increase in mechanical output power, indicating reduced motor efficiency.",
"relevant_features_from_schema": [
"power_motor_el_{axis}",
"power_motor_mech_{axis}",
"motor_iq_{axis}",
"motor_id_{axis}",
"motor_voltage_{axis}"
]
},
{
"anomaly_name": "motor_id_elevation",
"description": "The magnetizing current component Id at one or more axes is elevated, indicating a shift in the commutation phase that reduces torque-forming efficiency without necessarily increasing measured torque.",
"relevant_features_from_schema": [
"motor_id_{axis}",
"motor_iq_{axis}",
"power_motor_el_{axis}",
"motor_voltage_{axis}"
]
},
{
"anomaly_name": "iq_id_ratio_anomaly",
"description": "The ratio between the torque-forming current Iq and the magnetizing current Id deviates from the expected value, indicating commutation misalignment. In normal operation Id should be near zero; elevation relative to Iq is the key signature.",
"relevant_features_from_schema": [
"motor_iq_{axis}",
"motor_id_{axis}",
"motor_torque_{axis}",
"power_motor_el_{axis}"
]
},
{
"anomaly_name": "increased_computed_inertia",
"description": "Computed inertia at one or more axes is elevated above the nominal range for the current joint configuration, indicating an unexpected additional mass in the kinematic chain.",
"relevant_features_from_schema": [
"computed_inertia_{axis}",
"computed_torque_{axis}",
"target_acceleration_{axis}",
"torque_sensor_a_{axis}"
]
},
{
"anomaly_name": "payload_torque_absence",
"description": "Torque profiles during the transport phase show no evidence of payload loading. Expected gravity and inertia contributions from the carried object are absent across all axes.",
"relevant_features_from_schema": [
"torque_sensor_a_{axis}",
"torque_sensor_b_{axis}",
"computed_torque_{axis}",
"motor_torque_{axis}",
"motor_iq_{axis}"
]
},
{
"anomaly_name": "abrupt_torque_drop",
"description": "A sudden sharp decrease in torque sensor readings at one or more axes occurring mid-motion, indicating an abrupt loss of payload or contact force.",
"relevant_features_from_schema": [
"torque_sensor_a_{axis}",
"torque_sensor_b_{axis}",
"motor_torque_{axis}",
"joint_velocity_{axis}",
"computed_torque_{axis}"
]
},
{
"anomaly_name": "sustained_low_torque",
"description": "Torque sensor readings remain consistently below the expected level for a given motion phase over an extended period, indicating absence of expected payload or contact load.",
"relevant_features_from_schema": [
"torque_sensor_a_{axis}",
"torque_sensor_b_{axis}",
"motor_torque_{axis}",
"computed_torque_{axis}",
"target_torque_{axis}"
]
},
{
"anomaly_name": "torque_deviation_from_nominal",
"description": "Torque profiles across one or more axes deviate from the expected distribution for the commanded motion. Deviation may be positive or negative depending on whether the payload is heavier or lighter than nominal.",
"relevant_features_from_schema": [
"torque_sensor_a_{axis}",
"torque_sensor_b_{axis}",
"motor_torque_{axis}",
"computed_torque_{axis}",
"target_torque_{axis}",
"motor_iq_{axis}"
]
},
{
"anomaly_name": "pose_dependent_torque_anomaly",
"description": "Torque elevation at affected axes that varies with joint angle configuration rather than being constant, indicating a load whose effect depends on arm pose such as a cable applying varying tension as the arm moves.",
"relevant_features_from_schema": [
"torque_sensor_a_{axis}",
"torque_sensor_b_{axis}",
"joint_position_{axis}",
"motor_iq_{axis}",
"computed_torque_{axis}"
]
},
{
"anomaly_name": "torque_profile_temporal_shift",
"description": "The expected torque patterns for each motion phase occur at different times than nominal, indicating that the robot is executing an atypical joint trajectory due to an unusual approach or gripping configuration.",
"relevant_features_from_schema": [
"torque_sensor_a_{axis}",
"torque_sensor_b_{axis}",
"joint_position_{axis}",
"target_position_{axis}",
"motor_iq_{axis}"
]
},
{
"anomaly_name": "broadband_torque_noise",
"description": "Torque sensor and joint velocity signals exhibit elevated noise across all frequency bands, consistent with mechanical vibrations transmitted from an unstable mounting surface into the robot structure.",
"relevant_features_from_schema": [
"torque_sensor_a_{axis}",
"torque_sensor_b_{axis}",
"joint_velocity_{axis}",
"motor_velocity_{axis}",
"motor_iq_{axis}"
]
}
],
"root_cause_error_mapping": [
{
"fault_id": 1,
"root_cause": "damaged_screw_thread",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The screw thread is physically damaged, preventing proper engagement during tightening and producing an abnormal torque signature.",
"ur3_protocol": "Retract the screwdriver immediately to avoid cross-threading the plate hole. Discard the damaged screw and replace it with a new one from the feeder. Inspect the plate hole for any thread damage caused by the failed engagement attempt. Verify the torque signature returns to nominal on a slow test cycle before resuming production."
},
{
"fault_id": 2,
"root_cause": "extra_assembly_component",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "An unexpected object such as a washer is present in the assembly location, altering contact geometry and tightening dynamics.",
"ur3_protocol": "Retract before applying further tightening force. Remove the unexpected component from the assembly location and verify the mating surface is clean and unobstructed. Check upstream assembly steps to identify how the extra component was introduced. Resume the tightening cycle and confirm the torque profile matches nominal."
},
{
"fault_id": 3,
"root_cause": "missing_screw",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The robot attempts tightening but no screw is present, typically due to a pick failure or skipped step in the sequence.",
"ur3_protocol": "Halt the tightening motion and return to the pick position. Inspect the feeder to confirm screw availability and that the pick was successful before the next attempt. Check the gripper activation log to determine whether the pick step was skipped or failed silently. Retry the full pick-and-tighten sequence from the start."
},
{
"fault_id": 4,
"root_cause": "damaged_plate_thread",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The threaded hole in the plate is damaged, preventing proper screw engagement and risking cross-threading or stripping.",
"ur3_protocol": "Retract the screw immediately without applying further torque. Inspect the plate hole visually and with a thread gauge to assess the extent of damage. If the thread is salvageable, re-tap the hole with the correct tap size before retrying. If the damage is beyond repair, replace the plate. Do not attempt re-insertion until the hole thread is confirmed good."
},
{
"fault_id": 5,
"root_cause": "loosening_phase",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The robot is performing a screw-loosening operation rather than tightening, producing a distinct counterclockwise torque signature that may appear anomalous if only tightening is expected.",
"ur3_protocol": "Verify the current task phase in the program and confirm whether a loosening step is expected at this point in the sequence. If the loosening is unintended, halt the cycle, check the program logic for incorrect phase ordering, and restart from the correct step. If loosening is expected, no corrective action is required beyond confirming the screw disengages cleanly."
},
{
"fault_id": 7,
"root_cause": "motor_miscommutation",
"ur3_error_code": "C 39 A 1",
"ur3_error_name": "Max current deviation failure",
"ur3_description": null,
"ur3_protocol": "a) Stop the robot program and power-cycle the controller to reset the motor commutation state. b) Re-run a slow-speed diagnostic cycle on the affected joint to verify correct torque-forming efficiency. c) If the fault recurs after power-cycling, inspect the motor winding connections and commutation configuration in the servo drive. d) If the fault persists across multiple power cycles, replace the affected joint."
},
{
"fault_id": 8,
"root_cause": "gripper_activation_failure",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The vacuum gripper failed to activate at the pick phase, leaving the robot carrying no payload through the full transport trajectory.",
"ur3_protocol": "a) Check vacuum supply pressure at the source and verify the solenoid valve receives its activation signal via the I/O monitor. b) Inspect the vacuum line and fittings for leaks, kinks, or disconnections. c) Test the solenoid valve in isolation (manual I/O trigger) to confirm it opens and closes correctly. d) If the valve is functional, inspect the gripper cup for cracks or deformation that prevent suction from forming. e) Clear the fault, re-home the robot, and verify gripper activation on a slow test pick before resuming normal cycles."
},
{
"fault_id": 9,
"root_cause": "gripper_release_during_motion",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The vacuum gripper released the object mid-trajectory, causing an abrupt loss of payload and leaving the dropped object in an unknown location within the workspace.",
"ur3_protocol": "a) Stop the robot and locate the dropped object before resuming: it may have landed in the trajectory of the return motion. b) Check the I/O log to determine whether the solenoid OFF signal was commanded or spurious. c) Inspect the vacuum line for intermittent connections or pressure drops under dynamic loading. d) If the release was spurious, check for electrical noise on the gripper control line and verify connector seating. e) If not, check policy used. d) Re-home the robot, confirm gripper hold force on a static test before resuming transport cycles."
},
{
"fault_id": 10,
"root_cause": "additional_axis_payload",
"ur3_error_code": "C 153 A 0",
"ur3_error_name": "Protective Stop: Too high dynamics",
"ur3_description": "Check payload, center of gravity and acceleration settings. Log screen may contain additional information.",
"ur3_protocol": "a) Stop the robot and update the payload configuration to include the additional axis weight. b) Set the correct center of gravity offset for the modified arm configuration in the installation settings. c) Review and reduce motion accelerations and speeds to account for the increased effective inertia. d) Run a slow-speed test cycle to verify the dynamic loads stay within the robot's rated limits before resuming normal operation."
},
{
"fault_id": 11,
"root_cause": "collision_foam_object",
"ur3_error_code": "C 157 A",
"ur3_error_name": "Protective Stop: Collision detected by joint",
"ur3_description": "A soft object in the trajectory produced a transient TCP force spike. Foam typically does not trigger a protective stop but may at higher speeds or densities.",
"ur3_protocol": "a) Inspect the workspace and remove any soft obstructions from the programmed trajectory. b) If a protective stop occurred, acknowledge it in the robot controller interface and verify the arm posture is nominal before resuming. c) Reduce speed if repeated false-positive collision detections occur."
},
{
"fault_id": 13,
"root_cause": "cable_routed_on_robot",
"ur3_error_code": "C 173 A 1",
"ur3_error_name": "Robot motion causes too high joint torques on Shoulder",
"ur3_description": null,
"ur3_protocol": "a) Stop the robot and inspect all cable routing along the arm links. b) Re-route the cable to eliminate pose-dependent friction and excess loading on the affected joints, ensuring sufficient slack at all extreme configurations. c) Secure the cable with appropriate management clips so it does not drag or tension during motion. d) Reduce motion accelerations if re-routing is not immediately possible. e) Run a slow-speed test cycle monitoring joint torques to confirm loading returns to nominal before resuming normal operation."
},
{
"fault_id": 14,
"root_cause": "invalid_gripping_position",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The gripper closed at an off-center or tilted position due to a timing error in the pick sequence, resulting in asymmetric payload distribution throughout the transport phase.",
"ur3_protocol": "a) If the object is visibly misaligned or at risk of dropping, stop the robot and re-place the object at the nominal pick position before continuing. b) Review the pick sequence timing: identify and correct any sleep() delays or I/O latency that caused the gripper to close late. c) Verify gripper activation is synchronised with the arm being fully settled at the pick waypoint (zero velocity). d) Perform a slow-speed test pick and visually confirm symmetric grip before resuming normal cycles."
},
{
"fault_id": 15,
"root_cause": "unstable_mounting_platform",
"ur3_error_code": "C 173 A 0",
"ur3_error_name": "Robot motion causes too high joint torques on Base",
"ur3_description": null,
"ur3_protocol": "a) Stop the robot immediately and stabilise the mounting platform by locking all wheel brakes or re-securing the base fixture. b) Verify base rigidity across all planned robot configurations before resuming. c) Reduce motion speeds and accelerations until the mounting is confirmed stable. d) Inspect the robot base and mounting interface for mechanical damage caused by the vibration. e) Run a slow-speed test cycle to confirm joint torques return to nominal values."
},
{
"fault_id": 16,
"root_cause": "gearbox_overload",
"ur3_error_code": "C 70 A",
"ur3_error_name": "Close to gearbox shear limit",
"ur3_description": "Acceleration/deceleration too high. Mechanical problem in gear related to encoder mounting.",
"ur3_protocol": "a) Reduce acceleration and deceleration values in the motion program to lower peak gearbox loads. b) Power-cycle the controller to clear the fault state. c) Run a slow-speed test cycle to verify the joint operates without torque overload. d) If the fault recurs across multiple cycles, inspect the gearbox for mechanical damage and replace the joint if necessary."
},
{
"fault_id": 17,
"root_cause": "motor_encoder_stall",
"ur3_error_code": "C 85 A",
"ur3_error_name": "Motor encoder error",
"ur3_description": "The motor is receiving current commands but the encoder reports no position change, indicating the joint shaft is mechanically stalled or seized.",
"ur3_protocol": "a) Do NOT attempt to power through the stall: cut motor current immediately to avoid gearbox or winding damage. b) Identify and remove any mechanical obstruction before re-energising the joint. c) Power down and manually check the affected joint for free rotation across its full range. d) Inspect the encoder connector and cable for damage or loose seating that may have caused a false stall reading. e) Power-cycle the controller to clear the fault state. f) If the stall recurs with no external obstruction, the joint motor or gearbox is likely damaged: replace the joint."
},
{
"fault_id": 19,
"root_cause": "joint_position_limit_violation",
"ur3_error_code": "C 39 A 3",
"ur3_error_name": "Max motor-encoder speed exceeded",
"ur3_description": null,
"ur3_protocol": "a) Power-cycle the controller to clear the fault state. b) Review the motion program and verify all waypoints and blends stay within the configured joint position and speed limits. c) Reduce trajectory speeds or adjust the problematic waypoint. d) Run a slow-speed test cycle to confirm the joint operates within limits. e) If the violation recurs after program correction, inspect the joint encoder and replace the joint if necessary."
},
{
"fault_id": 20,
"root_cause": "idle_power_overconsumption",
"ur3_error_code": "C 61 A",
"ur3_error_name": "Idle power consumption too high",
"ur3_description": "The system is drawing more power than expected while idle.",
"ur3_protocol": "a) Check the braking resistor / energy dissipation unit cables and connections for loose or damaged contacts. b) Inspect the braking resistor for signs of overheating or physical damage. c) Check whether joint brakes are engaging correctly and not dragging while the robot is idle. d) Replace the braking resistor if damage is confirmed."
},
{
"fault_id": 21,
"root_cause": "singularity_passage",
"ur3_error_code": "C 154 A",
"ur3_error_name": "Protective Stop: Position in singularity",
"ur3_description": "Robot cannot move linear near a singularity.",
"ur3_protocol": "a) Avoid commanding linear (Cartesian) motion through or near the singularity configuration. b) Replace the problematic linear move with a joint-space motion command to bypass the singularity. c) Alternatively, re-plan the approach and departure waypoints so the straight-line path does not pass near the singularity."
},
{
"fault_id": 22,
"root_cause": "tcp_frame_misconfiguration",
"ur3_error_code": "C 156 A",
"ur3_error_name": "Protective Stop: Wrong payload or mounting detected, or something is pushing the robot when entering Free drive mode",
"ur3_description": "The robot may move unexpectedly due to wrong settings.",
"ur3_protocol": "Verify that the TCP configuration and mounting in the used installation is correct."
},
{
"fault_id": 23,
"root_cause": "payload_misconfiguration",
"ur3_error_code": "C 158 A",
"ur3_error_name": "Protective Stop: Collision detected by joint",
"ur3_description": "The joint torque model detected an unexpected resistive force consistent with a physical collision while the payload is specified as 0 kg, making the collision threshold very sensitive.",
"ur3_protocol": "a) Set the correct payload mass and center of gravity in the installation settings. b) Clear any obstruction from the workspace. c) Verify acceleration and speed settings are appropriate for the mounted tool."
},
{
"fault_id": 24,
"root_cause": "safety_plane_violation",
"ur3_error_code": "C 152 A",
"ur3_error_name": "Protective Stop: Position close to safety plane limits",
"ur3_description": "The robot TCP or a body link has approached or crossed a configured safety plane boundary defined in the safety configuration.",
"ur3_protocol": "a) Review safety plane positions in the safety configuration. b) Modify the robot program to keep all motion within the defined safety zones. c) Check that the correct safety configuration is active."
},
{
"fault_id": 25,
"root_cause": "external_arm_disturbance",
"ur3_error_code": "C 111 A",
"ur3_error_name": "Something is pulling the robot",
"ur3_description": null,
"ur3_protocol": "Check TCP configuration, payload and mounting settings."
},
{
"fault_id": 26,
"root_cause": "magnetic_encoder_misalignment",
"ur3_error_code": "C 74 A 1",
"ur3_error_name": "Invalid decode: Read head misalignment, ring damaged or external magnetic field present",
"ur3_description": "Magnetic encoder error (absolute encoder). Argument = sum of C 74 errors.",
"ur3_protocol": "Check grounding and shielding for EMC problems."
},
{
"fault_id": 27,
"root_cause": "motor_phase_fault",
"ur3_error_code": "C 71 A 12",
"ur3_error_name": "Phase 3 or multiple phases is unconnected or not working",
"ur3_description": "The wire is (1) damaged, (2) has been disconnected from the PCB, or (3) defect PCB.",
"ur3_protocol": "a) Check joint for damaged or loose connections. b) Replace the joint."
},
{
"fault_id": 28,
"root_cause": "payload_cog_misconfiguration",
"ur3_error_code": "C 162 A",
"ur3_error_name": "Protective stop likely caused by incorrectly specified payload mass and/or center of gravity",
"ur3_description": "Specifying an incorrect payload mass and/or center of gravity may cause poor robot performance and/or protective stops.",
"ur3_protocol": "Make sure the specified payload mass and center of gravity are correct."
},
{
"fault_id": 29,
"root_cause": "collision_hanging_cable",
"ur3_error_code": "C 157 A",
"ur3_error_name": "Protective Stop: Collision detected by joint",
"ur3_description": "A cable or wire dragging along the arm during motion produced a sustained asymmetric force on the joints, triggering the collision detection model.",
"ur3_protocol": "a) Power down and inspect the arm and tool flange for entangled cables or wires before resuming. b) Clear the workspace above and around the robot trajectory of any hanging cables. c) If a protective stop occurred, acknowledge it in the robot controller interface and perform a slow-speed test run to confirm the obstruction is fully removed."
},
{
"fault_id": 30,
"root_cause": "collision_cardboard_object",
"ur3_error_code": "C 157 A",
"ur3_error_name": "Protective Stop: Collision detected by joint",
"ur3_description": "The robot struck a cardboard object in its path. A free-standing box may be displaced without triggering a stop; a braced box generates enough resistive torque to trigger a protective stop.",
"ur3_protocol": "a) Remove the cardboard obstruction from the trajectory. b) Inspect the TCP and wrist links for any displacement or damage from the impact. c) If a protective stop occurred, acknowledge it in the robot controller interface, verify the arm posture, and perform a slow-speed test run before resuming normal operation."
},
{
"fault_id": 31,
"root_cause": "collision_rigid_object",
"ur3_error_code": "C 157 A",
"ur3_error_name": "Protective Stop: Collision detected by joint",
"ur3_description": "The robot collided with a hard, immovable object. The high contact stiffness produces an immediate large torque deviation that invariably triggers a protective stop.",
"ur3_protocol": "a) Do NOT resume motion before removing the rigid obstacle from the workspace. b) Physically inspect the TCP, tool flange, and all arm links for structural damage or loose fasteners. c) If no damage is found, acknowledge the protective stop, perform a slow-speed dry run across the full trajectory, and confirm clearance before restoring normal speed."
},
{
"fault_id": 32,
"root_cause": "peg_insertion_misalignment",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The peg approached the hole at an angular or lateral offset, causing the tip to jam against the hole rim rather than enter cleanly, producing elevated contact forces and position tracking errors.",
"ur3_protocol": "a) Retract the peg fully before attempting re-insertion. b) Inspect the peg tip for deformation from rim contact. c) Verify the approach waypoint alignment: correct any angular offset (target < 1°) and lateral offset (target < 1 mm) relative to the hole axis. d) Perform a slow-speed test insertion to confirm clean entry before restoring normal speed."
},
{
"fault_id": 33,
"root_cause": "hole_obstruction",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "A foreign object or debris lodged inside the insertion hole prevented full peg insertion, generating abnormal force buildup as the peg contacted the obstruction mid-stroke.",
"ur3_protocol": "a) Retract the peg immediately to avoid bending or overloading the wrist. b) Visually inspect the hole and remove any debris or foreign object with appropriate tooling (compressed air, tweezers). c) Verify the hole is fully clear before re-attempting insertion. d) If force anomalies persist after clearing, inspect the hole walls for damage caused by the obstructed insertion."
},
{
"fault_id": 34,
"root_cause": "incorrect_insertion_depth",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The insertion motion terminated at an incorrect Z depth due to a misconfigured endpoint, leaving the peg partially inserted (too shallow) or over-pushing against the hole bottom (too deep).",
"ur3_protocol": "a) If over-insertion occurred, retract carefully to avoid bending the peg against the hole bottom. b) Verify the insertion endpoint Z value against the nominal depth specification and correct the offset. c) Check the peg and hole bottom for damage if over-push force was significant. d) Perform a slow-speed test insertion to confirm correct final depth before resuming normal operation."
},
{
"fault_id": 35,
"root_cause": "peg_surface_contamination",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "Contamination or increased surface roughness on the peg raised insertion friction, producing stick-slip force patterns and higher-than-nominal contact force throughout the insertion stroke.",
"ur3_protocol": "a) Retract the peg and clean the peg surface thoroughly (isopropyl alcohol or appropriate solvent depending on contaminant type). b) Inspect the hole interior for transferred contamination that could affect subsequent insertions. c) Verify insertion force returns to nominal on a slow-speed test run before resuming. d) Identify the contamination source and implement a prevention measure if recurrent."
},
{
"fault_id": 36,
"root_cause": "fixture_displacement",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The insertion fixture shifted laterally from its nominal position, creating a mismatch between the programmed approach and the actual hole location.",
"ur3_protocol": "a) Retract the peg before adjusting the fixture to avoid lateral forces on the wrist during repositioning. b) Re-align the fixture to its nominal position using reference marks or a calibration tool and re-clamp securely. c) If the fixture cannot be repositioned exactly, update the approach waypoint or path to match the new fixture position. d) Perform a slow-speed approach to verify alignment before resuming normal insertion cycles."
},
{
"fault_id": 37,
"root_cause": "self_collision_link_interference",
"ur3_error_code": "C 157 A",
"ur3_error_name": "Protective Stop: Collision detected by joint",
"ur3_description": "The programmed trajectory drove the arm into a self-colliding configuration where a link contacted the robot's own body or mounting fixture, triggering an immediate protective stop.",
"ur3_protocol": "a) Do NOT jog the robot blindly: identify the self-colliding configuration from the joint state at stop time before moving any joint. b) Manually back out the arm to a safe posture using reduced-speed gravity-compensation (backdrive) mode or slow jog. c) Inspect all links and the mounting fixture for damage. d) Review and correct the motion that caused the self-colliding configuration (whether by adjusting waypoints, modifying trajectory generator parameters, or replanning the path) to ensure the arm stays clear of itself and the mounting fixture across the full motion range."
},
{
"fault_id": 38,
"root_cause": "missing_box",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The robot executed the full pick-and-place cycle but no box was present at the pick position. The gripper closed on empty air and the arm transported no payload.",
"ur3_protocol": "a) Halt the cycle and verify the pick position is loaded with the correct object before retrying. b) Check the upstream supply or operator workflow to determine why the object was absent. c) If automatic object detection is available, enable a pick-confirmation check (e.g. vacuum level or force threshold) so the robot aborts early when no object is gripped rather than completing an empty transport cycle."
},
{
"fault_id": 39,
"root_cause": "missing_peg",
"ur3_error_code": null,
"ur3_error_name": null,
"ur3_description": "The robot executed the full peg-in-hole cycle but no peg was gripped. The arm descended into the hole empty-handed and the insertion phase produced no contact force.",
"ur3_protocol": "a) Halt the cycle and verify the peg is available and correctly positioned for gripping before retrying. b) Check the gripper closure force or sensor feedback to confirm whether the peg was lost during pick or was never present. c) Inspect the peg supply fixture for misalignment or depletion. d) If automatic grip detection is available, enable a grip-confirmation check so the robot aborts before attempting insertion with an empty gripper."
}
],
"anomaly_ranking": {
"ranking_least_to_most_severe": [
{
"rank": 1,
"fault_id": 5,
"root_cause": "loosening_phase",
"severity": "negligible",
"justification": "Not actually a fault. A normal operational mode (disassembly, rework) that only looks anomalous to a monitor configured for tightening. Fix the monitor, not the process. Zero impact on safety, quality, or throughput."
},
{
"rank": 2,
"fault_id": 11,
"root_cause": "collision_foam_object",
"severity": "very low",
"justification": "Foam deflects on contact. Brief force spike, no protective stop, no damage. The only real concern is what the foam block is doing in the workspace in the first place — housekeeping issue, not a production issue."
},
{
"rank": 3,
"fault_id": 29,
"root_cause": "collision_hanging_cable",
"severity": "low",
"justification": "A cable dragging on the arm is benign for a single cycle. Real cost is long-term: cable wear, insulation damage, eventual short or signal loss. Fix during next scheduled maintenance window."
},
{
"rank": 4,
"fault_id": 30,
"root_cause": "collision_cardboard_object",
"severity": "low",
"justification": "A free-standing box gets pushed; a braced one triggers a stop. Either way, minimal damage risk. The anomaly itself is mild, and workspace cleanliness concerns are better tracked through a housekeeping KPI than flagged as a production fault."
},
{
"rank": 5,
"fault_id": 34,
"root_cause": "incorrect_insertion_depth",
"severity": "low",
"justification": "Waypoint error, software-fixable in minutes. Over-deep wastes some joint life; shallow creates a latent defect but typically gets caught at next-stage inspection. Low immediate risk."
},
{
"rank": 6,
"fault_id": 35,
"root_cause": "peg_surface_contamination",
"severity": "low",
"justification": "Higher friction, stick-slip behavior, insertion usually completes. Indicates contamination control weakness upstream but each individual cycle is low-consequence."
},
{
"rank": 7,
"fault_id": 22,
"root_cause": "tcp_frame_misconfiguration",
"severity": "low-medium",
"justification": "Self-limiting fault — the robot's own safety system catches it via a protective stop before damage occurs. Typically caught during commissioning or after a tool change. Low damage risk, moderate throughput hit while it's diagnosed."
},
{
"rank": 8,
"fault_id": 23,
"root_cause": "payload_misconfiguration",
"severity": "low-medium",
"justification": "Same category as TCP misconfiguration: the safety system catches it. Nuisance stops, throughput loss, but the robot stops before hurting itself or anything else. Trivial fix once diagnosed."
},
{
"rank": 9,
"fault_id": 28,
"root_cause": "payload_cog_misconfiguration",
"severity": "low-medium",
"justification": "Self-limiting via protective stops. Slightly worse than zero-payload because it can pass at some poses and fail at others, making it harder to diagnose."
},
{
"rank": 10,
"fault_id": 38,
"root_cause": "missing_box",
"severity": "medium",
"justification": "No hardware damage, but the cycle still completes and desyncs downstream stations. Empty carriers confuse buffers and can cause downstream starvation. Upstream feed problem that needs fixing at source, not just detection."
},
{
"rank": 11,
"fault_id": 3,
"root_cause": "missing_screw",
"severity": "medium",
"justification": "Quality escape risk. A unit leaves the station missing a fastener — if downstream inspection doesn't catch it, a defective product ships. No equipment risk but real customer and warranty exposure."
},
{
"rank": 12,
"fault_id": 39,
"root_cause": "missing_peg",
"severity": "medium",
"justification": "Similar to a missing fastener but with one subtlety: assemblies missing a peg are usually more visible downstream than missing screws. Slightly easier to catch, which is why it ranks just above missing_screw despite the similar mechanism."
},
{
"rank": 13,
"fault_id": 8,
"root_cause": "gripper_activation_failure",
"severity": "medium",
"justification": "Fingers fail to close — empty cycle, no drop. Mechanical or electrical fault in the end effector that will recur until serviced. Throughput loss plus maintenance demand, but no safety or damage concern."
},
{
"rank": 14,
"fault_id": 32,
"root_cause": "peg_insertion_misalignment",
"severity": "medium",
"justification": "Jamming at the hole rim damages both peg tip and hole edge. Burrs accumulate, tolerances degrade, eventually good parts start failing insertion. Cumulative tooling wear is the real cost."
},
{
"rank": 15,
"fault_id": 14,
"root_cause": "invalid_gripping_position",
"severity": "medium",
"justification": "Off-center finger grip means reduced contact area, slip risk during acceleration, and possible can deformation. With rigid cans, deformation itself becomes a quality defect (dented product)."
},
{
"rank": 16,
"fault_id": 10,
"root_cause": "additional_axis_payload",
"severity": "medium-high",
"justification": "Unmodeled mass on a link causes continuous over-torque on every cycle. Joint gearboxes and motors wear faster; eventually thermal faults or gearbox failure. Expensive repair if not caught early."
},
{
"rank": 18,
"fault_id": 2,
"root_cause": "extra_assembly_component",
"severity": "medium-high",
"justification": "A stray washer in an assembly is a shipped defect with field-failure potential — loose clamping force, vibration issues, eventual fastener loosening. A silent defect that can pass visual checks and escape is worse than a visible one that fails inspection."
},
{
"rank": 19,
"fault_id": 15,
"root_cause": "unstable_mounting_platform",
"severity": "high",
"justification": "Vibration in the base contaminates every operation. Every pick, every insertion, every screw-down gets a little worse. Hard to diagnose because it looks like many small problems instead of one big one. Systematic precision loss across the entire station."
},
{
"rank": 20,
"fault_id": 9,
"root_cause": "gripper_release_during_motion",
"severity": "high",
"justification": "Safety starts to dominate at this point in the ranking. A can dropped mid-trajectory — especially a full one under high acceleration — can hit a worker, damage equipment beneath the path, or ricochet unpredictably. Product loss is the least of the concerns."
},
{
"rank": 21,
"fault_id": 36,
"root_cause": "fixture_displacement",
"severity": "high",
"justification": "A shifted fixture means every insertion is slightly wrong. Scrap rate climbs systematically until detected. Worse, the mismatch can generate hard collisions between peg and rim, damaging tooling. Often discovered only via quality audit, after significant loss."
},
{
"rank": 22,
"fault_id": 33,
"root_cause": "hole_obstruction",
"severity": "high",
"justification": "Debris in the hole means forced insertion against resistance. Damages peg tip, scores hole wall, and often requires scrapping the workpiece. Points to a contamination control failure affecting many holes, not just this one."
},
{
"rank": 23,
"fault_id": 1,
"root_cause": "damaged_screw_thread",
"severity": "high",
"justification": "A cross-threaded fastener looks tight but isn't. Torque reading may even appear normal. Joint fails in service — in transport, under vibration, under thermal cycling. Classic latent defect that causes field failures and warranty claims."
},
{
"rank": 24,
"fault_id": 19,
"root_cause": "joint_position_limit_violation",
"severity": "high",
"justification": "The robot stopped itself, so direct damage is limited. But reaching a joint limit means either the program is wrong or the kinematics model is wrong — both are serious, and both can progress to worse failures (self-collision, mechanical damage) if the root cause isn't addressed."
},
{
"rank": 25,
"fault_id": 25,
"root_cause": "external_arm_disturbance",
"severity": "high",
"justification": "If the disturbance is an operator pushing on the arm, this is a direct human-contact incident and demands a safety investigation, not just a process adjustment. Even if it's just a tethered cable, the scenario means something is touching a moving robot that shouldn't be."
},
{
"rank": 26,
"fault_id": 37,
"root_cause": "self_collision_link_interference",
"severity": "very high",
"justification": "Robot damaging itself. Joint gearboxes, link castings, and tooling all at risk. Repair costs are high and downtime is long. Root cause is a fundamental planning error that must be fully resolved before any production resumes."
},
{
"rank": 27,
"fault_id": 31,
"root_cause": "collision_rigid_object",
"severity": "very high",
"justification": "Hard impact at full program speed. Major damage potential to joint gearboxes (the expensive parts), end effector, and whatever was hit. If a person were ever in that 'rigid object' position, this becomes a fatality scenario. Also reveals a failure in workspace safeguarding."
},
{
"rank": 28,
"fault_id": 4,
"root_cause": "damaged_plate_thread",
"severity": "critical",
"justification": "The plate is often the expensive part of the assembly — scrapping it hurts. But the real reason this ranks highest: a cross-threaded structural joint that passes torque-based quality checks and ships is a safety-critical latent failure. In an engine, chassis, pressure vessel, or structural application, this is how serious incidents happen years later."
}
]
},
"relevance_specs": {
"version": 1,
"description": "Per-fault relevance specs guiding sub-series sampling. Each spec declares where in an episode the fault's signature is observable, so that sampled windows for anomaly-sensitive templates are guaranteed to include the evidence. Consumed by src/question_generation/utils/relevance.py.",
"locality_definitions": {
"global": "Signature is present everywhere (or fault-absent, nominal). Uniform sampling.",
"event": "Signature is a short transient. Sampler enforces a minimum window length so the window is long enough to likely contain the event.",
"phase_gated": "Signature only manifests while the robot is in specific task phase(s). Window must overlap a matching phase run by at least min_overlap timesteps.",
"cumulative": "Signature is distributed. Window must meet a minimum length. Optionally, sampling starts no earlier than the first timestep of a gating phase."
},
"defaults": {
"event": {
"min_window_length": 40
},
"cumulative": {
"min_window_length": 40
},
"phase_gated": {
"min_overlap": 3
}
},
"specs": {
"0": {
"locality": "global",
"note": "nominal"
},
"1": {
"locality": "phase_gated",
"phases_by_task": {
"screwing": [
2
]
},
"note": "damaged_screw_thread during tightening"
},
"2": {
"locality": "phase_gated",
"phases_by_task": {
"screwing": [
2
]
},
"note": "extra_assembly_component during tightening (screwing only)"
},
"3": {
"locality": "phase_gated",
"phases_by_task": {
"screwing": [
2
]
},
"note": "missing_screw during tightening"
},
"4": {
"locality": "phase_gated",
"phases_by_task": {
"screwing": [
2
]
},
"note": "damaged_plate_thread during tightening"
},
"5": {
"locality": "phase_gated",
"phases_by_task": {
"screwing": [
6
]
},
"note": "loosening_phase"
},
"6": {
"locality": "global",
"note": "voraus_ad_class_0 — undocumented; defaulted to global"
},
"7": {
"locality": "cumulative",
"note": "motor_miscommutation — torque anomalies throughout motion"
},
"8": {
"locality": "cumulative",
"start_phase_ids_by_task": {
"pick_and_place": [
3
]
},
"note": "gripper_activation_failure — unloaded transport after grasp"
},
"9": {
"locality": "event",
"note": "gripper_release_during_motion — abrupt torque drop"
},
"10": {
"locality": "cumulative",
"note": "additional_axis_payload — torque bias throughout"
},
"11": {
"locality": "event",
"note": "collision_foam_object — brief TCP force spike"
},
"12": {
"locality": "global",
"note": "voraus_ad_class_7 — undocumented; defaulted to global"
},
"13": {
"locality": "cumulative",
"note": "cable_routed_on_robot — asymmetric drag throughout"
},
"14": {
"locality": "phase_gated",
"phases_by_task": {
"pick_and_place": [
3,
4,
5,
6,
7
]
},
"min_overlap": 5,
"note": "invalid_gripping_position — grasp through release"
},
"15": {
"locality": "cumulative",
"note": "unstable_mounting_platform — vibration throughout"
},
"16": {
"locality": "cumulative",
"note": "gearbox_overload — elevated current under load"
},
"17": {
"locality": "cumulative",
"note": "motor_encoder_stall — persistent tracking error"
},
"19": {
"locality": "event",
"note": "joint_position_limit_violation — protective stop"
},
"20": {
"locality": "cumulative",
"note": "idle_power_overconsumption — sustained abnormal draw"
},
"22": {
"locality": "cumulative",
"note": "tcp_frame_misconfiguration — wrong model throughout"
},
"23": {
"locality": "global",
"note": "payload_misconfiguration — any window suffices"
},
"25": {
"locality": "cumulative",
"note": "external_arm_disturbance — sustained pull"
},
"28": {
"locality": "cumulative",
"note": "payload_cog_misconfiguration — wrong gravity compensation"
},
"29": {
"locality": "event",
"note": "collision_hanging_cable — contact event"
},
"30": {
"locality": "event",
"note": "collision_cardboard_object — contact spike"
},
"31": {
"locality": "event",
"note": "collision_rigid_object — immediate deviation + stop"
},
"32": {
"locality": "phase_gated",
"phases_by_task": {
"peg_in_hole": [
1
],
"machine_tending": [
1
]
},
"note": "peg_insertion_misalignment"
},
"33": {
"locality": "phase_gated",
"phases_by_task": {
"peg_in_hole": [
1
],
"machine_tending": [
1
]
},
"note": "hole_obstruction"
},
"34": {
"locality": "phase_gated",
"phases_by_task": {
"peg_in_hole": [
1
],
"machine_tending": [
1
]
},
"note": "incorrect_insertion_depth"
},
"35": {
"locality": "phase_gated",
"phases_by_task": {
"peg_in_hole": [
1
],
"machine_tending": [
1
]
},
"note": "peg_surface_contamination"
},
"36": {
"locality": "phase_gated",
"phases_by_task": {
"peg_in_hole": [
0,
1
],
"machine_tending": [
0,
1
]
},
"note": "fixture_displacement — approach/insertion"
},
"37": {
"locality": "event",
"note": "self_collision_link_interference — protective stop"
},
"38": {
"locality": "phase_gated",
"phases_by_task": {
"pick_and_place": [
3,
4,
5,
6,
7
]
},
"min_overlap": 5,
"note": "missing_box — grasp through release"
},
"39": {
"locality": "global",
"note": "missing_peg"
}
}
}
} |