The purpose of this manual is to describe the workload and frequency of regular inspections, hygiene, and care for your Mujin System. Mujin is here every step of the way to ensure success and maximized return through various training and maintenance programs. For more information regarding training classes or maintenance support programs contact; [email protected].

Below topics will discuss the various tasks associated with inspection and hygiene for each major mechanical component. These tasks are vital to efficient and reliable fictionality. A clean machine is an efficient machine, and a clean work cell is a safe work cell.

Introduction

Purpose and Overview

Objective: Clarify that the manual serves as a complete guide for safe, efficient operation and maintenance, designed to ensure that all users are well-informed on the operational and safety requirements. Reinforce the focus on minimizing operational risks and preventing accidents.
Audience: Emphasize that this document is for operators, maintenance technicians, and supervisors who are responsible for day-to-day operations, emergency response, and troubleshooting tasks. Highlight the importance of prior training in equipment-specific safety procedures and general robotics knowledge, as recommended by the maintenance manual example.

Scope of Equipment [HG5] [DH6] Covered

Define the core systems covered in this manual, with each section further explored in detail to align with the maintenance manual’s depth:

CP500L Robot:

Description: Industrial robot arm with high-speed, precision movements designed for palletizing and other heavy-load tasks.

Key Features: Four degrees of freedom, a payload capacity of up to 500 kg, repeatability within ±0.5 mm, and built-in pneumatic valve harness for EOAT (end-of-arm tooling).

AMR (Autonomous Mobile Robot) M150:

Description: An automated mobile robot with QR-code-based navigation for material transportation within structured environments.

Key Features: Rated load capacity of up to 1500 kg, LIDAR and other safety sensors for obstacle detection, and automatic battery management.

Pallet Stacker (e.g., Qimarox PD1):

Description: Pallet stacking/dispenser unit that provides stable stacking and de-stacking within automated workflows.

Key Features: Adjustable forks, load stabilization, and capability for handling specific pallet sizes in alignment with automated workflows.

Stretch Wrapper WRTA200:

Description: A high-efficiency pallet wrapping machine with PLC-controlled pre-stretch and film-cutting mechanisms.

Key Features: Supports up to 4000 lbs of load, adjustable film tension with a maximum pre-stretch ratio of 250%, and multiple emergency stop points.

Pallet Labeler FoxIV:

Automatically applies labels to wrapped pallets for easy identification and tracking.

Integrated with the HMI and inventory management systems, ensuring label accuracy and reducing manual labeling errors.

Overview of Key System Features

List essential features of each system to provide users a preliminary understanding:

Safety Features: Highlight comprehensive emergency stop locations, interlocks, protective fencing, LIDAR-based safety zones, and Lockout-Tagout (LOTO) procedures per system.
User Interfaces: Briefly introduce the HMI controls for each system, noting specific interfaces like the GTP (Goods-To-Person) and WES (Warehouse Execution System) for broader task management. Ensure this section clarifies which interface handles which part of the operation.
Maintenance Tools and Diagnostics: Introduce built-in diagnostic tools available through the HMI and mention routine and emergency maintenance provisions, such as visual alerts, alarms, and manual override controls.

System Users

The personnel can be classified as follows.

Operator:

Turns the robot controller power on/off.

Starts the robot program from operator panel.

Trained maintenance worker:

Operates the System.

Services the System from inside the safety fence

Performs maintenance (repair, adjustment, replacement)

*Operators are not allowed to service the system from within the safety fence.

**Trained maintenance worker is allowed to work in the safety

fence. Works carried out in the safety fence include transportation, installation, teaching,

adjustment, and maintenance.

***To perform functions inside the safety fence, the person must be trained in proper system operation.

The following table lists the work outside the safety fence. In this table, the symbol “” means the work allowed to be carried out by the worker.

Task	Operator	Trained Maintenance
Turn Power ON/OFF to System	x	x
Select Robot Operation Mode		x
Reset Alarms	x	x
Reset Safety Functions	x	x
Start / Stop System	x	x
Emergency Stop System	x	x
Service System according to Operation Manual	x	x
Maintain System according to Maintenance Manual		x

Intended Use and Operating Environment

Approved Applications:

Clearly describe that each system component is purpose-built for repetitive material handling, pallet stacking, and transportation tasks, commonly in warehouses and industrial production lines.

Operational Constraints:

Define environmental restrictions, specifying safe operation temperatures (e.g., 0°C to 45°C), dust-free and dry conditions, and avoidance of corrosive substances that might damage equipment. These details ensure operational alignment with recommended maintenance conditions in the example document.

Prohibited Uses:

Reinforce prohibited applications, including:

Transporting personnel or performing tasks outside of the equipment’s load and design capacity.
Operating outside of prescribed conditions, including unapproved tools or payloads, or in extreme temperatures or high-dust environments.

Safety Precautions

This chapter must be read before using the System.

For detailed functions of the System operation, read the relevant operator's manual to understand fully its specification.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral equipment installed in a work cell.

For safe use of Mujin Systems, you must read and follow the instructions in the “Operations Manual” provided with your system.

Safety Information

General Safety Guidelines

Introduction to Safety Standards: Begin with a section explaining that strict adherence to safety guidelines is critical to prevent injury, system malfunctions, and costly downtime.
Safety Notations: Define and clarify important safety terms:
- WARNING: Situations that pose a serious risk of injury or death if not followed.
- CAUTION: Instructions to prevent potential damage to equipment or non-life-threatening injuries.
- NOTE: Additional helpful information for best practices.
Hazard Symbol Guide: Include a visual guide to the symbols used in the manual (such as “Electrical Hazard,” “Pinch Point,” “High Voltage”) to enhance understanding of specific dangers, as aligned with the safety standards in the maintenance manual.

Personnel Responsibilities and Authorized Tasks

Role Classifications: Detail the three key roles (Operator, Maintenance Technician, and Supervisor/Safety Officer), including their specific tasks and access permissions, which could be represented in a table format for clarity. This classification should be as follows:

Operator: Trained to turn the system on and off, initiate programmed tasks, and stop the system in emergencies.
Maintenance Technician: Authorized to perform system maintenance, troubleshooting, repairs, and adjustments, following LOTO and other advanced safety protocols.
Supervisor/Safety Officer: Responsible for enforcing safety compliance, overseeing operator training, and conducting routine safety audits.

Task and Access Table: Create a matrix, as seen in the maintenance manual, indicating permitted actions for each role (e.g., power on/off, LOTO, system reset, troubleshooting, etc.).

Lockout-Tagout (LOTO) Procedure

Purpose of LOTO: State that LOTO procedures are essential to prevent accidental power-up or hazardous energy release during maintenance.

Lockout-Tagout Best Practices

Lockout-tagout (LOTO) is an essential safety measure that must be followed when servicing or maintaining the Mujin system. LOTO is the process of disconnecting and isolating equipment from its energy source to prevent unexpected start-up or release of energy that could cause harm to personnel.

Before servicing or maintaining the system, the operator must ensure that the equipment is de-energized and cannot be restarted until the maintenance or servicing work is completed. LOTO procedures require locks and tags to prevent the equipment from being accidentally energized or re-energized during maintenance or servicing work.

A close-up of a lock on a box

Description automatically generated

Figure 35: LOTO for Power Disconnect

Close-up of a machine with a pressure gauge

Description automatically generated

Figure 36: Pressure relief valve

The LOTO process for the Mujin system involves the following steps:

Notify affected personnel: Inform all relevant personnel that maintenance or servicing work is about to take place.
Shut down the equipment: Follow the shutdown procedure outlined in the manual to cease equipment operation.
Door interlock lockout: After entering the system through the door, keep the door interlock key on you.
Disconnect the power sources: Ensure all energy sources are isolated.
There are multiple electrical power disconnects located in the system:
1. Robot cell: Each robot cell will have a main power disconnect located next to the panel.
2. Primary control panel: There will be a disconnect next to it.
3. Each PDP in the robot cell has a quick disconnect.
4. Each blower panel in the robot cell has a quick disconnect.
5. Pallet Stacker: The pallet stacker is powered through the power disconnect located near the pallet stacker.
6. AMR chargers: Each AMR charger is powered by a power disconnect located near it.

There are three pressure relief valves installed in each robot cell next to the blower.

Lock and tag: Lock and tag the equipment to prevent it from being accidentally energized or re-energized during maintenance or servicing work.
Test the equipment: Confirm the equipment is de-energized and cannot be restarted until the maintenance or servicing work is completed.
Conduct the maintenance or servicing work: Proceed with the required tasks safely.
Remove the locks and tags: Once maintenance or servicing work is complete, the operator can remove the locks and tags, then restore power to the equipment.

Safety Notations

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is indicated by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before using the robot. Warning labels play a critical role in communicating potential hazards associated with operating the robot cell and outlining necessary safety precautions. These labels are strategically placed throughout the system to ensure clear visibility and to serve as a constant reminder to operators and maintenance personnel of potential risks. It is crucial that all personnel working with or around the system familiarize themselves with the warning labels and adhere to the safety precautions they recommend. Regularly inspect the labels for any signs of wear, damage, or fading that may impact its legibility. If a label is damaged or missing, promptly report the issue and replace the label to ensure continuous safety awareness. Some of the warning labels around the system have been mentioned below:

Description	Labels
Robotic Area: Danger sign to protect and caution operators from entering the cell.
Not an Entrance: Sign to notify operators not to enter through the opening.
Compressed air: Warning sign to caution operators to bleed off air before servicing.
Falling material: Danger sign to warn operators of falling material from the pallets.
Stay clear of [LG7] moving conveyors: Sign to caution operators to stay clear of running conveyors. Follow LOTO procedure before servicing or repairs.
Pinch point warning: Alerts operators to areas where moving parts may cause crushing or pinching injuries if hands or fingers are caught between them.
Rotating machinery: Danger sign located around the cell to caution operators of AMR’s rotating.
High voltage warning: Indicates that a specific area or component of the robot cell contains electrical hazards that may cause electric shock or electrocution if not responsibly managed.
LOTO: Signs located near every device where LOTO procedure is required.

In addition to understanding and adhering to the information on warning labels, all personnel should follow the general and robot cell-specific safety guidelines provided in this manual to ensure a safe and efficient working environment.

Revision

Revision	Date	Name	Comments
V1.0	07/15/2024	Hitesh Gokaraju	Initial Release
V2.0	11/20/2024	Don Harmon	Pre-warranty release
V3.0	11/25/2024	Jonathan Abernethy	Project release

References

Operation Manual (230118_V1).

[MM8] [DH9]

Glossary of Terms

AMR	Autonomous Mobile Robot
Cell	Subsystem/component
Container	Pallet, conveyor, etc.
DC	Destination container
Destination	Place container for robot
E-stop	Emergency Stop
HMI	Human Machine Interface
IBOB	Inbound-Outbound Station
LED	Light Emitting Diode
LOTO	Lockout-Tagout
MHE	Material Handling Equipment
PCP	Primary Control Panel
PDP	Power Distribution Panel
RCP	Robot Control Panel
SC	Source container
SKU	Stock Keeping Unit
Source	Picking container for robot

Contact Information

Mujin Phone: 1.888.501.MUJN (6856)

Email: [email protected]

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: 7250 McGinnis Ferry Rd, Suwanee GA 30024

Mujin Asia

Phone: +81.3.4577.7638

Email: [email protected]

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: 3-8-5 Tatsumi, Koto-Ku, Tokyo 135-0053 Japan

Mujin EU

Phone: +31.970.102.05814

Email: [email protected]

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: Mujin Netherlands B.V. Achtseweg Zuid 241B 5651 GW Eindhoven NL

General Use and Installation

System Overview

CP500L Robot

Description: The CP500L is a high-performance articulated robot, optimized for heavy-duty palletizing and repetitive material handling applications.

Specifications:

Model: CP500L-A
Payload Capacity: 500 kg, supporting high load demands typical in industrial workflows.
Reach: Effective working radius of 3255 mm, enabling large-area coverage in a compact space.
Degrees of Freedom: Four (JT1 - JT4), providing flexible movement across multiple axes for precise item placement.
Position Repeatability: ±0.5 mm, ensuring consistency and accuracy in repetitive tasks.
Mass: 1650 kg

Operating Speeds:

Base (JT1): Capable of rotating at high speeds to position the arm efficiently across the workspace.
Wrist (JT4): Can rotate up to 180° per second for rapid adjustments, facilitating high-speed palletizing.
Built-In Utilities: Equipped with a pneumatic valve harness for operating end-of-arm tooling (EOAT) using air supply, essential for tasks like gripping and manipulating items.

Intended Use:

Material Handling and Palletizing: The robot is specifically designed for systematic, high-speed palletizing of items onto pallets or conveyors in industrial settings.
High-Speed, Repetitive Tasks: Built for applications requiring consistent movements, such as loading, unloading, and arranging products.

Prohibited Uses:

Human Transport or Interaction: Not designed for lifting or transporting humans.
Extreme Environments: Avoid usage in environments with temperatures below 0°C or above 45°C, as these extremes can degrade component performance.
Unauthorized Tooling: Avoid attaching unapproved tools or exceeding the 500 kg payload limit to prevent mechanical failures.

Safety Features:

Emergency Stop Buttons: Located around the robot cell for immediate shutdown if unsafe conditions arise.
Safety Fencing and Interlocks: Protective barriers surrounding the work area prevent entry during active operations, ensuring operator safety.
Pinch Point Warnings: Labels are strategically placed around jointed areas where accidental hand placement could lead to injury.
Protective Enclosures for Moving Parts: Reduces risks associated with high-speed movements.

Autonomous Mobile Robot (AMR) M150

Description: The M150 AMR is an autonomous vehicle designed for intra-facility material handling, transporting goods along predefined paths using advanced navigation and obstacle detection.

Specifications:

Dimensions: 1182 mm (L) x 832 mm (W) x 260 mm (H)
Weight: Approximately 225 kg
Load Capacity: Rated for up to 1500 kg, ideal for handling pallets and large loads.
Navigation Method: Utilizes inertial navigation with QR code-based positioning for precise route-following within controlled environments.
Battery Life: Capable of up to 9 hours of continuous operation; recharge time is about 1.5 hours.

Intended Use:

Automated Material Transport: Moves goods between locations within the facility without manual intervention, reducing transit time and labor requirements.
Warehouse and Production Facility Integration: Operates within designated pathways and predefined zones.

Prohibited Uses:

Transport of Personnel: Strictly intended for goods only.
Hazardous or Unstable Environments: Should not operate in areas with extreme dust, oil, or moisture, which can interfere with sensors and cause mechanical or electronic malfunctions.

Safety Features:

LIDAR-Based Obstacle Detection: Real-time obstacle avoidance within a 500 mm detection range, slowing or stopping the AMR when objects are detected in its path.
Emergency Stop Buttons: Placed on both sides of the AMR, allowing operators or nearby personnel to stop the robot in emergencies.
Battery Overload and Temperature Monitoring: Prevents overheating or overload by halting operations when unsafe battery conditions are detected.

Pallet Stacker (e.g., Qimarox PD1)

Description: The Qimarox PD1 pallet stacker automates the stacking and de-stacking of pallets within a conveyor system, streamlining material handling by preparing pallets for AMR transport or direct use.

Specifications:

Model: Qimarox PD1
Load Capacity: Optimized for standard pallet weights, adjustable for handling various pallet types.
Fork and Lifting Arm Adjustments: Configurable to fit pallet sizes, ensuring stability during stacking and minimizing the risk of tipping.
Cycle Speed: High-speed stacking for maintaining workflow efficiency in demanding environments.

Intended Use:

Pallet Handling: Stacks and dispenses pallets in synchronization with conveyor systems, supporting uninterrupted automated flow within the facility.

Prohibited Uses:

Oversized or Overloaded Pallets: Should not be used with pallets that exceed the standard size or weight specifications, as this could cause jamming or structural strain.
Human Interaction During Operation: Personnel should not handle pallets manually while the stacker is operating.

Safety Features:

Interlocks and Safety Sensors: Ensure operations pause if the stacker detects an anomaly, preventing unsafe situations.
Emergency Stop: Immediately halts operations if an unsafe condition is detected, minimizing risks associated with malfunctions.
Protective Enclosures for Forks and Arms: Reduces potential injury risk by restricting access to moving parts.

Stretch Wrapper WRTA200

Description: The WRTA200 is a high-speed, automated stretch wrapper designed to secure palletized loads by applying stretch film. Ideal for warehouses and distribution centers, it offers programmable wrapping patterns for diverse load types.
Specifications:
- Model: WRTA200
- Maximum Load Size: Can wrap loads up to 2.4 meters (94.5 inches) in height and 1.2 meters (47.2 inches) in width.
- Maximum Load Weight: Rated for up to 4000 lbs, accommodating standard pallets.
- Pre-Stretch Ratio: Adjustable pre-stretch up to 250%, reducing film usage and ensuring load stability.
- Power Requirements: 120V/1ph/60Hz, 15A
- Pneumatic Requirements: Operates with air pressure of 80-100 psi, optimizing film application and cut-off.
Intended Use:
- Pallet Wrapping for Load Security: Automates wrapping of stable, balanced pallet loads, ensuring each load is securely wrapped and ready for transport or storage.
- High-Volume Operations: Suitable for facilities with large volumes of palletized goods needing consistent wrapping.
Prohibited Uses:
- Unstable or Protruding Loads: Loads must be stable and within the dimensions outlined to avoid jamming or damage to the rotary arm and film carriage.
- Removal of Protective Guards: Operating without guards can pose serious risks and should be strictly avoided.
Safety Features:
- Emergency Stop (EMO): Emergency buttons are located strategically, allowing immediate cessation of operations if an issue arises.
- Safety Fencing: Protective fencing surrounds the rotary arm area to prevent unauthorized access while the machine is operational.
- Cut and Wipe System: Automates film cutting at the end of the wrapping cycle, reducing manual handling and associated risks.
- HMI Control Panel: Allows operators to adjust settings safely, reducing direct interaction with moving parts.

Pallet Labeler (Fox IV M6955)

Description: The Fox IV M6955 Pallet Labeler is an industrial-grade automated labeling system, ideal for high-volume and continuous operations.
Specifications:
- Model: Fox IV M6955
- Power Requirements: 90–264V AC with power-factor correction.
- Operating Temperature: 40°F to 104°F (5°C to 40°C).
- Air Supply: 80–100 psi, clean and dry.
- Label Roll Size: Maximum diameter of 16 inches with core sizes of 3", 5", or 6".
Intended Uses:
- Prints labels with barcodes, text, or graphics and applies them directly to products, cartons, or pallets.
- High Volume Operations: suitable for high-throughput environments like warehouses, manufacturing plants, and distribution centers.
- Seamless Integration: Integrates with warehouse management systems (WMS) and production lines for automated, synchronized operations.
Prohibited Uses:
- Using Non-Compatible Labels or Media: Avoid using labels, ribbons, or media that do not meet the manufacturer’s specifications (e.g., incorrect size, material, or adhesive type). Non-compliant media can cause jams, print quality issues, or damage the print engine.
- Operating Outside Environmental Conditions
- Overloading the Label Roll: Do not exceed the maximum label roll size (16” OD with a core size of 3”, 5”, or 6”).
- Using Improper Air Supply
- Applying Labels to Non-Stationary Objects
Safety Features:
- Emergency Stop (EMO): Emergency buttons are located strategically, allowing immediate cessation of operations if an issue arises.
- Safety Fencing: Protective fencing surrounds the Labeler and the Wrapper.
- Overload Protection: The system includes sensors and software controls to monitor labeler functions and prevent overloading or mechanical strain on the components.

Diagrams and Visual Aids

Component Layouts: Provide detailed, labeled diagrams of each component within the operational area, emphasizing E-stop locations, safety interlocks, and safety zones for each component.

Operational Zones: Illustrate safe operating zones and no-go areas, ensuring operators are aware of areas that should remain clear during operation.[MK10] [DH11]

Installation and Setup Procedures

Pre-Installation Site Requirements

Environmental Conditions:

Temperature Range: Ensure that the installation environment maintains a temperature between 0°C and 45°C. Excessive heat or cold can impact the robot arm’s sensors, motor function, and AMR battery life.
Humidity Control: Recommended humidity should not exceed 80% to prevent moisture buildup, which could interfere with electrical components and sensors.
Dust and Debris: The area should be kept as dust-free as possible. Use air filtration systems if necessary, especially in facilities prone to dust, to protect sensors and electronic components from contamination.

Floor and Surface Preparation:

Floor Flatness and Leveling: The floor should be level within ±5°. Use a leveling tool to verify flatness before positioning equipment. For the CP500L robot, a stable, vibration-free surface is essential to prevent misalignment during high-speed movements.
Load-Bearing Capacity: Ensure the floor is capable of supporting the weight of the equipment, particularly the CP500L robot (1650 kg) and pallet stacker, which may exert additional pressure when fully loaded.

Power and Air Supply Readiness:

Voltage and Circuit Requirements:
- CP500L Robot: Requires 480V, dedicated circuit.
- AMR Charger and Pallet Stacker: Confirm voltage compatibility with facility standards, typically 120V or 240V.
Compressed Air:
- Air Pressure: Systems such as the stretch wrapper and pneumatic tools require a consistent 80-100 psi air supply.
- Air Quality: Use filtered, moisture-free air to prevent contamination of pneumatic systems and maintain consistent pressure for tools.

Required Tools and Equipment

Installation Tools:

Torque Wrench (minimum range: 20-100 Nm) for securing bolts on heavy components like the robotic base and stacker.
Leveling Tools to confirm proper positioning and stability for all components, especially the robot base and conveyor systems.
Alignment Fixtures as needed for EOAT positioning on robotic arms, ensuring accuracy in end-effector placement.
Multimeter for verifying electrical connections and ensuring proper voltage and grounding across components.

Personal Protective Equipment (PPE):

Safety Gloves: To handle potentially sharp or heavy components during unboxing and installation.
Safety Goggles: Required during installation to protect eyes from dust or debris.
Steel-Toe Boots: Recommended due to the risk of heavy equipment components during installation.
Hearing Protection: For use during tests that may involve high-noise equipment.

Step-by-Step Installation Instructions

Step 1: Unboxing and Inspection

Carefully unbox each component and inspect for any visible damage. Ensure that all listed parts in the inventory checklist are present before proceeding with installation.

Step 2: Positioning the Equipment

CP500L Robot Base: Place the robot on the designated floor area. Use a leveling tool to ensure the base is stable, flat, and free from tilting.
AMR Charging Dock: Position the dock along a clear path for AMR access. Ensure that power cables are routed safely to avoid obstructions or tripping hazards.
Pallet Stacker and Stretch Wrapper: Position these components adjacent to conveyor entry/exit points. Ensure there is adequate space for pallet stacking, handling, and wrapping.

Step 3: Securing and Mounting

Robot Arm: Secure the robot base with high-tension bolts into the floor (follow floor anchor specifications if required). Confirm bolt torque settings with a torque wrench to prevent shifting during operation.
Pallet Stacker: Anchor the stacker to prevent movement during stacking and de-stacking. Ensure all safety interlocks are connected to the stacker controls to prevent operation if access doors are open.

Step 4: Electrical Connections

Connect each system to its designated power source. Verify:
- Grounding: All equipment must be grounded to prevent electrical shock hazards. Check grounding continuity with a multimeter.
- Voltage Compatibility: Ensure voltage levels match the specifications for each component (e.g., 480V for CP500L, 120V for stretch wrapper).
- Circuit Protection: Use dedicated breakers where necessary to prevent overloads, and verify connections are secure and insulated.

Step 5: Pneumatic Connections (for Systems Requiring Compressed Air)

Connect compressed air lines to the stretch wrapper and EOAT on the CP500L robot.
Verify air pressure meets the standard 80-100 psi range and ensure the air is filtered and moisture-free to prevent internal component wear or malfunction.

System Calibration and Initial Testing

Calibration of Robotic Arm (CP500L)

Initial Alignment: Power on the robot and set it to “Home” position. Ensure the EOAT is aligned properly.
Axis Calibration: Perform calibration for each axis (JT1 - JT4), checking movement accuracy and ensuring repeatability within ±0.5 mm. Use the robot’s pendant or HMI to monitor and verify calibration accuracy.
Tool Calibration: For EOAT, ensure vacuum and gripping functions are operating at correct pressure levels, confirming the pneumatic supply is consistent.

AMR Navigation Setup (M150)

QR Code Setup: Place QR codes or navigation markers along the AMR path as per layout guidelines. These markers are essential for accurate route-following.
Obstacle Detection Test: Run the AMR on a test path, checking that LIDAR sensors correctly detect and avoid obstacles within the 500 mm range.
Charging Dock Test: Ensure the AMR autonomously docks to the charger, and verify that the charging light indicators are functioning properly.

Pallet Stacker and Stretch Wrapper Testing

Pallet Stacker Test: Run a stacking/de-stacking cycle with empty pallets to ensure smooth operation. Adjust fork positioning for pallet size as needed.
Stretch Wrapper Cycle: Run a test wrap cycle, adjusting the film pre-stretch ratio and wrap settings as required. Verify that the cut and wipe system properly secures the film at the end of the wrap cycle.

Installation Verification Checklist

Power Connections: Confirm all connections are secure, voltage levels are correct, and grounding is intact.
Calibration Completion: Ensure all calibrations (robot axis, AMR navigation, stacker alignment) are finalized and verified for accuracy.
Safety Feature Verification:
- E-Stop Functionality: Test each emergency stop button to ensure immediate power cut-off.
- Interlocks and Fencing: Verify that safety interlocks on doors and protective fencing are functional, preventing operation when doors are open or fencing is breached.

Operational Readiness: Conduct a final test run of each component to ensure that it functions as expected within safe operating parameters.

System Start-Up Shutdown Procedures

System Start-Up

Pre-Operation Safety Checks:

Emergency Stop (E-Stop) Verification: Check all E-stop buttons on the Mujin controller, robot, AMR, pallet stacker, and stretch wrapper.
Interlocks and Fencing: Confirm interlocks engage securely and prevent access during operation.
Alarm Check: Clear any active alarms on the HMI or control panel before proceeding.

Power-On Sequence:

Activate Power Supply:
- Mujin Controller and Connected Devices: Begin by turning on all devices connected to the Mujin controller, followed by the primary power supply.
- AMR Docking Station: There are a total of seven chargers in the system. The AMR’s will either be docker to the charger or under the frames. Verify that the AMR’s are not complaining and have a solid green lights.
- Pallet Stacker and Stretch Wrapper: Power these systems to initialize.
- CP500L Robot Controller: Power on, setting the robot to its “Home” position.

System Initialization Check:

HMI System Check: Use the HMI for a complete system check, confirming operational status for the robot, AMR, and pallet stacker, and checking sensors and interlocks.
Daily Start-Up Log: Record system status for future troubleshooting and maintenance.

System Shutdown

Cease Active Tasks:

Pause Operations: Complete or safely terminate tasks via the HMI or control panel.
Power Down Sequence:
- Robot Arm: Return the robot to its “Home” position and power off.
- Pallet Stacker and Stretch Wrapper: Stop and power down these systems.
- AMR: Ensure it docks and powers down safely.

Secure and Inspect System:

Inspection: Look for wear, loose bolts, or signs of damage.
Shutdown Log: Document observations and any issues encountered.
Lock Out System (LOTO): Engage LOTO procedures if maintenance is scheduled.

Routine[LG12] Operation and Task Execution

Robotic Arm (CP500L) Operation

Task Initiation:

Select Program: Use the HMI to start the correct palletizing program.
Secure EOAT: Confirm the EOAT (End-of-Arm Tool) is attached and aligned.

Monitoring and Pausing Tasks:

Stay outside the movement range during operation, and use the HMI to pause if needed.
Deadman Switch: Hold the switch with moderate force during manual adjustments; releasing or pressing hard stops the robot.

Autonomous Mobile Robot (AMR) M150

Loading and Unloading:

Position in designated areas and ensure load stability.

Pathway and Battery Monitoring:

Clear pathways for optimal AMR efficiency, and monitor battery levels on the HMI.

Pallet Stacker (Qimarox PD1)

Loading and Monitoring:

Load pallets within weight limits and monitor stacking for misalignment. Use E-stop if necessary.

Stretch Wrapper WRTA200

Film Setup and Wrapping Cycle:

Load stretch film and select the desired wrapping mode on the HMI. Ensure consistent application by adjusting tension if needed.

Emergency Procedures and Safety Protocols

Emergency Stop (E-Stop) Usage

E-Stop Activation: Press in the event of unsafe conditions.
Post-E-Stop:
- Release by turning the E-stop button clockwise. Verify clear conditions before resuming operations.

Handling Power Failures

Immediate Response: Stabilize equipment and prepare for restart.
Safe Restart: Follow start-up procedures to prevent data loss and ensure system readiness.

Alarm and Error Code Resolution

Common Error Codes:

FinishedNoMoreTargetsNotEmpty: No valid picking target. Manually pick or adjust part placement.
FinishedRobotExecutionError: Robot stopped unexpectedly; check mode and ensure it’s set to Auto.

Safety Reminders During Operation

Safe Operating Zones and PPE

Maintain a minimum clearance of 500 mm around operational zones.
Wear PPE, including high-visibility vests near AMR pathways and ear protection near the stretch wrapper.

Regular Equipment Checks

Periodic Inspections:

Check for wear, loose connections, and ensure film tension on the stretch wrapper. Report issues promptly.

Mujin Controller Operation

Turning on the Mujin Controller

Procedure:

Turn on all peripherals and devices connected to the Mujin controller.
Turn on the Mujin controller’s primary power supply. The power button will light up blue, and the main screen will appear on the Mujin pendant once the controller boots up.
Note: The Mujin controller typically starts up automatically when power is supplied.

Turning off the Mujin Controller

Shutdown from Menu (Recommended):

Press the Mujin icon at the top left of the main screen.
Select the power button at the bottom left, then press "Shut Down."
Wait for the power button to turn orange, indicating shutdown completion.
Turn off all connected devices and switch off the primary power supply.

Shutdown via Power Button:

Alternatively, press the power button to shut down. The button will turn orange upon completion.

Emergency Power-Off (not recommended):

For immediate shutdown, press and hold the power button. This can lead to data loss.

Operating the Mujin Pendant

Holding the Pendant:
- Hold with both hands and press the Deadman Switch (DSW) on the back with moderate force.
Deadman Switch:
- Located on the left side of the pendant, the switch is three-positioned:
  - Not Pressed (off)
  - Pressed with Moderate Force (on)
  - Pressed Hard (off)

Mujin Controller Modes

Auto Mode:

Automatically processes orders, using the speed set on the Speed screen.
Note: No additional speed limits are applied.

Manual (MAN) Mode:

For setup and jogging at low speeds. A 15% speed limit applies, with further adjustments on the Speed screen.
Deadman Switch Required.

Check Mode:

For verifying order processing. Operates without extra speed limits but requires the Deadman Switch to be engaged.

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Changing Robot Speed

Procedure:

Press the Speed button in the top right corner of the Mujin pendant screen.
Adjust speed using the “-” and “+” buttons, then confirm by pressing [OK].

Emergency Stop

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To Stop:

Press the Emergency Stop button on the Mujin pendant.

To Release:

Turn the Emergency Stop button clockwise until it releases.

Moving to Home Position

Press the Home button on the Mujin pendant’s main or jog screen to return the robot to its home position.

Jogging the Robot

Preparation:

Set the pendant to MAN mode, then activate the Deadman Switch.

Jogging Modes:

Modes: J (joint axes), R (robot base), T (tool), W (world).
Note: Always jog at a safe speed and watch for obstacles.

Opening and Closing the Gripper (or Suction)

Procedure:

In MAN mode, use the Robot Control Button to open/close the gripper or control suction as needed.

Vision Calibration

Procedure:

Enter MAN mode, then go to Sensors > Calibration on the main screen.
Click on the Mujin Log on the top left corner of the page.

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Description automatically generated Click on Camera Calibration on the Home Page.

For multiple cameras, select the correct camera and proceed with calibration.

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Hit Play at the bottom of the screen to start calibrating the camera.

Apply Automatic Calibration ResultsÁ

ProcedureÁ

After finishing the vision calibration, press Result on the sensor screen.

The results of the camera calibration will be displayed on the screen (the “Sensor: Result” screen).

The “Intrinsic, Extrinsic, Results” tab near the top of the screen and the “Previous Result, Current Result” tab near the bottom of the screen allow you to compare the results:

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In the following steps, review the contents of “Extrinsic” and “Results” displayed near the top of the screen to determine whether to apply the camera calibration results.

After pressing Extrinsic near the top of the screen, check the image displayed on the left side of the screen for the following:

The calibration pattern must be detected on the image calibration board (green and red dots are displayed).
The XYZ axis (red, green, blue) must be displayed on the image calibration board.
The RMS error displayed in the upper left corner of the captured image must be 0.5 or less.

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After pressing Result near the top of the screen, check the following:

The RMS error displayed on the scatter plot on the left side of the screen must be 0.5 or less.
The values of “Camera Position” and “Previous Camera Position” may not be significantly different. If the difference between the X, Y and Z values of the previous and current result is within 10 mm, there is no problem.

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Note

If the RMS error is greater than 0.5 and the camera position difference is greater than 10 mm, the vision calibration must be performed again. If the RMS error does not drop below 1.0, please contact Mujin.

If the results of Step 2 or Step 3 are incorrect, adjust the camera position and correct the camera exposure, and then perform automatic calibration again.

Exposure correction for the camera is performed in the “Basesystem UI’s sensor exposure” screen.

On the right side of the screen, press the “-” or “+” buttons under “Exposure” to adjust the exposure until the calibration board is clearly visible, then press “Apply”. Do this for all cameras.

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If the results of Step 2 and Step 3 are correct, press Use current result.

You will be prompted to confirm that you want to apply the vision calibration results. Press OK to apply.

Error Recovery

Typical Errors:

FinishedNoMoreTargetsNotEmpty: Recover by manually picking missed items.
FinishedTooManyPickFailures: Address collapsing loads or suction issues.
FinishedRobotExecutionError: Set the controller to Auto mode and retry.

Error Recovery Screens:

Includes prompts for device confirmation, safety verification, and manual pick options if needed.

Operating at the Goods to Person (GTP)

Overview: The Goods to Person (GTP) system is a critical operational component designed to support warehouse automation by enabling operators to perform tasks efficiently with minimal manual intervention. This section provides comprehensive instructions on how to utilize the GTP system effectively to perform routine operational tasks, ensuring maximum productivity while adhering to safety protocols. Each task is broken down into detailed steps, with emphasis on safety, accuracy, and operational efficiency. The goal is to ensure that operators, regardless of their experience level, can successfully perform all required tasks.

Step-by-Step Instructions for Common GTP Tasks:

Logging In and Out of GTP

Logging In

Accessing the Interface: Begin by approaching the Human-Machine Interface (HMI) station. The HMI is the primary touchpoint where all GTP operations can be managed. Locate the terminal labeled "GTP Login."
Entering Credentials: On the login screen, enter your assigned user ID and password. These credentials are provided during your training or by your supervisor. Once entered, press the "Login" button.

(Figure 1: Login Screen)

Confirmation: After logging in, the system will confirm your access by displaying your name at the top right corner of the screen. You will then see the main menu with available tasks and settings options. Ensure that you have successfully logged in before proceeding to any operations.

Logging Out

Accessing Logout Option: At the end of your shift or when you are no longer using the GTP system, it is important to log out to secure the system. Navigate to the settings tab at the bottom left of the screen.
Completing Logout: Click the "Logout" button. Wait for the system to confirm that you have been logged out completely. Logging out prevents unauthorized access and keeps the system secure.
Verification: Verify that the screen returns to the main login prompt before leaving the HMI unattended.

(Figure 2: Log Out)

Goods to Person Overview

Connecting the Wrist Scanner

Selecting the GTP Application: Once logged in, select the "App Goods to Person" option from the side menu. This application allows you to interact directly with warehouse operations.
Connecting the Scanner: To operate hands-free, connect the wrist-mounted scanner. Locate the QR code at the top of the landing page on the HMI. Use the scanner to scan this QR code.
Confirmation of Connection: After scanning, you will receive a message saying "Scanner Connected" in green. This indicates that your wrist scanner is ready for use. If the message is not displayed, retry scanning or consult a supervisor.

(Figure 3: Goods To Person)

Daily Operations

Daily operations involve a variety of tasks, such as pallet defoiling, manual case picking, and pallet inspection. Each task is outlined below in detailed steps to ensure complete understanding.

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(Figure 4: Current Task)

(Figure 5: Valid Barcode Scan)

(Figure 6: Invalid Barcode Scan)

Pallet Defoiling

Step 1: Go to Designated Location and Scan Frame Barcode
- Navigate to Location: On the GTP interface, the designated location (e.g., "Zone 1-1") will be displayed. Proceed to this location as indicated on the screen.
- Scanning Frame Barcode: Once at the location, locate the barcode attached to the frame or rack. Use the wrist-mounted scanner to scan the barcode. A successful scan will be indicated by a green check mark icon on the HMI. This confirms that you are at the correct location and that the system has registered the pallet.
- Troubleshooting Failed Scans: If the scanning fails, ensure that you are in the correct location as indicated. Reposition the scanner to improve the angle and distance, and attempt to rescan. If issues persist, use the "Eject" option on the HMI to have the pallet relocated by a mobile robot.

Step 2: Scan Pallet SSCC

Locate the SSCC: The SSCC (Serial Shipping Container Code) is a unique identifier for the pallet. It is typically affixed on the side of the pallet for easy visibility.
Scanning the SSCC: Use your scanner to scan the SSCC. This will confirm that the pallet matches the expected inventory in the system. Successful scanning will update the task status on the HMI.
Handling Invalid Scans: If scanning fails, double-check the SSCC label for damage or smudges that may interfere with the scan. If necessary, clean the label or manually enter the code into the HMI.

(Figure 7: Scan SSCC)

Step 3: Remove Pallet Wrapping

Preparing to Defoil: Once the SSCC is successfully scanned, the system will instruct you to remove the pallet wrapping. Use a box cutter or safety knife to carefully cut away the stretch wrap.
Safety Precautions: Always cut away from your body and use gloves to protect your hands. Dispose of the wrapping in designated waste bins to maintain a clean and safe working area.
Confirming Task Completion: Once the wrapping is removed, press the "Next" button on the HMI or use the wrist scanner trigger to indicate completion.

(Figure 8: Remove Pallet Wrapping)

Step 4: Next Task or End Shift

Proceeding to Next Task: After removing the wrapping, you can proceed to the next task. The HMI will display the upcoming task, and you can press the "Next" button to continue.
Ending Shift: If it is the end of your shift, press the "End Shift" button to log out of the system. Ensure that any ongoing tasks are either completed or reassigned to another operator.

(Figure 9: Next Task or End Shift)

Manual Case Picking

Step 1: Go to Designated Location and Scan Frame Barcode

Follow the instructions as outlined in the Pallet Defoiling section to verify the location of the pallet.

Step 2: Go to Source Location and Scan Frame Barcode

Identifying the Source Location: The GTP interface will show the source location where items are stored. Navigate to this location.
Scanning the Frame Barcode: Scan the frame barcode to confirm the source pallet. This helps ensure that you are picking from the correct inventory.

Step 3: Pick and Place

Viewing Pack Formation: The HMI will display a 2D and 3D image showing how the cases should be picked and placed. This visual guide ensures that items are picked and arranged correctly to maintain pallet stability.
Handling Heavy Items: If any items are labeled as "Heavy" on the HMI, consider using lifting tools or request assistance to avoid injury.
Sandwich Label: If multiple pallets will be stacked together, the system will show a "Sandwich" label. Place items carefully to ensure stability during transport.
Confirming Completion: After placing all cases, use the scanner or HMI to mark the task as complete.

(Figures 10-11: Pick and Place details)

Manual Wrapping and Labelling of Pallets

Manual Pallet Wrapping

Step 1: Go to Designated Location and Scan Frame Barcode

Ensure the correct pallet is identified by scanning the frame barcode at the indicated location.

Step 2: Wrap the Pallet

Wrapping Process: Use the provided stretch film to wrap the pallet. Start at the base of the pallet and work upwards, ensuring that each layer of film overlaps by at least 50%. This helps secure the load during transport.
Adjusting Tension: Maintain consistent tension on the film to prevent it from loosening or tearing. Use the HMI instructions to adjust the tension settings as required.
Confirm Completion: Press "Next" on the HMI once wrapping is completed satisfactorily.

(Figure 21: Manual Wrapping)

Manual Pallet Labelling

Step 1: Print and Apply Label

Printing Labels: Use the label printer connected to the system to print the required number of labels. Verify that the labels contain correct information, such as the pallet ID and destination.
Affixing the Labels: Affix the labels securely to the specified areas on the pallet. Ensure that labels are positioned for easy scanning and visibility.
Confirm Task Completion: Use the scanner or HMI to confirm that labeling has been completed.

(Figure 22: Manual Labelling)

Initiating New Tasks via GTP

Summon Pallet

Step 1: Choose Method to Summon Pallet

SKU, Pallet ID, or Frame ID: The system allows you to summon a pallet by selecting from available methods such as SKU, Pallet ID, or Frame ID. Choose the appropriate method based on your task requirements.
(Reference to Figures 23-25: Summon Pallet details)

Step 2: Choose Pallet to Summon

Selection: Use the HMI to locate and select the specific pallet you want to summon. The system will confirm your selection and begin the summoning process.
Monitor Status: Keep an eye on the "Summon Status" page to track the progress. The pallet will be delivered to the GTP area by a mobile robot.

Request Slip Sheet Bin

Step 1: Choose Slip Sheet Bin from List

Selecting a Bin: Access the list of available slip sheet bins from the HMI. Select the one that needs to be emptied.
Confirming Request: Submit the request, and the mobile robot will automatically bring the bin to the GTP area for processing.

(Figures 26-27: Request Slip Sheet Bin)

GTP Settings

Modifying GTP Settings

Accessing Settings: To modify settings, navigate to the "GTP Settings" page on the HMI. This section allows you to adjust parameters such as the weight threshold for heavy items.
Changing Display Options: You can also select which GTP zones utilize the HMI screens. Make sure to save any changes before exiting the settings page.

(Figure 28: GTP Settings)

Safety Considerations:

General Safety: Operators should always be aware of their surroundings, especially when mobile robots are operating nearby. Stay clear of paths designated for robot movement.
Emergency Procedures: Each station is equipped with an emergency stop (E-Stop) button. Press this button in case of any unsafe conditions. Familiarize yourself with the locations of all E-Stop buttons.
Proper PPE Usage: Ensure proper personal protective equipment (PPE) is worn at all times, including gloves, safety shoes, and a high-visibility vest, to minimize the risk of injury during operations.

Operating the Mujin Warehouse Execution System (WES)

Overview: The Mujin Warehouse Execution System (WES) is an integral tool for efficiently managing warehouse activities. It acts as a bridge between the Warehouse Management System (WMS) and physical operations on the warehouse floor, ensuring that every task is executed with precision. This section provides a step-by-step guide on how to operate the WES effectively, covering everything from logging in to managing alarms, monitoring devices, and overseeing the complete order lifecycle.

Step-by-Step Instructions for Using the WES:

(Figure 1: System Dashboard)

Mujin Web User Interface

Interface Layout

Global Header: The global header at the top of the interface displays essential information, such as emergency stop (E-stop) statuses, door status, manual mode, and other key system states. These indicators are designed to provide users with immediate situational awareness, ensuring safety and efficiency in the warehouse environment.
Global Navigation Bar: On the left side of the screen, users will find the Global Navigation Bar. This panel allows navigation between different applications within the WES. These applications include options for managing alarms, device statuses, inventory, and metrics. Familiarizing yourself with the navigation bar is critical to efficiently accessing various functionalities.

(Figure 2: Interface Layout)

User Management

Access Control: Only users with administrative privileges can access the user management controls. Admins are responsible for managing groups, adding or removing users, and configuring application permissions.
How to Access User Controls: To manage users,

click on the username at the bottom left of the navigation bar. From there,

(Figure 3: Account)

click the "Open User Access Control" link at the top right of the page. This action will direct you to a detailed page for managing user groups and individual permissions.

(Figure 4: Open User Access Control)

Managing Groups and Users: Admin users can create new groups, add users to specific groups, or change user privileges.

(Figure 5: Group List)

Users should be assigned to groups that correspond to their role within the warehouse to ensure they have access to the appropriate WES functionalities.

Editing User Details: Admin users can also edit account information, such as passwords, and promote or demote user roles within the interface.

(Figure 6: User List)

You can assign any available users to groups and configure their application access permissions.

Figure 7: Group Detail

In the user list, admin users can edit account passwords, delete accounts, or promote users to admin.

(Figure 8: User Detail)

Logging In and Out

Logging In

Step 1: Navigating to Login Page:

To begin, approach a Mujin HMI terminal or a designated workstation with WES access. On the login screen, enter your assigned credentials, which typically consist of a username and password provided by your supervisor.

Step 2: Authentication:

After entering your credentials, click on the "Login" button. The system will validate your credentials. If successful, the main dashboard will be displayed, showing available tasks and system statuses.

Step 3: Initial Overview:

Once logged in, familiarize yourself with the interface. The dashboard provides an overview of system alerts, order processing status, and other essential real-time information.

Figure 9: Login

Logging Out

Step 1: Accessing the Account Page: When logging out, click your username located at the bottom left corner of the navigation bar. This will open the account information page.
Step 2: Confirming Logout: Click the "Logout" button to safely exit the system. Make sure to confirm that the logout is complete by verifying that the screen returns to the login prompt. This ensures that no unauthorized person gains access to the WES.

(Figure 10: Log Out)

Alarms and Notifications

Understanding the Alarm System

Alarm Icon: The alarm system is critical for the safety and efficiency of warehouse operations. The "Alarm Icon" is located on the global header. When an alarm occurs, it will flash red to alert operators to take immediate action.

(Figure 11: Alarm Icon)

Accessing Alarm Details: Click on the alarm icon to open the "Alarm Modal." The modal provides detailed information about ongoing and past alarms. By default, active alarms are displayed, but users can switch to view all alarms, including those that have been resolved.

(Figure 12: Alarm Modal)

Filtering Alarms: Use the filtering options to sort alarms by status, date, or type. This helps in quickly identifying specific issues and prioritizing actions accordingly.
Taking Action: Once an alarm is identified, follow the suggested steps to resolve the issue. Common issues may include safety scanner detections, robot faults, or inventory discrepancies.

Order Lifecycle Management

Order Lifecycle Monitor Overview

Daily Operation Overview: The "Daily Operation Overview" is your starting point for monitoring ongoing activities. It includes live performance metrics, historical data, and the current status of all active orders. Operators should routinely check this page to get an overview of warehouse performance during their shift.

(Figure 13: Daily Ops Layout)

Order Status Updates: As new orders are received, they appear on the overview page. The system displays whether orders are on schedule, delayed, or critical, allowing operators to prioritize actions.

(Figure 14: Order Status)

Performance Metrics: Real-time data, such as picking efficiency and average starve time, is also displayed. This helps operators maintain optimal warehouse performance by identifying areas needing attention.

Navigating the Order Information Page

Accessing Order Details: To see detailed information on a specific order, click on the order number in the "Order Information Page." This page lists the number of pallets built, cases picked, and the overall shipping status, which can be categorized as "On Time," "Delayed," or "Critical."
Understanding Order Status: For delayed or critical orders, operators can drill down to identify which pallets or cases are causing the delay. This enables quick decision-making to ensure that issues are resolved in a timely manner.
Built Pallets Page: After selecting an order, the "Built Pallets Page" provides detailed insights into how cases were picked, and if any issues occurred during the picking process. This page helps operators track any problems that need immediate correction.

(Figure 15: Build Pallets)

3. Inspecting Exceptional Pallets

Option 1:

Pallet Journey Page: Click on a pallet ID to navigate to its "Pallet Journey Page." This page provides a timeline view of the pallet's journey through the warehouse. It highlights key milestones and any events that impacted the pallet's processing, such as delays or exceptions.

(Figure 16: Pallet Journey)

Option 2:

Order Lines Page: Alternatively, click on a built pallet row to access its "Order Lines Page." This page provides granular details for each order line associated with the pallet, including SKU details, quantity, and related processing rules.

(Figure 17: Order Lines)

System Device Status

Device Overview

Accessing Device Status:

The "System Device Status" page allows users to monitor the operational health of various devices across the warehouse. This includes Safety Scanners, Robot Cells, Material Handling Equipment (MHE) Cells, and Inbound Outbound (IBOB) Stations.

(Figure 18: Device Overview)

Device Indicators:

Each device is categorized by its current status: Error, Warning, Offline, or Running. Doors are marked as either Open or Closed, with "Closed" being the optimal condition for operational safety.

(Figure 19: Device Indicators *Reference Only)

Navigating Device Details:

Click on a category to see more detailed device statuses. This ensures that operators can quickly identify and address any issues that arise within a specific section of the warehouse.

(Figure 20: Equipment Selection)

Robot Cells and MHE Cells

Robot Cells: The "Robot Cell" page displays the status of each component within the robot cells, such as robot arms, grippers, cameras, and doors. Users can interact with the Mujin Digital Twin to visualize device operations.
Switching Between Cells: Use the drop-down menu to switch between different robot or MHE cells. This feature allows you to focus on a particular area of the warehouse, ensuring all equipment is functioning as expected.
Monitoring Safety Scanners: The "Safety Scanner & Door" page provides an overview of all safety devices within the warehouse. If an object or person enters a restricted area, the safety scanner halts robot operations to prevent accidents.

Inventory Management

SKU Overview

Tracking Inventory: The "SKU Overview" page displays detailed information about each SKU, including its specifics, quantity, closest expiration date, and last replenishment status. This information helps in managing stock effectively and ensuring that products are available when needed.

(Figure 21: SKU Overview)

Detailed SKU Information: By selecting a specific SKU, users can view more detailed information, such as dimensions, weight, and replenishment data. This helps in optimizing the storage and retrieval processes for each SKU.

(Figure 22: SKU Information)

Location Overview

Visualizing Inventory Locations: The "Location Overview" page allows users to visually monitor inventory through the Mujin Digital Twin. A collapsible list on the left displays all pallets, while the digital twin on the right provides a visual representation of their actual location.

(Figure 26: Location Overview *Reference Only)

Search and Filters: Use the search and filter functions to easily locate pallets based on status, shipping status, or expiration date. This feature ensures that operators can quickly find specific items, improving operational efficiency.

(Figure 27: Filters in the location Overview Page *Reference Only)

Metrics and Performance Monitoring

Metrics Dashboard

Key Performance Indicators (KPIs):

The metrics section provides users with real-time data on various KPIs, including system performance, picking efficiency, and robot uptime. These metrics are crucial for identifying bottlenecks and optimizing workflows.

Navigating Metrics:

Metrics are displayed in different tabs based on the area of the warehouse, such as "Robot Cells" or "GTP Cells." Use the left sidebar to view key metrics, and refer to the right panel for detailed visualizations, including graphs and performance charts.

(Figure 29: Metrics)

Safety Considerations

General Safety: Always be mindful of warehouse safety protocols. The WES is designed with several safety features, such as E-stop buttons and safety scanners. Make sure to familiarize yourself with the locations and functions of these devices.
Emergency Procedures: In case of emergency, activate the nearest E-stop and notify your supervisor. All operations will halt, ensuring that immediate hazards are mitigated.
PPE Requirements: Operators must always wear personal protective equipment (PPE), including gloves, steel-toe boots, and high-visibility vests, to maintain safety standards during WES operation.

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General Care And Maintenance

Maintenance Procedures

Preventive Maintenance Schedule

Overview:

Performing regular preventive maintenance on each component helps ensure reliable operation, prolongs equipment lifespan, and minimizes unexpected breakdowns. The following maintenance intervals—daily, weekly, monthly, quarterly, and yearly—are designed to help users keep each component in optimal working condition and to reduce downtime.

Maintenance Intervals:

Daily:

Visual Inspection: Conduct a walk-around inspection of all components. Look for obvious signs of wear, leaks, or damage that could indicate an issue.
Bolt and Connector Check: Ensure bolts and fasteners on the EOAT (End-of-Arm Tool), robot joints, and stacker are tight. Loose connections can lead to misalignment or equipment malfunction.
Sensor Cleanliness: Wipe sensors clean, especially LIDAR on the AMR and sensors on the EOAT, to maintain accuracy. Dust or smudges can interfere with readings.

Weekly:

Cleaning and Debris Removal: Use a soft brush or cloth to clean joints, sensors, and exposed parts. This prevents dust buildup, which can cause overheating or sensor interference.
Film Tension Check (Stretch Wrapper): Confirm that the film tension is set correctly. Misaligned tension can cause improper wrapping, affecting load stability.

Monthly:

Lubrication of Moving Parts: Apply a thin layer of lubricant to key areas, such as the robot arm’s joints, conveyor rollers, and fork assemblies on the pallet stacker. Proper lubrication reduces friction and wear on parts.
E-Stop and Interlock Test: Test each emergency stop button and interlock function on fencing or access doors. Regular testing ensures these safety features work when needed.

Quarterly:

Calibration of Sensors and Navigation Systems: Perform calibration checks on AMR navigation systems, robotic arm axes, and EOAT positioning. Calibrating these components ensures accuracy and alignment, especially if the equipment has been in frequent use.
Pneumatic System Inspection: For components using compressed air (like the EOAT or stretch wrapper), check hoses, fittings, and seals for leaks or signs of wear. Replace any worn parts as needed to maintain consistent pressure.

Yearly:

Full System Calibration and Alignment: Schedule a comprehensive calibration and alignment session for all robotic arm axes, AMR navigation, EOAT, and stacker forks.
Replacement of High-Wear Parts: Certain parts, like drive belts, rollers, and bearings, may need replacement annually to maintain optimal performance and avoid unexpected breakdowns【46†source】【47†source】.

Routine Maintenance Tasks

Robotic Arm (CP500L) Maintenance

Daily:
- Inspect Arm Joints: Look for signs of wear or looseness around the arm’s joints, especially areas that are heavily used. Small wear or looseness can turn into larger issues if not addressed early.
- Confirm EOAT Stability: Ensure the EOAT is securely attached and aligned, as misalignment can lead to inaccurate handling.
Weekly:
- Lubrication of Joints: Lightly lubricate the arm’s moving joints. Over time, the robot’s joints can experience increased friction without proper lubrication, leading to wear.
Monthly:
- Calibration Check for Accuracy: Run a calibration test on each joint axis via the HMI (Human-Machine Interface). If the arm shows any drift from its standard alignment, adjust it immediately.
Yearly:
- Comprehensive Joint Inspection: Disassemble and inspect internal components in the joints for any signs of wear. Replace bearings or other friction-affected parts as needed【47†source】.

Autonomous Mobile Robot (AMR) M150 Maintenance

Daily:
- LIDAR and Obstacle Sensor Cleaning: Wipe the LIDAR sensor and other navigation sensors with a soft, lint-free cloth to remove dust or particles that might interfere with path detection.
Weekly:
- Battery Health Review: Check the AMR battery’s performance through the HMI. Observe for any signs of overheating or reduced charge times, which may indicate wear on the battery.
Monthly:
- Navigation Alignment Check: Ensure QR code markers are aligned and visible along the AMR’s path. Realign or clean QR codes if any drift or misalignment is detected.
Quarterly:
- Firmware Updates: Run firmware updates for the AMR through the HMI, if available, to maintain compatibility with system components and optimize performance【46†source】【47†source】.

Pallet Stacker (e.g., Qimarox PD1) Maintenance

Daily:
- Interlock and Door Check: Confirm that access doors are properly closed and interlock systems are engaged before use. Interlocks help ensure that the machine will stop if doors are opened.
- Fork Alignment: Check that stacker forks are properly aligned to avoid pallet jamming or mis-stacking.
Weekly:
- Lubrication of Lift Mechanism: Lubricate the lift mechanisms with the specified lubricant to reduce friction and prevent damage to moving parts.
Monthly:
- Inspection of Forks and Hydraulic System: Look for visible wear or signs of hydraulic leaks. Leaks in the hydraulic system can reduce lifting power and damage internal components.
Yearly:
- Full Calibration of Fork Alignment: Perform a thorough calibration of the stacker’s forks and lifting mechanisms, especially if there’s been any change in stacking accuracy【47†source】.

Stretch Wrapper (WRTA200) Maintenance

Daily:
- Film Roller and Tension Inspection: Check for smooth film roller operation, and verify that film tension remains consistent.
Weekly:
- Adjustment of Film Tension: Confirm that the film tension is appropriate for the load type. Adjust as needed via the HMI to ensure secure wrapping.
Monthly:
- Lubrication of Rotating Arm: Apply a light coat of lubricant to the pivot points of the rotating arm to maintain smooth movement.
Quarterly:
- Inspection of Film Carriage Motor and Cut-and-Wipe System: Clean the motor housing and verify that the cutter blade is sharp to ensure precise cutting and wiping after each wrap cycle【46†source】【47†source】.

Inspection and Replacement of Wear Parts

Identifying High-Wear Components

Robotic Arm (CP500L): Bearings, drive belts, and EOAT connectors are high-wear parts that require frequent inspection. Listen for abnormal sounds, observe vibrations, or check for any looseness that may indicate wear.
AMR M150: Wheels, navigation sensors, and the battery are common wear points. Check for wheel tread wear, recalibrate sensors if navigation issues arise, and inspect the battery for consistent charge retention.
Pallet Stacker: Forks, hydraulic seals, and lift rollers are high-wear components. Replace forks showing significant wear or seals with visible leaks to prevent operational delays.
Stretch Wrapper: Film carriage rollers, tensioner components, and the cutter blade require frequent checks. Replace parts showing signs of wear to ensure proper wrapping tension and cutting quality【47†source】.

Replacement Criteria and Procedure

Replacement Guidelines:

Bearings and belts (CP500L): Replace yearly or sooner if signs of vibration or abnormal sound arise.
Battery cells (AMR): Replace when charging duration decreases significantly or overheating occurs.
Hydraulic seals (Pallet Stacker): Replace if hydraulic fluid leaks or reduced lifting power is observed.
Cutter blade (Stretch Wrapper): Replace every 6 months or if the film shows uneven cuts【46†source】【47†source】.

Calibration and Adjustment Procedures

Robotic Arm Calibration

Axis Calibration:

Using the HMI, calibrate each robotic arm axis. The robot should move to reference positions for verification. If any misalignment is observed, perform the necessary adjustments to bring the robot within tolerance.

EOAT Adjustment:

After extended usage or any EOAT replacement, re-align and recalibrate the tool, ensuring it can operate within its designated accuracy and pressure limits.

AMR Navigation Calibration

QR Code Re-Alignment and LIDAR Sensitivity:

Ensure QR codes along pathways are visible and aligned. If the AMR exhibits navigation drift, recalibrate the LIDAR sensor sensitivity through the HMI to maintain detection accuracy.

Pallet Stacker and Stretch Wrapper Adjustments

Fork and Arm Alignment (Pallet Stacker):

Adjust forks every six months to maintain stacking accuracy and ensure smooth pallet handling.

Film Tension and Cutter Alignment (Stretch Wrapper):

Adjust film tension via the HMI and ensure the cut-and-wipe mechanism contacts the film correctly. Calibrate monthly to avoid wrapping inconsistencies【47†source】【46†source】.

Maintenance Safety Protocols

LOTO Procedures:

Preparation: Notify all personnel of pending maintenance, power down equipment, and apply lockout tags to secure all power sources.
Verification: After lockout, test the equipment to confirm it cannot be powered on, ensuring technician safety during service.

Personal Protective Equipment (PPE):

Required PPE: Safety gloves, goggles, and steel-toe boots are essential when handling moving parts or dealing with high-pressure systems.

Handling Hazardous Materials:

Lubricants and Cleaners: Follow MSDS safety guidelines. Wear gloves and avoid direct contact with skin and use only approved cleaning methods around sensitive electronics【47†source】.

Overview of Troubleshooting Approach

Purpose:

This section provides clear, structured guidance for resolving common issues that may arise during equipment operation. The goal is to enable operators to identify and address issues quickly while maintaining a safe environment. Troubleshooting steps are organized from general to component-specific tasks, allowing users to troubleshoot efficiently and safely.

General Troubleshooting Sequence:

Identify the Issue: Begin by observing any alerts, error codes, or unusual behavior in the system.
Consult the Error Code Table: Cross-reference any codes displayed with the table in Section 7.2 to understand potential causes.
Isolate the Issue: If possible, separate parts or test components independently to pinpoint the root cause.
Adjust Environment Factors: Check that temperature, humidity, and cleanliness are within acceptable ranges, especially for sensors and electronics.
Incremental Testing: Make one adjustment or replacement at a time, monitoring the system’s response before proceeding to the next step.

Basic Troubleshooting Principles:

Isolate Variables: If multiple potential causes exist, isolate each one to determine which affects system performance.
Incremental Adjustments: To avoid confusion, change one variable at a time and observe its impact on system performance.
Environmental Factors: Confirm that the operating environment meets manufacturer specifications. Temperature fluctuations, dust accumulation, and high humidity can impair sensor accuracy and electronic function.

Safety Reminders:

LOTO Procedures: Follow Lockout-Tagout protocols to secure power sources before accessing internal components.
Use of PPE: Wear safety gloves, goggles, and other PPE as recommended when handling machinery or chemicals.
Verify Stability: After troubleshooting and reassembly, check that all parts are securely fastened and stable before powering up.

Error Code Table

Common Error Codes and Alarms

Error Code Reference Table: The following table contains common error codes, possible causes, and suggested corrective actions. Each code is assigned a severity level to indicate the urgency of response.

Error Code	Description	Component	Severity	Possible Causes	Corrective Action
E101 - Overcurrent	Motor overcurrent detected on JT1	CP500L Robot	Critical	Excessive load, motor fault	Reduce load, check motor connections, restart
E202 - Overtemperature	Joint 2 motor overheating	CP500L Robot	Critical	Extended use, obstructed ventilation	Pause, cool, inspect vents, ensure proper airflow
Finished E-Stopped	Emergency Stop activated	All Components	Critical	E-stop button engaged	Inspect for hazards, reset E-stop, resume if safe
A501 - Low Air Pressure	Insufficient air pressure detected	Robot Arm/AMR	Moderate	Leak in air line, clogged filter	Check air lines, replace filters, reset system
PalletStackerFull	Stacker reached full capacity	Pallet Stacker	Moderate	Excess pallets blocking mechanism	Remove pallets, clear stacker path
MobileRobotLowBattery	AMR battery at low charge	AMR	Moderate	AMR battery below operating level	Dock AMR to charging station
E601 - Communication Lost	Lost connection between robot and HMI	Robot/AMR	High	Loose cable, network interruption	Check cable, reconnect, or reboot network
E701 - Environmental Alert	Temperature or humidity out of range	All Components	Low	Environmental conditions outside spec	Stabilize room temp/humidity to recommended levels
A302 - Pallet Overload	Pallet exceeds weight limit	Pallet Stacker	High	Pallet weight too heavy	Adjust load to within max capacity, restart

Corrective Actions for Selected Codes

E101 - Overcurrent on JT1:

Step 1: Clear any visible obstructions around JT1 and ensure the EOAT is securely attached.
Step 2: Reduce the load weight to fall within the robot’s recommended payload.
Step 3: Restart the system and verify that the error does not reappear. If the error persists, inspect the motor’s power connections and consult maintenance.

A501 - Low Air Pressure:

Step 1: Locate the air pressure gauge or indicator, noting any drops below recommended levels.
Step 2: Inspect air lines for leaks or disconnected hoses, securing any loose connections.
Step 3: Replace the air filter if clogged, ensuring adequate airflow, then reset the system.

E601 - Communication Lost:

Step 1: Check the network or communication cable connecting the robot or AMR to the HMI.
Step 2: Reconnect any loose cables and reboot the HMI if needed to re-establish communication.
Step 3: If communication is not restored, reset the network router or contact IT support.

E701 - Environmental Alert:
- Step 1: Confirm room temperature and humidity levels are within recommended limits (typically 0°C - 45°C and up to 80% humidity).
- Step 2: If environmental control is available, adjust the settings for stability.
- Step 3: If conditions cannot be corrected, limit equipment operation to low-speed functions to prevent sensor errors.

Severity Level Guide

Critical: Immediate action required to prevent damage or halt unsafe conditions. System operations may be halted until the issue is resolved.
High: Address promptly to avoid escalation. Failure to act may lead to degraded performance or unsafe operations.
Moderate: Attention needed, but system operation can continue with caution until corrective action is possible.
Low: System operation can proceed normally; address the issue at the next available maintenance interval.

Component-Specific Troubleshooting Procedures

Robotic Arm (CP500L)

Issue: Inaccurate Positioning or Repeatability Issues

Possible Causes: Calibration drift, mechanical wear, or loose EOAT.
Corrective Actions:
1. Verify EOAT Attachment: Check if the EOAT (End-of-Arm Tool) is securely attached to the robot arm. Tighten bolts or connectors if loose.
2. Perform Calibration Check: Access the HMI and perform a calibration test for each robot axis. Follow on-screen prompts to adjust any misalignment.
3. Lubricate Joints: Apply the recommended lubricant to all major joints and moving parts to reduce friction that may cause drift.
4. Test Position Accuracy: Conduct a series of test movements and measure for repeatability within ±0.5 mm tolerance. If issues persist, consult maintenance for further diagnostics.

Preventive Tip: Regularly check EOAT alignment and calibrate the robot on a monthly basis to maintain optimal positioning accuracy.
Issue: Motor Overheat (E202 - Overtemperature)
- Possible Causes: Extended operation under heavy load, blocked ventilation, or friction in joints.
- Corrective Actions:
  1. Power Down and Cool: Immediately power down the robot and allow the motor to cool to avoid damage.
  2. Inspect Ventilation: Check for dust or debris blocking the ventilation openings on the motor. Clean vents using a soft brush or compressed air if necessary.
  3. Reduce Load and Cycle Time: Lower the robot’s workload or extend pauses between cycles if overheating is a recurring issue, as excessive strain on the motor can lead to repeated overheating.
  4. Restart System: Once the motor has cooled, power up and test the robot to confirm normal temperature operation.
Preventive Tip: Keep the operating environment within specified temperature limits and inspect ventilation monthly to prevent motor overheating.

Vision Camera Calibration:

Issue: Product placement or grasping point drift
- Possible Causes: Calibration of camera has drifted or misaligned over period of time. Dust on the sensors might cause it.
- Corrective Actions:
  1. Clean the Sensors: Ensure the cameras are wiped clean and the does not have any object in the field of view. Make sure the cameras do not have physical damage during the cleaning process.
  2. Recalibrate Cameras: Use the HMI to recalibrate the Cameras in the Robot Cell.

Perform Automatic Calibration

Procedure for Performing Automatic Calibration

To begin the vision calibration, it is necessary to switch the robot into manual mode (MAN). This can be done using either the main control panel or the Mujin HMI interface. Switching to manual mode allows for safe and precise adjustments to be made during the calibration process.
Next, navigate to the Sensor Calibration settings by selecting Sensors > Calibration at the bottom of the main screen. This action will open the "Sensor: Calibration" screen, which is where all calibration operations are managed.

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If your system is equipped with multiple cameras, you will need to select the specific camera that requires calibration from the list displayed on the calibration screen. It is important to ensure that you select the correct camera for calibration, as each camera may require different adjustments.

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Once the appropriate camera is selected, proceed to set the calibration parameters. Adjust the Main, Intrinsic, Extrinsic, and Relative Positions for the selected camera as needed. If your system uses a combination of ENSENSO and color cameras, follow these specific guidelines:
For the row labeled "ensenso_gigecolor_1", ensure that Intrinsic and Relative Position are selected.
For the row labeled "ensenso_l_raw", make sure that Main and Extrinsic are selected.

To ensure the robot remains in manual mode and is ready for calibration, hold the Mujin pendant with both hands and press the Deadman Switch using moderate force with your left hand. The Deadman Switch Icon located at the top of the screen should light up red, indicating that the switch is engaged. It is crucial not to release the Deadman Switch until the calibration process is complete, as doing so will interrupt the procedure. The calibration process may take several minutes.

To initiate the calibration, press the Play button on the interface. This will start the automatic calibration sequence, during which the system will make adjustments to align the vision parameters accurately with the robot’s positioning.

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Note: If any issues arise during calibration, such as error messages interrupting the process, the calibration board not being captured, or the calibration pattern not being recognized, please contact Mujin support for further assistance.

Apply Automatic Calibration Results

Procedure for Applying Calibration Results

Once the vision calibration process is complete, it is important to review and apply the calibration results. Start by pressing the Result button on the sensor screen, which will display the calibration outcomes on the "Sensor: Result" screen.

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In order to properly evaluate the calibration results, you will need to utilize the Intrinsic, Extrinsic, Results tab near the top of the screen and the Previous Result, Current Result tab near the bottom. These tabs allow you to compare the newly obtained calibration data with the existing settings to identify any discrepancies.

After selecting Extrinsic near the top of the screen, carefully examine the image displayed on the left side. The calibration pattern must be clearly detected on the image calibration board, and the green and red dots should be visible, indicating successful detection. Additionally, the XYZ axis, represented by red, green, and blue lines, must be displayed on the image calibration board. It is also essential to confirm that the RMS error displayed in the upper left corner is 0.5 or less.

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Next, press Result near the top of the screen to further verify the calibration data. The RMS error displayed on the scatter plot must also be 0.5 or less. Additionally, compare the Camera Position and Previous Camera Position values; these should not differ significantly. If the difference in the X, Y, and Z values between the previous and current result is within 10 mm, the calibration is considered successful.

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Note: If the RMS error exceeds 0.5 or if the camera position difference is greater than 10 mm, the vision calibration must be performed again. If the RMS error does not fall below 1.0 after multiple attempts, please contact Mujin support for additional assistance.

If the calibration results are incorrect, adjustments may need to be made to the camera’s positioning or exposure settings before attempting the calibration again. To adjust the camera exposure, navigate to the Base system UI’s sensor exposure screen. Use the “-” or “+” buttons under Exposure to modify the exposure until the calibration board is clearly visible on the screen, then press Apply. Repeat this adjustment process for all cameras in the system to ensure uniformity.

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Once all calibration results have been verified and are satisfactory, press Use current result to apply the new calibration settings. You will be prompted to confirm this action—press OK to finalize and apply the calibration results.

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Link: https://docs.mujin.co.jp/en/user_manual/calibration-vision.html?highlight=camera+calibration[HG1] [DH2]

Preventive Tip: Regularly inspect the cameras and check the product placement and product grasp points.

Autonomous Mobile Robot (AMR)

Issue: Navigation Drift or Misalignment (E101)
- Possible Causes: Misaligned QR codes, dust on LIDAR sensors, or outdated navigation calibration.
- Corrective Actions:
  1. Clean and Inspect QR Codes: Ensure QR codes along the AMR’s path are clean and aligned. Use a microfiber cloth to wipe off dust or debris.
  2. LIDAR Sensor Cleaning: Gently clean the LIDAR sensor using a lint-free cloth, as sensor clarity is critical for accurate navigation.
  3. Recalibrate Navigation: Use the HMI to recalibrate the AMR’s navigation system, following the prompts to ensure alignment.
  4. Test Navigation Path: Run the AMR along a test path to verify alignment and accuracy.
Preventive Tip: Regularly inspect and clean QR markers and LIDAR sensors on a weekly basis to maintain precise navigation.
Issue: Battery Depletion (MobileRobotLowBattery)
- Possible Causes: Low battery charge, high-frequency usage, or battery deterioration.
- Corrective Actions:
  1. Dock for Charging: Guide the AMR to its charging station and ensure it is securely docked for charging.
  2. Check Battery Health on HMI: Access the HMI to view the battery’s current health status. If it is not holding a full charge, the battery may be nearing the end of its life.
  3. Replace Battery if Necessary: If battery health remains poor after charging, schedule a replacement.
Preventive Tip: Monitor battery health monthly via HMI and avoid high-speed, continuous operations to maximize battery lifespan.

LED Indicator Table for AMR (Autonomous Mobile Robot)

LED Color	Indicator Status	`	Action Required
Green	Solid	AMR is in normal operation mode.	No action needed; system is functioning as expected.
	Blinking	AMR is in standby or low-power mode.	Prepare for charging if battery is low.
Blue	Solid	AMR is currently charging at its dock.	Ensure charging completes before resuming tasks.
Yellow	Blinking	Minor issue detected (e.g., minor obstacle).	Monitor AMR; obstacle may clear or need adjustment.
Red	Solid	Critical error (e.g., sensor fault or E-stop).	Immediately check HMI for specific error details; clear obstructions if safe.
	Blinking	Battery critically low or significant fault.	Dock AMR for immediate charging; troubleshoot as needed if error persists.
Purple	Solid	Connection issue (e.g., network disconnect).	Inspect network connections; reboot AMR if unresolved.
White	Flashing	System boot-up or firmware update in progress.	Wait for process completion before initiating tasks.

Pallet Stacker and Stretch Wrapper

Troubleshooting Alarms and Common Issues

The following table outlines key alarms, likely causes, and corrective actions for the Stretch Wrapper WRTA200. Each alarm includes step-by-step solutions, ensuring that operators can address and resolve these issues efficiently.

Alarm	Problem	Likely Cause	Corrective Action
Emergency Stop Activated	E-stop button pressed	System start-up or manually engaged	Release E-stop buttons; press rearm push button to re-enable the system
Safety Fence Door Open	Safety fence door not closed	Operator access for maintenance or error	Close fence door; reset E-stop loop by pressing rearm push button .
Fence Door Locking Issue	Fence not locking properly	Faulty lock or incorrect key-switch position	Check lock insertion; verify key-switch functionality and door closure . t Curtain Fault**
Low Air PPSI)	Insufficient air pressure in system	Drop in pressure or filter-regulator issue	Verify pressure at regulator; inspect and replace filters if blocked .
VFD Fault	Variable frequency drive error	VFD malfunction or configuration error	Identify faulty VFD in control panel; press rearm to clear fault .
*Film Supply Depletedlm roll is empty or torn	End of film roll or break in film	Thread new film; secure tail in clamp .
*Carria	Carriage gate open during operation	Improper gate closure or misaligned proximity sensor	Fully close gate; verify yellow proximity sensor light is "ON" through carriage hood .
Carriage Motion Problem	Carriage fails to reach up/down p	VFD issue or limit switch fault	Operate manually; inspect VFD, and verify limit switch operation .
Rotation Out of Position	Rotation not in home or n	Faulty sensor or air brake operation	Adjust proximity sensor for accurate home detection; inspect air brake .
Push Arm Motion Issue	Arm fails to reach retracted/extended positcient air pressure or sensor misalignment	Check air pressure; align proximity sensor to 1/16 inch for optimal range .
Rotation Bumper Hidden	Object or debris blocking rotation	Blocked pysical interference with rotary arm	Clear obstacles; ensure photoeye aligns with bumper reflector .
Carriage Gate Position	Proximity sensor issue with gate latch	Misalignroximity sensor	Adjust latch alignment to trigger sensor only when fully closed .

Detailed Corrective Actions for Frequent Issues

Emergency Stop Issues:

**Cause*aged manually or during power-up.
Solution:
1. Step 1: Inspect E-stop buttons for any inadvertent engagement.
2. Step 2: Release all engaged E-stops, ensuring no active faults in surrounding zones.
3. Step 3: Press the rearm button on the control panel to reset the system.

Fence Door Locking Issue:

Cause: Safety fence door is not properly locking, preventing system start.
Solution:
1. Step 1: Check that the door is fully closed, ensuring the latch aligns with the lock.
2. Step 2: Confirm that the key-switch for locking is in the correct position.
3. Step 3: Verify that the green door lock light on the HMI is lit before resuming operations.

Low Air Pressure:

Cause: Air supply drops below 40 PSI, interrupting operations.
Solution:
1. Step 1: Check air pressure gauge on the filter-regulator to confirm pressure.
2. Step 2: Inspect air lines for leaks, and replace the air filter if needed.
3. Step 3: Resume operation once pressure stabilizes above the minimum threshold.

Film Supply Issues:

Cause: Film is torn or depleted, causing system halt.
Solution:
1. Step 1: Open the film carriage and replace the roll if empty.
2. Step 2: If the film is torn, rethread the film through rollers, securing it in the clamp.
3. Step 3: Ensure film is properly aligned and tensioned before resuming.

Carriage Motion Problem:

Cause: Carriage fails to reach commanded up or down positions.
Solution:
1. Step 1: Operate carriage manually via control panel to test VFD functionality.
2. Step 2: Check limit switch functionality, confirming they detect raised and lowered positions.
3. Step 3: Replace faulty switches or recalibrate VFD settings as necessary.

Rotation Home Position Issues:

Cause: Rotation not detected in home position due to sensor or brake issues.
Solution:
1. Step 1: Manually reset rotation to home via control panel.
2. Step 2: Adjust proximity sensor for accurate detection within the specified sensing range.
3. Step 3: Test air brake operation to ensure stability in home position.

Push Arm Motion Fault:

Cause: Cut and wipe arm fails to fully retract or extend.
Solution:
1. Step 1: Inspect air pressure; adjust as needed to ensure sufficient force.
2. Step 2: Align the proximity sensor to optimal range for retracted detection.
3. Step 3: Tighten all arm bolts to maintain structural stability during operation.

Advanced Diagnostic Procedures

Overview: Advanced diagnostics allow operators and technicians to perform in-depth checks on system components. These procedures are particularly useful when recurring issues arise or if component performance degrades. The following diagnostic tools and methods help ensure each part of the system is functioning optimally.

Calibration Check and Synchronization

Objective: To ensure precise alignment and synchronization for components such as robotic arms, AMRs, and stretch wrappers, which are critical for maintaining operational accuracy and reducing wear on parts.

Robotic Arm Calibration:

Purpose: Calibration maintains the arm’s ability to reach and manipulate objects with accuracy. Misalignment can lead to errors in picking, placing, or wrapping operations.

Procedure:

Initiate Calibration: Access the calibration menu via the HMI. Select “Axis Calibration” and follow prompts to place the robotic arm in its reference positions.

Check Axes for Drift: Using calibration tools, observe each joint for any deviation from the expected alignment. Slight discrepancies can cause cumulative errors in movement.

Adjust as Needed: Adjust any out-of-tolerance axes as specified in the manual until movement is within acceptable tolerance levels.

Test Post-Calibration: After adjustments, perform a test run to ensure accuracy, logging results for future reference.

AMR Path and Navigation Calibration:

Purpose: Ensures the AMR accurately follows designated paths and responds to environmental markers like QR codes or navigation beacons.

Procedure:

QR Code Verification: Visually inspect QR codes on the AMR’s path to ensure clarity and alignment.

Run LIDAR Calibration: On the HMI, initiate the LIDAR calibration process. The AMR will adjust its sensor settings to improve detection accuracy.

Test Navigation Accuracy: Select a sample route and observe the AMR’s navigation along this path. If it deviates, make necessary adjustments to QR code positioning or recalibrate LIDAR.

Stretch Wrapper Synchronization:

Purpose: Synchronizes the rotation, film carriage movement, and film tension to ensure consistent wrapping. Misalignment or desynchronization can result in uneven film application.

Procedure:

Initialize Rotation Calibration: Use the HMI to bring the wrapper to its home position. Verify that the rotational arm is aligned and properly calibrated.

Verify Film Tension Settings: Ensure the film tension is set per load specifications, adjusting the film carriage speed and tension via the HMI if necessary.

Run Test Wrap: Perform a test wrap on a sample load. Observe the film application and adjust synchronization parameters to ensure consistent and even wrapping.

Data Logging and Event Review

Objective: Regular logging and event reviews provide a record of component performance, helping to identify patterns or recurring issues for preventive action. This practice is essential for troubleshooting complex or intermittent problems.

Fault Logging:

Purpose: Documents all errors and corrective actions for each fault, helping operators identify recurring issues and track equipment reliability.

Procedure:

Access Fault Log via HMI: Review the log history of any recent faults. Each entry provides a timestamp, error code, and a brief description.

Record Corrective Actions: After addressing an issue, update the log with details of the corrective action taken, including any part replacements or calibrations performed.

Analyze for Patterns: Review logs weekly to identify patterns, such as repeated faults that could indicate underlying component wear or environmental factors affecting performance.

Event Review:

Purpose: Helps assess recent events or sequences of operation, such as system start-ups or shutdowns, to pinpoint when faults occur and under what conditions.

Procedure:

Review Start-Up and Shutdown Logs: Check logs for any unusual patterns during equipment start-ups or shutdowns, as these can sometimes reveal early indicators of mechanical or software issues.

Analyze Event Sequences for Errors: Examine event timestamps to see if errors arise under specific conditions (e.g., heavy loads, continuous operation). This helps narrow down troubleshooting steps.

Document Findings: Record any correlations or observed trends in a maintenance log. Share findings with maintenance teams during routine inspections or preventive maintenance sessions.

Sensor and Proximity Switch Testing

Objective: Test sensors and proximity switches to ensure they detect objects and positions accurately, critical for components such as the stretch wrapper, robotic arm, and AMR. Sensor misalignment can cause operational delays or errors in handling materials.

Proximity Sensor Testing (e.g., for Pallet Stacker or Wrapper):

Purpose: Ensures sensors reliably detect pallet positions, gate closures, or rotational arms at specific points.

Procedure:

Access Proximity Sensors: Locate each proximity sensor according to the manual. Most are mounted near access gates, rotational arms, or pallet loading zones.

Test Activation Range: Gradually move an object (such as a metal object for inductive sensors) toward the sensor to determine its activation distance. Adjust as needed to ensure consistent detection within the designated range.

Check Alignment: Align sensors to avoid signal interference. Misaligned sensors may cause delayed or missed detections, impacting stacking or wrapping precision.

LIDAR and Optical Sensor Testing (AMR):

Purpose: Verifies that sensors detect environmental markers and avoid obstacles accurately. - Procedure: 1. Run Diagnostic Mode on HMI: Enter the diagnostic mode on the AMR’s HMI and select “LIDAR Test.” 2. Place Test Objects Along Path: Set a few objects along the AMR’s navigation path to check that the LIDAR and optical sensors recognize obstacles. 3. Verify Detection and Response: Confirm that the AMR slows or stops in response to obstacles. Adjust sensor sensitivity if obstacles are not consistently detected.

Vibration and Temperature Monitoring

Objective: Periodically monitor vibration and temperature levels in key components (e.g., motors, drive systems) to detect early signs of wear or overheating, which can lead to breakdowns.

Vibration Monitoring for Motors: - Purpose: Detects mechanical issues in motors, such as unbalanced loads or worn bearings.

Procedure:

Install Vibration Meter: Attach a vibration meter to motor casings, particularly for heavy-duty systems like the robotic arm.

Record Baseline Vibration: Note the baseline vibration levels during normal operation. An increase in vibration may indicate misalignment or bearing wear.

Analyze Readings Over Time: Compare weekly readings to identify any trends. Unusual spikes in vibration levels suggest potential mechanical issues requiring inspection.

Temperature Monitoring for Motors and Drives: - Purpose: High temperatures can indicate overloading or internal friction in drive components. - Procedure: 1. Use a Thermal Imaging Tool: Take readings on motor surfaces to detect hot spots. Record temperatures and compare them to the manufacturer’s recommended range. 2. Evaluate Temperature Changes: A consistent rise in temperature over time may signal a need for lubrication or part replacement.

Recovery Procedures

Overview: Recovery procedures are essential for safely restoring operations after unexpected events such as emergency stops, power failures, or network communication losses. These procedures will guide operators step-by-step through the recovery process, ensuring each component is secure, calibrated, and fully operational before resuming tasks.

Emergency Stop (E-Stop) Recovery

Objective: To ensure the safe resumption of system operations after an emergency stop has been activated. E-stop procedures prioritize safety by halting all movements instantly, and recovery should be conducted carefully to avoid equipment damage or personnel injury.

Procedure:

Inspect for Hazards:

Action: Begin by checking the surrounding area for any immediate hazards that may have triggered the E-stop. Look for obstacles near moving parts, confirm that no personnel are within operational zones, and ensure clearances are established around the robot, AMR, or other automated components.
Additional Detail: E-stops are often used in scenarios where a hazard or obstruction has been detected, so it’s essential to confirm that these issues have been cleared. Failure to do so may result in further interruptions or damage upon reactivation.

Release E-Stop:

Action: Once the area is confirmed safe, carefully disengage the E-stop. Rotate the E-stop button clockwise to release it, ensuring the button returns to its normal, unpressed position.
Additional Detail: Depending on the equipment, there may be multiple E-stops throughout the system. Ensure all E-stops are disengaged before proceeding, as even one remaining engaged may prevent the system from rearming.

Reset the System:

Action: After releasing all E-stops, navigate to the HMI or main control panel and locate the reset or rearm option. Initiate the reset sequence, which will clear any active error signals and allow the system to prepare for safe operation.
Additional Detail: During the reset sequence, the system may conduct a brief safety check. Allow this process to complete fully before proceeding, as bypassing or interrupting the reset may leave the system in an unstable state.

Verify System Status:

Action: Use the HMI to check status indicators on each component, looking for green lights or operational signals indicating readiness. Components in error mode should be resolved before continuing.
Additional Detail: Some systems may display amber or warning indicators, which require investigation before resuming full operation. If any component remains in fault mode, consult its specific troubleshooting guide to address any lingering issues.

Resume Operations:

Action: Once the system is confirmed safe and operational, resume the interrupted task from the HMI or main control panel. Observe the first few cycles to ensure smooth operation and that no residual issues remain from the E-stop.
Additional Detail: If the E-stop was triggered due to a specific task or area, consider performing a test cycle in a safe mode or with reduced speed. This helps verify system stability before resuming regular operations.

Power Failure Recovery

Objective: Safely restore all system components following a power failure or outage. Power failures can disrupt system alignments, configurations, and ongoing tasks, so careful attention is required to avoid further complications upon recovery.

Procedure:

Confirm Power Stability:

Action: Ensure that the facility’s power supply is stable. For systems with backup power or uninterruptible power supplies (UPS), confirm that the power transition was smooth and free from fluctuations or surges.
Additional Detail: Power fluctuations can damage sensitive equipment. If a power surge occurred, inspect equipment for signs of damage, such as burnt odors, unusual sounds, or physical changes.

Inspect All Components:

Action: Perform a visual inspection to verify that each component is in its expected position. For example, robotic arms should be in their home position, AMRs should be docked or in standby mode, and other devices should be idle.
Additional Detail: Misalignments can occur when power is interrupted mid-task. Ensure that no unexpected movements or misalignments are present that could interfere with safe operation.

Reboot the Control Systems in Proper Sequence:

Action: Restart each system component in a specific order:
- AMR Docking Station: Power on the AMR docking station first to ensure it can charge when needed.
- Secondary Systems: Power up any auxiliary equipment, like pallet stackers and stretch wrappers, which are essential for initial task preparation.
- Robot Controller: Start the robot controller last, ensuring it can establish stable connections to all relevant systems on startup.
Additional Detail: A recommended power-up sequence prevents unexpected faults or configuration errors. For systems with an automatic power-up sequence, verify that each component completes initialization before the next step.

Recalibrate Key Components (if needed):

Action: If alignment issues are noticed after power restoration, recalibrate alignment-sensitive devices such as AMRs, robotic arms, or stretch wrappers. Access the calibration options on the HMI and follow on-screen prompts to complete recalibration.
Additional Detail: Calibration should be performed at regular intervals, especially after any power interruptions, to maintain precision. Recalibrating all components at once can help minimize discrepancies between devices.

Resume Operations:

Action: After all components have powered on and passed initial checks, restart the task from the HMI. Observe the system’s response and confirm all components are functioning as expected without errors.
Additional Detail: Perform a brief system test, especially if the power interruption occurred mid-operation. This helps confirm that all components are synced and that no data loss or misalignment issues remain.

Communication Loss Recovery

Objective: Resolve issues when a component loses communication with the main control system, which can disrupt coordination and may prevent certain tasks from starting.

Procedure:

Identify the Disconnected Component:

Action: Use the HMI to view the system status and determine which device or component has lost communication. The HMI may display a “Disconnected” or fault status for affected components.
Additional Detail: Communication loss can be network-based (e.g., Ethernet or Wi-Fi) or due to a physical connection issue. Identifying the root cause is crucial for efficient troubleshooting.

Check Physical Connections:

Action: Inspect all network and power connections between affected components. Ensure all cables are properly secured and look for any damage, fraying, or loose connectors.
Additional Detail: Loose or damaged cables are a common source of communication issues. Replacing worn cables periodically can reduce occurrences of communication loss.

Reset Network Devices (if needed):

Action: If the issue persists, restart network devices such as routers, switches, or hubs. After rebooting, verify that the control system reconnects to these devices.
Additional Detail: Network resets can briefly interrupt communication for other components. Ensure the network reset is scheduled during a safe period, such as downtime or reduced operations, to minimize impact.

Reboot the Disconnected Component:

Action: If the communication issue remains unresolved, perform a manual reboot on the disconnected component. Use the HMI to initiate a “Rescan” or “Reconnect” function to re-establish communication.
Additional Detail: Some components may require a soft reset (reboot without power-down) while others may need a hard reset (complete power cycle). Check the component’s manual for specific guidance.

Verify System Reconnection:

Action: After rebooting and reconnecting the component, check its status on the HMI. Look for indicators showing “Online” or “Connected” status. If errors persist, consult the specific troubleshooting section for further diagnostics.
Additional Detail: Log any persistent communication faults in the maintenance records. These may indicate underlying network issues or signal interference that require more extensive diagnostics.

Resume Operations:

Action: Once all components are reconnected, resume the task from the HMI. Observe system performance closely to ensure smooth resumption and check for any lag or response delays.
Additional Detail: Communication errors may occasionally cause configuration discrepancies. Verify that all components are properly synchronized and settings are as expected before resuming regular operations.

Routine Recovery Maintenance Tips

Weekly E-Stop and Power Supply Checks:
- Detail: Perform weekly checks on all emergency stops to ensure they are operational and properly configured. Regularly inspect power supplies, UPS systems, and backup batteries for reliable performance during power interruptions.
Scheduled Network Inspections:
- Detail: Periodic network inspections help ensure all devices maintain stable communication. Inspect cables and connections monthly, particularly in high-traffic or vibration-prone areas.
Backup System Configurations:
- Detail: Maintain up-to-date backups of configuration settings for AMRs, robotic arms, and other programmable devices. This can expedite recovery after power loss or communication failures.
Recalibration Post-Recovery:
- Detail: After any significant power or communication event, recalibrate alignment-sensitive components to avoid long-term drift and maintain precision.

Maintenance Support and Escalation

Overview: Maintenance support and escalation protocols follow a structured workflow, ensuring that all issues are addressed promptly, documented thoroughly, and escalated according to their severity. This workflow is designed to enhance communication and traceability from the moment a support event is created until its resolution. The escalation process uses clearly defined severity levels, response timelines, and prioritized actions to ensure effective issue management.

Escalation Workflow

The escalation process follows these stages, with clear responsibilities at each level to ensure that all issues are appropriately addressed:

Operations Stage:

Operators perform routine troubleshooting per maintenance manual instructions, identifying any issues that cannot be resolved with standard procedures.

Initial Troubleshooting by Maintenance:

If operators are unable to resolve an issue, it is escalated to the internal maintenance team. Maintenance personnel troubleshoot using advanced diagnostic tools and procedures outlined in the manual.

Escalation to Mujin Support:

If maintenance cannot resolve the issue, they escalate it through the Mujin Support Portal. A formal support event is created, including issue documentation and relevant logs.
Response Management: Support events are prioritized according to the severity level, which defines response timelines and escalation paths. This enables systematic handling from initial analysis to potential on-site support if necessary.

Severity Levels and Escalation Protocol

Each support event is assigned a severity level to determine the response priority, action timeline, and escalation requirements. Below is a detailed breakdown of each severity level:

Severity Level	Definition	Response Time	Action	Escalation
Level 1: Urgent	Major functionality loss; operating at less than 70% capacity, or major physical damage causing system downtime.	1-3 Hours	Root Cause Analysis	Customer Support
		3-6 Hours	Recovery Execution	Director of Support
		6-8 Hours	Summary Report and Recovery Execution (mobilization for on-site support)	Global CTO
Level 2: High	Key functionality loss; operating at less than 85% capacity, major component failure without recovery estimate, or a systematic error affecting other systems.	1-8 Hours	Root Cause Analysis	Customer Support
		8-16 Hours	Summary Report	Local Support Manager
		16-24 Hours	Recovery Execution (on-site if required)	Acct Manager, Director of Support
Level 3: Medium	Minor functionality loss; component failure causing partial functionality loss with minimal operational impact.	1-8 Hours	Root Cause Analysis & Recovery Execution	Customer Support
		16-48 Hours	Summary Report & Recovery Execution	Local Support Manager
		48-72 Hours	Optional on-site mobilization	Acct Manager, Director of Support
Level 4: Six Sigma	Issues or missing functionality outside of defined design; enhancement requests or minor product adjustments.	TBD	Input Collection	Tier 1 Support
		21 Days	Feature Proposal	Tier 1 Support
		60 Days	Feature Prioritization	Product Development Team

Issue Documentation and Reporting Requirements

To ensure thorough tracking and effective response, operators and maintenance teams must document issues comprehensively:

Error Codes and Alarms: Record specific error codes, alarms, and related HMI messages. Detail affected components and include screenshots or logs if available.
Time and Frequency: Note the time and date of the incident and any patterns in occurrence frequency. This assists in identifying recurring issues and potential root causes.
Troubleshooting Steps Taken: Document all troubleshooting steps performed, including resets, recalibrations, and part replacements. This prevents redundancy and allows the maintenance team to pursue more advanced diagnostic steps.
Environment and Operational Context: Include details of operational conditions such as task load, environmental factors (e.g., temperature), and any recent configuration changes.

Escalation Protocol and Responsibilities

Step 1: Supervisor Notification:

Action: Operators report unresolved issues to their immediate supervisor, providing a summary and key documentation.
Additional Detail: Supervisors assess the impact on production and initiate formal escalation as required, helping prioritize resource allocation.

Step 2: Maintenance Request Submission:

Action: The maintenance team creates a formal maintenance request, attaching complete documentation. They may also consult historical logs to identify if the issue is part of a pattern.
Additional Detail: Clear, detailed requests ensure the maintenance team arrives prepared with the right tools and resources.

Step 3: Coordination with Maintenance Team:

Action: Maintenance and support teams coordinate an on-site review. This may involve troubleshooting sessions, equipment adjustments, or part replacements.
Additional Detail: On-site coordination allows for real-time insights and verification of fixes, especially for intermittent issues.

Step 4: Summary Report and Status Update:

Action: Maintenance completes a summary report outlining root causes, corrective actions taken, and recommended future preventive measures.
Additional Detail: Routine follow-ups ensure that both operators and maintenance teams are aware of any adjustments or procedural changes made, creating a feedback loop to prevent similar issues.

Examples of Escalated Issues and Priorities

Example 1: Persistent Robotic Arm Alignment Error:

Severity Level: Level 2 – High. Frequent misalignments after recalibration indicate a possible mechanical fault or software calibration issue.
Escalation Path: Initiate a Root Cause Analysis within 1-8 hours, followed by on-site intervention if necessary.

Example 2: Power Interruptions to Specific Components:

Severity Level: Level 1 – Urgent if affecting safety-critical functions; Level 3 – Medium if impact is limited to non-critical components.
Escalation Path: Conduct immediate troubleshooting within 1-3 hours, followed by on-site support if interruptions continue.

Example 3: Recurring VFD Fault on Stretch Wrapper:

Severity Level: Level 2 – High, as it impacts wrapping consistency and operational efficiency.
Escalation Path: Complete Root Cause Analysis within 8 hours and pursue repairs or replacement based on findings.

Operator Responsibilities Post-Escalation

Observing Equipment Behavior:

Detail: After any maintenance intervention, operators should carefully monitor the equipment for recurrence of symptoms, performance deviations, or unusual sounds.

Logging Observations:

Detail: Document all relevant observations in the maintenance log, especially if symptoms reappear within the same shift or operational cycle.

Implementing Preventive Measures:

Detail: Follow all preventive instructions from maintenance, such as adjustments to operational procedures or updated calibration schedules. Ensure that procedural changes are clearly communicated to all relevant team members.

Appendices and Additional Resources

Overview:

This section provides quick access to essential resources, including contact information, troubleshooting checklists, and maintenance schedules. It is designed to support operators by centralizing key information that may be needed during troubleshooting, maintenance, or escalation.

Contact Information for Support

For technical support related to the Mujin system, contact should be initiated through the internal escalation and service ticket process. Direct contact with Mujin Support may be made by authorized personnel only, following established escalation protocols outlined in Section 7.6.

Escalated Contact Details:

Mujin US Support:
- Phone: 1.888.501.MUJN (6856)
- Email: [email protected]
- Website: https://support.Pepsi.mujin-corp.com
- Address: 7250 McGinnis Ferry Rd, Suwanee, GA 30024
Don Harmon:
- Title: Service Director, Mujin Corp.
- Email: [email protected]
- Phone (Direct): +1.404.670.1747
- Phone (Office): +1.404.963.1117
- Website: https://mujin-corp.com
- Address: 7250 McGinnis Ferry Rd, Suwanee, GA 30024
Mark Collman:
- Title: Account Manager
- Email: [email protected]
- Phone (Office): +1.404.963.1117
Michael Klahold:
- Title: Local Support Manager[MK3] [DH4]
- Email: [email protected]
- Phone (Cell): +1.404.877.2095

Note: All contact with external support should be made only through the appropriate escalation channels and designated personnel, per established internal protocols.

Troubleshooting and Maintenance Checklists

Daily Start-Up Checklist:

Inspect E-stop functionality and verify that all safety mechanisms are operational.
Check for power stability and confirm system status on HMI.
Inspect robotic arms, AMRs, pallet stackers, and stretch wrappers for proper alignment and readiness.

Weekly Maintenance Checklist:

Test key components for wear or alignment drift, including joints, sensors, and air pressure levels.
Ensure that LIDAR sensors, QR markers, and other navigation aids are clean and aligned.
Review calibration settings for robotic arms and AMRs to confirm they meet operational tolerances.

Monthly System Check:
- Conduct full system calibration for all alignment-sensitive components.
- Review system logs for recurring faults and document any trends or patterns.
- Inspect network and physical connections, including cables, switches, and power sources.

Note: Checklists are meant to supplement standard operating procedures, offering structured reminders for essential tasks.

Quick Reference for LED Indicators

General LED Indicator Guide:
- Green LED: Normal operation or standby.
- Red LED: Error or fault; consult troubleshooting.
- Yellow LED: Maintenance or caution required; system may still operate but requires attention.
AMR-Specific Indicators:
- Green, Blinking: Standby mode.
- Red, Steady: Emergency stop or critical fault.
- Blue, Blinking: Standby for charging.
Robotic Arm and Wrapper-Specific Indicators:
- Yellow, Blinking: Waiting for safety clearance or object detection in the path.
- Red, Blinking: Calibration or alignment error; recalibration required.

Note: For a comprehensive LED indicator guide, refer to component-specific troubleshooting procedures in Section 7.

Maintenance Log Template

Purpose: Use this template for structured logging of maintenance activities, recurring issues, and preventive measures. Accurate logs facilitate faster troubleshooting and trend analysis for recurrent problems.

Maintenance Log Template:

Date/Time of Maintenance:
Component or System:
Error Code or Symptom:
Initial Observations:
Corrective Action Taken:
Follow-Up Required (Y/N):
Operator Initials:

Recommended Spare Parts List

Critical Spare Parts:

Robotic Arm (CP500L):
- Spare EOAT attachment parts
- Replacement sensors
AMR:
- LIDAR sensors
- Battery packs
Stretch Wrapper:
- Spare film rolls
- Replacement cutting mechanism

Glossary of Common Terms and Acronyms

AMR (Autonomous Mobile Robot): A mobile robot that transports loads autonomously within the operating area.
Analog Sensor: Supplies a proportional signal corresponding to the distance from the sensor to a target.
Autoheight: A feature where a photoeye sensor monitors the height of the carriage in relation to the load height. It signals the PLC to stop the carriage when the appropriate height is reached.
Dancer Bar: A roller on the carriage that controls the film tension as it wraps around the load.
EOAT (End-of-Arm Tool): The tool attached to the end of a robotic arm, designed to perform various tasks.
Film Tension: The resistance in the film feed, achieved by controlling the film’s speed relative to the rotation speed, creating a tight wrap around the load.
Firmware: The software embedded in the device (e.g., AMR, HMI, stretch wrapper) that controls its basic operations and can be updated for functionality improvements.
Heat Wire: A thin strand used in the stretch wrapper to cut the film after wrapping is complete.
HMI (Human Machine Interface): Often a touchscreen used by operators to interact with and control automated systems, displaying system status and allowing parameter adjustments.
LED (Light Emitting Diode): Indicators showing system status (e.g., operational, fault) through light signals.
Overlap: The amount of film overlap on each layer during upward or downward wrapping.
Overwrap: The film applied past the top of a stacked load to secure it.
Photoeye: An optical sensor that detects the presence of an object, commonly used in automated systems for positioning.
PLC (Programmable Logic Controller): A digital computer used for automation, controlling processes like wrapping cycles and handling sensor inputs.
Pre-stretch: Stretching the film before it leaves the carriage, often expressed as a percentage, to ensure consistent wrapping tension and material efficiency.
Proximity Sensor: A non-contact sensor that detects nearby objects, commonly used for positioning and safety interlocks.
Roping: Bunching the stretch film to create a "rope" for additional reinforcement around a load.
VFD (Variable Frequency Drive): Controls the speed of an AC motor by adjusting the power frequency, used in equipment like stretch wrappers and robotic arms for precise movement control.
Wrap Patterns: Programmable settings determining how a load is wrapped, such as the number of wraps and film tension, which can be adjusted via the HMI.
Wrap Zone: The designated area in which the wrapping equipment rotates around the load to apply the film.

Note: Refer to this glossary for clarification on technical terms used throughout the operating and maintenance manual.

Closing Statement

Thank you for following the operational, troubleshooting, and maintenance guidelines provided in this manual. Ensuring the safe and efficient use of Mujin equipment relies on the diligence and expertise of each operator and support team member. Please remember:

Always adhere to the recommended safety protocols, routine maintenance schedules, and troubleshooting procedures.
For unresolved issues, follow the escalation processes outlined in Section 7 to ensure prompt support and resolution.
Use the resources and contact information in Section 8 as needed, and consult the internal support team for further assistance.

Your commitment to these guidelines helps maintain a safe workplace, minimizes downtime, and enhances overall system performance. For any suggestions on improving this manual or adding resources, please contact the internal support team.

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