Critical Components
9
Require vibration isolation
High Risk
14
Require protective packaging
Spare Parts (P1)
11
Must ship alongside robot
Transit Duration
~6
Days by rail — rough handling
Rail shipping context: Train transport in India involves significant vibration (5–50 Hz broadband), shock events at coupling/shunting (up to 3–5g), humidity swings, and uncontrolled orientation changes. All packaging recommendations assume NO climate control and NO careful handling by rail staff.
Component-Level Shipping Risk
| Component | Assembly | Transit Risk | Failure Mode in Transit | Packaging Required | Spares to Ship |
|---|---|---|---|---|---|
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Ball Screw Lift + THK HGW20 Rails
PA Lift — 200W servo, ±2mm backlash tolerance
|
PA | CRITICAL | Shock load at rail coupling can damage ball screw preload. Rail carriage binding if rails knocked out of parallel. Contamination from dust ingress. Backlash can open up from >2mm to 5–8mm. |
Lock carriage at center travel with mechanical clamp or zip-tie
Tape over all rail gaps with foam-backed tape — no dust ingress
Wrap screw + rail assembly in VCI (anti-corrosion) film
Surround with 50mm closed-cell PE foam on all 6 sides
Mark crate: THIS SIDE UP — no inversion
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CRBH6013A Crossed Roller Bearing
PA Turntable — tilt tolerance <2°, zero backlash required
|
PA | CRITICAL | Vibration-induced preload loss during transit. Raceway brinelling from repeated shock impact. Any bearing play >0.1mm causes tilt >2° = bin contents shift = safety incident at bank. |
Lock turntable rotation with bolt-through fixture or wooden block wedge
Do NOT allow turntable to spin freely during transit
Cushion PA assembly on 4 vibration-isolating rubber mounts inside crate
Wrap bearing housing in bubble wrap + PE foam before crating
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Kinco iWMC 400W Drive Motors
Mother — 2× motors, 48V, 8.2Nm, EtherCAT, zero field hours
|
Mother | CRITICAL | EtherCAT encoder damage from shock — causes navigation position error. Motor shaft bearing damage from lateral loads if wheels unsupported. New 48V system with no field baseline; any connector damage = no navigation. |
Block all 4 drive wheels with wooden chocks — zero free rolling in crate
Wrap motor bodies in bubble wrap — protect encoder connectors
EtherCAT connectors: tape with stretch wrap or fit dust caps
Mother ships upright (not tipped on side)
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Kinco MD60 Climb Motor + Compliance Block
Child — NEW compliance block, highest field error on V3 (RPN 240)
|
Child | CRITICAL | Compliance block (new design) has unknown resonance characteristics — may amplify rail vibration. Motor brake engagement can be knocked loose by shunting shock. Encoder cable connector fatigue from sustained vibration. |
Engage motor brake electronically before shutdown — verify it holds
Wrap motor + gearbox in foam sleeve, secure to chassis — no free movement
Zip-tie encoder cables to strain relief bracket
Add foam pad between compliance block and crate floor to damp resonance
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Cubemars AK70-10 Latch Motor
Child — Brake + absolute encoder, #4 field error on V3 (RPN 200)
|
Child | CRITICAL | Latch mechanism must be FULLY RETRACTED before shipping — if extended, latch arm can be sheared by crate side wall during rough handling. Gear mesh can shift if bracket bolts loosen from vibration. |
Retract latch fully and secure with a zip-tie through the latch hole
Torque-check all latch bracket bolts to spec before crating
Wrap latch arm in bubble wrap to protect pinion teeth
Tape Cubemars connector — connector pull-out is the #1 failure mode
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Feetech SM260BL Fork Motor
Child — 260kgcm, EtherCAT (new protocol), zero field hours at this spec
|
Child | CRITICAL | Fork must be fully retracted — any extension means fork hits rack or crate. EtherCAT connector on SM260BL is non-standard; crimp failure from vibration causes complete fork loss. 3x torque upgrade means any misfire post-transit damages rack. |
Retract fork fully before shutdown — verify mechanically, not just via software
Secure fork guide rails with foam inserts to prevent rattle
EtherCAT connector: wrap with self-amalgamating tape
After arrival: run torque limit calibration before first pick
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48V LFP/LMFP Battery Packs
Mother + Child — New BMS, 26700 cells, zero field charge cycles
|
MotherChild | HIGH | Rail shipment in India may violate DG goods regulations for Li-ion >100Wh (each pack is ~240Wh). BMS connector intermittency from vibration = cell imbalance on first charge. Temperature swings on uncooled goods wagon can trigger BMS protection cut-off. |
Verify rail DG classification — may require lithium battery declaration
Ship batteries at 30–40% SoC (LFP safe transport SoC)
Wrap battery pack in ESD foam — prevent cell-to-cell shorting
Place inside fireproof battery bag if available
Separate from robot body if permitted by space — reduces DG class
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Mother-Child Dock Interface
Aligner tracks + compliant top plate — NEW design, tight tolerance
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Mother | HIGH | Child must be undocked from Mother for shipping — if shipped docked, rail vibration can fatigue the compliant plate and cause misalignment. Aligner track pins can be bent by lateral shock. Any >5mm misalignment after arrival = child fails to dock. |
Ship Mother and Child as separate units in same crate
Wrap aligner track pins with foam tube to protect from bending
Cover dock receiver with cardboard template to prevent debris ingress
Do alignment check (visual) on arrival before first dock attempt
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Staubli 195771 Charging Connectors
Mother + Charging Dock — NEW with LMFB feedback pins, untested
|
DockMother | HIGH | LMFB feedback pins are small-gauge — vibration causes micro-fretting corrosion on pin surfaces. Any fretting = intermittent dock detection = robot never confirms charge = dead by morning. Connector housing can crack if not supported during shipping. |
Fit rubber dust caps on all Staubli connectors before shipping
Wrap connector housings in bubble wrap — support from underneath
Apply dielectric grease to all pins before reseating caps
Inspect pin faces with magnifier on arrival
|
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LP-24 / YM-20 Inter-Module Connectors
All assemblies — NEW connectors replacing GX16/DH-24, untested in vibration
|
All | HIGH | All connectors are new design — vibration pull-out force not characterized. Rail vibration at 20–50Hz can cause intermittent opens on poorly-seated connectors. On arrival: any connector problem causes cryptic errors at power-on with no history to debug. |
Cable-tie all connectors to nearest strain relief point before shipping
Label every connector with tape flag (donor + receiver) before tying
Do a tug test on every connector before crating — must not pull out at 5N
On arrival: wiggle-test all connectors before power-on
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Omron PLC + M100 Charge Controller
Charging Dock — controls charging, silent failure RPN 280
|
Dock | HIGH | PLC mounted on DIN rail — rail clip can loosen from vibration. If PLC shifts, terminal block wiring can pull out. Silent failure: dock looks connected but doesn't charge. First indication is flat battery at 6am. |
Add lock screws or safety wire to all DIN rail clip points
Wrap full electrical panel in anti-static foam before crating dock
On arrival: check all terminal block screw torque before power-on
Verify charging current >0.5A within 2 min of dock connection
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PA Door Mechanism
PA — electromechanical with interlock, chronic V3 failure, "improved" in Neo
|
PA | HIGH | Door mechanism ships as part of PA — if door is in open position during transit, hinge and actuator can be bent by accidental load. Door interlock switch (micro-switch) is vibration-sensitive. V3 had chronic door failures — Neo is unvalidated. |
Close and latch door fully before shipping — tape closed with 3 strips
Foam pad between door face and PA frame to prevent rattle
On arrival: 10-cycle door test before any full-system power-on
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Scaime Load Cell (PA Turntable)
PA — vibration causes >1g drift, tolerance critical for bin detection
|
PA | HIGH | Load cell is a strain gauge assembly — sustained vibration can zero-drift the baseline by 2–5g. On arrival, the cell will need recalibration. If not recalibrated, bin-present detection will use wrong threshold and either miss bins or false-trigger. |
No action needed for shipping itself — cell is robust
On arrival: mandatory recalibration with known weights before any PA cycle
Zero the load cell with no bin, then verify with 1kg test weight
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Floor QR Navigation Tags
Site infrastructure — 22+ tags, must be installed flat at site
|
Site | MED | QR tag sheet stock can be bent or creased in transit — even slight bowing causes intermittent read failures. If tags ship rolled, they won't adhere flat. Navigation fails on any unreadable tag. |
Ship tags flat between two rigid cardboard sheets — never rolled
Wrap in plastic bag to prevent moisture absorption (rail humidity)
Carry 5 spare tags above minimum count
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EtherCAT + 48V Wiring Harness
All — New harness, wiring arrives Mar 13, crimps untested in field
|
All | HIGH | New crimped harness — vibration can cause crimp barrel fatigue on fine-gauge EtherCAT wires. Any open crimp = EtherCAT bus faults on one or more motors = navigation/fork/turntable error. Very hard to debug at site without oscilloscope. |
Bundle all cables with velcro ties every 15cm — no free-hanging runs
Add adhesive foam saddle clamps at any cable routing corners
Carry spare crimping tool + terminals at site
On arrival: visual inspection of all crimps; pull-test key connectors
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Crate & Padding Specification
Mother Unit Crate
- Plywood crate, min 18mm walls. Internal dims: robot + 100mm clearance all sides
- 4× rubber anti-vibration mounts (M8, 10kg rated) between Mother base and crate floor
- Wheel chocks: 4× wooden wedges, glued to crate floor — no rolling
- Battery disconnected and taped at terminal — 30–40% SoC
- Top foam layer: 50mm PE closed-cell over entire robot body
- Crate label: FRAGILE — PRECISION ELECTRONICS — NO INVERSION
- Silica gel pack (200g) inside sealed crate — moisture control
Child Unit Crate (separate from Mother)
- Child ships in separate crate — do NOT nest inside Mother dock
- Climb motor: foam sleeve secured with velcro strap to prevent vibration
- Latch: fully retracted, zip-tied. Fork: fully retracted, verified mechanically
- 4 corner rubber mounts between child frame and crate floor
- Upright shipping only — mark orientation clearly with arrows
- 50mm PE foam on all exposed protrusions (climb rollers, fork tips)
- Bubble wrap on all encoder connector housings
PA Unit Crate
- Heaviest crate (~80kg with crate) — needs forklift pockets on crate base
- Ball screw carriage: mechanically locked at center travel (clamp or bolt-through)
- Turntable: rotation locked with wooden block wedge + zip-tie through housing
- Linear rails: taped over with foam-backed masking tape — all 4 slots
- Door: closed, taped, foam between door and frame
- Load cell: no special packaging, but recalibrate on arrival
- 6× rubber anti-vibration mounts (M10, 20kg rated) — PA is heaviest unit
Crate & Shipment Summary
Per-Crate Specification
Minimum spec for rough rail handling — 3–5g shunting shocks
Wall material
18mm marine plywood (min) — no MDF
Inner cushion
50mm closed-cell PE foam all 6 sides
Vibration mounts
4–6× rubber anti-vib mounts per crate
Fragile label
All 6 faces — Hindi + English
Orientation
THIS SIDE UP on 4 faces (arrow + text)
Moisture control
200g silica gel per crate, crate sealed
Strapping
2× steel straps cross-wise around crate
Total Shipment
All units + spares box — Mar 18 dispatch
Crate 1
V3 Mother (~60kg gross)
Crate 2
V3 Child (~40kg gross)
Crate 3
PA + Charging Dock (~100kg gross)
Crate 4
Spares box — see list below (~10kg)
DG declaration
Required — 2× LFP 240Wh batteries
QR/RFID tags
Flat-packed in Crate 4 between rigid board
Tools
Crimp tool, torque wrench, multimeter in Crate 4
Spare Parts — Must Ship With Robot
P1 — Critical Spares (site down if missing)
| Part | Qty | Reason |
|---|---|---|
| Kinco iWMC 400W drive motor | 1 | Zero field hours — unknown failure rate |
| Kinco MD60 climb motor | 1 | #1 operational risk, RPN 240 |
| Feetech SM260BL fork motor | 1 | New EtherCAT, no field data |
| CRBH6013A turntable bearing | 1 | Brinelling risk in transit |
| Staubli 195771 connector | 1 | Silent failure = no charge |
| LP-24 connector set | 5 sets | All new connectors, untested in vibe |
| YM-20 connector set | 5 sets | All new connectors, untested in vibe |
| Floor QR navigation tags | 5 extra | Any damage = navigation failure |
| BMS fuse set (Mother + Child) | 2 sets | New BMS, zero charge cycles |
| EtherCAT cable 1m (per motor) | 4 | Crimp fatigue from vibration |
| 48V DIN rail power relay | 1 | Dock charging single point of failure |
P2 — Recommended Spares (hours of downtime if missing)
| Part | Qty | Reason |
|---|---|---|
| Compliance block assembly | 1 | New design, unknown resonance |
| Latch pinion gear | 1 | V3 #4 error — tooth wear risk |
| Latch return spring | 2 | Spring fatigue from shock |
| Aligner track pin set | 1 set | Bending risk from lateral shock |
| Door actuator | 1 | V3 chronic door failures |
| Door interlock micro-switch | 2 | Vibration-sensitive component |
| 26700 LFP cells | 4 cells | Cell imbalance after thermal cycling |
| PLC terminal block (spare) | 4 | DIN rail vibration pullout |
| Bin-level RFID tags | 2 per level | Site install, damage risk |
| Load cell calibration weights | 250g/500g/1kg | Must recalibrate on arrival |
| Ferrule crimp set + ratchet tool | 1 kit | Harness repair at site |
Pre-Ship Checklist (Complete Before Crating — Mar 17–18)
Mother Unit
Battery at 30–40% SoC — verify on BMS display
Battery terminal disconnected and taped
All 4 wheel chocks installed and secured to crate
Drive motor EtherCAT connectors dust-capped
Staubli 195771 connector dust-capped + dielectric grease
All LP-24/YM-20 connectors seated + tug-tested
Dock aligner pins wrapped in foam tube
50mm PE foam over top and sides
Child Unit
Fork fully retracted — verified mechanically (not just software)
Latch fully retracted — zip-tied through latch hole
Climb motor brake engaged — verify by hand (shaft should not turn)
Climb motor encoder cable zip-tied to strain relief
Latch pinion gear wrapped in bubble wrap
Child battery at 30–40% SoC, terminal disconnected
Compliance block foam pad on all 4 sides
Fork guide rail foam inserts in place
PA + Charging Dock
Ball screw carriage mechanically locked at center
Turntable rotation locked — wedge + zip-tie
Linear rails taped over with foam-backed tape
PA door closed, taped (3 strips), foam inside gap
All DIN rail terminal block screws torque-checked
PLC + M100 panel wrapped in anti-static foam
Charging Staubli connector dust-capped
DG declaration prepared for 2× LFP 240Wh batteries
On-Arrival Inspection (Mar ~24–25, Before Any Power-On)
Visual + Mechanical
Inspect crates for crush damage before opening
Check aligner track pins — not bent or deformed
Ball screw: smooth by hand, zero binding along full travel
Turntable bearing: rotate by hand — no roughness or play
Staubli connector pins: magnifier inspection, no fretting
All LP-24/YM-20 connectors: wiggle-test, should not pull out at 5N
Pre-Power Checks
Recalibrate load cell: zero + 1kg test weight
PLC terminal block screw torque check before energizing
Battery cell voltages balanced within 50mV before charging
Remove all shipping locks (turntable wedge, ball screw clamp, fork zip-tie, latch zip-tie)
EtherCAT wiring visual inspection: all crimps seated
Remove all foam inserts and packing material from inside assemblies
First Power-On Sequence
Power on Mother only — no Child docked — verify no fault codes
PA door: 10 open-close cycles before any lift/rotate command
Charging: dock Mother, verify charge current >0.5A within 2 min
Kinco PID tuning: 10-cycle nav run, log position error at each QR tag
First climb: do with empty Child — listen for any bind or grind
First turntable rotation: slow speed, confirm no rattle or chatter