TL;DR
Case drops and gripper pressure faults almost always come from a cracked vacuum cup, an air line fitting leak, or a gripper pad worn past the grip depth. Inspect the EOAT visually before chasing electrical faults.
What you might see
- cases dropped mid-cycle by the pick head
- gripper pressure alarm on the HMI
- vacuum cup leakdown or vacuum loss fault
- pick-and-place cycle completing but cases placed out of position
Likely causes
Worn or cracked vacuum cups losing the seal needed to hold the case during transit
Air supply fitting on the EOAT leaking, reducing gripper pressure below the sensing threshold
Gripper friction pad worn smooth on a mechanical clamp-type head
EOAT mechanical damage from a previous dropped case or collision
Required tools
- LOTO kit (electrical and pneumatic)
- Replacement vacuum cups (EOAT-specific part number)
- Push-in fitting seating tool
- Vacuum pressure gauge or HMI I/O screen
Safety first
- Lock out both electrical power and the pneumatic supply to the palletizer before working on the EOAT. Residual air pressure causes unexpected gripper movement.
- A dropped case from height is a falling object hazard. Ensure no personnel are under the palletizer head during any powered test.
Procedure
- 1
Lock out the palletizer and lower the head to a safe working height or use a ladder platform to reach the EOAT.
Warning: Lock out the main power AND the pneumatic supply to the EOAT before touching the gripper head. Residual air pressure can cause sudden gripper movement when connections are loosened. - 2
Inspect each vacuum cup for cracks, cuts, or deformation. Replace any cup that does not make a flat, smooth sealing face.[1]
- 3
Check all air line push-in fittings on the EOAT for secure seating. Re-seat any fitting that is not fully bottomed out.
- 4
Restore pneumatic supply and check the vacuum pressure reading at the head (read from the HMI I/O or a local gauge). Compare to the grip specification.
- 5
For mechanical clamping heads, measure the friction pad thickness. Replace pads below the minimum wear dimension.
- 6
If all wear items are in specification and the fault persists, check the vacuum generator (venturi or pump) for blockage or leakage.
- 7
Return the palletizer to service and run 5 pick cycles manually in jog mode before returning to auto.
Sources
Columbia / Okura Columbia FL / GP / HL Palletizer (Robotic / Conventional) general technical documentation, Columbia / Okura
Industrial palletizer EOAT maintenance, vacuum cup and gripper inspection, general material handling references (general)
More guides for Columbia / Okura Columbia FL / GP / HL
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