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Monthly Maintenance

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

Air System Drains​

The air compressor and the regulator should be drained monthly to reduce damage to the pressure system. There are various revisions of the air compressor drain as shown in Figure 2 and Figure 3 below. There is also an auto drain configuration that requires draining of an external water tank every 6 months as shown in Figure 4.

Draining the Compressor Air Tank (Manual TT drain systems) 1. Locate the Air Compressor.​

  • a. The air compressor is located at the bottom of the primary rack (rack with operator HMI).

  • b. Open the left door and locate the compressor underneath the robot controller.

  1. Locate the handle at the base of the tank or handle at the end of a braided hose extender.

Figure 2: Air Compressor Drain. Figure 3: Air Compressor Drain Extension.

  1. Slowly rotate the handle to initiate the release of air.

  2. Allow the valve to remain open for approximately 2 seconds after liquid has stopped draining.

  3. Close the valve and shut the door.

  4. The compressor will run until it has reached its target tank pressure.

Draining the Air Compressor External Water Tank (Auto drain systems) The auto-drain configuration consists of a

solenoid at the end of the air compressor drain extension as well as an external 13-gallon water tank that sits on the floor underneath the rack. The solenoid valve and water tank are connected via a rubber hose and quickdisconnect connection at the inlet of the water tank as shown in Figure 4. The water tank should be removed and emptied every 6 months.

  1. Locate the water tank.

    • a. The water tank is located at the bottom of the primary rack (rack with operator HMI).

    • b. Open the both doors and locate the tank resting on the floor.

Figure 4: Auto-Drain Setup

  • c. Slide the collar back on the

connection to release the water tank.

  • d. Take the water tank to an approved location for dumping wastewater.

Draining the Robot Base-of-Arm (BoA) Regulator​

  1. Locate the regulator at the base of the robot.

  2. Locate the air release button, indicated by the blue arrow, on the bottom of the regulator.

  3. Press the button for approximately 2 seconds after the liquid has drained from the regulator.

BoA Camera and EoA Tool Wipe Down​

To clean the EoA camera, laser scanner, TOF sensor, and BoA camera, use dry, clean air to remove any dust or particles. If any dirt remains, gently wipe the sensors with a soft, lint-free cloth and non-streaking glass cleaner or isopropyl alcohol. Be sure to remove all residue from the sensors after cleaning.

Phot​

  • Audits

Not currently available.

Photo audits are used to visually inspect critical battery components on a semi-regular basis. Performing this task regularly can potentially mitigate downtime by marking assets ahead of time for preventative maintenance.

Critical Checks – DM Codes:​

Checking the DM Codes on the battery (or any other location) should be focused on readability of the code. Any damaged codes should be replaced.

  1. Scratches / Marking

  2. Peeling (stickers only)

  3. Fading / Contrast

  4. Human-readability

Critical Checks – Battery Pin Plates / Pins:

Any battery pin plates that show signs of excessive wear or damage should be replaced immediately to prevent additional damage to the gripper and other battery pins.

  1. Rust

  2. Discoloration

  3. Damage 4. Dirt, Oil, or Grease

Batteries may be quarantined in the rack to wait for pin plate replacements. While quarantined, the pin plate may be removed if needed to return for repair or to perform maintenance. If the pin plate is removed, it is critical to reinstall properly. Follow the instructions in Section 5.6.2.

Manual Cart Inspection​

The manual cart should be inspected monthly to ensure proper function. Inspections steps are as follows:

  1. Turn the switch to the “ON” position and verify that the battery indicator shows an illuminated battery level in the “CHARGED” range.

    • a. If battery level is in the “RECHARGE” range, charging is required.

  2. Locate the up and down buttons on the handheld controller.

  3. Standing behind the lift, away from the lifting mechanism, raise the mechanism to its highest point.

  4. Lower the battery lifting mechanism to its lowest point.

    • a. Pay careful attention to the Figure 6: Manual Cart Controls

    • lifting chain during this process. If at any point, the chain develops slack, stop movement immediately and do not stand underneath.

    • b. Carefully raise the mechanism until any slack in the chain is no longer visible.

    • c. Slack in the chain indicates that the mechanism is not sliding up and down properly.

    • d. Standing behind the cart, attempt to raise and lower the mechanism in the binding area to grease any catch points. Do not allow the chain to fold over on itself at any point.

    • e. Once the cart can achieve full travel without any catching or binding, inspection can proceed to the next step.

  5. Raise cart to a comfortable level for inspection of the battery lifting mechanism

Figure 7: Battery Lifting Mechanism

  1. Move to the front of the cart and inspect bolted joint torque stripes for any indication of loosening.

  2. Inspect the battery interaction plate (pin cup) for any signs of excessive metal wear or burring inside of the pin cavity (see Figure 8).

  3. Inspect the plastic sliding surface for any signs of excessive sliding wear, cracks, or damage to the surface.

  4. Slide the entire mechanism along the shaft, using provided handles, to ensure full side to side travel.

  5. Cycle the leveling handle to ensure proper movement of the leveling mechanisms.

  6. If any damage is found, take and send pictures to engineering for review.

Figure 8: Manual Cart - Battery Interaction Plate (Pin Cup and Sliding Surface.

  1. If all components appear to be tight and in
  • working order, locate a forklift and attempt battery removal and installation to ensure full functionality.

  1. After a functional test, lower mechanism to its lowest point and move cart back to its storage position.

  2. Plug cart into wall for charging.