More Factory Robots, Predictive Maintenance in Focus
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As factories deploy more robots, predictive maintenance is being proposed to identify early signs of wear in robot joints, reducers, motors and controllers. The approach uses equipment data such as vibration, temperature, motor current, torque and controller alarms to judge condition, so that maintenance decisions are based on actual condition rather than a fixed schedule. According to International Federation of Robotics (IFR) data, about 5 million industrial robots were in operation worldwide in 2025, up 11% year on year. The report says an unexpected failure of a single robot can affect an entire work cell and production line, and earlier warnings can reduce unplanned downtime, improve spare-parts planning and make maintenance windows more controllable.
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- The Robot ReportWhy predictive maintenance matters more as factories add robots
As factories deploy more robots, predictive maintenance uses equipment data such as vibration, temperature, motor current, torque, and controller alarms to identify early signs of wear in joints, reducers, motors, and controllers, so maintenance decisions are based on actual condition rather than a fixed schedule. IFR data shows that about 5 million industrial robots were in operation worldwide in 2025, up 11% year over year, and an unexpected failure of a single robot could affect an entire work cell and production line. Earlier warnings can reduce unplanned downtime, improve spare-parts planning, and make maintenance windows more controllable.
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