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No proposed solution matched my case (no formulas in excel, short worksheet names, creates new file everday, etc.). In fact, my report was running perfectly fine for several months and is distributed daily to dozens of folks.
My solution was - remove all images from Report Text tool. I'm not sure what the issue was but this seemed to fix the excel message. Report is less pretty but oh well :)
I'm glad you were able to get it to work @MsBindy, and without editing content_types xml file? If you use 7-zip (it's free) you can delete the calcchain.xml file without renaming it or extracting it first.
I did report this and others to Alteryx, but there seems to be zero interest in fixing it.
Wanted to mention here I discovered my cause for the xl/workbook.xml error. People have before mentioned that having too long of a sheet name can cause this - apparently having quotes or apostrophes in the sheet name is problematic as well. I wouldn't be surprised if there are other special characters that will cause this problem if they are included in the sheet name.
I am getting the same error on a excel (.xlsx) workbook with no macros. In my workflow I had been trying out the output to specific cell method:
eg. write to file or database> users\username\desktop\document.xlsx|||$B2'>output options>overwrite file (remove)> skip field names.
After the workflow is executed there are no errors, however the "repair" error pops up endlessly when trying to open the document even in spite of renaming the document and the output (a single field) is not output to the specified cell after the document repair option is selected.
Note though that there is no error if you do not specify a specific cell/cell range.