I've had a few of my UR5Es fail with a C45041 Error about a missing Force-Torque sensor in the last week.  When the first robot failed on Tuesday, we swapped with another unused robot and it temporarily fixed the problem.   The plant just called and said the problem reoccurred on the first robot, and the same problem happened on another robot in the same cell.

The original problem happened on Polyscope 5.9.   We upgraded them to 5.11 with no changes.  Newer robots, still under warranty.   Here is a video of the machine:  https://www.youtube.com/watch?v=0PhGCsveb5Y

Has anyone seen a similar problem?  The Message in the log and HMI is  ToolA : C450A4: Force-Torque sensor:  Force-Torque Sensor is expected, but it cannot be detected.    

I am having this same issue. I have rebooted the robot and took the end effector off to clean the pin connectors. I have even deleted and reloaded the force copilot URcaps. It still is not working and I cannot even turn the robot on to move it.

We're still struggling with the issue.  Multiple robots and issues at this point.  

Make sure you're running the latest copilot urcap.  1.20 I think.  We have had to replace a number of tool-flange torque-sensors to keep our customer running.

Make sure you have a case open with UR.  Jacob with UR in Indiana has been fantastic in helping us work through the issue. 

Thank you, Arnold. I have been working through our supplier (I believe they have opened a case with UR) and they have a replacement tool-flange force torque sensor coming. I will double-check my URcap version to ensure it is the latest one.

Hi may I ask if you got this issue sorted? I got this one today as well...

Sorry mate, seems it is an empty comment?@arnoldgauge 

Sorry about that, not sure what happened to my comment.

In any event, yes.  UR replaced the tool-flanges of the robots with the issue and the problem has not recurred.  

Not sure.  We upgraded software (both Polyscope and Co-pilot) with no impact.  It was intermittent, we could sometimes run a for a time, then the problem would happen again.  When it happened, the robot wouldn't boot.

The robots it happened on, were all purchased within a few weeks of one another.  

Replacing the tool-flange fixed the issue.  

Same here, UR replaced the tool flange and that resolved the issue.

In our case, UR sent us a replacement Tool-Flange, that includes the Force Torque sensor.   The replacement part fixed the issue.