Industrial Fault Library
Practical troubleshooting for common automation faults — symptom, root cause, diagnosis and fix, with the equipment and spare parts that solve them.
Labels Wrinkling, Flagging or Bubbling: Applicator Troubleshooting
Cosmetic label defects come from a mismatch between label material, adhesive, surface energy and application geometry. A defect-to-cause map that fixes it without endless trial and error.
Troubleshoot →Conveyor Belt Mistracking (Running Off to One Side): Causes and Correction
A belt that drifts sideways causes edge wear, spillage and jams. Mistracking is a geometry and tension problem — chasing it with belt replacements wastes money. The systematic correction order.
Troubleshoot →Machine Vision False Reject Rate Too High: Causes and How to Reduce It
A vision system rejecting good parts is usually a lighting-stability, threshold, or handling-variation problem — not the algorithm. A structured way to cut false rejects without missing real defects.
Troubleshoot →Pneumatic Cylinder Slow, Weak or Jerky: Diagnosis and Fixes
A cylinder that lost speed or force is usually leaking air, starved of flow, or suffering seal/lubrication wear. How to isolate supply, valve, cylinder and load in minutes.
Troubleshoot →PLC Communication Loss (Profinet/EtherCAT/Modbus): Systematic Troubleshooting
Intermittent fieldbus dropouts are usually physical layer, addressing, or noise — rarely the CPU. A layer-by-layer method that finds the fault fast instead of swapping cards blindly.
Troubleshoot →Servo Motor Overheating / Overload Alarm: Why It Happens and How to Solve It
A servo overheating or throwing an overload (OL) alarm is a duty-cycle, tuning, or mechanical problem far more often than a failed motor. How to read the real cause from current and cycle data.
Troubleshoot →Photoelectric Sensor False Triggering or Missed Detection: Root Causes and Fixes
Intermittent sensing on a production line is usually ambient light, reflectivity, or alignment — not a dead sensor. A diagnostic checklist for diffuse, retroreflective and through-beam types.
Troubleshoot →VFD Overcurrent (OC) Fault: Causes, Diagnosis and How to Fix
A VFD tripping on overcurrent (OC/OC1/OC2/OC3) usually points to acceleration, short-circuit, or load problems. Step-by-step diagnosis by when the fault occurs, plus the parameters to check.
Troubleshoot →Can’t find your fault, or need help diagnosing it?
Submit your problem →