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Robot Troubleshooting 160

Robotics Training

Class Information

Tooling U classes are offered at the beginner, intermediate, and advanced levels. The typical class consists of 12 to 25 lessons and typically requires at least two hours of instruction time.

Class Name:	Robot Troubleshooting 160
Description:	In this class, you will be introduced to the troubleshooting process and will learn how to identify problems and their causes. It will also go through some problems specific to robots and identify common causes and solutions.
Prerequisites:	none
Difficulty:	Beginner
Number of Lessons:	15

Class Outline

Objectives
What Is Troubleshooting?
Using Specifics to Identify Problems
Evaluating Troubleshooting Data
The Impact of Cost
Working Backward
Proposing Potential Fixes
Testing Solutions
Applying Permanent Solutions
Troubleshooting: End Effectors
Troubleshooting: Pneumatic Systems
Troubleshooting: No Motion
Troubleshooting: Loss of Positioning (Mechanical)
Troubleshooting: Loss of Positioning (Feedback)
Summary

Class Objectives

Describe troubleshooting.
Describe techniques for identifying problems with specifics.
Describe the process of evaluating troubleshooting data.
Describe the impact of cost on the troubleshooting process.
Describe the process of working backward.
Describe the process of proposing potential fixes.
Describe the process of testing solutions.
Describe the process of applying permanent solutions.
Describe the process of troubleshooting end effectors.
Identify common causes of pneumatic system problems.
Identify common causes of lack of robot motion.
Describe mechanical reasons for a robot's loss of positioning.
Describe feedback errors that cause a robot’s loss of positioning.

Class Vocabulary
check sheet		A document used to collect data, such as robot performance statistics, during the troubleshooting process. It is generally a simple form that can be filled out on the shop floor.
cost		The total monetary amount incurred during all steps of a process, including expenses such as labor, materials, or energy. Cost can be used to prioritize problems in the troubleshooting process.
downtime		Unproductive blocks of time during which machine operations cease, often due to mechanical problems.
encoder		A measuring device for motion control that is divided into a fixed number of increments called counts. In a typical encoder, one revolution equals one million counts.
fishbone diagram		A troubleshooting tool that can be used to visually diagram the causes and effects of a problem. Additional possible causes are added as extra lines that branch out from the center, much like the bone structure of a fish.
grid shift		A type of positioning error caused by bad or missing feedback or parameter settings. Grid shifts occur when a robot essentially jumps to a new setpoint and then continues from that point functioning normally.
marker pulse		A point on an encoder that provides a repeatable home location for positioning applications. A marker pulse occurs once per revolution.
overshoot		To exceed a set value. Overshoots can be caused by lubrication problems.
profit		The total monetary amount remaining when costs are deducted from revenue. Maximizing profit is a goal of all manufacturing facilities.
revenue		The total monetary amount that a company receives, from sales or other operations. Revenue minus cost equals profit.
root cause		The origin of the problem. Troubleshooting attempts to identify the root cause of a problem rather than simply addressing the symptoms.
troubleshooting		A systematic approach to solving problems quickly and efficiently. Troubleshooting often involves a logical process of elimination to identify the true source of a problem.
undershoot		To fall short of or below a set value. Undershoots can be caused by mechanical binds.