Safety Precautions

            This chapter must be read before using the System.

For detailed functions of the System operation, read the relevant operator's manual to understand fully its specification.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral equipment installed in a work cell.

For safe use of Mujin Systems, you must read and follow the instructions in the “Operations Manual” provided with your system.

System Users

 The personnel can be classified as follows.

Operator:

Turns the robot controller power on/off.

Starts the robot program from operator panel.

Trained maintenance worker:

Operates the robot.

Services the System from inside the safety fence

Performs maintenance (repair, adjustment, replacement)

*Operators are not allowed to service the system from within the safety fence.

**Trained maintenance worker is allowed to work in the safety

fence. Works carried out in the safety fence include transportation, installation, teaching,

adjustment, and maintenance.

***To perform functions inside the safety fence, the person must be trained in proper system operation.

The following table lists the work outside the safety fence. In this table, the symbol “” means the work allowed to be carried out by the worker.

Safety Notations

            To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is indicated by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before using the robot. Warning labels play a critical role in communicating potential hazards associated with operating the robot cell and outlining necessary safety precautions. These labels are strategically placed throughout the system to ensure clear visibility and to serve as a constant reminder to operators and maintenance personnel of potential risks. It is crucial that all personnel working with or around the system familiarize themselves with the warning labels and adhere to the safety precautions they recommend. Regularly inspect the labels for any signs of wear, damage, or fading that may impact its legibility. If a label is damaged or missing, promptly report the issue and replace the label to ensure continuous safety awareness. Some of the warning labels around the system have been mentioned below:

            In addition to understanding and adhering to the information on warning labels, all personnel should follow the general and robot cell-specific safety guidelines provided in this manual to ensure a safe and efficient working environment.

Lockout-Tagout Best Practices

            Lockout-tagout (LOTO) is an essential safety measure that must be followed when servicing or maintaining the Mujin system. LOTO is the process of disconnecting and isolating equipment from its energy source to prevent unexpected start-up or release of energy that could cause harm to personnel. 

            Before servicing or maintaining the system, the operator must ensure that the equipment is de-energized and cannot be restarted until the maintenance or servicing work is completed. LOTO procedures require locks and tags to prevent the equipment from being accidentally energized or re-energized during maintenance or servicing work. 

Figure 35: LOTO for Power Disconnect

Figure 36: Pressure relief valve

            The LOTO process for the Mujin system involves the following steps: 

1. Notify affected personnel: Inform all relevant personnel that maintenance or servicing work is about to take place.
2. Shut down the equipment: Follow the shutdown procedure outlined in the manual to cease equipment operation. 
3. Door interlock lockout: After entering the system through the door, keep the door interlock key on you.
4. Disconnect the power sources: Ensure all energy sources are isolated.
   There are multiple electrical power disconnects located in the system:
   1. Robot cell: Each robot cell will have a main power disconnect located next to the panel.
   2. Primary control panel: There will be a disconnect next to it.
   3. Each PDP in the robot cell has a quick disconnect.
   4. Each blower panel in the robot cell has a quick disconnect.
   5. Pallet Stacker: The pallet stacker is powered through the power disconnect located near the pallet stacker.
   6. AMR chargers: Each AMR charger is powered by a power disconnect located near it.

There are three pressure relief valves installed in each robot cell next to the blower.

1. Lock and tag: Lock and tag the equipment to prevent it from being accidentally energized or re-energized during maintenance or servicing work. 
2. Test the equipment: Confirm the equipment is de-energized and cannot be restarted until the maintenance or servicing work is completed. 
3. Conduct the maintenance or servicing work: Proceed with the required tasks safely. 
4. Remove the locks and tags: Once maintenance or servicing work is complete, the operator can remove the locks and tags, then restore power to the equipment. 

[JA1] [JA2] 

Figure 37: LOTO locations

            By following LOTO procedures, the operator can ensure that the Mujin system is safely maintained or serviced without the risk of unexpected start-up or release of energy that could cause harm to personnel.

Revision

1. System Overview

This section provides a comprehensive overview of the system components, their roles, and operational interactions to enable safe and effective use. The system integrates advanced robotics, handling mechanisms, and user interfaces to optimize material handling and palletization tasks.

1. Robot Arm FANUC R-2000iC:

• Central Role: 
  • The R-2000iC is integral to automation processes, excelling in high-precision pick-and-place, stacking, palletizing, and welding tasks.
• Specifications:
  • Max Payload: 210 kg
  • Reach: 2655 mm
  • Position Repeatability: ±0.05 mm
  • Operational Environment: 0–45°C, 10–95% humidity (non-condensing)
• Key Features:
  • End-of-Arm Tool (EOAT): Customizable for gripping, welding, or material handling tasks.
  • Dress Pack: Facilitates efficient cable and hose management, reducing wear and interference.
  • Vision System: Optional FANUC iRVision for advanced object recognition, precise positioning, and enhanced automation capabilities.

1. Pallet Dispenser Palomat AMR

• Functionality:

• Automates the stacking and destacking of pallets, reducing manual labor and increasing efficiency.
• Equipped with precision lifting arms and advanced sensors for smooth and consistent pallet handling.
• Compatible with various pallet sizes and types, ensuring flexibility in operations.

• Key Adjustments:

• Air Pressure: Regulated for optimal lifting and placement performance. Check and adjust air pressure to maintain steady operation.
• Sensor Calibration: Ensure sensors are properly aligned and calibrated to detect pallets accurately and prevent misalignment during stacking or destacking.
• Height Adjustment: Configurable to handle different pallet stacks, accommodating warehouse-specific needs.

• Safety Features:

• Integrated emergency stop buttons for quick intervention.
• Advanced collision detection systems to prevent accidents during pallet movement.

1. Safety and Controls

• Electrical Panels:
  1. Centralized system for power distribution, emergency stops, and status monitoring.
  2. Access restricted to authorized personnel.
• User Interfaces:
  1. Goods-to-Person (GTP) and Warehouse Execution Systems (WES) interfaces for real-time task management and device health monitoring.

1. Integrated Software Systems

• Vision and Navigation:
  • Vision systems for precision in robotic tasks.
  • Autonomous Mobile Robots (AMRs)[MK3]  for pallet transport, equipped with safety and status indicators.

1. Preventive Maintenance Highlights

• Diagnostics for print-and-apply systems to ensure operational continuity.
• Maintenance logs and schedules are integrated to predict and avoid downtime.

References

1. Operation Manual (220108_V2.1).

Glossary of Terms

Preface[AR4] [AR5] [AR6] 

            The purpose of this manual is to describe the workload and frequency of regular inspections, hygiene, and care for your Mujin System. Mujin is here every step of the way to ensure success and maximized return through various training and maintenance programs. For more information regarding training classes or maintenance support programs contact; support@mujin-corp.com.  

            Below topics will discuss the various tasks associated with inspection and hygiene for each major mechanical component. These tasks are vital to efficient and reliable fictionality. A clean machine is an efficient machine, and a clean work cell is a safe work cell. 

Contact Information

Mujin NA

Phone: 1.888.501.MUJN (6856)

Email: support@mujin-corp.com 

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: 7250 McGinnis Ferry Rd, Suwanee GA 30024

Mujin Asia

Phone: +81.3.4577.7638

Email: support@mujin-corp.com 

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: 3-8-5 Tatsumi, Koto-Ku, Tokyo 135-0053 Japan

Mujin EU

Phone: +31.970.102.05814 

Email:  support@mujin-corp.com

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: Mujin Netherlands B.V. Achtseweg Zuid 241B 5651 GW Eindhoven NL

1. General use and safety

1. General Use and Safety  for the FANUC R-2000iC

2. Terminology List

Understanding key terms associated with the CP500L robot is critical for safe operation and maintenance. Below are key terms, along with concise descriptions to ensure that all users, regardless of expertise, have a solid grasp of the equipment’s functionality:

  FANUC R-2000iC: A high-performance, six-axis articulated industrial robot designed for material handling, palletizing, welding, and other heavy-duty applications. It is ideal for high-speed operations in demanding industrial environments due to its precision and reliability.

  Controller: The FANUC R-30iB Plus, which acts as the brain of the system, processing user commands and managing the robot’s movements and operational parameters. It offers advanced motion control and integrated safety systems.

  Safety Fence: A robust protective barrier surrounding the robot’s operational workspace. It ensures personnel do not inadvertently enter the robot’s range while it is in operation, significantly reducing the risk of injury.

  Lockout-Tagout (LOTO): A mandatory safety procedure to ensure the robot is completely powered down during maintenance or repairs. This eliminates the risk of accidental startup or movement.

  Brake Release Unit: A manual override mechanism to release the brakes on the robot’s joints (axes) for manual movement during emergencies or system malfunctions.

  Axes (J1 - J6): The six points of movement in the robot, enabling highly articulated operations:

• J1: Rotates the base for broad reach.
• J2: Controls the lower arm for forward and backward movements.
• J3: Raises and lowers the upper arm for vertical positioning.
• J4, J5, J6: Provide wrist articulation for precise orientation and manipulation.

  Valve Harness: A built-in utility system providing pneumatic power to the robot’s tools and end-of-arm tooling (EOAT) via integrated tubing, ensuring seamless functionality of external devices.

To ensure optimal performance and safety, it is important to familiarize yourself with the technical specifications and layout of the FANUC R-2000iC robot and its controller. This section provides essential details about its capabilities, helping operators and technicians understand its operational limits

1. Machine Layout and Specifications

To ensure optimal performance and safety, it’s important to familiarize yourself with the technical specifications and layout of the FANUC R-2000iC. This section provides key technical details about the robot's capabilities, ensuring that operators and technicians have a complete understanding of its operational limits:

• Model: FANUC R-2000iC series
• Type: Six-axis articulated industrial robot, designed for heavy-duty applications requiring high precision and reliability.
• Degrees of Freedom: 6 (The robot has six axes, enabling complex movement and articulation for versatile tasks.)
• Maximum Payload: The robot is rated to handle up to 210 kg, making it ideal for demanding palletizing and material handling operations.
• Maximum Reach: The robot’s arm can extend up to 2655 mm, providing a broad working radius suitable for large-scale operations.
• Position Repeatability: The robot can consistently return to a specific position within ±0.05 mm, ensuring exceptional accuracy in repetitive and precision tasks.
• Palletizing Capacity: Approximately 900–1200 cycles per hour, depending on the payload and task complexity, optimizing throughput in industrial applications.
• Mass: 1,590 kg (robot weight without additional options).
• Operating Speed:
  • J1-J3 (Base and Arms): Up to 120° per second for broad movements.
  • J4-J6 (Wrist): Up to 180° per second for rapid and precise wrist articulation.
• Built-in Utilities: Includes integrated air and signal line harnesses for operating end-of-arm tooling (EOAT), such as pneumatic grippers or welding torches.

1. Intended Use and Prohibited Uses

2. Intended Uses

The FANUC R-2000iC is a high-performance robot specifically engineered for industrial applications requiring precision, flexibility, and high payload capacity. Its key uses include:

• Material Handling: Efficiently transporting, lifting, and positioning heavy objects such as parts, boxes, containers, or materials on assembly lines or workstations.
• Palletizing: Automating the stacking and unstacking of materials on pallets in a systematic and efficient manner, enabling rapid, repetitive cycles without manual intervention.
• Repetitive High-Speed Tasks: The FANUC R-2000iC excels in operations requiring consistent, high-speed movement over extended periods, such as pick-and-place, sorting, and loading tasks.

Operators must adhere to the recommended applications to ensure optimal performance and maintain operational safety. Misuse or operation outside of intended applications may compromise safety and system efficiency.

1.  Prohibited Uses

It is critical to avoid using the FANUC R-2000iC in applications outside of its design parameters, including:

• Lifting Humans or Living Beings: The robot is not designed for lifting, transporting, or interacting with humans or living beings directly under any circumstances.
• Operation in Extreme Environments: Avoid operating the robot in areas where temperatures fall below 0°C or exceed 45°C, or in environments with excessive humidity or condensation. Extreme conditions can compromise performance and damage internal components.
• Unauthorized Tooling or Payloads: Attaching unauthorized third-party tools, or exceeding the payload limit of 210 kg, may cause mechanical failures, decreased accuracy, or safety hazards.
• Exposure to Dust, Oil, or Corrosive Substances: Environments with excessive dust, oil mist, or corrosive chemicals can degrade components, compromise seals, and pose electrical safety risks, reducing the robot's reliability and lifespan.

Adherence to these guidelines is essential to ensure safe and efficient operation while maintaining the integrity of the robot.

1. User Types and Qualifications

2. Operator

The operator oversees the daily operation of the FANUC R-2000iC, ensuring it functions correctly and safely. Responsibilities include executing basic commands, monitoring performance, and initiating emergency stop procedures when necessary.

• Minimum Qualification: Completion of basic operational training, including proficiency with the R-30iB Plus controller, understanding safety features, and practicing emergency protocols.

1. Mechanical Installer

The mechanical installer is responsible for setting up and installing the robot. This includes mounting, aligning, and ensuring the robot’s mechanical stability as per the manufacturer's installation guidelines.

• Minimum Qualification: Demonstrated experience with mechanical systems, including alignment and assembly procedures for industrial robots. Familiarity with FANUC’s installation manuals and tools is required.

1. Electrical Installer

The electrical installer ensures all electrical connections are securely and accurately configured, and power is safely routed to the robot and controller systems. They are responsible for verifying the integrity of the electrical wiring and grounding.

• Minimum Qualification: Certification in industrial electrical systems, with specific training in the R-30iB Plus controller’s electrical schematics and safety systems. Familiarity with high-voltage handling is essential.

1. Maintenance Worker

Maintenance personnel conduct routine inspections, repairs, and component replacements for the FANUC R-2000iC. They are also tasked with managing emergencies such as system malfunctions, ensuring the robot is quickly restored to operational condition.

• Minimum Qualification: Advanced training in industrial robotics maintenance, with an emphasis on FANUC systems. Proficiency in safety protocols such as Lockout-Tagout (LOTO) and emergency stop troubleshooting is required. Familiarity with FANUC diagnostic tools and preventive maintenance schedules is essential[JA7] .

1. Responsibility Matrix

1. Safety Instructions

Safety is paramount when operating the FANUC R-2000iC. This section outlines critical safety instructions that must be always adhered to to prevent injuries, equipment damage, and operational downtime.

1. General Safety Guidelines

• Pre-Operation Inspection:
  • Inspect all robot components for damage or wear before startup.
  • Verify that all cables and connectors are secure and free of damage.
  • Ensure the workspace is clear of unauthorized personnel, tools, and materials.
  • Confirm that all safety fences, light curtains, and emergency stop systems are in place and functional.
• Workspace Preparation:
  • Maintain a clear and unobstructed area around the robot during operation.
  • Only authorized and trained personnel may be in the vicinity of the robot when it is active.
  • Clearly label and secure hazardous areas to prevent accidental entry.
• Personal Safety:
  • Wear appropriate personal protective equipment (PPE), including safety shoes, gloves, and helmets.
  • Avoid loose clothing or accessories that could be caught in the robot’s moving parts.
  • Always be alert and attentive to the robot’s movements.

1. Startup Procedures

• System Boot-Up:
  • Follow the startup sequence detailed in the R-30iB Plus controller manual.
  • Verify the functionality of all emergency stop systems before initiating operations.
  • Conduct a visual inspection to ensure there are no obstructions in the robot's path.
• Initial Movements:
  • Run the robot in teach mode for the first cycle to confirm that all axes move smoothly and as intended.
  • Address any irregularities or unexpected movements immediately with the help of qualified maintenance personnel.

1. Shutdown Procedures

• Standard Shutdown:
  • At the end of operations, follow the controller's shutdown sequence to power down the robot safely.
  • Ensure the robot has come to a complete stop before entering the work area.
  • Disconnect power if maintenance or inspection is required.
• Emergency Stop:
  • In the event of an emergency, activate the emergency stop (E-Stop) button immediately to cut power to the robot.
  • Familiarize yourself with the locations of all E-Stop buttons on the robot, controller, and within the workspace.
  • Do not reset or restart the robot until the hazard has been addressed and resolved by trained personnel.

1. Startup Procedure

1. [Inspect System]
   • Check for loose components or visible damage.
   • Verify that all safety guards and interlocks are functional.
   • Ensure the area is clear of unauthorized personnel.

↓

2. [Power On]
   • Activate the main power switch at the control panel.
   • Confirm that all emergency stop buttons (EMOs) are released.
   • Check for green status lights on the HMI indicating readiness.

↓

3. [Initialize Equipment]
   • Use the HMI to home robotic arms, pallet dispensers, and labeling systems.
   • Run initial system diagnostics to confirm all sensors and actuators are operational.

↓

4. [Start Operations]
   • Begin the production process by pressing the “Start” button on the control panel or HMI.
   • Monitor the system for any unusual behavior during startup.

1. Shutdown Procedure

1. [Stop Operations]
   • Cease all active tasks by pressing the "Stop" button on the HMI or control panel.
   • Allow the system to finish ongoing processes (e.g., moving pallets to the correct positions).

↓

2. [Power Off]
   • Turn off non-essential systems using the Mode Selector Switch.
   • Power down the main control panel.
   • Disconnect the power source if maintenance is required.

↓

3. [Post-Inspection]
   • Clean the equipment to remove debris or residue.
   • Inspect for signs of wear or damage on mechanical components.
   • Log any observations in the maintenance record.

1. Installation and Maintenance

2. Installation Guidelines

Proper installation is essential for safe and efficient operation of the FANUC R-2000iC. The robot must be mounted on a stable, vibration-free surface. Use high-tension bolts to securely fasten the robot base. Ensure the floor’s flatness is within ±5° to maintain proper alignment and functionality. Follow all grounding and electrical connection guidelines specified in the controller manual.

1. Preventive Maintenance Schedule

To ensure long-term reliability and performance, adhere to the following maintenance schedule:

• Daily:
  1. Visually inspect the robot and controller for damage or wear.
  2. Check all cables, connectors, and protective sleeves for secure connections and signs of deterioration.
  3. Test emergency stop buttons and ensure proper operation.
• Weekly:
  1. Inspect and tighten any loose bolts or fasteners.
  2. Test safety interlocks and verify Dual Check Safety (DCS) system functionality.
• Monthly:
  1. Perform a detailed inspection of motor seals, hoses, and cable harnesses.
  2. Lubricate moving parts per the manufacturer’s specifications.
  3. Test the brake release unit to ensure it functions properly in an emergency.

• Annually:
  1. Conduct a full diagnostic run using FANUC’s diagnostic tools to evaluate the system's health.
  2. Replace worn components, including seals, bearings, and drive belts, as necessary.
  3. Verify alignment and recalibrate the robot axes if needed.

1. Daily Maintenance Checklist

General:

• Perform a visual inspection of the equipment for any visible damage, debris, or contamination.
• Clean all surfaces, ensuring no dust or dirt obstructs sensors or moving parts.
• Check that emergency stop buttons (E-Stop) are functional.

Equipment-Specific Tasks:

• FANUC R-2000iC Robot:
  • Inspect joints and wiring for wear, damage, or leaks.
  • Listen for unusual sounds during operation and investigate any grinding or vibrations.
• GeekPlus AMR P800:
  • Test LiDAR sensors for obstacle detection.
  • Inspect wheels and ensure smooth rotation.

1. Weekly Maintenance Checklist

General:

• Clean all sensors and verify proper alignment.
• Tighten bolts and fasteners to specified torque values.
• Lubricate moving parts where recommended.

Equipment-Specific Tasks:

• FANUC R-2000iC Robot:
  • Inspect pneumatic system connections for leaks and check pressure (0.147 to 0.588 MPa).
  • Clean joints and cables to prevent debris accumulation.
• GeekPlus AMR P800:
  • Clean LiDAR and cameras, ensuring unobstructed operation.
  • Inspect chassis and wheels for wear.

1. Monthly Maintenance Checklist

General:

• Conduct a detailed inspection of all components, including electrical connections, mechanical parts, and safety systems.
• Replace any worn filters or parts to maintain operational efficiency.

Equipment-Specific Tasks:

• FANUC R-2000iC Robot:
  • Lubricate all joints and inspect air filters for clogging.
  • Test and recalibrate safety interlocks.
• GeekPlus AMR P800:
  • Perform diagnostics on the battery and charging systems.
  • Check the lifting mechanism for smooth operation.

1. Emergency Procedures and Troubleshooting

2. Emergency Stop

The FANUC R-2000iC system is equipped with multiple emergency stop (E-Stop) buttons strategically located around its operational area, including on the R-30iB Plus controller and the teach pendant. Pressing any of these buttons will immediately halt all robot movements and cut off power to the system, ensuring the safety of personnel and equipment.

1. Troubleshooting Common Issues

To ensure smooth operation of the FANUC R-2000iC, the following troubleshooting steps can help resolve common issues:

• Issue: The robot fails to start.
  • Solution:
    • Verify that the power supply is connected and operational.
    • Ensure that no emergency stop buttons are engaged.
    • Check the R-30iB Plus controller for any error messages or alarms, and address them using the troubleshooting section in the operator’s manual.
• Issue: The robot’s movements are erratic or sluggish.
  • Solution:
    • Inspect the workspace for any obstructions or debris interfering with the robot’s movement.
    • Verify the controller's motion parameters and recalibrate if needed.
    • Restart the system to clear potential temporary errors.
• Improvement: A detailed troubleshooting guide with step-by-step instructions for diagnosing and resolving more complex issues can be found in the R-2000iC maintenance manual[JA8] [JA9] .

Note: In the event of a power outage and you are unable to reset the system from the mujin pendant or door interlocks. The robot needs to be power cycled from the i30rb controller unit located under the conveyor directly behind the robot riser.

1. Personal Safety and Required PPE

The following personal protective equipment (PPE) is mandatory for all personnel working with or near the FANUC R-2000iC system:

• Safety Helmet: Protects against head injuries from falling objects or accidental collisions with the robot or its components.
• Safety Gloves: Prevents cuts, abrasions, or injuries when handling sharp or heavy materials during maintenance or operation.
• Protective Eyewear: Shields the eyes from dust, debris, or accidental fluid spills during operation or maintenance.
• Hearing Protection: Required in environments where noise levels exceed 80 dB, such as during high-speed operations or in manufacturing settings.

1. Noise Levels

Under normal operating conditions, the FANUC R-2000iC emits noise levels below 75–80 dB(A), depending on the speed and type of operations performed. In cases of prolonged or high-speed operations, operators should wear hearing protection if noise levels become uncomfortable. To minimize noise, ensure regular maintenance of moving parts, including lubrication of joints and inspection of drive systems.

1. Environmental Conditions

The FANUC R-2000iC is designed for use in controlled industrial environments. The following guidelines ensure optimal operating conditions:

• Dust and Debris: Keep the workspace free of excessive dust, oil, or debris to prevent contamination of sensors, cables, and mechanical parts.
• Corrosive Substances: The robot should not be exposed to corrosive chemicals or environments, as these may damage components and seals.
• Temperature Range: Operate the robot in environments with temperatures between 0°C and 45°C.
• Humidity Levels: Maintain a relative humidity level below 95% (non-condensing) to avoid electrical issues or corrosion.
• Environmental Monitoring: Regularly monitor the workspace to ensure conditions remain within these parameters.

Adhering to these environmental and noise guidelines will enhance the reliability and longevity of the FANUC R-2000iC.

1. General Use and Safety for AMR GeekPlus P800

2. Introduction[JA10] 

The GeekPlus P800 is a state-of-the-art Autonomous Mobile Robot (AMR) designed for automated material handling in industrial environments, including warehouses and production facilities. This manual provides critical safety guidelines, detailed operational instructions, and a comprehensive maintenance schedule to ensure the efficient and safe operation of the GeekPlus P800.

The purpose of this manual is to ensure that operators and maintenance personnel are thoroughly informed about the robot's features, limitations, and safe handling practices to prevent accidents and maximize the equipment's lifespan.

1. Intended Audience

This manual is intended for the following personnel:

• Operators: Individuals trained to handle the AMR during both routine and exceptional circumstances, including troubleshooting and emergency stop procedures.
• Maintenance Personnel: Certified professionals responsible for routine maintenance, troubleshooting, and repairs of the robot. Expertise in Lockout-Tagout (LOTO) procedures is essential for ensuring safe maintenance practices.

1. Safety Instructions

2. Terminology List

To ensure clarity, the following terminology is used throughout this manual:

• AMR (Autonomous Mobile Robot): A self-navigating robot designed to transport loads autonomously within structured environments such as warehouses.

1. EMO (Emergency Off): A safety mechanism, the EMO button is prominently located on the robot's exterior and stops all robot movements instantly in case of an emergency.

• LIDAR (Light Detection and Ranging): A laser-based sensor system used for obstacle detection, navigation, and monitoring the robot's surroundings.
• Mode Selector Switch: Allows the robot to toggle between automatic operation mode (for normal use) and maintenance mode (for servicing).
• LOTO (Lockout-Tagout): A safety protocol to ensure the robot is completely deactivated during maintenance by locking and tagging the power source to prevent accidental reactivation.

1. General Safety Guidelines

The following safety protocols must be adhered to for safe operation of the GeekPlus P800:

• Pre-Operation Safety Check:
  • Inspect all safety-critical systems, including LIDAR sensors, EMO buttons, and battery connections, before starting the robot.
  • Ensure the robot's path is free from obstructions, and the operating environment adheres to the specified conditions (e.g., flat, dry, and debris-free surfaces).
• Operational Environment:
  • Operate the GeekPlus P800 only on smooth, dry surfaces. Avoid areas with excessive dust, oil spills, or moisture, which may cause malfunctions or safety hazards.
  • Floors must meet specific tolerances, including no cracks wider than 8 mm and steps no higher than 5 mm, to maintain optimal performance.
• Safety Distance:
  • Personnel must maintain a minimum distance of 500 mm from the robot while it is in operation.
  • Clearly mark the robot’s path and restrict access to the operating zone during motion.
• Emergency Stop Functionality:
  • Test the EMO buttons on the robot’s exterior before each use. These buttons immediately halt all movements and ensure the robot remains inactive until the EMO is reset, and the system is verified safe for operation.

1.   General Operation

2. Intended Use

The GeekPlus P800 is engineered for the autonomous transportation of goods within structured industrial environments. Equipped with advanced navigation systems and QR code-based positioning, it can follow predefined routes with exceptional precision.

The robot is designed to seamlessly integrate into automated workflows, autonomously loading, transporting, and unloading materials while minimizing the need for human intervention. It is optimized for use in warehouse and factory settings that meet specific environmental conditions, such as flat, dry floors and a controlled ambient temperature.

1. Prohibited Uses

• Transporting Personnel: The GeekPlus P800 is strictly designed for transporting goods and must not be used to carry people under any circumstances.
• Hazardous Environments: The robot should not operate in conditions involving extreme dust, standing water, or explosive gases, as these exceed its design specifications and could result in malfunctions or safety hazards.

1. Key Specifications

The performance and physical specifications of the GeekPlus P800 are critical for its proper operation. Below are the key metrics for reference:

• Model: GeekPlus P800
• Dimensions: 1300 mm (L) x 900 mm (W) x 290 mm (H)
• Weight: Approximately 180 kg
• Rated Load Capacity: 1000 kg
• Navigation Method: Advanced LiDAR and QR code-based positioning for high-precision navigation and obstacle avoidance.
• Battery Life: Up to 8 hours of continuous operation on a full charge, with a charging time of approximately 2 hours.

1. Machine Configuration

2. Machine Layout and Components

The GeekPlus P800 is composed of several key systems, all designed to ensure smooth and safe operations:

• Emergency Stop Buttons (EMO):
   Located on both sides of the robot, these buttons are highly visible and accessible in case of emergencies. Pressing any EMO button will immediately halt all robot movements and cut power to the system.
• LIDAR Sensors:
   Strategically placed sensors provide real-time data for obstacle detection and navigation. The sensors have a detection range of up to 1,500 mm and will stop the robot if an obstruction is detected within this range.
• Mode Selector Switch:
   Allows toggling between automatic mode, where the robot follows pre-programmed routes, and maintenance mode, which enables manual operations such as diagnostic checks or controlled movements by trained personnel.

1. Detailed Safety Features

The GeekPlus P800 is equipped with an advanced array of safety features to prevent accidents and ensure smooth operations:

• Emergency Stop Function:
   When the EMO button is pressed, the robot's power is immediately cut off, bringing all movements to a complete halt. The system cannot resume operation until the EMO button is manually reset and all conditions for safe operation are confirmed.
• LIDAR Obstacle Detection:
  The LIDAR system detects obstacles in real time, prompting the robot to slow down and stop before reaching the obstacle. The robot remains stationary until the obstruction is cleared.
  • Detection Range: Up to 1,500 mm for large obstacles.
  • Limitations: Objects smaller than 200 mm may not be detected. It is essential to keep the operating environment free of small debris or hazards.

1. Maintenance and Safety

2. Lockout-Tagout (LOTO) Procedures

Before performing any maintenance on the GeekPlus P800, it is essential to engage the Lockout-Tagout (LOTO) procedure. This ensures that the robot is completely powered off and cannot be accidentally started during servicing. Follow these steps:

1. Shut Down the Robot:
    Use the Mode Selector Switch to power down the robot and place it in maintenance mode.
2. Apply LOTO Locks:
    Securely attach lockout devices to the robot's power source to prevent unauthorized re-energization.
3. Tag the Robot:
    Clearly label the robot with a tag indicating that it is under maintenance and must not be restarted until servicing is complete.

Only personnel with formal LOTO training and certification should perform these tasks to ensure compliance with safety standards.

1. Routine Maintenance Tasks

Regular maintenance of the GeekPlus P800 is essential to ensure its long-term reliability and prevent costly repairs. The following tasks should be performed routinely:

• Daily Inspections:
  • Check for visible damage, particularly around the wheels, sensors, and exterior casing.
  • Verify that the EMO buttons and LIDAR sensors are operational.
• Weekly Maintenance:
  • Clean the LIDAR sensors to ensure accurate obstacle detection.
  • Inspect the wheels for smooth rotation and check for obstructions or debris.
  • Examine moving components, such as the drive system, for wear and tear.
• Monthly Maintenance:
  • Conduct a detailed inspection of the robot’s battery, wiring, and internal systems.
  • Clean the charging port to ensure it is free of dust and debris.
  • Verify that all electrical connections are secure and that the robot is charging efficiently.

1. Residual Risks

Although the GeekPlus P800 is equipped with advanced safety features, there are certain residual risks that operators and maintenance personnel must remain aware of:

• Obstacle Collision:
   While the LIDAR system is effective in detecting obstacles, objects smaller than 200 mm may go undetected, posing a collision risk. The operating environment should be routinely inspected and cleared of small debris or hazards.
• Battery Hazards:
   Using an unauthorized charger or failing to follow proper charging procedures can lead to overheating, creating a fire hazard or causing damage to the robot’s battery system. Always use approved chargers and follow the manufacturer’s guidelines.

1. Personal Protective Equipment (PPE)

To ensure the safety of personnel working near the AMR, the following PPE should always be worn:

• Safety Gloves: To protect against sharp edges or hot surfaces.
• Protective Footwear: Steel-toe boots are recommended to protect against potential impacts from moving parts or falling objects.
• High-Visibility Clothing: Ensures that operators and maintenance personnel are easily visible within the robot’s operating environment.

1. Electrical Safety

2. Battery and Charging Safety

The GeekPlus P800 is powered by a high-capacity lithium-ion battery. Proper care during charging is essential to ensure safety and maintain the battery's longevity. Follow these guidelines:

• Approved Charger:
   Only use the original GeekPlus charger to prevent overcharging, overheating, or potential damage to the battery. Unauthorized chargers may compromise safety and void the warranty.
• Charging Process:

• Connect the robot to the charger after each operational cycle to ensure consistent performance.
• The charging port is located on the side of the unit and is protected by a dust cover.
• Regularly clean and inspect the dust cover to ensure it remains dry and free of debris to prevent malfunctions.

• Emergency Shutdown:
   In the event of overheating or overcharging, the GeekPlus P800 is equipped with an automatic shutdown mechanism to protect the battery.

• If this occurs, allow the battery to cool completely before attempting to recharge.
• Inspect the charger and robot for any visible issues before reconnecting.

1. General Use and Safety for the PALOMAT AMR 

2. Introduction

The PALOMAT AMR system is designed for the efficient stacking and de-stacking of empty pallets in collaboration with automated mobile robots (AMRs). This manual provides essential safety guidelines, operational procedures, and maintenance instructions to ensure the safe and efficient use of the PALOMAT AMR system.

• Audience: This manual is intended for operators, installers, and maintenance engineers responsible for handling the PALOMAT AMR system.
• Purpose: To promote safe operations, maximize efficiency, and ensure proper maintenance of the PALOMAT AMR system.

1. Safety Instructions

2. Terminology List

• PALOMAT AMR: Automated equipment designed to stack and de-stack empty pallets in conjunction with AMRs.
• Machine: The PALOMAT AMR unit and its integrated components.
• Operator: Qualified personnel trained to safely operate and oversee the system.
• Lifting Arms: Mechanized components that handle pallets during stacking or de-stacking.
• Guides: Structural features that ensure precise pallet placement and movement.
• Carrier Platform: Mechanized platform that moves pallets vertically to stack or de-stack them.
• AMR Docking Area: The area where the AMR aligns to interact with the PALOMAT unit.
• Safety Frame: Structural barriers designed to protect personnel from hazards during operation.

1. General Safety Guidelines

1. Pre-Operation Checks:
   • Confirm the emergency stop functions are operational.
   • Inspect all safety interlocks and ensure they are engaged.
   • Verify the area is clear of unauthorized personnel or obstructions.
2. Safety Fencing and Barriers:
   • Safety fences or barriers must surround the PALOMAT AMR system to protect unauthorized personnel from entering the operational area.
   • All doors and access points must be interlocked to prevent operation while they are open.
3. Personal Protective Equipment (PPE):
   • Operators and maintenance personnel must wear appropriate PPE, including safety shoes, protective clothing, and helmets where applicable.
4. Operational Guidelines:
   • Never operate the system with damaged or substandard pallets. Pallets must meet the specified quality requirements.
   • Do not exceed the maximum stack height or weight capacity defined for the PALOMAT AMR system.
5. AMR Interactions:
   • Ensure the AMR docking alignment is correct before initiating pallet transfer.
   • Regularly inspect the QR code markings and alignment guides to prevent misoperations.
6. Emergency Stops:
   • Familiarize all operators with the location and functionality of emergency stop buttons on the PALOMAT unit.
   • Emergency stops should be tested daily to ensure reliability.
7. Training and Authorization:
   • Only trained and authorized personnel are allowed to operate or maintain the PALOMAT AMR system.
   • Comprehensive training on safety, operation, and maintenance must be completed before personnel are authorized to use the equipment.

1. Specific Safety Instructions for PALOMAT AMR

2. Before Use

• Inspect the System: Conduct a visual inspection for any visible damage to the PALOMAT AMR, including the docking area and lifting mechanisms.
• Verify Safety Interlocks: Ensure all safety interlocks, including those on the safety fencing and access doors, are functioning correctly.
• Clear Operational Area: Confirm that all personnel are outside the safety perimeter and the AMR docking area is free of obstacles.
• Check Anchoring: Ensure the PALOMAT AMR is securely anchored to the floor, and all mounting points are intact.
• AMR Integration Check: Verify the AMR docking alignment and the operational readiness of the AMR for seamless interaction.

1. Operation

• Follow Load Specifications: Operate within the specified pallet size and weight limits detailed on the PALOMAT AMR type plate.
• Do Not Bypass Safety Features: Never disable safety interlocks, remove protective fencing, or bypass other safety systems while the machine is operational.
• Monitor Stacking Process: Continuously observe the stacking and de-stacking process to ensure pallets are correctly handled and the lifting arms are properly aligned.
• AMR Coordination: Ensure proper communication and synchronization between the AMR and PALOMAT to avoid collisions or errors during pallet transfers.

1. Maintenance and Repair

• Lockout-Tagout (LOTO): Always follow the LOTO procedure to cut off power and air supply before performing maintenance tasks.
• Regular Inspections: Schedule regular inspections to identify worn or damaged parts, and replace them as needed.
• Qualified Personnel Only: Maintenance and repairs should only be carried out by trained and qualified personnel.
• AMR Docking Maintenance: Periodically inspect and clean the docking area to ensure proper alignment and prevent operational disruptions.

1. Emergency Stop and Safety Circuits

• Emergency Stop Buttons: The PALOMAT AMR is equipped with emergency stop buttons integrated into its safety circuits. Pressing these buttons will immediately disconnect power and stop the machine’s operation.
• Interlock Verification: Ensure that all door and fencing interlocks are functional and halt operations if any safety mechanisms are compromised.
• Routine Testing: Test emergency stop and safety circuits daily to confirm functionality and compliance.

1. Fork and Lifting Arm Adjustments

Proper adjustments to the forks and lifting arms are crucial to prevent instability and ensure safe pallet handling. Follow these guidelines for adjustment:

• Fork Positioning:
  • Pallet width 800 mm: Position 1
  • Pallet width 1000 mm: Position 2
  • Pallet width 1200 mm: Position 3
• Adjustment Warnings:
  • Incorrectly positioned forks can cause pallets to fall or stacks to become unstable.
  • Always double-check fork alignment and settings before operation.

1. Residual Risks for PALOMAT AMR

While the PALOMAT AMR system is equipped with extensive safety measures, certain residual risks may remain:

• Falling Pallets: Poor-quality pallets or improper stacking can result in pallets falling during operation or transfer.
• Pneumatic Hazards: Trapped air in the pneumatic system can lead to unexpected movements. Always vent air from cylinders before performing maintenance.
• Docking Risks: Misalignment during AMR docking may lead to operational errors or damage to equipment.

1. General Operation

2. Intended Use

The PALOMAT AMR system is specifically designed to stack and de-stack empty pallets in conjunction with automated mobile robots (AMRs) within warehouse and logistics environments. The system must not be used for any purposes other than its intended application.

Prohibited Uses:

• Lifting People or Non-Pallet Objects: The system is not designed for lifting personnel or any objects other than empty pallets.
• Overloading: Do not exceed the specified load capacity of the system.
• Out-of-Spec Pallets: Do not operate the system with pallets that are damaged, deformed, or otherwise unsuitable for automated handling.

1. Pallet Handling and Stack Safety

• Pallet Quality: Only use high-quality pallets that are free from damage, missing boards, nails, or any other defects that may interfere with stacking or de-stacking operations.
• Load Stability: Ensure that each pallet’s load is stable and capable of supporting the weight of additional stacked pallets.
• Alignment: Verify that pallets are properly aligned before and during operations to prevent tilting or falling.

1. Machine Configuration

2. Machine Layout and Specifications

• Working Load Limit (WLL): The maximum load capacity of the PALOMAT AMR is displayed on the type plate and a visible warning sticker. Ensure this limit is never exceeded during operation.
• Fork and Lifting Arm Adjustments:
  • Refer to the provided adjustment table to configure the lifting forks and arms according to pallet size:
    • 800 mm width: Position 1
    • 1000 mm width: Position 2
    • 1200 mm width: Position 3

Proper configuration ensures safe and efficient stacking and de-stacking of pallets, minimizing the risk of equipment damage or accidents.

1. Machine Setup and Calibration

• Docking Area Calibration:
  • Ensure that the AMR docking area is correctly calibrated to align with the PALOMAT system for precise pallet transfer.
  • Use alignment tools, such as a laser guide or positioning system, to verify proper alignment.
• Pallet Detection Sensors:
  • Regularly test and calibrate the sensors that detect pallet presence to ensure they are functioning accurately.
  • Replace or clean sensors if they fail to detect pallets or provide false readings.
• Safety Frame Installation:
  • Confirm that the safety frame is securely installed around the PALOMAT AMR system to prevent unauthorized access during operation.
  • Verify interlocks on the safety frame doors to ensure they halt the machine’s operation if opened.

1. Installation and Setup for PALOMAT AMR

2. Setup Instructions

• Regulatory Compliance:
   Ensure the PALOMAT system is installed in compliance with local and regional regulations, including workplace safety and equipment installation standards.
• Secure Anchoring:
   Verify that the PALOMAT AMR is securely anchored to the floor, ensuring stability during operation. Use appropriate mounting hardware as recommended by the manufacturer.
• System Integration:
   Confirm the system is properly integrated with the AMR and other automation systems, including conveyor or docking stations. Verify that communication and synchronization between the PALOMAT AMR and the AMR are functioning as intended.
• Safety Checks:
   Conduct a thorough safety inspection to ensure all safety interlocks, emergency stops, and protective mechanisms are operational before commencing use.

1. Fencing and Safety Provisions

• Compliance with Standards:
   The fenced safety area surrounding the PALOMAT AMR must comply with all relevant safety standards to prevent unauthorized access and protect personnel from hazards.
• Strength and Durability:
   The fencing must be strong enough to withstand any potential impacts, including falling pallets or accidental contact with equipment.
• Access Control:
   Ensure all access points to the fenced area are equipped with safety interlocks that automatically halt operations if breached.
• Clearance and Visibility:
   Maintain adequate clearance around the PALOMAT AMR for safe operation, and ensure the area is well-lit to enhance visibility during inspections and operations.

1. Routine Maintenance

2. Daily Maintenance

• Visual Inspection:
  • Check for signs of wear and tear on mechanical parts such as lifting arms, forks, and the carrier platform.
  • Inspect the AMR docking station for any obstructions or debris that may disrupt operations.
• Cleaning:
  • Wipe down the exterior and moving parts with a dry microfiber cloth to remove dust and debris.
  • Ensure the QR code labels and alignment marks on the floor are clean and free from obstructions.

1. Weekly Maintenance

• Lubrication:
  • Apply appropriate lubricants to moving components such as lifting arms, forks, and the carrier platform as recommended in the manual.
• Sensor Functionality Check:
  • Test all sensors to confirm accurate pallet detection and system alignment.
• Pneumatic System Inspection:
  • Check for air leaks in the pneumatic cylinders and ensure pressure levels are within the specified range.

1. Monthly Maintenance

• Structural Integrity Check:
  • Inspect bolts and mounting points to ensure the system is securely anchored to the floor.
  • Verify the structural condition of the safety frame and ensure all interlocks are operational.
• Pallet Compatibility Test:
  • Test with different pallet sizes and weights within the system’s specifications to ensure smooth operation.

1. Annual Maintenance

• Full System Check:
  • Perform a comprehensive inspection of all mechanical, pneumatic, and electrical components.
  • Replace worn parts, including sensors, pneumatic seals, or lifting arm mechanisms, as needed.
• Software Updates:
  • Check for and apply software updates to ensure compatibility with the AMR and the latest operational features.

1. Troubleshooting

2. Common Issues

• Pallet Misalignment:
  • Cause: Incorrect placement of pallets or AMR docking misalignment.
  • Solution: Realign pallets and verify AMR positioning. Adjust the forks and lifting arms as needed.
• Sensor Malfunction:
  • Cause: Dirty or damaged sensors.
  • Solution: Clean or replace the affected sensors and recalibrate the system.
• Pneumatic System Failure:
  • Cause: Air leaks or blocked lines.
  • Solution: Check for leaks, tighten fittings, or replace damaged pneumatic components.

1. Emergency Protocols

• Emergency Stop Activation:
  • In case of system failure, press the emergency stop button to immediately halt all operations.
  • After resolving the issue, reset the emergency stop and perform a system restart following the operational checklist.

1. Responsibility Chart with Maintenance Schedule

2. Operator Tasks

1. Maintenance Team Tasks

1. Roles and Responsibilities Summary

2. Operator:

• Responsible for monitoring the system during daily operations.
• Performs visual inspections and ensures safety measures are in place.
• Reports issues promptly to the maintenance team.

1. Maintenance Team:

• Handles detailed inspections, cleaning, calibration, and diagnostics.
• Performs repairs, replacements, and system servicing.
• Ensures compliance with all maintenance schedules and safety protocols.

1. Care and Maintenance[DH11] 

Preventative maintenance is an ongoing process that should be practiced daily to ensure optimum performance of your Mujin system. Small disruptions in the work cell environment can cause unwanted end results when the system is not properly maintained. Therefore, regular cleaning and upkeep of your system is related to the efficiency of your system. Cleaning schedules for each mechanical unit require Daily, Weekly, Monthly, Quarterly, and yearly maintenance to be performed. The schedule for each system is defined below by subsystem specific to your Mujin system.

1. Automated Mobile Robot (AMR) - Geek Plus AMR Systems

The Geek Plus AMR systems are advanced autonomous mobile robots (AMRs) designed for use in industrial environments such as warehouses and production lines. This section outlines the essential maintenance procedures and safety precautions to ensure their smooth and efficient operation.

1. General Maintenance

2. Service and Maintenance:

• Regular maintenance ensures the AMR remains efficient and prolongs its service life. Neglecting routine service may lead to unexpected breakdowns.
• All maintenance tasks must be performed by trained personnel familiar with the robot’s operation and safety protocols.
• Maintenance records should be meticulously documented, including logging routine checks, repairs, and any parts replaced to ensure a detailed history of the robot’s service.

1. Precautions for Maintenance:

• Effective communication between on-site and off-site personnel is crucial during maintenance. Ensure all staff are aware of when the AMR is being serviced.
• Only use Geek Plus-approved parts for repairs or replacements to guarantee compatibility and maintain the robot’s warranty.
• During maintenance, ensure the environment is clean and suitable for the robot. Avoid areas with excessive dust, moisture, or debris that could interfere with sensors or moving parts.

1. Preventative Maintenance

2. Weekly Routine Service and Maintenance:

• Clean the robot's surface to remove dust and dirt. Accumulation of debris can damage sensors or affect performance.
• Check all indicator lights, including those for power, error status, and operational mode, to ensure they are functioning correctly.
• Test emergency stop buttons and ensure that motor enabling buttons are operational.
• Inspect and test the obstacle detection system for accuracy and functionality.
• Examine the wheels for abnormal noise, wear, or damage, and ensure the lifting mechanism operates smoothly without unusual sounds.
• Visually inspect the robot shell for defects, cracks, or other damage.
• Clean and inspect the charging port to ensure proper alignment and absence of dirt or foreign objects.

1. Annual Service and Maintenance:

• Overall Robot Condition:
  • Ensure smooth operation without sticking, deviation, or skidding.
  • Verify the robot docks and charges correctly without repeated attempts.
  • Test the lifting mechanism for smooth and accurate operation.
  • Check the obstacle detection system for accurate readings and no false alarms.
• Appearance and Structural Integrity:
  • Ensure the robot’s exterior is clean and undamaged.
  • Confirm that emergency stop buttons, selectors, and control panels work correctly.
  • Inspect and clean the driving wheels, applying lubricating oil as necessary.
  • Check for wear on driven wheels and replace if needed.
• Fasteners and Electrical Systems:
  • Tighten all fasteners and inspect wiring for damage or loose connections.
  • Remove dust from internal components to prevent sensor interference.
  • Check the battery and electrical components' voltage for proper function.

1.  Simple Troubleshooting

2. Common Issues and Solutions:

1. Robot Stops During Operation:
   • Cause: Unrecognizable or dirty QR codes.
   • Solution: Clean the QR codes to remove dirt or smudges obstructing them.
2. Abnormal Obstacle Avoidance:
   • Cause: Malfunctioning or misconfigured sensors.
   • Solution: Adjust sensor parameters or replace malfunctioning sensors.
3. Indicator Light Issues:
   • Cause: Emergency stop button pressed or low battery.
   • Solution: Verify emergency stop button status and recharge the battery.
4. Route Congestion/Deadlock:
   • Cause: Multiple robots in close proximity or conflicting routes.
   • Solution: Manually move a robot or reset the route configuration.
5. Lifting and Lowering Errors:
   • Cause: Misaligned rack or faulty QR code.
   • Solution: Realign the rack, clean or adjust the QR code, and reset the lifting mechanism.
6. Skidding with Load:
   • Cause: Dirty or uneven floor or stuck wheels.
   • Solution: Clean the wheels and floor surface and reset errors.
7. System Interface Stuck:
   • Cause: Software malfunction.
   • Solution: Restart the system interface and reconnect.

1. Mechanical Maintenance

2. Inspect mechanical parts regularly for wear or damage and replace as needed to prevent failures during operation.

3.  Electrical Maintenance

4. Inspect electrical components, including wiring, control boards, and sensors, to ensure proper function.
5. Verify that all power and communication cables are secure and functioning. Loose or damaged wires must be repaired promptly.

6. Routine Service

7. Follow the weekly and annual service schedules outlined to ensure efficient AMR operation. Routine checks help identify and address potential issues early.

8. Safety Instructions

9. General Safety Instructions:

10. Pay close attention to electrical safety. All maintenance tasks involving electrical components must follow proper grounding procedures.
11. Use only certified components to ensure compliance with safety standards.
12. Handle and store batteries according to the manufacturer’s instructions to avoid extreme conditions.

13. Operational Safety:

14. Ensure no persons or obstacles are within the robot’s working range during operation. Use barriers and warning signs to prevent unauthorized access.

15. Emergency Procedures:

16. Familiarize yourself with emergency stop button locations and operations. Press the button immediately in case of an emergency.

17. Error Codes and Recovery:

18. Use error codes displayed by the robot interface to identify issues. Consult the troubleshooting guide to resolve them.

19.  Advanced Troubleshooting:

20. Use sensors and diagnostic tools to identify problems. Isolate the issue (mechanical, electrical, or software-related) and address it accordingly.

21. Frequency of Inspections, Maintenance, and Cleaning

22. Inspections:

Daily: Visually inspect for visible damage, dirt, or debris.

Weekly: Inspect cables, e-chains, and the robot shell for wear.

1. Maintenance:

Weekly: Inspect and replace damaged parts as needed. Clean mechanical components.

Every 6 Months: Tighten bolts and inspect mechanical and electrical integrity.

1. Cleaning:

Daily: Clean the robot’s surface to remove dirt and debris.

Weekly: Clean sensors and ensure lenses are dust-free.

1. Robot FANUC R-2000ic

The FANUC palletizing robot is a high-performance system designed for industrial applications. Proper maintenance ensures efficient and safe operation, minimizes downtime, and extends the lifespan of the robot. This section provides a comprehensive guide for preventative maintenance, general care, and troubleshooting. Following these steps will help keep your FANUC robot in optimal condition.

1. Preventative Maintenance for FANUC Palletizing Robot

Preventative maintenance is essential to avoid unexpected failures. The following tasks should be completed at specified intervals to maintain optimal performance.

1. Daily Maintenance

1. Visual Inspection:
   • Walk around the robot to inspect for visible signs of wear, damage, or leaks. Focus on critical areas such as joints, arms, wiring, and connectors.
   • Example: Look for cracks in the robot's casing, wear on cables, or hydraulic fluid leaks that might indicate seal damage.
   • Action: Report any irregularities immediately to prevent further damage.
2. Unusual Noises and Vibrations:
   • Listen for grinding, squealing, or rattling noises during operation. These can indicate mechanical issues such as misalignment or worn components.
   • Excessive vibration may suggest loose or misaligned parts.
   • Action: Stop the robot immediately if abnormal noises or vibrations are detected and investigate the root cause.
3. Safety Guards and Interlocks:
   • Confirm that all safety barriers, protective fences, and interlocking systems are operational and intact.
   • Test emergency stop buttons and other safety mechanisms for proper functionality.
   • Tip: Verify that no personnel are in the robot's operating zone while it is running.

1. Weekly Maintenance

1. Cleaning and Dust Removal:
   • Wipe down the robot's joints and moving parts using a dry or slightly damp cloth to prevent dust buildup, which can lead to friction and wear.
   • Important: Avoid using water directly on the robot to prevent damage to electrical components.
2. Bolt Tightness:
   • Check the tightness of bolts using a torque wrench, especially around the base and arm sections. Loose bolts can reduce stability and precision.
   • Reference: Consult the robot manual for the specific torque values required for different bolt types.
3. Pneumatic System Inspection:
   • Inspect air lines for leaks and confirm that air pressure is within the manufacturer’s recommended range (e.g., 0.147 to 0.588 MPa).
   • Tip: Listen for hissing sounds near air connectors to detect leaks. Tighten connections or replace defective components as necessary.

1. Monthly Maintenance

1. Filter Replacement:
   • Inspect air filters for dirt or clogs. Replace filters as needed to ensure efficient operation of the pneumatic system.
   • Tip: Stock spare filters to avoid downtime caused by delayed replacements.
2. Emergency Stop Testing:
   • Perform a comprehensive test of the emergency stop system and other safety mechanisms, such as light curtains and sensors, to verify quick and effective responses.
   • Safety Note: Conduct these tests in a controlled environment to minimize the risk of damage during sudden halts.

1. Annual Maintenance

1. Comprehensive Inspection:
   • Inspect all mechanical and electrical components for wear, corrosion, or damage, particularly on parts subjected to frequent movement, such as joints and bearings.
   • Example: Examine seals, gaskets, and cable connections for signs of degradation and replace them if necessary.
2. Grease Replenishment:
   • Replace or replenish grease in the robot's joints and speed reducers according to the manufacturer's recommendations to ensure smooth operation and reduce wear.
3. Software and Firmware Updates:
   • Update the robot’s software and firmware to ensure compatibility, security, and enhanced performance.
   • Tip: Schedule updates during non-operational hours to prevent interruptions in production.

1. General Care for FANUC Palletizing Robot

Maintaining a FANUC palletizing robot involves more than addressing issues; it requires creating and sustaining an optimal working environment to ensure reliable performance and a prolonged lifespan.

1. Environmental Conditions

1. Temperature and Humidity:
   • Operate the robot in a clean, dry environment with temperatures between 0°C and 45°C and humidity levels between 35% and 85% (non-condensing).
   • Tip: Avoid environments with excessive dust, corrosive chemicals, or strong vibrations, as these can significantly reduce the robot's lifespan and performance.
2. Avoid Harsh Conditions:
   • Do not expose the robot to excessive heat, moisture, or direct sunlight.
   • Install vibration dampening systems if the robot is situated near machinery that generates vibrations.

1. Mounting

1. Secure Mounting:
   • Ensure the robot is firmly mounted to a flat, stable surface. The base should be leveled within ±5 degrees for optimal precision.
   • Tighten the mounting bolts to the torque values specified in the robot’s installation manual.
2. Safety Note:
   • Verify that the floor or mounting platform is vibration-free. Excessive vibrations can compromise the robot’s accuracy and lead to wear on moving components.

1. Air and Electrical Connections

1. Regular Inspections:
   • Periodically check the air system and electrical connections for leaks, loose wires, or wear.
   • Ensure all connections are insulated properly and that air pressure remains within the manufacturer’s specified range.
2. Tip:
   • Robots that frequently start and stop during operations should have their wiring harnesses and connectors inspected regularly for signs of stress or wear.

1. Troubleshooting

2. Common Issues and Solutions

1. Power Supply Problems:
   • Issue: The robot fails to start or experiences intermittent power loss.
   • Solution: Check the power supply and verify that all electrical connections are secure. Inspect for blown fuses or loose wires and replace as necessary.
2. Motor and Joint Issues:
   • Issue: Motors overheat, or joints fail to move smoothly.
   • Solution:
     • Inspect motors for overheating and ensure adequate ventilation.
     • Verify that joints are properly lubricated. Replace faulty motors following the manufacturer’s guidelines.
3. Pneumatic System Leaks:
   • Issue: Low air pressure or visible leaks reduce the robot’s performance.
   • Solution: Confirm that air pressure is within the range specified in the manual. Replace damaged hoses or filters promptly.

1. Troubleshooting Steps

1. Error Code Identification:
   • If an error code is displayed, refer to the FANUC troubleshooting manual to diagnose the issue. Each error code includes detailed descriptions and actionable steps to resolve the problem.
2. Perform Basic Checks:
   • Inspect all power, air, and data connections to ensure they are secure.
   • Verify that the robot is securely mounted, and all safety barriers are in place.
3. Restart and Verify:
   • After resolving the issue, restart the robot to confirm it is functioning properly.
   • Tip: Document recurring errors and consult with FANUC technical support for long-term solutions.