4.2. Inspection Items and Cycles

4.2. Inspection Items and Cycles

 

Table 4‑2Inspection Items and Cycles

No.	Inspection cycle				Inspection item	Inspection method	Reference	Remarks
	Daily	Every three months	Every six months	Every one year
Common for the manipulator and each axis
1	○				Cleaning of the manipulator	Check for impurities with eyes
2		○			Inspection of the wirings	Check the cables for any damage with eyes. Cable fixing bracket fastening bolts. Check the paint markings with eyes. Check for any damage to the cable cover with eyes.
3		○			Main bolts	Check the paint markings with eyes.
4				○	Limit switches /dogs	Check the on and off functions of the limit switches.	It should be checked that the emergency stop lamp is turned on when the limit switch is turned on.
5	○				Motors	Check for any abnormal heating. Check for any abnormal sound.
6				○	Brakes	Check whether the brake works when the brake release switch is turned on and off. Note) When the brake release switch is turned on, the arm or operating axis will fall, so turn it off within one second when checking.	The arm or end effector should not fall when the brake release switch is turned off.
S, H and V axes
7	○				Reducers	Check for any abnormal sound. Check for any vibration.
8	○		○		Gas springs Pressure	Check the pressure.	125 ~ 140bar
9			○		Gas springs Bearings	Check the bearing part for any overheating, impurities or vibration.	Grease at the bearing part should be maintained properly.
R2, B, and R1 axes
10		○			Reducers	Check for any abnormal sound. Check for any vibration.
11		○			End effector fastening bolts	Check the paint markings with eyes.
12		○			Clearance	Check for any clearance by rotating each axis in the right and reverse directions.	There should be no clearance felt with hands.

 

n If the robot is used in adverse conditions (for example, spot welding, grinding, etc.), you need to shorten the inspection cycles to secure the performance of the robot system.

 

n Inspect all cables that can be seen, and replace damaged ones.

 

n Check the mechanical bumpers for any deformation or damage. If a bumper is damaged or a dog is bent, replace it immediately.

 

n Check the tightening torques of the main bolts shown in [Figure 4.1].

 

n Check for an abnormal sound in auto mode and teaching mode to check the power transmission systems (motors, reducers, etc.) for any abnormality.

 

n  Inspect the gas spring periodically to maintain the proper working pressure, and inject gas when the pressure drops.

 

n  Replace the gas spring after using it for a certain period of time.

 

n  Replace the gas spring every 20,000 hours or when the proper working pressure (125 bar–140 bar) cannot be maintained even after gas is injected.

 

n  If the load estimation has been performed correctly, the pressure of the gas spring can be checked from the teaching pendant. Therefore, use the gas spring pressure test function by referring to the Controller Function Manual.

There are two pressure test methods: “Command-based gas spring pressure test” and “Gas spring pressure test at stop position.”

It is recommended to use the “Command-based gas spring pressure test” method, which has higher accuracy.

 

n  If the teaching pendant generates an error or warning related to the gas spring pressure drop, you must check the pressure of the gas spring.