14652_chapter 17 safety maintenance training and quality

8/9/2019 14652_Chapter 17 Safety Maintenance Training and Quality

1/20

Chapter 17

Safety , Training , Maintenance and

Quality


2/20

Safety

Safety: It is the state from being protected fromdifferent types of harm/injury or any kind ofdamage.

We use robot in Industrial application to removehuman operator from potentially hazard workenvironment such as welding, painting, assembly,pick and place (such as packaging and palletizing),

product inspection, and testing. Hazard environment contains heat, noise ,fumes,

radiation, toxic gases etc.


3/20


4/20


5/20

OSHA (Occupational Safety and health Act)

came in 1971 in US by labor dept which

ensures safety and rights of human operator .

Examples are wages, health issues, pensions,

home etc.


6/20

Use of Robots

3 occasions when humans are close enough to themachine to be exposed to danger.

1) During Programming of the robot

2)During operation of the robot cell , when humans work inthe cell.

3)During maintenance of the robot.

Risks can be : collision b/w you and robot.Electrical shocks , objects dropped from robot gripper/tools,hydraulic and Pneumatic pressure released from the robotpower supply.


7/20

Solutions to the above specified problems


8/20

During Programming of the robot

During programming the motion of robot

joints and arms can be made very slow.

Certain safety features can be designed into

the robot work cell such as emergency switch

and different sensors(Optical sensors) to

detect the presence of humans which are very

close to the robot.


9/20

During operation of the robot cell

when humans work in the cell.

Humans should work in the cell, conditionaly the

robot power can be controlled either ON/OFF.

The Robot should be placed in physical barriers to

limit the intrusion into the cell.

The periphery of the robot cell must be defined

to the outside the farthest reach of the robot.

Physical barrier :3 options

solutions


10/20

During maintenance of the robot.

1) Power can permanently turned OFF.

2) Use of Dead man Switches.

The safety in the cell objects the safety to the

humans as well as to the objects placed in the

cell.


11/20

National Bureau of standards define 2

levels of safety sensor in robots

level 1 detects the presence of intruder in the

perimeter boundry of the workcell without

regard to the location of the intruder.

Level 2 designed to detect the presence of an

intruder in the region between the workcell

boundary and the robot work volume.

Level 3 intruder detection in the immediate

vicinity of the robot


12/20


13/20


14/20

Training

Trainingis the acquisition of knowledge, skills as a result of the teaching ofvocational or practical skills and knowledge that relate to specific tasks.

Training is getting divided into five categories.

Awareness-Provides a survey of robotics, including technology, application,economics and Social Implications.

Justification: Training in the justification deals with economic issues and unique

problems that arises due to the presence of robots. Application :Training in the application is designed principally for technical

people(Engineers, Production Engineer, scientists etc. The people design differentrobot for different applications or same robot with different Programs.

Operations and Maintenance: Training in operations and Maintenance is providedfor Production Manager and maintenance personnel .These persons are providedwith detailed knowledge and technical skills to represent the equipment. This

includes programming , operations , Maintenance and repair of the robot. Thetypical training course may run from minimum 1-2 days to 1-2 weeks.

Safety: Training in safety is provided to all workers, engineers and scientists togenerate awareness against all operations of the machine.


15/20

Maintenance

Maintenance involves fixing any sort of

mechanical or electrical device against any

broken or out of service state.

Robot does not need maintenance, their

reliability is good, they state is generally

stable.

Maintenance staff should be highly skilled,

highly trained personnel should be employed.


16/20

Maintenance staff

The Staff of the company should be trained and Skilledfor doing modification in the robot.

The Maintenance staff is responsible for two things:

1) Preventive Maintenance: Planned

2) Emergency Maintenance: When a robotmalfunctions or breaks down during regular operationEM come into play.

In EM staff must respond as quickly as possible to the

problem. The downtime should be very less to avoiddependency of the robot on other machine.

The crew present at the site should call service call.


17/20

The crew has three functions at the

emergency time:

1) diagnose the problem

2) actual repair

3) checkout the problem to verify the problem

has been rectified.


18/20

Preventive Measurement(PM)

PM is to service the equipment at periodicintervals to reduce the breakdown of themachine.

It consists of Checking ,cleaning and possiblyreplacing certain mechanical and ElectricalComponents of the robot at regular timeinterval.

The PM is calculated through Mean timebetween Failure.


19/20

Mean time between Failures indicates how

long on average the machinery will operate

between breakdowns.

Robot operation for any task can be given by

Availability= (Mean Time B/w Failure.-Mean

Time To Repair)/ Mean Time B/w Failure.


20/20

Quality Improvement

Quality of the manufactured product will be improvedby employing robots instead of humans.

The inclusion of robots will bring consistency inhandling and processing of the parts and less damage

to the work-parts due to smooth handling But employing humans will help us to find defects and

variation in the product.

Robot are highly repeat , regular and obedient.

They require less time as compared to humans While doing work such as molding , die casting robot

are much consistent and bring uniformity to theproduct.

14652_chapter 17 safety maintenance training and quality

Documents