PMB40203
MAINTENANCE AND RELIABILITY SYSTEMS
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
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MAINTENANCE AND RELIABILITY SYSTEMS
CONTENT
A.
INTRODUCTION ....................................................................................................... 3
B.
OBJECTIVE ............................................................................................................... 4
C.
ORGANISATIONAL SETUP AND CHAIN OF RESPONSIBILIES .................. 5
D.
REPAIR PROGRESS ............................................................................................... 6
E.
BENEFIT OF PRVENTATIVE MAINTENANCE FOR KUKA ROBOTICS ...... 7
F.
ROBOT PREVENTATIVE MAINTENANCE CHECKLIST ................................. 9
G.
PREVENTIVE MAINTENANCE SCHEDULES .................................................. 10
H.
ROBOTICS LOG ..................................................................................................... 12
I.
ROBOTICS MONITORING SYSTEM FORM ..................................................... 13
I.
CONCLUSION.......................................................................................................... 18
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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 or 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.
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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
decline to a minimum.
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.
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C. ORGANISATIONAL SETUP AND CHAIN OF
RESPONSIBILIES
MAINTENANCE
SUPERINTENDENT
ENGINEERING
ASSISTANT
FACILITIES
FOREMEN SHOPS
FOREMEN
FOREMEN
MAINTENANCE
PLANING &
SCHEDULING
FOREMEN
ENGINEERING
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FIELD FOREMEN
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D. REPAIR PROGRESS
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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.
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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
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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 checkups. 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
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G. PREVENTIVE MAINTENANCE SCHEDULES
i.
•
Daily Check :
Clean sensors and optics within the robot cell and visually check
component parts for damage before daily operation
•
ii.
•
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
iii.
•
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
•
Check 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
iv.
•
v.
•
1-year (3,840 hours) Checks:
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)
vi.
•
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.
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4-year (15,360 hours) Checks:
•
Replace the Mechanical Unit cables
•
Replace the lithium battery in the CPU
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H. ROBOTICS LOG
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I. ROBOTICS MONITORING SYSTEM FORM
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I. CONCLUSION
It is possible to have a successful preventive maintenance program. From a
cost reduction viewpoint it is 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.
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