I've attached a few photos of what our group ran into over the weekend. This is the "rack and pinion" from underneath one of our vision robots that runs on a track to load completed parts into a rack. For the most part the robot sits stationary during the job with only short runs back and forth on the track until it goes to load it's first part into the rack and during this the robot runs the full length of the track into the rack, sets the part, and then runs the full length of the track to exit the rack once the drop has been completed. It does this ten times per rack but the travel gets shorter and shorter as the rack fills up. The major wear areas are at the two points where the robot is "accelerating" and "deccelerating" at a pretty quick speed.
So my question is what would be more beneficiary to correct this issue?
Would slowing down the ACCEL/DECCEL of this axis be a good start? (I would like to avoid slowing the line down but you can't win them all)
Was this maybe caused by a misalignment or lack of proper lubrication? *EDIT* the more I think about it the more I believe the gears teeth are not properly “meshed” with the track and maybe there is a gap between the teeth. This is really hard to see being that it’s underneath the robot but I’m going to take some photos with my phone and see if I can get a clear shot. We may just need to shim the servo a bit to get this closed in.
The linear bearings all seem perfectly fine as well at the rails.
We have a second line that is literally identical except it was setup by a different integrater/programmer so all the equipment is the same to a "T" but the programs are entirely different and that line is showing minumal wear. The line in question uses one taught position and relys on Voffset to find the other 9 spots whereas our line that is still in good condition uses PR's for every point and then the vision adjusts X and Y. So this sticks out to me that maybe it could be something as a simple program change as far as acceleration limits or something along those lines?
Our first shift guys replaced the rack and then when I got here I replaced the drive gear so I could begin reteaching the jobs. So everything is running currently but I want to know what you guys think of this and what we could try to do to prolong the life of this new track without effecting tact time to much. If you need to know anything else about the program or setup please ask.
When I get in to work tomorrow I'm going to start trying to compare some variables and stuff and see if I can find any differences so if you guys have some you think I should check let me know! Thank you all in advance.