What is Preventative Maintenance?
Preventative Maintenance is a proactive strategy that involves regularly inspecting, servicing, and maintaining equipment, machinery, or facilities to prevent unexpected breakdowns and costly repairs. Glenn Metalcraft runs preventative maintenance (PM) on our robots every year to ensure they are performing at their best. This process is performed to ensure that the joints are lubricated, inspecting motors, cabinets, all-around maintenance of the robot, and fully charged batteries. It helps run them safely and effectively while also extending their lifespan. By keeping grease, batteries, and cables fresh, our robots stay in optimal condition and extend the life of the robots up to 80,000 – 100,000 hours of operation. We currently have a robot that has over 88,000 hours of operation and still performs to its best ability due to running preventative maintenance yearly.
Without proper maintenance, robots can develop problems like contamination, misalignment, and component wear. This leads to breakdowns and unscheduled downtime. These problems can also negatively impact a robot’s performance and the quality of the products it produces. When doing a PM on our robots we can detect issues they may be having such as damaged motors, damaged cables, internal joint damage, and reducer damage.
As stated by Josh Post our Automation Specialist, “This video shows one of our robots performing what I like to call, The Grease Dance. After we do preventative maintenance, we must run all of the joints. A PM is done every three years or 11,000 hours which is equivalent to 458.33 days. Typically, it has been Glenn Metalcrafts practice to perform this yearly”.
Performing preventative maintenance on a FANUC robot involves a series of steps to ensure the robot operates efficiently and to prevent potential breakdowns. Here are the typical steps to take:
1. Safety First
- Power Down: Ensure the robot is powered down and locked out to prevent accidental activation.
- Notify Personnel: Inform all relevant personnel about the maintenance activities.
2. Visual Inspection
- Inspect Exterior: Look for any signs of damage, wear, or leaks on the robot’s exterior.
- Check Cables: Ensure all cables are intact, properly connected, and free of damage or wear.
- Check Connectors: Inspect connectors for corrosion or damage.
3. Mechanical Components
- Grease Bearings and Gears: Lubricate all necessary mechanical components as per the manufacturer’s specifications.
- Inspect Belts and Pulleys: Check for proper tension and wear.
- Check Bolts and Fasteners: Ensure all bolts and fasteners are tight and secure.
4. Electrical Components
- Inspect Wiring and Connections: Look for signs of wear, damage, or loose connections.
- Check Batteries: Inspect and replace the robot’s batteries if necessary.
- Test Sensors and Switches: Ensure all sensors and switches are functioning properly.
5. Controller and Software
- Backup Programs and Data: Make sure all important data and programs are backed up.
- Update Software/Firmware: Update to the latest software or firmware versions if necessary.
- Check Controller Connections: Inspect connections between the controller and the robot.
6. Pneumatics and Hydraulics (if applicable)
- Inspect Lines and Hoses: Check for any leaks or damage.
- Check Pressure Levels: Ensure pressure levels are within specified ranges.
- Test Actuators and Valves: Verify that actuators and valves are operating correctly.
7. Calibration and Testing
- Calibrate the Robot: Perform calibration routines to ensure accuracy.
- Run Test Cycles: Execute test cycles to verify proper operation.
- Monitor Performance: Observe the robot’s performance for any irregularities.
8. Documentation and Reporting
- Record Maintenance Activities: Document all maintenance activities, including any findings and actions taken.
- Report Issues: Report any major issues or potential problems to the relevant personnel.
9. Final Check and Power Up
- Reinspect: Perform a final inspection to ensure all components are in proper working order.
- Remove Lockout/Tagout: Remove lockout/tagout devices.
- Power Up the Robot: Power up the robot and monitor for normal operation.
By following these steps, the team at Glenn Metalcraft ensures that our FANUC robot remains in good working condition and minimize the risk of unexpected downtime.
