Robot Assessment Report

Transcription

1 Robot Assessment Report Report Date Report Responsible Customer Information Company Name Address N/A Location N/A Controller Information Controllers S/N Controller Time (Hours) REPORT DESCRIPTION The robot assessment report is an ABB method to evaluate robot usage. The robot usage is measured based on the assessment performed by the ABB technician. The assessment includes production information, evaluation of robot environment as well as recording real production cycles also called reference cycles. The report is designed to evaluate the robot usage, identify the main factor influencing life time of the equipment in order to define the adequate maintenance strategy. REPORT RECOMMENDATION

2 Robot Information: IRB /2.55 (ROBOT) Audit Date Audit Responsible Robot Type IRB /2.55 Production Criticality Average Robot Age 54 Environment Plant Air Production Time SIS Maintenance History Major PM Application Type Material Handling Operating Time (hours / day) 16 Work Envelope 5 Tool Weight (kg) Program Speed (mm/s) 308 Center of Gravity (mm) 300 Cycle Time (sec) 40 Work Load Stress Low ROBOT USAGE INFORMATION ESTIMATED WORK ENVELOPE Work envelop plots present the motion trajectory of the robot within the working range of the robot model. The top and side envelope-views provide an accurate view of the main working areas for the robot and indicate if the robot is operating close to its working range limits. The graphs also indicate high-speed sequences with red color plots.

3 RELATIVE AXIS USAGE Relative usage plot presents percentage of usage of each axis in comparison with the total robot usage. Large pie slice show a large usage and small pie slice show a small usage. ANGULAR SPEED AND INVERSIONS Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Inversions per minute Avg. angular speed (degrees/sec) Angular movement per min (degrees) This table presents key parameters to estimate cable life expectancy. Analysis of the reference cycles provides the number of inversions, the average angular speed, and total angular movement for each axis. These parameters are key characteristics for axis usage. High figures emphasize which parameter is the most critical for the axis.

4 TORQUE USAGE The torque usage plot presents an evaluation of the torque of each axis during the robot reference cycles. The scale is "Low", "Medium" and "High" where "Medium" stands for normal robot usage regarding torque usage. "Low" is below normal usage and "High" above. High level of torque is often the result or combination of high axis constraints like high speed, fast inversion, heavy load and extreme reach. A high level of torque indicates high mechanical constraints and should be mitigated with reduced maintenance intervals (inspection, and replacement) to maintain the optimal condition of the robot.

5 CONCLUSIONS AXIS AND CABLE WEAR RATES Axis wear rate provides a summary evaluation of the wear rate of each axis (mechanical parts) during the robot cycle. A higher value indicates a harder usage for each axis. The scale is "Low", "Medium" and "High". ("Medium" refers to normal robot usage regarding axis wear rate. "Low" is below normal usage and "High" above.). The axis wear rate graph provides a rapid overview to identify which axis requires most attention for maintenance activities. A high wear rate indicates high mechanical constraints and should be mitigated with reduced maintenance intervals (inspection and replacement) to maintain the optimal condition of the robot. CRITICAL FACTORS INFLUENCING LIFE OF ROBOT Wrist Wear Factor: The wrist wear factor is similar to the main wear factor but it only considers tooling factors and the program speed. It is used to provide a numerical value for wear of the wrist. Remaining Lifetime: The remaining lifetime is the ratio between the adjusted lifetime and the expected lifetime given by the manufacturer. The result is given in percent of the expected lifetime. All Key Parameters: A higher value indicates a harder usage, the scale is from 0 to 5.

6 MAINTENANCE PLAN The maintenance plan lists the main components of the robot with maintenance frequency for inspection (I), lubrification (L) or replacement (R). Maintenance frequencies are calculated based on the robot assessment and evaluation of the robot usage. The data provided for the replacement of main components is based on normal usage of the robot, excluding collisions, excessive wear or other external environmental factors affecting robot performance. ABB recommends the following maintenance activities: Component (I) (L) (R) Cable axis 1-4 Yearly Cable axis 1-6 Yearly Cable axis 5 Yearly Cable axis 5-6 Yearly Gear box axis 1 Yearly Gear box axis 2 Yearly 4000 Gear box axis 3 Yearly Gear box axis 4 Yearly Gear box axis 5 Yearly Gear box axis 6 Yearly Motor axis 1 Yearly Motor axis 2 Yearly Motor axis 3 Yearly Motor axis 4 Yearly Wrist unit Yearly I = Inspect L = Lubricate R = Replace