Powertrain TSG Job Report

Department: Unit Assembly

Facility: Rocker Cover FIPG

Date: 12/02/2020

Job Detail: Robot Collision

 R100 and R200 collided during auto cycle, causing damage to the robot mounted
field IO module and associated cabling.

Work carried out:

 Checked I.P camera footage and noted a physical collision between the two robots –
R100 had just finished placing a part on buffer 1 and R200 had just finished placing a
sealed part into the HRA0 engine in OP20 – both were then on route to home
position ready for the next job.
 Checked R100 program ‘PLACE_BUFFER_1’ for the Collision Zone request program
call – see below:

The call can be seen here just before

positions 5 and 10 – these are the
moves from above buffer 1 to home

This means the collision zone with

R200 is requested after the part has
been deposited on the buffer table
and the part check is complete
 Also checked the programs for buffers 2 and 3 which all were the same.

 Checked the R200 program ‘PLACE_HR13’ for the same call:

The call can be seen here just before

positions 11, 6 and 7

This means the collision zone with

R100 is requested after the part has
been placed on the engine and the
robot has returned to the pounce
position above the engine

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 Checked the ROBOT logic within ‘COLL_REQ’ – see below:

Collision Request TO PLC

Collision Ready FROM PLC

Collision Release TO PLC

 Checked the PLC logic for the Collision Control block:

Collision Request TO PLC –

R100 DO[75]

Collision Request TO PLC –

R200 DO[75]

Collision Release TO PLC –

R100 DO[76]

Collision Release TO PLC –

R200 DO[76]

Collision Ready TO Robot –

R100 DI[75]

Collision Ready TO PLC –

R200 DI[75]

 Checked the usage of R100 and R200 Collision Ready signals to ensure they are not
written to anywhere else:

Only one instance of

Collision Ready TO PLC –
R100 DI[75]

Only one instance of

Collision Ready TO PLC –
R200 DI[75]

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Practical Investigation:

 Ran both robots to the positions seen in the breakdown manually.

 Ran from TP making sure that the collision zone request was called simultaneously
on both robots – R100 took precedence as expected.
 Simultaneously ran both from the teach pendants (R200 moves first) to ensure the
collision zones were working as they should do – tested out OK.
 Ran the same as above but opposite (R100 moves first) – tested out OK

Conclusion

 No real conclusion as of yet as everything appears to work as it should

 Monitored after the cell was back up and running – even saw the same scenario as
seen in the breakdown and R100 waited for R200 to clear the zone first?
 Have noticed a couple of potential areas which need further investigation at the
weekend which could become a potential collision IF some preceding logic
was slow to react

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