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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
© ABB Group March 20, 2013 | Slide 13
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