stéphane chateau, october 2010 abb robotics service rrc ... · abb robotics service rrc parts...

ABB Robotics Service RRC Parts Repair & Robot Reconditioning

Stéphane Chateau, October 2010

© ABB Group March 20, 2013 | Slide 2

Parts & Logistics Backend units

SE Part Support DE

Logistic Center

CZ Repair

Reconditioning

CN Part Support

JP Part Support MX

Repair

Reconditioning

41 Frontend units

Common Management System

Common Offering

Supply Management (Sourcing), Quality Management (certifications),

Life Cycle Management, Price Management

New Parts Exchange

Parts Repair Parts

Reconditioned

Products

© ABB

February 4, 2010 | Slide 3

Common Service Support from backend units

Parts and Logistics Certified Part Repair and Robot Reconditioning

CZ

MX

Standardized repair procedures,

e.g. wrist IRB 1400

© ABB Group , Certified Repair Center March 20, 2013 | Slide 5

Focusing countries of Ostrava

Ostrava

© ABB Group March 20, 2013 | Slide 6

Ostrava today

© ABB Group , Certified Repair Center March 20, 2013 | Slide 7

Focusing countries of San Luis Potosi

San Luis Potosi

© ABB Group March 20, 2013 | Slide 8

Certified Center, Parts Repair & Robot Reconditioning Guidelines

Part repairs and Reconditioning of robots need a high

level of competence, tools, test bench and are only

handled by the Certified Repair Centers.

Only ABB original parts are used in the repair

process and the reconditioning process

Our targeted models are S4C, S4C+, IRC 5,

The spare parts repair delivery time to customers is

2-3 weeks.

© ABB Group March 20, 2013 | Slide 9

© ABB Group March 20, 2013 | Slide 9

Products definition

Robots reconditioning : 3 products

Reconditioned robots (Premium, Standard, Basic)

Customer property refurbishment (after 6-7 years)

Mechanical arm exchange

Customer A ABB stock Refurbishment ABB stock refurb robots Customer B

Refurbishment Customer A

ABB stock

Refurbishment

Customer B

Old mechanical unit (ABB property)

Customer A

© ABB Group March 20, 2013 | Slide 10

Process

Stock

Final

configuration

Manipulator

audit

Manipulator

cleaning

refurbishment

Manipulator

tests

Repair

Cabinet,

boards

cleaning

Cabinet

audit

Cabinet tests

Refurbishment

Paint

Pre Tests,

calibration

Repair

Cabinet

Manipulator Manipulator

dismounting

Cabinet

dismounting

Running

Mini 16h

Final test

Stock

Audit

Refurbishment

Final tests

Customer configuration

Paint

Starting Temporary repair

1st starting

© ABB Group March 20, 2013 | Slide 11

Audit

Audit

Visual inspection

Dynamic behavior

Play measurement

Brake control

Motors control

Report

Objectives

To evaluate the

condition of the robot :

Decision if

refurbishment is

possible (YES/NO)

Define a detailed

refurbishment plan

Premium Refurb.

Standrad Refurb.

Basic Refurb.

© ABB Group March 20, 2013 | Slide 12

Audit 152 checking points

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Audit Visual inspection

Objectives

Check

Gearboxes leakage

Shocks

Cracks foundries

Cleanliness

….

© ABB Group March 20, 2013 | Slide 14

Audit Dynamic behavior

Objectives

To detect

Noise, slapping

Irregular movements

Instability on point :

vibrations

Remarks

The slapping, the noise are

warning play, wear

pinion/bearing, pollution of oil

© ABB Group March 20, 2013 | Slide 15

Audit Play measurement

Objectives

To measure the play for

each axis

Measurements taken

with dial indicators and

with established

positions

Measurement without

load (axis 2 and 3 :

equilibrium position)

Remarks

References : criteria

identical to a new robot

© ABB Group March 20, 2013 | Slide 16

Audit Oil analysis

Objectives

To determine oil/grease

pollution

Metal particles

Remarks

The oil analysis is an

HELP

Allows to determine if a

component is in

destruction phase

(bearing, pinion,…)

© ABB Group March 20, 2013 | Slide 17

Audit Brakes control

Objectives

To control slippage

Remarks

Test with nominal load

Robot in running

© ABB Group March 20, 2013 | Slide 18

Audit Motors control

Objectives

To control insulations

Detection degradation

of the insolents short

cut

Remarks

Controls are taken on the

base of the manipulator

In the event of wrong

values, the cable

manipulator and the

motor are controlled

independently

© ABB Group March 20, 2013 | Slide 19

Refurbishment

Manipulator refurbishment:

Oil and grease replacement

Lubrication bearing axis 1

Manipulator dismounting

Cleaning

Manipulator mounting

Standard and systematic

replacement of some parts

SMB Board battery

replacement

Internal cables

© ABB Group March 20, 2013 | Slide 20

Refurbishment

Manipulator Refurbishment

Bearings replacement

Parallel arm

Articulations of

balancing units

Articulation between

axis 2 and 3

Guiding ring rods on

balancing units

replacement (IRB6400)

© ABB Group March 20, 2013 | Slide 21

Refurbishment

Manipulator refurbishment:

Standard and systematic

replacement of some

parts

Process “Press standing”,

Foundry : bearing axis 1

Replacement of other

parts according to Audit

report

Tests

© ABB Group March 20, 2013 | Slide 22

Refurbishment Wrist unit

Manipulator Refurbishment

Wrist

Replacement of the

intermediate wheel

bearing axis 5

Adjustment of play

axis 5

Replacement of the

bearing, sealing

articulation motor

axis 6

Motor axis 6

replacement

© ABB Group March 20, 2013 | Slide 23

Refurbishment Controller

Cabinet refurbishment:

Cabinet dismounting

Trafo, cables, …

Complete interior and exterior cleaning

Components cleaning

Drive unit

Power unit

Board

Computer

I/O

© ABB Group March 20, 2013 | Slide 24

Refurbishment Controller

Cabinet refurbishment:

Standard and

systematic

replacement of some

parts

Fans

Filter

Contactors

Batteries

Floppy disc

Gasket

© ABB Group March 20, 2013 | Slide 25

Refurbishment Teach pendant

Teach pendant

Standard and

systematic

replacement of some

parts

Keyboard

replacement

Top housing

replacement

© ABB Group March 20, 2013 | Slide 26

Refurbishment

Parts replaced Oil and grease replacement

Cleaning

© ABB Group March 20, 2013 | Slide 27

Tests

Running test after

refurbishment

Calibration & TCP test

Accuracy test before

final running test

Running test

Accuracy test after

final running test

1 hour

16/24 hours

© ABB Group March 20, 2013 | Slide 28

Refurbishment Safety stickers

Paint & Safety labels

© ABB Group March 20, 2013 | Slide 29

What you received As good as new one

© ABB Group March 20, 2013 | Slide 30

Differences from ABB with traders

Fully refurbished robot (Premium or Standard)

Customized robot (example CP/CS, I/O board, Cables

length…)

Robots are delivered with CE-IIB document. This is

required to be able to create the CE-IIA document.

We will be in line with the new machine Directive 13849

during 2010

Robots are delivered with all documentation on CD.

Robots are delivered with key-disk.

Warranty: Full warranty on parts and hours.

© ABB Group March 20, 2013 | Slide 31

Quality

© ABB Group , Certified Repair Center March 20, 2013 | Slide 32

Price Management Categorizing parts on customer value and competition

Global Sales Price

Delivery time

New Part

Exchange

Part

100

60

New Cost

Repair Cost

GM

GM

40 Repaired

Part

GM

Part

packages

Discount

© ABB Group , Certified Repair Center March 20, 2013 | Slide 33

Repair Process

Part arrival in Ostrava

Audit at reception

Prepare repair estimate

Day 2/3

?

Day 4/13

Day 14

Repair process Cannot be repaired

or estimate rejected

by LDU :

- Scrapped

- Sent back

- Audit invoiced

LDU accept the estimate

Return shipment

Y

Y

N

N

© ABB Group March 20, 2013 | Slide 34

Repair 3 products

Repairable parts

Wrists

Motors

FlexPendant/TeachPendant

© ABB Group March 20, 2013 | Slide 35

Repair What we need for a repair

Traceability

Components

Genuine parts

Knowledge/skill

Training/support from manufacturer

Drawings/ technical data

Tools

Tests before and after repair

Test bench (validated by manufacturer)

© ABB Group March 20, 2013 | Slide 36

Repair Traceability

All the parts are identified at

the arrival

LBU

Part article number

Serial number

All the documents are

stored in a data base

All the steps for the repair

Technician name

Date

© ABB Group March 20, 2013 | Slide 37

Repair Processes

Standard process for each task

© ABB Group March 20, 2013 | Slide 38

Repair Components

We buy all

components directly

to the manufacturer or

supplier (following

manufacturer

specifications)

© ABB Group March 20, 2013 | Slide 39

Repair Technical data

Drawings and technical

data from manufacturer

Working instructions

© ABB Group March 20, 2013 | Slide 40

Repair Tools

To assemble and

disassemble the parts

Specific tools, ….

© ABB Group March 20, 2013 | Slide 41

Repair Test bench

Allows a fast and

reliable diagnosis

Certify the repair

© ABB Group , Certified Repair Center March 20, 2013 | Slide 42

Our repair workshop Wrist line

© ABB Group March 20, 2013 | Slide 43

Arguments for Certified Repair & Reconditioning

Centralized competence

Controlled processes = Quality

Investments in Assets / Tools / Test benches

Access to original data (drawing, BOM…) with support from original manufacturer

Direct contact with original suppliers for repair

Use only original components

Buy back power

Central inventory available

Repaired parts available in the reconditioning of robots

© ABB Group March 20, 2013 | Slide 44