The Picking Waypoint Simulated as Reachable in Software, But Unreachable by the Real Robot

Symptoms:

The space restrictions for the robot and bins are extremely strict. The picking waypoint can be reached in the simulation in the software, but the real robot cannot.

When manually operating the robot using the teach pendant to move it to this point, an error 'Special mechanical interference' is reported. However, if you turn off the soft limits of the real robot, and then manually operate the robot using the teach pendant, it can successfully reach the workobject picking waypoint.

Affected Software Versions:

Software: All versions.

Robot: Yaskawa GP180.

Possible Cause:

In addition to the soft limits between the axes 2 and 3, there are also dynamic limits to prevent other joints from colliding with the foundation. In the software, there are no restrictions on this situation.

Solution:

For joints in improper positions, modify their soft limits.