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Main System Components Installation

The installation of this system is set up such that the robot plate is located on the floor first. Once set into position, the surrounding racks are located by templates, using the robot plate as the datum. Next, the robot will be installed onto the plate and finally, the fencing will be installed to close out the cells shape. These components can be identified in Figure 2 above. Further detail can be found in the sections below.

Moving the Robot Plate​

The robot plate is a 48” x 48” x 1.5” thick steel plate weighing approx. 1000 lbs. The plate is shipped on a wooden pallet but moving the plate to its final location requires lifting via a four (4) leg chain sling rated for the stated weight.

  1. Start by attaching four (4) M20x30mm eyebolts into 4 of the 8 M20 tapped locations on the plate. These eyebolts should be evenly spaced to ensure the plate remains level as shown in Figure 11.

  2. Attach the legs of the chain sling to each of the four eyebolts.

  3. Lift the plate to its final position, ensuring squareness with surrounding walls.

  4. The plate should be oriented such that the two (2) M6 tapped holes for the BOA camera, highlighted in the image below, are facing the direction of the hallway.

Figure 11: M20 Lifting Locations

Locating the Robot Plate​

Using the documentation coordinated between the manufacturer, seller, and customer, locate the robot plate with as much care as possible.

All other system locations are based on the location of the robot plate.​

Securing the Robot Plate to the Ground​

The robot plate is secured to the concrete floor with eleven (11) – ¾” X 9 ¾” “Hilti Hit-Z” anchor rods. These threaded rods are secured to the floor with “Hilti HY 200-R” adhesive. Concrete thickness should be confirmed 6” minimum before continuing this installation.

Figure 12: Concrete Anchor Locations

  1. With a 7/8” concrete drill bit and using the eleven outer 7/8” thru-holes as drill guides, Drill each hole into the concrete to within 1” of the concrete thickness.

    • a. Min depth is 4 ¾” and max depth is 8”.

    • b. Do not drill all the way through concrete as the adhesive will need a solid bottom surface to properly fill the hole.

  2. Vacuum as much concrete dust from the holes as possible. The holes do not have to be perfectly clean for proper installation.

  3. Follow the instructions included with the Hilti adhesive for proper installation and cure time of the anchor rods.

  4. Once adhesive has fully cured around anchors, remove any excess adhesive from the threads and robot plate to provide a flat surface for the mounting fasteners.

  5. Place two (2) ¾” washers and a ¾” nut on each anchor and torque to 110ft-lbs (150N-m).

  6. A torque stripe should be applied to each nut for visual inspection of long-term tightness.

  7. The plate is now ready to accept the robot.

Moving the Robot​

The robot is shipped on a steel pallet with dedicated fork pockets. The robot weighs approx. 3219lbs. Ensure the forks are fully inserted through the entire pallet before moving the robot. There are two options for moving the robot from the shipping pallet to the robot plate mounted to the floor: Lifting with a 3 leg chain sling, or lifting with attachable forklift pockets.

Lifting Robot with Chain Sling​

The robot can be lifted with a 3-leg chain sling using the attachment points shown in the image below. Pay special attention to the slings under tension to ensure they are not touching joint motors or pinching wiring. Sling legs should be adjusted in length such that the robot is level to the ground when lifted.

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  • What should we watch out for?

  • X

  • Y

  • Z

Figure 13: Lifting Robot with Chain Sling.

Lifting Robot with Attachable Fork Pockets​

If ceiling height is a concern, the robot can be lifted using attachable fork pockets as shown in the image below:

Purchased Parts:

  • Kawasaki P/N: 60154-2711 (QTY 2 Needed)

Figure 14: Lifting Robot with Fork Pockets.

Securing the Robot to the Mounting Plate​

The robot is secured to the mounting plate with eight (8) M20 x 65mm Socket Head Caps Screws (min CL 10.9). These screws shall be torqued to 318 ft-lbs (431 N-m). A torque stripe should be applied to each bolt for visual inspection of long-term tightness.

Figure 15: Robot Mounting Locations

Lifting the Charging Racks​

Lifting from Battery Side (Standard)​

Charging racks are designed to be lifted underneath the second shelf of each rack as shown in the image below. Racks are shipped with chargers temporarily removed from this area so that forks can slide underneath the second shelf horizontal rack members. Doors will need to be opened to allow the forks to fully sit under both rack members of the second shelf. Chargers are to be returned to these empty positions once the racks are placed in their final locations. Further detail on charger installation can be found in Section 27.

Figure 16: Typical Rack Lifting Location

Figure 17: Important Keep Out Zones Around Rack Lifting Areas

Lifting from Door Side​

If a rack needs to be lifted from the door side to place in its final position; the following steps should be followed below to gain access to the fork pockets from this side of the rack:

  1. Remove any plastic wrap around the rack

  2. Cut any zip ties holding the rack doors together and closed.

  3. Open the doors of the rack and locate the backside of the fork pockets

    • a. These pockets come standard with a cap on the backside to provide door protection during shipping.

  4. Using an 8mm wrench, remove the fork pocket covers by removing the qty 3 – M5 screws on the sides and bottom of the cap.

  5. Place the caps and fasteners in a bag in preparation for shipping back to Lion Power.

Removing the Lifting Pockets​

Once the rack is placed in its final position:

  1. Remove the M5 screws at the front and back of the lifting pocket and remove the pocket from the rack.

    • a. These pockets will be shipped back to Lion Power for reuse.

  2. Reinstall any chargers in the positions of the fork pockets. See section 27 for details.

Locating Primary Rack Five (5)​

After the robot plate has been located on the floor, the primary rack 1 can be located based off the robot plate.

Figure 18: Rack 5 Floor Placement

  1. Using the supplied floor template, align the template along both sides of the robot plate and mark the intended corners of both front “rack five” feet as shown in the image below.

  2. Lifting the rack into position, align the feet with the corner markings as closely as possible.

  3. After the rack is located, use a 3/8” concrete drill bit and drill two (2) holes per foot pad for a total of eight (8) holes, using the foot holes as drill guides.

  4. Secure the rack to the floor with two (2) 3/8” x 3 ½” concrete screws per foot.

Locating Rack Four (4)​

After the robot plate has been located on the floor, rack two can be located based off the robot plate.

Provide Image of Templated Layout​

  1. Using the supplied floor template, align the template along both sides of the robot plate and mark the intended corners of both front “rack one” feet as shown in the image below.

  2. Lifting the rack into position, align the feet with the corner markings as closely as possible.

  3. After the rack is located, use a 3/8” concrete drill bit and drill two (2) holes per foot pad for a total of eight (8) holes, using the foot holes as drill guides.

  4. Secure the rack to the floor with two (2) 3/8” x 3 ½” concrete screws per foot.

Locating Rack Three (3)​

After the robot plate has been located on the floor, rack four can be located off the robot plate.

Provide Image of Templated Layout​

  1. Using the supplied floor template, align the template along both sides of the robot plate and mark the intended corners of both front “rack one” feet as shown in the image below.

  2. Lifting the rack into position, align the feet with the corner markings as closely as possible.

  3. After the rack is located, use a 3/8” concrete drill bit and drill two (2) holes per foot pad for a total of eight (8) holes, using the foot holes as drill guides.

  4. Secure the rack to the floor with two (2) 3/8” x 3 ½” concrete screws per foot.

Locating Rack Two (2)​

After the robot plate has been located on the floor, rack four can be located off the robot plate.

Provide Image of Templated Layout​

  1. Using the supplied floor template, align the template along both sides of the robot plate and mark the intended corners of both front “rack one” feet as shown in the image below.

  2. Lifting the rack into position, align the feet with the corner markings as closely as possible.

  3. After the rack is located, use a 3/8” concrete drill bit and drill two (2) holes per foot pad for a total of eight (8) holes, using the foot holes as drill guides.

  4. Secure the rack to the floor with two (2) 3/8” x 3 ½” concrete screws per foot.

Locating Rack One (1)​

After the robot plate has been located on the floor, rack five can be located based off the robot plate.

Provide Image of Templated Layout​

  1. Using the supplied floor template, align the template along both sides of the robot plate and mark the intended corners of both front “rack one” feet as shown in the image below.

  2. Lifting the rack into position, align the feet with the corner markings as closely as possible.

  3. After the rack is located, use a 3/8” concrete drill bit and drill two (2) holes per foot pad for a total of eight (8) holes, using the foot holes as drill guides.

  4. Secure the rack to the floor with two (2) 3/8” x 3 ½” concrete screws per foot.