Switching controllers between robots

  • Hi all!

    I have a question to community according switching D controllers between robots ZX165.


    I have two D42F-C001 controllers with ZX165U B robots, but first robot has a problem with 1st axis gear and controller from second robot is missing a lot of parts.

    Can I combine working controller from first robot together with second robot?

    If so, how looks that procedure?

  • What have Kawasaki said regarding procedure, have you asked them?

    I have two D42F-C001 controllers with ZX165U B robots, but first robot has a problem with 1st axis gear and controller from second robot is missing a lot of parts.

    Can I combine working controller from first robot together with second robot?

    If so, how looks that procedure?

    There are a lot of questions with a remark about swapping controllers in terms of electrical setup and internal programs, procedures are only applicable when replacing 'same for the same'.


    So how can anyone advise, when you don't mention what missing parts there are.

    - Are both robots dressed in exactly the same way.

    - Are controllers electrically the same in terms of boards, safety and external IO interfacing.


    In automation:

    - They have standby robot already dressed.

    - They have standby controller already electrically configured with the boards required for line.


    If robot is mechanically faulty, maintenance swap out old robot with new robot.

    - Power up, choose arm id question to use controller side for robot model and zeroing information.

    - Check mechanical zero is correct, programs and locations and then back into operation.


    If controller is faulty and no time to fix, maintenance swap out old controller with new controller.

    Then either:

    - Backup suspect controller and transfer data to new controller, including same firmware.

    - Swap CPU board from suspect controller to new controller.

    - Then power up, choose arm id question to use robot side for robot model and zeroing.

    - Check mechanical zero is correct, programs and locations and then back into operation.


    ALL Kawasaki boards have (including card rack backplane) have dipswitch/jumper configurations which need to be checked and confirmed the same.


    ALL Kawasaki controllers store information on CPU board, so effectively exchanging CPU boards exchanges controllers as long as ALL board dipswitch/jumper configurations and boards are the same.

  • Thank you for your answer.

    To be more precise.


    These robots with controlles are in warehouse of my company. There were used before on production line, but contract ended. I was just wondering if I will be able from two robots with controllers make one fully working set. I know that one controller is not working, because of missing parts, but no one can assure me, if it is fully functional even with all parts inside. Also, I want to make this operation as cheap as I can, so buying spare parts is not considered.


    What have Kawasaki said regarding procedure, have you asked them?

    No I haven't. I thought I ask here first.



    Both robots are exactly the same, no tools, no additional devices on them. S/N are 4036 and 4037. Both controllers with whole wiring and boards are also the same, as they were working on the same line with the same configuration. They were just handling robots, bought from local supplier many years ago.


    According to your information in my case replacing can look like that:

    Quote

    If robot is mechanically faulty, maintenance swap out old robot with new robot.

    - Power up, choose arm id question to use controller side for robot model and zeroing information.

    - Check mechanical zero is correct, programs and locations and then back into operation.


    Assuming that controller is my base and I change robot the situation should look like written above.

  • These robots with controlles are in warehouse of my company. There were used before on production line, but contract ended. I was just wondering if I will be able from two robots with controllers make one fully working set. I know that one controller is not working, because of missing parts, but no one can assure me, if it is fully functional even with all parts inside. Also, I want to make this operation as cheap as I can, so buying spare parts is not considered.

    Without sounding condescending, specifically it sounds like you have a box of jumping frogs.

    Unless you have 'known' good parts, you could be seeing your own arse very quickly.


    What I mean by this is the obvious, you have a lot of kit, but have no assurances that any of it works and on top of that, you want to be cheap as possible and without any option of buying spare parts.


    So the overall is make one system out of 2.

    - Are you intending in repurposing it do the same application, or do you wish it to be a 'clean' one.

    - Do you know what should be or shouldn't be included in a normal working system.

    - Have you any backup file saves of either controller to reference to.

    - Have you replacement batteries for the RAM and Encoders ready to install.

    - Provide pictures of the inside of both controllers and I can advise further.

  • I work very closely with a company in the UK whom purchase and repurpose 2nd user systems and very often the same questions are asked over and over again when you don't have specific product knowledge.


    Understand what you are buying first:

    - Prior knowledge of basic parts for a standard system by OEM, do they have the bare minimum.

    - See them with power applied to them.

    - See them working, or displaying errors if not working, some life signs at least gives some guidance.

    - If power cannot be applied, then assume faulty, missing parts and prepare to spend more money.

    - Possibility, that if they assure you all is good, may just need new batteries and good to go as is.


    So in your case:

    - Have you a full compliment of basic controller boards, if so, install in card rack.

    - Correct umbilical's required to connect between controller and robot and connect up.

    - Connect Teach Pendant.

    - Assume internal controller cabling and internal robot harnessing is intact.

    - Apply power whilst placing finger in ear and see if life exists without bang, smoke or fire.

    - If life exists, don't wipe everything until you make file save first, could save a lot of time in long run.

  • I was working as a system integrator in automotive business for a few years so I know sth about robots, but the problem which i mentioned above is connected more to maintenance side and I have some gaps in knowledge.


    - Are you intending in repurposing it do the same application, or do you wish it to be a 'clean' one.

    I have planned to make this robot as a learning station for newbies or to improve skills of i.e. maintenance. We have a lot of robots on production line, but we have no proper learning station and sending people for training is very rare.

    - Do you know what should be or shouldn't be included in a normal working system.

    Yes, I do.

    - Have you any backup file saves of either controller to reference to.

    That shouldn't be a problem. Maintenance makes regular backups.

    Quote from kwakisaki

    - Have you replacement batteries for the RAM and Encoders ready to install.

    Yes, I have.

    - Provide pictures of the inside of both controllers and I can advise further.

    Maybe in 2 months i will have some time to start the switching operation, so if any further problem occurs I will write again in this post.

  • Thank you for your offer. This is my side project doing on my own when I have some time and I don't know if I can get any funds to finish this. Especially in time when my company is looking for savings everywhere.

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