Mujin Support Maintenance Certification

Program Materials

Welcome to the Mujin System Training course!

This session is designed to give operators and maintenance personnel a solid understanding of the Mujin system, its components, and how to operate, maintain, and troubleshoot key equipment safely and efficiently.

Introductions

Meet the Trainers and Trainees: 

Take a moment to introduce yourself, meet the instructors, and connect with fellow participants. This session is designed to be interactive, so feel free to ask questions and share your experiences.

Course Outline: 

The training will cover essential modules, including an introduction to the system, key components, safety protocols, and maintenance best practices.

System Introduction

System Overview

The Mujin system is an integrated automation platform designed to streamline material handling in warehouses and manufacturing environments. It includes a range of automated components, such as:

• Robot Arm: Automates tasks like pick-and-place and material handling, leveraging advanced Mujin grippers, sensors, and vision systems to deliver precise and efficient performance.
• Mujin Controller: Central system that coordinates all robot operations, including AMRs, robotic arms, and other equipment.
• AMR (Autonomous Mobile Robot): A robot that autonomously transports pallets and frames across the warehouse, enhancing efficiency and mobility.
• IBOB (In/Out Buffer): is where pallets are received or exit the storage arena, ensuring efficient material flow in and out of the system.
• Gripper: The end-effector used by robot arms to pick up or manipulate objects.
• Robot Arm: A mechanical arm used for tasks such as material handling and assembly.
• Vision System: Sensors (like cameras and LiDAR) that help robots perceive their surroundings.
• E-stop (Emergency Stop): A safety feature that immediately halts robot operations in case of an emergency.

Safety Brief

Safety is a top priority when operating and maintaining the Mujin system. This section covers key safety guidelines, but it is important to note that your employer is responsible for ensuring you receive proper safety training for your specific tasks.

Safety Considerations:

• Lockout/Tagout (LOTO): Always apply LOTO procedures before performing maintenance or repairs. Isolate energy sources, lock, tag them, and verify that systems are de-energized.
• Stored Energy Hazards: Be aware of electrical charges, compressed air, and mechanical tension. Discharge capacitors, release stored mechanical energy, and use appropriate PPE (gloves, goggles, etc.).

Robot Cells & AMR Pathways:

• Robot Cells: Never enter active robot cells unless emergency stops are engaged. Verify the system is inactive before entering.
• AMR Pathways: Ensure AMR paths are clear of obstacles to allow smooth operation.
• Personal Protective Equipment (PPE): Always wear appropriate PPE such as gloves, safety goggles, safety-toe shoes, and hearing protection.
• Emergency Procedures: Familiarize yourself with emergency stop buttons (E-stop) and evacuation procedures in case of an emergency.
• Training: Only authorized personnel should operate or service the system. Proper training is required to ensure safe and efficient system use.

Key System Components Overview:

IBOB Zone

Function Overview:

The IBOB system ingests loaded pallets for processing and outputs empty pallets stacks or other items for storage or reuse, ensuring smooth material flow and efficient handling for both inbound and outbound operations. AMRs retrieve and transport pallets seamlessly within the IBOB zone.

Operations:

• Pallets are loaded into the IBOB.
• AMRs retrieve and transport them to unloading areas.
• The Mujin Control System tracks and optimizes the flow with area scanners and several photo eyes

Maintenance:

• Clean and align both area scanners and each photo eye.
• Verify with a pallet on a frame that the overhang photo eyes hold the pallet to an ideal tolerance on top of the frame.

Troubleshooting:[AK1] 

• Ensure all photo eyes are in the proper state
• Safety scanners are not faulted or dirty

QuickTron M150 Autonomous Mobile Robot (AMR)

Function Overview: 

The QuickTron M150 AMR is an automated robot responsible for transporting pallets between designated areas in the facility, including storage and processing zones. The M150 uses LiDAR object detection, QR code scanners, and integrated safety features to operate independently within predefined pathways, ensuring safe and efficient pallet transfer.

Operations:

Navigation & Task Execution:

1. Task Initiation: Tasks are assigned through the Warehouse Execution System (WES), which manages routing, scheduling, and task priority based on system requirements.
2. Loading & Unloading: The AMR automatically aligns with pallets in the IBOB or storage arena. It adjusts its position to engage and securely lift the frame, which the pallet is situated on, before transporting it to the designated unloading point.

System Controls:

1. Human-Machine Interface (HMI): Operators can monitor the AMR's status, battery levels, and operational state (e.g., idle, in transit, loading).
2. Manual Control Override: For situations requiring direct control, the AMR features a manual mode accessible via the HMI. Operators can engage manual control to navigate around unexpected obstacles or realign the AMR with its task.

Maintenance:

Preventive Maintenance Schedule:

1. Daily: Inspect LiDAR sensors and bumpers for cleanliness. Clean any dust or debris with a microfiber cloth to ensure optimal sensor performance.
2. Weekly: Check all wheels and drive mechanisms for signs of wear. Ensure screws and fasteners are securely tightened.
3. Monthly: Inspect the battery compartment for any signs of wear or corrosion and confirm that charging connectors are in proper working condition. Test the emergency stop button for immediate response and reset.

Safety Checks:

1. LiDAR: Ensure sensors are free from obstructions and calibrated correctly. Test by placing a controlled obstacle in the AMR’s path to confirm accurate detection and stopping.
2. Emergency Stop Functionality: Test the EMO button on the AMR to ensure immediate system shutdown when pressed.
3. Charging Station Inspection: Verify that the AMR docks and charges properly without alignment issues. Check charging indicators for proper functionality and battery health.

Troubleshooting:

Common Issues:

1. Navigation Errors: If the AMR fails to navigate accurately, inspect the LiDAR and area scanners for any obstructions. Check the HMI for any navigation error codes and recalibrate sensors if necessary.
2. Battery Charging Issues: If the AMR is not charging properly, inspect connectors for debris or wear. If necessary, clean connectors with a dry cloth and ensure the AMR is fully aligned when docking.
3. Obstacle Detection Sensitivity: If the AMR frequently stops due to false detections, recalibrate the sensitivity settings on the HMI or verify that the LiDAR sensor is clean and unobstructed.

Fault Codes & Reset Procedures:

1. Familiarize operators with common AMR fault codes displayed on the HMI, such as low battery, alignment errors, or navigation faults. Provide quick solutions or reset instructions for each.
2. For persistent issues, use the HMI to perform a soft reset or restart the AMR. If issues persist, log the error for further investigation by the maintenance team.

Kawasaki CP500L Robot Arm Training Outline

Function Overview: 

The Kawasaki CP500L Robot Arm is a high-precision, heavy-duty robotic arm designed for palletizing operations. With a maximum payload of 500 kg and advanced motion capabilities, it efficiently handles large and heavy pallets, ensuring accurate placement in stacking and unstacking tasks. Integrated sensors and position monitoring provide precise control and consistency in automated workflows.

Operations:

Palletizing and Positioning:

1. Movement Range: The CP500L operates with four axes, offering a range of motion that covers up to a 3,255 mm reach and 400 mm of vertical movement of the J3 joint, which enables flexible positioning across the palletizing area.
2. Control Interface: Operations are managed through an HMI and pendant, allowing operators to initiate tasks, adjust speed settings, and monitor real-time positioning.
3. Cycle Efficiency: Capable of up to 1,000 cycles per hour, the CP500L is designed for continuous use in demanding environments, balancing speed with precision to optimize throughput.

System Controls:

1. Pendant Operation: The CP500L’s teach pendant allows operators to manually jog the arm for precise adjustments and to set start and stop positions in custom tasks.
2. Mode Selection: Operators can toggle between automatic, manual, and maintenance modes on the HMI or pendant, depending on operational requirements.
3. Fault and Status Monitoring: System status, including error messages, cycle counts, and axis performance, is accessible through the HMI for proactive monitoring and troubleshooting.
4.  

Maintenance:

Daily:
 Conduct a visual inspection of all arm joints, housings, and dress pack for wear, dust buildup, or damage. Ensure the workspace is clear of debris.

Weekly:
 Check the alignment of the arm’s axes and monitor for any loose bolts or fasteners. Clean all external sensors with a microfiber cloth, particularly those tracking arm position.

Monthly:
 Perform a full inspection of the dress pack and internal cables/hoses to check for wear, obstruction, or damage. Lubricate arm joints and check the dress pack components according to the manufacturer’s recommendations.

Safety Checks:

1. Emergency Stop Testing: Test the emergency stop buttons located on the HMI and pendant to ensure immediate shutdown capability.
2. Work Area Clearance: Confirm that all safety barriers around the robot’s workspace are intact and positioned correctly to prevent unauthorized access.

Troubleshooting:

Common Issues:

1. Joint Misalignment: If the robot’s joints seem misaligned, inspect each axis for wear or debris. Use the HMI or pendant to recalibrate positioning as necessary.
2. Overheating Warnings: If the arm overheats, check for proper ventilation and clear any dust or debris from air intakes. Reduce cycle speed temporarily to allow cooling.
3. Positioning Inaccuracy: If the arm’s placement is inaccurate, recalibrate the axes and inspect for loose bolts or worn gears. Verify that the encoder readings on each axis are accurate.

Fault Codes & Reset Procedures:

1. Review the HMI for any error codes that may display specific faults, such as overload or axis misalignment. Follow the troubleshooting guide for each code to quickly resolve common issues.
2. In case of repeated errors, perform a soft reset via the HMI. If the issue persists, log the fault and escalate to maintenance personnel for a more detailed inspection.

Mujin L-Shape Mega Gripper Training Outline

Function Overview: 

The Mujin L-Shape Mega Gripper is an end-of-arm tool designed for high-precision pallet handling tasks, including secure gripping and releasing of cases during stacking and de-stacking operations. Engineered for compatibility with the CP500L Robot Arm, the gripper includes vacuum and mechanical components that provide reliable, controlled handling of varied case sizes and weights.

Operations:

Gripping and Release Mechanism:

1. Vacuum System: The gripper uses a powerful vacuum system to hold cases securely.
2. Alignment Adjustments: The gripper can be aligned for optimal grip on cases, minimizing slippage and ensuring correct placement within tight tolerances.
3. Release Function: Operators can configure the release speed and strength through the HMI, allowing for controlled placement in stacking or de-stacking operations.

System Controls:

1. Gripper Control via HMI: Operators manage gripping and release settings through the teach pendant, including suction pressure levels and release timing.
2. Manual Control Mode: For fine adjustments or maintenance, the gripper can be manually operated using the Mujin pendant, providing the ability to test suction and release actions outside of automated tasks.
3. Sensor Feedback: The gripper is equipped with sensors to confirm grip status, providing real-time feedback to the HMI to ensure secure handling before movement begins.

Maintenance:

Preventive Maintenance Schedule:

1. Daily: Clean the vacuum nozzles and suction cups to prevent buildup that could interfere with suction strength. Inspect the exterior for any visible wear or damage.
2. Weekly: Check the vacuum seals and hoses for signs of wear, replacing them as needed. Verify that all bolts securing the gripper to the arm are tightened to specification.
3. Monthly: Test the vacuum pressure to ensure it is within operational range, adjusting as needed to match the manufacturer’s specifications.

Safety Checks:

1. Emergency Release Testing: Test the emergency release function to confirm that the gripper will release its load safely if a fault or shutdown occurs.
2. Pressure Monitoring: Confirm that the gripper’s vacuum pressure does not exceed safe operational levels. This prevents undue strain on the system and reduces risk of accidental drops.
3. Sensor Alignment: Ensure that all position sensors on the gripper are properly aligned and responsive to inputs, providing accurate feedback on grip status.

Troubleshooting:

Common Issues:

1. Loss of Suction: If the gripper fails to hold cases securely, inspect the vacuum hoses for leaks or obstructions. Clean the suction cups and check the vacuum pressure settings on the HMI. Periodically, the vacuum modules need to be rebuilt to return them to optimal operation.
2. Misalignment with Cases: If the gripper does not align correctly with cases, recalibrate the gripper’s position relative to the arm using the HMI settings. Adjust positioning for secure grip.
3. Slow-Release Response: If the gripper releases cases too slowly or not at all, verify that the vacuum release function is fully operational and adjust release settings on the HMI.

Fault Codes & Reset Procedures:

1. Use the HMI to check for fault codes related to the gripper, such as low vacuum pressure or sensor misalignment. Refer to the troubleshooting guide to identify quick solutions for each code.
2. For persistent issues, perform a soft reset of the gripper settings via the HMI, and if issues continue, log the error and escalate to maintenance for detailed inspection.

Qimarox Pallet Stacker and Dispenser (PD1) Training Outline

Function Overview: 

The Qimarox Pallet Stacker and Dispenser (PD1) automates the handling of empty pallets by stacking or de-stacking them for smooth material flow, streamlining pallet availability for both loading and unloading operations. This machine operates within the conveyor system, enhancing efficiency and reducing manual handling in the process.

Operations:

Pallet Loading & Unloading:

1. Stacking: Pallets are loaded into the dispenser, which stacks them in a designated area until they are ready for use.
2. De-Stacking: The dispenser releases pallets one at a time as needed, supporting a continuous flow for loading/unloading processes.
3. Height Adjustment: Configurable settings allow for different stacking and de-stacking heights based on pallet requirements.

System Controls:

1. Operated through an HMI interface that allows monitoring of stack levels and operational modes.
2. Adjust settings for stack height and release interval based on operational requirements.
3. Ensure regular checks of HMI settings for accuracy and update according to production needs.

Maintenance:

Preventive Maintenance Schedule:

1. Daily: Clean the area around the dispenser, remove any dust or debris from sensors and conveyor sections.
2. Weekly: Verify the alignment of photo eyes and area scanners used for pallet detection. Test each sensor by placing a pallet on the conveyor and confirming proper sensor response.
3. Monthly: Check the stacker’s lifting mechanism and ensure all moving parts are lubricated as per manufacturer specifications to prevent wear and mechanical issues.

Safety Checks:

1. Inspect all safety interlocks to ensure they are fully operational.
2. Confirm that emergency stop functions are accessible and active and test them for response time.
3. Verify that the safety scanners detect any obstructions, stopping the machine as expected.

Troubleshooting

Common Issues:

1. Misaligned Pallet Detection: If the machine fails to detect pallets, check and align photo eyes to the proper height. Ensure that the photo eyes are free from dust or dirt.
2. Faulted Safety Scanners: Inspect scanners to ensure they are not dirty or damaged. Clean with a dry cloth and verify proper function by testing with a standard pallet.
3. Lifting Arm Misalignment: If pallets are not stacking correctly, realign lifting arms according to the machine's calibration settings.

Fault Codes & Reset Procedures:

1. Familiarize operators with the most common error codes displayed on the HMI and provide quick reference solutions.
2. In case of frequent stacking errors, reset the system using the HMI restart function and perform a manual cycle test.

Fox IV 6955 Pallet Labeler Training Outline

Function Overview: 

The Fox IV 6955 Pallet Labeler is an automated print-and-apply system designed to label pallets with barcodes or other identification labels during material handling processes. Equipped with a Zebra print engine and an Allen-Bradley PLC, the labeler operates continuously in industrial environments, supporting efficient and precise labeling with options for remote monitoring and quick adjustments.

Operations:

Label Printing and Application:

1. Print Engine: The 6955 uses a Zebra ZE511 or ZE521 print engine, capable of printing at resolutions up to 600 dpi and equipped with a color touchscreen for status monitoring and adjustments.
2. Application Process: The labeler applies labels to pallets with precision, handling up to 16-inch label rolls for extended production runs. Settings can be adjusted for application speed, positioning accuracy, and label dimensions.
3. Integration with WES: The system integrates with warehouse execution systems (WES) to receive labeling instructions and apply labels based on production needs and pallet specifications.

System Controls:

1. HMI Controls: The system’s HMI allows operators to monitor label application status, adjust print settings, and troubleshoot minor issues.
2. Remote Diagnostics: The labeler is equipped with on-board analytics, enabling operators to view diagnostic data remotely to predict maintenance needs and avoid downtime.
3. PLC Integration: An Allen-Bradley PLC controls the 6955 labeler’s operations, enabling real-time feedback, automated adjustments, and easy integration with conveyor and other handling systems.

Maintenance:

Preventive Maintenance Schedule:

1. Daily: Clean the printhead and rollers to maintain print quality, remove any dust or debris from the media compartment, and inspect the exterior for visible wear.
2. Weekly: Inspect the label roll, media path, and ribbon for alignment and signs of wear. Replace components as necessary. Tighten any loose fasteners on the print engine and application assembly.
3. Monthly: Calibrate the printhead pressure and label sensors for consistent application accuracy. Inspect the pneumatic components, such as air hoses and valves, for leaks or damage and check air pressure levels.

Safety Checks:

1. Emergency Stop Verification: Ensure the emergency stop function on the HMI and physical button are operational, providing immediate shutdown if needed.
2. Sensor Alignment and Function: Confirm that all sensors (e.g., label detection and application sensors) are properly aligned and calibrated, allowing the system to detect labels accurately and apply them in the correct location.
3. Pneumatic Safety: Check air pressure settings and ensure that pneumatic lines are free of damage. Verify that all pressure levels are within safe operational ranges to prevent misapplication of labels.

Troubleshooting:

Common Issues:

1. Label Misalignment: If labels are applied incorrectly, inspect the printhead alignment and label sensor settings. Adjust label positioning on the HMI as needed and ensure the label roll is loaded correctly.
2. Poor Print Quality: If print quality deteriorates, clean the printhead, adjust the print darkness setting, and ensure the printhead pressure is set correctly. Replace the ribbon if it shows signs of wear.
3. Frequent Sensor Errors: If the label sensor triggers errors frequently, recalibrate the sensor and clean any dust or debris from the sensor path. Adjust sensor sensitivity settings as needed.

Fault Codes & Reset Procedures:

1. Use the HMI to identify common fault codes, such as low ribbon or media errors. Follow the troubleshooting steps for each code displayed on the HMI or refer to the manual for detailed instructions.
2. For recurring issues, perform a soft reset using the HMI. If problems persist, document the fault and escalate it for advanced troubleshooting or repairs by maintenance personnel.

Wulftec WRTA-200 Stretch Wrapper Training Outline

Function Overview: 

The Wulftec WRTA-200 is an automatic stretch wrapper designed for securing pallet loads with stretch film. Equipped with robust controls and variable wrap settings, it ensures stable, efficient pallet wrapping suited to high-throughput environments. This wrapper includes automated film threading, adjustable pre-stretch ratios, and a durable turntable, allowing operators to optimize load containment based on pallet type and stability requirements.

Operations:

Wrapping Process:

1. Automatic Film Threading: The WRTA-200 is equipped with an auto-threading mechanism, reducing manual handling of the film and allowing faster wrapping starts.
2. Adjustable Wrap Settings: Operators can configure the number of top and bottom wraps and adjust the tension for different pallet types. These settings ensure customized load containment and stability.
3. Turntable and Top Platen Control: The turntable provides consistent rotation speed, and the optional top platen stabilizes taller or irregular loads during the wrap cycle.

System Controls:

1. HMI Controls: The HMI panel enables operators to select wrap parameters, adjust film tension, and monitor system status, including cycle completion and fault codes.
2. Mode Selection: Operators can switch between manual and automatic modes. In automatic mode, the wrapper can be started with a single button, while manual mode allows finer control over each step.
3. Safety Fencing and Light Curtains: The system includes safety features to restrict access during operation, ensuring personnel remain clear of moving parts.

Maintenance:

Preventive Maintenance Schedule:

1. Daily: Inspect the turntable and film carriage for debris or damage. Clean the area around the machine to prevent obstructions and ensure the film roll is properly secured and free of tears.
2. Weekly: Check the film rollers for smooth rotation and inspect the chain drives and belts for tension and wear. Lubricate the moving parts according to the manufacturer’s guidelines.
3. Monthly: Inspect the turntable bearings and verify the top platen's pressure settings if applicable. Clean the photo-eye sensors to ensure accurate load detection and test the emergency stop for responsiveness.

Safety Checks:

1. Emergency Stop Verification: Ensure that all emergency stops are functional. Test the e-stop and verify that it immediately halts machine movement.
2. Light Curtains and Safety Barriers: Check that light curtains and barriers around the wrapper are properly aligned and functioning. Perform a test by breaking the light curtain to confirm it stops the machine.
3. Film Tension and Brake Testing: Verify that the film tension and brake system are calibrated correctly to avoid film tearing or unstable wrapping.

Troubleshooting:

Common Issues:

1. Film Breakage: If the film breaks frequently during wrapping, inspect the film roll for damage and ensure it is loaded correctly. Adjust the pre-stretch setting if needed.
2. Inconsistent Wraps: If wraps are loose or uneven, check the film tension setting and pre-stretch ratio. Ensure the turntable speed is consistent and the film rollers are clean.
3. Turntable or Carriage Malfunctions: If the turntable or film carriage does not operate smoothly, inspect the motor and belts for wear. Check for obstructions in the film path or debris on the turntable.

Fault Codes & Reset Procedures:

1. Use the HMI to identify any error codes, such as low film tension, turntable errors, or motor overload. Follow the troubleshooting steps provided on the HMI for each code.
2. For recurring issues, perform a soft reset of the wrapper using the HMI. If the issue persists, log the error and contact maintenance for a thorough inspection.

Key Takeaways:

• Regular Maintenance: Consistent inspections and preventive maintenance are crucial to avoid system downtime.
• Safety Protocols: Always prioritize safety and follow the LOTO procedure, wear appropriate PPE, and know emergency protocols.
• System Monitoring: Stay vigilant for system alerts and take action immediately if anything seems out of order.
• Training: Ensure you are properly trained before operating or servicing any part of the Mujin system.

By following these best practices and maintaining a proactive approach to safety and system maintenance, you'll help ensure the efficient and safe operation of the Mujin automation system.