RMA Evaluation Report

First Name

Last Name

Employee position

Phone

Opened by

Opened date

RMA №

Rev

LOCATION

Customer

Ambient temperature

Pollution/Dust level

Project

Relative humidity

Vibration level

Agressive environmental conditions

Chemicals

Other

Oils

None

Quantity of production lines with Kinegge actuators

ROBOTIC WELDING CELL

Letter

№

ACTUATORS

Model

S/N

Commissioning date:

Quantity of Kinegge actuators on the problem production line

Total number of Kinegge actuators on location

Total number of Kinegge actuators with failure

GUN

Type

Ratio

Welding gun manufacturer

Gun Flexion

CONTROL

Robot manufacturer

Model

Control system

Software

Version

MAINTENANCE HISTORY

Last maintenance date:

Maintenance frequency

Previous failure

FAILURE

Robot errors №1

Robot errors №2

Robot errors №3

Robot warnings №1

Robot warnings №2

Robot warnings №3

Abnormal noise

No robot errors/warnings

Software

Version

Links to photo/video of failure:

Stage of welding cycle at which failure occurs:

Electrodes closing

Force squeeze

Welding

Electrodes opening

Other:

Errors/warnings rate:

One-off

Repetitive

Rate

Welding forces/times welding in the cycle:

Welding force 1, kN

Time welding 1, s

Welding force 2, kN

Time welding 2, s

Welding force 3, kN

Time welding 3, s

Welding force 4, kN

Time welding 4, s

Power supply at the moment of failure:

Current at the moment of failure:

Power supply stability:

Stability

Surges

Dips

Description

Actuator rod doesn’t move

Actuator doesn’t hold the force

Actuator doesn’t generate the specified force

Actuator is overheat

Value of rod movement doesn’t match the data of the feedback

Vibration actuator

Rod rotates and doesn’t move

External noise when the actuator is operating

Other

Other description:

INSPECTION

Backup

Backup name

Backup date

Setting

Motor file

Correct

Incorrect

File name

Setting by Kinegge start-up guide

Yes

Connection (electrical installation circuits)

Circuits integrity

Intact

Damaged

Insulation resistance

Intact

Damaged

Power supply motor from control system

Correct

Incorrect

Feedback signal circuit

Correct

Incorrect

Power supply brake from control system:

Correct

Incorrect

Control

Manual control

Yes

No-load current

No-load current with electrode

Name audio file:

Links to audio file

No-load current

No-load current without electrode:

Name audio file:

Links to audio file

External noise without electrode

Yes

Brake

Option

Yes

Remove

Click

No click

Apply

Click

No click

No-load current with brake applied

Holding torque

Resolver (only Kuka)

Resolver Kuka:

Yes

Bandwidth

Under load current

Current/Torque 1

Force 1

Calibration match 1*

Yes

Current/Torque 2

Force 2

Calibration match 2*

Yes

Current/Torque 3

Force 3

Calibration match 3*

Yes

Current/Torque 4

Force 4

Calibration match 4*

Yes

Current/Torque 5

Force 5

Calibration match 5*

Yes

*Calibration match – confirmation of compliance of the force/current (torque) relationship, obtained by calibrating the
gun on location

Traces file name:

Links to traces* file:

*Traces – timing diagrams of the robot axes operation according to given variables (current, position and etc.)

Recalibration

Current/Torque 1

Force 1

Current/Torque 2

Force 2

Current/Torque 3

Force 3

Current/Torque 4

Force 4

Current/Torque 5

Force 5

«Troubleshooting Guide» robot

Action 1

Effect 1

Action 2

Effect 2

Action 3

Effect 3

Action 4

Effect 4

Action 5

Effect 5

«Troubleshooting Guide» Kinegge

Action 1

Effect 1

Action 2

Effect 2

Action 3

Effect 3

Action 4

Effect 4

Action 5

Effect 5

REASON FAILURE

Actuator

Actuator failure

Reason:

Previously actuator failure

Circuit

Circuit failure

Reason:

Previously circuit failure

Settings control system

Settings control system failure

Reason:

Previously

Previously settings control system failure

Gun

Gun failure

Reason:

Previously

Previously gun failure

ACTIONS

Actions

Sending the actuator to the service center

Installing the correct motor file

Setting by Kinegge start-up guide

Reinstalling circuit

Reinstalling actuator on gun

Checking TCP adjustment after replacing welding caps

Improvement of the gun design

Other…

Other taken actions:

PREVENTIVE ACTIONS

Other taken actions:

Comments

Please fill up RMA Evaluation Report form:

LOCATION

ROBOTIC WELDING CELL

ACTUATORS

GUN

CONTROL

MAINTENANCE HISTORY

FAILURE

INSPECTION

Backup

Setting

Connection (electrical installation circuits)

Control

No-load current

No-load current

Brake

Resolver (only Kuka)

Under load current

Recalibration

«Troubleshooting Guide» robot

«Troubleshooting Guide» Kinegge

REASON FAILURE

ACTIONS

PREVENTIVE ACTIONS