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How to Fix the Palletizing Error: “Resource‑Intensive Instruction in the Program”

Troubleshoot USB and program-related causes behind this error on Robotiq’s Palletizing Solution

This article helps you resolve the error message “Resource-Intensive Instruction in the Program,” which can appear during palletizing operations. This issue is typically linked to USB communication problems between the Universal Robots controller and Robotiq’s PLC.

Log Example: In the "kern.log" file, the following entries signal communication problems:

Jan 13 15:24:04 localhost kernel: r8152 2-3:1.0 ethrq: Stop submitting intr, status -71
Jan 13 15:24:04 localhost kernel: r8152 2-3:1.0 ethrq: Tx status -71
Jan 13 15:24:05 localhost kernel: usb 2-3: USB disconnect, device number 2
Jan 13 15:25:14 localhost kernel: usb usb1-port1: disabled by hub (EMI?), re-enabling...
Jan 13 15:25:16 localhost kernel: usb usb1-port1: Cannot enable. Maybe the USB cable is bad?
Jan 13 15:25:18 localhost kernel: usb usb1-port1: unable to enumerate USB device

Root Cause Analysis: These log entries suggest a hardware issue along the communication line between the UR controller and Robotiq’s PLC.

Troubleshooting Steps:

  1. Check the physical and electrical environment

    • Ensure proper grounding of the robot cell.

    • Confirm stable power supply without voltage drops or surges.

    • Look for sources of electromagnetic interference (EMI) around the robot.

    • If possible, test the robot setup in a different electrical environment.

  2. Verify USB power requirements

    • If using a USB switch or hub, ensure it has its own external power source.

    • Drawing too much current from a single USB port can cause communication failures.

  3. Test the USB ports and connected components

    • Make sure the Robotiq Ethernet-to-USB adapter has a lit blue LED to confirm it is powered.

    • Try different USB ports on the robot controller.

    • Use a powered USB hub to connect both the dongle and the Ethernet-to-USB adapter to the same port.

    • Alternatively, connect them directly to the teach pendant's USB port.

    Optimize the robot program

    • Add small delays (e.g., Wait: 0.2s) after certain instructions to reduce communication load.

    • Avoid constant evaluations in IF/ELSEIF conditions that reference continuously updating inputs.

  4. Check for program file encoding issues

    • Ensure program names and comments do not contain special or unsupported characters.

    • Corrupted characters can lead to unusual behavior and errors.

Conclusion
Following these steps will help identify and resolve USB-related or program structure issues causing the error “Resource-Intensive Instruction in the Program.” If the problem persists, collect your logs and hardware setup photos, then contact Robotiq Support.