Preventive Maintenance Procedures for AutoStore R5 Robots

TABLE OF CONTENTS

• TESTING SAFETY FUNCTIONS
• BATTERIES AND CHARGE CONNECTOR
• BELTS
• GRIPPER AND LIFT
  • GRIPPER MAINTENANCE PROCEDURE
  • CHECKING THE LIFT BANDS, GRIPPER GUIDES AND LIFT TABLE LEVEL
• TRACK SENSORS AND WHEELS
• CONNECTIONS
• PREP THE ROBOT TO GO BACK INTO THE SYSTEM

TESTING SAFETY FUNCTIONS

• Activate Service Wall Emergency Stop (E-stop): All movement will stop within 20 seconds
• After verifying a successful test (indicated by no further movement on the grid and a red stack light indication), release the Service Wall E-stop, toggle the keylock, and hit "Start" on the Console to resume system operations.

BATTERIES AND CHARGE CONNECTOR

• Prep step: Press the robot E-stop and then disconnect both battery connectors from the fuse box assembly to power off the robot. IF the E-stop is pressed, ensure it remains pressed until specified. 
• CLEAN inside and around charge house connector pins using vacuum and/or air device to remove dust/debris. 
• If using a rag to clean, ensure that a vacuum or air is used after the rag to ensure no debris remains.

BELTS

• Prep step: Ensure battery connectors are disconnected from the fuse box assembly. If the E-stop is pressed, ensure it remains pressed until specified.
  • INSPECT belts for signs of dry rot/debris/tears/cracking. REPLACE belt IF found. 
    • Note:  superficial cracks in the outer rubber layer are not an indication that the belt requires replacing. The outer rubber layer protects the cord from mechanical wear, absorbs shock and provides good rolling performance on the pulleys. The cord inside is what gives the belt its integrity, and as long as the cord is not frayed or damaged, the belt is good to use.

    • As long as the cord and the internal rubber surface (which is in contact with the pulley) are not damaged, there is no need to replace the belt.

GRIPPER AND LIFT

• Prep step:  Set the robot offline using toggle switch on control panel. Place a bin in service area in a cell which the robot can manually pick up. Add 2, 15 kg(total of 66lbs) weights to the bin (evenly placed) to simulate max weight. Reason: A weighted bin will be used to test functionality of the lift/gripper mechanisms.

GRIPPER MAINTENANCE PROCEDURE

• CHECK for excessive noise/stuttering/slowness on lift motors by operating the robot using the lift toggle switch. Lower gripper onto prepared bin and OBSERVE picking up / lowering bin in the service area. CHECK that the lift brake release solenoid is working and CHECK for wear on the lift gear teeth as the gripper lowers onto the bin. IF irregularities are found with the lift movement, REPLACE motor. IF there are irregularities with the lift brake releasing or engaging, REPLACE lift brake assembly. IF excessive wear is found on the lift gear teeth, REPLACE lift gear assembly. Follow replacement with test to confirm issues are resolved. Repeat process IF necessary to investigate further.

CHECKING THE LIFT BANDS, GRIPPER GUIDES AND LIFT TABLE LEVEL

1. ENSURE gripper remains lowered onto the prepared bin, INSPECT the strip band for indications of tearing/shearing/cuts/warping. IF found, REPLACE the entire R5 strip kit set.
2. INSPECT Gripper guides for cracks/damage/looseness. They may also be bent, causing them to not point straight down. TIGHTEN gripper guides by screwing them hand tight IF loose. IF cracks/damage are found and/or guides can't be tightened, or if they aren't straight, REPLACE gripper guide set. 
3. INSPECT the strip band for signs of dust/dirt/debris accumulation while the gripper remains lowered onto the prepared bin. INSPECT for "streaking". CLEAN the band using a clean, microfiber/lint proof rag (use of 100% isopropyl alcohol is allowable on). The robot gripper may be lifted off of the prepared bin once cleaning is completed. 
4. INSPECT that the gripper is level using the leveling bar(in the spare parts locker) to adjust the strip reel positioning.  TIGHTEN set screw on brass reels using Hex key to 2Nm. IF looseness persists after tightening the brass reel, REPLACE robot strip kit w/ reels.

TRACK SENSORS AND WHEELS

• INSPECT the track sensors for dirt, debris, or damage (scratches or cracks). Clean the track sensors using a lint proof dry rag IF track sensors are not damaged. 
• CHECK the driving wheels for signs of damage/scuffs/wear. Check for dry rot on the wheel. Check for any separation of rubber wheel(s) adhered to aluminum rim. IF problems are found on a single wheel or multiple wheels, REPLACE only the problematic wheels. 
• CLEAN drive wheels gears behind the rim using vacuum cleaning, air device, and/or using a clean, dry (lint free) rag.

CONNECTIONS

• Check that the power board connections are fully inserted. 
• Check that the CPU board connections are fully inserted.
• Check that the radio connections are installed fully. Check that the antenna bolts are torqued hand tight. Inspect the antenna for signs of damage (bent or crushed). Replace antenna if damage is found.  

PREP THE ROBOT TO GO BACK INTO THE SYSTEM

1. Ensure that the robot covers are installed, and that the robot is ready for operation within the grid. 
2. Make sure that the battery connectors are plugged in and then release the robot E-stop to power on the robot. 
3. Manually move the R5 to the entry/exit cell position designated on the service grid (Robot Entry Area).  
4. Set the robot to online.
5. Verify that the gripper is lifted to the top position using the manual lift switch, and make sure that all wheels are setting in their proper position within the track. 
6. Follow the “Add Robot Procedures” to place the robot back into service.