FANUC Robot M-20iB
MECHANICAL UNIT
MAINTENANCE MANUAL MARNB20IB11161E REV. A This publication contains proprietary information of FANUC America Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC America Corporation. FANUC America Corporation 3900 W. Hamlin Road Rochester Hills, Michigan 48309–3253
B-83755EN/01
Copyrights and Trademarks Trademarks This new publication contains proprietary information of FANUC America Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC America Corporation. The descriptions and specifications contained in this manual were in effect at the time this manual was was approved for printing. FANUC America Corporation, hereinafter referred to as FANUC, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. FANUC manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC products and/or systems. Such systems consist consist of robots, extended axes, axes, robot controllers, application software, the KAREL® programming language, INSIGHT® vision equipment, and special tools. FANUC recommends that only persons who have been trained in one or more approved FANUC Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintai n FANUC products and/or systems and their respective components. Approved training necessitates that that the courses selected be relevant to the type of system installed and application performed at the customer site.
WARNING This equi pment g enerates, enerates, uses, and can radiate radiofrequency energy energy and if not ins talled and used used in accordance with the inst ructi on manual, may may cause interference to radio communi cations. As temporarily permitted by r egulation, it has not been tested tested for compli ance with th e limi ts for Class A computing devices purs uant to Subp art J and Part 15 of FCC Rules, Rules, whi ch are designed to provi de reasonable reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever whatever measure may be required to correct the interference.
Copyrights and Trademarks Trademarks This new publication contains proprietary information of FANUC America Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC America Corporation. The descriptions and specifications contained in this manual were in effect at the time this manual was was approved for printing. FANUC America Corporation, hereinafter referred to as FANUC, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. FANUC manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC products and/or systems. Such systems consist consist of robots, extended axes, axes, robot controllers, application software, the KAREL® programming language, INSIGHT® vision equipment, and special tools. FANUC recommends that only persons who have been trained in one or more approved FANUC Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintai n FANUC products and/or systems and their respective components. Approved training necessitates that that the courses selected be relevant to the type of system installed and application performed at the customer site.
WARNING This equi pment g enerates, enerates, uses, and can radiate radiofrequency energy energy and if not ins talled and used used in accordance with the inst ructi on manual, may may cause interference to radio communi cations. As temporarily permitted by r egulation, it has not been tested tested for compli ance with th e limi ts for Class A computing devices purs uant to Subp art J and Part 15 of FCC Rules, Rules, whi ch are designed to provi de reasonable reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever whatever measure may be required to correct the interference.
FANUC conducts courses on its systems and products on a regularly scheduled basis at the company's world headquarters in Rochester Hills, Michigan. For additional information contact FANUC America Corporation Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 www.fanucamerica.com For customer assistance, including Technical Support, Service, Parts & Part Repair, and Marketing Requests, contact the Customer Resource Center, 24 hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers should call 011-1-248-377-7159. Send your comments and suggestions about this manual to:
[email protected]
Copyright © 2016 2016 by FANUC FANUC America Corpor ation Al l Ri gh ts Reser ved The information illustrated or contained herein is not to be reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC America Corporation. AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®, PalletTool®, SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered Trademarks of FANUC.
FANUC reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™, AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™, ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™, ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™, AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™, Center Finder™, Clean Clean Wall™, DualARM™, LR Tool™, MIG Eye™, MotionParts™, MultiARM™, NoBots™, Paint Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks II™, PAINTWorks III™, PalletMate™, PalletMate PC™, PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™, Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™, SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3 Controller™, SYSTEM R-J3iB Controller™, SYSTEM R-J3iC Controller™, SYSTEM R-30iA Controller™, SYSTEM R-30iA Mate Controller™, SYSTEM R-30iB Controller™, SYSTEM R-30iB Mate Controller™, TCP Mate™, TorchMate™, TripleARM™, TurboMove™, visLOC™, visPRO-3D™, visTRAC™, WebServer™, WebTP™, and YagTool™.
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©FANUC CORPORATION 2016 No part of this manual may be reproduced in any form.
All specifications and designs are subject to change without notice.
Patents One or more of the following U.S. patents might be related to the FANUC products described in this manual.
FANUC America Corporation Patent List 4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745 5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944 5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218 5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092 6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621 6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143 6,378,190 6,385,508 6,425,177 6,477,913 6,490,369 6,518,980 6,540,104 6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773 6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422 7,399,363
FANUC CORPORATION Patent List 4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207 4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504 4,956,594 4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,004,968 5,006,035 5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,716 5,111,019 5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360 5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057 5,329,469 5,333,242 5,337,148 5,371,452 5,375,480 5,418,441 5,432,316 5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478 5,463,297 5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758 5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194 5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,572,103 5,581,167 5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,624,588 5,630,955 5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295 5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138 5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135 5,812,408 5,841,257 5,845,053 5,872,894 5,887,122 5,911,892 5,912,540 5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 5,988,850 6,023,044 6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693 6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898 6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011 6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,298,283 6,321,139 6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,869 6,382,012 6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979 6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588 6,680,461 6,696,810 6,728,417 6,763,284 6,772,493 6,845,296 6,853,881 6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802 7,038,165 7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848 7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294 7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,315,650 7,324,873 7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488 7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192 7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121
Conventions WARNING Information appearing un der the " WARNING" caption conc erns the protection of personnel. It is boxed and bolded to set it apart from t he surrounding t ext.
CAUTION Information appearing under the "CAUTION" caption concerns the protection of equipment, software, and data. It is boxed and bolded to set it apart from the surrounding text.
Note Information appearing next to NOTE concerns related information or useful hints.
O r i g i n al I n s t r u c t i o n s
Thank you very much for purchasing FANUC Robot. Before using the Robot, be sure to read the "FANUC Robot SAFETY HANDBOOK (B-80687EN)" and understand the content.
No part of this manual may be reproduced in any form.
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The appearance and specifications of this product are subject to change without notice.
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The products in this manual are controlled based on Japan's “Foreign Exchange and Foreign Trade Law". The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual, we endeavor to include all pertinent matters. There are, however, a very large number of operations that must not or cannot be performed, and if the manual contained them all, it would be enormous in volume. It is, therefore, requested to assume that any operations that are not explicitly described as being possible are "not possible".
Safety FANUC America Corporation is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for y our application and installation can be best determined by safety system professionals. FANUC America Corporation therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC America Corporation systems. According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. Ensure that the robot being used is appropriate for the application. Robots used in classified (hazardous) locations must be certified for this use. FANUC America Corporation therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC America Corporation training course and become familiar with the proper operation of the system. Persons responsible for programming the system–including the design, implementation, and debugging of application programs–must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.
CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:
The safety of people and equipment
Use of safety enhancing devices
Techniques for safe teaching and manual operation of the robot(s)
Techniques for safe automatic operation of the robot(s)
Regular scheduled inspection of the robot and workcell
Proper maintenance of the robot
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Safety
Keeping People Safe The safety of people is always of primary importance in any situation. When applying safety measures to your robotic system, consider the following:
External devices
Robot(s)
Tooling
Workpiece
Using Safety Enhancing Devices Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices:
Safety fences, barriers, or chains
Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches
Setting Up a Safe Workcell A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety.
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Sponsor your personnel for training in approved FANUC America Corporation training course(s) related to your application. Never permit untrained personnel to operate the robots. Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot. Use anti–tie–down logic to prevent the operator from bypassing safety measures. Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell. Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the area defined by the maximum motion range of the robot, including any tooling attached to the wrist flange that extend this range.
Safety
Position all controllers outside the robot work envelope. Never rely on software or firmware based controllers as the primary safety element unless they comply with applicable current robot safety standards. Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell. Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end–use application. Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope. Install special guarding that prevents the operator from reaching into restricted areas of the work envelope. Use interlocks. Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety. Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot. Make sure all external devices ar e properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro–magnetic interference (EMI), radio frequency interference (RFI), and electro–static discharge (ESD). Make provisions for power lockout/tagout at the controller. Eliminate pinch points. Pinch points are areas where personnel could get trapped between a moving robot and other equipment. Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely. Program the robot to load and unload material safely. If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons. If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.
Staying Safe While Teaching or Manually Operating the Robot Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules:
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment.
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Safety
Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range. The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department. FANUC America Corporation recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.
WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.
Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked. Isolate the robot from all remote control signals that can cause motion while data is being taught. Test any program being run for the first time in the following manner:
WARNING Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.
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Using a low motion speed, single step the program for at least one full cycle.
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Using the programmed speed, test run the program continuously for at least one full cycle.
Using a low motion speed, test run the program continuously for at least one full cycle.
Make sure all personnel are outside the work envelope before running production.
Staying Safe During Automatic Operation Advise all personnel who operate the robot during production to observe the following rules:
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Make sure all safety provisions are present and active.
Safety
Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts. Understand the complete task the robot is programmed to perform before initiating automatic operation. Make sure all personnel are outside the work envelope before operating the robot. Never enter or allow others to enter the work envelope during automatic operation of the robot. Know the location and status of all switches, sensors, and control signals that could cause the robot to move. Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency. Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue its activity. If the robot is running in a pattern, do not assume it will continue to run in the same pattern. Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.
Staying Safe During Inspection When inspecting the robot, be sure to
Turn off power at the controller. Lock out and tag out the power source at the controller according to the policies of your plant. Turn off the compressed air source and relieve the air pressure. If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. If power is needed to check the robot motion or electrical circuits, be prepared to press the EMERGENCY STOP button, in an emergency. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
Staying Safe During Maintenance When performing maintenance on your robot system, observe the following rules:
Never enter the work envelope while the robot or a program is in operation. Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist.
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Safety
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope. Test the teach pendant for proper operation before entering the work envelope. If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately. Whenever possible, perform maintenance with the power turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3–phase power source at the controller. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only.
Release or block all stored energy. Before working on the pneumatic system, shut off the system air supply and purge the air lines. Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person. Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked. Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel.
WARNING Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction.
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Safety
Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. When replacing or installing components, make sure dirt and debris do not enter the system. Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses. Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices ar e operating normally.
KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.
Programming Safety Precautions Implement the following programming safety measures to prevent damage to machine tools and other external devices.
Back–check limit switches in the workcell to make sure they do not fail. Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. Use handshaking protocol to synchronize robot and external device operations. Program the robot to check the condition of all external devices during an operating cycle.
Mechanical Safety Precautions Implement the following mechanical safety measures to prevent damage to machine tools and other external devices.
Make sure the workcell is clean and free of oil, water, and debris. Use DCS (Dual Check Safety), software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.
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Safety
KEEPING THE ROBOT SAFE Observe the following operating and programming guidelines to prevent damage to the robot.
Operating Safety Precautions The following measures are designed to prevent damage to the robot during operation.
Use a low override speed to increase your control over the robot when jogging the robot. Visualize the movement the robot will make before you press the jog keys on the teach pendant.
Make sure the work envelope is clean and free of oil, water, or debris.
Use circuit breakers to guard against electrical overload.
Programming Safety Precautions The following safety measures are designed to prevent damage to the robot during programming:
Establish interference zones to prevent collisions when two or more robots share a work area. Make sure that the program ends with the robot near or at the home position. Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage. In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials.
NOTE: Any deviation from the methods and safety practices described in this manual must conform to the approved standards of your company. If you have questions, see your supervisor.
ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personnel also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.
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Safety
Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools.
CAUTION Ensure that all ground cables remain connected. Never operate the paint robot with ground provisions disconnected. Otherwise, you could injure personnel or damage equipment. Paint robots are operated in three modes:
Teach or manual mode
Automatic mode, including automatic and exercise operation
Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or MCP. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.
Paint System Safety Features Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features:
Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are.
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Safety
Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are.
EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E–STOP buttons.
An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres.
A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released or pressed harder during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E–STOP other robots.
WARNING An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot.
Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. DCS (Dual Check Safety), limit switches and hardstops also limit travel by the major axes. EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SOC is in teach mode. When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings. System status is monitored by computer. Severe conditions result in automatic system shutdown.
Staying Safe While Operating the Paint Robot When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.
WARNING Observe all safety rules and guidelines to avoid injury.
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Safety
WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.
WARNING Enclosures shall not be opened unless the area is known to be nonhazardous or all power has been removed from devices within the enclosure. Power shall not be restored after the enclosure has been opened until all combustible dusts have been removed from the interior of the enclosure and the enclosure purged. Refer to the Purge chapter for the required purge time.
Know the work area of the entire paint station (workcell).
Know the work envelope of the robot and hood/deck and door opening devices.
Be aware of overlapping work envelopes of adjacent robots.
Know where all red, mushroom–shaped EMERGENCY STOP buttons are located.
Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move. Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor. Become familiar with the complete task the robot will perform BEFORE starting automatic mode. Make sure all personnel are outside the paint booth before you turn on power to the robot servo system. Never enter the work envelope or paint booth before you turn off power to the robot servo system. Never enter the work envelope during automatic operation unless a safe area has been designated. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled. Stay out of areas where you might get trapped between a moving robot, conveyor, or opening device and another object. Be aware of signals and/or operations that could result in the triggering of guns or bells.
Be aware of all safety precautions when dispensing of paint is required.
Follow the procedures described in this manual.
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Safety
Special Precautions for Combustible Dusts (Powder Paint) When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot.
Purge maintenance air should be maintained at all times, even when the robot power is off. This will insure that dust can not enter the robot. A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust when maintenance air is not present, it will be necessary to remove the covers and clean out any accumulated dust. Do not energize the robot until you have performed the following steps.
1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated dust. 2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static electricity and cause an explosion unless special precautions are taken. 3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust. 4. When the dust has been removed, the covers must be replaced immediately. 5. Immediately after the covers are replaced, run a complete purge cycle. The robot can now be energized.
Staying Safe While Operating Paint Application Equipment When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.
WARNING When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National Electrical Code.
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Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms. High Voltage: High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process.
Avoid any accumulation of combustible vapors or coating matter.
Follow all manufacturer recommended cleaning procedures.
Make sure all interlocks are operational.
Safety
No smoking. Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material.
Disable all air and paint pressure to bell.
Verify that the lines are not under pressure.
Staying Safe During Maintenance When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot.
Paint robots operate in a potentially explosive environment. Use caution when working with electric tools. When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area. For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards.
Be sure all covers and inspection plates are in good repair and in place.
Always return the robot to the ‘‘home’’ position before you disarm it.
Never use machine power to aid in removing any component from the robot. During robot operations, be aware of the robot’s movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems.
Whenever possible, turn off the main electrical disconnect before you clean the robot.
When using vinyl resin observe the following:
-
Wear eye protection and protective gloves during application and removal.
-
If there is contact with the skin, wash with water.
Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation. Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
When using paint remover observe the following:
-
Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.
-
Adequate ventilation is required. Overexposure could cause drowsiness.
-
Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then seek medical attention as soon as possible.
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SAFETY PRECAUTIONS This chapter describes the precautions which must be observed to ensure the safe use of the robot. Before attempting to use the robot, be sure to read this chapter thoroughly. Before using the functions related to robot operation, read the relevant operator's manual to become familiar with those functions. For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
DEFINITION OF USER
The user can be classified as follows.
Operator : Turns the robot controller power ON/OFF Starts the robot program with operator’s panel • •
Programmer : Operates the robot Teaches the robot inside the safety fence • •
Maintenance engineer : Operates the robot Teaches the robot inside the safety fence Maintenance (repair, adjustment, replacement) • • •
-
-
“An operator” cannot work inside the safety fence “Programmer”, “Teaching operator”, and “Maintenance engineer” can work inside the safety fence. The working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance, etc. To work inside the safety fence, the person must be trained on proper robot operation.
During the operation, programming, and maintenance of your robotic system, programmer, teaching operator and maintenance engineer must operate with circumspection by using following safety precautions. -
Adequate clothes for the operation Safety shoes A helmet
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DEFINITION OF SAFETY NOTATIONS
To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is indicated by " NOTE". Please read each "WARNING", "CAUTION" and "NOTE" before attempting to use the robots. Symbol
Definitions
WARNING
Used if hazard resulting in the death or serious injury of the user will be expected to occur if he or she fails to follow the approved procedure. Used if a hazard resulting in the minor or moderate injury of the user, or equipment damage may be expected to occur if he or she fails to follow the approved procedure. Used if a supplementary explanation not related to any of WARNING, and CAUTION is to be indicated.
CAUTION NOTE •
3
Check this manual thoroughly, and keep it handy for the future reference.
USER SAFETY
User safety is the primary safety consideration. As it is very dangerous to enter the operating area of the robot during its automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. safety.
Careful consideration must be made to ensure user
(1) We obligate the User to take a FANUC training courses.
FANUC provides various training courses. details.
Contact your local FANUC representative for
(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure user safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no user can enter the safety fence inside without passing through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.
The controller is designed to receive this interlocking signal of the door switch. When the safety fence is opened and this signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, refer to below Fig.3 (b). (4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). (5) Recommend to install the peripheral device outside of the motion range. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when a user enters the motion range. (8) If necessary, install a safety lock so that no one except the user in charge can turn the power on the robot. s-2
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The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock. (9) When adjusting each peripheral device independently, make sure to turn the power off the robot. (10) Operators must take the gloves off while manipulating the operator’s panel or teach pendant. Operation with gloved fingers may cause an operation error. (11) Programs, system variables, and other information can be saved on memory card or USB memories. Be sure to save the data periodically in case the data is lost in an accident. (12) The robot must be transported and installed by accurate procedure recommended by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers. (13) In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, the speed should be gradually increased to check the operation of the robot. (14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation. (15) Do not operate the robot under the following conditions. Otherwise, the robot and peripheral equipment can be adversely affected, or workers can be severely injured. Flammable Explosive Massive dose of Radiation Under water, high (heavy) Humidity Transport human or animals Stepladder (climb or hang down) Outdoor (16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external emergency , fence etc.) of robot, be sure to confirm the stop movement and do not take the wrong connection. (17) In preparing the trestle, please secure the maintenance engineer safety at high place in reference to Fig. 3 (c). Design with the Scaffolding and Safety-belt with circumspection.
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RP1 Pulsecoder RI/RO,XHBK,XROT RM1 Motor power/brake
EARTH
Safety 安全柵fence
Interlocking device and safety plug that are activated if the gate is opened. 扉が開いたときに作動するインタロック装置および安全プラグ Fig. 3 (a) Safety fence and safety gate
WARNING When you close a fence, please confirm that there is not a person from all directions of the robot. Dual chain
Emergency stop board orPanel Panel board board EAS1 EAS11 EAS2 EAS21
Single chain
Panel board
(Note) （Note） In case of R-30iA For the R-30 iB, the R-30 iB Mate TerminalsEAS1,EAS11,EAS2,EAS21 EAS1,EAS11,EAS2,EAS21 FENCE1,FENCE2 Terminals areorprovided on the are provided on the operation box or on the terminal block emergency stop board. of the printed circuit board. Refer the 0iA ELECTRICAL CONNCETIONS Chapter of In casetoof R-3 Mate CONNECTION of Terminals EAS1,EAS11,EAS2,EAS21 are provided i B emergency R-30 controller maintenance (B-83195EN) on the stop board manual or connector panel. or (in case of Ope n air type) i B Mate R-30 controller maintenance manual (B-83525EN) for details. Termianls FENCE1,FENCE2 are provided on the em ergency stop boar d. Refer to controller maintenance manual for details.
FENCE1 FENCE2 Fig. 3 (b) Connection diagram for the signal of safety fence
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Hook for safety belt Fence
Steps Trestle Pedestal for maintenance
Fig. 3 (c) Pedestal fo r maint enance
3.1
OPERATOR SAFETY
The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. Operator cannot work inside the safety fence. (1) If you don’t need to operate the robot, turn the power off the robot controller, or press the “EMERGENCY STOP” button, and then proceed your work. (2) Operate the robot system outside of the robot motion range. (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the dangerous area unexpectedly and the worker from entering a hazardous area. (4) Install one or more necessary quantity of EMERGENCY STOP button(s) within the operator’s reach in appropriate location(s) based on the system layout.
The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external EMERGENCY STOP button is pressed. See the diagram below for connection. Dual chain External stop button
Emergency stop board Panel board or Panel board
EES1 EES11 EES2 EES21
Single chain External stop button
(Note) Connect EES1 and EES11, EES2 and EES21 （Note） For the R-30iB, the R-30iB Mate Connect EES 1and EES11,EES2 and EES21or EMGIN1and EMGIN2. EES1,EES11,EES2,EES21 are on the emergency stop board In case of R-30iA
EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board. of Refer to the ELECTRICAL CONNCETIONS Chapter CONNECTION In case of R-30iAofMate EES1,EES11,EES2,EES21 are on the emergency stop boardo r R-30 manual (B-83195EN) i B controller maintenance or connector panel (in case of Open air type). R-30 i B Mate controller maintenance manual (B-83525EN) EMGIN1,EMGIN2 are on the emergency stop board. for details. Refer to the maintenance manual of the controller for d etails.
Panel board EMGIN1 EMGIN2
Fig. 3.1 Connection di agram for external emergency stop button
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SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the motion range of the robot. Please ensure the safety of programmer. (1) Unless it is specifically necessary to enter the robot motion range, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal condition. (3) If it is inevitable to enter the robot motion range to teach the robot, check the locations, settings, and other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area. (4) The programmer must be extremely careful not to let anyone else enter the robot motion range. (5) Programming must be done outside of the safety fence as far as possible. If programming needs to be done in the area of the safety fence, the programmer must take the following precautions: Before entering the safety fence area, ensure that there is no risk of hazardous situation in the area. Be ready to press the emergency stop button whenever it is necessary. Operate the Robot at low speed. Before starting programming, check the entire system status to ensure that no remote instruction to the peripheral equipment or motion would harm user. Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence. Teach pendant is provided with a switch to enable/disable robot operation from teach pendant and DEADMAN switch as well as emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes the stop of the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type) when pressed. (2) DEADMAN switch: Functions are different depending on the teach pendant enable/disable switch setting status. (a) Enable: Servo power is turned off and robot stops when the operator releases the DEADMAN switch or when the operator presses the switch strongly. (b) Disable: The DEADMAN switch is disabled. (Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot stops immediately. The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely. Based on the risk assessment by FANUC, number of operation of DEADMAN switch should not exceed about 10000 times per year. The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the teach pendant enable switch and the remote condition on the software.
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Mode
AUTO mode
T1, T2 mode
Teach pendant enable switch On Off On Off
Software remote condition
Teach pendant
Operator panel
Peripheral device
Local Remote Local Remote Local Remote Local Remote
Not allowed Not allowed Not allowed Not allowed Allowed to start Allowed to start Not allowed Not allowed
Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed Not allowed
Not allowed Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed
T1,T2 mode: DEADMAN swit ch i s effecti ve.
(6) To start the system using the operator’s panel, make certain that nobody is in the robot motion range and that there are no abnormal conditions in the robot motion range. (7) When a program is completed, be sure to carry out the test operation according to the following procedure. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed, and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test operation above, execute it in the automatic operation mode. (8) While operating the system in the automatic operation mode, the teach pendant operator must leave the safety fence.
3.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance engineer personnel, pay utmost attention to the following. (1) Must never be in the area during its operation. (2) A hazardous situation may occur when the robot or the system, are kept with their power-on during maintenance operations. Therefore, for any maintenance operation, the robot and the system must be put into the power-off state. If necessary, a lock should be in place in order to prevent any other person from turning on the robot and/or the system. In case maintenance needs to be executed in the power-on state, the emergency stop button must be pressed. (3) If it becomes necessary to enter the robot operation area while the power is on, press the emergency stop button on the operator panel, or the teach pendant before entering the area. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly. (4) When entering the area enclosed by the safety fence, the maintenance engineer must check the entire system in order to make sure that there is no dangerous situation around. In case the worker needs to enter the safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status must be carefully monitored. (5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off and the pressure in the piping should be reduced to zero. (6) Before the start of maintenance, check the robot and its peripheral devices are all in the normal condition. (7) Do not operate the robot in the automatic mode while anybody is in the robot motion range. (8) In maintaining the robot parallel to a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed. s-7
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(9) When a tool is mounted on the robot, or any moving device other than the robot is installed, such as belt conveyor, careful attention required for those motion. (10) Assign an expert near the operator panel who can press the EMERGENCY STOP button whenever he sees the potential danger. (11) In case of replacing a part, please contact your local FANUC representative. Wrong procedure may cause the serious damage to the robot and the worker. (12) Make sure that no impurity into the system in while (in) replacing or reinstalling components. (13) Turn off the circuit breaker to protect again electric shock in handling each unit or printed circuit board in the controller during inspection. If there are two cabinets, turn off the both circuit breaker. (14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may cause not only a damage to the internal parts of the controller but also a fire. (15) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the motion range and that the robot and the peripheral devices are not abnormal. (16) In case of remove the motor or brake, suspend the arm by crane or other equipment beforehand to avoid falling. (17) Whenever grease is spilled on the floor, remove them as soon as possible to prevent from falling. (18) The following parts are heated. If a maintenance engineer needs to touch such a part in the heated state, the worker should wear heat-resistant gloves or use other protective tools. Servo motor Inside of the controller Reducer Gearbox Wrist unit (19) Maintenance must be done with appropriate lightning. Be careful that those lightning will not cause any further danger. (20) When a motor, reducer, or other heavy load is handled, a crane or other equipmenthould be used to protect maintenance engineers from excessive load. Otherwise, the maintenance engineers would be severely injured. (21) Must never climb or step on the robot even in the maintenance. If it is attempted, the robot would be adversely affected. In addition, a misstep can cause injury to the worker. (22) Secure a pedestal and wear the safety belt in performing the maintenance work in high place. (23) Remove all the spilled oil or water and metal chips around the robot in the safety fence after completing the maintenance. (24) All the related bolts and components must return to the original place in replacing the parts. If some parts are missing or left (remained), repeat the replacement work until complete the installation. (25) In case robot motion is required during maintenance, the following precautions should be taken : Secure an escape route. And during the maintenance motion itself, monitor continuously the whole system so that your escape route will not become blocked by the robot, or by peripheral equipment. Keep vigilant attention for the potential danger. and to press the emergency stop button whenever it is necessary. (26) Periodic inspection required. (Refer to the robot mechanical manual and controller maintenance manual.) A failure to do the periodical inspection can may adversely affect the performance or service life of the robot and may cause an accident (27) After replacing some parts, a test run required by the predetermined method. (See TESTING section of "Controller operator’s manual". During the test run, the maintenance staff must work outside the safety fence. • • • • •
•
•
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4
SAFETY OF THE TOOLS AND PERIPHERAL EQUIPMENT
4.1
PRECAUTIONS IN PROGRAMMING
(1) Adopt a limit switch or other sensor to detect a dangerous state and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. (3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming in order not to interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system, and can be stopped according to the states.
4.2
PRECAUTIONS FOR MECHANISM
(1) Keep the component cells of the robot system clean, operate the robot where insulated from the influence of grease, water, and dust. (2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid. (3) Adopt limit switches or mechanical stoppers to limit the robot motion, and avoid the robot from collisions against peripheral devices or tools. (4) Observe the following precautions about the mechanical unit cables. Failure to follow precautions may cause mechanical troubles. Use mechanical unit cable that have required user interface. Do not add user cable or hose to inside of mechanical unit. Please do not obstruct the movement of the mechanical unit when cables are added to outside of mechanical unit. In the case of the model that a cable is exposed, please do not perform remodeling (Adding a protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable. When installing user peripheral equipment on the robot mechanical unit, please pay attention that equipment does not interfere with the robot itself. (5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid the system construction that power-off stop would be operated routinely. (Refer to bad case example.) Please perform power-off stop after reducing the speed of the robot and stopping it by hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type.) (Bad case example) Whenever poor product is generated, a line stops by emergency stop and power-off of the robot is incurred. When alteration is necessary, safety switch is operated by opening safety fence and power-off stop is incurred for the robot during operation. An operator pushes the emergency stop button frequently, and a line stops. An area sensor or a mat switch connected to safety signal operates routinely and power-off stop is incurred for the robot. Power-off stop is regularly incurred due to an inappropriate setting for Dual Check Safety (DCS). (6) Power-off stop of Robot is executed when collision detection alarm (SRVO-050) etc. occurs. Please try to avoid unnecessary power-off stops. It may cause the trouble of the robot, too. So remove the causes of the alarm. • • •
•
•
•
•
• •
•
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SAFETY OF THE ROBOT MECHANICAL UNIT
5.1
PRECAUTIONS IN OPERATION
(1) Operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality. (2) Before pressing the jog key, be sure to comprehend the robot movement by the key in advance.
5.2
PRECAUTIONS IN PROGRAMMING
(1) Design to arrange avoiding mutual interfere when various robot’s operation area crossover significantly. (2) Be sure to specify the predetermined work origin in a motion program so that the robot starts from the origin and terminates at the origin. Make it possible for the operator to distinguish easily that the robot motion has terminated at a glance.
5.3
PRECAUTIONS FOR MECHANISMS
Keep the motion range areas of the robot clean, and operate the robot in an environment free of grease, water, and dust.
5.4
PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons trapped in or sandwiched by the robot), brake release unit can be used to move the robot axes without drive power. Please order following unit and cable. Name Brake release unit Robot connection cable
Power cable
(*)
Specification A05B-2450-J350 (Input voltage AC100-115V single phase) A05B-2450-J351 (Input voltage AC200-240V single phase) A05B-2525-J047 (5m) A05B-2525-J048 (10m) A05B-2525-J010 (5m) (AC100-115V Power plug) (*) A05B-2525-J011 (10m) (AC100-115V Power plug) (*) A05B-2450-J364 (5m) (AC100-115V or AC200-240V No power plug) A05B-2450-J365 (10m) (AC100-115V or AC200-240V No power plug)
These do not support CE marking.
(2) Please make sure that adequate numbers of brake release units are available and readily accessible for robot system before installation. (3) Regarding how to use brake release unit, please refer to Robot controller maintenance manual.
CAUTION Robot systems installed without adequate number of brake release units or similar means are neither in compliance with EN ISO 10218-1 nor with the Machinery Directive and therefore cannot bear the CE marking. s-10
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WARNING Robot arm would fall down by releasing its brake because of gravity. Therefore, it is strongly recommended to take adequate measures such as hanging Robot arm by a crane before releasing a brake. In case of releasing the J2-axis motor brake J2軸モータブレーキを解除する場合
In case of releasing the J3-axis motor brake J3軸モータブレーキを解除する場合
Fall落下 down Fall down 落下
Fall down 落下
Method of supporting the robot arm
アーム支持方法
Sling スリング
(*) This figure is an example of floor mount. direction of fall is different according 図は床置き設置時の例です。 (*)The 設置角度によっては落下方向が異なり to the installation angle, so support ますので重力の影響を考慮し適切に支 the robot appropriately in consideration えてください。 of the influence of the gravity.
Fig. 5.4 Arm operatio n by t he release of J2/J3-axis motor brake and measures
6
SAFETY OF THE END EFFECTOR
6.1
PRECAUTIONS IN PROGRAMMING
(1) Circumspect program with sufficient delay required for the program after executing some control command in adopting actuators (pneumatic, hydraulic, and electric) (2) Adopt limit switches for the end effector, and control the robot system by monitoring the state. s-11
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STOP TYPE OF ROBOT
There are following three types of Stopping Robot.
Power-Off Sto p (Category 0 f oll owing IEC 60204-1) Servo power is turned off, and the robot stops immediately. Servo power is turned off when the robot is moving, and the motion path of the deceleration is uncontrolled. “Power-Off stop” performs following processing. An alarm is generated, and then the servo power turns off. Instantly the robot stops. Execution of the program is paused. Frequent Power-Off stop of the robot during operation can cause mechanical problems of the robot. Avoid system designs that require routine or frequent Power-Off stop conditions. • •
Contr oll ed stop (Categor y 1 foll owing IEC 60204-1) The robot is decelerated until it stops, and servo power is turned off. “Controlled stop” performs following processing. The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. The program execution is paused. An alarm is generated, and then the servo power turns off. •
•
Hold (Categor y 2 foll ow ing IEC 60204-1) The robot is decelerated until it stops, and servo power remains on. “Hold” performs following processing. The robot operation is decelerated until it stops. Execution of the program is paused. •
WARNING The stopping distance and time of Controlled stop are longer than those of Power-Off stop. A risk assessment for the whole robot system which takes into consideration the increased stopping distance and stopping time, is necessary when Controlled stop is used. When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is different according to the controller type or option configuration. There are the following 3 Stop patterns. Emergency stop button
External Emergency stop
FENCE op en
SVOFF in put
Servo disconnect
A
AUTO T1 T2
P-Stop P-Stop P-Stop
P-Stop P-Stop P-Stop
C-Stop -
C-Stop C-Stop C-Stop
P-Stop P-Stop P-Stop
B
AUTO T1 T2
P-Stop P-Stop P-Stop
P-Stop P-Stop P-Stop
P-Stop -
P-Stop P-Stop P-Stop
P-Stop P-Stop P-Stop
C
AUTO T1 T2
C-Stop P-Stop P-Stop
C-Stop P-Stop P-Stop
C-Stop -
C-Stop C-Stop C-Stop
C-Stop P-Stop P-Stop
Stop pattern
P-Stop: C-Stop: -:
Mode
Power-Off stop Controlled stop Disable s-12
SAFETY PRECAUTIONS
B-83755EN/01
The following table indicates the Stop pattern according to the controller type or option configuration. R-30iB/R-30iB Mate
Option Standard Controlled stop by E-Stop (A05B-2600-J570)
A (*) C (*)
(*) R-30 iB/R-30iB Mate does not have servo disconnect. R-30 iB Mate does not have SVOFF input. The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer to "Software version" in operator's manual of controller for the detail of s oftware version screen.
" Controlled stop by E-Stop" opt ion When "Controlled stop by E-Stop" (A05B-2600-J570) option is specified, the stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is the normal operation of the system. Alar m SRVO-001 Operator panel E-stop SRVO-002 Teach pendant E-stop SRVO-007 External emergency stops SRVO-408 DCS SSO Ext Emergency Stop SRVO-409 DCS SSO Servo Disconnect
Con di ti on Operator panel emergency stop is pressed. Teach pendant emergency stop is pressed. External emergency stop input (EES1-EES11, EES2-EES21) is open. In DCS Safe I/O connect function, SSO[3] is OFF. In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows: In Controlled stop, the robot is stopped on the program path. This function is effective for a system where the robot can interfere with other devices if it deviates from the program path. In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized. The stopping distance and time of Controlled stop is longer than the those of Power-Off stop, depending on the robot model and axis. Please refer to the operator's manual of a particular robot model for the data of stopping distance and time. •
•
•
When this option is loaded, this function cannot be disabled. The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING The stopping distance and time of Controlled stop are longer than those of Power-Off stop. A risk assessment for the whole robot system which takes into consideration the increased stopping distance and stopping time, is necessary when this option is loaded.
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SAFETY PRECAUTIONS
8 (1)
B-83755EN/01
WARNING & CAUTION LABEL Greasing and degreasin g label
Fig. 8 (a) Greasing and degreasing label
Description When greasing and degreasing, observe the instructions indicated on this label. (1) Open the grease outlet at greasing. (2) Use a hand pump at greasing. (3) Use designated grease at greasing.
CAUTION See Section 2.2 and 2.3 for explanations about specified grease, the grease amount, and the locations of grease inlets and outlets for individual models.
(2)
Step-on prohi biti ve label
Fig. 8 (b) Step-on prohibitive label
Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. s-14
SAFETY PRECAUTIONS
B-83755EN/01
(3)
High-temp erature warni ng label
Fig. 8 (c) High-temperature warni ng label
Description Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision tool as heat-resistant gloves.
(4)
Transpo rtation label
300kg 250kg×2
150kg×2 300kg
Fig. 8 (d) Transportation label
Description When transporting the robot, observe the instructions indicated on this label. (1) Using a crane Use a crane with a load capacity of 2940N (300kgf) or greater. Use two slings with each load capacity of 2450 N (250 kgf) or greater, sling the robot as shown Chapter 1 of operator’s manual. Use two M12 eyebolts with each load capacity of 1470 N (150 kgf) or greater. (2) Using a forklift Use a forklift with a load capacity of 2940N (300kgf) or greater. • •
•
•
CAUTION See Section 1.1 TRANSPORTATION of operator’s manual (B-83754EN) for explanations about the posture a specific model should take when it is transported. s-15
SAFETY PRECAUTIONS
(5)
B-83755EN/01
Transpo rtation proh ibit ive label (When transport equipment option A05B-1226-H072 is specified.)
輸送部材に衝撃を 与えないこと Do not have impact on this part 禁止撞击搬运用部件
輸送部材にチェーン などを掛けないこと Do not chain, pry, or strap on this part 禁止在搬运用部件上使 用锁链等物品固定或者 搬运机器人
Fig. 8 (e) Transportation prohibitive label
Description Keep the following in mind when transporting the robot. (1) Prevent the forks of the forklift from having impact on a transport equipment (2) Do not thread a chain or the like through transport equipment.
(6)
Greasing label (if greasin g kit A05B-1226-K031 is specifi ed)
Fig. 8 (f) Greasing label
Description When using a grease kit, observe the instructions indicated on this label. 1) Before filling the cylinder with grease from tube, squeeze the tube to make the grease in it soft. 2) Pushing in the plunger by 2.5 mm causes a grease of 1 ml to be pushed out.
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SAFETY PRECAUTIONS
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(7)
Installatio n label
Fig. 8 (g) Installation label
Description Assemble attached washers at installation of robot.
(8)
Operating space and payload label
Below label is added when CE specification is specified.
Fig. 8 (h) Operating space and payload l abel 150731
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PREFACE
B-83755EN/01
PREFACE This manual explains the maintenance procedures for the mechanical units of the following robots: Model name FANUC Robot M-20iB/25
Mechanic al uni t specifi cation No.
Maximum load
A05B-1226-B201
25kg
The label stating the mechanical unit specification number is affixed in the following position. Before reading this manual, verify the specification number of the mechanical unit.
T g k H G I ) 5 E ( W
T g H k G I ) 5 E ( W
) ) 2 1 ( ( ) 3 ) ( 4 (
) ) 2 1 ( (
E E P . T O A Y T N D
) 3 ) ( 4 (
E E P . T A O Y T D N
Position of label indicating mechanical unit specification number TABLE 1)
CONTENTS
LETTERS
(1)
(2)
(3)
(4)
(5)
Model name
TYPE
No.
DATE
WEIGHT kg (Without controller )
FANUC Robot M-20iB/25
A05B-1226-B201
p-1
SERIAL NO. IS PRINTED
PRODUCTION YEAR AND MONTH ARE PRINTED
210
PREFACE
B-83755EN/01
RELATED MANUALS For the FANUC Robot series, the following manuals are available: Safety handbook B-80687EN (bold) All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook R-30iB/ OPERATOR’S MANUAL R-30iB Mate (Basic Operation) controller B-83284EN OPERATOR’S MANUAL (Alarm Code List) B-83284EN-1 OPERATOR’S MANUAL (Optional Function) B-83284EN-2 ARC WELDING FUNCTION OPERATOR’S MANUAL B-83284EN-3 Spot WELDING FUNCTION OPERATOR’S MANUAL B-83284EN-4 DISPENSE FUNCTION OPERATOR’S MANUAL B-83284EN-5
FANUC Robot M-20iB Mechanical unit
Intended readers : Operator, System designer Topics : Safety items for robot system design, Operation, Maintenance Intended readers : Operator, programmer, Teaching operator, Maintenance engineer, System designer Topics : Robot functions, Operations, Programming, Setup, Interfaces, Alarms Use : Robot operation, Teaching, System design
MAINTENANCE MANUAL R-30iB : B-83195EN R-30iB Mate : B-83525EN
Intended readers : Maintenance engineer, System designer Topics : Installation, Connection to the controller, Maintenance Use : Installation, Start-up, Connection, Maintenance
OPERATOR’S MANUAL FANUC Robot M-20iB B-83754EN
Intended readers: System designer, Maintenance engineer Topics: Installation, connection to controller, maintenance Use: Installation, start-up, connection, maintenance
This manual uses following terms. Name
Terms in thi s manual
Connection cable between robot and controller Robot mechanical unit
Robot connection cable Mechanical unit
p-2
TABLE OF CONTENTS
B-83755EN/01
TABLE OF CONTENTS SAFETY PRECAUTIONS ............................................................................s-1 PREFACE ....................................................................................................p-1 1
CHECKS AND MAINTENANCE .............................................................1 1.1
PERIODIC MAINTENANCE .......................................................................... 1 1.1.1 1.1.2
1.2
CHECK POINTS............................................................................................ 4 1.2.1 1.2.2 1.2.3 1.2.4
1.3
2
MAINTENANCE TOOLS ............................................................................... 8 REPLACING THE BATTERIES (1.5 YEAR CHECKS) .................................. 9 REPLACING THE GREASE OF THE J1 TO J3 AXIS REDUCERS (3 YEARS (11520 HOURS) CHECKS) ........................................................11 2.2.1
2.3
GREASE SUPPLYING PROCEDURE FOR J4 TO J6-AXIS REDUCER (4 YEARS (15360 HOURS) PERIODICAL CHECK).................................... 14 TROUBLESHOOTING................................................................................. 16 BACKLASH MEASUREMENT..................................................................... 23
REPLA CING PARTS ............................................................................27 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17
5
Procedure for releasing remaining pressure from the grease bath (J1 to J3-axis) ..13
TROUBLESHOOTING ..........................................................................16 3.1 3.2
4
Confirmation of Oil Seepage....................................................................................4 Confirmation of the Air Control Set (option)...........................................................5 Check the Mechanical Unit Connectors ...................................................................6 Check of Fixed Mechanical Stopper and Adjustable Mechanical Stopper ..............7
PERIODIC MAINTENANCE .................................................................... 9 2.1 2.2
3
Daily Checks ............................................................................................................1 Periodic Checks and Maintenance............................................................................2
FIGURE OF DRIVE MECHANISM .............................................................. 28 REPLACING J1-AXIS MOTOR.................................................................... 30 REPLACING J1-AXIS REDUCER ............................................................... 32 REPLACING J2-AXIS MOTOR.................................................................... 35 REPLACING J2-AXIS REDUCER ............................................................... 38 REPLACING J3-AXIS MOTOR.................................................................... 40 REPLACING J3-AXIS REDUCER ............................................................... 43 REPLACING J4-AXIS MOTOR.................................................................... 45 REPLACING J4-AXIS REDUCER ............................................................... 47 REPLACING J5-AXIS MOTOR.................................................................... 50 REPLACING J5-AXIS REDUCER ............................................................... 52 REPLACING J6-AXIS MOTOR.................................................................... 55 REPLACING WRIST UNIT .......................................................................... 57 REPLACING J6-AXIS REDUCER ............................................................... 59 REPLACING J5/J6 BELT ............................................................................ 60 REPLACING SOLENOID VALVE ................................................................ 62 SEALANT APPLICATION............................................................................ 63
REPLA CING CAB LES ..........................................................................64 c-1
TABLE OF CONTENTS 5.1 5.2 5.3
CABLE WIRING........................................................................................... 65 CABLE FORMING ....................................................................................... 66 CABLE AND AIR TUBE REPLACEMENT ................................................... 67 5.3.1 5.3.2
6
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Replacing Cable K123 and Air Tube (Connector panel to J2 base).......................67 Replacing Cable K102,K103,K104,K105,K106,K108K and Air Tube (J2 arm to J3 arm) ............................................................................75
ADJUSTMENT ...................................................................................... 84 6.1 6.2
ADJUSTING TENSION OF BELT................................................................ 84 MASTERING ............................................................................................... 85 6.2.1 6.2.2 6.2.3 6.2.4
OVERVIEW...........................................................................................................85 RESETTING ALARMS AND PREPARING FOR MASTERING .......................88 FIXTURE POSITION MASTERING....................................................................89 VERIFY MASTERING .........................................................................................94
A
MAINTENANCE PARTS ....................................................................... 97
B
MECHANICAL UNIT CIRCUIT DIAGRAM AND AIR PRESSURE DIAGRAM............................................................................................102
C
PERIODIC MAINTENANCE TABL E ...................................................107
D
STRENGTH OF BOL T AND BOLT TORQUE LIST............................110
E
INSULATION AB OUT ARC WELDING ROBOT................................. 111 E.1
INSULATION AT THE WRIST................................................................... 111
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1. CHECKS AND MAINTENANCE
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1
CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures presented in this chapter. (See the APPENDIX C PERIODIC MAINTENANCE TABLE.)
NOTE The periodic maintenance procedures described in this chapter assume that the FANUC robot is used for up to 3840 hours a year. In cases where robot use exceeds 3840 hours/year, adjust the given maintenance frequencies accordingly. The ratio of actual operating time/year vs. the 3840 hours/year should be used to calculate the new (higher) frequencies. For example, when using the robot 7680 hours a year, the maintenance frequency should be doubled – i.e. the time interval should be divided by 2.
1.1
PERIODIC MAINTENANCE
1.1.1
Daily Checks
Clean each part, and visually check component parts for damage before daily system operation. Check the following items when necessary. Check items
Check points and management
Oil seepage
Check to see if there is oil on the sealed part of each joint. If there is an oil seepage, clean it. ” 1.2.1 Confir mation o f Oil Seepage”
Air control set
(When air control set is used) ⇒” 1.2.2 Confirmation of the Air Control Set”
Vibration, abnormal noises
Check whether vibration or abnormal noises occur. When vibration or abnormal noises occur, perform measures referring to the following section: ” 3.1 TROUBLESHOOOTING” (symptom: Vibratio n, Noise)
Positioning accuracy
Check whether the taught positions of the robot have not deviated from the previously taught positions. When displacement occurs, perform the measures as described in the following section: ” 3.1 TROUBLESHOOTING”(sympt om: Displacement)
Peripheral devices for proper operation
Brakes for each axis
Warnings
Check whether the peripheral devices operate properly according to commands from the robot and the peripheral devices. Check that the end effector drops 5 mm or less when the servo power is turned off. If the end effector (hand) drops more than the prescribed amount, perform the measures as described in the following section: ” 3.1 TROUBLESHOOTING” (symptom : Dropp ing axi s) Check whether unexpected warnings occur in the alarm screen on the teach pendant. If unexpected warnings occur, perform the measures as described in the following manual: ” R-30iB/R-30iB Mate CONTROLLER OPERATOR’S MANUAL (Alarm Code L ist )(B-83284EN-1)”
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1. CHECKS AND MAINTENANCE
1.1.2
B-83755EN/01
Period ic Checks and Maintenance
Check the following items at the intervals recommended below based on the total operating time or the accumulated operating time, whichever comes first. ( ○ : Item needs to be performed.) Check and maintenance intervals (Operating time, Acc umul ated op erat in g time) 1 3 1 month months year 320h 960h 3840h
○
○
Only 1st check
○
○
○
○
Only 1st check
○
○
Only 1st check
○
○
Only 1st check
○ Only 1st check
○
2 years 7680h
Check and maintenance item
Check points, management and maintenance method
Periodic maintenance table No.
3 4 years years 11520h 15360h
Cleaning the controller ventilation system
Check whether dust is accumulated in the controller ventilation system. Remove the dust if it exists.
Check for external damage or peeling paint
Check whether the robot has external damage or peeling paint due to interference with the peripheral devices. If an interference occurs, eliminate the cause. Also, if the external damage is serious, and causes a problem in which the robot will not operate, replace the damaged parts.
Check for water
Check whether the robot is subjected to water or cutting oils. If water is found, remove the cause and wipe off the liquid. Check whether the cable connected to the teach pendant, operation box and robot are unevenly twisted or damaged. If damage is found, replace the damaged cables.
Check for damages to the teach pendant cable, the operation box connection cable or the robot connection cable Check for damage to the end effector (hand) cable Check the connection of each axis motor and other exposed connectors Retightening the end effector mounting bolts
Check whether the end effector cables are unevenly twisted or damaged. If damage is found, replace the damaged cables. Check the connection of each axis motor and other exposed connectors. ” 1.2.3 Check the Mechanical Unit Connectors”
Retighten the end effector mounting bolts. Refer to the following section for tightening torque information: ”4.1 END EFFECTOR INSTALLATION TO WRIST of OPERATOR’S MANUAL (B-83754EN)”
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18
1
2
17
3
4
5
1. CHECKS AND MAINTENANCE
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Check and maintenance intervals (Operating time, Acc umul ated op erat in g time) 1 3 1 month months year 320h 960h 3840h
○
2 years 7680h
Check and maintenance item
○
Retightening the external main bolts
1st check
○
Check the mechanical stopper and the adjustable mechanical stopper Clean spatters, sawdust and dust
Only 1st check
○
Periodic maintenance table No.
3 4 years years 11520h 15360h
Only
○
Check points, management and maintenance method
○
Only 1st check
○
○
○
○
○
Replacing the mechanical unit batteries Replacing the grease of J1 to J3- axis reducers Supplying grease l to J4 to J6- axis reducers Replacing the mechanical unit cable Replacing the controller batteries
Retighten the bolts which were installed or removed during the inspection and exposed. Refer to the recommended bolt tightening torque guidelines at the end of the manual. Some bolts are attached with adhesive. Tightening the bolts with a torque greater than what is recommended might damage the adhesive. Therefore, follow the recommended bolt tightening torque guidelines when retightening the bolts. “ App endi x D, STRENGTH OF BOLT AND BOLT TORQUE LIST” Check that there is no evidence of a collision on the mechanical stopper, the adjustable mechanical stopper, and check the looseness of the stopper mounting bolts. ” 1.2.4 Check of Fixed Mechanical Stopper and Adjustabl e Mechanical Stopper” Check that spatters, sawdust, or dust does not exist on the robot main body. If dust has accumulated, remove it. Especially, clean the robot movable parts well (each joint, around the welding torch, conduit part, wrist axis hollow part and the cable protection sheath). The insulation failure occurs when the spatter has collected around the wrist flange or welding torch, and there is a possibility of damaging the robot mechanism by the welding current. (See Appendix C) Replace the mechanical unit batteries ” 2.1 REPLACING THE BATTERIES” Replace the grease and oil of each axis reducer and gearbox ” 2.2 REPLACING THE GREASE OF THE J1 TO J3 AXIS REDUCERS” Supply grease l to J4 to J6-axis reducers ” 2.3 GREASE SUPPLYING PROCEDURE FOR J4 TO J6-AXIS REDUCER”
6
7
8
9
10 to 12
13 to 15
Replace the mechanical unit cable Contact your local FANUC representative for information regarding replacing the cable.
16
Replace the controller batteries Chapter 7 Replacing batteries of R-30iB CONTROLLER MAINTENANCE MANUAL (B-83195EN) or R-30iB Mate CONTROLLER MAINTENANCE MANUAL (B-83525EN)”
19
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1. CHECKS AND MAINTENANCE
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1.2
CHECK POINTS
1.2.1
Confirm ation o f Oil Seepage
Check items Check whether there is oil on the sealed part of each joint. If there is oil seepage, clean each part.
Fig. 1.2.1 Check parts for oil seepage
Management Oil might accumulate on the outside of the seal lip depending on the movement condition or environment of the axis. If the oil viscosity changes, the oil might drip depending on the axis movement. To prevent oil spots, be sure to wipe away any accumulated oil under the axis components in Fig. 1.2.1 before you operate the robot. In case of oil seepage, please consider replacing the grease and the oil altogether. This replacement potentially can help improve the seepage situation. Also, motors might become hot and the internal pressure of the grease bath or oil bath may increase by frequent repetitive movement and use in high temperature environments. In these cases, normal internal pressure can be restored by venting the grease outlet. (When opening the grease outlet, ensure that grease is not expelled onto the machine or tooling.)
WARNING Hot grease might eject suddenly when you open the grease outlet. Attach bags for collecting grease, and use appropriate protective equipment such as heat-resistant gloves, protective glasses, a face shield, or a body suit if necessary.
If you must wipe oil frequently, and opening the grease outlet does not stop the seepage, perform the measures below. ”3.1 TROUBLESHOOOTING”(symptom: Grease leakage)
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1. CHECKS AND MAINTENANCE
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1.2.2
Confirmation of t he Air Control Set (option)
When an air control set is used, check the items below. Item
Check items
1
Air pressure
2
Leakage from hose
3
Drain
Check poi nts Check air pressure using the pressure gauge on the air control set as shown in Fig. 1.2.2. If it does not meet the specified pressure of 0.49MPa (5 kg/cm2), adjust it using the regulator pressure setting handle. Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required. Check drain and release it. When quantity of the drain is remarkable, examine the setting of the air dryer to the air supply side.
Pressure Adjusting Knob
2-6.5 x 16.5 Length round hole
Rc1/4 AIR OUTLET
Pressure gauge Rc1/4 AIR SUPPLY
Fig. 1.2.2 Air control set (option)
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1. CHECKS AND MAINTENANCE
1.2.3
B-83755EN/01
Check t he Mechanical Unit Connector s
Inspection points of the connectors Robot connection cables, earth terminal and user cables
Check items Circular connector: Check the connector for tightness by turning it by hand. Square connector: Check the connector for engagement of its lever. Earth terminal: Check the connector for tightness.
Remove this cover このカバーを外して and check here.
点検する事
Fig. 1.2.3 Connector Inspection points
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1. CHECKS AND MAINTENANCE
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1.2.4
Check o f Fixed Mechanical Stopp er and A djus table Mechanical Stopper
Check that there is no evidence of a collision on the fixed mechanical stopper and the adjustable mechanical stopper. If there is evidence of a collision on the stopper, replace it with a new one. Check the tightness of the stopper mounting bolts. If they are loose, retighten them. Refer to Section 6.2 for details regarding the adjustable mechanical stopper. J3-axis J3軸機械式ストッパ (プラス側) stopper mechanical (plus side) J1-axis mechanical stopper J1軸機械式ストッパ ・A290-7226-X206 A290-7226-X206 ・ボルト Bolt M12M12X40 x 40 11個 pc (締付けトルク 129Nm) (Tightening torque 129Nm)
J3-axis J3軸機械式ストッパ mechanical stopper (マイナス側) (minus side)
断面A-A A-A Section
A J2-axis J2軸機械式ストッパ mechanical stopper (マイナス側) (minus side)
When J1-axis mechanical J1軸機械式ストッパ選択時 stopper is specified A05B-1226-H051 A A05B-1226-H051 ・A290-7226-X207 ・ボルト M12X20 2個 A290-7226-X235 (締付けトルク Bolt M12 x 30 94Nm) 2 pcs (Tightening torque 94Nm)
J2-axis J2軸機械式ストッパ mechanical stopper (プラス側) (plus side)
Fig. 1.2.4 Check of fixed mechanical stopper and adjustable mechanical stopper
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1. CHECKS AND MAINTENANCE
1.3
B-83755EN/01
MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance procedures contained in this manual. (a)
Measuring instruments Instrument
Specifications
Vendor
Manufacturer model No.
Application
Tension meter
A97L-0218-0700
Mitsuboshi Belting Ltd.
DOCTOR TENSION TYPE-Ⅲ
Adjustment of belt tension
Instruments
Accuracy/Tolerance
Applications
Dial gauge accuracy Vernier calipers
1/100 mm 150 mm
Measurement of positioning and backlash
(b) Tools Torque wrench Width across flats 2.5, 3, 4, 5, 6, 8, 10 Cross-head screwdrivers Large, medium, and small sizes Straight-head screwdrivers Large, medium, and small sizes Nut driver Width across flats 7, 8, 13, 17 Hexagon wrench set Width across flats 2.5, 3, 4, 5, 6, 8, 10 Monkey wrench Middle, little Pliers Cutting pliers Nippers Gear puller Separator Offset box end wrench LOCTITE 243, 263, 518, 641 Grease applying kit : A05B-1226-K031 (This option includes the greasing syringe and the grease (80g) in the tube.) grease in tube (80g) : A05B-1139-K022
5
O
Fig. 1.3 Example of cylinder
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2. PERIODIC MAINTENANCE
B-83755EN/01
2
PERIODIC MAINTENANCE
2.1
REPLACING THE BATTERIES (1.5 YEAR CHECKS)
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every year. Also, use the following procedure to replace the batteries when the backup battery voltage drop alarm occurs.
Procedure for replacing the battery 1 2 3
Move the robot to the posture to remove the battery part cover. Keep the power on. Press the EMERGENCY STOP button to stop robot motion. Remove the hexagon stainless bolts (M5 x 14), then remove the cover and the gasket. If the cover could not be removed, insert a straight-head screwdriver into the arrow part, then remove it.
CAUTION Be sure to keep controller power turned on. Replacing the batteries with the power turned off causes all current position data to be lost. Therefore, mastering will be required again. 4 5 6 7 8
Remove the battery case cap. (Fig. 2.1) Take out the old batteries from the battery case. At this time, the battery can be taken out by pulling the stick in the center of the battery box. Insert new batteries into the battery case. Pay attention to the direction of the batteries. Close the battery case cap. Replace hexagon bolts by new article when they are removed. When reusing hexagon bolts, be sure to wind it with seal tape. Gaskets can be reused.
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2. PERIODIC MAINTENANCE
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Gasket ガスケット A290-7226-X318 A290-7226-X318 Cover カバー
A
Hexagon bolt 六角ステンレスボルト (6) M5M5X14 x 14 (6) Spec.: A97L-0318-0450#051410S
Arrow 矢印部 part
Detail A 詳細 A
Battery case バッテリケース
Battery spec. :A98L-0031-0005 バッテリ仕様:A98L-0031-0005 (単一アルカリ電池 4本) (D batery 4 pcs)
Fig. 2.1 Replacing th e battery
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Case cap ケースキャップ
2. PERIODIC MAINTENANCE
B-83755EN/01
2.2
REPLACING THE GREASE OF THE J1 TO J3 AXIS REDUCERS (3 YEARS (11520 HOURS) CHECKS)
According to Table 2.2 (a) and (b), replace the grease of the reducers of J1, J2, and J3-axes every 3 years or 11520 hours, whichever comes first.
天吊設置の場合 Upside-down mount
º
-90 wall mount -90°壁掛け設置の場合
º
+90 wall mount +90°壁掛け設置の場合
Fig. 2.2 (a) Installati on meth od Table 2.2 (a) Grease name and amount to b e replaced at regul ar int ervals of t hree years (11520 hours ) (J1/J2/J3-axis reducer) Grease supplying position
Amo un t o f gr ease to be app li ed
J1-axis reducer
790g(870ml)
J2-axis reducer
300g(330ml)
J3-axis reducer
170g(190ml)
Gun tip pressure
0.1MPa or less (NOTE)
Specified grease Kyodo Yushi VIGOGREASE
RE0
(Specification: A98L-0040-0174)
NOTE When using a hand pump, apply grease at a rate of approximately once per two seconds. WARNING Hot grease might eject suddenly when you open the grease outlet. Attach bags for collecting grease, and use appropriate protective equipment such as heat-resistant gloves, protective glasses, a face shield, or a body suit if necessary.
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2. PERIODIC MAINTENANCE
B-83755EN/01
For grease replacement or replenishment, use the postures indicated in Table 2.2 (b). For angle mount robots, consider the relative angle from the posture of a floor mount robot. Table 2.2 (b) Grease supplyi ng post ure (J1/J2/J3-axis reducer) Grease supplying positi on J1-axis reducer grease supplying posture J2-axis reducer grease supplying posture J3-axis reducer grease supplying posture
1 2 3 4 5 6
Posture J1
J2
J3
Arbitrary
Arbitrary
J4
J5
J6
Arbitrary
Arbitrary
Arbitrary
Floor mount Upside-down mount Wall mount -90 Wall mount +90 Floor mount) Upside-down mount Wall mount -90 Wall mount +90 Floor mount Upside-down mount Wall mount -90 Wall mount +90
Arbitrary
0 -90 90 -90 0 0 0 0
Arbitrary
0 180 0 0
Move the robot to the greasing posture described in Table.2.2 (b). Turn off controller power. Remove the hexagon bolt M8 x 10 from grease outlet. (Fig. 2.2 (b)) Remove the taper plug from grease inlet and attach grease nipple. Keep greasing until the new grease pushes out the old grease and comes out from each grease outlet. Release the remaining pressure using the procedure given in Subsection 2.2.1. In case of Upside-down mount, pull out about 130ml grease to make space of grease bath.
J3-axis reducer grease inlet J3軸減速機給脂口 Taper plug 1/8 テーパプラグ R1/4 J3-axis reducer grease outlet J3軸減速機排脂口 Hexagon bolt 六角ボルト M8 x 10 M8X10
J2-axis reducer grease inlet J2軸減速機給脂口 Taper plug 1/8 テーパプラグ R1/8 J2-axis reducer grease outlet J2軸減速機排脂口 Hexagon bolt M8 x 10 六角ボルト M8X10
J1-axis reducer grease inlet J1軸減速機給脂口 テーパプラグ R1/8 Taper plug 1/8 J1-axis reducer grease outlet J1軸減速機排脂口 六角ボルトbolt M8X10 Hexagon M8 x 10
Fig. 2.2 (b) Greasing po int o f J1 to J3-axis reducer Table 2.2 (c) Specification of hexagon bolts and taper plugs Parts name Hexagon bolt Taper plug
Specificati on
(M8 x 10) (R1/8)
A97L-0318-0410#081010S A97L-0001-0436#2-1D
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2. PERIODIC MAINTENANCE
B-83755EN/01
1 2 3
4 5 6
2.2.1
CAUTION Failure to follow proper greasing procedures may cause a sudden increase of the grease bath internal pressure and damage to the seal. This, could lead to grease leakage and abnormal operation. When greasing, observe the following precautions. Before starting to grease, remove the seal bolt of the grease outlet to allow the grease to come out. Supply grease slowly, using a manual pump. (once per two seconds) Whenever possible, avoid using an air pump, which is powered by the factory air supply. If the use of an air pump is unavoidable, supply grease with the pump at a pressure lower than or equal to the gun tip pressure (see Table 2.2 ( a)). Use grease only of the specified type. Grease of a type other than that specified may damage the reducer or lead to other problems. After greasing, release the remaining pressure from the grease bath using the procedure given in Subsection 2.2.1, and then close the grease outlet. To prevent an accident such as a fall or fire, remove all the excess grease from the floor and robot.
Procedure for r eleasing remaining p ressur e from the grease bath (J1 to J3-axis)
After applying grease, operate the robot more than 10 minutes as instructed below with one of the taper plugs and hexagon bolts of the grease inlet and outlet which is in high position uncapped to release the remaining pressure within the grease bath. Attach a recovery bag below the grease inlet and outlet to prevent output grease from splattering. Operating axis Grease replacement part
J1-axis reducer
J2-axis reducer
J3-axis reducer
J1-axis
J2-axis
J3-axis
Axis angle of 60 or more OVR 100 Arbitrary
J4-axis
J5-axis
J6-axis
Arbitrary Axis angle of 60 or more OVR 100
Arbitrary
Arbitrary Axis angle of 60 or more OVR 100
Arbitrary
If the above operation cannot be performed due to the environment of the robot, prolong the operating time so that an equivalent operation can be performed. (When the maximum allowable axis angle is 30 degrees, perform the twice operation for 20 minutes or more.) When you supply grease or oil to multiple axes, you can run the multiple axes at the same time. After completion of the operation, attach the taper plug and seal bolts to the grease inlets and outlets. When reusing the seal bolts, be sure to seal them with seal tape. After replacing grease, the internal pressure of the grease bath may rise if the robot is operated again under frequent inversion movement or a high temperature environment. In these cases, you can return to normal internal pressure by releasing the grease outlet just after robot operation. (When opening grease outlet, be sure that grease or oil is not spattered.) - 13 -
2. PERIODIC MAINTENANCE
2.3
B-83755EN/01
GREASE SUPPLYING PROCEDURE FOR J4 TO J 6-AXIS REDUCER (4 YEARS (15360 HOURS) PERIODICAL CHECK)
Supply the grease of the J4/J5/J6-axis reducers every four years or 15360 hours by using the following procedures. For the grease name and quantity, see the Table 2.3 (a). Table 2.3 (a) Grease for 4-year (15360 hours) peri odic al greasing Greasing poi nts
Greasing amount
J4-axis reducer J5-axis reducer
2.7g(3ml) 2.7g(3ml)
J6-axis reducer
2.7g(3ml)
Specified grease Harmonic grease 4BNo.2 Spec: A98L-0040-0230
For grease replacement, use the arbitrary postures.
-
CAUTION The following maintenance kits are prepared for the greasing. Greasing kit: A05B-1226-K031 (This a set of greasing syringe and grease in tube. (80g)) Grease in tube: A05B-1139-K022 (grease in tube. (80g))
CAUTION Failure to follow proper lubrication procedures may cause a sudden increase of the grease bath internal pressure and damage to the seal. This could lead to grease leakage and abnormal operation. When greasing, observe the following cautions. 1 Use specified grease. Use of non-approved grease may damage the reducer or lead to other problems. Do no use Harmonic grease SK-3 2 To prevent an accident such as a fall or fire, remove all the excess grease from the floor and robot. 3 When you use the grease greasing kit, massage the grease tube by hand to soften the grease before you fill a necessary amount in the injection syringe. Please install the nozzle in the point of the injection syringe. Remove the nozzle and replace the cap when you are finished using the injection syringe.
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2. PERIODIC MAINTENANCE
B-83755EN/01
1
2 3
4
Turn off controller power. Remove the hexagon bolts of the grease inlet. Supply a regulated amount of grease by using the injection syringe. Please note that grease might come out immediately after the grease has been supplied, or during the greasing. Even in this case, please do not supply grease beyond the regulated amount specified. Replace the hexagon bolts with new ones. When reusing the hexagon bolt, be sure to seal it with seal tape. J6-axis reducer grease inlet J6軸減速機給脂口 Hexagon bolt M5 x 10 六角ボルト M5X10 J5-axis reducer grease inlet J5軸減速機給脂口 Hexagon bolt M5M5X10 x 10 六角ボルト
J4-axis reducer grease inlet J4軸減速機給脂口 Hexagon六角ボルト bolt M8 x 10 M8X10
Fig. 2.3 Greasing poi nt o f J4/J5/J6-axis reducers Table 2.3 (b) Spec. of t he Hexagon bolt s Parts name Hexagon bolt Hexagon bolt
Specificati on
(M5 x 10) (M8 x 10)
A97L-0318-0410#051010S A97L-0318-0410#081010S
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3. TROUBLESHOOTING
3
B-83755EN/01
TROUBLESHOOTING
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems may become further complicated, if they are not corrected properly. Therefore, you must keep an accurate record of problems and take proper corrective actions.
3.1
TROUBLESHOOTING
Table 3.1 shows the major troubleshooting items that may occur in the mechanical unit and their probable causes. If you cannot pinpoint a failure cause or which measures to take, contact your local FANUC representative. Table 3.1 Troubleshooting Symptom Vibration Noise
Descripti on -
-
-
-
-
-
-
The J1 base lifts off the floor plate as the robot operates. There is a gap between the J1 base and floor plate. A J1 base retaining bolt is loose.
The rack or floor plate vibrates during operation of the robot.
Vibration becomes more serious when the robot adopts a specific posture. If the operating speed of the robot is reduced, vibration stops. Vibration is most noticeable when the robot is accelerating. Vibration occurs when two or more axes operate at the same time.
Cause [J1 base fastening] It is likely that the robot J1 base is not securely fastened to the floor plate. Probable causes are a loose bolt, an insufficient degree of surface flatness, or foreign material caught between the J1 base and floor plate. If the robot is not securely fastened to the floor plate, the J1 base lifts the floor plate as the robot operates, allowing the base and floor plates to strike each other, which, in turn, leads to vibration. [Rack or floor] It is likely that the rack or floor is not rigid enough. If they are not rigid enough, counterforce deforms the rack or floor, and responsible for the vibration.
Measure -
-
-
-
-
[Overload] It is likely that the load on the robot is greater than the maximum rating. It is likely that the robot control program is too demanding for the robot hardware. It is likely that the ACCELERATION value is excessive.
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If a bolt is loose, apply LOCTITE and tighten it to the appropriate torque. Adjust the floor plate surface flatness to within the specified tolerance. If there is any foreign material between the J1 base and floor plate, remove it.
Reinforce the rack or floor to make it more rigid. If reinforcing the rack or floor is impossible, modify the robot control program; doing so might reduce the vibration. Check the maximum load that the robot can handle once more. If the robot is found to be overloaded, reduce the load, or modify the robot control program. Vibration in a specific portion can be reduced by modifying the robot control program while slowing the robot and reducing its acceleration (to minimize the influence on the entire cycle
3. TROUBLESHOOTING
B-83755EN/01
Symptom
Descripti on
Cause
Measure time).
Vibration Noise (Continued)
-
-
Vibration or noise was first noticed after the robot collided with an object or the robot was overloaded for a long period. The grease of the vibrating or noise occurring axis has not been replaced for a long period.
-
There is some relationship between the vibration of the robot and the operation of a machine near the robot.
-
There is an abnormal noise after replacing grease. There is an abnormal noise after a long time. There is an abnormal noise during operation at low speed.
-
[Broken gear, bearing, or reducer] It is likely that the collision or overload applied an excessive force to the drive mechanism, thus damaging the gear tooth surface or rolling surface of a bearing, or reducer. Prolonged overloaded use may cause fretting fatigue on gear tooth surface or rolling surface of bearing and reducer. It is likely that foreign material caught in a gear, bearing, or inside the reducer has caused damage on the gear tooth surface or rolling surface of the bearing, or reducer. It is likely that foreign material caught in a gear, bearing, or within a reducer causes vibration. It is likely that, because the grease has not been changed for a long period, fretting occurred on the gear tooth surface or rolling surface of a bearing, or reducer due to metal fatigue by neglect greasing. Above causes will generate cyclical vibration and noise. [Noise from a nearby machine] If the robot is not grounded properly, electrical noise is induced on the grounding wire, preventing commands from being transferred accurately, thus leading to vibration. If the robot is grounded at an unsuitable point, its grounding potential becomes unstable, and noise is likely to be induced on the grounding line, thus leading to vibration. There may be an abnormal noise when using other than the specified grease. Even for the specified grease, there may be an abnormal noise during operation at low speed immediately after replacement or after a long time.
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-
-
-
-
Operate each axis individually to judge which axis has been vibrating. Remove the motor, and replace the gear, the bearing, and the reducer. For the specification of parts and the procedure of replacement, contact your local FANUC representative. Using the robot within its maximum rating prevents problems with the drive mechanism. Specific type and period of grease change will prevent troubles.
-
Connect the grounding wire firmly to ensure a reliable ground potential and prevent extraneous electrical noise.
-
Use the specified grease. When there is an abnormal noise even for specified grease, operate for one or two days on an experiment. Generally, an abnormal noise will disappear.
-
3. TROUBLESHOOTING Symptom Vibration Noise (Continued)
B-83755EN/01
Descripti on -
The cause of problem cannot be identified from examination of the floor, rack, or mechanical unit.
Cause [Controller, cable, and motor] If a failure occurs in a controller circuit, preventing control commands from being supplied to the motor normally, or preventing motor information from being sent to the controller normally, vibration might occur. Pulsecoder defect may be the cause of the vibration as the motor cannot propagate the accurate position to the controller. If the motor becomes defective, vibration might occur because the motor cannot deliver its rated performance. If a power line in a movable cable of the mechanical unit has an intermittent break, vibration might occur because the motor cannot accurately respond to commands. If a Pulsecoder wire in a movable part of the mechanical unit has an intermittent break, vibration might occur because commands cannot be sent to the motor accurately. If a robot connection cable has an intermittent break, vibration might occur. If the power supply cable is about to be snapped, vibration might occur. If the power source voltage drops below the rating, vibration might occur. It may vibrate when the invalid robot control parameter was set.
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-
-
-
-
-
-
Measure Refer to the Controller Maintenance Manual for troubleshooting related to the controller and amplifier. Also, replace the motor of the axis that is vibrating, and check whether vibration still occurs. To replace the motor, Contact your local FANUC representative. If vibration occurs only when the robot assumes a specific posture, it is likely that a mechanical unit is broken. Check whether the cable jacket of the robot connection cable is damaged. If so, replace the connection cable, and check whether vibration still occurs. Check whether the power cable jacket is damaged. If so, replace the power cable, and check whether vibration still occurs. Check that the robot is supplied with the rated voltage. Check that the robot control parameter is set to a valid value. If it is set to an invalid value, correct them. Contact your local FANUC representative for further information if necessary.
3. TROUBLESHOOTING
B-83755EN/01
Symptom Rattling
Descripti on -
-
-
Cause
While the robot is not supplied with power, pushing it by hand wobbles part of the mechanical unit. There is a gap on the mounting face of the mechanical unit.
[Mechanical unit mounting bolt] It is likely that overloading or a collision has loosened a mounting bolt in the robot mechanical unit.
-
Backlash is larger than the permissive value stated in the maintenance manual. (See Section 3.2.)
[Increase of backlash] It is likely that excessive force applied to the drive mechanism, due to a collision or overloading, has broken a gear or the inside of the reducer, resulting in an increase in the amount of backlash. Increasing the backlash resulting from the overloaded prolonged use wear the Gear and the Reducer. It is likely that prolonged use without changing the grease has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash.
-
-
-
-
-
-
-
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Measure Check the following retaining bolts tightness for each axis. If any of these bolts is loose, apply LOCTITE and bolt down with appropriate torque. - Motor retaining bolt - Reducer retaining bolt - Reducer shaft retaining bolt - Base retaining bolt - Arm retaining bolt - Casing retaining bolt - End effector retaining bolt Operate each axis at an individually to judge which axis has been vibrating. Remove the motor, and check whether any of its gears are broken. If any gear is broken, replace it. Check whether any other gear of the drive mechanism is damage. If there is no damage gear, replace the reducer. If the reducer is broken, or if a gear tooth is missing, replace the relevant component. Also, remove all the grease from the gearbox and wash the inside of the gearbox. After replacing the gear or reducer, add an appropriate amount of grease. Using the robot within its maximum rating prevents problems with the drive mechanism. Regularly changing the grease with a specified type can help prevent problems.
3. TROUBLESHOOTING Symptom Motor overheating
B-83755EN/01
Descripti on -
-
The motor overheated due to a rise in temperature in the installation area. After changing the Robot control program or the load, the motor overheat.
Cause [Ambient temperature] It is likely that the motor overheated when the ambient temperature rose, and could not release heat. [Operating condition] It is likely that the overcurrent is above the specified permissive average current.
Measure -
-
-
-
-
After a robot control parameter (load setting etc.) was changed, the motor overheated.
-
Symptom other than stated above
[Parameter] If data input for a workpiece is invalid, the robot cannot be accelerated or decelerated normally, so the average current increases, leading to overheat. [Mechanical unit problems] It is likely that problems occurred in the mechanical unit drive mechanism, thus placing an excessive load on the motor. [Motor problems] It is likely that a failure of the motor brake resulted in the motor running with the brake applied, thus placing an excessive load on the motor. It is likely that a failure of the motor prevented it from delivering its rated performance, thus causing an excessive current to flow through the motor.
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-
-
-
-
Reducing the ambient temperature is the most effective means of preventing overheat. If there is a source of heat near, it is advisable to install shielding to protect the motor from heat radiation. Relaxing the robot control program and load condition is effective to reduce the average current. Thus, prevent overheat. The teach pendant can monitor the average current. Check the average current when the robot control program launched. As for load setting, Input an appropriate parameter referring to Section 4.3 of the operator’s manual (B-83754EN). Repair the mechanical unit while referring to the above descriptions of vibration, noise, and rattling. Check that, when the servo system is energized, the brake is released. If the brake remains applied to the motor all the time, replace the motor. If the average current falls after the motor is replaced, it indicates that the first motor was faulty.
3. TROUBLESHOOTING
B-83755EN/01
Symptom Grease leakage
Descripti on -
Grease leaks from the mechanical unit.
Cause
Measure
[Poor sealing] Probable causes are a crack in the casting, a damaged O-ring, a damaged oil seal, or a loose seal bolt. The casting may crack with excessive force caused in a collision. An O-ring can be damaged if it is trapped or cut during disassembling or re-assembling. An oil seal may be damaged if dust scratches the lip. A loose hexagon bolt may allow grease to leak along the threads.
-
-
Dropping axis
-
An axis falls because the brake went out. An axis falls in standstill.
[Brake drive relay and motor] It is likely that brake drive relays are stuck to each other and keep the brake current flowing, thus preventing the brake from operating when the motor is reenergized. It is likely that the brake shoe has worn out or the brake main body is damaged, preventing the brake from operating efficiently. It is likely that oil or grease soaked through the motor, causing the brake to slip.
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If a crack develops in the casting, sealant can be used as a quick-fix to prevent further grease or oil leakage. However, the component should be replaced as soon as possible, because the crack might enlarge. O-rings are used in the locations listed below. - Motor coupling section - Reducer (case and shaft) coupling section - Wrist coupling section - J3 arm coupling section - Inside the wrist Oil seals are used in the locations stated below. - Inside the reducer - Inside the wrist Hexagon bolts are used in the locations stated below. - Grease drain outlet - For cover attachment Check whether the brake drive relays stuck each other or not. If they are found to be stuck, replace the relay. Replace the motor confirmed following symptoms. - Brake shoe is worn out - Brake main body is damaged - Oil soaked through the motor
3. TROUBLESHOOTING Symptom Displace ment
B-83755EN/01
Descripti on -
-
The robot moves to a point other than the taught position. The repeatability is not within the tolerance.
Cause [Mechanical unit problems] If the repeatability is unstable, probable causes are a failure in the drive mechanism or a loose bolt, and so on. If the repeatability is stable, it is likely that collision by an excessive load caused slip on the mounting face of each axis arm, and reducer. It is likely that the Pulsecoder is abnormal.
Measure -
-
-
-
-
BZAL alarm occurred
-
Displacement occurs only in a specific peripheral equipment.
Displacement occurred after a parameter was changed.
BZAL is displayed on the teach pendant screen
[Peripheral equipment displacement] It is likely that an external force was applied to the peripheral equipment, thus shifting its position relative to the robot. [Parameter] It is likely that the mastering data was rewritten in such a way that the robot origin was shifted.
-
-
-
-
It is likely that the voltage of the memory backup battery is low. It is likely that the Pulsecoder cable is defected.
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-
-
If the repeatability is unstable, repair the mechanical unit by referring to the above descriptions of vibration, noise, and rattling. If the repeatability is stable, correct the taught program. Variation will not occur unless another collision occurs. If the Pulsecoder is abnormal, replace the motor. Correct the setting of the peripheral equipment position. Correct the taught program. Re-enter the previous mastering data, which is known to be correct. If correct mastering data is unavailable, perform mastering again. Replace the battery. Replace the cable.
3. TROUBLESHOOTING
B-83755EN/01
3.2
BACKLASH MEASUREMENT
Measurement method 1 2 3
Maintain the robot in a specified posture. (See Table 3.2 (a).) Apply positive and negative loads to each axis as shown in Fig. 3.2 (a). Remove the loads and measure the displacement.
Measure backlash by applying positive and negative loads to each axis three times. Average the values measured in the last two measurements for each axis, and use the averages as a measured backlash for the respective axes.
Stop position 0 +10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis)
First step (Do not measure)
-10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis) +10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis) -10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis) 0kg
0kg
L1
Second step (B2 =L 1+ L2)
+10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis)
L2
0kg
-10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis)
L3
Third step (B3=L3+ L4)
0kg L4
Fig. 3.2 (a) Backlash measurement metho d
Backlash B is calculated using the following expression: B=
B2 + B3 2
Table 3.2 (a) Backlash measurement po stur e and positi on Measurement J1-axis axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
Measurement position
J1-axis
Arbitrary
80°
0°
0°
0°
±90°
J2-axis
Arbitrary
0°
82°
0°
0°
0°
J3-axis
Arbitrary
45°
-90°
-90°
90°
-90°
Rotation center of J5-axis
J4-axis
Arbitrary
45°
-90°
-90°
90°
-90°
100mm from rotation center of J4-axis
J5-axis
Arbitrary
0°
0°
90°
-90°
0°
180mm from rotation center of J5-axis
J6-axis
Arbitrary
0°
0°
0°
-90°
±90°
100mm from rotation center of J6-axis
Rotation center of J5-axis Rotation center of J3-axis of J2 arm
Table 3.2 (b) Backlash allo wance J1-axis J2-axis J3-axis Angle conversion (arc-min) Displacement conversion (mm) Distance between the rotation center and dial indicator (mm)
J4-axis
J5-axis
J6-axis
1.59 0.96
1.63 0.43
1.42 0.36
2.42 0.18
1.62 0.12
3.07 0.12
2081
905
865
250
250
134
NOTE When measuring backlash under circumstances where the distance between the rotation center and the dial gauge is different from those in the above table, make angle and displacement conversions according to the table. - 23 -
3. TROUBLESHOOTING
B-83755EN/01
2081 Loading position 負荷をかける位置
150
測定位置 position Measurement
J1 J1 J2 J2 J3 J3 J4 J4 J5 J5 J6
Arbitrary 任意 80º 80° 0º 0° 0º 0° 0º 0° ±90º
J6 ±90°
Fig. 3.2 (b) Backlash measured post ure for J1-axis
Measurement
測定位置 position
Loading position 負荷をかける位置
5 0 9
J1 Arbitrary J1 任意 J2 0º J2 0° J3 82º J3 82° J4 0º J4 0° J5 0º J5 0° J6 0º
J6
0°
Fig. 3.2 (c) Backlash measured post ure for J2-axis
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3. TROUBLESHOOTING
B-83755EN/01
J1
5 6 8
J1 J2 J2 J3 J3 J4 J4 J5 J5 J6 J6
Arbitrary
任意45 45° -90 -90° -90 -90° 90 90° -90 -90°
º º º º º
Loading position 負荷をかける位置
測定位置(J5回転中心) Measurement position (Rotation center of J5-axis)
Fig. 3.2 (d) Backlash measured post ure for J3-axis
J1 J1 Arbitrary 任意 J2 45º J2 45° J3 -90 º J3 -90° J4 -90º J4 -90° J5 90º J5 90° J6 -90º J6 -90°
Measurement position
測定位置
Loading position 負荷をかける位置
250
Fig. 3.2 (e) Backlash measured po stur e for J4-axis
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3. TROUBLESHOOTING
B-83755EN/01
Measurement position 測定位置
0 5 2
Loading position 負荷をかける位置
J1 J1 J2 J2 J3 J3 J4 J4 J5 J5 J6 J6
Arbitrary 任意 0º 0° 0º 0° 90º 90° -90º -90° 0º 0°
Fig. 3.2 (f) Backlash measured post ure for J5-axis
Loading position 負荷をかける位置
Measurement 測定位置 position
4 3 1
J1 J1 J2 J2 J3 J3 J4 J4 J5 J5 J6
Arbitrary 任意 0º 0° 0º 0° 0º 0° º -90 -90° ±90º
J6 ±90°
Fig. 3.2 (g) Backlash measured post ure for J6-axis
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4. REPLACING PARTS
B-83755EN/01
4 • •
•
•
REPLACING PARTS When replacing a part, adjustment is required. When removing or mounting a motor, apply force only in the shaft direction. If excessive force is applied in any other direction, the motor and/or reducer may be damaged. If a motor and associated parts to be assembled incur a phase mismatch, assembly might prove impossible. Carefully check the state of the parts before removing them. Assemble a new O ring and a gasket for securing the performance of seal after removing the parts.
NOTE Some gasket must not be reused. To maintain dust and drip preventive effects, replace those old gasket with new ones, and then assemble them. •
To secure the performance of the seal, replace seal bolts by new ones after replacing parts as much as possible. If it’s impossible, reuse them with applying LOCTITE 243 after peeling off the sealant.
NOTE When applying LOCTITE to a part, spread the LOCTITE on the entire length of the engaging part of the female thread. If applied to the male threads, poor adhesion can occur potentially loosening the bolt. Clean the bolts and the threaded holes and wipe off the oil on the engaging section. Make sure that there is no solvent left in the threaded holes. In this case, remove all the excess LOCTITE when you are finished screwing the bolts into the threaded holes. •
• • •
•
Observe the specified tightening torque strictly if it’s specified. If not specified, refer to the tightening torque specified in APPENDIX. Assemble the reducer to the vertical direction as much as possible when you assemble it. Tighten bolts in diagonally order uniformly in installing bolts to the reducer. When applying LOCTITE 518 to the reducer, be careful that the LOCTITE not to penetrate into the reducer. Stir and soften the grease well, and spread to the reducer.
NOTE Description of [LT243] means LOCTITE 243. Description of [LT518] means LOCTITE 518. Description of [LT641] means LOCTITE 641.
- 27 -
4. REPLACING PARTS
4.1
B-83755EN/01
FIGURE OF DRIVE MECHANISM
The drive mechanisms of each axis are shown in the Fig. 4.1 (a) to (e). J1-axis reducer J1軸減速機 (Hollow shaft) (中空シャフト)
Pipe パイプ
Input gear インプットギヤ
Center gear センタギヤ
J1-axis motor J1軸モータ J1 base J1ベース
Fig. 4.1 (a) Drive mechanism o f J1-axis J2-axis J2軸モータ motor
J2ベース J2 base
Input gear インプットギヤ J2-axis reducer J2軸減速機
Fig. 4.1 (b) Drive mechanism o f J2-axis
J3-axis motor J3軸モータ J3-axis reducer J3軸減速機
Input gear インプットギヤ Fig. 4.1 (c) Drive mechanism of J3-axis
- 28 -
4. REPLACING PARTS
B-83755EN/01
J4-axis motor J4軸モータ
Input gear インプットギヤ
Center gear センタギヤ J4-axis reducer J4軸減速機
Fig. 4.1 (d) Drive mechanism o f J4-axis Belt ベルト
J5軸モータ J5-axis motor
Pulley プーリ Bevel gear ベベルギヤ
J6軸減速機 J6-axis reducer
J5軸減速機 J5-axis reducer ベルト Belt J6軸モータ J6-axis motor
Pulley プーリ
Fig. 4.1 (e) Drive mechani sm o f J5/J6-axis
- 29 -
4. REPLACING PARTS
4.2
B-83755EN/01
REPLACING J1-AXIS MOTOR
Replacing p rocedure 1 2 3 4 5
Set dial gauges at the J1-axis, and prepare for single axis mastering after replacement. Turn off controller power. Remove washer bolts (1), then remove the plate (2) and the gasket (3). Remove cable K123 from the motor ass’y (5). Remove bolts (4) and motor assy (5). At this time, note that grease may go out.
3 5
2 1
4
Fig. 4.2 (a) Replacing J1-axis moto r (1/2) Parts name 1
WASHER BOLT
2
PLATE
3 4 5
GASKET BOLT MOTOR ASS’Y
Specifications
Q’ty
A97L-0318-0450#051410S It differs depending on the mechanical unit cables. A290-7226-X209 A6-BA-8X35 A290-7226-V201
10
- 30 -
1 1 3 1
Locking
Torque N-m (kgf-cm) 3.2Nm (33kgfcm)
4. REPLACING PARTS
B-83755EN/01
6 7 8 9
Wipe the grease of the gear (4) off. At this time, pay attention not to damage the tooth side. Remove the nut (6) and the plate (2), then remove the gear (4) from the motor (1). Attach new sheet (7) on new motor (1). Assemble it applying the procedure in the reversed sequence. At this time, pay attention to the following. Apply grease on surroundings about the gear. Confirm that the gasket (3) in Fig .4.2 (a) mounted firmly. Apply LOCTITE 518 on both sides of the washer (5). Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual. • • •
10
6 5 4 3 2
1
Fig. 4.2 (b) Replacing J1-axis moto r (2/2) Parts name 1 2 3 4 5 6 7
MOTOR PLATE O-RING GEAR BEARING WASHER NUT SHEET
Specifications
Q’ty
A06B-2232-B605 A290-7226-X202 JB-OR1A-G80 A290-7226-X204 A97L-0001-0195#0700000 A290-7226-X208 A6-N1-10S A290-7226-X227
1 1 1 1 1 1 1 1
Locking
LT518 LT243
Torque N-m (kgf-cm)
20Nm (196kgfcm)
7
A
A
A
Section A-A 断面 A-A
A
Fig. 4.2 (c) Attachment o f the sheet on th e J1-axis moto r
- 31 -
4. REPLACING PARTS
4.3 1 2
B-83755EN/01
REPLACING J1-AXIS REDUCER Set dial gauges at the J1-axis, and prepare for single axis mastering after replacement. Set the Quick Master Reference Reference Position. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual. Move the robot robot to the posture posture as shown in Fig. 4.3 (c), then support support it with a crane. Turn off controller power. Remove the cable K123 and the air tubes, then pull out out them from J1 pipe pipe to lower side. Remove washer bolts (4) and washer (5). Rig the J2 base and the upper side as shown in Fig. 4.3 (c).
3 4 5 6 7
1 2 3
4 5
Fig. 4.3 (a) Replacing J1-axis reducer (1/2) Parts name name 1 2 3 4
WASHER BOLT PLATE GASKET BOLT
5
WASHER
Specif pecifica icatio tions ns A97L-0318-0450#051410S A290-7226-X319 A290-7226-X313 A6-BA-12X40
Q’ty 6 1 1 16
A290-7226-X338
1
A290-7226-X339
2
- 32 -
Lockin Locking g
Torque orque N-m (kgfkgf-cm cm)) 3.2Nm (33kgfcm)
129Nm (1316kgfcm)
4. REPLACING PARTS
B-83755EN/01
8
Remove bolts (11), then remove remove the half union (13), the pin (14), the O-ring (12), the reducer (10), (10), the O-ring (9) and the gear (8) (with bearing) from the J1 base (7). Remove bolts (17), then remove the pipe (16) and the O-ring (15). Replace new reducer, and assemble it in the reversed sequence. . However, attach the pipe (16) and the O-ring (15) after mounting the reducer (10). Attach the cable K123 and air tubes referring to Section 5.3. At this time, pull out the cable after it pushes into the pipe on the tip ti p of the part of the relayed connector and it pass es it. Do not pull it out forcibly with the relayed connector caught. Attach the plate (2), the gasket (3) with bolts (1) on the J2 base. Apply grease to the J1-axis reducer. Refer to Section 2.2. Perform quick mastering and perform single axis mastering of J1-axis. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS and SINGLE AXIS MASTERING of the robot-specific Operator’s Manual.
9 10 11
12 13 14
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J1-axis motor shaft.
7 11
10
9
8
13 17
16
15 14
6
12
Fig. 4.3 (b) Replacing J1-axis J1-axis reducer (2/2) (2/2) Parts name name 6 7 8 9 10 11 12 13 14 15 16 17
OIL SEAL J1 BASE GEAR BEARING O-RING REDUCER BOLT O-RING HALF UNION PIN O-RING PIPE BOLT
Specif pecifica icatio tions ns A98L-0040-0274#07008507 A290-7226-X201 A290-7226-X205 A97L-0001-0192#1600000 A98L-0040-0041#268 A97L-0318-0223#120C-37 A97L-0318-0223#120C -37 A6-BA-12X95 JB-OR1A-G180 A97L-0142-0214#2H06-01S A97L-0142-0214#2H0 6-01S A290-7226-X340 JB-OR1A-G67 A290-7226-X203 A6-BA-5X14
- 33 -
Q’ty 1 1 1 1 1 1 20 1 1 1 1 1 4
Lockin Locking g
Torque orque N-m (kgfkgf-cm cm))
129Nm (1316kgfcm)
4. REPLACING PARTS
B-83755EN/01 Make sling go truough the stopper inside. スリングはストッパの内側を通るようにすること。 If内側が通せなければ、ストッパを外すこと。 it is impossible, remove the stopper. Stopper ストッパAA A290-7226-X423 ((1) 1) A290-7226-X423(1) Stopper ストッパBB A290-7226-X431(1) A290-7226-X431( A290-7226-X4311) (1)
ボルト Bolt A97L-0218-0494#M10X45BC A97L-0218-0494#M1 0X45BC(2) (2) A97L-0218-0494#M10X45BC A97L-0218-0494 #M10X45BC 締付けトルク 66Nm (670kgfcm) Tightening torque 66Nm (670kgfcm) Pinピン JB-PH-H7A-12X30S45C (2) JB-PH-H7A-12X30S45C JB-PH-H7A-12X30S45C (2)
Detail 詳細 AA
Adjust the sling length チェーンブロックを使用して スリングの長さを調整すること using a chain block.
A
J2=-20° J3=-30°
スリングがサイレンサー Remove the silencer ifにかかる場合は、 it contact slings. サイレンサーを外すこと。 Silencer サイレンサ A97L-0218-0036#10-01 A97L-0218-003 6#10-01 A97L-0218-0036#10-01
Detail B
詳細 B C B
Detail 詳細 CC Fig. 4.3 (c) Rigg Rigg ing method o f J1/J2-axis J1/J2-axis r educers
- 34 -
4. REPLACING PARTS
B-83755EN/01
4.4 1 2
REPLACING J2-AXIS MOTOR Set dial gauges at the J2-axis, and prepare for single axis mastering after replacement. Set the Quick Master Reference Position. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual. Turn off controller power. Support the J3 arm with a crane. Remove washer bolts (1), then remove the J2 arm cover L (2) and the gasket (3). Remove washer bolts (4), then remove the J2 base cover L (5) and the gasket (6). Remove washer bolts (7), then remove the cover B (8) and the gasket (9). Remove all relay connectors of J2 arm side.
3 4 5 6 7 8
2 1
3
7
8
9
6
5
4
Fig. 4.4 (a) Replacing J2-axis moto r (1/4) Parts name
Specifications
Q’ty
1
WASHER BOLT
A97L-0318-0450#051410S
7
2 3 4 5 6 7 8 9
J2 ARM COVER L GASKET WASHER BOLT J2 BASE COVER L GASKET WASHER BOLT COVER B GASKET
A290-7226-X306 A290-7226-X316 A97L-0318-0450#051410S A290-7226-X304 A290-7226-X314 A97L-0318-0450#051410S A290-7226-X347 A290-7226-X318
1 1 8 1 1 6 1 1
- 35 -
Locking
Torque N-m (kgf-cm) 3.2Nm (33kgfcm)
3.2Nm (33kgfcm)
3.2Nm (33kgfcm)
4. REPLACING PARTS 9 10 11 12 13 14
B-83755EN/01
Loosen 2 screws, remove the battery box (14) cover, then remove screws (19), then remove the battery box (14) and the battery line. Remove bolts (15), then remove the BB plate (17). Pull out the J2 arm side connectors, then remove all connections and the air tube relays. Remove bolts (10), the clamp plate (11), bolts (16), the clamp J2-2 (18), bolts (12) and the clamp J2-1 (13). Remove the J2-axis motor connector. Pull out cables from the J2 base side.
10
11
17 14 19
15
16
18
13 12
Fig. 4.4 (b) Replacing J2-axis moto r (2/4) Parts name
Specifications
Q’ty
10 11
BOLT CLAMP PLATE
A6-BA-5X10 A290-7226-X325
2 1
12 13 14 15 16 17 18 19
BOLT CLAMP J2-1 BATTERY BOX BOLT BOLT BB PLATE CLAMP J2-2 SCREW
A6-BA-5X10 A290-7226-X323 A98L-0004-0149 A6-BA-5X10 A6-BA-5X10 A290-7226-X327 A290-7226-X324 A6-SSA-4X10S
2 1 1 3 3 1 1 2
- 36 -
Locking
Torque N-m (kgf-cm)
4. REPLACING PARTS
B-83755EN/01
15 16
Remove bolts (20), then remove the shaft ass’y (21) and the gasket (22). Remove bolts (23), then dismount the motor ass’y (24).
CAUTION The J2 arm will move downward if removing the J2-axis motor ass’y. Fix the J2 arm by rigging it with a crane and slings to prevent collision to the surroundings.
24 22 21
23
20
Fig. 4.4 (c) Replacin g J 2-axis moto r (3/4) Parts name
Specificati ons
Q’ty
20
BOLT
A97L-0218-0423#051616
8
21
SHAFT ASS’Y
A290-7226-V303
1
22
GASKET
A290-7226-X317
1
23
SEAL BOLT
A97L-0218-0423#082216
4
24
MOTOR ASS’Y
A290-7226-V301
1
17 18 19
Locki ng
Torque N-m (kgf-cm) 7.9Nm (81kgfcm)
Remove the bolt (6), the washer (5), the gear (4) and the draw nut (3) from the motor (2) in Fig. 4.4 (d). Remove the bolt (1), the motor adapter (7) and the O-ring (8) from the motor (2) in Fig 4.4 (d). Assemble the motor in reverse procedure after replacing the motor (2). At this time, pay attention to the following. Confirm that the gasket (3), (6), (9), (22) in Fig. 4.4 (a), (b), (c) mounted firmly. Apply LOCTITE 518 on the both side of the washer (5). Apply grease to the J2-axis reducer. Refer to Section 2.2. Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual.
20 21
8 7
6
5
4
2
3
1
Fig. 4.4 (d) Replacing J2-axis moto r (4/4) Parts name
Specificati ons
Q’ty
Locki ng
1
SEAL BOLT
A97L-0218-0423#082216
3
2
MOTOR
A06B-2238-B605
1
3
DRAW UNT
A290-7221-X321
1
4
GEAR
A290-7226-X310
1
5
WASHER
A6-WM-5S
1
LT518
6
BOLT
A6-BA-5X75
1
LT243
7
MOTOR ADAPTER
A290-7226-X308
1
8
O-RING
A98L-0040-0041#259
1
- 37 -
LT243
Torque N-m (kgf-cm)
20Nm (204kgfcm)
7.9Nm (81kgfcm)
4. REPLACING PARTS
4.5 1 2
B-83755EN/01
REPLACING J2-AXIS REDUCER Set dial gauges at the J2-axis, and prepare for single axis mastering after replacement. Set the Quick Master Reference Position. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual. Move the robot to the posture as shown in Fig. 4.3 (c), then support it with a crane. Turn off controller power. Remove covers and the motor ass’y referring to Section 4.4. Disassembling the motor ass’y is not necessary. Remove bolts (1), washer (2), (3).
3 4 5 6
3
1
2
Fig. 4.5 (a) Replacing J2-axis reducer (1/2) Parts name 1 2 3
BOLT WASHER WASHER
Specifications A6-BA-12X30 A290-7226-X328 A290-7226-X329
Q’ty 16 2 1
- 38 -
Locking
Torque N-m (kgf-cm) 129Nm (1316kgfcm)
4. REPLACING PARTS
B-83755EN/01
7 8 9 10 11 12
Remove bolts (4), (5), then remove the J2 arm cover R (6). In this case, the grease may overflow. Remove bolts (7), then dismount the reducer (9). Replace the reducer (9) with a new one. Then assemble it in the reversed sequence. Attach other parts in the reversed sequence. Apply grease to the J2-axis reducer. Refer to Section 2.2. Perform quick mastering and perform single axis mastering of J1-axis. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS and SINGLE AXIS MASTERING of the robot-specific Operator’s Manual.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J2-axis motor shaft.
10
9 6
8
12
7
4 11 5
Fig. 4.5 (b) Replacing J2-axis reducer (2/2) Parts name
Specifications
Q’ty
Locking
Torque N-m (kgf-cm)
4
WASHER BOLT
A97L-0318-0450#052510S
3
3.2Nm (33Kgfcm)
5 6 7 8 9 10 11 12
WASHER BOLT J2 BASE COVER R BOLT O-RING REDUCER PIN O-RING PIN
A97L-0318-0450#055010S A290-7226-X303 A6-BA-10X35 JB-OR1A-G200 A97L-0318-0224#125N-146 A290-7226-X342 JB-OR1A-G145 A290-7226-X341
1 1 15 1 1 1 1 1
3.2Nm (33Kgfcm)
- 39 -
73.5Nm (750kgfcm)
4. REPLACING PARTS
4.6 1 2 3 4 5 6 7 8 9
B-83755EN/01
REPLACING J3-AXIS MOTOR Set dial gauges at the J3-axis, and prepare for single axis mastering after replacement. Turn off controller power. Support the J3 arm with a crane. Remove washer bolts (1), then remove the J2 arm cover L (2) and the gasket (3). Remove washer bolts (4), then remove the J3 cover H (5) and the gasket (6). Remove bolts (7), then remove the clamp J3-1 (8). Cut the cable ties which fix cables. Remove bolts (9), then remove the clamp J3-2 (10). Remove bolts (11), then remove the clamp J3-3 (12). (These are not attached depending on the specified option.) 4 5
9 6
10
3
2 1
11
12
8
7
Fig. 4.6 (a) Replacing J3-axis moto r (1/3) Parts name
Specifications
Q’ty
1
WASHER BOLT
A97L-0318-0450#051410S
7
2 3 4 5 6 7 8 9 10 11 12
J2 ARM COVER L GASKET WASHER BOLT J3 COVER H GASKET BOLT CLAMP J3-1 BOLT CLAMP J3-2 BOLT CLAMP J3-3
A290-7226-X306 A290-7226-X316 A97L-0318-0450#051410S A290-7226-X404 A290-7226-X424 A6-BA-5X10 A290-7226-X326 A6-BA-5X10 A290-7226-X416 A6-BA-5X10 A290-7226-X448
1 1 6 1 1 2 1 2 1 2 1
- 40 -
Locking
Torque N-m (kgf-cm) 3.2Nm (33kgfcm)
3.2Nm (33kgfcm)
4. REPLACING PARTS
B-83755EN/01
10 11 12
Remove bolts (13), then remove the shaft ass’y (14) and the gasket (15). Remove the cable K102, K104 from the motor ass’y (17), then pull out the cable from the J3 housing back side. Remove bolts (16), then remove the motor ass’y (17)
17 15
16
14
13
Fig. 4.6 (b) Replacing J3-axis moto r (2/3) Parts name 13 14 15 16 17
SEAL BOLT SHAFT ASS’Y GASKET SEAL BOLT MOTOR ASS’Y
Specifications A97L-0218-0423#051616 A290-7226-V303 A290-7226-X317 A97L-0218-0423#051616 A290-7226-V302
- 41 -
Q’ty 8 1 1 6 1
Locking
Torque N-m (kgf-cm) 7.9Nm (81kgfcm)
7.9Nm (81kgfcm)
4. REPLACING PARTS 13 14 15
B-83755EN/01
Remove the bolt (1), the motor adapter (7) and the O-ring (8) from the motor (2) in Fig. 4.6 (c). Remove the bolt (6), the washer (5), the gear (4) and the draw nut (3) from the motor (2) in Fig. 4.6 (c). Assemble it in the reversed sequence after exchanging motor by the new article. At this time, pay attention to the following. Confirm that the gasket (3), (6), (15) mounted firmly in Fig. 4.6 (a), (b). When assembling motor cables, apply Threebond 1401B on the screw head of the brake and power connector. Apply LOCTITE 518 on the both sides of the washer (5). Apply grease to the J3-axis reducer. Refer to Section 2.2. Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual. • •
•
16 17
8 7 6 5
4
3
2
1 Fig. 4.6 (c) Replacin g J 3-axis moto r (3/3) Parts name 1 2 3 4 5 6 7 8
SEAL BOLT MOTOR DRAW NUT GEAR WASHER BOLT MOTOR ADAPTER O-RING
Specifications A97L-0218-0423#061414 A06B-2215-B605 A290-7226-X312 A290-7226-X311 A6-WM-5S A6-BA-5X55 A290-7226-X309 JB-OR1A-G125
- 42 -
Q’ty 4 1 1 1 1 1 1 1
Locking
Torque N-m (kgf-cm) 9.6Nm (98kgfcm)
LT243
7.4Nm (75kgfcm)
LT518 LT243
7.9Nm (81kgfcm)
4. REPLACING PARTS
B-83755EN/01
4.7 1 2
REPLACING J3-AXIS REDUCER Set dial gauges at the J3-axis, and prepare for single axis mastering after replacement. Set the Quick Master Reference Position. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual. (All the axes are set to 0º before shipment.) Turn off controller power. Support the J3 arm with an crane. Remove covers and the motor ass’y referring to Section 4.6. Disassembling the motor ass’y is not necessary. Remove bolts (1) and washers (2).
3 4 5 6
2
1
Fig. 4.7 (a) Replacing J3-axis reducer (1/2) Parts name 1 2
BOLT WASHER
Specifications A6-BA-8X20 A290-7226-X336
Q’ty 15 1
- 43 -
Locking
Torque N-m (kgf-cm) 37.5Nm (380kgfcm)
4. REPLACING PARTS 7 8 9 10 11
B-83755EN/01
Remove bolts (3), then remove the J2 arm cover R (4) and the gasket (5). Remove bolts (8), dismount the reducer (9), then dismount the J3 casing from the J2 arm. Replace the reducer by new one. Then assemble it in the reversed sequence. Confirm the gasket (5) mounted firmly. Apply grease to the J3-axis reducer. Refer to Section 2.2. Perform quick mastering and perform single axis mastering of J3-axis. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS and SINGLE AXIS MASTERING of the robot-specific Operator’s Manual.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J3-axis motor shaft.
4
5
8
9
7
10
11 12
3 13 6
Fig. 4.7 (b) Replacing J3-axis reducer (2/2) Parts name 3 4 5 6 7 8 9 10 11 12 13
WASHER BOLT J2 ARM COVER R GASKET SPRING PIN O-RING BOLT REDUCER PIN O-RING O-RING PIN
Specifications A97L-0318-0450#051410S A290-7226-X305 A290-7226-X315 A6-PS-4X10S JB-OR1A-G130 A6-BA-6X35 A97L-0318-0225#42N-141 A290-7226-X343 JB-OR1A-G145 JB-OR1A-G105 A290-7226-X344
- 44 -
Q’ty 7 1 1 2 1 19 1 1 1 1 1
Locking
Torque N-m (kgf-cm) 3.2Nm (33kgfcm)
15.6Nm (160kgfcm)
4. REPLACING PARTS
B-83755EN/01
4.8 1 2 3 4
REPLACING J4-AXIS MOTOR Set dial gauges at the J4-axis, and prepare for single axis mastering after replacement. Turn off controller power. Remove bolts (1). And remove J3 cover H (2). Remove bolts (4), and remove the motor ass’y (5) with the gear. In this case, the grease may overflow.
CAUTION J4-axis will rotate when the motor was dismounted. Place the tip from J3 arm on the workbench, and avoid J3 arm from collision. 1 2 3
5 4
Fig. 4.8 (a) Replacing J4-axis moto r (1/2) Parts name 1 2 3 4 5
WASHER BOLT J3 COVER H GASKET BOLT MOTOR ASS’Y
Specifications A97L-0318-0450#051410S A290-7226-X404 A290-7226-X424 A6-BA-5X25 A290-7226-V402
- 45 -
Q’ty 6 1 1 3 1
Locking
Torque N-m (kgf-cm)
7.9Nm (81kgfcm)
4. REPLACING PARTS 5 6 7 8
B-83755EN/01
Wipe off the grease of the gear (3). In this case, pay attention not to damage the tooth surface. Remove cable from the motor (1). Remove the seal bolt (8), the washer plate (7), the J4 motor plate (5) and the gear (3). Assemble it in the reversed sequence after exchanging the motor and the O ring by the new article. At this time, pay attention to the followings. Confirm the oil seal (4) located in a proper position. Make sure that the lip will not turn over in attaching the motor. Apply Harmonic grease 4BNO.2 on surroundings of the gear referring to Fig. 4.9 (c). Confirm that the gasket (3) in Fig. 4.8 (a) mounted firmly. When assembling the motor cables, apply Threebond 1401B on the head of the brake, power connectors of the motor, then tighten them with torque [0.49 to 0.59Nm]. Apply LOCTITE 641 on the keyway of the motor. Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual. •
• • •
•
8
8
7
6 3 5
2
4 1
Fig. 4.8 (b) Replacing J4-axis moto r (2/2) Parts name 1 2 3 4 5 6 7 8
Specifications
MOTOR A06B-0116-B855#0048 KEY A97L-0118-0402#3X3X12BN GEAR J4-1 A290-7226-X409 OIL SEAL A98L-0040-0223#01001805 J4 MOTOR PLATE A290-7226-X407 O-RING A98L-0001-0347#S48 WASHER PLATE A290-7142-X203 SEAL BOLT A97L-0218-0423#030606
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Q’ty 1 1 1 1 1 1 1 3
Locking
Torque N-m (kgf-cm)
LT641
1.3Nm (13kgfcm)
4. REPLACING PARTS
B-83755EN/01
4.9 1 2
3 4 5 6 7 8 9 10 11
REPLACING J4-AXIS REDUCER Set dial gauges at the J4-axis, and prepare for single axis mastering after replacement. Set the Quick Master Reference Position. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual.(All the axes are set to 0º before shipment.) Turn off controller power. Support the J3 arm with slings. Remove bolts (1), then remove the J3 cover H (2). Remove bolts (4), then remove the clamp J4-1 (5). Dismount the J4-axis motor ass’y. Refer to Section 4.8. Remove bolts (6), (8) and washers (7), (9). Dismount the J3 arm. Remove the O-ring (10), the reducer (11) and the O-ring (12). Assemble it applying the procedure in the reversed sequence after exchanging reducer for the new article. When installing reducer, spread Harmonic grease 4BNo.2 on teeth of Wave generator, and be sure to install O-ring (10). (In case of J4-axis reducer, wave generator is assembled in reducer when it is shipped.) Apply LOCTITE 518 on the reducer mounting part. Refer to Fig. 4.9 (b). Apply Harmonic grease 4BNo.2 on the on surroundings of gear. Apply grease referring to Fig. 4.9 (c). •
• • •
NOTE Do not apply grease to the O-ring (10). Otherwise, hardening of sealant is prevented, causing a grease leak. 12
Perform quick mastering and perform single axis mastering of J4-axis. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS and SINGLE AXIS MASTERING of the robot-specific Operator’s Manual.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J4-axis motor shaft.
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4. REPLACING PARTS
B-83755EN/01
1 2 3
12
11
10 7
6
5 4
9
8
Fig. 4.9 (a) Replacing J 4-axis reducer Parts name 1 2 3 4 5 6 7 8 9 10 11 12
WASHER BOLT J3 COVER H GASKET BOLT CLAMP J4-1 BOLT WASHER BOLT WASHER O-RING REDUCER O-RING
Specifications A97L-0318-0450#051410S A290-7226-X404 A290-7226-X424 A6-BA-5X16 A290-7226-X417 A6-BA-5X55 A290-7226-X446 A6-BA-5X35 A290-7226-X447 (It is attached to the reducer) A97L-0318-0226#50 JB-OR1A-G115
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Q’ty 6 1 1 2 1 12 3 2 1 1 1 1
Locking
Torque N-m (kgf-cm)
7.9Nm (81kgfcm) 7.9Nm (81kgfcm)
4. REPLACING PARTS
B-83755EN/01
LOCTITE 518 applying area ロックタイト518塗布範囲
Fig. 4.9 (b) Applying sealant to the J3 housing Grease 給脂口 inlet
Grease グリース
Fig. 4.9 (c) Grease applyin g area of the J4-axis
- 49 -
4. REPLACING PARTS
4.10
B-83755EN/01
REPLACING J5-AXIS MOTOR
CAUTION WHEN PERFORMING LOAD ESTIMATION AFTER PARTS REPLACEMENT If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Remove the loads such as hands and perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). 1 2 3 4
Set dial gauges at the J5-axis, and prepare for single axis mastering after replacement. Turn off controller power. Remove the J3 arm cover of the J3 arm both side referring to Section 4.12. According to Fig. 6.1 (a), loosen the flange socket bolt (2) for belt tension adjustment, lower the tension of the belt (3), then remove the belt (3).
CAUTION The wrist will rotate if removing the belt (3). Place the wrist on the stand, and avoid the wrist from collision. 5
Loosen the flange socket bolt (5) for belt tension adjustment, lower the tension of the belt (3), then remove the belt (1).
CAUTION The wrist will move downward if removing the belt (1). Place the wrist on the stand, and avoid the wrist from collision. 6
Remove bolts (5), then dismount the motor ass’y (4).
5
1
2 4 3
Fig. 4.10 (a) Replacing J5-axis motor (1/3) Parts name 1 2 3 4 5 6
BELT FLANGE SOCKET BOLT BELT J5 MOTOR ASS’Y FLANGE SOCKET BOLT BOLT
Specifications A98L-0040-0312#007-100 A97L-0218-0504#M5X20 A98L-0040-0312#009-155 A290-7226-V403 A97L-0218-0504#M5X20 A6-BA-4X12
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Q’ty 1 2 1 1 2 3
Locking
Torque N-m (kgf-cm) 5.6Nm (57kgfcm)
5.6Nm (57kgfcm)
4. REPLACING PARTS
B-83755EN/01
Tension adjusting bolt テンション調整ボルト Tightening締付けトルク torque 5.6Nm (57kgfcm) 5.6Nm(57kgfcm)
Tension adjusting bolt テンション調整ボルト Tightening torque 5.6Nm (57kgfcm) 締付けトルク 5.6Nm(57kgfcm)
6 Fig. 4.10 (b) Replacin g J 5-axis moto r (2/3)
7 8 9
Remove cables from the motor (2). Remove the seal bolt (7), the plate (6), the motor pulley (5) and the key (4). Assemble it in the reversed sequence after exchanging motor for the new article. When assembling the motor cables, apply Threebond 1401B on the head of the brake, power connectors of the motor, then tighten those with torque [0.49 to 0.59Nm]. Apply LOCTITE 641 on the motor shaft and the key (4) and the pulley (5). Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual. •
• •
10
7
6
5 3
4
2 1
Fig. 4.10 (c) Replacing J5-axis moto r (3/3) Parts name 1 2 3 4 5 6 7
BOLT MOTOR J56 MOTOR PLATE KEY PULLEY J5-1 PLATE SEAL BOLT
Specifications A6-BA-5X16 A06B-0116-B855#0048 A290-7226-X408 A97L-0218-0402#3X3X12BN A290-7226-X410 A290-7226-X414 A97L-0218-0423#030808
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Q’ty 2 1 1 1 1 1 1
Locking
Torque N-m (kgf-cm) 5.6Nm (57kgfcm)
LT641 LT641 1.3Nm (13kgfcm)
4. REPLACING PARTS
4.11
B-83755EN/01
REPLACING J5-AXIS REDUCER
CAUTION WHEN PERFORMING LOAD ESTIMATION AFTER PARTS REPLACEMENT If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Remove the loads such as hands and perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). 1 2 3 4 5 6 7
Set dial gauges at the J5-axis, and prepare for single axis mastering after replacement. Turn off controller power. Remove both side of J3 arm cover. Remove bolts (12), then remove the J3 arm 2 (11). Remove the belt (1) referring to Section 4.10. Remove bolts (2), then remove the pulley (3). Remove the belt referring to Section 4.10.
CAUTION The wrist will move downward if removing the belt. Place the wrist on the workbench, and avoid the wrist from collision. 8 9 10
Remove bolts (9) and the washer plate A, B (8), then remove the wrist unit unit (7). Remove bolts (4), (4), then remove the reducer reducer (5). (5). At this time, note that grease may go go out. out. Replace reducer by new one, and assemble robot applying the procedure in the reversed sequence. At this time, pay attention below. Apply grease grease to inside of reducer, gear and bearing of wave wave generator generator and and install it horizontally. horizontally. (Refer to Fig. 4.11 (c)). Adjust the tension of the belt referring referring to Section 6.1 after the installation of of the belt. Apply sealant to the reducer referring to Fig. 4.11 (b) and Section 4.17. Apply LOCTITE 641 on the reducer shaft. Perform single axis mastering for J5/J6-axis. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual. •
• • •
11
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4. REPLACING PARTS
B-83755EN/01
1 10 2
3 11 5
12 7
9
4
6
8
Fig. 4.11 (a) (a) Replacing J5-axis J5-axis reduce Parts name name 1 2 3 4 5 6 7 8 9 10 11 12
BELT BOLT PULLY J5-2 FLANGE BOLT REDUCER WAVE GENERATOR WRIST UNIT WASHER PLATE A WASHER PLATE B BOLT GASKET J3 ARM 2 BOLT
Specif pecifica icatio tions ns A98L-0040-0312#007-100 A98L-0040-0312#007-100 A6-BA-4X12 A290-7226-X411 A97L-0218-0504#M4X16 A97L-0318-0227#80 (It is attached to the reducer) A290-7226-V501 A290-7226-X520 A290-7226-X521 A6-BA-4X25 A290-7226-X425 A290-7226-X403 A6-BA-5X25
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Q’ty 1 3 1 12 1 1 1 2 2 15 1 1 10
Lockin Locking g
Torque orque N-m (kgfkgf-cm cm)) 3.4Nm (33kgfcm) 4.0Nm (39kgfcm)
4.0Nm (39kgfcm)
5.6Nm (57kgfcm)
4. REPLACING PARTS
B-83755EN/01
LT518 Fig. 4.11 4.11 (b) Spread Spread rang e of sealant t o J5-reducer Grease グリース
Fig. 4.11 (c) (c) Grease Grease applyi ng area of th e J5-axis J5-axis
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4. REPLACING PARTS
B-83755EN/01
4.12
REPLACING J6-AXIS MOTOR
CAUTION WHEN PERFORMING LOAD ESTIMATION AFTER PARTS REPLACEMENT If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Remove the loads such as hands and perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). 1 2 3 4
Set dial gauges at the J6-axis, and prepare for single axis mastering after replacement. Turn off controller power. Remove washer bolts (1), then remove the J3 arm cover (2). Remove washer bolts (6), then remove the J3 arm cover (7).
CAUTION The wrist will move downward if removing the belt. Place the wrist on the workbench, and avoid the wrist from collision. 5
Loosen bolts (5), remove the belt (9), then remove the motor ass’y.
7 6 5
8 9 4
3 1
2
Fig. 4.12 (a) Replacing J6-axis motor (1/2) Name 1
WASHER BOLT
2 3
J3 ARM COVER GASKET
4 5
J6 MOTOR ASSY FLANGE BOLT
6
WASHER BOLT
7 8 9
J3 ARM COVER GASKET BELT
Specifications
Q’ty
A97L-0318-0450#051410S
6
A97L-0318-0450#052510S A290-7226-X405 A290-7226-X426
4 1 1
A290-7226-V404 A97L-0218-0504#M5X20 A97L-0318-0450#051410S A97L-0318-0450#052510S A290-7226-X405 A290-7226-X426 A98L-0040-0312#009-155
1 2 6 4 1 1 1
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Locking
Torque N-m (kgf-cm) 3.2Nm (31kgfcm)
5.6Nm (57kgfcm) 3.2Nm (31kgfcm)
4. REPLACING PARTS 6 7 8
B-83755EN/01
Remove cable K105, K106 from the motor (2). Remove the seal bolt (7), the washer (6), the pulley (5) and the key (4). Assemble the motor in the reversed sequence after exchanging motor and gasket for the new article. Confirm that the gasket (3), (8) in Fig .4.12 (a) mounted firmly. Apply LOCTITE 641 on the key (4) and the pulley (5). When assembling the motor cables, apply Threebond 1401B on the head of the brake, power connectors of the motor, then tighten them with torque [0.49 to 059Nm]. Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual. • • •
•
9
7
6
5 3
4
2 1
Fig. 4.12 (b) Replacin g J 6-axis moto r (2/2) Name
Specifications
Q’ty
1 2
BOLT MOTOR
A6-BA-5X16 A06B-0116-B855#0048
2 1
3 4 5 6 7
J56 MOTOR PLATE KEY PULLEY J6-1 PLATE SEAL BOLT
A290-7226-X408 A97L-0218-0402#3X3X12BN A290-7226-X412 A290-7226-X414 A97L-0218-0423#030808
1 1 1 1 1
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Locking
Torque N-m (kgf-cm) 5.6Nm (57kgfcm)
LT641 LT641 1.3Nm (13kgfcm)
4. REPLACING PARTS
B-83755EN/01
4.13
REPLACING WRIST UNIT
CAUTION WHEN PERFORMING LOAD ESTIMATION AFTER PARTS REPLACEMENT If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Remove the loads such as hands and perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). 1 2 3 4
Set dial gauges at the J5/J6-axis, and prepare for single axis mastering after replacement. Turn off controller power. Replacing both side of J3 arm cover of J3 arm. Remove belts (1), (4) referring to Section 4.15.
CAUTION When the belt (1), (4) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 6 7 8
9 10 11 12
Remove bolts (2), then pulley (3). Remove bolts (6), then pulley (7). Replace wrist unit (10) by new one and attach it. Attach reducer horizontally after apply greasing to gear of reducer. At this time, be sure to replace the gasket (9). Apply Harmonic grease 4BNo.2 to the lip of the oil seal lip. Assemble them in the reverse order. Adjust belt referring to Section 6.1. Install the J3 arm cover. Perform single axis mastering for J5/J6-axis. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual.
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4. REPLACING PARTS
B-83755EN/01
9 1 8
2 5 3 10 4
7 6
Fig. 4.13 Replacing the wrist unit Parts name 1 2 3 4 5 6 7 8 9 10
BELT BOLT PULLEY J5-2 BELT BOLT BOLT PULLEY J6-2 J3 ARM 2 GASKET WRIST UNIT
Specifications A98L-0040-0312#007-100 A6-BA-4X12 A290-7226-X411 A98L-0040-0312#009-105 A6-BA-5X25 A6-BA-4X12 A290-7226-X413 A290-7226-X403 A290-7226-X425 A290-7226-V501
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Q’ty 1 3 1 1 10 4 1 1 1 1
Locking
Torque N-m (kgf-cm) 3.4Nm (33kgfcm)
5.6Nm (57kgfcm) 3.4Nm (33kgfcm)
4. REPLACING PARTS
B-83755EN/01
4.14
REPLACING J6-AXIS REDUCER
CAUTION WHEN PERFORMING LOAD ESTIMATION AFTER PARTS REPLACEMENT If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Remove the loads such as hands and perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). 1 2
Set dial gauges at the J6-axis, and prepare for single axis mastering after replacement. Make to posture that J6 turns to the right upper and turn off the controller power as shown in Fig. 4.14. Remove bolts (1) and the reducer (2). In this case, the grease may overflow. Remove the seal bolt (3), the plate (4) and the wave generator (5). Remove the O-ring (6). Apply Harmonic grease 4BNo.2 on the bearing of the wave generator which is attached to new reducer, then attach it to the robot. Install new reducer (2) to the robot. At the same time, also replace O-ring (6) by new one. Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual.
3 4 5 6 7 8
1
2 3 4 5 6 7
Fig. 4.14 Replacin g th e J6-axis r educer Parts name 1 2 3 4 5 6 7
PLATED BOLT REDUCER SEAL BOLT PLATE WAVE GENERATOR O-RING KEY
Specifications A97L-0218-0496#M5X40BC A97L-0318-0228#50 A97L-0218-0423#041212 A290-7226-X509 (It is attached to the REDUCER) (It is attached to the REDUCER) A97L-0118-0402#5X5X10BN
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Q’ty 12 1 1 1 1 1 1
Locking
Torque N-m (kgf-cm) 7.9Nm (81kgfcm) 3.4Nm (13kgfcm)
4. REPLACING PARTS
4.15
B-83755EN/01
REPLA CING J5/J6 BELT
CAUTION WHEN PERFORMING LOAD ESTIMATION AFTER PARTS REPLACEMENT If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Remove the loads such as hands and perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3 4 5
Set dial gauges at the J5/J6-axis, and prepare for single axis mastering after replacement. Turn off controller power. Remove washer bolts (1). And remove J3 arm cover (2). Remove washer bolts (5). And remove J3 arm cover (6). In case of replacing J5 belt, loosen tension adjusting bolt and lower tension and remove belt referring to Fig. 6.1 (a). In case of replacing J6 belt, loosen tension adjusting bolt and lower tension and remove belt referring to Fig. 6.1 (b).
CAUTION 1 When the belt (8) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so That the wrist should not collide with surroundings. 2 When the belt (4) is removed, the wrist become possible to rotate. When end effector is attached, fix it so that the wrist should not collide with surroundings. 6
Replace the belt by new one and install in the reversed sequence. At this time, pay attention below. Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. Confirm that the gasket (3), (7) mounted firmly. Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the robot-specific Operator’s Manual. When replacing the J5 belt, perform not only J5-axis but also J6-axis when replacing J5 belt. • •
7
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4. REPLACING PARTS
B-83755EN/01
J6
J5
8 4 1
7
3 2
6
5
Locking
Torque N-m (kgf-cm)
Fig. 4.15 Replacing J5/J6 belt Parts name 1
WASHER BOLT
2 3 4
J3 ARM COVER GASKET BELT (J6)
5
WASHER BOLT
6 7 8
J3 ARM COVER GASKET BELT (J5)
Specifications A97L-0318-0450#051410S A97L-0318-0450#052510S A290-7226-X405 A290-7226-X426 A98L-0040-0312#009-155 A97L-0318-0450#051410S A97L-0318-0450#052510S A290-7226-X405 A290-7226-X426 A98L-0040-0312#007-100
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Q’ty 6 4 1 1 1 6 4 1 1 1
3.2Nm (31kgfcm)
3.2Nm (31kgfcm)
4. REPLACING PARTS
4.16 1 2 3 4 5
B-83755EN/01
REPLACING SOLENOID VALVE
Turn off controller power. Remove washer bolts (1), then remove the J3 arm cover 2 (2), and the plate or the gasket (3). Remove bolts (4), then remove the plate (6). Remove the bolts (5) then remove the solenoid valve (9). Replace solenoid valve by new one, and assemble them in the reversed sequence. Confirm that the gasket (3), (7) and (8) mounted firmly.
1
2
3
4
7
6
8
5 9
Fig. 4.16 Replacing Soleno id valve Parts name 1 2
4 5
WASHER BOLT J3 ARM COVER 2 PLATE GASKET BOLT BOLT
6
PLATE
7 8
GASKET GASKET
9
SOLENOID VALVE
3
Specificati ons A97L-0318-0450#052510S A290-7226-X406 A290-7226-X453 or A290-7226-X427 A97L-0218-0546#051616BC A97L-0218-0496#M4X12BC It differs depending on the mechanical unit cables. A290-7226-X428 A290-7226-X438 A97L-0218-0137#D1 or A97L-0218-0137#D2 or A97L-0218-0137#D3
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Q’ty 6 1
Locki ng
Torque N-m (kgf-cm) 3.2Nm (33kgfcm)
1 8 4 1 1 1 1
6.8Nm (69kgfcm) 2.0Nm (20kgfcm)
4. REPLACING PARTS
B-83755EN/01
4.17
SEALA NT APPLICATION
Washi ng and degreasing th e surfaces to be sealed 1
2 3 4
After dismounting the reducer from the member which installed the reducer, apply remover (LOCTITE Gasket Remover etc.) to the other adherent side from which the reducer was dismounted, then wait until the sealant (LOCTITE 518) becomes softened got soft (for about Approximate 10 minutes). Remove the softened sealant from the surface using a spatula. Blow air onto the surface to be sealed to remove dust from the tapped holes. Remove sealing surface and the other adherent side completely with cleaner transfused remover. Pay attention not to spray (spread) the oil and grease remover directly on the surface. Polish the surface of the other adherent side with an oil stone, and degrease with removal and cleaner again.
CAUTION Oil may drip from inside of the reducer. Check there is no oil drip thoroughly after finished degreasing. Ap pl yi ng Sealant 5
6
Make sure that the reducer and the other adherent side are dry. If they are still wet with oil and grease remover, wipe them dry. Make sure to use the clean cloth surface avoid from reattaching the wiped grease. Make sure that no ingredient of oil and grease remover is left on the threaded holes or anywhere. If some ingredient left on the surface, it may prevent stiffening the sealant. Apply sealant (LOCTITE 518) to the sealing surfaces.
CAUTION Refer to the each relevant axis reducer replacement descriptions as the sealant required locations differ from each axis. As sem bl y 7
8 9
To prevent dust from sticking on the surface sealant applied, mount the reducer as quickly as possible after sealant application. Pay attention not to touch the applied sealant. If the sealant is removed, apply the sealant again. After assembling parts, adhere the seal surface fixing with bolts and washers promptly. After assembling the reducer, wipe off any excessive overflowing sealant with a cloth or spatula. Do not use oil and grease remover.
CAUTION Start greasing or operation before the sealants cure may cause grease to leak. Make sure to leave at least one hour, and then start greasing or operation.
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5. REPLACING CABLES
5
B-83755EN/01
REPLA REPLACIN CING G CABL CAB L ES
Replace the cables every four years (15360 hours). When the cable is broken or damaged or shows signs of wear, replace it according to this chapter.
Precautions Precautions to be observed when handling the Pulsecod Pulsecod er cable cable The Pulsecoder cable is provided with a marking tie, as shown below, to warn against disconnecting the cable during transportation, installation, or maintenance. Once the cable with the marking tie is disconnected, mastering is required. Therefore, do not disconnect the cable except for the motor, the Pulsecoder, the reducer, and the cable replacement are required.
BATTERY BACKUP
DON'T DISCONNECT
コネクタ取外不可
Fig. 5 marking label
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5. REPLACING CABLES
B-83755EN/01
5.1
CABLE CAB LE WIRING WIRING
Followings are the routing of the robot cables.
K105 K105 (J5J6軸パワー) (J5/J6-axis power) K106 K106 (J5J6軸パルスコーダ) (J5/J6-axis Pulsecoder)
K107 K107 (EE(RIx8/ROx8)) (EE (RI x8 /RO x 8) K108 K108 (EE(RIx8/ROx2)+YV) (EE (RI x8 /RO x 8 + YV) K114 (オプション) K114 (option) (ASi) (ASi) K116 (オプション) K116 (option) (カメラ) (CAMERA) K117 (オプション) K117 (option) (イーサネット) (Ethernet) K118 (オプション) K118 (option) (力センサ・立体センサ) (Force sensor, 3D Laser Vision Sensor)
K102 K102 (J3-axis power) (J3軸パワー) K103 K103 (J4-axis power) (J4軸パワー) K104 K104 (J3/J4-axis Pulsecoder) (J3,J4軸パルスコーダ)
K109 (option) (ASi) K109 (オプション) K111 (ASi)(option) (CAMERA) K111 (オプション) (CAMERA) K112 (option) K112 (オプション) (Ethernet) (イーサネット) K113 (option) K113 sensor, (オプション) (Force 3D Laser (力センサ・立体センサ) Vision sensor)
K123 K101 (power, Pulsecoder) (パワー, パルスコーダ)
Fig. 5.1 5.1 Routing of the robot cables
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5. REPLACING CABLES
5.2
B-83755EN/01
CABLE FORMING
When replacing cables, clamp the cable at the position specified in Fig. 5.2 using a clamp or a cable tie. If fail to clamp cables in specific position, it will cause the cable slack or cable disconnection by improper pulling force. Refer to the Fig. 5.2 for the cable clamp. Relay on the J2 arm upper side J2アーム上部で中継
M1M
M 1 M
M1BK
M 1 B K
2 0 1 K
1 M 3 M
M3M
M 3 M
1 M 3 M
K102 M 4 M
M4M
M 5 M
M5M
3 0 1 K
1 M 4 M
1 M 4 M
K103
K B 4 M
M4BK K B 5 M
M5BK
1 M 6 M
5 0 1 K
M 6 5 M
M 6 5 M
1 M 5 M
M 6 M
K105 M 2 M
M 2 B K
K B 6 M
M6M
M6BK
M2M
M2BK
G B 2
M 1 P
M1P
BATTERYBACKUP DON'T
E E A
DISCONNECT
Rl N^ŽæŠO s Â
E E A K 1 0 8
EE
E E
E E B
Y V
E E B
YV
K108 K101
BACKUP KUP P BATTERY BAC 5 DON'T M
Rl N^ŽæŠO s Â
BATTERY
BACKUP
BATTERY
DON'T
BACKUP
DON'T
DISCONNECT
DISCONNECT
Rl N^ŽæŠO s Â
Rl N^ŽæŠO sÂ
K106
6 0 1 K P 6 5 M
BACKUP KUP P BATTERY BAC 6 DON'T M DISCONNECT
Rl N^ŽæŠO s Â
K123 P 3 M
M 2 P
BATTERYBACKUP DON'T DISCONNECT
BATTERYBACKUP DON'T
M2P
M 3 4 P
DISCONNECT
BACKUP
BATTERYBACKUP BATTERYBACKUP DON'T
DISCONNECT
DISCONNECT
Rl N^ŽæŠO sÂ
K104
Rl N^ŽæŠO sÂ
4 0 1 K P 4 3 M
BAC KUP P BATTERY BACKUP 4 DON'T M DISCONNECT
Rl N^ŽæŠO s Â
+ -
M3P
Rl N^ŽæŠO s Â
BATTERY
DON'T
Rl N^ŽæŠO s Â
M5P
DISCONNECT
M 5 6 P
G B 1
Fig. 5.2 Cable externals externals ch art of mechani cal unit (Basic cable)
- 66 -
M4P
M6P
5. REPLACING CABLES
B-83755EN/01
5.3
CABLE AND AIR TUBE REPLACEMENT
This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables. See Section 5.1 for the configuration of the mechanical unit cables. You must perform mastering after cable replacement. Refer to Chapter 6 or Chapter 8 THE OPERATOR’S MANUAL (B-83754EN) in advance. (If Pulsecoder cable is not replaced, mastering is not necessary.) In replacing cables, arrange the cable ties.
5.3.1 1
Replacing Cable K123 and Air Tube (Conn ector panel to J2 base)
Set the Quick Master Reference Position. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual. Turn off controller power and remove the robot connection cable from connector plate of back of J1-axis. Remove washer bolts (1), then remove the J2 arm cover L (2) and the gasket (3). Remove washer bolts (4), then remove the J2 base cover L (5) and the gasket (6). Remove washer bolts (7), then remove the cover B (8) and the gasket (9).
2 3 4 5
3
2 1
7 8
9
6
5
4
Fig. 5.3.1 (a) Replacin g cable K123 and air t ubes (conn ector p anel to J2 arm)
1 2 3 4 5 6 7 8 9
Parts name WASHER BOLT J2 ARM COVER L GASKET WASHER BOLT J2 BASE COVER L GASKET WASHE BOLT COVER B GASKET
Specifications A97L-0318-0450#051410S A290-7226-X306 A290-7226-X316 A97L-0318-0450#051410S A290-7226-X304 A290-7226-X314 A97L-0318-0450#051410S A290-7226-X347 A290-7226-X318
- 67 -
Q’ty 7 1 1 8 1 1 6 1 1
Locking
Torque N-m (kgf-cm) 3.2N-m (33kgf-cm)
3.2N-m (33kgf-cm)
3.2N-m (33kgf-cm)
5. REPLACING CABLES 6
B-83755EN/01
Remove washer bolts (10), then remove the cover U (11) and the gasket (12). 10 11 12
A
Detail A
詳細 A
Fig. 5.3.1 (b) Replacin g cable K123 and air tubes (con nector panel to J2 arm) Parts name
Specifications
Q’ty
10
WASHER BOLT
A97L-0318-0450#051410S
6
11 12
COVER U GASKET
A290-7226-X319 A290-7226-X313
1 1
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Locking
Torque N-m (kgf-cm) 3.2N-m (33kgf-cm)
5. REPLACING CABLES
B-83755EN/01
7 8 9 10 11 12 13
Loosen 2 screws, remove the battery box (17) cover, then remove the screw (22), remove the battery box (17) and the battery line. Remove bolts (18), then remove the BB plate (20). Pull out J2 arm side connectors, then remove the all connections and air tube relays. Remove bolts (13), the clamp plate (14), bolts (19), clamp J2-2 (21), bolts (15) and the clamp J2-1 (16). Remove the J2-axis motor connectors. Pull out cables from the J2 base side. Cut the cable ties on the plates.
13
14
20 17 22
18
19
21
16 15
Fig. 5.3.1 (c) Replacing cable K123 and air tub es (connector panel to J2 arm)
13 14 15 16 17 18 19 20 21 22
14
Parts name BOLT CLAMP PLATE BOLT CLAMP J2-1 BATTERY BOX BOLT BOLT BB PLATE CLAMP J2-2 SCREW
Specifications A6-BA-5X10 A290-7226-X325 A6-BA-5X10 A290-7226-X323 A98L-0004-0149 A6-BA-5X10 A6-BA-5X10 A290-7226-X327 A290-7226-X324 A6-SSA-4X10S
Q’ty 2 1 2 1 1 3 3 1 1 2
Locking
Torque N-m (kgf-cm)
Remove bolts (23), then separate the Clamp J1-2 (24) and the clamp J1-3 (24). At this time, do not cult the cable ties. 24 23
Fig. 5.3.1 (d) Replacin g cable K123 and air tubes (con nector panel to J2 arm)
23 24
Parts name BOLT CLAMP J1-2 CLAMP J1-3
Specifications A6-BA-5X10 A290-7226-X213 A290-7226-X214
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Q’ty 4 1 1
Locking
Torque N-m (kgf-cm)
5. REPLACING CABLES 15 16
B-83755EN/01
Remove bolts (26) and the connector panel (27). Remove air tubes and other connectors from the connector panel. Refer to Fig. 5.3.1 (f) for disassembling the HARTING connector.
26
27
28
25 No.1 pin 1番ピン Fig. 5.3.1 (e) Replacin g cable K123 and air t ubes (conn ector p anel to J2 arm) Parts name
Specifications
Q’ty
25
BOLT
A97L-0218-0546#040808BC
26 27 28
WASHER BOLT CON. PLATE GASKET
A97L-0318-0450#051410S (It differs depending on the cables.)
Locking
4
A290-7226-X209
10 1 1
Torque N-m (kgf-cm) 0.78N-m (8.0kgf-cm) 3.2Nm (33kgfcm)
Housing mounting bolt Insert Code pin, guide pin, guide bush or cross-recessed head machine screw Housing Remove the housing from the J1 connector late
Remove the code pin etc. Remove the insert from the housing
Remove the insert from the housing and the connector plate hole, then remove the cable from the J1 connector
Fig. 5.3.1 (f) Removing of the Harting connector
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5. REPLACING CABLES
B-83755EN/01
17 18 19
Remove bolts (30), then remove the plate. Remove bolts (31), then remove the terminal (32). Pull out cables to lower side.
32
31 30
29
Fig. 5.3.1 (g) Replacin g cable K123 and air tubes (con nector panel to J2 arm) Parts name 29 30 31 32
CLAMP J1-1 BOLT BOLT TERMINAL
Specifications A290-7226-X212 A6-BA-5X16 A97L-0218-0606#M5X8
Q’ty
Locking
Torque N-m (kgf-cm)
1 2 2 2
20
Replace cable and air tube for the new article and assemble them applying steps above in reversed sequence. Refer to Fig. 5.3.1 (h) to Fig. 5.3.1 (j) for cable forming. Replace removed covers and connector plates by new articles. If reusing them, apply LOCTITE 243 into tap holes.Confirm that the gasket mounted firmly. 21 Perform quick mastering. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual.
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5. REPLACING CABLES
B-83755EN/01
J1 base to J2 base J1ベース～J2ベース エアチューブマーキング Air tube marking
Black 黒
About 400mm About 2300mm
(a)
J1 connector panel side J1分線盤側
White 白
About 400mm About 2300mm ●
←J1分線板側 ←J1 connector panel side
X212
J2J2中継部側 relay part side
X213
A Clamp J1-1 J1-1 クランプ A290-7226-X212 (1)(1) A290-7226-X212
Cable marking position (a) ケーブルマーキング位置 (a)
BLUE GREEN
AIR(φ6 白) Air (φ6 black) AIR(φ8 黒)
ASi
CAM
SEN2
EN
WHITE
SEN1
EE M56P
M2P M34P
GRAY
M5M M6M
M2M M34M
Section A-A 断面 A-A
RED YELLOW
J1 connector J1分線盤側 panel side
A
J2中継部側 J2 relay part side
NOTE) 注） 1) Cable (SEN1, SEN2,SEN2, EE, M2P, M34P, M56P) array is random order in a group. 1) ケーブル（SEN1, EE, M2P, M34P, M56P）の配列はグループ内で順不同 。 However, do not twist cables between clamp A and B. ただし、クランプA-B間でケーブルにねじれの無いこと。 2) Clamp cables in order of [gray], [white], [green], [yell and red], [blue]. 2) "黄・赤"、"灰"、"白"、"緑"、"青"の順番でケーブルをクランプすること。
Cableケーブルマーキング位置 marking position (b) (b)
GREEN
CAM
Tie up with cable ties ケーブルタイで縛ること。
EN
Air (φ8BLACK) black) AIR(φ8
B
ASi
Air (φWHITE) 6 white) AIR(φ6
BLUE
SEN2
WHITE SEN1
EE M6M
M2P
M34M J1 connector panel side J1分線盤側
Clamp J1-2 クランプ J1-2 A290-7226-X213 A290-7226-X213 (1) Sheet シート A290-7226-X226 (1) A290-7226-X226
J2 relay part side J2中継部側
B
RED YELLOW
Make cable tie head position ケーブルタイの頭の位置を as shown in this figure 図の位置にすること
M34P
M5M M2M
Section B-B 断面 B-B
NOTE) 注） 1)1)Cable (SEN1, SEN2, EE, M2P, M34P, array is random order in a group. ケーブル（SEN1, SEN2, EE, M2P, M56P) M34P, M56P）の配列はグループ内で順 不同。 However,ただし、クランプA-B間でケーブルにねじれ無きこと。 do not twist cables between clamp A and B. "灰"、"白"、"緑"、"黄・赤"、"青"の順番でケーブルをクランプすること。 2)2)Clamp cables in order of [gray], [white], [green], [yell and red], [blue].
注） □はオプションケーブルです。ケーブルの種類によっては無い場合もあります。 Note) are option cables . Those do not exist depending on cable variations.
Fig. 5.3.1 (h) Replacin g cable K123 and air tubes (con nector panel to J2 arm)
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M56P
GRAY
5. REPLACING CABLES
B-83755EN/01
J2J2ベース～J2アーム base to J2 arm J2 relay part side J2中継部側
X324
A : gray A 灰色 B : Blue B 青色 C : yellow C 黄色 D : red D 赤色 E 緑色 E : green F 白色 F : white
● ●
X323 J1分線盤側 J1 connector panel side
J1 connector J1分線盤側 panel side
E F D C A B
A B C D E F
Cable marking ケーブル マーキング位置
position
J2 relayJ2中継部側 part side
C
Cable markingケーブルマーキング位 position
B
A
D
C D
C
E
D
F
CLAMP Clamp J2-1J2-1
A290-7226-X323 (1)
この図の配列でケーブルを交差させる事。 Cross cables according to arrays in this figure
A290-7226-X323 (1)
Clamp J2-2
クランプ J2-2
A290-7226-X324 A290-7226-X324 (1)(1)
M6M
AirAIR(φ6 (φ6 white) 白)
M5M
M2P
ASi EE
M6M
M34P
M5M
SEN2
M2P
CAM
Air (AIR(φ6 φ6 white) 白)
EN
EE
CAM
ASi
SEN2 M56P
SEN1 E
Air (AIR(φ8 φ8 black) 黒)
F
D
M2M
C
A
EN
E
B
M34M
F
D
C
A
B
SEN1
シート Sheet A290-7226-X332 (1) (1) A290-7226-X332 （ケーブルタイでA290-7226-X324 (Tighten it with cables to にケーブルと共締めすること。） A290-7226-X324 using cable ties.) AIR(φ8 BLACK) M56P M34P M2M
M34M
Section C-C 断面 C-C Section D-D 断面 D-D
Plate プレート A290-7226-X332 A290-7226-X322(1)(1) ボルト Bolt A6-BA-5X10 A6-BA-5X10 (2)(2)
Clamp J2-2 クランプ J2-2 A290-7226-X324 A290-7226-X324 (1) (1)
M2P,M2M, M2BK,GB1
Bindケーブルタイで縛ること。 them with cable ties
Fig. 5.3.1 (i) Replacing cable K123 and air tub es (connector panel to J 2 arm)
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5. REPLACING CABLES
J2 relay part J2中継部
B-83755EN/01
Sheet シート A290-7226-X335 (1) A290-7226-X335 (1) （ケーブルタイでA290-7226-X325 (Tighten it with cables to にケーブルと共締めすること。） A290-7226-X325 using cable ties.)
J2 relay part J2中継部側
●
J1 connector panel side J1分線盤側 Clamp plate クランププレート A290-7226-X325 (1) (1) A290-7226-X325
ケーブルマーキング位置 Cable marking position
F
E
Attach the joint asshown below エアチューブの終端に下記 のジョイントを取り付けること to the air tube end.
F
E J1 connector panel side J1分線盤側
J2 relay part J2中継部側
M34M EE M6M M34P
AirAIR(φ6 (φ6 white) WHITE)
SEN1
SEN1
EE M2P M6M
EN ASi
CAM
CAM
EN M5M M34M M56P
SEN2
Section 断面 E-E E-E
M5M M2P M56P
ASi SEN2 Air (φ8 black) AIR(φ8 BLACK)
M34P
Air (φ6 black) AIR(φ8 黒)
Section F-F 断面 F-F
Air (φ6 white)
AIR(φ6 白)
Cable arrays in group are random order. ケーブルの配列はグループ内で順不同。
Fig. 5.3.1 (j) Replacing cable K123 and air tub es (connector panel to J 2 arm)
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5. REPLACING CABLES
B-83755EN/01
5.3.2
Replacing Cable K102,K103,K104,K105,K106,K108K and Air Tube (J2 arm to J3 arm)
Replacing p rocedure 1
Set the Quick Master Reference Position. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual. Turn off controller power. Remove the J2 arm cover L and the gasket. Refer to Subsection 5.3.1. Pull out the J2 arm side connectors, then remove all connections and the air tube relays. Remove bolts (2), then remove the clamp J3-1 (1). Cut all cable ties which fix cables and tubes.
2 3 4 5
2
1 Fig. 5.3.2 (a) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm)
1 2
6 7 8
Parts name CLAMP J3-1 BOLT
Specifications A290-7226-X326 A6-BA-5X10
Q’ty 1 2
Locking
Torque N-m (kgf-cm)
Remove bolts (3), then remove the shaft (4) and the gasket (5). Remove bolts (6), then remove the J3 cover H (7) and the gasket (8). When replacing J3-axis motor cable K102, K104 or J4-axis motor cable K103, K104, remove connectors from each axis motor.
6 7
8
5
3 4 Fig. 5.3.2 (b) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm)
3 4 5 6 7 8
Parts name SEAL BOLT SHAFT GASKET WASHER BOLT J3 COVER H GASKET
Specifications A97L-0218-0423#051616 A290-7226-X307 A290-7226-X317 A97L-0318-0450#051410S A290-7226-X307 A290-7226-X424
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Q’ty 8 1 1 6 1 1
Locking
Torque N-m (kgf-cm)
3.2Nm (33kgfcm)
5. REPLACING CABLES 9
B-83755EN/01
Remove bolts (9), then remove the clamp J4-1 (10), then cut cable ties which fix cables.
10 9
Fig. 5.3.2 (c) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm) Parts name 9 10
10
BOLT CLAMP J4-1
Specifications A6-BA-5X10 A290-7226-X417
Q’ty
Locking
Torque N-m (kgf-cm)
2 1
Remove bolts (11), (13), then remove the clamp J3-2 (12) and the J3-3 (14). Remove the plate (16), (18) which are fixed to the clamp. Then cut cable ties which fix cables and remove the sheet (15), (17).
11
14
12
13
Fig. 5.3.2 (d) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm) Parts name 11 12
BOLT CLAMP J3-2
13
BOLT
14
CLAMP J3-3
Specifications A6-BA-5X10 A290-7226-X416 A6-BA-5X10 (When option is specified.) A290-7226-X448 (When option is specified.)
Q’ty 2 1 2 1
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Locking
Torque N-m (kgf-cm)
5. REPLACING CABLES
B-83755EN/01
15
16 18
17
Fig. 5.3.2 (e) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm) Parts name 15 16
SHEET PLATE
17
SHEET
18
PLATE
11 12 13 14
Specifications A290-7226-X449 A290-7226-X450 A290-7226-X449 (When option is specified.) A290-7226-X450 (When option is specified.)
Q’ty
Locking
Torque N-m (kgf-cm)
1 1 1 1
Remove washer bolts (19), then remove the J3 arm cover 2 (20) and the gasket (21). Remove all connectors and tubes which are connected to the J3 connector plate. Remove seal bolts (22), then remove the J3 connector plate. When replacing J5/J6-axis motor cable K105, K106, dismount the J5/J6-axis motor, then remove the connectors for motors. Refer to Section 4.10 and 4.12.
22 23
21 20 19 Fig. 5.3.2 (f) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm) Parts name 19 20 21 22 23
WASHER BOLT J3 ARM COVER 2 GASKET SEAL BOLT J3 CON.PLATE
Specifications A97L-0318-0450#052510S A290-7226-X406 A290-7226-X427 A97L-0218-0546#051616BC It differs depending on the cables
- 77 -
Q’ty 6 1 1 8 1
Locking
Torque N-m (kgf-cm) 3.2Nm
6.8Nm
5. REPLACING CABLES
B-83755EN/01
15 16 17
Remove bolts (24), then remove the clamp J4-2 (25). Cut all cable ties which fix cables. Pull out all cables from the J2 arm side. Replace cable and air tube for the new article and assemble them applying steps above in reversed sequence. Refer to Fig. 5.3.2 (h) to Fig. 5.3.2 (l) for cable forming. Replace removed covers and connector plates by new articles. If reusing them, apply LOCTITE 243 into tap holes.Confirm that the gasket mounted firmly. 18 Perform quick mastering. Refer to the QUICK MASTERING, QUICK MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual.
25 24
Fig. 5.3.2 (g) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm) Parts name 24 25
BOLT CLAMP J4-2
Specifications A6-BA-5X16 A290-7226-X418
Q’ty 2 1
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Locking
Torque N-m (kgf-cm)
5. REPLACING CABLES
B-83755EN/01
X326
J2 arm to J3 casing J2アーム～J3ケーシング
J2 relayJ2中継部側 part side X416
●
X446
J3 connector panel side J3分線盤側
Cross the cables as shown in this figure 下図に示すようにケーブルを交差させる事。
H
ケーブルマーキング位置 Cable clamp position
G
H Cable clamp position ケーブルマーキング位置 クランプ J3-2 Clamp J3-2 A290-7226-X416 (1) (1) A290-7226-X416 J3分線盤側 J3 connector panel side
J2 relay J2中継部側 part side
Cable clamp position ケーブルマーキング位置
I
Clamp クランプJ3-1 J3-1 A290-7226-X326 (1)(1) A290-7226-X326
G
I Clamp クランプJ3-3 J3-2 A290-7226-X448 A290-7226-X448 (1)(1)
H202 H252
H201 H251
H203 H253 EN ASi
白) Air AIR(φ8 (φ8 white) Air (AIR(φ8 φ8 black) 黒)
SEN2
CAM
Air (φ6 white) AIR(φ6 白)
Air (AIR(φ6 φ6 white) 白)
SEN1
Air (AIR(φ8 φ8 black) 黒)
黒) Air (AIR(φ8 φ8 black)
M56P
M56P
M56P
M34P
M34P
EE
EE M3M M3M M5M
M6M M4M
M34P M3M
M3M
M3M
M3M M3M M5M
M6M M4M
EE
M6M
M3M M3M M5M
M4M
断面 G-G Section G-G
M56P M34P M3M
SEN2
CAM
SEN1
ASi
M6M M4M M5M M3M M3M
EN
Air (φ6 白) white) AIR(φ6
断面 I-I Section I-I
AIR(φ8 Air (φ8 黒) black) EE
Section H-H 断面 H-H Fig. 5.3.2 (h) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm)
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5. REPLACING CABLES
B-83755EN/01
Plate in the J3 casing J3ケーシング内板金
Sheet シート
A290-7226-X449 (1)
A290-7226-X449 (1)
ケーブルタイで縛ること。 Bind them with cable ties.
Plate プレート A290-7226-X450 (1)(1) A290-7226-X450 ボルト A6-BA-5X10 (2) Bolt
Clamp J3-2 クランプ J3-2 A290-7226-X416 A290-7226-X416 (1)(1)
断面 J-J Section J-J J
J
A6-BA-5X10 (2)
Clamp J3-3 クランプ J3-2 A290-7226-X448 (1)
When using option cables オプションケーブル使用時
A290-7226-X448 (1)
Sheet
シート
A290-7226-X449 (1)(1) A290-7226-X449
Bind them with cable ties. ケーブルタイで縛ること。 Plate プレート A290-7226-X450 (1) A290-7226-X450 (1)
ボルト Bolt
断面 K-K Section K-K
A6-BA-5X10 (2)
A6-BA-5X10 (2)
K
K
Fig. 5.3.2 (i) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm)
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5. REPLACING CABLES
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Inside ofJ3ケーシング内1 the J3 casing 1
If a solenoid valve exists (電磁弁がある場合) Air AIR (red)(赤)
L
L
Make this cable comes to このケーブルを手前側 にして交差させる事。
front side and cross it
断面 L-L Section L-L
Clamp J3-1 クランプ J3-1 A290-7226-X326 (1) A290-7226-X326 (1) Boltボルト A6-BA-5X10 (2)
M
A6-BA-5X10 (2)
M 断面 M-M Section M-M For オプションケーブル用 option cable クランプ J3-2
Clamp J3-3 A290-7226-X448 (1) ボルト
A290-7226-X448 A6-BA-5X10 (2)(1) Bolt A6-BA-5X10 (2) In case of H203, H253
H203, H253の場合
Ferrite core フェライトコア
A45L-0001-0329 (3) A45L-0001-0329 (3)
ASi, CAM, SEN1ケーブルを
フェライトコアに通すこと。（順不同） Pass ASi, CAM SEN1 cables
into the ferrite core. (randam order)
Clamp J3-2 A290-7226-X416 クランプ J3-2 (1) A290-7226-X416 (1)
Boltボルト
A6-BA-5X10 (2)
A6-BA-5X10 (2)
Fig. 5.3.2 (j) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm)
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5. REPLACING CABLES
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Inside of the J3 casing 2 J3ケーシング内2 ●
J3分線盤側 J3 connector panel side
X418
X417 J4軸減速機側 J4-axis reducer side
N ケーブルマーキング位置 Cable marking position
J3分線盤側 J3 connector panel side
J4軸減速機側 J4-axis reducer side
Clamp J4-1 クランプ J4-1
A290-7226-X417 (1)
N
A290-7226-X417 (1)
H202 H252
H201 H251 M6M M5M M56P
M6M M5M AIR(φ8 Air (φ8 赤) red)
M6M
M56P AirAIR(φ8 (φ8 black) 黒)
Air (φ8 white)
EE
EE
AIR(φ6 Air (φ6 白) white)
CAM
SEN2 EN
At X417 marking position, wind yellow vinyl tape ケーブルをパイプに通す前にマーキング箇所で dually before pass the cables into the pipe. 黄色ビニルテープを2重に巻くこと。（全仕様） (For all specifications)
ASi
AIR(φ6 白) Air (φ6 white)
AIR(φ8 白)
AIR(φ8 赤) Air (φ8 red) AirAIR(φ8 (φ8 black) 黒)
M5M M56P
AIR(φ8 黒) Air (φ8 black)
H203 H253
EE
SEN1
Section N-N 断面 N-N
Fig. 5.3.2 (k) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm)
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5. REPLACING CABLES
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J3 casing to J3 arm inside J3ケーシング～J3アーム内
●
J4-axis reducer side J4減速機側
X417
J3 connector panel side J3分線盤側
X418 ケーブルマーキング位置 Cable marking position
O J3 connector panel side J3分線盤側
J4-axis reducer side J4減速機側
Clamp J4-2 クランプ J4-2 A290-7226-X418 (1) (1) A290-7226-X418
O
At X417 marking position, wind yellow vinyl tape ケーブルをパイプに通す前にX417マーキング箇所で dually before pass the cables into the pipe. 黄色ビニルテープを2重に巻くこと。（全仕様）
SEN1
(For all specifications)
EE
SEN2 ASi
AIR(φ8 RED)
AIR(φ8 RED) M5M
M5M
M5M
EN
EE
M6M M56P
M6M M56P
M6M M56P
CAM
AIR(φ8 WHITE) H201 H251
AIR(φ8 BLACK)
EE
AIR(φ6 WHITE) H202 H252
AIR(φ8 BLACK)
AIR(φ6 WHITE) H203 H253
AIR(φ8 BLACK)
Section O-O 断面O-O Fig. 5.3.2 (l) Replacing cable K102,K103,K104,K105,K106,K108 and air tubes (J2 arm to J3 arm)
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6. ADJUSTMENT
6
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ADJUSTMENT
Mastering associates the angle of each robot axis with the pulse count value supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for obtaining the pulse count value; corresponding to the zero position.
6.1
ADJUSTING TENSION OF BELT
Please use the following tension meters for the tension adjustment of the belt. Instrument
Tension meter
1
Specifications
Vendor
A97L-0218-0700 Mitsuboshi Belting Ltd.
DOCTOR TENSION TYPE-Ⅲ
Application
Adjustment of belt tension
Place the robot in the posture to avoid the influence of the gravity to J5-axis. (recommended posture: J3=0 ,J5=±90 ) Remove the bolt and arm cover (refer to Chapter 4). Adjust it so that it may loosen tension-adjusting bolts and the tension may reach a specified value. Attach arm cover. When gasket is attached, be sure to replace gasket by new one. In this time, tighten the bolt with the specified torque. °
2 3 4
Manufacturer model No.
°
CAUTION
The tension of the belt deteriorates slowly, but this is a normal symptom.If belt is adjusted frequently. it shorten the life of belt, please don’t adjust belt except case of replacing motor, reducer etc. Tension adjusting bolt テンション調整ボルト Tightening torque 5.6Nm (57kgfcm)
締付けトルク 5.6Nm(57kgfcm)
Fig. 6.1 (a) Adjusting tension of J5 belt
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6. ADJUSTMENT
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Tension adjusting bolt テンション調整ボルト Tightening torque 5.6Nm (57kgfcm)
締付けトルク 5.6Nm(57kgfcm)
Fig. 6.1 (b) Adjusting t ension of J6 belt Table 6.1 (a) Measurement condi tio n of J5 belt (for t ension meter)
BELT TENSION MASS WIDTH SPAN
69.0 - 59.0N 0.0231kg/m 7mm 177mm
Table 6.1 (b) Measurement con diti on of J 6 belt (for tensio n meter)
BELT TENSION MASS WIDTH SPAN
6.2
88.0 - 78.0N 0.0231kg/m 9mm 300mm
MASTERING
Mastering associates the angle of each robot axis with the pulse count value supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for obtaining the pulse count value; corresponding to the zero position.
6.2.1
OVERVIEW
The current position of the robot is determined according to the pulse count value supplied from the Pulsecoder on each axis. Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However, mastering is required under the following conditions: Motor replacement Pulsecoder replacement Reducer replacement Cable replacement Batteries for pulse count backup in the mechanical unit have gone dead.
WARNING
Robot data (including mastering data) and Pulsecoder data are backed up by their respective backup batteries. Data will be lost if the batteries die. Replace the batteries in the controller and mechanical units periodically. An alarm will alert you when battery voltage is low.
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6. ADJUSTMENT
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Mastering method Table 6.2.1 describes the following mastering methods. Table 6.2.1 Type of masterin g
Fixture position mastering Zero-position mastering (witness mark mastering) Quick mastering
Quick mastering for single axis
Single-axis mastering Mastering data entry
This is performed using a mastering fixture before the machine is shipped from the factory. This is performed with all axes set at the 0-degree position. A zero-position mark (witness mark) is attached to each robot axis. This mastering is performed with all axes aligned to their respective witness marks. This is performed at a user-specified position. The corresponding count value is obtained from the rotation speed of the Pulsecoder connected to the relevant motor and the rotation angle within one rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will not be lost. (All axes at the same time) This is performed at a user-specified position for one axis. The corresponding count value is obtained from the rotation speed of the Pulsecoder connected to the relevant motor and the rotation angle within one rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will not be lost. This is performed for one axis at a time. The mastering position for each axis can be specified by the user. This is useful in performing mastering on a specific axis. Mastering data is entered directly.
This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during replacement of parts. For other mastering methods, refer to OPERATOR'S MANUAL. Once mastering has been performed, positioning (calibration) is necessary. Positioning is an operation which recognizes the current robot position based on the newly mastered robot pulse counts.
CAUTION
1 If mastering is performed incorrectly, the robot may behave unexpectedly. This is very dangerous. For the reason, the Master/Cal screen is designed to appear only when the $MASTER_ENB system variable is 1 or 2. After performing positioning, press the F5 ([DONE]) on the Master/Cal screen. The $MASTER_ENB system variable is reset to 0 automatically. And the Master/Cal screen will disappear. 2 Before performing mastering, it is recommended that you back up the current mastering data. 3 When the motion range is mechanically 360 degrees or more, if J1/J4 axis to which the cables are connected is turned one turn in the correct mastering position, the cables in the mechanical unit are damaged. If the correct rotation position is not clear because the axis is moved too much during mastering, remove the connector panel or cover, check the states of the internal cables, and perform mastering in the correct position. For the checking procedure, see Fig. 6.2.1 (a) and (b).
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6. ADJUSTMENT
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Gasket ガスケット A290-7226-X209
A290-7226-X209
J1 connector pane J1分線盤 Hexagon bolt ボルト M5M5X14 x 14 (9)(9) Spec.: A97L-0318-0450#051410S
Checkの時 that the cables are J1=0 ケーブルが捻れていないことを not twisted with the 確認してください。 J1-axis placed in 0º v
Fig. 6.2.1 (a) Check the cables (J1-axis)
六角ステンレスボルト Hexagon bolt M5X14 (6) M5 x 14 (6) Spec.: A97L-0318-0450#051410S
Check that the cables are J4=0°の時 not twisted with the ケーブルが捻れていないことを 確認してください。 J4-axis placed in 0º
Gasket ガスケット A290-7226-X424 A290-7226-X424
Fig. 6.2.1 (b) Check the cables (J4-axis)
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6. ADJUSTMENT
6.2.2
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RESETTING ALARMS AND PREPARING FOR MASTERING
Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and display the positioning menu.
Alar m di spl ayed “SRVO-062 BZAL” or “SRVO-075 Pulse not established”
Procedure 1
Display the positioning menu by following the steps 1 to 6. 1 Press the [MENU] key. 2 Press [0 NEXT] and select [6 SYSTEM]. 3 Press the F1 ([TYPE]), and select [Variable] from the menu. 4 Place the cursor on $MASTER_ENB, then key in “1” and press the [ENTER] key. 5 Press the F1 ([TYPE]), and select [Master/Cal] from the menu. 6 Select the desired mastering type from the [Master/Cal] menu.
2
To reset the “SRVO-062 BZAL” alarm, follow steps 1 to 5. 1 Press the [MENU] key. 2 Press [0 NEXT] and select [6 SYSTEM]. 3 Press the F1 ([TYPE]), and select [Master/Cal] from the menu. 4 Place the cursor on the F3 ([RES_PCA]), then press the F4 ([YES]). 5 Cycle power of the controller.
3
To reset the “SRVO-075 Pulse not established” alarm, follow the steps 1 to 2. 1 After cycling controller power, the message “SRVO-075 Pulse not established” appears again. 2 Move the axis for which the message mentioned above has appeared in either direction till the alarm disappears when you press the [RESET] key.
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6. ADJUSTMENT
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6.2.3
FIXTURE POSITION MASTERING
Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the predetermined fixture position. Fixture position mastering is accurate because a dedicated mastering fixture is used. When mastering the robot, arrange the robot to meet the following conditions. Make the robot mounting base horizontal. (The overall levelness of the robot mounting surface shall be 1 mm or less.) Remove the tooling and other parts from the wrist. Make sure no external forces are exerted on the robot.
As A s s emb li ng t he f i x t ur e bas e 1
Assemble the fixture base as shown in Fig. 6.2.3 (a), (b). 治具プレートA Fixture plate A A290-7226-X912 A290-7226-X912
Fixture plate B 治具プレートB A290-7226-X913 A290-7226-X913
Base plate ベースプレート A290-7226-X9111 A290-7226-X911 A290-7226-X91
ボルト Bolt M5X16 M5 x 16 (2) (2)
Bolt ボルト M5 x 16 (2) (2) M5X16
Fig. 6.2.3 6.2.3 (a) (a) Assembling t he base side fixt ure base ブラケット Bracket A290-7226-X908 A290-7226-X908
Bracket plate A ブラケットプレートA A290-7226-X909 A290-7226-X909
Bolt ボルト M5X16 M5 x 16(2) (2)
Bracket plate B ブラケットプレートB A290-7226-X910 A290-7226-X910
Fig. 6.2.3 (b) Assembling the wrist side fixture base
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Bolt ボルト M5 x 16 (2) M5X16 (2)
6. ADJUSTMENT 2
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Adjust the dial gauge to 3.00 mm using the calibration block, and tighten it with M5 bolt as shown in Fig. 6.2.3 (c). (Do not tighten the bolt too strongly or the dial gauge might break.)
C B
A
ボルト Bolt M5X16 (6) M5 x 16 (6) プレート Plate
Dial gauge ダイヤルゲージ (All dial gauge indicate 3mm in calibration.) (全てのダイヤルゲージが較正ブロック突き当て時に
目盛りの読みが3mmになるよう調整)
Assembling method of the dial gauge ダイヤルゲージの組付け方
E m m 0 2
Bolt M5 ボルトM5 Clamp クランプ Calibration 較正ブロック block
F D
Fig. 6.2.3 6.2.3 (c) (c) Mountin g dial g auges
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6. ADJUSTMENT
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3
Assemble the fixture base on the J1 base as shown in Fig. 6.2.3 (d). hen hen assembling pin A290-7226-X915, pay attention to the direction of the pin refer to Fig. 6.2.3 (d). Pin ピン A290-7226-X914 A290-7226-X914
ダイヤピン Diamond locating pin A290-7226-X915 A290-7226-X915 A290-7226-X91 5 Bolt ボルト M10 x 20 (2) M10X20 (2)
ピン A290-7226-X915 A290 -7226-X915 Assembling method of the pinの組み付け A290-7226-X915 A290-7226-X915
ロボット正面 Robot front
Assemble the pins to ピンの面取部と show ロボット正面の位置関係 the position of chamfered が図のようになるように part of pin and robot front in ピンを組み付けること this figure
Fig. 6.2.3 6.2.3 (d) (d) Assemblin g th e fixtu re base
4
Assemble the fixture to the wrist flange as shown in Fig. 6.2.3 (e).
Face for dial gauge ダイヤルゲージCを C 当てる面
ダイヤルゲージD,E,Fを Face for dial gauge D, E and F 当てる面 Pin ピン A290-7022-X965 A290-7022-X965
ボルト Bolt M6X16 (4) M6 x 16 (4) Face for dial gauge ダイヤルゲージA,Bを A and B 当てる面
Fig. 6.2.3 (e) Assembling the fixture to the wrist flange
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6. ADJUSTMENT
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Mastering 1 2 3 4
Press the [MENU] key to show screen menu. Press [0 NEXT] and select [6 SYSTEM]. Press F1 [TYPE] to show screen switch menu. Select Master/Cal. Master/Cal scree will be displayed. SYSTEM Master/Cal
AUTO JOINT 10 % TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Press 'ENTER' or number key to select. [ TYPE ] LOAD
5
RES_PCA
DONE
Release brake control, and jog the robot into a posture for mastering. A to E (see Fig. 6.2.3 (e)) of the fixture attached to the wrist are dial gauges A to E (see Fig. 6.2.3 (c)) and make adjustments so that dial gauges A to E indicate 3 mm. A posture as shown in Fig. 6.2.3(f) should be taken. See this figure for reference.
NOTE
Brake control can be released by setting the system variables as follows: $PARAM_GROUP.$SV_OFF_ALL : FALSE $PARAM_GROUP.$SV_OFF_ENB[*] : FALSE (for all axes) After changing the system variables, switch the controller power off and on again. 6
Select “1 FIXTURE POSITION MASTER” and Press F4, YES. "MASTER POSITION" shown in Fig. 6.2.3 (f) is set at this position. SYSTEM Master/Cal
AUTO JOINT 10 % TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <12200039> <2000319> [ TYPE ] LOAD RES_PCA DONE
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6. ADJUSTMENT
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7
Select “7 CALIBRATE“ and press F4 [YES]. Position arrangement will be performed Alternatively, cycle power of the controller to perform position arrangement. SYSTEM Master/Cal
AUTO JOINT 10 % TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <0.000><45.035><-105.024> <0.000><-74.976><0.000>
8
After positioning is completed, press F5 [DONE]. DONE
F5
CAUTION
No check is made on the axis movable range during mastering. Be very careful when operating the robot. Continuing axis movement may bump into the mechanical stopper. 9
Return brake control to the original setting, and cycle power of the controller.
Mastering posture マスタリング姿勢
J1 0.000° J2 45.035° J3 -105.024° J4 0.000° J5 -74.976° J6 0.000°
Fig. 6.2.3 (f) Mastering post ure
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6. ADJUSTMENT
6.2.4 1
2
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VERIFY MASTERING
How to verify that the robot is mastered properly: Usually, positioning is performed automatically when the power is turned on. To check whether mastering has been performed correctly, examine if the current displayed position matches the actual robot position by using one or more of the procedures described below: (1) Reproduce a particular point in a program. Check whether the point agrees with the specified position. (2) Set all axes of the robot to their 0-degree (0 rad) positions. Check that the zero-degree position marks indicated in MASTERING chapter of the OPERATOR’S MANUAL are aligned. There is no need to use a visual aid. (3) Using fixtures, set the robot to the mastering position in the same way as when performing mastering. Check that the displayed current position agrees with the actual mastering position. If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been invalidated as a result of an alarm described in 2. Alternatively, the mastering data in system variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation error or some other reason. Compare the data with the values indicated on the supplied data sheet. This system variable is overwritten whenever mastering is performed. Whenever mastering is performed, record the value of the system variable on the data sheet. Alarm types displayed during mastering and their solution method: (1) BZAL alarm This alarm is displayed if the Pulsecoder's backup battery voltage decreases to 0 V while the power to the controller is disconnected. Furthermore, if the Pulsecoder connector is removed for cable replacement, etc. this alarm is displayed as the voltage decreases to 0. Check to see if the alarm will disappear by performing a pulse reset (See Section 6.2.2.). Then, cycle controller power and check if the alarm disappears or not. The battery may be drained if the alarm is still displayed. Perform a pulse reset, and turn off and on the controller power after replacing the battery. Note that, if this alarm is displayed, all the original data held by the Pulsecoder will be lost. Mastering is required. (2) BLAL alarm This alarm is displayed if the voltage of the Pulsecoder's backup battery has fallen to a level where backup is no longer possible. If this alarm is displayed, replace the battery with a new one immediately while keeping the power turned on. Check whether the current position data is valid, using the procedure described in 1. (3) Alarm notifications like CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL may indicate trouble with Pulsecoder; contact your local FANUC representative.
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APPENDIX
APPENDIX
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A
A. MAINTENANCE PARTS
MAINTENANCE PARTS Table A (a) Cables Parts name
Specificatio ns
K102 K103 K104 K105 K106 K107 K108 K109 K111 K112 K113 K114 K116 K117 K118 K121 K123
A660-2008-T022 A660-4005-T614 A660-4005-T615 A660-4005-T616 A660-4005-T617 A660-4005-T618 A660-4005-T619 A660-8019-T904 A05B-1226-D001 A660-2008-T023 A660-8019-T906 A660-8019-T907 A05B-1226-D002 A660-2008-T024 A05B-1226-D003 A660-8020-T003 A660-8020-T294
Remarks J3 power J4 power J3/J4 Pulsecoder J5/J6 power J5/J6 Pulsecoder EE24P EE18P+SV J1 ASi J1 camera J1 Ethernet J1 sensor J3 ASi J3 camera J3 Ethernet J3 sensor Earth for J1 camera RMP
Table A (b) Motor Parts name αiS8/6000 αiS12/4000 αiS4/5000 βiSR1/6000 βiSR0.5/6000
Specificatio ns A06B-2232-B605 A06B-2238-B605 A06B-2215-B605 A06B-0116-B855#0048 A06B-0115-B855#0048
Remarks J1-axis J2-axis J3-axis J4/J6-axis J5-axis
Table A (c) Reducer Specifications
Remarks
A97L-0318-0223#120C-37 A97L-0318-0224#125N-146 A97L-0318-0225#42N-141 A97L-0318-0226#50 A97L-0318-0227#80 A97L-0318-0228#50
J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis
NOTE When arranging in the reducer machine unit, the waving generator is built into the main body of the reducer machine beforehand as for J4-axis reducer. As for J5/J6 reducers, the waving generator is separated from the main body of the reducer machine.
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A. MAINTENANCE PARTS
APPENDIX
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Table A (d) Gear Parts name Gear J1-1 Gear J1-2 Gear J2-1 Draw nut Gear J3-1 Draw nut GearJ4-1
Specificatio ns
Remarks
A290-7226-X204 A290-7226-X205 A290-7226-X310 A290-7221-X321 A290-7226-X311 A290-7226-X312 A290-7226-X409
J1-axis input gear J1-axis center gear J2-axis input gear J2-axis motor J3-axis input gear J3-axis motor J4-axis input gear Table A (e) Bearing
Parts name Bearing Bearing Bearing
Specificatio ns
Remarks
A97L-0001-0192#1600000 A97L-0001-0192#32Z000A A97L-0001-0195#0700000
J1-axis reducer J2/J3 support 2 pcs/per 1 robot J1-axis motor
Table A (f) Pulley, key Parts name Pulley J5-1 Pulley J5-2 Pulley J6-1 Pulley J6-2 Key
Specificatio ns
Remarks
A290-7226-X410 A290-7226-X411 A290-7226-X412 A290-7226-X413 A97L-0118-0402#3X3X12BN
J5-axis motor J5-axis belt J5-axis motor J6-axis belt J5/J6-axis motor 2 pcs/per 1 robot
Table A (g) Belt Parts name Belt Belt
Specificatio ns
Remarks
A98L-0040-0312#007-100 A98L-0040-0312#009-155
J5-axis J6-axis
Table A (h) Gasket Parts name Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket
Specificatio ns
Remarks
A290-7226-X209 A290-7226-X210 A290-7226-X313 A290-7226-X314 A290-7226-X315 A290-7226-X316 A290-7226-X317 A290-7226-X318 A290-7226-X424 A290-7226-X425 A290-7226-X426 A290-7226-X427 A290-7226-X428 A290-7226-X429 A290-7226-X436 A290-7226-X438 A290-7226-X451
J1 base J1 base J2 base J2 base J2 arm J2 arm J2/J3 shaft 2 pcs/per 1 robot J2 arm J3 casing J3 arm J3 arm 2 pcs/per 1 robot J3 arm J3 arm J3 arm (When A05B-1226-H203,H253 are specified) (When A05B-1226-H002,H003,H004 are specified) (When A05B-1226-H501 is specified) Table A (i) Sponge
Parts name Sponge Gasket
Specificatio ns
Remarks
A290-7226-X452 A290-7226-X454
2 pcs/per 1 robot (When A05B-1226-H502 is specified) (When A05B-1226-H002,H003,H004 is specified)
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B-83755EN/01
A. MAINTENANCE PARTS
APPENDIX Table A (j) O-ring
Parts name O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring
Specificatio ns A98L-0001-0347#S48 A98L-0040-0041#259 A98L-0040-0041#268 JB-OR1A-G80 JB-OR1A-G105 JB-OR1A-G115 JB-OR1A-G125 JB-OR1A-G130 JB-OR1A-G145 JB-OR1A-G180 JB-OR1A-G200
Remarks J4-axis motor J2-axis motor J1-axis reducer J1-axis motor J3-axis reducer J4-axis reducer J3-axis motor J3-axis reducer J2/J3-axis reducer 2 pcs/per 1 robot J1-axis reducer J2-axis reducer
Table A (k) Seal bolt Parts name
Specificatio ns
Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt
A97L-0218-0423#030606 A97L-0218-0423#030808 A97L-0218-0423#051616 A97L-0218-0423#061414 A97L-0218-0423#082216 A97L-0218-0546#052016BC A97L-0318-0410#051010S
Seal bolt
A97L-0318-0410#081010S
Remarks 3 pcs/per 1 robot 2 pcs/per 1 robot 8 pcs/per 1 robot 4 pcs/per 1 robot 7 pcs/per 1 robot 6 pcs/per 1 robot J5/J6-axis reducer grease inlet 2 pcs/per 1 robot J1/J2/J3-axis reducer grease inlet 3 pcs/per 1 robot
Table A (l) Plated bolt Parts name Plated bolt Plated bolt
Specificatio ns A97L-0218-0496#M10X45BC A97L-0218-0496#M5X40BC
Remarks 2 pcs/per 1 robot 24 pcs/per 1 robot
Table A (m) Flange bolt, washer bol t Parts name Flange bolt Flange bolt Washer bolt Washer bolt Washer bolt Washer bolt
Specificatio ns A97L-0218-0504#M5X20 A97L-0218-0504#M4X16 A97L-0318-0409#M4X10S A97L-0318-0450#051410S A97L-0318-0450#052510S A97L-0318-0450#055010S
Remarks 4 pcs/per 1 robot 12 pcs/per 1 robot 4 pcs/per 1 robot 77 pcs/per 1 robot 11 pcs/per 1 robot
Table A (n) Washer Parts name Washer Washer Washer Washer Washer Washer Washer Washer Washer Washer Washer
Specificatio ns A290-7142-X203 A290-7226-X208 A290-7226-X328 A290-7226-X329 A290-7226-X336 A290-7226-X338 A290-7226-X339 A290-7226-X414 A290-7226-X446 A290-7226-X447 A97L-0142-0471#16
Remarks J4-axis motor J1-axis motor J2-axis reducer 2 pcs/per 1 robot J2-axis reducer J3-axis reducer J1-axis reducer J1-axis reducer 2 pcs/per 1 robot J5/J6-axis motor 2 pcs/per 1 robot J4-axis reducer 3 pcs/per 1 robot J4-axis reducer J1 base 4 pcs/per 1 robot
- 99 -
A. MAINTENANCE PARTS
APPENDIX
B-83755EN/01
Table A (o) Seal w asher Parts name Seal washer Seas washer
Specificatio ns
Remarks
A97L-0218-0427#1220 A97L-0218-0427#1420
(When A05B-1226-H202,H203,H252,H253 is specified) 2 pcs/per 1 robot Table A (p) Pin
Parts name Pin Pin Pin Pin Pin Pin
Specificatio ns
Remarks
A290-7226-X340 A290-7226-X341 A290-7226-X342 A290-7226-X343 A290-7226-X344 JB-PH-H7A-12X30S45C
J1-axis reducer J2-axis reducer J2-axis reducer J3-axis reducer J3-axis reducer J3 stopper base
Table A (q) Spring pi n, stopper, wrist unit, sheet Parts name
Specificatio ns
Spring pin Stopper A
A6-PS-4X10S A290-7226-X206
Stopper
A290-7226-X234
Stopper B Stopper A Stopper B Stopper A Stopper B Stopper C Wrist unit
A290-7226-X235 A290-7226-X330 A290-7226-X346 A290-7226-X423 A290-7226-X431 A290-7226-X441 A290-7226-V501 A290-7226-X227 A290-7226-X333 A290-7226-X430 A290-7226-X332 A290-7226-X335 A290-7226-X449
Sheet Sheet Sheet Sheet
Remarks J2 arm cover R J1 stopper J1 adjustable stopper (When A05B-1226-H053 is specified) J1 stopper J2 stopper floor side J2 stopper rear side J3 stopper base J3 stopper plate J3 stopper rubber Including J5/J6-axis reducer J1-axis motor J2armcoverL J3arm For J2-axis cable protection For J2 arm cable protection For J3-axis cable protection Table A (r) Air tu be
Parts name
Specificatio ns
Remarks
Air tube
A97L-0218-0010#ACL4R003
Air tube
A97L-0218-0010#BCL4R003
Air tube
A97L-0218-0010#BBL4R003
Air tube
A97L-0218-0010#CCL4R003
8mm BLACK AIR1 8mm WHITE AIR2 (When A05B-1226-H201,H251 are specified) 6mm WHITE (When A05B-1226-H202,H203,H252,H253 are specified) 8mm RED (When A05B-1226-H202,H203,H252,H253 are specified)
Table A (s) Join t Parts name Joint Joint
Specificatio ns A97L-0142-0214#KQ2L0800 A97L-0142-0214#L0800X35
Remarks AIR 2 AIR 1
- 100 -
A. MAINTENANCE PARTS
APPENDIX
B-83755EN/01
Table A (t) Soleno id valve
(Either the following is installed by the option specification) (except H001) Parts name Solenoid valve Solenoid valve Solenoid valve
Specificati ons A97L-0218-0137#D1 A97L-0218-0137#D2 A97L-0218-0137#D3
Remarks Double solenoid x1 (2 position x 1) Double solenoid x 2 (2 position x 2) Double solenoid x 3 (2 position x 3)
Table A (u) Battery Parts name Battery
Specificati ons A98L-0031-0005
Remarks D battery/1.5V alkali
4pcs/ per 1 robot
Table A (v) Grease Parts name
Specificati ons
Remarks
Grease
A98L-0040-0174#16KG
Kyodo Yushi VIGOGREASE RE0 (J1/J2/J3-axis)
Grease Greasing kit Grease in tube
A98L-0040-0230 A05B-1226-K031 A05B-1139-K022
Harmonic grease 4BNo.2 (J4/J5/J6-axis)
- 101 -
B. MECHANICAL UNIT CIRCUIT DIAGRAM AND AIR PRESSURE DIAGRAM
B
APPENDIX
B-83755EN/01
MECHANICAL UNIT CIRCUIT DIAGRAM AND AIR PRESSURE DIAGRAM JC-VCTF-2X0.5SQ (0.5SQ*2C) φ5.8
GB2 B1 B2
(0V(BT1-BT6))
A63L-0002-0066#R04DX A63L-0002-0066#CRM A1 (6V(BT1-BT6)) A2
( D-1200 X-KEY ) A63L-0001-0648#81810SB A63L-0001-0653#10A2C
J1 MOTOR (αiS8/6000-B) M1M
A66L-0001-0401#10 (1.25SQ*10C) φ9.5
A J1U1 B J1V1 A63L-0002-0128#810SL3SJ A63L-0001-0653#04AC
M1BK A
A63L-0001-0848#E10SL1 A63L-0001-0850
BK(J1) C B BKC(J1)
M1P 8 5V(J1) 9 10 0V(J1)
A66L-0001-0464#1 (0.2SQ*4P+DRAIN) φ6.7
A66L-0001-0401#10 (1.25SQ*10C) φ9.5
D J1G1 C J1W1
A63L-0001-0648#81810SB A63L-0001-0653#10A2C
4 6V(BT1) 5 XPRQJ1 6 PRQJ1 7 0V(BT1)
1 (24VF(F1)) 2 (0V(F1)) 3 FG
J2 MOTOR (αiS12/4000-B) M2M A J2U1 B J2V1
A63L-0002-0128#810SL3SJ A63L-0001-0653#04AC
D J2G1 C J2W1
M2BK A
A63L-0001-0848#E10SL1 A63L-0001-0850
BK(J2) C B BKC(J2)
M2P 8 5V(J2) 9 10 0V(J2)
A66L-0001-0464#1 (0.2SQ*4P+DRAIN) φ6.7
4 6V(BT2) 5 XPRQJ2 6 PRQJ2 7 0V(BT2)
1 (24VF(F2)) 2 (0V(F2)) 3 FG
BATTERY
RMP 1 2 3 4 5 6
BK(J1) J1U1 J1V1 J1W1 J1G1 XROT
7 RI1 8 9 10 11 12
RO1 RI7 5V(J1,J2) PRQJ1 XPRQJ1
13 14 15 16 17 18
BK(J2) J2U1 J2V1 J2W1 J2G1 24VF(OT,A1-A4 F1-F3)
19 RI2 20 21 22 23 24
RO2 RI8 5V(J3,J4) PRQJ2 XPRQJ2
6V (BT1,BT2,BT3, BT4,BT5,BT6)
+
J1 CONNECTOR PANEL 25 26 27 28 29 30
BK(J3) J3U1 J3V1 J3W1 J3G1 XHBK
31 RI3
37 38 39 40 41 42
BK(J4) J4U1 J4V1 J4W1 J4G1
43 RI4
49 50 51 52 53 54
BK(J5) J5U1 J5V1 J5W1 J5G1
55 RI5
61 62 63 64 65 66
Han 72DD (2.5SQ 10A) BK(J6) BKC(J1-J6) J6U1 J6V1 J6W1 J6G1
67 0V(A1,A2,B1-B6 F1-F3) 32 RO3 44 RO4 56 RO5 68 RI6 33 RO7 45 RO8 57 RI9(XPPABN) 69 RO6 34 5V(J5,J6) 46 0V(J1,J2) 58 0V(J3,J4) 70 0V(J5,J6) 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6 G FG
JC-VCTF-2X0.5SQ (0.5SQ*2C) φ5.8
( -
K123 A660-8020-T294 A66L-0001-0401#14 (1.25SQ*14C) φ9.5
A63L-0001-0460#062KMXX A63L-0001-0456#ASL
単一電池 SIZE D
M3M1 A1 J3U1 A2 BK(J3) A3 J3W1
(
D-3200 XX-KEY
)
0V (BT1,BT2,BT3, BT4,BT5,BT6)
062KMFXX ASLT,ASNT B1 J3G1 B2 J3V1 B3 BKC(J3)
)
A63L-0001-0812#R06DX A63L-0001-0812#CRM
M4M1 A1 J4U1 A2 BK(J4) A3 J4W1
F06DX CTM,CTS B1 J4G1 B2 J4V1 B3 BKC(J4)
( D-2100 X-KEY ) A66L-0001-0574 (0.2SQ*6P+DRAIN) φ7.7
A63L-0002-0066#R12DX A63L-0002-0066#CRM A63L-0002-0066#CR2L
F12DX CTM,CT2L A1 PRQJ3 B1 XPRQJ3 A2 6V(BT3,BT4) B2 0V(BT3,BT4) A3 PQRJ4 B3 XPRQJ4 A4 5V(J3,J4) B4 0V(J3,J4) A5 24VF(F3) B5 0V(F3) A6 B6 FG
M34P
( D-1200 X-KEY )
A66L-0001-0591*3 (0.2SQ*2C+0.3SQ*4C) φ7.7
A63L-0001-0875#SC
1 2 3 4 5 6
K102 A660-2008-T022
A66L-0001-0591 (0.2SQ*2C+0.3SQ*4C) φ7.7
A63L-0001-0848#E10SL1 A63L-0001-0850
J3U1 J3V1 J3W1 J3G1 BK(J3) BKC(J3)
M3P 8 5V(J3) 9 10 0V(J3)
K103 A660-4005-T614
A63L-0001-0865#1 A63L-0001-0864#CS A66L-0001-0574 (0.2SQ*6P+DRAIN) φ7.7
K104 A660-4005-T615
J3 MOTOR (αiS4/5000-B) M3M
A66L-0001-0591*2 (0.2SQ*2C+0.3SQ*4C) φ7.7
A63L-0001-0812#R12DX A63L-0001-0812#CRM A63L-0001-0812#CRS
M56M
( D-2100 X-KEY )
A66L-0001-0574 (0.2SQ*6P+DRAIN) φ7.7
A63L-0002-0066#R12DY A63L-0002-0066#CRM A63L-0002-0066#CR2L
A63L-0001-0812#R12DY A63L-0001-0812#CRS
A63L-0001-0812#R12DZ A63L-0001-0812#CRS
(
A1 PRQJ5 A2 6V(BT5,BT6) A3 PQRJ6 A4 5V(J5,J6) A5 A6
B1 B2 B3 B4 B5 B6
EE-A
( D-2100 Y-KEY )
D-2100 Z-KEY
J5U1 BK(J5) J5W1 J6U1 BK(J6) J6W1
M56P
( D-1200 Y-KEY )
A66L-0001-0459 (0.2SQ*24C) φ8.3
A1 A2 A3 A4 A5 A6
F12DX CTM B1 J5G1 B2 J5V1 B3 BKC(J5) B4 J6G1 B5 J6V1 B6 BKC(J6)
A1 A2 A3 A4 A5 A6
RI1 RI2 RI3 RI4 RI5 RI6
B1 B2 B3 B4 B5 B6
)
RO3 RO4 RO5 RO6 RO7 RO8
A66L-0001-0591 (0.2SQ*2C+0.3SQ*4C) φ7.7
A66L-0001-0574 (0.2SQ*6P+DRAIN) φ7.7
0V(BT5,BT6)
XPRQJ6 0V(J5,J6)
F12DY CTS RI7 RI8 XPPABN XHBK RO1 RO2
K106 A660-4005-T617
A66L-0001-0459 (0.2SQ*24C) φ8.3
F12DZ CTS
EE-B A1 A2 A3 A4 A5 A6
K105 A660-4005-T616
F12DY CTM,CT2L XPQRJ5
FG
B1 B2 B3 B4 B5 B6
0V(A1,B1-B3) 0V(A2,B4-B6)
24VF(A1) 24VF(A2) 24VF(A3) 24VF(A4)
Fig. B (a) Circuit diagram of mechanical unit (Standard cable)
- 102 -
M4P 8 5V(J4) 9 10 0V(J4)
A66L-0001-0591 (0.2SQ*2C+0.3SQ*4C) φ7.7
1 J4U1 4 J4G1
M4BK 2 BK(J4) 3
A63L-0001-0848#E10SL1 A63L-0001-0850
1 (24VF(F3)) 2 (0V(F3)) 3 FG
J4 MOTOR (βiSR1/6000) M4M 2 J4V1 3 J4W1
A63L-0001-0865#2 A63L-0001-0864#CS
4 6V(BT3) 5 XPRQJ3 6 PRQJ3 7 0V(BT3)
1 BKC(J4) 4
4 6V(BT4) 5 XPRQJ4 6 PRQJ4 7 0V(BT4)
1 2 3 FG
B. MECHANICAL UNIT CIRCUIT DIAGRAM AND AIR PRESSURE DIAGRAM
APPENDIX
B-83755EN/01
A63L-0001-0865#1 A63L-0001-0864#CS
J5 MOTOR (βiSR0.5/6000) M5M 2 J5V1 3 J5W1
A63L-0001-0865#2 A63L-0001-0864#CS
M5BK 2 3
A63L-0001-0848#E10SL1 A63L-0001-0850
BK(J5)
M5P 8 5V(J5) 9 10 0V(J5)
A63L-0001-0865#1 A63L-0001-0864#CS
4 5 6 7
6V(BT5) XPRQJ5 PRQJ5 0V(BT5)
1 2 3 FG
1 J6U1 4 J6G1
M6BK 2 3
A63L-0001-0848#E10SL1 A63L-0001-0850
1 BKC(J5) 4
J6 MOTOR (βiSR1/6000) M6M 2 J6V1 3 J6W1
A63L-0001-0865#2 A63L-0001-0864#CS
1 J5U1 4 J5G1
BK(J6)
M6P 8 5V(J6) 9 10 0V(J6)
1 BKC(J6) 4
4 5 6 7
6V(BT6) XPRQJ6 PRQJ6 0V(BT6)
1 2 3 FG
A05B-1226-H201,H251
K107 A660-4005-T618
J3 CONNECTOR PANEL EE A63L-0002-0210#25WR24S 4 RI4 3 RI3 2 RI2 1 RI1 9 XPPABN 8 RI8 7 RI7 6 RI6 5 RI5 15 RO5 14 RO4 13 RO3 12 RO2 11 RO1 10 XHBK 20 0V(A2) 19 0V(A1) 18 RO8 17 RO7 16 RO6 24 24VF(A4) 23 24VF(A3) 22 24VF(A2) 21 24VF(A1)
A05B-1226-H202,H203,H252,H253 J3 CONNECTOR PANEL K108 A660-4005-T619 10 XHBK 16
4 RI4 9 XPPABN 15 20 24VF(A4)
A63L-0001-0509#200S 3 RI3 2 RI2 1 RI1 8 RI8 7 RI7 6 RI6 5 RI5 14 0V(A2) 13 0V(A1) 12 RO8 11 RO7 19 24VF(A3) 18 24VF(A2) 17 24VF(A1)
A05B-1226-H002 A63L-0002-0205#13SB A63L-0002-0205#2428SCFA 1 R01 2 RO2 3 R03 4 RO4 5 RO5 6 RO6 7 8 0 V(B 1) 9 0V( B2) 10 0V(B3) 11 0V(B4) 12 0V(B5) 13 0V(B6)
YV
13PB 2428PCFA
YV 3 7 11
2 RO2 6 10 13
1 R01 5 4 9 0V(B2) 8 0V(B1) 12
SOLENOID VALVE A97L-0218-0137#D1
A05B-1226-H003 YV
13PB 2428PCFA
3 R03 2 RO2 1 R01 7 6 5 4 RO4 11 0V(B4) 10 0V(B3) 9 0V(B2) 8 0V(B1) 13 12
SOLENOID VALVE A97L-0218-0137#D2
A05B-1226-H004 YV
13PB 2428PCFA
3 R03 2 RO2 1 R01 7 6 RO6 5 RO5 4 RO4 11 0V(B4) 10 0V(B3) 9 0V(B2) 8 0V(B1) 13 0V (B6) 12 0V( B5)
- 103 -
SOLENOID VALVE A97L-0218-0137#D3
B. MECHANICAL UNIT CIRCUIT DIAGRAM AND AIR PRESSURE DIAGRAM
APPENDIX
J1 CONNECTOR PANEL ASi1 MS3102A20-27PY J S10 I S9 H
S8
A K
S11
M
S13
N S14 G S7
ASi-A
A63L-0001-0812#R20DX A63L-0001-0812#CRS
A1 A2 A3 A4 A5 A6 A7 A8 A9
S1 B
S2
D
S4
L S12
F S6
A66L-0001-0464#2 (0.2SQ*8P+DRAIN) φ8.7
C S3 K109 A660-8019-T904
E S5
( D-2100 X-KEY )
S1 S3 S5 S7 S9 S11 S13
B1 B2 B3 B4 B5 B6 B7 B8 B9
DRAIN
A10
B-83755EN/01
J3 CONNECTOR PANEL
F20DX CTS S2 S4 S6 S8 S10 S12 S14
ASi2
A66L-0001-0464#2 (0.2SQ*8P+DRAIN) φ8.7
11 12 13 14 15 16
17 18 19 20
K114 A660-8019-T907
A63L-0002-0072#20SN S11 5 S5 S12 6 S6 S13 7 S7 S14 8 S8 9 S9 DRAIN 10 S10
1 2 3 4
S1 S2 S3 S4
B10
Fig. B (b) Circu it di agram for mechanic al unit cables (user cable (ASi)
J1 CONNECTOR PANEL CAM1 A63L-0001-0098#13R-11P D LED+ C LED4 GND(VIDEO) 3 TRG 7 VIDEO 6
K111 A0 5B-1 22 6-D0 01 A66L-0001-0676 (0.08SQ*4C+0.25SQ*4C) φ8.0
CAM-A
A63 L-00 02 -00 66 #R 20 DX A63L-0002-0066#CRL
B 12V A 0V 2 GND(VD,TRG) 1 VD GND(HD) 5 HD
( D-1200 X-KEY ) K121 A660-8020-T003
A1 A2 A3 A4 A5 A6 A7 A8 A9
B1 0V B2 GND(VD) B3 GND(TRG) B4 12V B5 GND(HD) B6 B7 B8 DRAIN B9 GND(VIDEO)
A10
F20DX CTL VIDEO LED VD TRG LED+ HD
J3 CONNECTOR PANEL A66L-0001-0676 (0.08SQ*4C+0.25SQ*4C) φ8.0
CAM2
A63L-0002-0098#13RB-11S
A 0V 1 VD
K116 A05B-1226-D002
B 2
12V
C LEDD LED+ 3 TRG 4 GND(VIDEO) 7 VIDEO GND(HD)
GND(VD,TRG)
5 HD
6
B10
Fig. B (c) Circuit d iagram for mechanical un it cabl es (Camera cable (CAM))
J3 CONNECTOR PANEL
J1 CONNECTOR PANEL A66L-0001-0575 (0.15SQ*4P+DRAIN) φ6.5
A63L-0002-0113#F A63L-0002-0113#CA7476
EN1
2 RXD+ 1 TXD+
3 TXD4 RXD-
A63L-0002-0066#R08DX A63L-0002-0066#CRM
K112 A660-2008-T023
EN-A (
D-1200 X-KEY
)
A1 TXD+ A2 RXDA3 DRAIN,SHIELD A4
F08DX CTLM B1 RXD+ B2 TXDB3 B4
A66L-0001-0575 (0.15SQ*4P+DRAIN) φ6.5
A63L-0002-0113#F A63L-0002-0113#CA7476
EN2
2 RXD+ 1 TXD+
K117 A660-2008-T024
3 TXD4 RXD-
Fig. B (d) Circu it di agram for mechanic al unit cables (Ethernet cable (EN))
J3 CONNECTOR PANEL J1 CONNECTOR PANEL SEN A63L-0001-0453#10A0301 A63L-0001-0453#15DM A63L-0001-0453#CA6103 A63L-0001-0453#CA6104 A63L-0001-0453#A-9908 A63L-0001-0453#A-9909
A1 A2 A3 A4 A5
0V(3DL) 0V(3DL) LON1 (LED-) (LED+B)
B1 B2 B3 B4 B5 G
24V(3DL) LON2 (LED+A) (LED+C) DRAIN
C1 C2 C3 C4 C5
24V(FS) 0V(FS) TX1 TX2 (LED+D)
A66L-0001-0400#1*2 (0.3SQ*3P+0.2SQ*2P+DRAIN) φ6.2
K113 A660-8019-T906
A63L-0002-0066#R20DY A63L-0002-0066#CR2L A63L-0002-0066#CRM
( D-1200 Y-KEY )
F20DY CT2L CTM A1 (LED+A) B1 (LED-) A2 (LED+C) B2 (LED+B) A3 24V(3DL) B3 (LED+D) A4 LON2 B4 LON1 A5 0V(3DL) B5 0V(3DL) A6 DRAIN(A) B6 A7 B7 A8 2 4V ( FS ) B 8 0V(FS) A9 TX1 B9 TX2 A10 DRAIN(B) B10
SEN-A
3DL
A63L-0002-0072#12SN
8 24V(3DL) 9 24V(3DL) 1 0V(3DL) 7 DRAIN(A) 12 LON2 10 LON1 2 0V(3DL) 6 (LED+D) 11 (LED+A) 3 (LED-) 5 (LED+C) 4 (LED+B)
A66L-0001-0400#1*2 (0.3SQ*3P+0.2SQ*2P+DRAIN) φ6.2
FS
K118 A05B-1226-D003
A63L-0002-0098#07R-6S 6 5 4
24V(FS)
1 0V(FS) 2 TX2 3 TX1
Fig. B (e) Circuit diagram fo r mechanical u nit cables (Force sensor, 3D Laser Visio n sensor cable (FS, 3DL))
J3 CONNECTOR PANEL CAM2 A63L-0002-0098#13RB-11S A 0V 1 VD 5
B 12V C (LED-) D (LED+) 2 GND(VD,TRG) 3 TRG 4 GND(VIDEO) HD 6 GND(HD) 7 VIDEO
J3 CONNECTOR PANEL CAM2 A63L-0002-0098#13RB-11S A 0V 1 VD 5
B 12V C LEDD LED+ 2 GND(VD,TRG) 3 TRG 4 GND(VIDEO) HD 6 GND(HD) 7 VIDEO
A66L-0001-0676 (0.08SQ*4C+0.25SQ*4C) φ8.0
CAM3
HR10-10R-12P(01) 1 0V
2 12V 10 3 GND(VIDEO) 11 TRG 4 VIDEO 5
K251 A660-2007-T614
A66L-0001-0676 (0.08SQ*4C+0.25SQ*4C) φ8.0
8 GND(TRG) 12 GND(VD) 7 VD GND(HD) 6 HD
CAM3
HR10-10R-12P(01) 1 0V
2 12V 10 3 GND(VIDEO) 11 TRG 4 VIDEO 5
K252 A660-4005-T400
9 TRG
9 TRG 8 GND(TRG) 12 GND(VD) 7 VD GND(HD) 6 HD
LED A63L-0002-0098#07R-3P A66L-0001-0143 (0.2SQ*6C) φ5.3
1 LED+ 2
3 LED-
Fig. B (f) Circu it di agram for mechanic al unit c ables (Hand cable for camera)
- 104 -
B. MECHANICAL UNIT CIRCUIT DIAGRAM AND AIR PRESSURE DIAGRAM
APPENDIX
B-83755EN/01
J3 CONNECTOR PANEL A63L-0001-0888#15L12P A63L-0001-0888#CCA8
3DL
8 24V(3DL) 9 24V(3DL) 1 0V(3DL) 7 DRAIN(A) 12 LON2 10 LON1 2 0V(3DL) 6 (LED+D) 11 (LED+A) 3 (LED-) 5 (LED+C) 4 (LED+B)
A66L-0001-0400#1 (0.3SQ*3P+0.2SQ*2P+DRAIN) φ6.2
3DL3
A63L-0001-0233#10-8
1 LON1 8 2 LON2 9 3 0V(3DL) 10 4 2 4V(3D L) 5
K122 A660-8020-T009
7 2 4V (3 DL ) 6 0V(3DL) DRAI N
Fig. B (g) Circuit diagram for mechanical unit cables (3D Laser Vision sensor cable)
J3 CONNECTOR PANEL FS A63L-0002-0098#07R-6S 6 5 4
24V
1 0V 2 TX2 3 TX1
FORCE SENSOR(6AXES) A66L-0001-0178#03P (0.3SQ*3P+DRAIN)
FS3 A63L-0002-0098#10R-4P 1 0V 2 TX2
SENSOR CABLE A660-2007-T615
4 24V 3 TX1
Fig. B (h) Circuit diagram for mechanical unit cables (Force sensor cable)
J1 connector plate AIR 1
J3 arm
J1 connector plate AIR 2
J3 housing Exhaust port
RO1
RO2
B1
A1
Fig. B (i) Air pr essure diagram (Double solenoid valve x 1 A05B-1226-H002 is specified)
J1 connector plate AIR 1
J3 arm
J1 connector plate AIR 2
J3 housing Exhaust port
RO3 RO1
RO2 RO4
B2
A2
B1
A1
Fig. B (j) Air pr essure diagram (Double solenoid valve x 1 A05B-1226-H003 is specified)
- 105 -
B. MECHANICAL UNIT CIRCUIT DIAGRAM AND AIR PRESSURE DIAGRAM
APPENDIX
B-83755EN/01
J1 connector plate AIR 1
J3 arm
J1 connector plate AIR 2
J3 housing Exhaust port
RO5
RO3 RO1
RO2 RO4
RO6
B3
A3
B2
A2
B1
A1
Fig. B (k) Air pr essure diagram (Double solenoid valve x 3 A05B-1226-H004 is specified)
- 106 -
B-83755EN/01
C
APPENDIX
C. PERIODIC MAINTENANCE TABLE
PERIODIC MAINTENANCE TABLE
- 107 -
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-83755EN/01
FANUC Robo t M-20iB
Working time (H) Items
Periodic Maintenance Table
Check time
Check for external
Oil Grease amount
First
3
6
9
check months months months 320
1
2
year
years
960
1920
2880
3840
4800
5760
6720
7680
8640
9600
10560
1 damage or peeling paint
0.1H
-
○
○
○
○
○
○
○
○
○
○
○
2 Check for water
0.1H
-
○
○
○
○
○
○
○
○
○
○
○
0.1H
-
○
○
○
4 (Loosening)
0.1H
-
○
○
○
5 Tighten the end effector bolt
0.1H
-
○
○
○
0.5H
-
○
○
○
0.1H
-
○
○
○
○
○
○
○
○
○
Check the end effector
3 (hand)cable
Check the motor connector.
Tighten the cover and main
6 bolt t i 7 n u l a c 8 i n a h c 9 e M
Check the fixed mechanical stopper and adjustable mechanical stopper Remove spatter and dust etc. Replacing battery Replacing grease of J1 axis
10 reducer
Replacing grease of J2 axis
11 reducer
Replacing grease of J3 axis
12 reducer
Supplying grease to J4-axis
13 reducer
Supplying grease to J5-axis
14 Reducer
Supplying grease to J6-axis
15 reducer
Replacing cable of
16 mechanical unit
0.1H 0.1H
●
-
0.5H
870ml
0.5H
330ml
0.5H
190ml
0.5H
3ml
0.5H
3ml
0.5H
3ml
4.0H
-
0.2H
-
0.2H
-
0.1H
-
Check the robot cable, teach r 17 pendant cable and robot
e l connecting cable l o r t Cleaning the controller n18 o ventilation system C
19 Replacing battery *1
*1 *2
○ ○
○
Refer to manual of controller. ●: requires order of parts ○: does not requires order of parts
- 108 -
○ ○
○
○
○ ○
○
○
○
B-83755EN/01
APPENDIX
C. PERIODIC MAINTENANCE TABLE
3
4
5
6
7
8
years
years
years
years
years
years
11520 12480 13440 14400 15360 16320 17280 18240 19 20 0 20 16 0 21 12 0 2 20 80 2 30 40 2 40 00 2 49 60 25 92 0 26880 27840 28800 29760 30720
It em
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
1
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
2
○
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
○
○
○
○
○
6
○
○
○
○
○
7
○
○
○
○
○
8
●
●
●
●
●
●
●
●
●
○ ○
○
○
9 10 11 12
●
13
●
14
●
15
●
16
○ ○
l u a h r e v O
○
○ ○
○
○
○
○ ○
○
●
○
○
○ ○
○
○
○
17 ○
○
○
18 19
- 109 -
D. STRENGTH OF BOLT AND BOLT TORQUE LIST
D
APPENDIX
B-83755EN/01
STRENGTH OF BOLT AND BOLT TORQUE LIST
NOTE When applying LOCTITE to a part, spread the LOCTITE on t he entire length of the engaging part of the female thread. If applied to the male threads, poor adhesion can occur potentially loosening the bolt. Clean the bolts and the threaded holes and wipe off the oil on the engaging section. Make sure that there is no solvent left in the threaded holes. In this case, remove all the excess LOCTITE when you are finished screwing the bolts into the threaded holes. Use the following strength bolts. Comply with any bolt specification instructions as specified. Hexagon socket head bolt made of steel: Size M22 or less: Tensile strength 1200N/mm2 or more Size M24 or more: Tensile strength 1000N/mm2 or more All size plating bolt: Tensile strength 1000N/mm2 or more Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc.) Tensile strength 400N/mm2 or more Refer to the following tables if the bolts tightening torque are not specified. Recommended bolt tightening torques
Unit: Nm
Hexagon socket head button bolt Hexagon socket head Hexagon socket head Hexagon socket head Hexagon bol t bolt (steel) Nominal bolt (stainless) flush bolt (steel) Low-head bolt diameter (steel) Tightening torque Tightening torque Tightening torque Tightening torque Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit M3
1.8
1.3
0.76
0.53
M4
4.0
2.8
1.8
1.3
1.8
1.3
1.7
1.2
M5
7.9
5.6
3.4
2.5
4.0
2.8
3.2
2.3
9.6
5.8
4.1
7.9
5.6
5.5
3.8
――――
――――
――――
―――
M6
14
M8
32
23
14
M10
66
46
27
19
32
23
26
19
M12
110
78
48
33
31
180
130
76
53
73
51
M16
270
190
120
82
98
69
(M18)
380
260
160
110
140
96
M20
530
370
230
160
190
130
(M22)
730
510
M24
930
650
(M27)
1400
960
M30
1800
1300
M36
3200
2300
―――― ―――― ―――― ―――― ――――
―――― ―――― ―――― ―――― ――――
―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ――――
45
(M14)
―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ――――
―――― ―――― ―――― ―――― ――――
―――― ―――― ―――― ―――― ――――
9.8
- 110 -
14
9.6
13
9.3
APPENDIX
B-83755EN/01
E
E. INSULATION ABOUT ARC WELDING ROBOT
INSULATION ABOUT ARC WELDING ROBOT
The arc welding robot performs welding, using a welding torch attached to its end effector mounting face via a bracket. Because a high welding current flows through the welding torch, the insulating material must not permit bolting directly from the welding torch bracket to mounting face plate. If no due consideration is taken, a poor insulation caused by a pileup of spatter can allow the welding current to leak into robot mechanical units, possibly damaging the motor or melting the mechanical unit cable jackets.
E.1 -
-
-
INSULATION AT THE WRIST Insulate the end effector mounting surface. Insulation material which is inserted between the end effector mounting surface and the welding torch bracket must be different, and bolt them separately referring to Fig. E.1. Insert the insulating material between the torch bracket and faceplate to ensure the two are electrically isolated. When installing the insulating material, be sure to set the crack in the torch holder away from that of the insulating material to prevent spatter from getting in the cracks. Allow a sufficient distance (at least 5 mm) at the insulating materials in case a pileup of spatter should occur. 5mm5mm以上 or more
Torch bracket トーチブラケット トーチ Torch
Robot ロボット手首 wrist
Insulation material 絶縁部材固定ボルト mounting bolts
Torch bracket mounting bolts トーチブラケット固定ボルト
Bad 悪い例 example Insulation 絶縁部材 material (ベークライト等) (bakelite etc.)
Fig. E.1 Insulation at the wrist
-
Even after the insulation is reinforced, it is likely that, if a pileup of spatter grows excessively, current may leak. Periodically remove the spatter.
- 111 -
INDEX
B-83755EN/01
INDEX
ADJUSTING TENSION OF BELT................................84 ADJUSTMENT...............................................................84
Replacing Cable K102,K103,K104,K105,K106,K108K and Air Tube (J2 arm to J3 arm) ........................ ......... 75 Replacing Cable K123 and Air Tube (Connector panel to J2 base) ....................... ................ 67 REPLACING CABLES ....................... ........................ ... 64 REPLACING J1-AXIS MOTOR............ ........................ 30 REPLACING J1-AXIS REDUCER...................... .......... 32 REPLACING J2-AXIS MOTOR............ ........................ 35 REPLACING J2-AXIS REDUCER...................... .......... 38 REPLACING J3-AXIS MOTOR............ ........................ 40 REPLACING J3-AXIS REDUCER...................... .......... 43 REPLACING J4-AXIS MOTOR............ ........................ 45 REPLACING J4-AXIS REDUCER...................... .......... 47 REPLACING J5/J6 BELT ...................... ........................ 60 REPLACING J5-AXIS MOTOR............ ........................ 50 REPLACING J5-AXIS REDUCER...................... .......... 52 REPLACING J6-AXIS MOTOR............ ........................ 55 REPLACING J6-AXIS REDUCER...................... .......... 59 REPLACING PARTS.... ...................... ....................... .... 27 REPLACING SOLENOID VALVE ....................... ........ 62 REPLACING THE BATTERIES (1.5 YEAR CHECKS)...................... ....................... ...... 9 REPLACING THE GREASE OF THE J1 TO J3 AXIS REDUCERS (3 YEARS (11520 HOURS) CHECKS)..................... . 11 REPLACING WRIST UNIT ....................... ................... 57 RESETTING ALARMS AND PREPARING FOR MASTERING........................................ ...................... 88
BACKLASH MEASUREMENT .................... ................ 23 CABLE AND AIR TUBE REPLACEMENT ................. 67 CABLE FORMING ...................... ....................... ........... 66 CABLE WIRING............................................................65 Check of Fixed Mechanical Stopper and Adjustable Mechanical Stopper.......................................................7 CHECK POINTS ...................... ...................... .................. 4 Check the Mechanical Unit Connectors............................6 CHECKS AND MAINTENANCE .................... ............... 1 Confirmation of Oil Seepage.............................................4 Confirmation of the Air Control Set (option)....................5 Daily Checks.....................................................................1 FIGURE OF DRIVE MECHANISM..............................28 FIXTURE POSITION MASTERING.............................89 GREASE SUPPLYING PROCEDURE FOR J4 TO J6-AXIS REDUCER (4 YEARS (15360 HOURS) PERIODICAL CHECK)..............................................14
SAFETY PRECAUTIONS ..................... ....................... s-1 SEALANT APPLICATION ....................... .................... 63 STRENGTH OF BOLT AND BOLT TORQUE LIST . 110
INSULATION ABOUT ARC WELDING ROBOT..... 111 INSULATION AT THE WRIST .................... .............. 111 MAINTENANCE PARTS ....................... ...................... . 97 MAINTENANCE TOOLS................................................8 MASTERING ....................... ........................ .................. 85 MECHANICAL UNIT CIRCUIT DIAGRAM AND AIR PRESSURE DIAGRAM....................................102
TROUBLESHOOTING....................... ....................... .... 16 VERIFY MASTERING........ ....................... ................... 94
OVERVIEW ...................... ...................... ...................... . 85 Periodic Checks and Maintenance ........................ ............ 2 PERIODIC MAINTENANCE .................... ................... 1,9 PERIODIC MAINTENANCE TABLE.........................107 PREFACE ....................... ...................... ....................... ..p-1 Procedure for releasing remaining pressure from the grease bath (J1 to J3-axis) ...................... ..................... 13
i-1
REVISION RECORD
B-83755EN/01
REVISION RECORD Editi on
Date
01
Nov., 2016
Contents
r-1
