Mechanical Engineering - Service Report

J O B R E P O R T S H E E T (JRS) Customer : Wyeth – Canlubang Factory Report status : Partial report Period from : 06/02/2022 Final report To : 06/02/2022 N ° 0004 Country : Philippines Town : Canlubang, Laguna From : Darwin Legaspi Profile : EMET To : Sami Khan, Yutthana Sukhanakhin Machine type : Robot Palletizer – SLS PV410 – BR027 A & B Requested by : (PME, CCM, PMS) Yutthana Sukhanakhin Job description : Commissioning, Production Support Wed. 06/01/22 Cost imputation : ISM on site : (If present) BR027A – diagnosis and resolution of the recurring issue of pallet misalignment at full pallet conveyor BR027B – continuous production monitoring Customer explications: Customer reported that the recurring issue where the loaded pallet on the full pallet conveyor is misaligned causing the robot to crash on the completed pallet while carrying the next pallet. Customer also reported an issue regarding Case Packer A air pressure dropping albeit having a separate header (instead of being on a tee) with Case Packer B. Immediate observations: The mentioned issue rarely happens; therefore, it is not a system fault, the machine cannot complete a single pallet if this is a major system fault. Intervention Progress: 06/02/2022 (Thursday) Time : 10 hours Description Plant Re-entry BR027A – Root cause analysis and acquisition of a solution for the : customer explication BR027B – production monitoring This photo was taken by the customer when an operator noticed some of the boxes on the full stack fell It is visibly noticeable that the pallet is misaligned Pallet is also banked and stuck to the chain guide of the full pallet conveyor. The photo is taken after the operator pressed the “end of series” button on the HMI. Upon analogy of the photo, this initial diagnostic Page - 1 - sur 3 was made: Depicts that the pallet is really far to its designated location, even a faulty or overpressure pallet centering guide does not have the force to make the pallet jump and shift that far. These shows that the robot is still following the straight axis the way it is mastered / designed to perform because having the products as a reference focal point, products still follow a straight line. That is why the distances on the front and the back of the pallet is different and big shift can be seen. Pallet can move even if it is above the chain guide of the conveyor. Only that the pallet will move on an unusual manner of going sideways instead of a straight line Pallet centering just opens and closes the way it should perform. A misaligned pallet on starting on the pallet magazine is one suspected cause of the incident. Solution / Remedy: Thoroughly checked the pallet centering device of the full pallet conveyor of Line A  Reed switches are OK  Chain tension is PERFECT  Clamping device OK and UNOBSTRUCTED  Air Cylinder NOT COMPROMISED  Clamping Pressure is SATISFACTORY Some inconsistencies were found on the empty pallet stack on the pallet magazine, corrected it to follow a neat and uniform straight line. Robot B does not encounter this issue, therefore a close monitoring on the performance of Robot B in comparison with Robot A was made. After the observation, these are the results:  Robot B picks its pallet from the pallet magazine in this manner: Page - 2 - sur 3  Robot A on the other hand picks its pallet from the pallet magazine in this manner: - Both of the pictures are side profiles of a pallet that is being handled by the robotic palletizer. The red dots represent where the “claws” of the pallet gripper arm falls on the pallet. It is visible that there is a difference on how the palletizers pick the pallets from the magazine. A slight inconsistency on the neatness of the empty pallet stack can result to this: - Instead of hitting the hole of the pallet, gripper goes in to the solid part of the pallet. While on transit, the pallet constantly slips out of the pallet gripper’s grasp and the force of the robot grasp makes it go over the chain guides. To resolve the issue, Robot A was remastered (coordinate reintroduction) by to follow the same manner as robot B. in this case, giving it more Y+ coordinates by means of the teach pendant. This setup will be permanently assigned to the Robot CPU and customer does not have to repeat the set-up again for their convenience.   This setup provides the customer more tolerance to such inconsistencies on the empty pallet stack. The accepted pallet shift tolerance on the empty stack is now 40mm instead of the previous 8mm.  In addition to the robot remastering, certain changes were also made to give more security that the incident will not happen again. Page - 3 - sur 3 1. Movement of 3S1GP1 sensor – there were some reports that sometimes the sensor reads the interlayer pad as a pallet indicating a pallet transfer giving the robot a signal to put another empty pallet on the fulls conveyor. Reported simulation where the interlayer blocks the sensor triggering pallet transfer  To correct the issue, the sensor, 3S1GP1 was moved 50mm in the direction of the photoguards to ensure that the interlayer pad will not trigger it in any moment. 50mm  All full pallet presence and transit sensors are calibrated and re-checked if there is no unusual Page - 4 - sur 3 triggers even when the holes of the pallets are passing through. **NOTE: All of this changes made on the sensors will also be performed to Robot B. Page - 5 - sur 3 Conclusion Problem(s) remaining Installation incomplete Spare parts needed Bilable offer requested Additional men power needed Initial diagnostic that pallet misalignment and inconsistencies on the empty pallet stack on the pallet magazine is correct. Robot remastering gives the customer more tolerance to these inconsistencies greatly minimizing or even eliminating the chance for this incident to happen again. It is best advised that OP must still check every payload on the pallet magazine if all the pallet are in good condition and the stack is neat enough for the robot to efficiently do its work. OP must also check / re-calibrate sensor to reflector from time to time Page - 6 - sur 3