Skip to main content

Annual Maintenance

danger

Before beginning the inspection, make sure to power off the PowerHive system and disconnect it from the power supply. Lock out and tag out the power supply to prevent accidental reconnection during the inspection. Wear appropriate personal protective equipment (PPE) including safety glasses and steel-toed footwear.

The following are instructions for service tasks that need to be accomplished annually. The service tasks are integral to the proper functioning of this system and should be accomplished as described in the service manual.

Ensure to document all findings during the inspection process. This includes any abnormalities, recommended repairs, and general observations about the state of the system.

Take photos of any problem areas to accompany the written report.

Detailed Visual Inspection Wiring / Electrical​

The following section details the steps for performing an annual inspection of the wiring and electrical systems within the robotic cell. This inspection is crucial to ensure the efficient operation of the cell, minimize the risk of electrical hazards, and prolong the lifespan of the equipment.

  1. Visually inspect the robot cell's exterior. Look for: a. Signs of physical damage such as frayed wires, damaged insulation, or burn marks.

b. Drooping / falling cable harnesses.

  • c. Cables on the racks that may be in the way of or touching a battery when inserted.

    1. Check for any loose or disconnected wires and connectors. a. Robot Base of Arm (BoA) b. Main Rack Connections (Yellow cables) c. Battery Movement Areas (Interior rack charging bays)
    1. Verify the integrity of the grounding connections, ensuring that they are free of corrosion and securely fastened. a. Ground wire between Rack 1 and the Robot BoA.

  • b. Ground wire between Rack 1 HV and Rack 1 LV enclosure. c. Ground wire between Rack 1 LV enclosure and door.

    1. Inspect the control panel. Check for: a. Signs of overheating, discoloration, or damage.

  • Fencing / Bollards The following steps outline the process for inspecting the safety fence and bollards around the robotic cell. These barriers are crucial for maintaining a safe work environment by protecting workers from potential harm and preventing unauthorized access to the robot cell. 1. Inspect the safety fence for any signs of physical damage such as: a. Dents, Cracks, Corrosion b. Tampering, Unauthorized Modifications

    1. Inspect the bollards for similar signs of damage. Ensure that they are intact and properly anchored to the floor.
    1. Ensure that all safety signage on the fence and bollards is clear, unobstructed, and legible.
    1. Check the stability of the safety fence and bollards. Push and pull at various points to test the integrity of the connections and the anchoring.
    1. Using a level, check to see if the fence and bollards are vertically aligned. Misalignment may indicate issues with the foundation or anchoring.
    1. Ensure the Light Curtains function properly if any adjustment is made to the fencing.

Robot Maintenance (Kawasaki Service Technician)​

The robotic arm will be serviced by a qualified Kawasaki Robot Technician annually to ensure that it operates safely and smoothly throughout the year.

Comprehensive Safety System Check​

Confirm that the floor scanner, light curtains, door latches, and emergency stop buttons are functioning properly. Follow steps in the applicable sections and record the completion in a paper log with your name and the date of the verification tests.

Components t

  • Check:

  1. Floor Scanner(s)

  2. Hallway and Robot Light Curtains

  3. Rack Door Locks / Latches

  4. E-Stops (each)

Floor Scanners​

Follow the steps in Section 8.1 Keyence SZ-V Inspection Procedure subsection 8.1.2 Regular (Periodic) Inspection

Hallway and Robot Light Curtains

Follow the steps in Section 8.2 Keyence GL-R Safety Fence Inspection subsection 8.2.2 Regular (periodical) inspection

Rack Door Latches​

Follow the steps in Rack Door Magnetic Locks, Section 5.1.3

Emergency Stops

Follow the steps in Emergency Stop Buttons, Section 5.1.4

Air Compressor Replacement (Manual Drain Version)​

The air compressor should be replaced annually as it is a low-cost item, and a replacement will help reduce robot down time. To replace the air compressor:

  1. Locate the “Inverter/Compressor 20A breaker inside of the LV box and turn the breaker off.

  2. Open the left door of Rack 1 to reveal the compressor location in the bottom left corner.

  3. Working from inside of the robot cell, locate the (+), (-), and ground connections at the back of the inverter and unscrew these electrical connections.

  4. Locate the yellow ethernet cable providing communication to the 5-port POE switch at the back of the inverter/compressor assembly.

  5. Lift the compressor shelf and remove the front hooks from the hangers. 6. Next, lift the back end from the support bracket and allow the compressor shelf to rest on the ground.

  6. Slide the shelf out to reveal the entire air compressor. 8. Unplug the compressor plug from the inverter. 9. Remove the rubber air line from the compressor by sliding the collar back on the fitting and pulling the rubber line (with mating fitting) from the compressor. A pop of air will be heard momentarily.

  7. Locate the 4 zip ties securing the compressor to the shelf and cut the ties. 11. At this point, the compressor can be removed from the shelf. To reinstall a new compressor, complete the steps above in the opposite direction.

Air Compressor Replacement (Auto-Drain Version)​

If the system is equipped with the auto-drain air compressor, additional connections are required to be removed to free the air compressor from the assembly.

  1. Locate the “Inverter/Compressor 20A breaker inside of the LV box and turn the breaker off.

  2. Open the left door of Rack 1 to reveal the compressor and water tank location in the bottom left corner and floor, respectively.

  3. Disconnect the drain connection from the water tank and remove the tank from the rack (empty if any water has accumulated).

  4. Working from inside of the robot cell, locate the (+), (-), and ground connections at the back of the inverter and unscrew these electrical connections.

  5. Locate the yellow ethernet cable providing communication to the 5-port POE switch at the back of the inverter/compressor assembly.

  6. Lift the compressor shelf and remove the front hooks from the hangers.

  7. Next, lift the back end from the support bracket and allow the compressor shelf to rest on the ground.

  8. Slide the shelf out to reveal the entire air compressor and drain plumbing.

  9. Locate the manual air release on the side of the compressor. Drain the tank completely of air.

  10. Remove the solenoid valve from its mounted position by removing the 2 – M3 screws holding it in place.

  11. Unplug the compressor plug from the inverter.

  12. Remove the rubber air line from the compressor by sliding the collar back on the fitting and pulling the rubber line (with mating fitting) from the compressor. A pop of air will be heard momentarily.

  13. Locate the 4 zip ties securing the compressor to the shelf and cut the ties.

  14. Once the compressor is free from the shelf, unscrew the 90-degree NPT connection at the base of the air tank to free the drain plumbing from the compressor. This will be reused on the new compressor.

  15. To reinstall a new compressor, first remove the stock drain plug.

  16. Ensure the tank female threads are cleaned of all previous thread sealant.

  17. Ensure 90-degree NPT fitting is cleaned of all previous thread sealant.

  18. Apply 3-5 new layers of PTFE thread sealant tape to the 90-degree elbow fitting before reinstallation into new compressor tank.

  19. Complete steps 1-13 in the opposite direction.

  • a. Ensure all electrical connections are tight.

  • b. Ensure all drain plumbing is tight and leak-free.

  • c. Ensure drain extension valve just upstream of the solenoid is open (handle rotated parallel to hose to allow tank to drain properly.

Rack Inspection​

Below are yearly inspection items related to the rack that are not already addressed in other sections of the manual:

Inspection of Spring-Loaded Brushes​

  1. Inspection of the spring-loaded brushes should take place inside of the robot cell using a flashlight.

  2. If any brushes appear darker or in any way different than the other brushes, proceed with the following steps:

  3. Wipe the brush contact surface with a clean rag and isopropyl alcohol. 4. Using a 120-grit sanding block, lightly remove any oxidation, charring, or high spots from the brush surface, taking care not to remove excessive material and create a non-flat surface.

Lock Check on Charger 480V Power Connection 1. Standing inside of the robot cell, each charger electrical connection should be checked to ensure that the quick-connects are fully seated. This should be performed with power turned off at the rack high voltage panel.

  1. Grab each side of the connection, twist clockwise to ensure no further rotation is possible.

  2. If any connections are loose, make a note in the annual review report.

Battery Retention Bracket Inspection 1. The battery retention bracket (front lip) on the robot side of each battery bay should be inspected to ensure there is no damage.

  1. If any damage is observed, replace the component. • Standard battery lip: 102151 • XL battery lip: 102585

Brush Bracket Assembly Inspection

1.The brush bracket assemblies should be inspected from the rack door side.
2.Ensure there is no chafing around the spring-loaded brush shunts. Check for
damage to the brush bracket.
3.Check for melted plastic around the brushes.
4.Check the terminals for melted plastic and ensure the lock washer is
flattened on both sides of terminal.
5.Ensure all connections into the NFC board (two connections) and the
chargers (two connections) are secure.
6.Ensure the bracket supporting the top edge of all the plastic brush assembly
brackets is damage-free.
7.Ensure the M8 bolts securing each brush assembly to the rack are secure
(torque stripe is intact)
  1. Ensure 2/0 cables from the charger to the brush assembly are free of any damage.

Cradle Inspection​

Cradle inspections shall be performed annually. Prior to performing the inspection, ensure that the battery is removed from the cradle.

Inspect the following:

  1. Ensure front lower and side battery retention brackets are fastened properly.

  2. Ensure there is no damage to the upper plastic pass-thru bracket.

  3. Power terminals

  • All four terminal screws shall be fully tightened; a quick check can be made by checking to see if the lock washer is flattened.

  • o Check for any evidence of melting surrounding the conduction pathways. Replace if present.

    1. The power button should illuminate when the cradle is turned on.

  1. Brush bracket assembly: Check for debris or oxidation on the copper brushes. If present, complete the following steps:

  2. Wipe the brush contact surface with a clean rag and isopropyl alcohol.

  • Using a 120-grit sanding block, remove the oxidation from the brush surface.

  • • Wipe surface again with a clean rag and apply a thin layer of “No-Ox ID A Special” or approved electrolytic grease to the surface.

    1. Check for damage to the brush bracket.

    • Check for melted plastic around the brushes.

    • o Check the terminals for melted plastic and ensure the lock washer is flattened on both terminals.

  1. Inspect the wire harness and look for any loose or charred wires.

Phot​

  • Audits

Not currently available.

Cleaning Up​

If no issues were detected during the inspection, reconnect the robot cell to the power supply, remove the lockout/tagout devices, and power up the system.

If issues were detected, do not reconnect the power supply. Instead, schedule necessary repairs as soon as possible.

Provide the documented report to the appropriate personnel, including the facility's maintenance team and management.