VALTM II MECHANICAL TEARDOWN COURSE OUTLINE 
FOR THE PUMA® 500 SERIES ARM

I	OBJECTIVE
	To enable students to safely	
	A. 	Program
	B.	Maintain
	C.	Troubleshoot
	D.	Adjust
	E.	Repair
	F.	Apply the PUMA(r) series robot

I I	CLASS STRUCTURE
	
	A.	Lecture 
	B.	Questions
	C.	Practical Hands-on Exercises
	D.	8 hours per day for 4 days, plus 4 hours on Friday to 
		allow for travel time, for a 1 week period (35 Hours)

I I I	INTRODUCTION
	
	A.	Safety in the Classroom
	B.	Classroom Procedure
	C.	Robot Definition
	D.	History of the PUMA(r)  Robot

IV	SYSTEM OVERVIEW

	A.	Components of the Systems
		1.	Controller 
		2.	CRT/TTY
		3.	Floppy Drive
		4.	I/O Section
		5.	Teach Pendant
		6.	Robot Arm

V	ROBOT ARM

	A.	Anthropomorphic Members 
	B.	Anthropomorphic Joints and Rotation Limits
	B.	Operating Envelope

VI	COORDINATE REFERENCE SYSTEMS

	A.	Definition of Measurement Reference Systems
	B.	Joint Coordinate Systems
		1.	Joint Rotation Limits
	C.	Cartesian Coordinate Systems
	D.	TOOL Coordinate Systems
	E.	Orientation, Altitude, TOOL Positioning Definitions

VII	PRINCIPLES OF CONTROL

	A.	Control Principles Block Diagram
		1.	Trace Command Signals
		2.	Trace Servo Board interpolation
		3.	Trace Closed Loop DC Motor drive system

VIII	SAFETY

	A.	Cautionary Levels in Manual
	B.	Safety Summary
	C.	Installation Safety Considerations

IX	OPERATION

	A.	Safety
	B.	Console Description
		1.	Front Panel
		2.	Top Panel
		3.	Back Panel
	C.	Start-Up Procedures
		1.	Non-auto
		2.	Auto
	D.	Calibration
	E.	Teach Pendant Description
	F.	Practical Exercise - Teach Pendant Operation

X	BASIC VAL(tm)

	A.	Notation
		1.	Modes and Prompts
		2.	Arguments
	B.	Commands and Instructions
	C.	Editing 
	D.	Practical Exercise - Creating a VALTM  Program
	E.	Editing Teach Mode Commands
	F	Practical Exercise - Executing and Aborting a program

XI	PROGRAM INSTRUCTIONS

	A.	Motion Instructions
	B.	Program Execution Speed
	C.	Hand Control
	D.	Practical Exercise - Pick and Place
	E.	Expressions
		1.	Using constants
		2.	Using constants and Mathematical operators
		3.	Using constants and functions

XII	DRIVE TRAINS
	
	A.	Joint 1
	B.	Joint 2
	C.	Joint 3
	D.	Joints 4, 5, and 6

XIII		DISASSEMBLY

		A.	Removal of Covers
		B.	Removal of Wrist Assembly
		C.	Removal of Minor Motors
			1.	Removal of Joint 4 Moter Assembly
			2.	Removal of Joint 5 Motor Assembly
			3.	Removal of Joint 6 Motor Assembly
		D.	Removal of Joint 3 Drive Assemblies
			1.	Remove Joint 3 Idler Cartridge Assembly
			2.	Remove Joint 3 Input Cartridge Assembly
			3.	Remove Joint 3 Motor Assembly
		E.	Remove Outer Link
		F.	Removal of Joint 2 Drive Assemblies
			1.	Remove Joint Idler Cartridge Assembly
			2.	Remove Joint Motor
		F.	Remove Air soleniod
		G.	Remove Wire Harness Assembly
		H.	Remove Inner Link
		I	Removal of Joint 1 drive assemblies
			1.	Remove Joint 1 Motor
			2.	Remove 2 Joint 1 Idler Cartridge Assemblies
			3.	Remove Joint 1 Bull Gear
		J	Remove Joint 1 Casting

XIV		ASSEMBLY

		A.	Install Joint 1 Casting
		B.	Assembly of Joint 1 Drive Assemblies
			1.	Install Joint 1 Bull Gear
			2.	Install Both Joint 1 Idler Cartridge Assemblies
			3.	Install Joint 1 Motor Assembly
		C.	Adjust Backlash
		D.	Install Wire Harness Assembly
		E.	Install Inner Link
		F.	Installation of Joint Drive Assemblies
			1.	Install Joint Idler Cartridge Assembly
			2.	Adjust Backlash
			3.	Install Joint 2 Motor Assembly 
			4.	Adjust Backlash
		G.	Install Air soleniod
		H.	Install Outer Link
		I.	Installation of Joint 3 Drive Assemblies
			1.	Install Joint 3 Idler Cartridge Assembly
			2.	Adjust Backlash
			3.	Install Joint 3 Input Cartridge Assembly 
			4.	Adjust Backlash
		J.	Install Wire Harness Assembly
		G.	Install Minor Motors
			1.	Install Joint 6 Motor Assembly
			2.	Install Joint 5 Motor Assembly
			3.	Install Joint 4 Motor Assembly
		H.	Install Wrist Assembly
		I.	Install Joint 3 Motor


XV	PERIODIC MAINTENANCE
	A.	Lubrication
	B.	Checking for Bearing Wear and Gear Backlash
	C.	Adjustment Procedure for Backlash
	D.	Practical Exercise - Backlash Adjustment

XVI	TROUBLESHOOTING & DIAGNOSTICS

	A.	Gathering Information
	B.	Applying Logic
	C.	Fault Isolation - General
	D.	Fault Isolation - Electronimation
	B.	Applying Logic
	C.	Fault Isolation - General
	D.	Fault Isolation - Electronic Diagram
	E.	Card Cage Layout
	F.	Troubleshooting Guide
	G.	Electric Block Diagram