LINKS:

SEQUENTIAL WORK CELL

Understand the operation steps of a work cell

ACTIVITY 1: Write steps in transfer sequence

Step the process through the work sequence using the MIMIC

ACTIVITY 2: Step through the transfer sequence

Operate system with unknown problem

ACTIVITY 3: Introduce problem and repeat transfer sequence

Create a sequence fingerprint table for normal operation

ACTIVITY 4: Build Sequence Fingerprint Table: Normal Operation

Create Sequence Fingerprint Table for problem operation

ACTIVITY 5: Repeat Sequence with Problem and list possible cause

Find cause of problem in a sequential operation

MICROCONTROLLER-BASED PROCESS

Label operating parts of basic process

ACTIVITY 6: Create Process Sketch of compressor

Brainstorm possible causes of process problem

ACTIVITY 7: Complete Possible Causes and Investigation sections of TSAG

Plan what to investigate in the process

Identify sub-systems and explain purpose of each

ACTIVITY 8: Complete “Purpose”on Systems Table

Create color-coded sketch identifying process sub-systemsBR

ACTIVITY 9 Color-Code the Screen Display

Develop Input / Output table showing I/O relationships

ACTIVITY 10 Complete Input / Output Table

Calibrate process input data values

ACTIVITY 11 Calibration Table Worksheet 12

Learn characteristics of effective operating instructions
Operate the process using the Mimic machine

ACTIVITY 12 Operate the Plant Air System

Complete Settings-Measurement Table for normal operation

ACTIVITY 13 Settings-Measurement (SM) Table

Explain the principles of analog to digital conversion
Discuss how comparitors are used in a process
Convert digital data to analog
Produce binary numbers with mimic and convert to decimal

ACTIVITY 14 Create Binary Numbers

Use Settings-Measurement Table to find cause of complex problem

ACTIVITY 15 Find the cause of a problem

Enter run time readings on system screen display

ACTIVITY 16 Systems Sketch Readings

Explain how to use binary data to monitor system operation
Optional use of Troubleshooting Action Guide

ACTIVITY 17 Complete a TSAG on plant air process

SKILLED CRAFT BY ROBOT

Describe problem in robotic spray-painting work cell
Discover what you need to know in a robotic work cell with a problem

ACTIVITY 18: What information do you need?

Explain stepper motors, encoders and resolvers
Discuss what makes robots move
Discuss robot control systems and user interfaces
Discuss what you can learn about robot Inputs and Outputs
Exlpain feedback in a robot system
State what set points are for
Explain how pulses control positioning
Define a teach pendant
Explain how analog and digital test points are used in troubleshooting a robotic system

ACTIVITY 19 Identify test point lights and record readings

ACTIVITY 20 Create a Systems Table for positioning systems

Discuss how an oscilloscope can be used in troubleshooting robot positioning

Operate the robot waist axis using the MIMIC

ACTIVITY 21: Complete SM Table for normal robot axis operation

Find causes of robot positioning problems by comparing normal and observed data

ACTIVITY 22: Enter in SM Table, problem conditions for robot

ACTIVITY 23: Find possible causes of the problem

Expand your thinking beyond the mechanical and electrical systems to include factors in a skilled process

ACTIVITY 24 Complete Process Table for application of spray paint finish

Find possible causes of painting problem

ACTIVITY 25: Find cause of spray paint finish problem using TSAG.

Return to Automated Processes and Machines course details

Phone: 847 729 4550
E Mail: bobfrye@troubleshootingcourse.com