LCR Self Repair Guide - directedmachines/customer-support GitHub Wiki

Table of Contents

Introduction

Welcome to the team of Manufacturing Technicians at Directed Machines. As part of our commitment to ensuring the safe manufacturing and operation of our products, this "LCR Self Repair Guide" has been created to provide you with an outline of the safety considerations, assembly process and proper usage of essential tools. By following these guidelines, you will not only ensure the reliability of our robots but also contribute to the safety and well-being of yourself, your colleagues, and our clients.

Safety First

Safety is our top priority. Always adhere to these safety guidelines:

  • Personal Protective Equipment (PPE): Wear appropriate PPE, including steel-toed shoes, safety goggles, gloves, hearing protection, and any other required gear while working.
    • ANY impact, cutting, or abrasion is dangerous and requires safety glasses for all parties in the room.
    • Dust or fume conditions warrant particulate filter masks (welding, grinding, sanding, woodworking, plastic working).
    • Gloves are to be work when fastening assemblies, but machines like the horizontal bandsaw can grab gloves and pull you in, so be thoughtful of when you do and dont use gloves.
    • Hearing Protection should be worn when anything over 85-90 dB is happening. At the very least, do not expose your ears to sounds that hurt or make you wince/flinch. 85 dB for 8hrs is as damaging as a brief, extremely loud sound!
  • Work Area: Keep your work area clean and organized to prevent accidents.
  • Training: Only operate tools you have been trained to use properly.
  • Emergency Procedures: Familiarize yourself with robot e-stops, fire exits, and first aid kits.
  • Communication: If you spot any potential safety hazards or have concerns, communicate with your supervisor immediately.
  • Mindfulness: Complacency, horsing around, and lack of awareness of your surroundings all lead to the most common methods of injury. It is important to always be mindful of, and responsible with, your body, your equipment, and your surroundings.

Assembly Stages

Build Stage

During the build stage, use the provided assembly’s item number and SAP to find the assembly instructions. Follow the provided assembly instructions carefully. Be sure to read and enact every detail of every slide before moving on to the next one. Ensure components are correctly aligned and secured as described and pictured. Pay attention to torque specifications and use the torque wrench as instructed in the next section.

Verify Stage

In the verify stage, use the QA checks mentioned at the end of the assembly instructions and double-check the assembly for accuracy and functionality. Ensure all parts are in the correct position and secured properly. If any inconsistencies are found, address them before proceeding. This is to be done before getting an Engineer to QA your assembly.

Checking for Leftover Parts

After assembly, check the cart and the work area to ensure no leftover parts. Leftover parts must be analyzed to determine if they were omitted from the build by mistake, mis-picked, or are from outdated instructions.

QA

Have the assigned Engineer or Technician QA and sign off on your assembly. Then return the cart, signed paperwork, and any spare parts to the warehouse.

Essential Tools and Their Proper Use

Torque Wrench

The torque wrench is used to apply specific torque values to fasteners, ensuring proper tightness without over-tightening. Our torque wrenches must be set to a specific value when used and returned to 10 ft-lb when not in use. Watch this YouTube tutorial to understand how to use a torque wrench correctly.

Angle Grinder

The angle grinder is used for cutting and grinding metal. Safety is paramount when using this tool. You must always use the blade guard and always use safety glasses. The blade attachments can explode and lodge in your flesh or eyes. Watch this YouTube tutorial to learn about angle grinder safety and usage.

Horizontal Bandsaw

The horizontal bandsaw is employed to cut various materials accurately. Ideally you will not need to use this machine. Proper material clamping and blade tensioning are vital. Watch this YouTube tutorial to master the safe operation of a horizontal bandsaw.

Bench Grinder

The bench grinder is useful for sharpening, shaping, and polishing material. Ideally you will not need to use this machine. Maintain proper wheel balance and use appropriate safety precautions. Watch this YouTube tutorial for bench grinder safety and proper usage.

Deeper Safety Specifics

Transportation

  • Driving more frequently makes us complacent
  • Remember your car drives differently with tools or other added weight in it

Falls, trips, slips

  • Weather changes this
  • Chips and debris on the floor are as dangerous as water sometimes
  • Horsing around a common cause

Violence and other injuries by person or animal

  • Might surprise some, but is statistically high
  • Always feel free to come to us with any personal safety concerns or mental health needs

Contact with objects and equipment

  • Caught between, struck, cuts, punctures
  • Loading and unloading LCR or other heavy equipment is a crush hazard, keep distance, use winch as safety
  • No loose or dangling hair, clothing, or accessories
  • Our automotive jacks should never be trusted, as they are a single, inexpensive hydraulic cylinder. Standard practice is to lower workpiece on to multiple jack stands

Exposure to harmful substances or environments

  • Absorb, ingest, inhale, inject/puncture
  • Electrical hazards
  • 85 dB for 8hrs is damaging!
  • Lead, cadmium, lithium grease, stainless steel work (chromium, molybdenum)

Fires and explosions

  • Sparks and oily rags are a huge fire hazard
  • We obviously have a huge plasma fire risk from things accidentally making contact across the terminals of any of our batteries of powered systems
  • Always inspect electrical cables for wear or fray
  • Never use extension cords coiled up, their impedance will heat them up and the outer layer can melt

Client property hazards

  • Weight limit areas
  • Hazardous terrain
  • Security measures or electrified fences
  • Dangerous animals. Never touch any bugs, especially ones that look "soft". Assume any animal will bite you. Report ANY wildlife related injuries so we can research and mitigate risks.

Working on robot, mower ePTO, implements, or equipment

  • E-stop the robot
  • Turn the large, red disconnect switch on the electronics tray to cut off power to the motor controllers
  • If working on any part with a motor (reduction, mower, ePTO or otherwise) unplug that motor's cable from the tray to ensure the motor cannot be spun by the LCR

Do not do any powered or dangerous work alone at the shop (this includes some heavy lifting). In an emergency it is essential to have someone who can come to your aid when you call for help.

Conclusion

By following the guidelines outlined in this "LCR Self Repair Guide," you are contributing to the excellence and safety of our robot manufacturing process. Remember, safety is not only a priority but a responsibility we all share. If you ever have questions or concerns, don't hesitate to reach out to your supervisor or a fellow team member. Thank you for your dedication to quality, safety, and our collective success!