The use of industrial robots in manufacturing is increasing, mainly in harsh conditions or situations requiring high work intensity and continuity. Branded robots have a lower failure rate and are therefore widely recognized.
Even with well-designed, highly integrated industrial robots that have a low failure rate, regular routine inspections and preventative maintenance are still necessary. Common types of robots include: articulated robots, Cartesian robots, Delta parallel robots, SCRA robots, and automated guided vehicles (AGVs). This article focuses primarily on the maintenance of articulated robots.
I. Maintenance and upkeep of industrial robot body
1. Routine maintenance
1) Cleaning robot
Clean the robot's base and arm regularly; high-pressure cleaning equipment can be used, but avoid spraying directly onto the robot; if the robot has a protective film such as grease, remove it as required. (Avoid using strong solvents such as acetone; avoid using plastic protective materials; to prevent static electricity, non-conductive surfaces such as spraying equipment and hoses must be wiped with a damp cloth. Do not use a dry cloth.)
2) Cleaning and maintenance of hollow wrists
Depending on the actual situation, hollow wrists need to be washed frequently to avoid the accumulation of dust and particles. Use a clean cloth that does not pill to clean them. After washing the wrists, you can add a small amount of petroleum jelly or similar substance to the surface of the wrists, which will make future cleaning easier.
3) Regular inspections
Check for oil leaks; check for excessive gear clearance; check for damage to the cables between the control cabinet, purging unit, process cabinet, and robot arm.
4) Inspection of fixing bolts
The fastening bolts and clamps that secure the robotic arm to the foundation must be kept clean and protected from water, acidic or alkaline solutions, and other corrosive liquids. If the galvanized layer or other anti-corrosion protective coating is damaged, the affected parts must be cleaned and coated with an anti-corrosion coating.
2. Axle Braking Test
During operation, the brakes of each axis motor will wear normally. To determine whether the brakes are working properly, a test must be performed at this time.
Test method: Check the brake of each axis motor as described below.
1) Move the robotic arm axis to the corresponding position, at which the total weight of the robotic arm and all loads reach their maximum values (maximum static load).
2) Motor power failure;
3) Check that all axes remain in their original positions;
If the robotic arm does not change position when the motor is powered off, the braking torque is sufficient. The robotic arm can also be moved manually to check if further protective measures are needed. When the mobile robot stops urgently, the brakes will assist in stopping, which may cause wear. Therefore, repeated testing is necessary throughout the machine's lifespan to verify that the machine maintains its original capabilities.
3. System lubrication
1) Lubrication of shaft pair gears and gears.
Ensure the robot and related systems are turned off and locked. Squeeze a small amount (1 gram) of grease into each grease nipple and lubricate each gear grease nipple individually. Do not inject too much grease to avoid damaging the seal.
2) Lubricate the hollow wrist.
The hollow wrist has 10 lubrication points. Only a few drops (1 gram) of lubricant are needed at each injection point. Do not inject too much lubricant to avoid damaging the wrist seal and the inner sleeve.
4. Check the oil level in each gearbox.
The location of the oil filling holes varies for each shaft, requiring targeted inspection. Some shafts need to be rotated to a vertical position before opening the cover for inspection.
5. Maintenance cycle (the time interval may be adjusted appropriately according to environmental conditions, robot operating hours, and temperature)
1) Routine maintenance frequency: once per day;
2) Axle brake test: once a day;
3) Lubricate the 3-axis auxiliary gear and gears: once every 1000 hours;
4) Lubricate the hollow wrist: 1 time/500 hours;
5) Lubricating oil in each gearbox: Change it once a year for the first time, and then every 5 years thereafter.
II. Maintenance of the System Control Cabinet
1. Maintenance Content
1) Check the controller's heat dissipation.
The controller must not be covered with plastic or other materials; sufficient clearance (>120mm) must be left behind and on the sides of the controller; the controller must not be placed near heat sources; no debris should be placed on top of the controller; avoid the controller being too dirty; avoid one or more cooling fans not working; avoid blockage of fan inlets or outlets; avoid excessively dirty air filter cloth; the front door of the controller must be kept closed when no operation is being performed inside.
2) Clean the teach pendant
The teach pendant should be cleaned at an appropriate frequency based on actual needs; although the panel coating can withstand the corrosion of most solvents, contact with strong solvents such as acetone should still be avoided; the teach pendant should be removed and placed in a clean place when not in use.
3) Clean the inside of the controller
The inside of the controller should be cleaned at appropriate intervals, such as once a year, depending on environmental conditions. Special attention should be paid to cleaning the cooling fan and air inlets/outlets. Use a dust brush for cleaning and then vacuum up the brushed dust. Do not use a vacuum cleaner to clean individual components directly, as this can cause electrostatic discharge and damage the parts. Always disconnect the power before cleaning the inside of the controller!
4) Clean or replace the filter cloth
To clean the filter cloth, rinse it 3-4 times in water at 30-40℃ with detergent. Do not wring the filter cloth dry; instead, let it air dry on a flat surface. Alternatively, you can use clean compressed air to blow the filter cloth clean.
5) Replace the battery regularly.
The measurement system uses a disposable battery (not a rechargeable battery); a message will appear in the log when the battery is replaced. The battery will have approximately 1800 hours of remaining charge after this message appears. (It is recommended to replace the battery when this message appears.) The battery only operates when the control cabinet is powered off. The battery's lifespan is approximately 7000 hours.
If the control cabinet controls the CBS unit in addition to the robot, or if an 8-axis robot is being used, the battery life is half of what was mentioned above (using two SMU units).
6) Check the cooler
The cooling circuit adopts a maintenance-free closed system design. All components of the external air circuit need to be inspected and cleaned regularly as required. When the ambient humidity is high, it is necessary to check whether the drain outlet drains regularly.
2. Maintenance frequency (the time interval can be adjusted appropriately according to environmental conditions, robot operating hours, and temperature)
1) General maintenance: once a day;
2) Clean/replace filter cloth: once every 500 hours;
3) Battery replacement for the measurement system: 2 times/7000 hours;
4) Replacement of computer fan units and servo fan units: 1 time/50,000 hours;
5) Check the cooler; once a month.
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