Embed Size (px)
Citation preview
Disclaimer under Finnish applicable law:
PLEASE READ THIS DISCLAIMER CAREFULLY BEFORE USING THIS MANUAL.
BY USING THIS MANUAL, YOU AGREE TO BE BOUND BY THE TERMS AND CONDITIONS BELOW.
The author presents the information on behalf of his employer Robogrind Oy to others involved such as robot operating companies.
Any unauthorized copying and distribution of any copyrighted material from this manual, without the copyright owner's permission, is strictly prohibited.
NO WARRANTIES:
THIS MANUAL AND THE INFORMATION, SOFTWARE AND OTHER MATERIAL AVAILABLE IN OR ACCESSIBLE VIA THIS MANUAL IS PROVIDED ON AN "AS IS" AND "AS AVAILABLE" BASIS WITHOUT WARRANTIES OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF TITLE, NONINFRINGEMENT OR IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THE AUTHOR DOES NOT WARRANT THAT FUTURE UPGRADINGS OF THIS BOOK WILL BE UNINTERRUPTED OR ERROR FREE OR THAT ANY INFORMATION GIVEN VIA SOFTWARE ON CD OR OTHER MEDIA ACCESSIBLE THROUGH THIS BOOK IS FREE OF VIRUSES, WORMS, TROJAN HORSES OR OTHER HARMFUL COMPONENTS.
UNDER NO CIRCUMSTANCES SHALL THE AUTHOR BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL, PUNITIVE OR CONSEQUENTIAL DAMAGES THAT RESULT IN ANY WAY FROM YOUR USE OF OR INABILITY TO USE THIS BOOK OR YOUR RELIANCE ON OR USE OF INFORMATION, SERVICES OR MERCHANDISE PROVIDED ON OR THROUGH THIS MANUAL, OR THAT RESULT FROM MISTAKES, OMISSIONS, INTERRUPTIONS, DELETION OF FILES, ERRORS, DEFECTS, DELAYS IN OPERATION, OR TRANSMISSION, OR ANY FAILURE OF PERFORMANCE IF GIVEN ON CD OR OTHER MEDIA.
INDEMNIFICATION:
YOU AGREE TO DEFEND, INDEMNIFY AND HOLD THE AUTHOR HARMLESS FROM ANY AND ALL LIABILITIES, COSTS AND EXPENSES, INCLUDING REASONABLE ATTORNEYS' FEES, RELATED TO ANY VIOLATION OF THESE TERMS AND CONDITIONS BY YOU.
© 2010 Robogrind Oy
Operation and Service Manual RG 550 MP updated to RP Robot 8 / 9 / 10 / 11 / 12 / 14
© Robogrind Oy Author:B. de Bos
INDEX OF THE MANUAL A Declaration of conformity B Technical details C Safety instructions D Quick start guide Know the robot Parts of the Robot Page 1 Control panel and display Page 6 Functions of the buttons / lights / switches Page 9 Single operating buttons and levers Page 10 Combinations of operating buttons Page 12 Installing Installation of the robot in the tank Page 14 Connecting cables and hoses to the frame Page 19 Positioning the frame in the tank Page 21 Entering the dome boom and grinder in the tank Page 25 Entering the primary boom for the barrel in the tank Page 29 Entering the secondary boom for the barrel in the tank Page 33 Turning the complete robot in the tank Page 37 Switching from dome ring to dome centre Page 39 Special adjustments Page 41 Grinding operation Preparations and best way to work Page 50 Effective grinding with the robot Page 51 Dome end grinding (ring) Page 53 Dome end grinding (centre) Page 57 Barrel / shell grinding Page 61 Point – to – point driving in Automatic mode Page 65 E Fault indicators F Contact information G Risk analysis
A
EU Declaration of Conformity
EU Declaration of Conformity of the machinery
The Manufacturer: Siipotec Oy
Address:
Ketolankuja 2 85100 Kalajoki Suomi - Finland
Tel. int. + 358 – 8 – 469 48 00 Fax. int. + 358 – 8 – 469 48 11 Email. [email protected] Internet. www.siipotec.fi Assures, that the RG 550 MP with serial number: 147014
- Satisfies the machine directive 98/37/EY examiners and its involving
changes and domestic statute orders that enactments them; - Satisfies the EMC-directive 89/336/ETY examiners and its involving
changes and domestic statute orders that enactments them;
- Satisfies the low current directive 73/23/ETY examiners and its involving changes and domestic statute orders that enactments them;
and in addition assures, that - Following uniformed standards (or parts/ spots) has been applied:
SFS – EN 292 -1 SFS – EN 292 -2 SFS – EN 294 SFS – EN 60204 – 1 SFS – EN 1050 SFS – EN 6000 – 7 – 706
Kalajoki, <date>
Raimo Siipo Managing Director
______________________
B
TECHNICAL DETAILS
Weight Data Weight of the V-top frame 120 kg Weight of the Bottom leg 40 kg Weight of the Shell boom 35 kg (incl. belt case) Weight of the Dome boom 50 kg (excl. belt case) Weight of the Dome grinder 35 kg Weight of the Power unit 700 kg (incl hydraulic oil)
Hydraulic Data Content of hydraulic oil 200 ltrs Type of Hydraulic oil, mineral* See below information* Hydraulic oil temperature 80 o C (max.)
Electrical data Power consumption 20 kWh Capacity grinding head 2 x 7 kW Power connector 63 Amp / 400 VAC / 5 Poles
Tank fitting data Maximum tank dimension 2600 mm Minimum tank dimension 1900 mm Minimum manhole diameter 450 mm
Top legs setting small tank 1850 mm thru 2250 mm Top legs setting big tank 2250 mm thru 2550 mm
Dry air data Consumption 200 ltr / min (excl. secondary connectors) Pressure 8 bar Local needed equipment (not included)
Safe hoisting device 1 (250 kg minimum / 2 speed)
Fixed analog telephone line 1
Analog telephone number 1
Dry air system 1
Power cable 1
Local wall plug 1
*Hydraulic oils (Robots without hydraulic cooling fan): Cool /dry environments (-250 C thru + 100 C): Renolin MR 20
Average environments (-00 C thru + 250 C): Renolin MR 20 Warm / moist environments (=>250 C ): Renolin MR 68 MC
*Hydraulic oils (Robots with hydraulic cooling fan): Warm / moist environments (=>250 C ): Renolin MR 15 VG 46 or Renolin
MR 20 VG 68 Average environments (-00 C thru + 250 C): Renolin MR 15 VG 46 or Renolin
MR 20 VG 68
C
SAFETY INSTRUCTIONS
Safety instructions
The device is allowed to be used only for mentioned purpose. Using the device in any other
way may cause serious harm to yourselves and damage the machine and / or the tank
container.
Read the manual before operating the device. Use the quick start only as a guide after this.
Always make sure that local safety rules and laws are in compliance with the technical and
operational instructions and documentations of the machine.
Do never use the machine in combination with water or any other liquid and do also not clean it
with that.
The device is allowed to be used and serviced solely by persons who have had proper operational
and service instruction from Robogrind Oy or persons licensed to do so.
Only the user of the device is allowed to be in the working area.
Cleaning and servicing is allowed only when the electricity is turned off and the compressed air
connection is turned off from the machine.
All markings have to be in readable condition. Damaged markings have to be replaced immediately.
Always wear personal safety means when working with this device;
- eye and hearing protection
- proper shoes, an overall and gloves
- independent respirator mask preferably connected to a clean air carbon filter.
(Only if the machine is connected to filtered clean air you may use the connectors on
the machine as shown in picture in spot 5.1.)
C
Only schooled and trained electricians are allowed to work on electrical installations.
Keep working area clean and free from additional objects.
Always make sure that the tank is washed and ventilated before starting operation.
Always make sure you have an cleaning attest proving the tank is safe to work in.
Measure the tank on oxygen level at least each day before entering.
Make sure wires and hoses are in proper shape before installing the machine.
Do not leave the machine unattended and secure it when in the tank and not in use for longer period
in time.
D
QUICK START INSTALLATION OF THE ROBOT RG550 MP Warning:
- This quick start manual provides pure basic guidelines only. - Be aware of hitting during lowering parts into the tank . It may cause serious damage!! - Never assume. Always check!!
Step by step installing: - Measure tank (be aware of the height of manhole flanges)
- Set radius on:
o Bottom leg
o Dome grinding boom (if needed for the job)
o Both barrel grinding booms (if needed for the job)
o Change gas cylinder fixing if needed (1.80 thru 2.20mtr =small / 2.20 thru 2.60mtr is large
tank)
- Connect ground cable to the tank frame
- Turn on the main switch
- Bring all needed hoses / wiring and control panel within reach on the tank
- Lower the bottom leg in the tank with hinge on top (out centre of manhole)
- Lower the top frame into the tank and hook onto bottom leg
- Lift frame to allow the bottom leg to find its position
- Lower frame until bottom leg wheels are standing and top frame falls into position
- Fix bottom leg (two speed bolts)
- Connect bottom leg wiring to frame electrical cabinet
- Connect main power cables (two plugs and air connector) and top leg hydraulic lines (2 pieces)
- Lift whole frame slightly and straighten bottom leg
- RELEASE TENSION FROM LIFTING CHAIN!!
- Open hydraulic valves and push top legs out (slightly hit barrel until robot is stable)
- CLOSE VALVES !!
- Check if frame is straight in all directions. Correct if needed
- Measure distance left and right. Correct if needed.
- Open hydraulic valves again and push arms into green area
- CLOSE VALVES !!
- Visual check again if frame is straight in all directions and, if yes, set 0000 in display
- Drive the frame forward in order to connect required boom(s)
Step by step barrel grinding (1 boom): - Lower primary boom into the tank and fix in frame centre.
- Position the belt case by removing the bolt and fix it to air cylinder (rotate boom if necessary to get
the belt case into the tank)
- Bring air hoses though the center and connect on other side at wiring cabinet
- Bring hydraulic hoses (3 pieces) through the centre and connect to motor
Step by step barrel grinding (2 booms):
- Rotate primary boom in vertical position (belt case on down side)
- Lower secondary boom into the tank and connect it to primary boom (2 speed bolts)
D
- Position the belt case by removing the bolt and fix it to air cylinder (rotate boom if necessary to get
the belt case into the tank)
- Connect hydraulic hose (1 piece fixed on secondary boom) to primary boom
- Bring hydraulic hoses through the centre and connect to secondary boom
- Connect air lines to Primary boom
Step by step dome end grinding: - Lower the boom into the tank and connect to frame centre - Lower the grinding head into the tank and connect to the boom - Put electrical wires (fixed to wiring box on frame) though the frame centre and connect to the
boom. - Put air lines trough the centre and connect at wiring box on the frame (make sure the belt case has
room to rotate freely in all directions)
- Put hydraulic lines (3 pieces) through the centre and connect to belt case assembly
General for grinding positioning: - Drive frame towards the dome end if frame is visually straight.
- Straighten the frame by measuring and manual adjusting the top legs
- Set display on 0000 after straightening
- Switch on laser and mark the laser point on the dome end (used for barrel grinding only).
- Check and set grinding settings in display according to the settings list
- Learn computer the fix and teach area before starting grinding (experienced operators may do this
differently and thus faster).
- Start grinding / refining just outside the area which may need treatment.
1
KNOW THE ROBOT
- V shaped top frame (2 top legs)
- Bottom leg
- Primary boom (arm) for shell grinding (including a belt case)
- Secondary boom (arm) for shell grinding (including a belt case)
- Boom (arm) for dome end grinding
- Belt case for dome end grinding
- Control panel
- Power unit (electrical and hydraulics)
- Cable for earth connection (green / yellow)
- Main power cable with 64 Amp 5 pin plug (3 x phase / 1 x nill / 1 x earth)
Secondary boom and belt case
and belt case
Primary boom and belt case
Top frame
Top Leg / Leg 2 Top Leg / Leg 3
Bottom Leg / Leg 1
2
Central Axle
Wiring box
Leg 2
Leg 3
Leg 1
Foot support / bracket
Emergency switch lever
3
The electrical cabinet at the frame
1 Main cable plug
2 Emergency switch
3 Steering cable plug
4 Work pressure indicator
5 Back pressure indicator
6 Bottom leg plugs
7 Back pressure
8 Work pressure
9 Belt pressure
10 Laser switch
11 Dome boom cable (in newer robots a plug)
12 Belt pressure switch 14 Work pressure valve
1
5
4
2
3
6
8 7 9
11 10 11
12
14
4
Dome end Boom & Grinder unit
Dome Boom
Contact Wheel
Fixing Pins
Belt case Bracket
Belt case
5
Primary and Secondary boom
Central Bracket Belt Case
Primary Shell Boom
Seconday Shell Boom
Central Bracket
Belt Case
Hydraulic Unit
Electric & CPU Unit
6
EXPLANATION OF THE CONTROL PANEL AND DISPLAY
The control panel is used to monitor all operational settings of the robot and helps you with various
displays. By using the panels, buttons and levers the required operation mode is chosen.
By using the display buttons the auto mode settings are chosen.
Power On Running mode Alarm Ring / Centre Indicator light Indicator light Indicator light switch
Forward / Reverse Switch Manual /0/ Auto 0 / Run / Switch Pressure switch Power on Button Boom rotate Grinder out Barrel / End Lever Switch Teach button Move frame Extend Leg Lever Hydraulic On / off Fix switch Button Rpm controller hydraulics Earth leaking Display Emergency stop Indicator light
7
Scrolling through the various display screens is rather easy.
Each time the F1 button is pushed another screen is shown, indicating the operational settings and
or data entered by the operator of the robot. In this part we only show the various screens with
minimal of information. In the chapter “effective grinding” each screen will become clear.
This screen shows the inclination figure of the frame It shows “if the frame is standing vertical straight” 0 means straight. At 30 the frame makes an automatic straightness correction. With the F2 button you are able enter the “first straightness data” in the computer on “0”
This screen shows the number of grinding booms you use You may choose between 1 or 2 booms by pushing the F2 button upon use. In fact you choose “single hydraulic system” or “double
hydraulic system”
This screen shows you the step of the frame in automatic mode. You may choose between 0 / 25 or 50 by pushing the F4 button upon the robot settings list.
This screen shows you the radius of the tank. It should be changed upon tank dimensions by using the F3 and / or F4 button. Proper setting is needed to find required end result of operations.
This screen shows you the time settings for the belt It has a count down function as of the minutes set according to the settings list. At 0 it shuts down the robot. If set on 60 minutes the belt keeps running.
8
This screen shows you the total running hours of the robot It cannot be changed and is used for follow up Maintenance & Repair.
This screen shows you the Offset in cm used in dome end grinding. The setting is calculated and cannot be changed.
This screen shows you the speed of the contact area over the surface of the tank. The needed setting comes forth out of a settings list and can be changed by using the F3 and / or F4 button. Proper setting is needed to find the required end result of operations.
This screen shows you the step of the dome end grinder along the boom during dome centre grinding. It should be changed upon the settings list by using the F3 and / or the F4 button. Proper setting is needed to find the required end result of operations
This screen shows you rpm of the grinder motor Required setting can be reached by using the RPM controller for hydraulics on the control panel. (other visible settings are no longer in use)
This screen shows you the information about point to point
driving
Required setting can be reached by pushing the F3 or F4 buttons Activation of this setting can be reached by pushing the F2 button.
9
THE FUNCTIONS OF SWITCHES, BUTTONS AND INDICATOR LIGHTS ON THE
CONTROL PANEL.
The power On button To switch the robot in standby mode
The Earth leaking indicator light Indicates a electrical malfunction / shortcut to earth
As soon the power button is pushed it should turn off.
The Power on indicator light Indicates if the machine is standby or switched off
The Run indicator light Indicates if the machine is running in auto mode
The Alarm indicator light Indicates machine failures
Barrel / End switch Operational mode for dome end grinding or
Operational mode for barrel grinding
Ring / Centre switch Operational mode for dome end ring grinding or
operational mode for dome end centre grinding
Works only if Barrel /End switch is set to “End”
Frame or Leg lever To be used for extension of the top legs or frame
movement. Both in manual mode.
Boom or Grinder lever To be used for rotation of the centre axle (thus booms)
or for dome grinder in and out. Both in manual mode.
Forward or Reverse switch Determines the frame stepping direction in automatic mode
Fix button Multiple function button.
Teach button Multiple function button.
Rpm controller Determines the Rpm of the hydraulic pump (and with that the
Rpm of the hydraulic grinding motors)
Hydraulic On / Off switch Switches the hydraulic system on and off
0 / Run / Pressure switch 0 position means off
Run position switches the grinder motors on
Pressure position provides work pressure on cylinders
Manual / Auto switch Operational mode for Manual or Automatic running
Emergency switch Stops each process on instant when pushed
10
SINGLE OPERATING BUTTONS AND LEVERS Left and right movement of the lever makes
the dome grinder moving in or out along the
dome boom.
Left and right movement of the lever makes Up and down movement of the lever makes
Makes the frame run forward or backward the central axle (thus booms) rotate
Used in manual mode only Both used in manual mode only.
The Fix button is used for removal of a The Teach button is used to enter a memory
memory point. The point where boom rotation point. The point where boom rotation direction
direction change and frame stepping would change and frame stepping should take place
take place. Used in automatic mode. Used in automatic mode.
Operational choice. Makes the frame step
forward or backward in automatic mode.
Fix
Teach
Frame For Rev
Boom
Grinder Out In →+
Legs
Frame
11
The hydraulic switch operates the main Determines the rotation speed of the
Hydraulic pump (thus grinder motors) hydraulic pump (thus grinder motors)
Once the operational mode for dome-end
grinding has been chosen this switch
Determines the operational mode for dome- determines in which part of the dome-end
end or barrel grinding. you want to operate.
Switches between manual and automatic Switches to running of grinder motors and
running mode. to working pressure + running grinder motors
Some extra information on these two buttons: In manual mode the grinder motors can be
switched on and run. In manual mode it is not possible to switch on to pressure.
Once switched to automatic mode the “Run” position makes the central axle (thus boom)
rotate as well as the grinder motors and switching to pressure becomes possible.
Hydraulic 0 I
Grinder rotation
Grinding 0 Run Press
O Man. Auto
Barrel End
Centre Ring
12
COMBINATIONS OF OPERATING BUTTONS
Manual mode - Top Leg extension / shortening
In combination with a constant pushed Fix button the Legs lever up- or downward movement will extend or shortens the top legs.
Manual mode - Move leg 2 only -- forward or backward
In combination with a constant pushed
Fix button the Frame lever left or right
movement will move leg 2 forward or
backwards.
Manual mode - Move leg 1 only -- forward and backward
In combination with a constant pushed
Teach button the Frame lever left or right
movement will move leg 1 forward or
backwards.
Legs +↑
↓- Fram
e + ←
→ -
Fix
Fix
Legs
Frame + ←
→ -
Teach
Legs
Frame + ←
→ -
13
INSTALLING
Installation of the robot in the tank
Connecting the hoses and cables to the frame
Positioning the frame in the tank
Entering the dome grinding boom and grinding head into the tank
Entering the primary barrel grinding boom into the tank
Entering the secondary barrel grinding boom into the tank
Turning the complete robot into the tank
Switching from dome ring to dome centre
Special adjustments
14
INSTALLATION OF THE ROBOT IN THE TANK. A first important explanation! The device consists of different components: Top frame, lower leg and abrasive belt booms.
Always make sure when lifting the device into the tank that the wirings won’t
damage during this and therefore would cause dangerous situation inside in the tank when the
device is assembled for use. Before assembling always check the device on completeness and
harmless cabling and wires.
The whole operation should be conducted by two employees of which one is on top of the tank and
the other inside as of the moment of actual installing the top frame. Per step the actions of the
employee inside the tank and actions of the employee on top of the tank will be described.
Each set of steps is clarified with pictures on the next page.
The steps are equaly numbered in both parts
The description below is followed by a series of pictures enlightening each step
Be aware that the employee inside is always in command!!
The employee outside simply has to follow his orders and be of help and lookout!!
15
Step 1
(both employees) Measure the tanks actual bare cylinder diameter / radius (be aware of differences
due to flanges. They should not be included). If this measurement is not done properly the machine
might not function to full satisfaction.
Step 2
(both employees) Set length of the lower leg to the correct tank radius by releasing the 2 snap
fasteners. The lower leg has a measuring tape that helps to find the correct dimension. The
measuring tape should comply exactly with the radius of the tank and can be read at lowest point of
the upper leg.
Unlock the fasteners, set the correct height, lock the fasteners and adjust is done.
Remember to lock fasteners properly and check the gear bars on full grip with the safety pin!
Step 3
(both employees) Adjust the length of necessary booms (the booms in use could differ per job).
For this you have to release 6 Alan bolts of the main central bracket. Shift the bracket along the
boom to reach required length. (See chapter “special adjustments”).
Step 4
(both employees) If necessary adjust the top legs length to big or small tank dimensions (see for
this chapter “special adjustments”)
Step 5
(both employees) Make sure necessary hoses and cables are on top of the tank before starting :
a main electrical wire (to connect to frame wiring box)
b “two in one” small hydraulic hose (used for extending the top legs)
c “three in one” large hydraulic hose (used for running main grinder)
d “two in one” large hydraulic hose (used for secondary grinder)
e control panel.
Step 6
Switch on the main power of the machine and check air pressure (min. 7,5 bar)
Now one employee enters the tank and the other stay’s on top.
16
STEP 1 Manhole Shell Flange
Wrong OK
STEP 2
Bottom leg not Bottom leg is
proper installed proper installed
STEP 3
STEP 6
17
Step 7
(employee on top) Use the hoist to lift the lower leg into the tank.
(employee inside) Make sure the hinge side of the bottom leg is pointing upwards, the leg is in
length of the tank and leave it to wait for connection to the top frame.
Step 8
(employee on top) Lift the frame horizontal out of the stand by using hoist and turn it vertical.
Turn it so that the left leg of the frame is pointing down. Just “slip” the device into the tank
trough the maintenance hatch.
(employee inside) Help control the movements in this narrow environment and once in the tank
turn the frame horizontal again.
Step 9
(employee on top) Use the hoist to lower the frame (upon command of the employee inside)
(employee inside) Lower until it’s hook reaches the hinge side of the lower leg.
Push the hook into the hinge and keep the hinge in the back side of the hook during all movements.
Step 10
(employee on top) Lift the frame (upon command of the employee inside)
(employee inside) During lifting the bottom leg will now position itself under the top frame as a
consequence of its own weight.
Step 11
(employee on top) Lower the whole assembly until the wheels of the bottom leg touch the tank’s
floor (upon command of the employee inside)
(employee inside) The top frame will now fall in exact position on the bottom leg bracket. Fasten
the snap fasteners evenly. Leave the whole frame “hanging and standing” in the hoisting chain.
18
STEP 7
STEP 8
STEP 9
.
STEP 10
STEP 11
19
CONNECTING THE CABLES AND HOSES TO THE FRAME
Step 12
(employee inside) Connect the two electrical cables from the bottom leg to the frame wiring box.
Make sure this is done with care and in straight movement. The plugs fit in one way only and
cannot be changed coincidentally.
Step 13
(employee on top) Lower the main power supply cable (a) into that tank.
(employee inside) Connect two plugs and the air connector. Fix the whole cable with the bolt to the
bottom leg to release its weight.
Step 14
(employee on top) Lower the hydraulic hoses (b) into the tank which should be used for top leg
extension.
(employee inside) connect them to the main hydraulic connectors on the frame.
20
Step 12
.
Step 13
Step 14
21
POSITIONING THE FRAME IN THE TANK
Step 15
(employee inside) Open the main hydraulic valves, and keep frame as straight as possible by
balancing it.
(employee on top) Take away any strain from the hoisting chain! Switch on power and hydraulics.
Adjust hydraulics to low Rpm (appr. 600) Extend the top legs by keeping the “FIX button” pushed
in and moving the “LEGS lever” upwards. (command from inside that the frame is fixed and lightly
stable).
(employee inside) The legs should just hit the barrel and the frame should be lightly stable. Close
hydraulic valves. Measure if there is a difference in length of the left and right leg. If any difference
adjust this (see chapter Special adjustments).
22
Step 15
Open the main hydraulic valves
Switch on power Adjust low Extending the top legs and hydraulics Rpm
Close hydraulic valves Measure distance left and right
Legs +↑
↓- Fram
e + ←
→ -
Fix
23
Step 16
(employee inside) If there remains no difference between left and right top leg open the hydraulic
valves again and extend top legs into the middle of the green area as marked on both top legs. Close
valves after this!
(employee on top) solely works on commands during extending the top legs
Step 17
(Employee inside) Take over the control panel. Check the frame visual on vertical straightness and
at if the frame is on 90 degree on the barrel. This can be adjusted by rotating the small wheels on
the back side of each electrical motor.
If the position appears to be ok find the inclination display by pushing the F1 button. As soon this
display is shown push the F2 button. The computer has now been told that the frame is straight and
starts measuring and correcting inclination as of that position.
After having installed the frame booms need to be connected to it. Depending on the work to be performed in the tank this could either be the boom for:
- Dome grinding (see page 25 thru page 28) - The boom(s) for shell / barrel grinding (see page 29 thru 32 for the primary and page 33 thru
36 for the secondary boom)
24
Step 16
Step 17 Set “0”when straightened
25
ENTERING THE DOME GRINDING BOOM AND GRINDING HEAD INTO THE TANK
Step 18
(employee inside) Move the frame into position in a way the central boom connector is just out of
the centre line of the manhole.
Step 19
(employee inside) Rotate the pin of the central connection into right position
Step 20
(employee on top) Use the hoist to lower the dome boom into the tank until the connecting bracket
is in position of the central axle of the frame (upon commands of the employee inside).
(employee inside) Push the central connector into the axle of the frame and fix the central nut.
Step 21
(employee on top) Lower the grinding head into the frame (on commands of the employee inside)
(employee inside) Position the two pins and push them into the fittings. Fix the Alan-bolt and drive
the frame backwards from under the manhole (might the grinding head still be in surrounding of the
manhole drive “grinder in”)
26
Step 18
Step 19
Step 20
Step 21
Boom
Grinder Out In →+
Boom
Grinder
Out In
→+
27
Step 22
(employee inside) Put the three* air lines through the frame centre to the other side and connect
them to the frame wiring box. Air lines are labeled “pressure”, “ back pressure” and “belt pressure”.
Step 23 (Updated robots MP to RP)
(employee inside) Put the electrical wire (two plugs and hanging under the frame wiring box)
through the centre of the frame and connect it to the boom (cannot be mistaken)
Step 23 (Robots 15 and further)
(employee inside) Put the electrical wires, fixed to the boom, through the centre of the frame and
connect it to the plugs under the frames wiring box.
Step 24
(employee on top) Lower the “three in one” hydraulic hoses (c) into the tank.
(employee inside) Put the hoses from frame cabinet side (opposite side of the rotating boom)
through the middle axle of the frame to the side the boom is. Connect them onto the grinding head
(cannot be mistaken).
The employee outside is now ready
The employee inside can start positioning the robot for dome grinding operation. (See chapter
Effective robot operation)
*Machines with a mechanical belt tension system only have two airline
28
Step 22
Step 23
Step 23
Step 24
29
ENTERING THE PRIMARY BARREL GRINDING BOOM INTO THE TANK
Step 18
(employee inside) Move the frame into position in a way the central boom connector is just out of
the centre line of the manhole.
Step 19
(employee inside) Rotate the pin of the central connection into right position
Step 20
(employee on top) Use the hoist to lower the boom into the tank until the connecting nut is in
position of the central axle of the frame (upon commands of the employee inside).
(employee inside) Push the central connector into the axle of the frame and fix the big nut.
Step 21
(employee inside) Disconnect the nut on the air cylinder which until then secured the belt case in
horizontal position. Keep the air cylinder aside and rotate the belt case in about 30 degree position
(move the boom slightly if necessary to create free rotating space for the belt case).
Fix the air cylinder to the back side bracket at the belt case.
30
Step 18
Step 19
Step 20
Step 21
Boom
Grinder Out In →+
31
Step 22
(employee inside) Put the three* air lines through the frame centre to the other side and connect
them to the frame wiring box. The belt is now getting free from the surface due to air pressure and
the boom can be rotated.
Step 23
(employee on top) Lower the “three in one” hydraulic hoses (c) into the tank.
(employee inside) Put the hoses from one side (opposite side of the rotating boom) through the
middle axle of the frame to the side the boom is. Connect them onto the grinding head (cannot be
mistaken).
The employee outside is now ready
The employee inside can start positioning the robot for single arm barrel grinding operation. (See
chapter Effective robot operation)
*Machines with a mechanical belt tension system only have two airlines
32
Step 22
Step 23
33
ENTERING THE SECONDARY BARREL GRINDING BOOM INTO THE TANK
Step 24
(employee inside) Rotate the primary boom in vertical downward position (belt case below).
Step 25
(employee on top) Lower the secondary boom into the tank (upon commands of the employee
inside) in such a way that the bracket with snap fasteners is in “hook position”
(employee inside) When bracket is in “hook position” push the bracket firmly straight onto the
fixing bracket of the primary boom and fix the snap fasteners.
Step 26
(employee inside) Disconnect the nut on the air cylinder which until then secured the belt case in
horizontal position. Keep the air cylinder aside and rotate the belt case in about 30 degree position
(move the boom slightly if necessary to create free rotating space for the belt case).
Fix the air cylinder to the back side bracket at the belt case.
Step 27
(employee inside) Connect the three* airlines to the connector position on the primary boom.
The belt is now getting free from the surface due to air pressure and the boom can be rotated.
*Machines with a mechanical belt tension system only have two air lines
34
Step 24
Step 25
Step 26
Step 27
Boom
Grinder Out In →+
35
Step 28
(employee on top) Lower the hydraulic “two in one” hydraulic hoses (d) into the tank.
(employee inside) Put the hoses from one side (opposite side of the rotating booms) through the
middle axle of the frame to the side the boom is. Connect them onto the grinding head (cannot be
mistaken).
Step 29
(employee inside) Connect the remaining hydraulic hose, which is fixed to the secondary boom,
onto the last remaining connector on the primary boom.
The employee outside is now ready
The employee inside can start positioning the robot for single arm barrel grinding operation. (See
chapter Effective robot operation)
36
Step 28 Step 29
37
TURNING THE COMPLETE ROBOT IN THE TANK. Step 1 Move the frame under the manhole in a way the hoisting bracket is in the middle of the manhole. Make sure the booms are in proper position for minimal weight influence:
o One boom in use Vertical down o Two booms in use Horizontal
Hand the control panel to the employee on top. Step 2 (Employee on top) Lower the hoisting chain (Employee inside) Connect the overhead crane to the hoisting bracket. (Employee on top) Take away most of the tolerance out of the hoisting chain so the machine will be stabilized when top legs are moved inward. Be sure however to never put strain on the hoisting device / chain when the top legs are still against the surface. This will surely damage the machine in the long run or immediately when strain is too high! Step 3 (Employee inside) Open the hydraulics valves and keep both hands on the middle part of the frame. Put one foot against the bracket on the bottom leg so you stand firm. Command to shift top legs in (Employee on top) Adjust hydraulics to low RPM (appr 600) by rotating the RPM controller. Shift top legs in by continuously pushing the fix button and moving the “Legs lever” step wise until
both top legs get free from the surface and totally shifted inward. Step 4 (Employee on top) Take away the weight of the robot by slightly hoisting it until the wheels get free from the bottom. (Employee inside) Rotate the frame 180 degrees so the booms are now at your side. Go to the other side after that. Step 5 (like step 15 at installing) (Employee on top) Lower the frame until the wheels hit the bottom again. Take away any strain from the hoisting chain! (employee inside) keep frame as straight as possible by balancing it. (employee on top) Extend the top legs by keeping the “FIX button” pushed in and moving the “LEGS lever” upwards. (command from inside that the frame is fixed and lightly stable). (employee inside) The legs should just hit the barrel and the frame should be lightly stable. Close hydraulic valves. Measure if there is a difference in length of the left and right leg. If any difference adjust this (see chapter Special adjustments).
38
Step 1 Step 2 Step 3
Do not position your hands here for these parts are shifting!
Position them here!
Foot Bracket
Legs
Frame
Legs
+↑
↓-
Frame + ←
→
-
Fix
39
SWITCHING FROM DOME RING TO DOME CENTRE (RG550RP and 550MP to RP). Grinding dome ends is done in two positions of the belt case. Usually the operation is started with the dome ring however this depends on the job in the tank. At start, like mentioned in the chapter “Entering dome grinding boom and grinding head into the
tank (Step 18 thru 24), the grinding head is positioned right for dome ring. After having the dome ring operation completed the next steps should be taken for the dome centre position; Step 1 Move the dome grinder unit inward until there is enough space to have the belt case rotated by 90 degrees. Step 2 Change the position of the air connectors at the wiring box on the frame. “Back pressure becomes
Work Pressure” and “Work Pressure becomes back Pressure”. Be aware that the moment you do so the belt case will start moving by a rotation of 90 degrees ! Step 3 Since the frame was at distance from the dome end, drive it forward.
40
Step 1 Step 2 Step 3
Boom
Grinder Out In →+
Legs
Frame
41
SPECIAL ADJUSTMENTS
Extending or shortening the top legs for bigger or smaller tanks
Total diameter variation 192 thru 260 cm
Small tank diameter variation from 192 thru 225 cm
Big tank diameter variation from 225 thru 260 cm
Since extension of the top legs by shifting is limited by the length of the hydraulic cylinder another mechanical option is foreseen. This option makes it possible to use the machine in a wide range of diameters. In order to adjust for smaller or bigger tanks following action should be taken:
- Shift arms out to maximum position - Remove the bolt fixing the gas cylinder piston* - Reposition the gas cylinder pistons by manually moving the outer part of the legs
*Be aware! If the piston bolt is removed the outer part of the leg could run inward. It is best to block it before removing the bold.
Position for big tanks
Position for small tanks
In order to be able to centre the frame it is obvious both left and right positions need to be similar.
42
Alignment / centering of the frame with the top legs.
In some cases the frame does not allow to be centered at once. The measured distance left and right differs. The maximum deviation allowance for that is 1 cm! Cause for this could be a deformation in the tank. In those cases a special adjustment is needed. Perform handling in following order if such is case:
- Divide the difference between left and right by two and remember that. - Open the hydraulic valve of the longest top leg. - Move the arm inward until the frame is loosened from the barrel again - Then take it in further. As far as the “remembered value” (half of the difference
between left and right) - Close the hydraulic valve. - Open the valve of the shortest top leg. - Move that leg outward until the frame hits the barrel again and is slightly fixed. - Close the hydraulic valve - Measure left and right
o If ok, put top legs in green area o If not ok, repeat the actions above
Example: Both top legs are barely fixed to the barrel. Measurements show that the left top leg is 5 cm longer than the right top leg. The difference is 5cm so the left leg should be 2,5cm shorter and the right leg 2,5 cm longer (2,5 + 2,5 = 5 or 5 : 2 = 2,5). You should then shorten the left leg first by 2,5cm followed by extending the right leg with 2,5cm
The measured distance should be similar on the left and right top leg
43
Setting the boom length ( for both barrel and dome grinding booms):
Depending on the tank radius the length of the boom needs to be set. For this each boom has been accommodated with measuring tapes as well as a marker on the central brackets. The marker of the central bracket should point at the figure which complies with the radius measured. The length of the boom can be adjusted by loosening the brackets Alan bolts and shifting the bracket to the required dimension. It might well be that the tapes are not 100% accurately fixed on the boom. In case of barrel (shell) grinding you should always have at least two fingers and at maximum three fingers of space between the surface and the contact wheel. In case of the dome grinding boom you should have 2 or 3 fingers of space between the end of the boom and the surface of the barrel.
44
Allignment of the two shell booms The two shell booms should be aligned in all normal system tank treatments. Meaning that both grinding belts are exactly at the opposite of each other. It is however possible in some particular cases that you require them to be off line bases on your case judgment. In order to align or off line them the booms can be shifted. For this loosen the 4 bolts of the central fixing bracket. Shift the boom into required position and re-fix the bolts.
45
Alignment of the belts
In order to have full profit from the belts lifetime as well as to find an end result in maximum quality is it important to have the belt lined out on the contact wheel. Meaning that the belt is running in the middle of the contact wheel. If so the sides of the belt are running parallel with the sides of the contact wheel. Might this not be the case the system should be lined out. Two different belt running systems are in use:
Mechanical belt tension system Pneumatic belt tension system For both systems counts that the back wheels position determines the alignment of the belt. Changing that position changes the position of the belt. “ top IN” Belt running outward
“ top OUT” Belt running inward “ top OK” Belt in line Above pictures show following adjustment consequences:
- If the belt is moving outward the back wheel should be adjusted to the “top OUT” direction.
- If the belt is moving inward the back wheel should be adjusted to the “top IN” direction.
46
For both systems a same sequence of steps should be used during adjustment so the machine will not get damaged during that operation as well as for safety reasons:
- Switch of the hydraulics - Run wheels manually during adjustment. Next if it looks ok - Switch on hydraulics but put Rpm on lowest speed possible (contact wheel running) - Fine tune the adjustment Next if that goes well - Increase speed step by step to maximum and check if the belt keeps his line
Adjustment of the mechanical belt tension system Use a good Alan key with T shape and handle bar. In that case your hands are away from the running belt. Adjustment has to be done very carefully. Always start with loosening both bolts needed but only rotate just a few millimeters (450 max) per adjustment. After loosening fix the other bolts. Check all bolts crosswise on fastening after the adjustment operation. Be aware that even the last crosswise fastening could influence the belt alignment. Moving the back wheel in the “top IN” direction Moving the back wheel in the “top OUT” direction
Loosen slightly Fasten
Loosen slightly Fasten
47
Adjustment of the pneumatic belt tension system
Moving the back wheel in the “top IN” direction
Moving the back wheel in the “top OUT” direction
1 Slightly loosen the nut
2 Slightly rotate the bolt OUT
3 Fix the nut
1 Slightly loosen the nut
2 Slightly rotate the bolt IN
3 Fix the nut
48
49
GRINDING OPERATION.
Preparations and best way to work
Effective grinding with the robot
Dome end grinding
Dome ring
Dome centre
Barrel / shell grinding
Point – to – Point driving in auto mode
50
PREPARATIONS AND BEST WAY TO WORK
Preparations
Unfortunately the robot is not able to reach all parts of the tank due to its construction and two
dimensional movement. For that reason some parts need to be treated manually before installing the
robot:
1 A square around the man lid
2 A square around the top valves
3 A square around the siphon tube holder
4 A square around the bottom valve
5 A triangle if a temperature gauge is fitted in the dome
6 A circle of approximately 25 to 30 cm diameter in the centre of the dome-end
What needs to be prepared depends on the tank.
Way to work
Although each job per tank is different it is advised to keep to following process in order to
minimize robot handling:
1 Grind the first dome
2 Refine the first dome
<Turn robot>
3 Grind the second dome
4 Refine the second dome
<change booms>
5 Grind first half of the barrel (shell)
6 Refine first half of the barrel
<Turn robot>
7 Grind second half of the barrel
8 Refine second half of the barrel
<remove one boom>
9 Grind and refine the left over spot on the bottom under the man lid
51
EFFECTIVE GRINDING WITH THE ROBOT
The robot has been installed now. Depending on the job with the dome grinding boom or with one or both shell grinding booms and is standing near the man hole after that. We now have to perform grinding operation but before we go there two topics need to be addressed:
- the movements of the robot -- Step - the movement of the boom (s) -- Stroke
The Stroke: The booms rotate up to maximum of 4200 Within that maximum each “stroke length” can be set as well as the area in which this stroke takes place. The Step at barrel (shell) grinding: In case of shell and dome ring grinding the whole frame makes a “Step” after each stroke of the booms. This step is made in chosen direction (forward / backward switch). And the length of the step can be set at the control panel display by searching the right display and push the F…button The step at dome ring grinding: In case of shell and dome ring grinding the whole frame makes a “Step” after each stroke of the
booms. The direction of the step cannot be chosen and is always backwards. The length of the step can be set at the control panel display by searching the right display and push the F…button The step at dome centre grinding: In case of dome centre grinding the step is not made by the frame but in that case the belt case / grinding unit “Steps” along the boom. The grinder unit then only steps from outer circle towards
inner circle. The length of the step can be set at the control panel display by searching the right display and push the F…button Determining the place and length of the stroke of the boom(s) in combination with the step: This can be done by using the “Fix” and the “Teach” buttons on the control panel. With the fix button the setting in the computer is deleted on that point the boom is rotating towards. With the teach button another memory point is entered and this is then where the boom changes direction and a step takes place. Example: As soon the robot is set on automatic the boom starts rotating. Push fix. The boom keeps rotating just as long as until the teach button is pushed. The boom rotation direction changes and the robot makes its step. Push Fix. The boom rotates to the other direction until the moment the teach button is pushed. On both ends the robot has been told the ending points for rotation and it keeps rotating and stepping in between the area set.
52
Dome centre “stroke and step” Dome ring “stroke and step”
Barrel “stroke and step”
Rotation direction of the boom
Push Fix
Push Teach
A step is made and Rotation direction changes
Push Fix
Push Teach
A step is made and Rotation direction changes
Robot is now stepping between these points in automatic mode
53
DOME END GRINDING Dome ring
Step 1
Drive the frame forward* towards the dome end by using the “Frame lever” on the control panel. During this driving the robot may stop without any warning. The alarm light starts to flicker. This is normal and caused by the inclination safety on the frame (remember to have set it on 0 during installing the robot). Just wait a few seconds and you will see that the inclination is corrected by automatic movement of the bottom leg. *Driving forward can best be done with the belt case in downward position in order to eliminate gravity a bit, thus positively influencing “running out of inclination” Step 2 Once the dome is reached the straightness of the robot must be checked and related to the dome end (herewith removing your initial visual inclination setting). Do this by measuring from the dome ends circular weld seam towards the centre of each axle. The distances should be same. If not, correct them by moving the knob on the back side of the required motor. After straightening go to the inclination display and then push the F2 button to set and store the “0 inclination point” in the
computer. Step 3 Check all switches on the control panel:
- Barrel / End switch on “End” - The Centre / Ring switch on “Ring” - Hydraulics of and on switch to “On” - Forward / Backward switch on “Back”
Step 4 Check all the settings of the robot by pushing the F1 button which guides you through the displays.:
- Rpm according to the job and settings list - Step according to the settings list (most common 5mm) - Boom speed according to the settings list - Put number of booms on 1 - Check and set the tanks radius (half the diameter) - Check Offset reading (is auto calculated and cannot be set) - Enter the belt life time according to settings list.
54
Step 1
Step 2
Step 3
Step 4
Legs
Frame
Barrel End
Centre Ring
Hydrauli
c 0 I
Grinder rotation
55
Step 5
Drive the contact wheel in correct position by using frame forward/backward and shifting grinder out. The best position of the contact wheel is when it is half way in the curve of the ring and as close to the surface as you may get it. Distance surface to contact wheel approx 2 or 3 cm. Be aware though! The bracket on which the belt case is fixed should be free of the surface! Step 6
Now manually rotate the boom one circle in order to see if the bracket or contact wheel does not hit the surface somewhere. If so this could be caused by either the fact that the robot frame is not in centre or the tank is deformed.
Step 7
If all installments and settings as given in step 2 thru 6 seem to be correct automated grinding operation can be performed. Act as follows:
- Turn the work pressure down to zero (0) - Turn the manual_ 0_ auto switch to auto. The booms starts rotating - Turn the 0_ run _ pressure switch to pressure. The hydraulics start running and pressure is
released. - Immediately but slowly increase work pressure to required setting (settings list)
The frame start stepping at each end of a stroke.
Check the robot on proper running and result of this at the surface. Leave the tank
Position change of the dome grinder unit
The position of the grinder unit differs when dome ring or dome centre grinding is performed. Changing of the position cab be achieved by a change of air hoses like described in the chapter “switching dome ring to dome centre” Switch back-pressure and work pressure connection on the frame wiring box. Make sure the grinder unit has enough room to rotate in new position for it could hit the surface or the centre boom fixing bracket. Position change from ring to centre Shift grinder unit in (“grinder in” lever) until there is enough room to rotate the contact wheel along the barrel. Do not shift it too far for than the backside of the belt case will hit the central bracket of the boom. Position change from centre to ring Move the frame (“frame backward” lever) backwards until there is enough room to rotate the contact wheel along the dome end.
56
Step 5
Step 7
Position change
Boom
Grinder
Out In
→+
Legs
Frame
Grinding 0 Run Press
O Man. Auto
57
Dome centre
Step 1b a
Drive the frame forward* towards the dome end by using the “Frame lever” on the control panel. During this driving the robot may stop without any warning. The alarm light starts to flicker. This is normal and caused by the inclination safety on the frame (remember to have set it on 0 during installing the robot). Just wait a few seconds and you will see that the inclination is corrected by automatic movement of the bottom leg. *Driving forward can best be done with the belt case in downward position in order to eliminate gravity a bit, thus positively influencing “running out of inclination” Step 1b b Or proceed out of ring treatment by changing the position of the grinding unit and just check if the robot is still straight. Step 2b Once the dome is reached the straightness of the robot must be checked and related to the dome end (herewith removing your initial visual inclination setting). Do this by measuring from the dome ends circular weld seam towards the centre of each axle. The distances should be same. If not, correct them by moving the knob on the back side of the required motor. After straightening go to the inclination display and then push the F2 button to set and store the “0 inclination point” in the
computer. Step 3b Check all switches on the control panel:
- Barrel / End switch on “End” - The Centre / Ring switch on “Centre” - Hydraulics of and on switch to “On”
Step 4b Check all the settings of the robot by pushing the F1 button which guides you through the displays.:
- Rpm according to the job and settings list - Boom step according to the settings list. - Boom speed according to the settings list - Put number of booms on 1 - Check and set the tanks radius (half the diameter) - Check Offset reading (is auto calculated and cannot be set) - Enter the belt life time according to settings list.
58
Step 1b
Step 2b
Step 3b
Step 4b
Legs
Frame
Barrel End
Centre Ring
Hydrauli
c 0 I
Grinder rotation
59
Step 5b
Drive the contact wheel in correct position by using frame forward/backward and shifting grinder out/in. The best position of the contact wheel is when it is half way in the curve of the ring and as close to the surface as you may get it or, if proceeding after ring grinding, it should hit where the ring grinding started. Distance surface to contact wheel approx 2 or 3 cm. Be aware though! The bracket on which the belt case is fixed should be free of the surface! Step 6b
Now manually rotate the boom one circle in order to see if the bracket or contact wheel does not hit the surface somewhere. If so, this could be caused by either the fact that the robot frame is out of inclination, out of centre or the tank is deformed.
Step 7b
If all installments and settings as given in step 2 thru 6 seem to be correct automated grinding operation can be performed. Act as follows:
- Turn the work pressure down to zero (0) - Turn the manual_ 0_ auto switch to auto. The booms starts rotating - Turn the 0_ run _ pressure switch to pressure. The hydraulics start running and pressure is
released. - Immediately but slowly increase work pressure to required setting (settings list)
Check the robot on proper running and result of this at the surface.
Leave the tank
Grinding the middle part of the dome centre
In bigger tanks it might be necessary to shift the dome boom one more time in order to reach the middle part of the dome. This is then caused by the fact that the grinder unit is at the end of the rotating spindle. If this is case the bracket needs to be loosened, the boom shifted inwards after which the bracket is fastened again. The “new radius should then be read (marking on the bracket and tape on the
boom) and entered into the display.
60
Step 5b
Step 7b
Grinding 0 Run Press
O Man. Auto
Boom
Grinder
Out In
→+
Legs
Frame
61
BARREL / SHELL GRINDING
Depending on the job to be performed install the robot with a single or with double boom. Make sure the robot is straight and centered Rotate the booms manually to be sure the belt cases do not hit the surface.
Step 1
Drive the frame forward* towards the dome end or any other place that needs treatment by using the “Frame lever” on the control panel. During this driving the robot may stop without any warning. The alarm light starts to flicker. This is normal and caused by the inclination safety on the frame (remember to have set it on 0 during installing the robot). Just wait a few seconds and you will see that the inclination is corrected by automatic movement of the bottom leg. *Driving forward can best be done with the belt case in downward position in order to eliminate gravity a bit, thus positively influencing “running out of inclination”
Step 2 Once the dome is reached the straightness of the robot must be checked and related to the dome end (herewith removing your initial visual inclination setting). Do this by measuring from the dome ends circular weld seam towards the centre of each axle. The distances should be same. If not, correct them by moving the knob on the back side of the required motor. After straightening go to the inclination display and then push the F2 button to set and store the “0 inclination point” in the
computer.
Step 3
Check if the space between the contact wheel and the surface is no less than 2 and no more than 3 fingers.. If this is not correct it could be caused by improper boom length or deformation of the tank
Step 4
Rotate the boom(s) one whole round and check:
- If the contact wheels do not hit the surface. This might be caused by off centered installation wrong installation of the boom(s) or deformation of the tank. If the robot is off centered – re install
- Check if the whole circle, if needed to grind, can be reached without the booms running “out of circle” (420
0).. If the booms do not rotate far enough go one whole round backwards.
62
Step 2
Step 3
63
Asof the next steps it is only a repetition of previous explained settings checks
Step 5
Check all switches on the control panel: - Barrel / End switch on “Barrel” - The Forward / Backward switch in right position - Grinder rotation speed is set according the settings list - Hydraulics of and on switch to “On”
Step 6 Check all the settings of the robot by pushing the F1 button which guides you through the displays.:
- Rpm according to the job and settings list - Boom step according to the settings list. - Boom speed according to the settings list - Put number of booms on 1or 2 depending on the booms used - Check and set the tanks radius (half the diameter) - Enter the belt life time according to settings list.
Step 7 - Switch to auto mode and start the grinding process.
It is now of importance to check if the belt is touching the surface of its full 80 mm.
If such is not the case it could well be the robot is not fully straightened. Finetune this by
rotating the knob on the back side if the motors. Once straight switch on the laser and put a
marking around the red dot on the dome. This marker will then be your reference for the
total process.
64
65
POINT- TO – POINT DRIVING IN AUTOMODE (Setting of the lateral frame running
distance)
It is possible to teach the robot the distance it should walk during the barrel grinding process.
Step 1
Go to the FTP screen which shows you a “set point” / “Activation indicator” / Actual running
distance.
Step 2
Drive the robot to the starting point
Step 3
Enter the required distance you want to move the robot by pushing the F3 (decrease) or F4
(increase) buttons. Distances can be chosen from 10cm thru 120cm.
Step 4
In order to activate the program push the F2 button (NOP => ACT)
Step 5
Start the grinding process in either forward or backward mode.
The yellow “ON” indicator light will flash if the FtP is activated.
In “Frame Backward setting” the actual distance indicator will count up from zero to set distance.
In “Frame Forward setting” the actual distance indicator will count down from set distance to zero.
Either way the machine will automatically shut down if the limit is reached. The screen will then
show FRAME LIMIT / Change direction)
Step 6
Change direction (Backward / Forward) and start the process. The robot will now run same distance
again in opposite direction.
66
Step 1
Step 4
Step 5
Actual value: Run or the remaining distance ( depend on frame direction)
Setpoint F3 decrease / F4 increase setpoint
No Operation Activation indicator
ACTive indicator
ACTivate (F2)
E
MACHINE ERRORS / TROUBLE SHOOTING
The software is able to provide some basic error information via the display.
With this information helping you to guide you in the right direction during trouble shooting.
Beside this we provide you with some basic errors which you could encounter during installation of
the frame.
On top of that we provide you with a table to help and simplify trouble shooting.
This table can be found as an attachment of the M&R manual and is based on most common
failures of the machine over the last 5 years.
Display errors
ERROR SHOWN IN
DISPLAY
CAUSE FOR THE ERROR FIRST ACTION
Error 1: Pulse sensor / Boom No pulses coming from the pulse
sensor of the boom.
Inform M&R electrician
Error 2: Pulse sensor / Leg 1 No pulses coming from the pulse
sensor of leg 1 (Leg 1 is the Bottom
Leg)
Inform M&R electrician
Error 3: Pulse sensor / Leg 2 No pulses coming from the pulse
sensor of leg 2
(Leg 2 is ……………….)
Inform M&R electrician
Error 4: Pulse sensor / Leg 3 No pulses coming from the pulse
sensor of leg 3
(Leg 3 is………………….)
Inform M&R electrician
Error 5: Tension Leg 2 Leg 2 tension sensor is on Inform M&R electrician
Error 6: Frame tilt Inclination of the frame out of range Check and put frame in
straight position.
Error 7: Tension leg 3 Leg 3 tension sensor is on Inform M&R electrician
Error 8: Hyd unit Frequency converter of Hydraulics
error
Inform M&R electrician
Error 9: SSI error Error in dome grinder positioning Inform M&R electrician
E
Mechanical errors you could encounter during installation:
OPERATIONAL ERROR
MANUAL MODE
MOST COMMON CAUSE ACTION
Frame does not stay centered
when not in use
Worn gas cylinders
External / internal leaking of the
hydraulic cylinders
Leaking of valves at frame
Change gas cylinders
See M&R manual for
hydraulic check
Frame pushed to one side (either
left or right) when adjusting top
legs for centering.
Worn gas cylinder.
Bottom leg wheels standing out of
the middle line (leg not vertical)
Change gas cylinders
Reposition the bottom
leg.
Can’t reach the green area when
putting pressure on top legs at
frame installing
Gas cylinder is still in “small tank
position”
Reposition the fixing of
the gas cylinders
OPERATIONAL ERROR
AUTOMATIC MODE
MOST COMMON CAUSE ACTION
Dome grinder makes improper
step
Fault in SK20 relay setting Inform M&R mechanic
Frame getting out of line during
operation
Irregularity of the tank surface Control and adjust frame
when needed
E
Description per error and its follow up to solve `first aid on operator level`
F
Contact information
Device type: RG 550 RP
Contacts Robogrind Oy
Ketolankuja 2 85100 Kalajoki Suomi Finland www.robogrind.fi Bob de Bos (Business Manager) Per address: Oude Maasweg 50 3197KJ Botlek Rt Cell. +31 (0) 6 – 4193 5594 Tel. +31 (0) 10 – 469 48 00 Fax. +31 (0) 10 – 469 48 11 [email protected]
Siipotec Oy
Ketolankuja 2 85100 Kalajoki Suomi Finland www.siipotec.fi Tel. Int. +358 – 8 – 469 48 00 Fax. Int. +358 – 8 – 469 48 11 Raimo Siipo [email protected]
www.robogrind.fi
F
Risk assessment
Object / activity :
Date : 14-11-2009
Working with the RG550mpG
S P SxP
Act Danger Existing control Severity Probability Risk Action necessary Responsible
Set up tankcontainer No escape area, jam doors
etc.
Control work environment 1 1 1
Climb up the ladder Fall / slip Safety shoes, handgloves 2 2 4 Make possible to climb container via
steps or stairs
Climb up the ladder Fall / slip Non-skid profile on steps 2 2 4 ditto
Set up handrail Fall of container Safety shoes, handgloves, 3
point stance
3 1 3 Create fall protection
Open customs lid Crush / injury Work handgloves 2 1 2
Check if the tank is not under
pressure
Choking / injury by remaining
product
Control air line on
decompressing
3 1 3 Education decompressing /
instruction
Vent tank Hear damage Hearing protection / place
sound silencer
3 1 3 Education decompressing /
instruction
Open manhole lid Crush / injury Work handgloves / instruction 2 1 2
Measure oxygen / free of gas Explosion / asphyixiation Procedure tank entering and fill
in percentages
3 1 3
Set up tankladder Slip / fall / injury Place ladder well / instruction 2 2 4 Instruction, don't place the ladder in
the length direction of the tank
Set up tankladder Slip / fall / injury Control rubber ladder 2 1 2 Instruction
Enter tank Fall / slip Safety shoes / instruction 1 1 1
Enter tank Asphysixiation Measure oxygen RIE 036 3 1 3 Instruction
Remove ladder Bump / injury Communication between the
man on and the man in the
tank
2 1 2
Remove ladder Damage tank Control rubber ladder 1 1 1
Installing the robogrind Lifting injury Use crane and pulley 2 1 2
Installing the robogrind Clench Work handgloves 1 1 1
Installing the robogrind Clench Communication between the
man on and the man in the
tank
2 1 2
Installing the robogrind Damage tank Use the right pulley 1 1 1
Installing the robogrind injure man in tank Use the right pulley 3 1 3
Installing the robogrind Clenching due to falling down Only loosen if the frame is
fixed and standing straight
3 1 3
Act Danger Existing control Severity Probability Risk Action necessary Responsible
Installing the robogrind Damage tank due to falling
down
Only loosen if the frame is
fixed and standing straight
1 1 1
Page 1 of 3 6-3-2010
Risk assessment
Object / activity :
Date : 14-11-2009
Working with the RG550mpG
Installing the robogrind Injury/ clench man in tank Follow the proper installing
procedure
2 1 2 Working instruction
Installing the robogrind Injury/ clench man in tank Communication between the
man on and the man in the
tank
2 1 2
Connect hydraulics Injury Work handgloves 1 1 1
Connect hydraulics Oil leakage Quick connection 1 1 1
Connect hydraulics Oil leakage due to bursting of
the hose
Regular maintenance
robogrind and accessories
1 1 1
Connect hydraulics Eye injury due to bursting of
the hose
Safety glasses 3 2 6 Control on use of glasses
Robogrind trial run Clench between tankwall and
robogrind due to falling
Operate robogrind always
away from the body
3 1 3
Robogrind trial run Clench between tankwall and
robogrind due to falling
Emergency stop on machine 3 1 3
Robogrind trial run Suffocation Permanent dust exhaust 3 1 3 Personal safety means
Robogrind trial run Suffocation Use breathing protection 3 2 6 Independent breathing apparatus
Robogrind trial run Injury by dust in eye Safety glasses 2 1 2
Set up tankladder Slip / fall / injury Communication between the
man on and the man in the
tank
2 2 4 Instruction, don't place the ladder in
the length direction of the tank
Set up tankladder Slip / fall / injury Control rubber ladder 2 1 2 Instruction
Climb up the ladder Slip / fall / injury Place ladder well / instruction 2 2 4 Instruction, don't place the ladder in
the length direction of the tank
Descend tank Fall / bump Safety shoes / instruction 1 1 1
In operation Damage tank due to falling
down
The safety in the robogrind 1 1 1
In operation Oil leakage Regular maintenance
robogrind and accessories
1 1 1
Change abrasives Slip / fall due to dust in the
tank
non skid shoes 2 1 2
Act Danger Existing control Severity Probability Risk Action necessary Responsible
Change abrasives Slip / fall due to dust in the
tank
Remove dust after each grind
job
2 2 4
Turning robogrind around Slip / fall due to dust in the
tank
non skid shoes 2 1 1
Page 2 of 3 6-3-2010
Risk assessment
Object / activity :
Date : 14-11-2009
Working with the RG550mpG
Turning robogrind around Slip / fall due to dust in the
tank
Remove dust after each grind
job
2 2 4
Turning robogrind around Clench between tankwall and
robogrind due to falling
Hang robogrind in crane before
moving
2 1 2
Turning robogrind around Clench between tankwall and
robogrind due to falling
Operate robogrind always
away from the body
2 1 2
Turning robogrind around Suffocation due to lack of
oxygen
Use breathing protection 3 2 6 Independent breathing apparatus
connect on machine
Turning robogrind around Damage tank due to falling
down
Hang robogrind in crane before
moving
1 1 1
Taking out robogrind Lifting injury Use crane and special hoist
chain
2 1 2
Taking out robogrind Clench Work handgloves 1 1 1
Taking out robogrind Clench Communication between the
man on and the man in the
tank
2 1 2
Taking out robogrind Damage tank Use the special hoist chain 1 1 1
Taking out robogrind injure man in tank Use the special hoist chain 3 1 3
Taking out robogrind injure man in tank Communication between the
man on and the man in the
tank
2 1 2
Taking out robogrind Injury due to falling dorn Hang robogrind in crane before
moving
2 1 2
Taking out robogrind Damage tank Hang robogrind in crane before
moving
1 1 1
Inspection after working in tank Damage to tank surface Don't leave materials/tools
behind
1 1 1
Climb up the ladder Slip / fall / injury Place ladder well / instruction 2 2 4 Instruction, don't place the ladder in
the length direction of the tank
Descend tank Fall / bump Safety shoes / instruction 1 1 1
Close manhole lid Crush / injury Work handgloves 2 1 2
Act Danger Existing control Severity Probability Risk Action necessary Responsible
Close custom lid Crush / injury Work handgloves 2 1 2
Lower handrail Fall of container Instruction 3 2 6 Make possible to descend container
via steps or stairs
Lower handrail Crush / injury Work handgloves 2 1 2
Descend Fall / slip Safety shoes, handgloves 2 2 4
Descend Injury by jumping Instruction 2 2 4
Page 3 of 3 6-3-2010
