Operation of Machine
3. General & Preventive Maintenance
1.Maintenance Cautionary Notes
1.1 Important Precautions.
READ this manual before operating or servicing this equipment.
-
ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
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SAVE 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 analogue components to the equipment with power connected or damage may result.
-
Do not use any chemicals to clean this equipment, unless otherwise stated in this manual.
-
When using compressed air to blow down this equipment, do not direct the air stream at electric/pneumatic or other sensitive devices. Ensure correct PPE is used appropriately.
-
Do not wet wash any of the equipment unless stated to do so.
-
Report all defects immediately to your supervisor or manager.
-
When first installed all surfaces must be cleaned of all foreign material.
-
Remove the Product after changeover the recipe.
Ensure all energy sources are isolated before attempting to clean this machinery. All loose products should be gently brushed off the machine components with a small hand brush. If a vacuum system is installed for cleaning purposes use a small application head to remove loose product from this equipment.
Where applicable, follow the manufactures instructions stated in the original equipment manual. All safety warnings and cautionary advice must be observed.
Cleaning should occur at the end of each day’s production or before maintenance work. Cleaning of every station and work area on the process and line equipment is very important.
Clean with a dry lint free cloth or soft brush; use a vacuum attachment if installed.
Include cleaning for these areas:
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All access points including guards.
-
All the floor area underneath and around the machine.
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Sensors and switches.
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Motors and gearbox units.
-
Pneumatic cylinders and fittings.
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Internal and external surfaces and the dust extraction ducting including flexible tubing.
-
All product contact surfaces must be cleaned to an acceptable hygiene level.
If the product has been exposed to moisture and solidified a scraper with a hard plastic blade can be used. Under no circumstances is a metal blade scraper to be used. Once the hardened product has been removed the scraper and the cleaned area must be wiped down. Any wet areas after washing must be cleaned using a clean dry cloth. Wipe all areas afterwards using a clean dry cloth.
1.2 Personnel.
-
Only qualified personnel are permitted to operate, adjust, service or maintain `BRML' equipment.
-
Personnel are prohibited from interfering with machinery in any way when it is in operation.
1.3 Safety.
WARNING
Safety screens and covers must be maintained where fitted and replaced in the correct position after maintenance or servicing is completed.
1.4 Service, Repair & Adjustments
-
Before servicing or repairing, stop the machine and disconnect all energy sources.
-
Maintenance and adjustments must be performed with all energy sources isolated unless otherwise specified in this manual.
-
To isolate the machinery, refer to the “warning” page in this manual.
1.5. Pneumatic Supply
-
High pressure pneumatic systems are dangerous.
-
Do not service or troubleshoot systems with the compressed air supply on. Be sure to bleed off any trapped compressed air before working on components since it is possible to have high pressures trapped in the pneumatic or gas lines.
2.Maintenance Specifications
2.1 Pneumatic Cylinder Torques
For further information please refer to the OEM or the manufacturer.
2.2 Pneumatic System Settings.
Pneumatic Pressure – Regulator.
3. Maintenance Schedule
3.1 Magazine and Picture Frame Maintenance Schedule
3.1.1 Motors, Gearboxes, & Brakes.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Grease electric motors if required.
X
Inspect motor brake adjustments.
X
Inspect oil level.
X
3.1.2 Belts and Pulleys/Chains and Sprockets.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect for product build up
X
Inspect chain and sprockets.
X
Inspect belts and pulleys.
X
Inspect belt/chain tension
Inspect belt/chain alignment.
X
X
3.1.3 Chassis and Fasteners
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect all nuts and Bolts
X
Inspect for product build up.
X
Inspect for stress fatigue fractures
X
3.1.4 Bearings, Bushes and Cam Tracks.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
Inspect all bolts
X
Inspect and Grease bearings, as applicable
Deep clean motor & bearing housing
Inspect and Grease bearings, as applicable.
Inspect linear bearing tracks.
X
X
Inspect linear bearing bolts.
6 Monthly
X
X
X
3.1.5 Counter, Knobs and Handwheels
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
Check smooth operation and rotation.
X
Clean Knobs and Handwheels.
Inspect cam tracks (If Applicable)
Inspect and Grease bearings, as applicable.
Inspect linear bearing tracks.
X
X
Inspect linear bearing bolts.
6 Monthly
X
X
X
Grease spherical ball ends where applicable.
3.2 Infeed Conveyor Maintenance Schedule
3.2.1 Bearings, Bushes and Cam Tracks.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
Inspect all bolts
X
Inspect and Grease bearings, as applicable
Deep clean motor & bearing housing
Inspect and Grease bearings, as applicable.
Inspect linear bearing tracks.
X
X
Inspect linear bearing bolts.
6 Monthly
X
X
X
3.2.2. Motors, Gearboxes, & Brakes.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Grease electric motors if required.
X
Inspect motor brake adjustments.
X
Inspect oil level.
X
3.2.3 Belts and Pulleys/Chains and Sprockets.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect for product build up
X
Inspect chain and sprockets.
X
Inspect belts and pulleys.
X
Inspect belt/chain tension
Inspect belt/chain alignment.
X
X
3.2.4 Pneumatic and Vacuum System
Task ID.
Inspect vacuum filters
Clean vacuum cups
Inspect all pneumatic cylinder mounts.
Clean vacuum filters
Inspect the pneumatic service unit.
Inspect valves
Test pressure and inspect sensor switch settings.
Inspect all regulators and settings.
Test all pneumatic cylinders for air leaks.
Test all pneumatic cylinders for air leaks.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
X
X
X
X
X
X
X
X
X
X
3.2.5 Chassis and Fasteners
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect all nuts and Bolts
X
Inspect for product build up.
X
Inspect for stress fatigue fractures
X
3.3 Main Drive Maintenance Schedule
3.3.1 Bearings, Bushes and Cam Tracks.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
Grease linear bearings.
X
Inspect bushes.
Inspect cam tracks
Inspect and Grease bearings, as applicable.
X
Inspect linear bearing tracks.
X
X
X
Inspect linear bearing bolts.
X
Grease spherical ball ends where applicable.
X
6 Monthly
3.3.2. Motors, Gearboxes, & Brakes.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Grease electric motors if required.
X
Inspect motor brake adjustments.
X
Inspect oil level.
X
3.3.3. Belts and Pulleys/Chains and Sprockets.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect for product build up
X
Inspect chain and sprockets.
X
Inspect belts and pulleys.
X
Inspect belt/chain tension
Inspect belt/chain alignment.
X
X
3.3.4 Chassis and Fasteners
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect all nuts and Bolts
X
Inspect for product build up.
X
Inspect for stress fatigue fractures
X
3.4. Enclosure Maintenace Schedule.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Clean photo eyes, reflectors and proximity sensors
X
Inspect the fan filter in control console (if fitted).
X
Inspect proximity switch adjustments.
X
Inspect reed switches.
X
Inspect mechanical switches.
X
Inspect the PLC battery indicator.
X
Inspect wiring (visual).
X
Inspect all other switches and buttons.
X
Test 24-volt DC supplies for adjustment.
X
All cabinet wiring shall be inspected prior to power up
X
X
Random ferrule tagging visual check, should be clear and readable
Random Point to Point (resistance test)
X
Random Point to Ground (resistance test)
X
Earth bonding test shall not execute 0.1 ohms between bounded item and earth bus bar, use megger to check earthing
X
Randomly check the wiring for proper crimping & termination (Tug test)
X
Check the cabinet are connected to a suitable earthing point in the FAT premise
X
Check all MCB's for the correct rating protection (refer to Electrical Drawing)
X
Switch ON circuit breaker 'MCB', check voltage on its output terminals.
X
Ensure no alarm on the IO modules after power up of the 24V DC field power supply
X
For each type of power feed, measure voltage & total system current with system "No-Load" condition and record the results
X
3.5 Plucker Unit Maintenance Schedule
3.5.1 Bearings, Bushes and Cam Tracks.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
Inspect all bolts
X
Inspect and Grease bearings, as applicable
Deep clean motor & bearing housing
Inspect and Grease bearings, as applicable.
Inspect linear bearing tracks.
X
X
Inspect linear bearing bolts.
6 Monthly
X
X
X
3.5.2. Motors, Gearboxes, & Brakes.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Grease electric motors if required.
X
Inspect motor brake adjustments.
X
Inspect oil level.
X
3.5.3 Belts and Pulleys/Chains and Sprockets.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect for product build up
X
Inspect chain and sprockets.
X
Inspect belts and pulleys.
X
Inspect belt/chain tension
Inspect belt/chain alignment.
X
X
3.5.4 Pneumatic and Vacuum System
Task ID.
Inspect vacuum filters
Clean vacuum cups
Inspect all pneumatic cylinder mounts.
Clean vacuum filters
Inspect the pneumatic service unit.
Inspect valves
Test pressure and inspect sensor switch settings.
Inspect all regulators and settings.
Test all pneumatic cylinders for air leaks.
Test all pneumatic cylinders for air leaks.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
X
X
X
X
X
X
X
X
X
X
3.5.5 Chassis and Fasteners
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect all nuts and Bolts
X
Inspect for product build up.
X
Inspect for stress fatigue fractures
X
3.6 Pickhead Maintenance Schedule.
3.6.1 Pneumatic and Vacuum System
Task ID.
Inspect vacuum filters
Clean vacuum cups
Inspect all pneumatic cylinder mounts.
Clean vacuum filters
Inspect the pneumatic service unit.
Inspect valves
Test pressure and inspect sensor switch settings.
Inspect all regulators and settings.
Test all pneumatic cylinders for air leaks.
Test all pneumatic cylinders for air leaks.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
X
X
X
X
X
X
X
X
X
X
3.6.2 Fasteners
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect all nuts and Bolts
X
Inspect for product build up.
X
Inspect for stress fatigue fractures
X
3.7 Case Erector Maintenance Schedule
3.7.1 Bearings, Bushes and Cam Tracks.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
Inspect all bolts
X
Inspect and Grease bearings, as applicable
Deep clean motor & bearing housing
Inspect and Grease bearings, as applicable.
Inspect linear bearing tracks.
X
X
Inspect linear bearing bolts.
6 Monthly
X
X
X
3.7.2. Motors, Gearboxes, & Brakes.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Grease electric motors if required.
X
Inspect motor brake adjustments.
X
Inspect oil level.
X
3.7.3 Belts and Pulleys/Chains and Sprockets.
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect for product build up
X
Inspect chain and sprockets.
X
Inspect belts and pulleys.
X
Inspect belt/chain tension
Inspect belt/chain alignment.
X
X
3.7.4 Pneumatic and Vacuum System
Task ID.
Inspect vacuum filters
Clean vacuum cups
Inspect all pneumatic cylinder mounts.
Clean vacuum filters
Inspect the pneumatic service unit.
Inspect valves
Test pressure and inspect sensor switch settings.
Inspect all regulators and settings.
Test all pneumatic cylinders for air leaks.
Test all pneumatic cylinders for air leaks.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
X
X
X
X
X
X
X
X
X
X
3.7.5 Chassis and Fasteners
Task ID.
Daily.
Weekly.
Monthly.
3 Monthly
6 Monthly
Inspect all nuts and Bolts
X
Inspect for product build up.
X
Inspect for stress fatigue fractures
X
3.8 Robot Maintenance Schedule
3.6.1 Pneumatic and Vacuum System
Task ID.
Check for abnormal noise or vibration
Inspect cables & connectors
Clean exterior and clear debris
Check joint movement for smoothness
Inspect base & bolts for tightness
Test emergency stop & safety devices
Inspect teach pendant & cable
Clean the fan and ventilation grilles (if accessible).
Ensure brakes hold position properly (if applicable).
Open the controller (if safe and authorized) to check for dust buildup, loose wiring, or signs of overheating.
Daily.
Monthly
3 Monthly.
6 Monthly
Annual
X
X
X
X
X
X
X
X
X
X
Test battery voltage levels and condition (especially for absolute encoder batteries).
Look for signs of wear or cracking on the arm or base.
Inspect end-of-arm tooling (gripper, welder, etc.) for stability and alignment.
Verify that collaborative mode limits (force, speed, etc.) are functioning correctly.
Backup robot data and settings.
X
X
X
Ensure cooling fans are working properly.
Replace the battery in the robot controller (if applicable).
X
X
X
X
4. Maintenance Procedures
4.1. Bushes and Cam tracks.
4.2. Pneumatic Service Units.
4.3 Belts and Pulleys/Chains and Sprockets.
4.4 Drive Belt Tension.
Fig 1
4.5 Chain Tension.
4.6 Pneumatic Cylinders.
4.7 Pneumatic Cylinder Mounts.
Inspect the clevis pins, trunnions and rod ends for excessive wear – report all defects to your supervisor.
4.8 Chassis and Fasteners.
4.9 Photo Electric Sensors.
Note: Click on the Image for the Manual
4.10 Pneumatic Energy System.
4.11 PLC Battery Check.
4.12 Fan Filter.
Inspect the fan filter in MCC cabinet every month.
4.13 Vacuum Filters and Valves.
4.14 Vacuum Cups
4.15 Pneumatic Service Units.
For default pneumatic settings, please refer to “Maintenance Specification” in section 4.2.
5. Lubrication System
lubrication system is a critical component of any machinery that relies on the movement of mechanical parts. The purpose of a lubrication system is to provide lubrication or oil to the various moving parts of a gears or machinery to reduce friction and wear and tear, prevent overheating, and increase the lifespan of the machinery.
5.2 Bearings
5.3 Gear Motor / Gearbox
Servo Motor Maintenance Procedure
1.
Step
Action
Switch OFF the main power supply to the servo system and apply Lockout/Tagout (LOTO) procedure.
2.
2.Ensure the servo drive DC bus voltage is fully discharged before starting maintenance
3.
Remove dust and foreign materials from the servo motor body using a dry, lint-free cloth or air blower.
Inspect the motor body for any physical damage, cracks, or overheating marks
4.
Check mounting bolts and ensure the motor is securely fastened. Tighten if required
Inspect power and encoder cables for damage, wear, or loose connections. Secure or replace if necessary.
Check proper grounding (earthing) connection of the motor.
Inspect the shaft coupling for looseness or misalignment. Adjust or replace if required.
Manually rotate the motor shaft (if safely disconnected) to ensure smooth movement without abnormal noise.
Restore power and run the motor in jog/manual mode. Check for smooth operation and abnormal vibration.
Monitor motor temperature and verify there are no abnormal sounds during operation.
Check the servo drive for alarm history and clear any faults if present.
Record all inspection results and corrective actions in the maintenance logbook.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Camera Maintenance Procedure
1.
Step
Action
Switch OFF the vision system and apply Lockout/Tagout (LOTO) procedure if connected to production machinery.
2.
Ensure power supply to the camera, lighting controller, and vision PC is completely turned OFF before inspection.
3.
Clean the external surface of the camera body using a dry, lint-free cloth. Do not use water or harsh chemicals.
Clean the camera lens using compressed air first, then wipe gently with lens cleaning solution and microfiber cloth.
4.
Inspect the lens for scratches, cracks, oil contamination, or focus ring looseness.
Check camera mounting brackets and ensure all bolts are tight and securely fastened. Tighten if required.
Verify camera alignment and field of view. Adjust if misalignment is observed.
Inspect lighting system (ring light/backlight/bar light) for brightness consistency, flickering, or damaged LEDs.
Inspect Ethernet/USB/CameraLink cables for wear, bending, loose connectors, or damage. Replace if necessary.
Check proper grounding (earthing) of the camera and lighting controller.
Power ON the system and verify live image quality (focus, brightness, contrast).
Run test inspection in manual mode and confirm detection accuracy and trigger timing.
Record all inspection results and corrective actions in the maintenance logbook.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14
15.
Check vision software for alarm history, communication errors, or dropped frames.
Backup inspection program/settings and record maintenance findings in maintenance logbook.
6. Maintenance Drawing
Click on the below Assemblies for the Maintenance Drawings: -
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16614-1401-A Outer Carton Magazine Assembly
-
16614-1401-B Inner Carton Magazine Assembly
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16614-1501-A Plucker Assembly for outer carton
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16614-1501-B Plucker Assembly for inner carton
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16614-1601-A Picture Frame Assembly for outer carton
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16614-1701- Main Drive
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16614-1801- Flap Floding
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16614-2301-Infeed Conveyor
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16614-2501- Robot Pick Head
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16614-2701- Booklet Pick And Place
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16614-2901- Camera Mounting
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16614-3101-Outfeed Conveyor
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16614-3201- Inner Carton Pick & Place
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16614-3601- Inner Carton Conveyor
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16614-4101- Quttaro 665 Robot
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16614-5301 Rejection Bin