PMB40203 MAINTENANCE AND RELIABILITY SYSTEMS KUKA YOUNG POTENTIAL AWARD PREVENTIVE MAINTENANCE MANUAL FOR KUKA ROBOTICS NAME : LUKAS ANAK JOEL NO ID : 58218119033 PROGRAM : MSE LECTURE : D R JAYA BHANU RAO SUMMITION DATE : 14 SEPT 2021 1[PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS CONTENT INTRODUCTION... OBJECTIVE. ORGANISATIONAL SETUP AND CHAIN OF RESPONSIBILIES REPAIR PROGRESS. BENEFIT OF PRVENTATIVE MAINTENANCE FOR KUKA ROBOTICS ROBOT PREVENTATIVE MAINTENANCE CHECKLIST PREVENTIVE MAINTENANCE SCHEDULES ROBOTICS LOG... ROBOTICS MONITORING SYSTEM FORM. CONCLUSION... 10 2 13 18 zom™rmoogo> 2|PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS A. INTRODUCTION Every robot needs preventative maintenance ensure top-level performance and consistency on the production line. When robots do not have regular preventative maintenance checks performed, it can cause parts and components to break down or malfunction, which can cause a slowdown or shutdown of your production. Industrial robots that are properly maintained can last for many years, even decades, before needing to be replaced. By keeping a regular preventative maintenance schedule, you are extending the life of your robot exponentially. Different robotics companies recommend different amounts of time between preventative maintenance. For example, FANUC Robotics states that planned preventative maintenance for your industrial robot should be performed every 3,850 hours of 12 months, whichever comes first for your robot. However, KUKA Robotics recommends preventative maintenance after 10,000 hours for their robots. It is important to check the manual for your specific robot to see what time frame is best. No matter what length of time your manual recommends, by scheduling maintenance in this way, we are able to prevent costly downtime that is unplanned due to mechanic issues. While planned maintenance may shut down production for a short time, it is nothing compared to the production time you may lose if your robot stops working. 3|PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS B. OBJECTIVE The use of robots has brought many benefits to manufacturers, but in order for them. to continue seeing those benefits a robot equipment maintenance program must be implemented. The most common form of a robot maintenance program is preventive maintenance. Preventive maintenance is the planned maintenance of facilities and equipment, designed to eliminate unexpected breakdowns and increase the life span of robots. These programs are critical for the performance of a robot to remain reliable. Preventive maintenance involves expanding the life of robotic equipment through __ painting, lubrication, cleaning, adjusting, and minor part replacements. It uses testing, periodic inspections, and pre-planned maintenance activities in order to correct or prevent any problems that may arise. The main purpose is to keep breakdowns and MS) decline to a minimum S Most robot's breakdown as a result of wear and tear, but preventive maintenance prevents this from happening for several years. With the prevention of breakdowns manufacturers’ productivity and quality are increased. Costs are reduced through preservation of assets; meaning that robotic equipment lasts longer eliminating the spending of money to replace it year after year. It also has the potential to produce greater ROI. With an increased life span, robots prove to be well worth the investment for manufacturers. 4|PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS C.ORGANISATIONAL SETUP AND CHAIN OF RESPONSIBILIES MAINTENANCE SUPERINTENDENT ENGINEERING ASSISTANT FACILITIES FOREMEN SHOPS FOREMEN FOREMEN MAINTENANCE PLANING & SCHEDULING FOREMEN ENGINEERING FIELD FOREMEN 5|PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS D. REPAIR PROGRESS 6|PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS E. BENEFIT OF PRVENTATIVE MAINTENANCE FOR KUKA ROBOTICS There are many reasons to prioritize preventative maintenance for robotic systems. Some of the most significant benefits of preventative maintenance include: + Early detection: First, preventative maintenance allows you to identify potential issues with industrial robots before they become big repair problems Noticing a part is about to wear out during a basic maintenance check and quickly replacing it is much cheaper and easier than waiting for that part to fail, possibly taking other parts of the robot and whatever it is working on with it. + Longevity : Preventative maintenance for industrial robots also allows you to extend the life of those robots dramatically. Even if nothing is obviously wrong, when a robot is poorly cared for, it may put additional stress on the machine's, parts. You may not notice it in day-to-day performance, but over time, those stresses can add up and put an end to the robot's life long before its due + Efficiency: Well-maintained machines also tend to operate more efficiently. Even if your robots seem to be working without the recommended preventative maintenance, it's likely that you're sacrificing efficiency and spending more on operating costs. To help robots work efficiently, you need to proactively maintain them. + Control: By doing regular preventative maintenance, you control how a robot's repairs will affect your business. If a maintenance check reveals a problem, your company can solve the problem in stages. or fix it at a time when the robot would normally not be in operation or can have its duties replaced by another robot. This means you can dramatically reduce or eliminate downtime, preserving your productivity. Contrast that with your whole production line grinding to a halt unexpectedly. + Cost savings: Another advantage of proactively maintaining industrial robots is that it can save you from costly repairs or replacements that may otherwise arise. Generally, preventative maintenance tasks are more affordable than emergency repairs in the case of a breakdown. Your business can also save money by avoiding unplanned downtime and keeping your operations in full swing. T|PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS Robot Preventative Maintenance Features: + Backup of controller memory including teach pendant programs and application software + Monitor/observe the robot in motion noting any cable wear, irregular motion, or noises + Replace robot batteries to ensure robot positional data during power loss + Replace controller batteries to prevent loss of software and programming during power loss + Replenish internal grease based on robot model's specifications + Check motor brakes for slippage + Clean controller ventilation and filters to ensure proper heat exchange + Clean and perform visual inspection of robot mechanical unit, end of arm tooling, and cabling [PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS F. ROBOT PREVENTATIVE MAINTENANCE CHECKLIST While every type of robot will have its own maintenance schedule, there are many different maintenance items you'll want to account for during your routine check- ups. Here are some general recommended maintenance tips: + Back up controller memory + Inspect brake operation + Inspect teach pendant + Check overtravel limits ‘+ Monitor robot in motion, inspecting robot, harness, and cables + Check robot repeatability + Listen for excessive audible vibration and noise + Tighten external bolts + Check for defective seals and grease/oil leakage + Clean chips and debris from robot + Grease joints, bushing, and balancer housing + Check controller cables, cable connections, power suppliers, and safety equipment; replace if necessary + Test batteries in controller and robot arm; replace if necessary + Clean vents and cooling fans with compressed air: replace filters if necessary + Clean light curtains 9|PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS G.PREVENTIVE MAINTENANCE SCHEDULES vi 10 | Page Daily Check : Clean sensors and optics within the robot cell and visually check component parts for damage before daily operation Check Mechanical Unit for grease/oil leakage or exudation First 1-month (320 hours) Checks : Ventilation of the robot controller’ cooling fans — keep these clean for efficient air flow First 3-month (960 hours) Checks: Check Mechanical Unit Cables — free from severe kinks, pinch points, cuts or tears in the wire insulation, check for secure terminations Retighten external main mounting bolts Clean chips and debris from Mechanical Unit Cheek the end effector or end of arm tool and its’ mounting bolts or screws, tighten appropriately Check robot connection cables (T.P. Cable, EE Cable, Vision Cables) — free from severe kinks, pinch points, cuts or tears in the wire insulation, check for secure terminations 1-year (3,840 hours) Check: Grease balancer housing (if so equipped) 1.5-year (5,760 hours) Checks: Replace batteries in the mechanical unit (these are backup batteries to maintain the robot's factory alignments — don't let these batteries die or you may be in for some unpleasant work to re-zero your robot) 3-year (11,520 hours) Checks: Replace the grease of each axis. This is not an idle warning — use only the grease recommended by your robot's manufacturer — the robot controls are sensitive, and grease can affect robot motion and operation.PMB40203 MAINTENANCE AND RELIABILITY SYSTEMS vil. 4-year (15,360 hours) Checks: + Replace the Mechanical Unit cables © Replace the lithium battery in the CPU [PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS H.ROBOTICS LOG Robot Inspection Checklist Team Number (ene ey wae Size Inspection o ‘Robot fis within starting size restrictions (18° x 18° x 16") does not touch walls or celing ofthe siting box! Robot |g ‘should be measured WITH Team ID # Plates stalled Overall Inspection oooocco00000CceE0 ay SEE ESTEE 7 |D_ Robot displays colored VEX Team Identification plates on atleast (2) opposing sides. R19 ee ee et ae = | Robot does NOT contain any components that could entangle or damage the playing-field or cther robots. R3 1D Robot does NOT contain any sharp edges or comers. RS 2 A a oe aan smeinoige aa [0 VEX Parts Inspection oo00c000000000 GALL Robot components are (or are IDENTICAL to) OFFICIAL VEX Products as sold on VEXrobotics.com (No 3D uM printed functional parts are allowed) Robot does not use VEX products not intended for use as a robot component or any VEX packaging. es aed tt ero sano ena ____|_e Any grease is used only in moderation on components that do not contact the field, objects, or other robots. Rle D_ Any non shattering plastic on the robot was cut from @ single sheet of 0.070" material not larger than 12°24". RTE D_ Robot has only (1) VEX EOR Microcontroller. RO OT a % 2 teeter a ana ciaaanio TS Bean tenn ero ae re ge wn gene ne ‘of pneumatics, oto ccaaitsoeninnrnmimaaamanae as Sealer enw enantio heinemcs me |_ Robot uses a maximum of (1) Y-Cable per each 3-wire Motor Por (cannot “Y" off a 2-wire Motor Port) JR Robot uses (1) VEX 7.2V (Robot) Power Pack as the primary power source. R13 Ci the Robot has a Power Expander, it has a 2nd 7.2V (Robot) Power Pack RID G_ Robot uses a maximum of (1) VEX Power Expander RIS D_ Robot has a charged $V Backup Battery connected Rise Ce aa ce Robot is not controlled by more than (2) VEX hand-held transmitters. RI 9 Sacer ey ee a C_NO Method of attachment NOT provided by the VEX Design System is used. (Welding, Gluing, etc.) RISD Robot uses @ maximum of two (2) VEX pneumatic air reservoirs. (Maximum 100 psi per air reservoir) RB Field Control Check oo00c000000000 [G_ Robot successfully completes the "Field Control Check” Procedure, See Inspection Guidelines. Rat O Robdot enters Autonomous mode when prompted with no driver control for duration of Autonomous. R20 D_The Hand-held Controlier(s) ONLY control the robot when robot is in Driver mode. R20 PTC Verifcation Testing oooc0000000000 arenas 7 ae ass Fal Tested By. s Final inspection Pass / Fal Inspector Signature: ‘Team initials: [PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS |. ROBOTICS MONITORING SYSTEM FORM Kano: rtmaton Maintenance checklist: Robot System — FC LJ KAA Order data Calcwone AAR Coos roxs cutomarnn onuna na. ret at SeRaTGARSTSN eontpavon TT cae SS cue SIR Sa SE Rte Ree Comune, Tae, a setente Operating hours 9930hrs Year of manuf. ‘Application Mounting position [JFicor []Ceiling []Wall Pedestal Special variant [Foundry []FoundryPius Jaretic Dore Basic inspecton [West maintenance [aMain axis maintenance -(] Backlash measurement EdMinor elect. maintenance [] Msjorelectr maintenance [Data bschupon spare HOD] inspection SafeOperation Basic inspection Manipulator Activity Evaluation of degree of fouling ‘Testrun/ wsual mepecton ‘Sear units ‘ai 1 ‘ais 2 Ais is diss Ais 6 (Check ‘i 1 ‘Asis 2 erorm maetenng ais 3 ‘is 4 diss Ais 6 Cieaning Lubseaton & g oo jooo0 joo|oOoooo0 jooo0o0o0 jo fe ‘Comments / Results / Article no. Evaluation CD Heavy touting Running noises Sealing Gear backlash iitili Mastering done. Mastering done. Mastering done. Mastering done. Mastering done. Mastering done. Rotating column ‘Visual inspection Intemal energy supply Ext energy supply, A1-3 Ext energy supply, A3-6 ‘Lubrication Intemal energy supply Ext energy supply, A1-3 Energy supply (Hose packages) Gf UE ier Re |AR RRReee PeRee | g oo jO00 jogjoooo0o00 jo000o0o jo 1B [PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS KuKA Robot Automation Maintenance checklist: Robot System KC LIC AA ‘maintenance (Malaysia) Sdn Bhd Basic inspection ‘Manipulator Activity Done | not ok] N%,| Comments / Results / Article no. Robot fastening Visualinspecton | | O | O ‘Normal Connectors Check wlolfo ‘Normal Mechanical damage Vevalinspeston | | O | O ‘Normal ‘Counterbalancing Visual inspection system, mechanical Running noses | | O | @ Not Relsed Motors, axes 1-6 Visual inspection ®/oO/oO ‘Normal Robot controler ‘aetivty ‘one | nerox| N,| Comments / Results Article no. Archiving ‘Memory dumponHoo [| & | 0 | O ‘Done, Normal CD-ROM drive Function test B/o|o ‘Normal Floppy disk Function test elolo ‘Normal use Function test w/O/oO ‘Normal Internal cabinet fan ‘Check wl oto ‘Cleaned External cabinet fan Check wlolo ‘Cleaned PC fan Check w/oO|oO Cleaned STOP, Function test w/oOl;oO ‘Normal Visual nepection Kor Display ajojo Normal Cable w®)o/;a ‘Normal Keyboard Olw@/|o ‘Some buttons not functioning Enabiing device Function test B/o|/|o ‘Normal Battery ‘Voltage test wiolo ‘Exchanged Power supply unit Voltage test_ @/oO/o0 Normal, ‘Cabinet seals (Check alolo ‘Normal Microfiter (KRC2) Exchange ifnecessary | | O | O Normal ‘Connectors ‘Check wloOlo ‘Normal Service sticker ‘Attach wfolfo ‘Normal ‘Activity Manipulator Dow] nor] MERE] _Commenta/Reaut Arico no. ‘Axis 4 gear unit Oil change wl] Oo Oo Done “Axis 5 gear unit ‘Oil change wl oOo oO Done Axis 6 gear unit Oil change B o o Done. ttinor electrical msiatonence Robot controler ete Dane | nor] MS] Comments /Resuts Arce no. Cleaning Control cabinet Inside Bia Qa Csaned Heat exchanger @/ oO oa Cleaned Major electrical maintenance Robot controller ‘Activity (ox | notoK] NSE] Comments / Results / Article no. ‘Cabinet seals Exchange itnecessary | BJ | O oO Nemnel ‘Internal cabinet fan_ ‘Exchange ifnecessary | & oO a ‘Normal ‘External cabinet fan Exchange ifnecessary | a a ‘Normal PC fan Exchange trecessary | | Ol | Ol Nomal “Motherboard battery ‘Exchange itnecessary | Bd oO oO Exchanged 4|PagePMB40203 MAINTENANCE AND RELIABILITY SYSTEMS KUKA Robot Automation Maintenance checklist: Robot System (Malaysia) Sdn Bhd Figure 1.0: Draining the gear oil rom Axis-1 Figure 2.0: Draining the gear oil from Axis-2. Figure 3.0: Draining the gear oil from Axis-3 Figure 4.0: Draining the gear oll from Axis-4 15 [PagePMB40203 KUKA Robot Automation (Malaysia) Sdn Bhd MAINTENANCE AND RELIABILITY SYSTEMS Maintenance checklist: Robot System ale + Figure 5.0: Draining the gear oil from Axis-5. a Figure 6.0: : Draining the gear oil from axis-6 Figure 7.0: Filling new gear oil into Axis-1 Figure 8.0: Filling new gear cil into Avis-2 CAUsers\ 2018)\sit € 16 | PagePMB40203 KUKA Robot Automation (Malaysia) Sdn Bhd MAINTENANCE AND RELIABILITY SYSTEMS Maintenance checklist: Robot System a" Figure 9.0 Filing new gear cil into Axis-3 Figure 10.0: Filling new gear oil into axis-4 Figure 12.0: Filling new gear oil on axis-6.PMB40203 MAINTENANCE AND RELIABILITY SYSTEMS |. CONCLUSION It is possible to have a successful preventive maintenance program. From a cost reduction viewpoint itis essential, but it does entail risk. When the proper care is. taken, the risks, however, can be minimized. In order to minimize risk, preventive maintenance has to be carefully planned and carried out by well-trained and motivated workers. The biggest benefits of a PM program occur through painting, lubrication, cleaning and adjusting, and minor component replacement to extend the life of equipment and facilities. 18 [Page