SEPTEMBER 2020 MAINTENANCE
A lack of skilled
engineers and
old equipment
has created a
perfect storm in
UK robotics
wiring and brakes were
built. Reusing an older robot
which may not comply
with current standards in a
production cell could have
potential consequences which
should be mitigated at the
outset by checking, and, if
necessary, upgrading to bring
it up to scratch.
For example, it is a
requirement to fully check a
robot braking systems under
rated load conditions prior to
re-using a robot in a cell, which
requires simulated testing of
the appropriate test weights
and programs to ensure the safe
stopping of the robot under
emergency conditions.
Refurbish or Replace?
The choice of whether to
refurbish or replace your
robot depends on a number
of factors, including, but not
limited to, the nature of your
application, any requirements
relating to availability and
reliability and, perhaps most
importantly, your budget.
Refurbishing a robot will
invariably present a cheaper
option than upgrading to a
newer model. In most cases,
robots can be returned to a
‘like-new’ condition relatively
cost eff ectively, but, as with
pretty much anything, you
should be wary that you get
what you pay for.
For this reason, it
is advisable to use the
manufacturer that supplied the
robot in the fi rst place, as they
will be best placed to have the
necessary original parts and
spares needed to carry out the
task. ABB for example, will
replace a customer’s robot
arm with an identical fully
tested refurbished unit.
Before being labelled
as an ABB-certifi ed
remanufactured robot,
every second-hand unit
undergoes rigorous
checks, including a
detailed inspection and
a minimum 16-hour
functioning test. Each
remanufactured robot
comes with a two-year
warranty and buyers of
refurbished equipment
enjoy the same level of support from local service
teams, including installation and training, as they
would with the purchase of a new ABB robot.
Unlike third-party refurbishes who only
fi x faulty parts, we completely remanufacture
our robots using original ABB design plans,
specifi cations and dimensional data. This
guarantees that the robots off er the same levels
of quality, performance, durability and safety
as a new ABB robot.
Each remanufactured robot can also be
upgraded to the latest controller, which
unlocks new functionalities such as ABB Ability
Connected services or the latest version of
RobotStudio®, ABB's simulation and offl ine
programming software. Upgrades can also
unlock the potential of collaborative robotics,
with ABB’s SafeMove 2 software providing
businesses with the opportunity to enable robots
to work alongside operators without the need for
extensive guarding, which helps to cut both the
cost of an installation and the overall footprint,
ideal for locations where space is at a premium.
Of course, you only have to look at the
example of the iPhone to realise that technology
moves on apace, such that yesterday’s state-ofthe
art gadget can quickly become outdated.
Originally launched in 2007, the iPhone has
since had many upgrades, with the capabilities of
today’s version of the device far exceeding those
of the original model. To a lesser extent, the same
is true of robots.
The current generation of controllers,
software and accessories such as vision and
gripping systems are far in advance of their
forbears, such that it may eventually be both
more practical and less costly in the long term to
opt for a new model rather than refurbishing an
existing one or buying second hand.
Summary
While your current robot may well be helping
to get you by, recent events show that it pays
more than ever to look ahead to the future and
consider whether it will continue to deliver the
sort of performance that will keep you ahead of
the competition.
this poses the risk that, whilst
they may look the same, they
may not match the quality
of the original components,
potentially compromising
either the effi ciency or the
safety of the robot.
Another option may
be to use spares from
decommissioned units.
Although this presents a
short-term solution, it carries
its own risks, particularly in
just-in-time applications such
as in the automotive and food
and beverage industries where
an unexpected failure of a
component could lead to costly
and potentially catastrophic
downtime.
Another complication is the
reduced availability of skilled
engineers and programmers.
This is especially the
case in the UK, where the
combination of a very low
adoption rate for industrial
robots and a shortage of
engineers has created a perfect
storm where there is an
insuffi cient pool of resources
to service the robot market. In
the same way that components
become more expensive as
they become harder to fi nd,
the same applies to fi nding
engineers qualifi ed to fi x older
or obsolete units.
Safety considerations
Developments in safety
legislation in recent years have
touched almost every aspect
of industry, and robots are no
exception. Safety legislation has
changed since the robot and its
safety systems, emergency stop
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