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The assessment should open with the user being in a manufacturing facility and approached by an avatar supervisor and asked to determine what is happening in the palletizing cell that is currently out of operation. The user will then locate the palletizing cell within the environment (flashing red light above the cell) and approach the avatar located in the work cell. 

When the user approaches the work cell, the following conditions should be present within the work cell:

  1. Red flashing light Alarms on both sides of the palletizer, the HMI screen is displaying an “Error 4:  Robot Faulted, see HMI or Teach Pendant for Details”.  The system has automatically placed itself in Manual Mode due to the fault condition.
  2. The arm will be stopped in the position where it picks boxes from the conveyor.

The initial conversation that takes place between the user and the cell operator should consist of the following questions:

  1. What was happening when the robot malfunctioned?
  2. What alarm is showing on the HMI?
  3. What have you tried so far to correct the problem?

In our scenario – the alarm showing on the screen should be ERROR 4 – ROBOT FAILURE

There will be several “hints” in the environment to help the user determine where they should begin their troubleshooting.  Our malfunction will lie within the pneumatic line coming into the work cell that, for the purposes of this prototype, will be corrected by another avatar introduced later in the scenario. Our end user will focus only within the confines of our work cell environment.

The user will have several options when beginning their troubleshooting. They can begin at the end effector, begin by checking the values and sensor system coming from the robot arm, or begin by checking the pneumatics coming into the robot.  For our scenario, we are beginning with the pneumatic line coming into the robot as that is what causes the malfunction within the work cell.

Is there pressure at the regulator?  Yes – Even with water in the lines, there is still pressure if the plant air supply/compressor is charged/running.

Is there pressure at the switch? (Possible switch malfunction) Yes

Does the air shutoff exhaust valve function and exhaust system pressure when actuated:  No – when the user actuates the shutoff exhaust valves, not normal exhaust sounds are noticed.  It takes a period of time (Example 10 seconds) for the pressure to drop and get an air pressure fault on the HMI versus instantaneous under normal conditions.

Determination is made that there is a problem with the line coming into the cell. 

The next step is to remove the pneumatic exhaust muffler connected to the work cell shut off valve to determine the cause of the odd exhaust sounds.  Before removing the muffler, the end user will have to lock out and tag out the pneumatic line and blead off pressure in the system as applicable.  When the end user removes the muffler from the connector, he will immediately see that water is in the line. The water will drain from the system through the open exhaust port initially at a bit of pressure but then taper off like a garden hose being shut off.

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