Operation of Machine
Sub-Assemblies Introduction
1. Magazine Conveyor Assembly
1.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Magazine Conveyor Assembly
1.2 Magazine Conveyor Assembly
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The magazine assembly is used to store products before feeding into the system.
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The magazine conveyor is loaded manually by the operator.
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The products are positioned properly for robot pick operation.
-
The assembly ensures continuous availability of products for further processing.
1.3. Maintenance
Important Precautions:
-
Read this manual carefully before operating or servicing the equipment.
-
Always disconnect power and wait at least 30 seconds before connecting or disconnecting any internal harnesses. Failure to follow this may result in serious damage or destruction of the equipment.
-
Always follow proper precautions when handling static-sensitive devices.
-
Retain this manual for future reference.
-
Do not allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
-
Do not connect or disconnect any digital or analog components while the equipment is powered ON, as this may cause damage.
Click below to access the Maintenance Schedule for the Magazine Conveyor Assembly.
1.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
1.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
1.6 Spare List
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
5
5
1
1
1
1
1
4
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
5
5
5
5
1
1
2
1
1
1
10
1
2. IRB 1200 Robot
2.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
IRB1200 Robot
2.2 IRB 1200 Robot
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The IRB robot picks the product from the Magazine Assembly.
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The robot performs pick-and-place operation to transfer the product into the machine for wrapping.
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The robot ensures accurate positioning of the product during transfer.
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The assembly enables smooth and automated feeding of products into the wrapping process.
2.3. Maintenance
Important Precautions:
-
Read this manual carefully before operating or servicing the equipment.
-
Always disconnect power and wait at least 30 seconds before connecting or disconnecting any internal harnesses. Failure to follow this may result in serious damage or destruction of the equipment.
-
Always follow proper precautions when handling static-sensitive devices.
-
Retain this manual for future reference.
-
Do not allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
-
Do not connect or disconnect any digital or analog components while the equipment is powered ON, as this may cause damage.
Click below to access the Maintenance Schedule for the IRB 1200 Robot.
2.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
2.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
2.6 Spare List
Note: Click on the Description for details about Spare parts
3.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
1
2
2
2
3. Scara Robot 1 (P&P from Multivac machine)
3.1. 3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Scara Robot 1
(P&P from Multivac machine)
3.2 Scara Robot 1 (P&P from Multivac machine)
-
The SCARA Robot 1 receives the product from the Wrapping Machine (Customer Scope) along with a signal from the Multivac machine indicating the quantity to be picked.
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Based on the signal, the robot performs pick-and-place operation with a maximum capacity of 10 products per cycle.
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The robot ensures accurate and synchronized handling of the product during transfer.
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The robot places the product onto the Infeed Conveyor 1 Assembly.
3.3. Maintenance
Important Precautions:
-
Read this manual carefully before operating or servicing the equipment.
-
Always disconnect power and wait at least 30 seconds before connecting or disconnecting any internal harnesses. Failure to follow this may result in serious damage or destruction of the equipment.
-
Always follow proper precautions when handling static-sensitive devices.
-
Retain this manual for future reference.
-
Do not allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
-
Do not connect or disconnect any digital or analog components while the equipment is powered ON, as this may cause damage.
Click below to access the Maintenance Schedule for the Scara Robot 1 (P&P From Multivac Machine).
3.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
3.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
3.6 Spare List
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
5
5
1
1
1
1
1
4
9.
10.
11.
12.
13.
1
1
1
10
1
4. Collection Conveyor
4.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Collection Conveyor
4.2 Collection Conveyor
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The Collection conveyor assembly receives the product from the SCARA Robot 1 Assembly.
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After the product is placed by the robot, the conveyor indexes to move the product forward.
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The conveyor moves the product step-by-step based on the indexing signal.
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The product is then conveyed to the Flipping Assembly for further operation.
4.3. Maintenance
Important Precautions:
-
Read this manual carefully before operating or servicing the equipment.
-
Always disconnect power and wait at least 30 seconds before connecting or disconnecting any internal harnesses. Failure to follow this may result in serious damage or destruction of the equipment.
-
Always follow proper precautions when handling static-sensitive devices.
-
Retain this manual for future reference.
-
Do not allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
-
Do not connect or disconnect any digital or analog components while the equipment is powered ON, as this may cause damage.
Click below to access the Maintenance Schedule for the Infeed Conveyor.
4.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
4.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
4.6 Spare List
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
1
2
2
15
1
2
5. Pick & Place Assembly for Fliping
5.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Pick & Place Assembly for Fliping
5.2 Pick & Place Assembly for Fliping
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The pick & place assembly receives the product from the Infeed Conveyor 1 Assembly.
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The assembly picks 10 products and performs flipping operation using servo and pneumatic mechanisms.
-
After flipping, the products are placed onto the Infeed Conveyor 2 Assembly.
-
The assembly performs pick-and-place operation continuously for product transfer.
5.3. Maintenance
Important Precautions:
-
Read this manual carefully before operating or servicing the equipment.
-
Always disconnect power and wait at least 30 seconds before connecting or disconnecting any internal harnesses. Failure to follow this may result in serious damage or destruction of the equipment.
-
Always follow proper precautions when handling static-sensitive devices.
-
Retain this manual for future reference.
-
Do not allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
-
Do not connect or disconnect any digital or analog components while the equipment is powered ON, as this may cause damage.
Click below to access the Maintenance Schedule for the Pick & Place Assembly.
5.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
5.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
5.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
2
2
2
2
1
1
1
1
1
1
1
18.
19.
20.
6. Inspection Conveyor
6.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Inspection Conveyor
6.2 Inspection Conveyor
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The Inspection conveyor assembly receives the product from the Pick & Place Assembly for Flipping.
-
A safety sensor is provided before the detection sensors; if it is energized (for example, if any person puts hand to remove the product), the machine will go into abort or de-energized condition.
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The conveyor indexes to move the products forward step-by-step.
-
The assembly has 10 sensors for latch/product detection, and based on product presence, a signal is given to the SCARA Robot 2 & 3 Assembly for pick-and-place operation.
6.3. Maintenance
Important Precautions:
-
Read this manual carefully before operating or servicing the equipment.
-
Always disconnect power and wait at least 30 seconds before connecting or disconnecting any internal harnesses. Failure to follow this may result in serious damage or destruction of the equipment.
-
Always follow proper precautions when handling static-sensitive devices.
-
Retain this manual for future reference.
-
Do not allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
-
Do not connect or disconnect any digital or analog components while the equipment is powered ON, as this may cause damage.
Click below to access the Maintenance Schedule for the Infeed Conveyor 2.
6.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
6.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
6.6 Spare List
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
1
2
2
15
1
2
7. Scara Robot 2 & 3
7.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Scara Robot 2 & 3
7.2 Scara Robot 2 & 3
-
The SCARA Robot 2 & 3 receive the product from the Inspection Conveyor Assembly based on product presence signal.
-
SCARA Robot 2 picks 3 products at one pick, and SCARA Robot 3 also picks 3 products at one pick from the conveyor.
-
The robots perform synchronized pick-and-place operation to transfer the products into the Main Drive Assembly.
-
The robots place the products individually until a total of 12 products are filled in one slot of the main drive.
7.3. Maintenance
Important Precautions:
-
Read this manual carefully before operating or servicing the equipment.
-
Always disconnect power and wait at least 30 seconds before connecting or disconnecting any internal harnesses. Failure to follow this may result in serious damage or destruction of the equipment.
-
Always follow proper precautions when handling static-sensitive devices.
-
Retain this manual for future reference.
-
Do not allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
-
Do not connect or disconnect any digital or analog components while the equipment is powered ON, as this may cause damage.
Click below to access the Maintenance Schedule for the Scara Robot 2 & 3.
7.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
7.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
7.6 Spare List
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
2
2
5
2
2
2
2
8. Collation Conveyor
8.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Collation Conveyor
8.2 Collation Conveyor
-
The Collation Conveyor assembly receives the product from the SCARA Robot 2 & 3 Assembly.
-
The robots place the products into the main drive pockets.
-
The products are filled individually until 12 products are filled in each pocket.
-
The main drive is operated by the customer with the help of servo, and the products are manually picked by the custome
8.3. Maintenance
Important Precautions:
-
Read this manual carefully before operating or servicing the equipment.
-
Always disconnect power and wait at least 30 seconds before connecting or disconnecting any internal harnesses. Failure to follow this may result in serious damage or destruction of the equipment.
-
Always follow proper precautions when handling static-sensitive devices.
-
Retain this manual for future reference.
-
Do not allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
-
Do not connect or disconnect any digital or analog components while the equipment is powered ON, as this may cause damage.
Click below to access the Maintenance Schedule for the Main Drive.
8.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
8.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
8.6 Spare List
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
1
2
2
10
1
2
7.
1
30