Error and troubleshoot
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      How to address the Palletizing Solution Error "Resource-Intensive Instruction in the Program".

      This article provides troubleshooting steps for resolving USB communication issues between the UR controller and Robotiq’s PLC in the Palletizing Solution, focusing on hardware integrity, environmental factors, power management, and optimization.

      Issue Overview: When customers encounter an error indicating a "resource-intensive instruction" in their program, this is often linked to a USB communication issue within the Robotiq Palletizing Solution. The error typically points to a hardware problem disrupting communication between the Universal Robots (UR) 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. Environmental Factors Check:

        • Grounding Issues: Ensure the palletizing setup is properly grounded to prevent static discharges.
        • Power Line Stability:
          • Monitor for voltage drops or surges during operation.
        • Electro-Magnetic Interference (EMI): Though palletizers are CE-certified for EMI, localized interference could still cause problems. Running the same setup in a different environment can help isolate this issue.

      2. USB Power Management:

        • If using a USB switch to connect multiple devices to the UR controller, ensure it is externally powered. Drawing too much power from a single USB port can cause communication failures.

      3. Component Replacement and Port Testing:

        • Check if the Robotiq Ethernet-USB adapter is ON (a blue LED should appear on the adapter) and test with different USB ports.
        • Test connecting both the dongle and Ethernet-USB adapter on the same USB port using an externally powered USB switch.
        • Alternatively, connect both devices to the USB port on the teach pendant.

      4. Program Optimization:

        • High-frequency calls in robot programs can cause reliability issues. If your program includes repeated, rapid instructions without delays, consider adding small delays to improve stability.
          • For example, after setting a variable to "off," add a Wait: 0.2 instruction to reduce the frequency of calls.
          • Check for any IF or ELSEIF conditions that are "Check expression continuously".

      5. File and Character Encoding Issues:

        • Special characters in program names or comments may cause unexpected behavior.

      Next Steps if Issue Persists: If all troubleshooting steps fail:

      • Send photos or a video of the setup, including the inside of the UR controller and Robotiq controller to the following support email (support@robotiq.com).