Operation of Machine
Troubleshooting
1. Overview
If a mechanical fault has occurred then the machine will have to be shut down and inspected for the probable cause (e.g., loose belt or chain, broken component, loss of air pressure, etc.)
1.1 Mechanical Parts Trouble shooting
The filled Cartons are entering the Outfeed Conveyor and the Capacitive sensor detect the products inside the Carton. The Cartons are rejected which not have the products and the cartons are moved out.
Faults
Trouble Symptoms
Probable Causes
Tests & the Remedy
Induction Motors
Fail to start without load.
MCB Trips
(Automatic switch trips off, slow start with electro-magnetic noise)
1.Short circuit of circuit switches
2.Incorrect wiring
3.Poor contact at terminals
4.Windings grounded & Broken winding
1.Check circuit switches and replace.
2.Check wiring according to nameplate or refer electrical drawing.
3.Lock tightly
4.Factory Repair
Loading after start
MCB Trip (Fail to restart due to trip-off of automatic switch)
1.Insufficient capacity of fuse
2.High load at low voltage
1.Replace fuse if wiring permits.
2.Check circuit capacity and reduce load
Motor overheats
1.Motor Overloaded or intermittent overload.
2.Motor improperly connected to the Circuit
3.Electric Shock
4.A lack of ventilation
If there is something blocking the ventilation holes for your electric motor, then hot air won’t escape.
1.Remove the Load, run motor Idle. Give it General Inspection. Apply Load Gradually & note characteristics. Inspect for Localized heating.
2.Check Motor Line Connections
3.Check the Earthing of the Motor.
4.Scheduling regular maintenance on your motor can help reduce this risk.
Bearing Overheats
1.High Belt tension.
2.misalignment between motor & machine shaft
3.High Bearing noise
1.Adjust Belt tension.
2.Re-align.
3.Replace the damage bearing
Noise
Electro-magnetic noise induced by electricity.
1.Occurrence from its first operation
2.Sudden sharp noise & smoky
1.coulb be normal.
2.short circuit of windings, Factory repair
Mechanical noise caused by machinery.
1.Loose belt sheave
2.Loose coupling
3.Rubbing as a result of ingression of foreign materials
4.Wind noise
5.Bearing abrasion or they lack lubricating oil.
6.The rollers are misaligned
1.Adjust key and lock the screw.
2.Adjust the position of couplings, lock key and screw.
3.Clean motor interior and ventilation ducts
4.Noise induced by air flowing through ventilation ducts.
5. Have the Induction motor serviced:
(i) Change or clean the bearings.
(ii) Change or add the lubricating oil.
6.Realign the rollers
Vibration
Electro-magnetic vibration
1.Short circuit of windings
2.Open circuit of rotor
Factory repair
Mechanical vibration
1.Unbalanced rotor & Unbalanced fan
2.Unsymmetrical centers between belt sheaves
3.Rollers Central points of couplings do not lie on the same level.
4.Improper mounting installation
1.Factory repair.
2.Align central points
3.Adjust the rollers central points of couplings to the same level.
4.Lock the mounting screws
Pneumatic System
Actuator Moving Abnormally Slow
Excessive air choke
1.Flow control valve incorrectly adjusted.
2.Plugged air silencer.
3.Air leak or squeezed tube
4.Plugged filter
5.Damaged cylinder or seal
1.Readjust the valve.
2.Replace or clean silencer.
3.Repair air leak or tube.
4.Replace air filter.
5.Replace cylinder or seal.
Pressure too low
1.Damaged or incorrectly adjusted pressure regulator valve
2.Plugged filter
3.System leaks
4.Directional or other valve open due to dirt or failed pilot circuit.
5.Cylinder pipe, piston or seal damaged
1.Replace regulator or readjust rating as shown in drawing.
2.Replace filter.
3.Fix leaks.
4.Locate damaged part and clean or replace it.
5.Repair or renew damaged parts.
Filter / Regulator / Lubrication Unit
Air leak at regulator
1.Continuous air leak from the small vent hole in the regulator bonnet
2.Failure of the diaphragm
1.The regulator should be scheduled for repair. Overhaul kits with diaphragm and seals are available for most standard regulators.
2.Replace a diaphragm or the seals as soon as possible after the leak is discovered.
Pressure problems
If diaphragm is cracked or broken
A high velocity air leak at the vent hole will occur. Replace diaphragm.
Filter problems
Over-contaminated, the filter element will create a pressure drop which may affect system operation
Clean or replace the filter element regularly
Directional Control Valve Not Changing Position
Coil not picking up.
Electric failure
Clean or replace the filter element regularly
Valve spool stuck
1.Impurities between spool and sleeve
2.valve pilot not working
1.Replace valve.
2.Replace or clean piloting part.
Proportional valve not responding.
1.Valve not receiving set value from program.
2.Set value received but valve not responding
1.Locate and fix electric failure.
2.Replace the proportional valve.
Air Cylinders
No movement
1.Pressure too low
2.Piston seal leak
3.Scored cylinder bore
1.Check pressure at cylinder to make sure it meets circuit requirements.
2.Operate valve to cycle cylinder.
-Observe fluid flow at valve exhaust ports at end of cylinder stroke.
-Replace piston seals if flow is excessive
3.Replace necessary parts.
-Eliminate contaminants from air supply.
Erratic movement
1.Load misalignment
2.Large difference between static and dynamic friction
1. Re-align cylinder and load.
2.Install flow control valves to provide back pressure to control stroke.
Cylinder body seal leak
1.Loose tie rod
2.Seal deterioration - soft, gummy
3.Seal deterioration - hard, brittle. Usually due to temperature extremes.
Repair or replace.
Rod gland seal leak
1.Torn or worn seal
2.Seal deterioration - hard, brittle. Usually due to temperature extremes.
1.Examine piston rod for dents, gouges or score marks. Repair or replace.
-Check gland bearing for wear. Repair or replace.
2.Replace seals and shield cylinder from temperature extremes.
Vibration
Gearbox
Overheats
Gear case becomes unusually hot.
1.Overload
2.Insufficient or excessive lubricating oil
3.Contaminated oil
4.Oil viscosity is improper
5.Bearing are improperly mounted
6.Shaft is connected improperly
7.Air vent port is closed
8.Ambient temperature is too high
1.Decrease load or use a larger model.
2.Adjust oil level so it aligns with mark on oil gauge
3.Flush interior and replace oil.
4.Change oil with one having the proper viscosity.
5.Reassemble and tighten properly
6.Align properly
7.Remove rubber plug from oil cap
8.Install cooling fan or move to cooler area
Noise
Unusual or excessive noise
1.Improper meshing
2.Bearings are damaged or worn
3.Overloaded
4. Insufficient oil
5.Oil seal is not wet with oil
6.Bearing are improperly mounted
1.Adjust properly
2.Replace bearings
3.Decrease load or use a larger model
4.Add oil so level aligns with oil gauge
5.Lubricate
6.Adjust the bearing
Vibration
Vibration is excessive
1.Gear teeth are worn.
2.Bearings are worn or damaged
3.Mounting bolts are loose
1.Replace wheel
2.Replace bearings
3.Tighten
Oil Leaks
Oil Leaks
1.Oil seal is defective.
2.Cover mounting bolts are loose
3.Air does not escape
4.Excessive oil
1.Replace oil seal
2.Tighten bolts
3.Check oil cap.
4.Adjust oil level so it aligns with mark on oil gauge.
Servo Motor
Servo Motor Overheating
1.A very high supply voltage that exceeds the specified maximum value.
2.An overloaded motor or the servo motor is started up too frequently.
3.Worn bearings or the bearings were replaced with an incorrect type.
4.A high ambient temperature within the motor’s working environment.
1.Reduce the voltage being supplied to the servo motor; for example, by adjusting the tapping point of the servo motors’ supply transformer.
2.Reduce off-peak or peak loads for load shedding
3.Have the servo motor serviced; repair worn-out bearings, replace the wrong type of bearings and reconfigure the rotor.
4.Reduce the ambient temperature in the motor surroundings by adopting appropriate cooling measures.
​Bearing Failure
Unlubricated Bearing
Grease lubrication or bearing replacement.
Dusty Brake
high-pitched squeal from your servo motor
soak up the oil, and lead to friction and screeching.
Produces Smoke or Burning Odo
1.Loose servo motor coupling
2.Unbalanced supply voltage, which might be too high.
3.Bearing abrasion or they lack lubricating oil.
4.Presence of impurities like sand in the lubricating oil.
5.Presence of noise on the motor feedback signal wires or the controller speed reference signals
1.Check and fasten the servo motor coupling.
2.Check and adjust the supply voltage accordingly, to ensure that the servo motor is receiving appropriate amount of power.
3.Have the servo motor serviced:
(i) Change or clean the bearings.
(ii) Change or add the lubricating oil.
4.nspect all motor and controller cables, wiring and connections.
5.Verify that the servo motor is grounded properly.
1.Servo motor is overheating.
2.Too much lubricant, overheating or they’re worn.
3.Burning servo motor windings or wiring
1.inspect its ventilation or cooling system. & If it’s blocked by either accumulated dirt or dust particles, be sure to clean it as recommended.
2.Ensure that you service the servo motor or have the bearings repaired/changed.
3.Ensure that the servo motor is grounded properly
- Check all the motor wiring to ensure that the wires are contactless
Abnormal Noise
Excessive Vibration
1.Uneven or big air gap caused by worn bearings or bearing abrasion.
2.Misalignment of the servo motor with the load being driven.
3.The rotating shaft of the servo motor is bending.
4.The coaxial of the servo motor coupling is too low, especially where a belt pulley is used.
5.Improper servo motor mounting.
1.Check, repair or change the bearings if necessary.
2.Check alignment of the motor with driven load, couplings, and for any possible shim movement.
3.Check and correct both motor and load balance issues.
4.If the servo motor is belt coupled, remove the belt pulley and see if the coaxially is still too low or if the motor is still out of balance.
5.Inspect for worn or loose servo motor mounts.
Vibration
Noise
​
Somke
​
Over Heats
​
2. Equipments Alarms Troubleshooting
Should a program or operational fault occur please refer to digital touch screen. In most cases the screen will detail the cause of the fault and its location.
Each alarm starts with a 3- or 4-digit number. This is called an Error Code. The First Part of the Error Code defines the type of device, and the second part defines the type of fault. Each Type of Device will have a range of error Codes. For example, Cylinders have Error Codes ranging from 100 to 200. For most devices we have limited this range to be 100. Below is a list of the Device Types and on the following pages there are tables that can be referenced that specify all the types of alarms associated with a device and actions to solve each fault.
A Typical Alarm would be displayed as shown below:
For example: -
Device Tag
SC6401 Telescopic Lifter 1 Motion servo ON Reset ControlFault
Device Description
Type of Fault
Please find the below Alarms List
2.1 Cylinder Faults
All Cylinder Faults will have an Error Code between 100 and 200.
A Typical Cylinder Alarm is displayed as follows:
[101] CY1801, Minor Flap Folding Cylinder Reed Alarm
Cylinder Faults
Sr.no
Type of Faults
Possible Cause
Solutions​
101
Reed Alarm
Cylinder has both Reed switches on at the Same time.
-
Check the Position of Both Reed Switches on the Cylinder.
-
Check the for-cable damage.
-
Check electrical terminations.
102
Extend Alarm
The Cylinder Extend Solenoid is ON, and the Extend Reed Switch has been off for a period of time greater than the Extend Fault time.
-
Check the Position of the Extend Reed Switch on the Cylinder.
-
Check the Cylinder has not been damaged.
-
Check for cable damage.
-
Check electrical terminations.
-
Check the Extend Fault time preset. This can be adjusted from the Cylinder Faceplate screen.
103
Retract Alarm
The Cylinder Retract Solenoid is ON, and the Retract Reed Switch has been off for a period of time greater than the Retract Fault time.
-
Check the Position of the Retract Reed Switch on the Cylinder.
-
Check the Cylinder has not been damaged.
-
Check for cable damage.
-
Check electrical terminations.
-
Check the Retract Fault time preset. This can be adjusted from the Cylinder Faceplate screen.
110
Manual Extend Enabled
The Cylinder Manual Extend Function has been enabled. This will override all other control.
-
When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
111
Manual Retract Enabled
The Cylinder Manual Retract Function has been enabled. This will override all other control.
-
When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
112
Manual OFF Enabled
The Cylinder Manual OFF function has been enabled. This will override all other control.
-
When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
2.2 Miscellaneous Input Faults
All Miscellaneous Input Faults will have an Error Code between 400 and 500.
A Typical Miscellaneous Inputs Alarm is displayed as follows:
[401] PE2301, Rob 1 Rejection Bin Eye Alarm
Miscellaneous Input Faults
Error Code
Type of Faults
Possible Cause
Solutions​
401
Alarm
​This is a general Fault for a miscellaneous Input. It is generally raised when the input is ON when it is expected to be off.
-
Check the operation of the Device. For Example, check that a photocell is switching on and off when objects pass in front of it.
-
Check for cable damage.
-
Check electrical terminations.
-
Check PLC input is switching.
402
Evaluation Error, contact 1 or 2 failed to switch or switched too late
This is a Fault specific to a Safety Device. For example, a Guard Switch. On a dual channel safety device, the two channels have not switched within the specified time period, or one of the channels has not switched at all.
-
Check the alignment of the safety switch if it is a guard switch.
-
Check the Contacts on the device if it is an E-Stop.
-
Check for cable damage.
-
Check electrical terminations.
403
Error in the test pulse wiring.
This is a Fault specific to a Safety Device. For example a Guard Switch. The power source at the input terminal is from a different source from that configured in the Safety program.
-
Check for cable damage.
-
Check electrical terminations.
-
Check the contacts on the safety device.
404
Channel 1 Input Test Pulse Error
This is a Fault specific to a Safety Device. For example a Guard Switch. The test pulse on a input is different from that configured in the program or has not been received.
-
Check for cable damage.
-
Check electrical terminations.
-
Check the contacts on the safety device.
405
​
Channel 2 Input Test Pulse Error
This is a Fault specific to a Safety Device. For example a Guard Switch. The test pulse on a input is different from that configured in the program or has not been received.
-
Check for cable damage.
-
Check electrical terminations.
-
Check the contacts on the safety device.
406
Triggered while machine Running
​This is a Fault specific to a Safety Device. The Safety Device has been triggered while the machine was running.
-
This is used to log if the machine has been E-Stopped, a guard switch has been opened or a light Curtain has been triggered while the machine was in a running state.
410
Manual ON Enabled
The Miscellaneous Input Manual ON Function has been enabled. This will override all other control. This can be used to force a signal ON.
-
When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
411
Manual OFF Enabled
The Miscellaneous Input Manual OFF Function has been enabled. This will override all other control. This can be used to force a signal OFF.
-
When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
2.3 Miscellaneous Output Faults
All Miscellaneous Output Faults will have an Error Code between 500 and 600.
A Typical Miscellaneous Output Alarm is displayed as follows:
[501] SV2701, MG Vacuum Generator 1 Alarm
Miscellaneous Output Faults
Error Code
Type of Faults
Possible Cause
Solutions​
501
Alarm
This is a general Fault for a miscellaneous Output.
-
Check the operation of the Device.
-
Check for cable damage.
-
Check electrical terminations.
-
Check PLC input is switching.
510
Manual ON
The Miscellaneous Output Manual ON Function has been enabled. This will override all other control. This can be used to force a signal ON.
-
When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
511
Manual OFF
The Miscellaneous Output Manual OFF Function has been enabled. This will override all other control. This can be used to force a signal OFF.
-
When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
2.4 Air Pressure Fault
Air Pressure low alarm shows when incoming air pressure is low.
A Typical Air Pressure Fault is displayed as follows:
SV0401, Air Pressure Low Fault
Air Pressure Fault
Error Code
Type of Faults
Possible Cause
Solutions​
501
Air Pressure Low Fault
Air Pressure low alarm shows when incoming air pressure is not equal or greater than the sated value on the pressure switch.
-
Check the Incoming air Pressure is not less than 5bar/ low.
-
Check the incoming air ON/OFF knob. It will be ON position.
2 .5 Telescopic Lifter
Telescopic Lifter Assembly
Sr.no
Mechanical of Faults
Possible Cause
Solutions​
1
Vertical Lifter Not Moving
-
No power supply
-
Servo motor fault
-
Jammed telescopic rod
-
Loose or broken wiring
-
Limit switch malfunction
-
Check and restore power
-
Reset/replace servo motor
-
Remove obstruction and clean mechanism
-
Reconnect or replace wiring
-
Inspect and recalibrate limit switches
2
Jerky or Uneven Movement
-
Dry or worn bearings
-
Lack of lubrication
-
Misaligned guide rails
-
Servo calibration issue
-
Replace worn bearings
-
Apply proper lubrication
-
Realign rails
-
Recalibrate the servo motor
3
Excessive Noise During Movement
-
Damaged bearings
-
Loose mechanical fittings
-
Rail contamination (dust/debris)
-
Replace damaged bearings
-
Tighten mounting hardware
-
Clean rails and apply lubricant
4
Camera Shaking or Blurry Output
-
Loose camera mount
-
Vibration from servo
-
Faulty camera cable
-
Dirty lens
-
Tighten camera mount
-
Add vibration dampers
-
Replace/secure camera cable
-
Clean lens
2.6 Camera
Camera Faults
Possible Cause
Solutions​
Loose / Shaky Camera
-
Loose mounting screws
-
Weak or damaged mounting bracket
-
Vibration from telescopic lifter
-
Misaligned camera holder
-
Tighten all camera mounting screws
-
Replace or reinforce mounting bracket
-
Install vibration pads on mount
-
Re-align camera holder/frame
Blurry Image
-
Dirty lens
-
Lens out of physical focus
-
Camera vibration during movement
-
Dust on sensor area
-
Clean lens with microfiber cloth
-
Adjust lens focus ring
-
Add vibration isolators
-
Clean sensor housing
Mechanical Faults
Camera Misalignment
-
Mount plate shifted
-
Impact or sudden shock
-
Incorrect installation of camera bracket
-
Tighten mount plate screws
-
Re-align camera orientation
-
Reinstall bracket properly
Camera Housing Damage
-
Physical impact
-
Excessive tightening of screws
-
Wear or fatigue of plastic housing
-
Replace damaged housing
-
Use proper screw torque
-
Inspect housing periodically
No Video Output
-
Power cable disconnected
-
Damaged power wire
-
Faulty camera power supply
-
Burnt internal component
-
Reconnect power cable
-
Replace damaged wire
-
Test/replace power supply
-
Replace camera module
Black Screen / Power Drop
-
Loose power pin
-
Weak connector contact
-
Voltage drop on the power line
-
Secure or change power pin
-
Replace weak connector
-
Stabilize power input
Electrical Faults
Intermittent Output
-
Damaged data cable
-
Loose pin connection
-
Faulty electrical connector
-
Replace data cable
-
Tighten connector pins
-
Replace electrical connector
Camera Overheating
-
Overcurrent or incorrect voltage
-
Blocked ventilation causing heat buildup
-
Internal short or damaged component
-
Check and correct voltage supply
-
Improve airflow around camera
-
Replace camera if internal damage is found
Distorted Image
-
EMI interference (motor cables, power lines)
-
Poor grounding
-
Damaged shielding in camera cable
-
Shield or reroute cables
-
Ensure proper grounding
-
Replace shielded camera cable
​3.Operations Troubleshooting
3.1 Once the machine is installed, the machine's critical parameters cannot be changed by the operator; the BRML team is to be involved to make changes to these parameters.
In case the admin provides these authorities to the operator or any other user, the following might be the circumstance.
-
The robots/cobots are not homing.
-
Camera & scanner might be inaccurate rejection or acceptance.
-
The machine is not able to home & run smoothly.
-
Robot collision with the surrounding area might result in permanent damage to the robot.
-
Servo functionality might be affected.
And communicate with the BRML team and explain the problems. The BRML team solves the problem & runs the machine.
​
3.2 If the software is corrupted. The BRML team has to be involved in making a solution to the problem.
4.Trouble Shooting
4.1 Robot Stuck or collides
Condition:
1.Robot moves to the pick position and collides with the filled tray stack.
2.Robot moves to place position and collides with the empty tray stack
.3.Robot stops with any type of collision
Auto Recovery: (Robot auto recovery only works if the robot collides with the picking stack) the robot is programmed to auto recover from this error. If the Robot is in a safety minor contact stop condition (Blinking red and blue color lights on the robot end effector) then it will auto recover and moves away from the picking position for the camera to recapture the image and continue its process.
Manual Recovery: If the robot is in a safety major contact stop condition then manual recovery steps to be taken.
1.Press emergency stop push button on the robot pendent.
2.Open emergency stop push button on the robot pendent.
3.The robot pendent starts high speed blinking of colors red, green and blue.
4.Wait for the robot end effector light color to turn light blue.
5.Press and hold the free button on the robot end effector you will hear break release sound from the head.
6.Push and align the robot away from the stack while holding the free button.
7.Warning: if you release the free button wait for the robot breaks to actuate and again press the free button and wait for the clicking sound of the break release.
8.After you are done pushing the robot away from the stack. Release the free button and wait for the robot to hold its position.
9.Press and hold the stop button on the robot pendent for 5 seconds.
10.Robot will make some minor movements and energizes itself.
11.You will see constant blue light on the end effector.
12.You can now start the machine back on from the HMI screen.
13.Note: After you start you will need to provide the starting tray number and confirm it.
4.2 Servo Stops functioning.
Condition:
1.Servo Alarm on the HMI.
Recovery: Check the alarm details on the servo drive screen. Refer the manual to identify the alarm description and take recommended actions as per the manual instructions. Most of the servo alarms are directly cleared from the HMI alarm acknowledge button.
4.3 Dolly presence sensor alarm.
Condition:
1.Filled Tray Dolly present sensor alarm.
2.Empty Tray Dolly present sensor alarm.
Recovery: Check the designated dolly location if it’s located properly or not. And also check if the sensor is powered on. Ensure to verify sensor has green light glowing over it. That is its power feedback.