90213-1016DED F-Zeroing Motor Replace

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N ZEROING INSTRUCTIONS

MOTOR REPLACEMENT INSTRUCTIONS

KAWASAKI HEAVY INDUSTRIES, LTD. ROBOT DIVISION

90213-1016DED

1. Outline of Zeroing

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N

Preface This manual is subject to change without prior notice and without our legal responsibility.

Kawasaki pursues a policy of continuing improvement in design and specification of the product. The right is therefore, reserved to vary this manual without prior notice. This manual is copyrighted and all rights are reserved by KHI.

This manual may not, in whole or part, be reproduced in any form or by any means without prior written permission from KHI.

This manual is prepared with the best care but anyway it is impossible to exclude any misinterpretation by the user or any spelling mistakes. In case of doubts or if the robot behavior is different from that reported in this manual please would you get in touch with the nearest Kawasaki or Kawasaki’s agent.

KHI cannot anticipate every possible circumstance that might involve a potential

hazard. If a procedure, work method or operating technique not specifically recommended by KHI is used, you must satisfy yourself that it is safe for you and others. In this case you are completely responsible for eventual damages on human bodies or things.

If you discover physical defects in the manual, KHI will replace the manual at no charge during 90 days period after you purchased the robot.

If you do not observe warnings and/or cautions to be taken in the manual as described below, it might result in the serious injuries or damages on human bodies or robots. Therefore you must take extreme care to observe these warnings and cautions.

All rights reserved. Copyright  1999 by KAWASAKI HEAVY INDUSTRIES, LTD.

1

!

WARNING

1. For the confirmation of acceptability and effectiveness of drawings, detailed specification of documents, procedures etc. it shall be still


insufficient. Therefore, if you desire to operate/serve/maintain/adjust/modify, and

to do miscellaneous works, you must pay utmost attentions to them. 2. Those persons who engage with the operation/service of your system, they must strictly observe all safety regulation at all times. Never replace and/or adjust the inside parts provided in your Robot

system while the power source is being turned ON so as to ensure your own safety.

[ SYMBOLS ]

Whenever you see the symbols shown below in this manual or on the machine, read and understand their messages.

!

DANGER

This danger symbol identifies special warnings or procedures which, if not strictly observed, will result in serious injury or death.

!

WARNING

This warning symbol identifies special warnings or procedures which, if not strictly observed, could result in serious injury or death.

!

CAUTION

This caution symbol identifies special instructions or

procedures which, if not correctly followed, may result in injury. [ NOTE ]

This note symbol identifies supplementary information, or to emphasize a point or procedure, or to give a tip for easier operation.

2


This Instru ction Manual describe the Zeroing instructions and Motor replacement instructions of KAWASAKI ROBOT F Series.


You are recommended to well understand the contents of this Instruction Manual fully, as well as to look to your own safety for the zeroing work and for the replacement of motors.

For the details of the replacement of motors and the zeroing work in the encoder section, please refer to separately prepared "H20 Encoder Replacement Instructions".

!

WARNING

Those persons who are qualified to engage in the motor replacement work should be restricted to those who have received the maintenance course in the special education & training program arranged by our Service Group.

3

CONTENTS 1. Outline of Zeroing..................................................................................................... 5


2. How to Preset Encoder............................................................................................ 6 3. Rough Zeroing (1) (All Axes Collectively) .............................................................. 8 4. Rough Zeroing (2) (Each Axis Individually) .........................................................10 5. Accurate Zeroing....................................................................................................12 5.1.Preparation work of accurate zeroing................................................................... 13 5.2. Zeroing of JT2 ..................................................................................................... 15 5.3. Zeroing of JT3 (Except for FS10X, FS30N, FS30L, FS45C, FS45N)................... 17 5.4. Zeroing of JT3 (In case of FS10X, FS30N, FS30L, FS45C, FS45N)................... 19 5.5. Zeroing of JT4 ..................................................................................................... 21 5.6. Zeroing of JT5 ..................................................................................................... 23 5.7. Zeroing of JT6 ..................................................................................................... 25

6. Caution to be Taken at Motor Replacement........................................................28 7. Outline of Motor Replacement..............................................................................29 8. Prior to Replace Motor (Encoder).........................................................................30 9. Summary of Motor Replacement Work................................................................31 10. Works to be carried out Before Replacement of Motors..................................33 11. Replacement Instruction for Motors...................................................................35 11.1. Replacement of 100 W Motor............................................................................ 35 11.2. Replacement of 200 W Motor............................................................................ 37 11.3. Replacement of 475W Motor............................................................................. 39 11.4. Replacement of 1.0 KW Motor........................................................................... 41 11.5. Replacement of 2.1 KW Motor........................................................................... 43 11.6. Replacement of 3.1 KW Motor........................................................................... 45 11.7. Replacement of 4.2 KW Motor........................................................................... 47 12. Adjustment of Timing Belt..................................................................................... 50 Appendix: Figure of Motor Replacement .................................................................... 52

4




The outline of the zeroing is as shown below: ž Shipping inspection

Preset of encoder

process of robot

ž After replacing motor

Rough zeroing

ž All axes collectively

ž Each axis individually

Accurate zeroing

In case accurate zeroing is carried out, use the following instruments and jigs: l Zeroing jig(1) l Zeroing jig(2) l Digital inclinometer

(plate) Mfg. by KHI

l Zeroing jig(3)

(plate) Mfg. by KHI

l Zeroing jig(4)

Mfg. by NIIGATA SEIKI Levelnic DL-S1

(plate) Mfg. by KHI

(Angle) Mfg. by KHI

In case of motor replacement, prepare instruments, tools, and grease as follows: l Torque wrench l Grease contained disulfide l Dial gauge molybdenum(MOLYCOAT etc.) l Grease for gear (SUN LIGHT GREASE No.1) l Grease for H/D

400mm or more

ž M 4 Hex. wrench

(HARMONIC GREASE 4BNo.2)

ž M 5 Hex. wrench

l Grease for RV reduction unit and

ž M 6 Hex. wrench

Cyclo reduction unit

ž M 8 Hex. wrench

(MOLY WHITE RENo.00)

ž M10 Hex. wrench ž M12 Hex. wrench 5

l Plus (+) screw driver (Large, Small)

2. How to Preset Encoder

2. How to Preset Encoder Controller


l Set to the switches of operation panel as shown below:

Place the “CONTROL

Release the

Press the

Place the

“TEACH/REPEAT” POWER” switch in the “EMERGENCY “MOTOR STOP” switch. POWER” switch switch in the

Place the

“HOLD/RUN”

switch in the “RUN”

Arm

l Press the “AXIS” key and set to the standard posture (HOME posture) as shown below:

JT6

0 point gauge mark position

1

-

-

+

6

+

JT5

žžž

0 point gauge mark position JT4


JT3



JT1


At the standard posture, make sure that 0 point gauge mark of the each axis is coincided accurately. 0 point gauge mark position

6




Preset

The preset of the encoder is executable on AS software. Example of preset through keyin g-in on the keyboard:

Referring to AS display on the screen, enter the Preset Command as shown below: (Example) : Preset of JT1:

Z

Z

1

0

1

For example: For JT1:101 For JT2:102 For JT3:103 For JT4:104 For JT5:105 For JT6:106 For JT7:107

Enter applicable axis No. as shown above.

[[ Encoder rot. counter reset (1st axis) [[. current angle (deg.mm)? X

Are you sure (Enter 1 to execute)? 1 >

Enter the present arm angle here.

When the arm angle is being set to 0°, enter 0°,

and when it is a certain angle(Ex. 15.4°), enter the value.

!

CAUTION

After making sure the axis to make preset, enter the applicable axis No.

7

3. Rough Zeroing (1) (All Axes Collectively)


CAUTION


!

This zeroing method is a method through which all robot axes are changed collectively. When you desire to replace the motor/encoder one by one, do not apply this zeroing method. Wris t section is a structure that the phenomenon to exert the influence on zero point of other axes “generation phenomenon” occurs.

Arm

l Upon completion of encoder preset, keep the robot arm under the standard posture (HOME posture).

8




Controller

l Press the “EMERGENCY STOP” switch and set the “MOTOR POWER” to “OFF”.

l Make rough zeroing with all axes collectively.

Z

Z

E

R

O

0

ò

JT1

JT2

JT3

JT4

JT5

JT6

set data XXXXXX

XXXXXX

XXXXXX

XXXXXX

XXXXXX XXXXXX

cur data XXXXXX

XXXXXX

XXXXXX

XXXXXX

XXXXXX XXXXXX

Set current values of all joints as zeroing data? (Enter 1 to set)

The value displayed on this line is

presently set up

zeroing set value

The value

In case rough zeroing executes.

In case rough zeroing exits.

displayed on this line is present

1

encoder value

l Display present value on screen and confirm.

W

H

E

R

E

ò

JT1

JT2

JT3

JT4

JT5

JT6

0.000

0.000

0.000

0.000

0.000

0.000

X[mm]

Y[mm]

Z[mm]

O[deg]

A[deg]

T[deg]

XXXXXX XXXXXX XXXXXX

XXXXXX XXXXXX XXXXXX

Makes sure these values.

If these values are 0, it is OK.

9

4. Rough Zeroing (2) (Each Axis Individually)

4. Rough Zeroing (2) (Each Axis Individually) CAUTION


!

Only through zeroing according to this procedure (rough zeroing of each axis), you can not obtain accurate linear path accuracy and shift amount.

This procedure is prerequisite to the motor encoder replacement instruction described below. Therefore, surely read also this page when the motor encoder is required to replace.

Wrist section is a structure that the phenomenon to exert the influence on zero point of other axes “generation phenomenon” occurs. Therefore,

Arm

l Match the 0 point on the axis to be matched by using the arm 0 point gauge mark.

JT6

0 point gauge mark position JT5 0 point gauge mark position

JT4




JT1


!

CAUTION

When the motor is required to replace, if you set the “CONTROL POWER ” to “ON” and “MOTOR POWER” to “ON”, the joint might be out of motion. Therefore, execute the preset without fail.

10




Controller


l Operate preset.

+ See “2. How to Preset Encoder”.

l Make rough zeroing of the each axis.

Z

Z

E

R

O

1

Example, When JT1 is required to

ò

carry out zeroing enter the axis

No. as “1” after input the ZZERO

Current angle (deg.mm) ?

ò

0

or

ò

Encoder value? (Current = xxxxxx, Enter 1 to the current value)

ò

1

(If stops at halfway,

key is only depressed.)

ò

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to change)

ò

(If re-enter is required, 0 key is only depressed.)

ò

Setting completed.

* In the same way as above make zeroing on JT2∼JT6 one by one.

11

5. Accurate Zeroing

5. Accurate Zeroing


Arm

Remove the cover as a preparation as shown in figure below to put the inclinometer on the robot arm.

And, remove paint, rust, and burr, etc. on the each zeroing jig installing surface enough with the whetstone etc. Datum level (D)

Datum level (B)

Datum level (C)

Datum level (A)

12

JT4 motor

5. Accurate Zeroing

5. Accurate Zeroing 5.1. Preparation work of accurate zeroing

CAUTION


!

Accurate zeroing is applied only to JT2 ∼ JT6. For JT1, normally accurate zeroing is not required. Controller



Release the

Press the

Place the

Place the

“TEACH/REPEAT”

“HOLD/RUN”

POWER” switch in the “EMERGENCY “MOTOR STOP” switch. POWER” switch switch in the


Arm

l First, execute rough zeroing described before over all axes. And, match all axes in the state of 0°.

l Install the zeroing jig(1) to the datum level (A) of the lower arm section as shown below. Then place the inclinometer. Be careful of the inclinometer placing direction. Level

Digital display

Measuring direction

-

+

Inclinometer Zeroing jig(1)

Power switch HOLD/RUN sel.

!

[0-ADJUST] volume

0.01/0.001 unit sel.

CAUTION

Once the inclinometer is adjusted by volume control,

never touch and change the adjusted value.

13

5. Accurate Zeroing


5. Accurate Zeroing

Arm

l Next, set the various switches provided to the inclinometer as follows: Power

:ON

HOLD/RUN

:RUN

Turn the “0-ADJUST” volume control and adjust the digital display is set to 0.00 mm/m.

!

CAUTION

Depending on condition, “0-ADJUST” volume control can not be set to 0. In this case, set the display to a clear and adequate value; for example, -1.00mm/m.

14

5. Accurate Zeroing

5. Accurate Zeroing


5.2. Zeroing of JT2 Controller



Place the

Press the

Release the


Place the

“HOLD/RUN”


Arm

l Install the zeroing jig(2) to the datum level(B) of the lower arm section as shown below.

Then place the inclinometer, pay attention not to touch with the “0-ADJUST” volume control. Be careful of the inclinometer placing direction. Measuring direction

-

+

Zeroing jig (2)

Inclinometer

l Press the “AXIS” key provided on the Multi Function Panel, and move JT2.

On this occasion, move JT2 until the inclinometer display may equal to the value set on the datum level(A) (Standard:0.00).

For example, if the set value at the datum level(A) is 0.00, move the axis until the value at the datum level(B) becomes 0.00±0.01.

15

5. Accurate Zeroing


5. Accurate Zeroing

Controller

l Press the “EMERGENCY STOP” switch and set the “MOTOR POWER” to “OFF”. When you execute the “MOTOR POWER” as “ON”, the message of “Turn OFF Motor power” is displayed.

l Make zeroing of JT2.

Z

Z

E

R

O

2

ò

Current angle(deg.mm) ?

ò or

0

ò


ò

1



ò


* When zeroing value is out of 268419072∼268451840, execute encoder preset again.

ò


ò

Setting completed.

In this way, the zeroing of JT2 has been completed.

16

5. Accurate Zeroing

5. Accurate Zeroing 5.3. Zeroing of JT3 (Except for FS10X, FS30N, FS30L, FS45C, FS45N)


Controller



Press the

Release the

Place the


Place the

“HOLD/RUN”


Arm

l Install the zeroing jig(3) to the datum level(C) of the upper arm section as shown below.

Then place the inclinometer, pay attention not to touch with the “0-ADJUST” volume control. Be careful of the inclinometer placing direction.

-

+

Zeroing jig (3)


On this occasion, move JT3 until the inclinometer display may equal to the value set on the datum level(A) (Standard : 0.00).

!

CAUTION

At zeroing, do not move axes except JT3. (especially JT2).

17

5. Accurate Zeroing

5. Accurate Zeroing


Controller l Press the “EMERGENCY STOP” switch and set the “MOTOR POWER” to “OFF”.

When you execute the “MOTOR POWER” as “ON”, the message of “Turn OFF Motor power” is displayed.


Z

Z

E

R

O

3

ò


ò

0

or

ò


ò

1



ò



ò


ò

Setting completed.


18

5. Accurate Zeroing

5. Accurate Zeroing 5.4. Zeroing of JT3 (In case of FS10X, FS30N, FS30L, FS45C, FS45N)


Controller


Press the

Release the


Place the


Place the

“HOLD/RUN”


Arm

l Move JT4 at +90°, and make the robot to posture to which does not receive the influence of JT5 easily as shown below.ê

l Place the zeroing jig(2) on the datum level (D) of the flange surface as shown below.

Then place the inclinometer, pay attention not to touch with the “0-ADJUST” value control. Be careful of the inclinometer placing direction.

-

+

Zeroing jig (2)

Move JT4 at +90°



!

CAUTION

At zeroing, after matching JT4 to the above posture, do not move axes except JT3 (especially JT2). 19

5. Accurate Zeroing

5. Accurate Zeroing





Z

Z

E

R

O

3

ò


ò

0

or

ò


ò

1



ò



ò


ò

Setting completed.


20

5. Accurate Zeroing

5. Accurate Zeroing 5.5. Zeroing of JT4 Controller




Release the

Press the

Place the

Place the


“HOLD/RUN”


Arm

l Referring to the figure below, while keeping the standard posture (HOME posture), move JT3 forward at 90° (-90°) and move JT5 upper-ward at 90°(+90°) viewed from rear.

-

Move JT3

+

Move JT5

at -90°

Referring to the left figure, if the posture is set automatically, follow the procedures bellow:

at 90°

Set to “REPEAT” side. Set to “RUN” side

To axis coincidence accurately, positioning accuracy range key-in the below: DO ACCURACY 0.1

-

+

Keeping the standard posture (HOME posture), key-in the below:

DO DRIVE 3, -90

and

l Place the zeroing jig(1) to the datum level (A) of the lower arm section at the direction as shown above

(clockwise inclination of arm is measured), make zero adjustment by turning “0-ADJUST” value. (If 0 setting is difficult, set adequate value.) Be careful of the inclinometer placing direction.

ê

l Referring to the figure above, place the zeroing jig (2) on the datum level (D) of the flange surface. Be careful of the inclinometer placing direction.

ê



21

!

CAUTION

At zeroing, do not move axes except JT4.

5. Accurate Zeroing


5. Accurate Zeroing

Controller




Z

Z

E

R

O

4

ò


ò

or

0

ò


ò

1



ò



ò


ò

Setting completed.


22

5. Accurate Zeroing

5. Accurate Zeroing 5.6. Zeroing of JT5


Controller



Release the

Press the

Place the


Place the

“HOLD/RUN”


Arm

Execute the zeroing of JT5 at the robot arm standard posture (HOME posture).

l First, set JT2, JT3 and JT4 to 0°. (You can return posture to 0° by the HOME command.)

ê

l Place the zeroing jig(2) on the datum level (D) of the flange surface as shown below. Then place the

inclinometer, pay attention not to touch with the “0-ADJUST” value control. Be careful of the inclinometer placing direction.

-

+

Zeroing jig (2)



!

CAUTION


23

5. Accurate Zeroing

5. Accurate Zeroing





Z

Z

E

R

O

5

ò


ò or

0

ò


ò

1



ò



ò


ò

Setting completed.


24

5. Accurate Zeroing

5. Accurate Zeroing 5.7. Zeroing of JT6


Controller



Release the

Place the

Press the

Place the


“HOLD/RUN”


Arm

l Move only JT3 forward at 90° (-90°) in the standard posture (HOME posture).

Referring to the figure below, install the zeroing jig (4) to the wrist flange face (datum level (D) ). Then place the inclinometer. Be careful of the inclinometer placing direction.

Referring to the left figure, if the posture is set

Move JT3

+

-

automatically, follow the procedures bellow:

at -90°

Zeroing jig(4)

Set to “REPEAT” side. Set to “RUN” side

To axis coincidence accurately, positioning accuracy range key-in the below:

+

-

DO ACCURACY 0.1

Keeping the standard posture (HOME posture), key-in


-

6

+

On this occasion, move JT6 until the

inclinometer display may equal to the value set on the datum level (A) (Standard : 0.00).

25

!

CAUTION


5. Accurate Zeroing

5. Accurate Zeroing





Z

Z

E

R

O

6

ò


ò

or

0

ò


ò

1



ò



ò


ò

Setting completed.


26

5. Accurate Zeroing

5. Accurate Zeroing


Controller l Completion of all axes accurate zeroing of JT2∼JT6.

Press “MOTOR POWER” switch to “ON”.

l To axis coincidence accura tely, key-in the positioning accuracy range.

D

O

A

C

C

U

R

A

C

Y

0

.

l Set the robot to HOME posture (HOME position).

*HOME posture (HOME position) means here the mechanical origin.

D

O

H

O

M

E

l Display the present value on screen and confirm.

W

H

E

R

E

ò

JT1

JT2

JT3

JT4

JT5

JT6

0.000

0.000

0.000

0.000

0.000

0.000

X [mm]

Y [mm]

Z [mm]

0 [deg]

A [deg]

T [deg]

XXXXXX

XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX

Make sure these values.

If these values are 0, it is OK.

27

1

6. Caution to be Taken at Motor Replacement

6. Caution to be Taken at Motor Replacement Prior to start the motor replacement work, pay special attention to the following contents so as to ensure


safety.

!

WARNING

Prior to start the motor replacement work, press the "EMERGENCY

STOP" switch provided in the controller basic operation section without fail. Then the motor power in the robot system will be turned OFF.

If it is required to change the angle of the specified axis, first turn ON the

motor power. Next, after setting up the specified axis to a desirable posture, again turn

!

CAUTION

¤ When a motor is required to dismount from the assembly and required to replace with a new one, do not apply excessively strong shocks to the motor and encoder.

¤ Motors shall be stored safely within the specified ambient temperature and moisture. ¤ For screws which are not necessary for the motor dismounting and

replacement, they must not be removed, as well as for motor covers, they must not be opened.

¤ If the motor is required to connect with the encoder, put the motor shaft pin into the U-groove of the encoder shaft.

28

7. Outline of Motor Replacement

7. Outline of Motor Replacement AC servo motors used mainly in the KAWASAKI Robot System can be divided into two types; one is an


encoder-separable type from the motor section as a unit, and the other is an encoder-unseparable type. w Small-sized motors of which motor capacity is 100 W, 200 W, 475 W, 1 KW and likes are represented by a one-piece structure (the motor part and the encoder part are being assembled as a set).

This means that even if either the motor or the encoder has failed, it should be replaced with a new one as a set.

w Large-sized motors of which motor capacity is 2.1 KW, 3.1 KW, 4.2 KW and likes are represented by a separable structure (the motor section can be separated into the motor part and the encoder part).

This means that if either the motor or the encoder has failed, it can be replaced with a new one separately.

w For the replacement of separable-type H20 Model Encoder, please refer to separately prepared “H20 Encoder Replacement Instructions”.

Type

One-piece structure

Motor Capacity

FA06N, L, E FC06N FS06N, L FS10C, N, E

100W

JT4 JT5 JT6

Type

One-piece structure

Separable structure

29

FS30N, L FS45C, N

FS10X

JT5 JT6

JT4 JT5 JT6

200W

JT4 JT5 JT6

JT4

3.1KW

JT3

JT3

4.2KW

JT1 JT2

JT1 JT2

475W

JT3

1.0KW

JT1 JT2

JT3 JT1 JT2

2.1KW

Separable structure

FS10L FA20N FC20N FP20N FS20C, N

Motor Capacity

Motor Type

Motor Assy P/N

100W

P50B05010DCX

50601-1136

200W 475W

P50B05020DCX P50B07050DCX

50601-1143 50601-1138

1.0KW 2.1KW 3.1KW

P60B13100HCX P60B13150HCX P60B13200LCX

50601-1139 50601-1123 50601-1125

4.2KW

P80B22450RCX

50601-1121

8. Prior to Replace Motor (Encoder)

8. Prior to Replace Motor (Encoder) Prior to re place the motor with a new one, first of all, you must make sure whether the present motor is


prerequisite to replace with a new one or not. In particular, when an encoder-separable motor is used, make sure that the present trouble is not caused by the failure of the encoder itself.

In other words, only after making sure that the trouble is not caused by the encoder itself, you must start the motor replacement work.

[ Encoder separable type ]

· Robot motion is abnormal.

· Positioning accuracy is variable. Is oscillation available?

NO Is abnormal noise heard?

Is abnormalNO heat generated?

YES

Is rattle found in mechanics?

Check on mechanical

parts and repair/replace

NO

YES

YES

Is the encoder value affected by any mechanical interferences?

NO

Can’t brake be released?

YES

NO

Replace encoder with a new one.

YES

YES

Even after

Check on mechanical

replacement,

parts and repair/replace

errors are still

NO

Does brake slip?

Check on surrounding

YES

cables and boards.

NO

Is inside of motor disconnected?

YES

NO

Replace motor with a new one.

Are other erroneous causes observed? NO

YES

(One-piece

structured

small

sized motor should be replaced Errors occur even after replacement.

The trouble might not be caused by the failure of the motor/encoder. Even though the motor/encoder has replaced with a new one, if the error can not be removed, the control system is required to check/adjust. 30

9. Summary of Motor Replacement Work

9. Summary of Motor Replacement Work Actually when the motor replacement work is carried out, prepare the measuring instruments, tools, oils &


greases etc. as shown below: l Dial gauge

l Molybdenum disulfide grease (including MOLYCOAT)

l SUN LIGHT GREASE No.1

l LOCTITE 242

l THREE BOND 1212

l MOLY WHITE RE No.00

(For Cyclo Reduction Unit/RV Reduction Unit)

l HARMONIC GREASE 4B No.2

l Tools

(For H/D)

Motor capacity 100W 200W 475W

1.0 KW 2.1 KW 3.1 KW 4.2 KW

Torque wrench

Torque wrench (M4) for hexagonal-bar attachment: about 150 mm in length Torque wrench (M4) for hexagonal-bar attachment: about 150 mm in length Torque wrench (M5) for hexagonal bar attachment: about 150 mm in length Torque wrench (M6): for hexagonal bar attachment : about 280mm in length. Torque wrench (M10) for hexagonal-bar attachment: about 280 mm in length Torque wrench (M10) for hexagonal-bar attachment: about 280 mm in length Torque wrench (M12) for hexagonal-bar attachment: about 280 mm in length

l Exclusively designed removing jigs and pulley puller (for large-sized motor) Part No.

50514-1010

Applicable Models (Axes)

For FS30N, L (JT1 and 2) For FS45C, N (JT1 and 2) For FS10X (JT1 and 2)

!

WARNING

¤ When a motor is required to remove from an assembly, support the arm safely so as to prevent the arm from dangerous falling.

¤ When a motor is required to replace with a new one, surely turn OFF the "MOTOR POWER" and "CONTROL POWER" switches. 31




Motor replacement work and its confirmation

w Record the robot's present location.

w Set a dial gauge to a place in the forward part of the arm for the axis of which the motor will be replaced. Next, record the values measured by the dial gauge. + See "10. Works to be carried out Before Replacement of Motors".

w If recording disables, preset - zeroing shall be executed after the replacement of the motor without fail.

Motor replacement work

w When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail. w In order to prevent a robot arm from accidental falling/rotating, the arm must be supported by a crane/forklift truck, or must be put on a support.

w Replace the motor of which capacity may coincide with the applicable model, and with replacement object axes. + See "11. Replacement Instruction for Motors".

Works to be carried out after motor replacement

w First, move the robot arm, until the applicable value may coincide accurately with the value measured by the dial gauge. w If encoder values can not be recorded successfully, preset and zeroing shall be executed.

Confirmation to be carried out after motor replacement

w Execute repeat run on the program, and make playback the robot motions. Then make sure whether any error/abnormality is observed or not.

w If preset and zeroing have been executed, re-teach the applicable program again.

32

10. Works to be carried out Before Replacement of Motors

10. Works to be carried out Before Replacement of Motors Actually before the motor replacement work is carried out, it is prerequisite to record the robot's present


position. The recording of the robot's present position is represented by the followings:

w Reading of Encoder Values

w Confirmation of Absolute Position of the Arm at that Time (Confirmation by using a Dial Gauge)

In this section, how to measure values so as to make sure the arm's absolute position, is explained.

On this occasion, the encoder must be normal and accurate, as well as the display of the encoder values is precise.

(1) Press the "AXIS" key provided on the Multi Function Panel, and move the robot arm, until an adequate posture is obtained.

(2) Set the dial gauge to an adequate place (such as to a hand) provided in the forward part from the axis of which the motor will be replaced.

Set the dial gauge to places shown in the figures (on the next page and the consecutive pages)

!

CAUTION

Surfaces on which a dial gauge is required to set shall be

selected to be flat as far as possible. Moreover, the surfaces shall be at right angles to the rotation of the axis of a motor to be replaced.

(3) Match the value of the dial gauge with 0.

Then keeping this posture, record the encoder values of axis.

(Record as adequate positional variables by executing HERE Command.)

(4) Carry out the motor replacement work in an easily accessable posture.

On this occasion, be careful that the dial gauge position does not move.

33

10. Works to be carried out Before Replacement of Motors

10. Works to be carried out Before Replacement of Motors When JT2, 3 and 5 are required to replace


When JT1 is required to replace

JT3,5

JT2

JT1

When JT4 and 6 are required to replace

JT4,6

34

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors !

WARNING


¤ When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail.

¤ When a motor is required to replace with a new one, do not carelessly make the robot arm fall down or rotate.

To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support by using a crane/forklift truck.

11.1. Replacement of 100 W Motor Also, see "Figure of Motor Replacement". Model A xes

FA06N, L, E / FC06N / FS06N, L / FS10C, N, E JT4 JT5 JT6

FS10X JT5 JT6

(1) First, remove the covers from the designated places.

(2) Next, disconnect the connector for motor power cable from the axis of motor to be replaced.

Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly. (Cut off "Insulock" provided for the fixing of vinyl sheet to be used for the protection of Connector for encoder

connector parts.)

Connector for motor power cable

ò

(3) Remove the servo-motor fixing bolts (M4 Hexagon socket head cap bolt - 4 bolts). Loosen the bolts of the motor bracket for JT5 or 6. And remove the timing belt.

When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 150mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work.

M4 Hexagon socket head cap bolt

Connector for encoder Connector for motor power cable

H/D wave generator

Pulley JT4 JT5, 6 Snap ring 35

M3 Hexagon socket set screw Tightening torque : 1.47Nžm (15kgfžcm)


11. Replacement Instruction for Motors (4) Remove the servo-motor.

!


CAUTION

Since the pulley or the wave generator is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

(5) i) For JT5 and 6

Remove the snap ring from the end of the removed servo-motor, and remove the pulley.

ii) For JT4

Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the wave generator.

!

CAUTION

When the pulley or the wave generator is removed, be careful not to give excessively strong forces to the servo-motor.

(6) Install the once removed pulley or wave generator as specified in item (5) above to the new

servo-motor. In the course of parts installation, be careful not to make a mistake in the selection o f the direction. First, coat “LOCTITE 242” over the surfaces of the hexagon head socket set screws for the fixing of the wave generator. Next, tighten the socket set screws firmly. Tightening torque is 1.47N žm (15kgfžcm).

Coat gear grease (HARMONIC GREASE 4B No.2) over the surface of the wave generator.

(7) Assemble the new servo-motor.

Tightening torque is 3.43 Nžm (35kgfžcm).

[ NOTE ]

Refer to “12. Adjustment of Timing Belt” detail for the adjustment method of timing belt.

(8) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were befo re.

(9) Re-install the covers to the designated places as they were before.

36



WARNING





11.2. Replacement of 200 W Motor Also, see "Figure of Motor Replacement". Model Axis

FS10L / FA20N / FC20N / FP20N / FS20C, N JT4 JT5 JT6



Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly. (Cut off "Insulock" provided for the fixing of vinyl sheet to be used for the protection of connector parts.)

Connector for encoder


ò

(3) Remove the servo-motor fixing bolts (M4 Hexagon socket head cap bolt - 4 bolts). When actually the

bolts are required to remove, use a torque wrench for hexagonal bar attachment (Length = about 150 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. Connector for encoder



JT5, 6

Pulley H/D wave generator Snap ring Snap ring

37

JT4



!


CAUTION

Since the pulley or the wave generator is installed to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

(5) i) For JT5 and 6

Remove the snap ring from the end of the removed servo-motor, and remove the pulley.

ii) For JT4

Remove the snap ring from the end of the removed servo-motor, and remove the wave generator.

!

CAUTION

When the pulley or the wave generator is removed, be careful not to give excessively strong forces to the servo -motor.

(6) Install the once removed pulley or wave generator as specified in item (5) above to the new

servo-motor. In the course of parts installation, be careful not to make a mistake in the selection of the direction.

Coat gear grease (HARMONIC GREASE 4B No.2) over the surface of the wave generator.


Tightening torque is 3.43 Nžm (35kgfžcm).

[ NOTE ]


(8) Re-connect the connector for motor power cable and the connector for encoder, and other connectors as they were before.


38



WARNING





11.3. Replacement of 475W Motor Also, see "Figure of Motor Replacement". Model Axis

FA06N, L, E / FC06N / FS06N, L / FS10C, N, E JT3

FS30N,L/FS45C,N JT4,5,6

FS10X JT4






ò

(3) Remove the servo-motor fixing bolts (M5 Hexagon socket head cap bolt - 4 bolts). Loosen the bolts of motor bracket for JT5 or 6. And remove the timing belt.

When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 150 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work.

Connector for encoder Connector for motor power cable

JT4 of FS30N, L / FS45C,


N / FS10X

JT3 of FA06N, L, E / FC06N / FS06N, L / FS10C, N, E Gasket Input gear

Input gear Snap ring 2-M4 Hexagon socket set screw 39

Tightening torque:3.43Nžm(35kgfžcm)

Pulley Snap ring

JT5and 6 of FS30N, L / FS45C, N



CAUTION


!

Since the gear or the pulley is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo -motor at its mounting/dismounting. Straightly mount/dismount the motor.

(5) i) For JT3 of FA06N, L, E / FC06N / FS06N, L / FS10C, N, E

Loosen the fixing screws from the end of the once removed servo-motor, and remove the gear. At the same time, remove the gasket from the motor mounting face.

ii) For JT4 of FS30N, L / FS45C, N / FS10X

Remove the snap ring from the end of the once removed servo-motor, and remove the input gear.

iii) For JT5 and 6 of FS30N, L /FS45C, N

Remove the snap ring from the end of the once removed servo-motor, and remove the pulley.

!

CAUTION

When the gear or the pulley is removed, be careful not to give excessively strong forces to the servo -motor.

(6) Install the once removed gear, gasket or pulley as specified in item (5) above to the new servo-metor. In the course of parts installation, be careful not to make a mistake in the selection of the gear

direction. First, coat “LOCTITE 242” over the surfaces of the hexagon socket set screws for the fixing of the gear. Next, tighten the hexagon socket set screws firmly. Tightening torque is 3.43Nžm(35kgfžcm). Coat the following gear grease over the surface of the gear.

w Input gear of RV Reduction Unit or Cyclo Reduction Unit žžžžžžžžMOLY WHITE RE No.00


The Tightening torque is 6.86 Nžm (70kgfžcm).

[ NOTE ]


(8) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before.


40



WARNING


¤ When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail. ¤ When a motor is required to replace with a new one, do not carelessly

make the robot arm fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support by using a crane/forklift truck.

11.4. Replacement of 1.0 KW Motor Also, see "Figure of Motor Replacement". Model A xes

FA06N, L, E / FC06N / FS06N, L / FS10C, N, E JT1 JT2

FS10L / FA20N / FC20N / FP20N / FS20C, N JT3






ò

(3) Remove the servo-motor fixing bolts (M8 Hexagon socket head cap bolt - 4 bolts).

When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. Connector for encoder



Input gear

Gasket 2-M4 Hexagon socket set screw Tightening torque =3.43 N?m (35 kgf?cm) 41




(4) Remove the servo-motor.

!

CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

(5) Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the gear. At the same time, remove the gasket from the motor mounting face.

!

CAUTION

When the gear is removed, be careful not to give excessively strong forces to the servo -motor.

(6) Install the once removed gear and gasket as specified in item (5) above to the new servo-motor.

In the course of parts installation, be careful not to make a mistake in the selection of the gear direction.

First, coat “LOCTITE 242” over the surfaces of the hexagon socket set screws for the fixing of the gear. Next, tighten the hexagon socket set screws firmly. The tightening torque is 3.43N žm (35kgfžcm).

Coat the following gear grease over the surface of the gear.

• Input gear of Cyclo Reduction Unit .............................MOLY WHIT E RE No.00


The tightening torque is 29.4N žm (300kgfžcm).



42



WARNING



¤ When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure

safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck.

¤ Check to see if the encoder unit itself is repairable or not without fail. The encoder itself is also replaceable.

¤ If the encoder is normal and serviceable, and only the motor is required to replace with a new one, first, remove the encoder from the motor, and after re-installing the motor, the encoder is required to install to the newly replaced motor. For the details of mounting/dismounting procedures of

11.5. Replacement of 2.1 KW Motor Also, see "Figure of Motor Replacement". Model A xes

FS10L / FA20N / FC20N / FP20N / FS20C, N JT1 JT2

(1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly.


Open here, and

disconnect cable.

ð


Encoder cover


43


11. Replacement Instruction for Motors (2) Remove the servo-motor fixing bolts (M10 Hexagon socket head cap bolt - 4 bolts). When actually the


bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work.


!

CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply

excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

(4) Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the gear. At the same time, remove the gasket from the motor mounting face.

!


CAUTION

When the gear is removed, be careful not to give excessively strong forces to the

Input gear

servo-motor.

Gasket

2-M6 Hexagon socket set screw

Tightening torque =11.76 N?m (120 kgf?cm)

(5) Install the once removed gear and gasket as specified in item (4) above to the new servo-motor. In the course of parts installation, be careful not to make a mistake in the selection of the gear direction. First, coat “LOCTITE 242” over the surfaces of the hexagon socket set screws. Next, tighten the socket set screws firmly. The tightening torque is 11.76Nžm (120kgfžcm). Coat the following gear over the surface of the gear. • Input gear of Cyclo Reduction UnitžžžžžžžžžžMOLY WHITE RE No.00 (6) Assemble the servo-motor. The tightening torque is 56.84 Nžm (580kgfžcm). (7) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before. (8) Re-install the encoder cover as they were before.

!

CAUTION

Recommended tightening torque is 0.784 Nžm (8 kgfžcm). The nylon washer deforms if the socket head cap bolt of the encoder cover is tightened too much and the effect of the seal is lost.

44



WARNING



¤ When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck.

¤ Check to see if the encoder unit itself is repairable or not without fail. The encoder itself is also replaceable.

¤ If the encoder is normal an d serviceable, and only the motor is required to replace with a new one, first, remove the encoder from the motor, and after re-installing the motor, the encoder is required to install to the newly replaced motor. For the details of mounting/dismounting procedures of Encoder (Model H20), please refer to separately prepared "H20 Encoder Replacement Instructions".

11.6. Replacement of 3.1 KW Motor Also, see "Figure of Motor Replacement". Model Axes

FS30N, L / FS45C, N/FS10X JT3

(1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly.


Open here, and

disconnect cable.

ð

ð


Encoder cover

45



11. Replacement Instruction for Motors (2) Remove the servo-motor fixing bolts (M10 Hexagon socket head cap bolt - 4 bolts). When actually the


bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work.


!

CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply

excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

Gasket

M10 Hexagon socket

Gear

head cap bolt

M6 Hexagon socket set screw

Tighteining torque = 11.76 Nžm (120kgfžcm) (4) Loosen the hexagon socket set screw from the end of the removed servo-motor, and remove the gear. At the same time, remove the gasket from the motor mounting face.

!

CAUTION

When the gear is removed, be careful not to give excessively strong forces to the servo-motor.

(5) Install the once removed gear and gasket as specified in item (4) above to the new servo-motor. First, coat "LOCTITE 242" over the surface of hexagon socket head set screw for the fixing gear. Next, tighten the socket set screw firmly. The tightening torque is 11.76N žm (120kgfžcm) Coat the following gear grease over the surface of the gear. • Input gear of RV Reduction Unit žžžžžžMOLY WHITE RE No.00 (6) Assemble the servo-motor. The tightening torque is 56.84Nžm (580kgfžcm) (7) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before. (8) Re-install the encoder cover as they were before.

!

CAUTION

Recommended tightening torque is 0.784 Nžm(8 kgfžcm). The nylon washer deforms if the socket head cap bolt of the encoder cover is tightened too much and the effect of the seal is lost.

46



WARNING


¤ When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch with out fail. ¤ When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck. ¤ Check to see if the encoder unit itself is repairable or not without fail. The encoder itself is also replaceable. ¤ If the encoder is normal and serviceable, and only the motor is required to replace with a new one, first, remove the encoder from the motor, and after re -installing the motor, the encoder is required to install to the newly replaced motor. For the details of mounting/dismounting procedures of Encoder (Model H20), please refer to separately prepared "H20 Encoder Replacement Instructions".

11.7. Replacement of 4.2 KW Motor Also, see "Figure of Motor Replacement". Model Axes

FS30N, L / FS45C, N JT1 JT2

FS10X JT1 JT2

(1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly. Connector for encoder encoder cover

Open here, and

disconnect cable.

M12 Hexagon socket

M4 Hexagon socket

head cap bolt

head cap bolt


Connector cover

Connector for

motor power cable

Connector M4 Hexagon socket head cap bolt

47

for braking




(2) Remove the servo-motor fixing bolts (M10 Hexagon socket head cap bolt - 4 bolts). When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. (3) Remove the servo-motor.

!

CAUTION

¤ If the dismount of the servo-motor is difficult, utilize tap for bolt-pulling in the motor flange section (M12 x 4 places). ¤ Be careful that the weight of the servo-motor is very heavy to handle (approx. 30kg).

Since the taper section of the gear is too tight to pull out unless the below mentioned jigs (pulley puller) are used. On the contrary, if you pull out the gear forcibly without using such exclusively designed and specified jigs, the servo-motor might be broken and the motor replacement work becomes very dangerous. Therefore follow the below procedures without fail. (4) Attach the jigs (rod, pipe and bolt) to the servo -motor. On this occasion, be careful not to apply excessively strong forces to the motor section and the encoder section. Moreover, loosen the center bolt in the Input gear tip by about 5mm. Approx. 5mm

Input gear

Center bolt

Rod

Loosen the center bolt approx. 5mm in length,

Bolt

Pipe

and make sure that the bolt is not pulled out.

Input gear

This procedures is prerequisite to afford a

Center bolt

(M10 Hexagon socket head cap bolt)safety

stopper which is useful when the input

(5) Attach “Pulley puller” to the jig.

Bar

48

Pulley puller


11. Replacement Instruction for Motors (6) Remove the input gear provided in the taper shaft section by using “Pulley puller”.

CAUTION


!

When the input gear is too tight to disconnect, if you forcibly disconnect it, be careful that the input gear might be suddenly jump out and might hit the stopper provided on the center bolt head.

7)

Remove the center bolt. Then remove the input gear.

(8) Coat special grease (Molybdenum disulfide grease) over the surface of the taper shaft section.

After that, install the once removed input gear and center bolt as specified in item(7) above to the new servo-motor.

(9) Once, tighten the input gear firmly by applying 56.84N žm (580kgfžcm) torque.

After that, remove it again. Re-install the input gear by applying 17.15 Nžm (175kgfžcm) torque after coat “LOCKTITE 242” over the surface of the center bolt.

Grip flat part provided in the input gear with the wrench when tightening. The motor brake might slip.

!

CAUTION

While the input gear is being tightened by applying 56.84Nžm

(580kgfžcm) of high torque and installed, it might result in unable to take away the input gear from the assembly in the next disassembling work. In other words, it is necessary once to loosen and to re-tighten the input gear by applying 17.15Nžm(175kgfžcm) of low torque.

(10) Assemble the servo-motor. Tightening torque is 98N žm (1000kgfžcm).


(12) Re-install encoder cover as they were before.

!

CAUTION

Recommended tightening torque is 0.784 Nžm(8kgfžcm). The nylon washer deforms if the socket head cap bolt of the encoder cover is tightened too much and the effect of the seal is lost.

49

12. Adjustment of Timing Belt

12. Adjustment of Timing Belt Adequate tension : Referring to the below figure, when you the center of belt at pressure F[N], to a degree


that the belt deflects about δ mm.

F [N]

Adjustment procedures:

δ mm

(1) Rotate 1 turn and loosen the 4 motor bracket mounting bolts.

(2) Move the motor bracket and adjust the distance between axes of the pulleys. And make the tension of the belt suitable as specified below.

(3) Tighten the mounting bolts.

Model

Axis

Pressure F [N]

Deflection δ [mm]

FA06N, L, E FC06N FS06N, L FS10C, N, E, X

JT5

3.5∼5.0

3.4

JT6

3.5∼5.0

2.2

JT5

4.0∼5.0

3.6

JT6

4.0∼5.0

2.3

JT5

9.5∼12.0

4.9

JT6

9.5∼12.0

3.3

FS10L FA20N FC20N FP20N FS20C, N

FS30N, L FS45C, N

50


.

51

MEMO

Appendix: Figure of Motor Replacement

Appendix: Figure of Motor Replacement FS Series


l



Motor for JT3



Motor for JT2


Connector for

Motor for JT1

52

motor power cable




Motor for JT6

Connector for

Connector for

encoder

encoder

Connector for

motor power cable

Connector for

motor power cable Motor for JT5

Connector for

motor power cable


53

Motor for JT4


.

54

MEMO

90213-1016DED F-Zeroing Motor Replace

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