Troubleshooting robots and robot program, the electrician job description.
ROBOT TROUBLESHOOTING: RTS01
By Larry Bush
On Tuesday, I was called in early to assist the shift electrician on Robot
6. When the shift electrician and I examined the robot head on #6, the A
& B grippers were both bent in the same direction about
It would have done no good for anyone to attempt to carry out a MODPOS
(Modify Position) until the mechanical repairs were made. The shift
electrician told the shift supervisor who asked us to carry out the
repairs because the only shift maintenance mechanic was busy with repairs
on one of the cup sealing machines.
We straightened out the grippers and then did a "Tune" (minor
MODPOS) on Robot 6 at Position 10 (Picking empty racks for
placement on Indexer). Robot 6 was not picking up cups and dropping them.
It was having a problem picking up the empty racks because the robot head
had been crashed at some point in the near past.
The third shift electrician came in and took over. I was called to work
on Robot 3. The third shift electrician couldn't get the robot tuned
properly so he did a "warm reboot" on Robot 6. This reloaded the
program and the program parameters from the last " program
Fifteen minutes later the third shift electrician was able to carry out
a successful "Tune" on Robot 6. There were no more problems
after the tune with Robot 6 that only picks up full and empty racks.
In the meantime, I changed out a solenoid valve on Robot 3 and then
found a broken wire in a connection box on the robot head. The solenoid
valve was controlled by the broken wire. That solenoid valve controlled
two grippers on Robot 3.
Robot 3 does not pick up cups, only full trays and empty trays. I
repaired the broken wire and Robot 3 ran with no problems. Changing the
solenoid was probably unnecessary as the broken wire was supposed to
energize the solenoid coil.
Nobody mentioned Robot 5 or Robots 1, 4,or 8 having any problems or
dropping any cups Monday or Tuesday. We observed Robot 4 placing cups on
the outfeed conveyor. The robot was not dropping cups, but it was moving
down to the "Drop" position rather slowly in comparison to the
"Drop" by Robot 8.
We are not authorized to make changes to that portion of the program. That is the Plastic Process Engineer's area as far as I know.
Later that week, the Process Engineer tuned the program on Robot 4 and decreased the amount of time the robot took while moving the product. This shortened the production time for each evolution by the four robot cell unit.
Reducing the time for that maneuver allowed the production lines to increase case production by the thousands of cases over a year's time. The time saved was in the seconds, but when counted over and over, 24 hours a day and seven days a week, the time adds up rapidly.
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About the Author: Larry Bush has been an electrician for 47 years, and in maintenance management for 22 years. Download his e-Book "Emergency Diesel Electric Generators" and the "Maintenance Policy and Procedures Manual" !!Please copy this article onto your websites, just keep all links and credits in place. Thank You