Whether you're in Pharma, Biotech, Chem, Energy, Shipping, Foods, general engineering or alternatively the automotive or aerospace supply chains, using robotic material handling immediately increases your production, standardises your quality, produces predictability, and frees up your work force for higher level tasks. So what's the right move for your company now? And you've heard a lot of noise about the latest breakthroughs in robotics. Needless to say caution is required to connect to the correct pins in the plugs and not short out to any neighboring pins.You already have some degree of testing and manufacturing automation in your production. This will eliminate the robot wiring, power supply in the controller, etc - if above test (moving axis by hand with external power supply connect directly to brake at the motor) shows the brake is now operating correctly then move the power supply down to the brake pins in the power connection plug on the base of the robot. I would have the controller power off (and locked out), also the robot power plug at the base of the robot unplugged to isolate the controller completely.

If there is still any doubt about the brakes get a known good 24 VDC bench power supply and connect it directly to the brake at the motor power plug - again axis 2 and 3 will drop so unless you can support these axis safely do not release their brakes. With manual release of the brake you should be able to move axis 1, 4, 5, 6 one at a time by hand (2 and 3 will drop on a large robot like the IRB4400 so not safe to try a manual movement of those two). Multiple axis not working sounds like power to brake system or main power to controller/drive unit - but the controller should report errors if there was under voltage. To clarify you now have all brakes releasing?

Abb spider robot video