12 - RPL - Troubleshooting

Troubleshooting

This chapter provides troubleshooting information for both the Robot and the Pallet Loader System. It includes a symptom table listing known alarms along with recommended corrective actions.

Symptom Table

Symptom	Cause	Corrective Action
The default motions are blank on the Robot Motions Setup page on the control	The defaults included in the configuration did not load properly	See the section Manually Load Motion Files below for how to manually load the information in the configuration to the Haas control.
The robot frames are empty and not loaded in the control.	The frames did not load properly from the configuration rpp.zip file.	Load the Robot Frames directly from the USB. Follow the instructions in the Load Robot Frames section below.
When going to other stations than A1, the robot goes to a position that doesn't match the position of the pallet holder.	The robot frame may need to be adjusted.	See the Adjust Robot Frames page below for how to adjust the frames values to compensate for the issue.
Parts machined on the zero-point clamp are out of tolerance.	Zero-point clamp surface is not flat.	See Service News: RPL Troubleshooting - Check Zero Point Vise Flatness

Manually Load Motion Files

1

Go to the HBC site to download the configuration for the machine.

Press the Service [1] button.

Press the Activation [2] button.

Press the NGC - Configuration option [3].

2

Enter the serial number for the machine [1].

Note: Do Not use the serial number for the RPL.

Press Get Details [2].

Make sure the information entered is correct and then press Download [3].

3

Navigate into the configuration folder [1].

Select the Serial number_rpp.zip file [2].

Press Extract [3] at the top and then press Extract All [4].

Then navigate into the rpp.zip file and confirm that it has the same files as shown in the image [5].

If this is an initial RPL setup then confirm that the following files are in the folder:

ROBOTFRAMES.rfm
wsToLsMotion.xml
wsToShelfMotion.xml

Put the zipped SN_rpp.zip on a USB drive.

4

Put the USB drive with the zipped SN_rpp.zip file into the Haas control.

Press [List Program] on the Haas control and then go to the USB tab [1].

Scroll down until you find the SN_rpp.zip file and highlight it [2].

Press [F2] [3] to copy the SN_rpp.zip file into the User Data/My Robot/ directory.

5

After pressing [F2] the "Copy To" window [1] will appear on the center of the control.

Highlight the User Data/ directory [2] and press the right arrow to enter the folder.

Then highlight the My Robot/ directory [3] and press the right arrow to enter that folder.

Inside the User Data/My Robot/ directory press [Enter] [4] to copy the SN_rpp.zip file into the directory.

Note: It doesn't matter what is highlighted when you press [Enter]. Just verify that the current directory at the top [5] shows User Data/My Robot/

To confirm that the file zip file was copied, go to the User Data window and then navigate to the My Robot/ folder and confirm that the SN_rpp.zip file [6] is now in showing.

6

Important: After confirming that the file was copied to the correct location, cycle power on the machine.

The machine needs to power cycled in order for the files in the SN_rpp.zip file to be loaded to the control.

Load Robot Frames File

1

In the configuration in the SN_rpp.zip file there is a file named ROBOTFRAMES.RFM.

Extract this file and put it on a USB.

Press [List Program] and then go to the USB tab [1].

Highlight the ROBOTFRAMES.RFM file [2] and press [Enter] to checkmark it.

Press [F4] and then select Load Robot Frames [3].

2

Press the [Current Commands] button and navigate to the Robot tab. Go into frames and highlight the Shelf frame [1].

Press [ENTER] and make sure that the values shown in the frame match what were on the ROBOTFRAMES.RFM file.

After you confirm that the frame values were loaded, press [UNDO] [3] to exit back to the Frames page.

Adjust Robot Frames

1

Adjust the robot frames needs to be done when the robot doesn't move to the correct position on locations towards the right side of the shelf (Stations A3, A4, or A5).

For example the setup pallet may be in the correct spot at station A1, but then at station A5 the setup pallet is higher than the pallet holder creating a gap between the pallet holder.

This would be an indicator that the frame needs to be adjusted.

You can adjust this by changing the value for P in the Shelf frame. Rotating around P [1] would change the frame so that the setup pallet moves across the shelf at a consistent height.

The image shows how the frame adjusts the robot motion moving across the shelf [2].