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1. Appendix 71 Appendix 1 Configuration flag ir c eee ec ed ice Dese ceed ene teas Appendix 71 1Before starting use 1 Before starting use This chapter explains the details and usage methods of the instruction manuals the basic terminology and the safety precautions 1 1 Using the instruction manuals 1 1 1 The details of each instruction manuals The contents and purposes of the documents enclosed with this product are shown below Use these documents according to the application For special specifications a separate instruction manual describing the special section may be enclosed Safety Manual Standard Specifications Robot Arm Setup to Main tenance Controller Setup Basic Operation to Maintenance Explanation of Functions and Operations Troubleshoot ing Explains the common precautions and safety measures to be taken for robot handling system design and manufacture to ensure safety of the operators involved with the robot Explains the product s standard specifications factory set special specifications option configuration and maintenance parts etc Precautions for safety and technology when incorporating the robot are also explained Explains the procedures required to operate the robot arm unpacking transportation installation confirmation of operation and the maintenance and inspection procedures Explains the
2. 2 9 229 GFOUNAINE Dro edurFES GE miile 2 10 1 Grounding methods 5 0 EL tan cans 2 10 2 Groundingbroe dures EE EE eod bic tete eb ua telae EE 2 10 2 2 6 Connecting with the controller ee ee ee ee Ge ee ee ee ee tnnt ee nsn ee sanata snas tassa sns ee Ge ee essa 2 11 23 Setting the decedit 2 12 2 3 1 Installing the teaching pendant T B 2 2 0 4400 2 12 1 Installing with the control power OFF mmmmmnenemnemaenevnenavnenaenevaenevaemaenevaemavaemaennaemamaemmemamae 2 12 2 3 2 Setting the origin with the origin data input method 2 13 1 Confirming the origin data ee ee ee 2 13 2 Turning ON the control 2 13 9 Preparing the T B ce ritiene oe ee ee teen ee ele De uod dd ca EE 2 14 4 Selecting the origin setting method m mremeenemnenamnemaenavaenannemaenannanuenamaenunaemavaemaemamae 2 15 5 Inputting the origin data RE detecte tente r
3. 3 Timing belt tension f Belt pressing force s Span length d Belt slack 5 20 e O Fig 5 7 Belt tension The timing belt can satisfactorily convey the drive and keep a durable force only when it has an adequate tension The belt tension should not be too tight or too lose Instead it should be adjusted to a degree that elasticity is felt when the belt is pressed with the thumb If the belt tension is too weak the belt loosening side will vibrate On the other hand if the belt tension is too strong a sharp sound will be heard and the belt tension side will vibrate The detailed adjustment tension is shown in Fig 5 7 Check and adjust with the belt pressing force f and the slack amount d between span s Maintenance and inspection procedures 5 47 5Maintenance and Inspection 5 3 4 Lubrication 1 Lubrication position and specifications J6 axis air bleed bolt M4 J2 axis air bleed bolt M4 2 J2 axis lubrication port 5 J6 axis lubrication bolt J3 axis air bleed bolt M4 3 J3 axis lubrication port Base view 1 J1 axis lubrication port J1 axis air bleed bolt M4 J5 axis air bleed bolt M4 4 5 axis lubrication bolt AEN y 59e ViewB View A Fig 5 8 Lubrication positions 5 axis type 5 48 Maintenance and inspection procedures 5Maintenance and Inspection J6 axis air bleed bolt M4 B J4 axis air bleed bolt M4
4. TS 5 52 5 5 Resetting the eer N ee A A uea VV 5 53 5 5 1 Mechanical stopper method 22 2 2 4 01101 ee ee ee ee ee ee ee ee ee ee ee 5 53 a 5 53 VA Vea AIRE En su ees NR ee taa antavat S 5 54 3 d2 axis ucc eme ede kode Ee We eese ba ER NE 5 55 4 J3 axis origin Seth g NR a a 5 56 5 axis origin setting Only 6 type 2222 1 2444 981000010 5 58 D 95 axis origin Setting ici aca ies tet ee ot em A ais 5 60 7 d6 AXIS uua ee ee Vee ee oe ke eed ge RE ea Ne 5 61 8 All asis onan setting 5 63 5 9 2 metHod vie Rue 5 65 9 5 3 User origirimiethod se e 5 68 5 5 4 Recording the origin data 22 2 2 4 22 ee ee Ge ee ee ee ee ee ee ee ee ee 5 69 1 Confirming the origin data label 22 5 69 2 Confirming the origin data ie ee ee 5 69 3 Recording the origin data c o bo i Oe ede Ee 5 69 4 Installing the cover ete rri GEE rentes cesare edited 5 69
5. 3 While holding down the deadman switch hold down the MOVE X keys The brakes will be released while the keys are held down 4 With both hands slowly move the J1 axis in minus direction and contact the axis against the mechanical stopper 5 Press the key The cursor will move to AXIS DESIGNATION 6 Designate the axis for which the origin is to be set Set 1 for the 1 axis and set 0 for the other axes Then press INP Next a confirmation screen will appear 7 Press the 1 and INP keys The origin posture will be set 8 Setting of the origin is completed 9 Refer to 5 5 4Recording the origin data on page 69 in this manual and record the origin data on the origin data seal To release the brakes move the cursor to the Brake axis No with the lt or key The brakes be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately Origin setting axis designation Q Move the cursor to the Axis Designation axis No in the origin setting with the lt or key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and dis
6. INP 95 exe 1 EXECUTE 1 Press the 5 key on the Menu screen to select the Maintenance screen 2 Press the 4 key to select the Origin Setting screen 3 Press the 3 key to select the jig method Then press the 1 key and the INP key to turn the servo OFF In this state securely fix the transportation jig A onto the base section with the two fixing bolts M4 x 12 Resetting the origin 5 65 5Maintenance and Inspection 2 Mechanical interface 1 Calibration jig 3 Bolt 4 Install the calibration Jig on the mechanical MB X 12 4 bolts interface 2 and insert the pin 4 to carry out the EI positioning MP ao corel Tighten the bolt 3 in this state and securely fix the jig After fixing remove the pin 4 Pin T MC 5 axis type 5 Designate the axis for which the brakes are to lt JIG gt 12345678 lt JI 12345678 be released BRAKE 00000000 BRAKE 11101100 For the 6 axis robot press 1 key six times for SET AXIS 00000000 SET AXIS 11101100 the 5 axis robot press the 1 key three times ORIGIN NOT DEF ORIGIN NOT DEF the 0 key once and the 1 key twice B 05 J6 1 DEF 0 ABC 6 One worker must hold the calibration jig handle Designate the brakes release axis or the robot arm 6 axis type lt JIG gt 12345678 JIG 12345678 BRAKE 00000000 BRAKE 11111100 7 While the other worker is holding down the SET A
7. 5 44 Maintenance and inspection procedures 5Maintenance and Inspection 2 Inspection adjustment and replacement of the J5 axis timing belt 3 Motor 1 Motor installation screw M3 X 14 socket bolt 2 Timing belt KK lt BS SS Fig 5 6 Inspection adjustment and replacement of J5 axis timing belt Inspection method 1 The inspection and adjustment methods of the J5 axis timing belt are shown in Fig 5 6 2 Follow Fig 5 4 or Fig 5 5 and remove the No 2 arm covers L 3 Visually check that the symptoms listed in 1 to 5 above have not occurred on the belt 4 Check the belt tension degree by pressing the enter of the belt lightly approx 6 8N as shown in Fig 5 7 Belt tension The belt should slacken by approx 2 mm Maintenance and inspection procedures 5 45 5Maintenance and Inspection Adjustment method 1 The inspection and adjustment methods of the J5 axis timing belt are shown in Fig 5 6 2 Lightly loosen the four motor installation screws 1 Do not loosen too far 3 While checking the timing belt 2 tension degree move the motor 3 in the direction of the arrow in the drawing until it is at an adequate tension position A slot is provided so that the motor can be moved 4 When the moved in the direction of arrow a the belt will be tensed and when moved in the direction of arrow b the belt will be loosened 5 Do not loosen the belt too much causing it to come off t
8. 4 J4 axis lubrication port J2 axis air bleed bolt M4 2 J2 axis lubrication port 6 J6 axis lubrication port 3 axis lubrication port J3 axis air bleed bolt M4 Base view 1 J1 axis lubrication port J1 axis air bleed bolt M4 J5 axis air bleed bolt M4 5 J5 axis lubrication port View B ViewA Fig 5 9 Lubrication positions 6 axis type Maintenance and inspection procedures 5 49 5Maintenance and Inspection Table 5 5 Lubrication specifications Lubrication interval Lubrication amount Cover to remove guide 1 Parts to be method Lubrication oil lubricated E Default charge amount maker J1 axis reduction gears Grease Shoulder cover i Harmonic grease SK 1A 2000Hr 40g 17g EN J3 axis reduction gears Japan Harmonic Systems J4 axis reduction gears Grease nipple 2000Hr EE 6 axis type only WA 610 6 2g rease J5 axis reduction gears Harmonic grease SK 1A 2000Hr 6 5g 1 6g No 2 arm cover R Japan Harmonic Systems J6 axis reduction gears 2000Hr 3 5g Wrist cover The grease nipple position is shown in Fig 5 8 for the 5 axis type and in Fig 5 9 for the 6 axis type The lubrication specifications for each place are shown in Table 5 5 Before lubricating refer to Fig 5 4Installing removing the cover 5 axis type on page 42 for the 5 axis type and Fig 5 5Installing removing the cover 6 axis type on page 42 for the 6 a
9. NCAU TION Always use a crane to tilt the robot Tilting it by hand could lead to the robot tilting over or to personal injuries or physical damage 2 Refer to Table 3 2 and Fig 3 2 and insert the movement range change stopper into the angle position to be changed Then securely fix with the bolt M4 20 3 This completes the setting of the robot arm Wire View from bottom of base Front of robot Floor Fig 3 2 Installation of motion range change option 2 Setting the parameters 1 Change the values of the first element J1 axis minus side and second element J1 axis plus side of the joint movement range parameter MEJAR Set the value to the angle corresponding to the position where the movement range change stopper was inserted in 1 Setting the robot arm above Refer to the separate Instruction Manual Detailed Explanation of Functions and Operations for details on changing the parameter 2 To change the movement range on the minus side the mechanical stopper origin parameter MORG must be changed in addition to the above parameter Set the first element value of parameter MORG to the value indicated in Table 3 3 Refer to the separate Instruction Manual Detailed Explanation of Functions and Operations for details on the operations Changing the motion range 3 33 Slnstalling the option devices Table 3 3 Change valve of parameter side Change angle Change value for M
10. X M X X E 3 X Ner 7 Y Z TY 5 type 6 type The current position is set as the arc centering on the Z axis and the axis moves along that arc expands and contracts in the radius direction and moves vertically At this time for the 6 axis type the flange surface posture is maintained Also while maintaining the flange surface position the flange surface orientation changes Fig 2 16 Cylindrical jog operation 2 20 Confirming the operation 2Unpacking to Installation 1 Joint jog operation Select the joint jog mode Press the MOVE JOINT keys to select the joint JOINT LOW jog mode JOINT will appear at the upper left of the W 34 50 JOINT screen 2000 move E 80 00 Joint jog mode BET Set the jog speed Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH JOINT LOW 3 5 10 30 50 70 100 E Mere TER When the MOVE keys are pressed the E 250700 TE override will decrease in the reverse order The currently set speed will appear on the upper right of the screen Set the override to 10 here for confirmation work J1 axis jog operation 7 2 lt STEP X STEP X 41 qun SPACE MOVE 5 type 6 axis type When the MOVE X J1 keys are pressed the J1 axis will rotate the plus direction Wh
11. 6 axis type only When the MOVE B J5 keys are pressed the J5 axis will rotate in the plus direction When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE J6 keys are pressed the J6 axis will rotate the plus direction When the MOVE C J6 keys are pressed Rotate in the minus direction 2 28 Confirming the operation 5 Cylindrical jog operation Select the cylindrical jog mode CYLNDER LOW R 134 50 22000 ae 2 280 00 Cylindrical jog mode Set the jog speed CYLNDER LOW R 7134 50 Z 280 00 Set the ME Lu Moving along an arc centering on the Z axis S 2 HZ MOVE 8 ex Vertica Radius Control point 5 type ES iis MOVE E 2Unpacking to Installation Press the MOVE XYZ keys and then press only the XYZ key CYLNDER will appear at the upper left of the screen Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH 3 5 10 30 50 70 100 When the MOVE 7 keys are pressed the override will decrease in the reverse order The currently set speed will appear on the upper right of the screen Set the override to 10 here for confirmation work STEP 7 Vertica 7 X 000 JRadius Control point Id n J2 MOVE 9 gt 6 axis type The directio
12. NCAUTION Elbow cover Upper arm Don t hold the resin cover when carrying the robot as this may lead to breakage BU147D428H01 NCAUTION wW w o prevent dropping the robot must be b carried by two persons as illustrated a BU147D774H01 NCAUTION T Arm fixing plate Elbow cover Upper arm Don t hold the resin cover when carrying the robot as this may lead to breakage BU147D428H01 NGAUTION wW W To prevent dropping the robot must be d carried by two persons as illustrated j i BU147D775H01 Fig 2 4 Transportation of robot arm Transportation by people 5 axis 1 The robot must be transported by two workers Place the robot on a dolly etc and move it to near the installation place Transporting the robot with the following grips should be limited to placing the robot on the frame or dolly and to positioning 2 When transporting with the grips one worker should hold the shoulder section grip A and the other should hold the base section grip B The workers should support the arm from the side of the robot with their bodies and lift the robot If the robot is held from the left right sides or if a cover without a grip is held the robot could tilt over the cover could be damaged or accidents such as dropping could occur 3 When transporting the robot do not apply force on the cover or apply a strong impact on the robot N CAUTION To prevent ac
13. NOT DEF ORIGIN NOT DEF 12 Refer to 5 5 4Recording the origin data on page 69 in this manual and record the origin data on the origin data seal This completes the setting of the origin with the jig method Resetting the origin 5 67 5Maintenance and Inspection 5 5 3 User origin method The procedure for setting the origin with the user origin method is explained below This operation is carried out with the teaching pendant Set the MODE switch on the front of the controller to TEACH and set the ENABLE DISABLE switch on the teaching pendant to ENABLE to enable the teaching pendant The operation method is shown below When setting the origin for the first time using this method carry out the operations in order from step 1 For the second and following time move the robot arm to the user origin position with jog operation and accurately position all axes Then start the procedure from step 4 1 Determine the user origin position Move the robot to the position to be set as the origin with jog operation Refer to 2 4Confirming the operation on page 18 for details on the jog operation Caution This position is left as a guideline to position all axes with jog operation when setting the origin again with this method 2 Enter the joint jog mode and display the joint coordinates on the teaching pendant screen Record the value of the axis for which the origin is to be set 3 Input the value recorded in the us
14. OH Monthly inspection Monthly inspection Monthly inspection 3 month inspection Monthly inspection Monthly inspection 1000H Monthly inspection 3 month inspection 6 month inspection 2 45 o gt 5 Monthly inspection Monthly inspection 1500H Monthly inspection 3 month inspection Monthly inspection Monthly inspection Monthly inspection 3 month inspection 6 month inspection Yearly inspection Guideline for inspection period For one shift 8 Hr day X 20 days month X 3 months approx 500 Hr 10 Hr day X 20 days month X 3 months approx 600 Hr For two shifts 15 Hr day X 20 days month X 3 months approx 1000 Hr 2000H Caution When using two lines the 3 month inspection 6 month inspection and yearly inspection must be carried out when half the time has passed Fig 5 1 Inspection schedule Maintenance and inspection interval 5 37 5Maintenance and Inspection 5 2 Inspection items The inspection items for the robot arm are shown below Also refer to section 5 Maintenance and inspection in the From Controller Setup to Maintenance manual and inspect the robot arm 5 2 1 Daily inspection items Carry out the daily inspections with the procedures given in Table 5 1 Table 5 1 Daily inspection items details Procedure Inspection item details Remedies Before turning power ON Check the following items before turning the power ON Are any
15. ORIGIN OK 1 4 1 EKEGUTE 5 Set the origin 1 DEE lt MECHA gt 12345678 BRAKE 00001000 SET AXIS 00001000 ORIGIN COMPLETED 5 60 Resetting the origin Front of base mm The 5 direction in the drawing shows the case when the J4 axis is at the mechanical stopper position 6 axis type 6 Press the key The cursor will move to AXIS 7 Designate the axis for which the origin is to be set Set 1 for the 5 axis and set 0 for the other axes Then press INP Next a confirmation screen will appear 8 Press the 1 and INP keys The origin posture will be set 9 Setting of the origin is completed 10 Refer to 5 5 4Recording the origin data on page 69 in this manual and record the origin data on the origin data seal 5Maintenance and Inspection Releasing the brakes To release the brakes move the cursor to the Brake axis No with the lt or key The brakes can be released only for the axis for which 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately Origin setting axis designation lt gt Move the cursor to the Axis Designation axis No in the origin setting with the lt or key The origi
16. RIGHT LEFT Note amp B is shows the binary Fig 6 1 Configuration flag RIGHT LEFT 2 ABOVE BELOW This means in which side the J5 axis is in comparison with the plane through both the J3 and the J2 axis FL 1 Flag 1 amp BOOOO 0000 T 1 BELOW Note amp B is shows the binary J3 axis 5 axis type 6 axis type Fig 6 2 Configuration flag ABOVE BELOW Configuration flag Appendix 71 6Appendix 3 NONFLIP FLIP 6 axis robot only This means in which side the J6 axis is in comparison with the plane through both the J4 and the J5 axis J4 axis 6 axis type NON FILIP J6 axis flange surface FL 1 Flag 1 8 B 0000 0000 1 1fO NONFLIPY FLIP Note amp B is shows the binary Fig 6 3 Configuration flag NONFLIP FLIP Appendix 72 Configuration flag pe A MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100 8310 TELEX J24532 CABLE MELC NAGOYA WORKS 1 14 YADA MINAMI 5 HIGASHI KU NAGOYA JAPAN A lt JUL 2000 MEE Printed in Japan on recycled paper Specifications are subject to change without notice
17. Refer to 2 3 Setting the origin on page 12 for details on setting the origin 2 axis type 6 Each axis moves independently The 5 axis type does not have the J4 axis Fig 2712 Joint jog operation 2 18 Confirming the operation 2Unpacking to Installation 5 axis type 6 axis type While maintaining the flange surface posture the axis moves straight along the XYZ coordinate system Also while maintaining the flange surface position the flange surface orientation changes Fig 2 13 XYZ jog operation O zi 9 T Control point 5 axis type 6 axis type While maintaining the flange surface posture the axis moves straight along the tool coordinate system Also while maintaining the flange surface position the flange surface orientation changes With the 5 axis type the axis moves only in the X and Y axis directions of the tool coordinates Fig 2714 Tool jog operation Confirming the operation 2 19 2Unpacking to Installation 5 type 6 axis type The axis moves straight along the XYZ coordinate system At this time the flange surface posture is not maintained Also the flange surface orientation changes The flange surface position changes at this time Fig 2715 3 axis XYZ jog operation 2 2 O Ne N O 5 KO Vertical a m d Radius Arc Radius Arc Control point 4 Y Y Control point 2
18. Safety Precautions Use the robot within the environment given in the specifications Failure to do so could lead to a drop or reliability or faults Temperature humidity atmosphere noise environment etc Transport the robot with the designated transportation posture Transporting the robot in a non designated posture could lead to personal injuries or faults from drop ping Always use the robot installed on a secure table Use in an instable posture could lead to positional deviation and vibration Wire the cable as far away from noise sources as possible If placed near a noise source positional deviation or malfunction could occur Do not apply excessive force on the connector or excessively bend the cable Failure to observe this could lead to contact defects or wire breakage Make sure that the workpiece weight including the hand does not exceed the rated load or tolerable torque Exceeding these values could lead to alarms or faults Securely install the hand and tool and securely grasp the workpiece Failure to observe this could lead to personal injuries or damage if the object comes off or flies off during operation Securely ground the robot and controller Failure to observe this could lead to mal functioning by noise or to electric shock accidents Indicate the operation state during robot operation Failure to indicate the state could lead to operators approaching the robot or to incorrect operation When ca
19. T B screen and the robot will not move Refer to section 1 Joint jog operation on page 21 and move the robot to a position where linear movement is possible and then carry out Tool jog Confirming the operation 2 25 2Unpacking to Installation lt gt When appears on the T B screen display If the robot is moved outside the movement area with any of the axes an will appear In this case move the axis in the opposite direction m LOW In the example on the left further linear movement in the same direction is not possible 360 00 4 28000 M 17000 Changing the flange surface orientation The 5 axis type does not have this movement 5 type 6 axis type The flange position does not change When the MOVE A J4 keys are pressed 6 axis type The X axis will rotate in the plus direction of the tool coordinate system 5 type There is no operation When the MOVE A J4 keys are pressed Rotate in the minus direction When the MOVE B J5 keys are pressed 6 axis type The Y axis will rotate in the plus direction of the tool coordinate system 5 type There is no operation When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE J6 keys are pressed 6 axis type The Z axis will rotate in the plus direction of the tool coordinate system 5 axis type There is no operation When the MOVE
20. and follow the instructions This work can be commissioned to the Mitsubishi Service Department for a fee Never disassemble etc the parts not described in this manual The maintenance parts etc required for the user to carry out maintenance and inspection are described in 5 4Maintenance parts on page 52 of this manual Always contact your dealer when parts are needed N CAUTION The origin of the machine system could deviate when this work is carried out Review of the position data and re teaching will be required 5 3 1 Robot arm structure An outline structure drawing of the 5 axis type robot arm is shown in Fig 5 2 and of the 6 axis type robot arm in Fig 5 3 Each part is as shown below 1 The J1 axis rotation is driven by the J1 axis motor 1 and reduction gears 2 arranged in the shoulder Non excitation magnetic brakes are mounted in the Jlaxis motor 1 2 The J2 axis rotation is driven by the J2 axis motor 3 and J2 axis reduction gears 4 arranged in the shoulder Non excitation magnetic brakes are mounted in the J2 axis motor 3 to prevent the arm from dropping by its own weight when the power is OFF 3 The J3 axis rotation is driven by the J3 axis motor 5 and J3 axis reduction gears 6 arranged in the elbow block Non excitation magnetic brakes are mounted in the J3axis motor 5 as with the J2 axis motor 4 J4 axis rotation section only 6 axis type The J4 axis rotation is driven by the J4 axis motor 7 and J4 a
21. inspection procedures 5 41 5Maintenance and Inspection 5 3 2 Installing removing the cover 7 Wrist cover 6 No 2 arm cover 5 No 2 arm cover Fig 5 4 Installing removing the cover 5 axis type 7 Wrist cover 2 e 4 Elbow cover NN 6 2 arm cover Fig 5 5 Installing removing the cover 6 axis type 5 42 Maintenance and inspection procedures 5Maintenance and Inspection Table 5 3 Cover names w mem e Battery cover Shoulder cover No 1 arm cover For 5 axis type 1 Elbow cover J Lr RN Elbow cover J 8 JNetamewedQ NR S JNetamewet G Table 5 4 Cover installation screw list De rete 1 Refer to Fig 5 4 when using the 5 axis type robot arm and Fig 5 5 when using the 6 axis type robot arm 2 The names of the covers are given in Table 5 3 and a list of the cover installation screws is given in Table 5 4 3 There are some covers that may be difficult to remove due to the robot posture In this case change the robot posture with jog operation and then remove the cover 4 When attaching the cover after maintenance and inspection use the detaching procedure in reverse The part Nos and symbols in Table 5 3 and Table 5 4 correspond to Fig 5 4 and Fig 5 5 Maintenance and inspection procedures 5 43 5Maintenance and Inspection 5 3 3 Inspection maintenance and replacement of timing belt This robot uses a timing belt for the driv
22. is used to invalidate the emergency stop from the T B This is also used to install the T B with turning the controller s power supply ON 2 12 Setting the origin 2Unpacking to Installation 2 3 2 Setting the origin with the origin data input method 1 Confirming the origin data Origin data history table Origin Data History Serial 5804008 ate Default the origin data sheet enclosed with the VI S29 arm or on the origin data history table O6DTYY attached to the back side of the battery cover Refer to Fig 2 10 Referring to Fig 5 10 Replacing the battery on page 51 remove the battery A12 Z0 cover and confirm the value Method J 1 J 2 J 3 J 4 5 6 The value given in the default setting column is the origin settings set with the calibration jig before shipment AlphabetO 0 Zero Note Meanings of symbols in method column E Jig method Note that the 5 axis type does not have N Not used the J4 axis SP Not used Fig 2 10 Origin data label N WARNING Always install remove the cover with the controller control power turned OFF Failure to do so could lead to physical damage or personal injury should the robot start moving due to incorrect operations 2 Turning ON the control power N CAUTION Confirm that there are no operators near the robot before turning the power ON 1 Turn the controller POWER switch ON The control power will be turned an
23. key input 2 and then the 9 key input 9 V 4S29 will appear at the D data on the teaching pendant screen 3 Press the key and move the cursor to the J1 input position 4 Input the J1 value in the same manner as above 5 Input the J2 J3 J4 J5 and J6 values in the same manner Note that the J4 axis is not required for the 5 axis type 6 After inputting all of the values press the INP key The origin setting confirmation screen will appear 7 Press 1 CB P and key to end the origin setting 2Unpacking to Installation Moving the cursor gt Press the 1 1 1 Ee 1 gt keys Q Inputting characters Q Hold down the CHAR key and press the key with the character to be input on the lower right Three character will scroll each time the character key is pressed Correcting an input O O After returning one character by pressing the DEL key input the character again 6 Installing the battery cover Return the battery cover removed in section 1 Confirming the origin data on page 13 to its original position This completes the setting of the origin with the origin data input method to do so could lead to the robot moving because of incorrect operations or to physical damage or personal injury N W ARNIN Always remove and install the cover with the controller power turned OFF Failure Q O If the origin input data is incor
24. of origin data label and axis The method for inputting the origin data is explained below The value shown in Fig 2 10will be input as example XT B screen Keys used DATA D 90000 1 000000 000000 3 000000 000000 5 000000 000000 DATA D 00000 1 000000 000000 3 000000 000000 5 000000 000000 DATA D MDbooo 1 000000 000000 3 000000 000000 5 000000 000000 SPD POS t SPD POS Hh lt DATA D V 00 1 000000 000000 3 000000 000000 5 000000 000000 A TY J4 J2 2 GHI 9 amp O RPL INP EXE lt DATA gt D V S29 1 0000 000000 3 000000 000000 5 000000 000000 lt DATA gt D V S29 1 A B amp 8F G Y5 3 H 7 2H B 1L 2 99A37 K8 amp 6P lt DATA gt D V S29 CHANGES TO ORIGIN B ERR execute HH 1 o FE 2 16 Setting the origin POS e eub POS is CHAR 6 5 STU 1 Confirm that the cursor is at the D position on the T B display screen 2 Input the D value V S29 Inputting V Press the key once while holding down the CHAR key V will appear so release the CHAR key V will be set Inputting 1 Press the key three times while holding down the CHAR key 1 will appear so release the CHAR key 1 will be set In the same manner while holding down the CHAR key press the 7 71 key twice and the STU key once input S Release the CHAR key and press the 2
25. of the robot installation bolts loose Securely tighten the bolts Visual Are any of the cover tightening screws loose Securely tighten the screws Visual Are any of the hand installation bolts loose Securely tighten the bolts Visual Is the power supply cable securely connected Securely connect Visual Are the machine cables between the robot and controller securely Securely connect connected Visual Are there any cracks foreign contamination or obstacles on the robot Replace with a new part or take remedial measures and controller cover Is any grease leaking from the robot arm After cleaning replenish the grease Visual Drain the drainage and remedy the air leaks replace the part Is there any abnormality in the pneumatic system Are there any air leaks drain clogging or hose damage Is the air source normal Visual After turning the power ON Turn the power ON while monitoring the robot Bd Is there any abnormal motion or abnormal noise when the power is Follow the troubleshooting section turned ON During operation try running with an original program Check whether the movement points are deviated Follow the troubleshooting section Check the following points if there is any deviation 1 Are any installation bolts loose 2 Are any hand installation section bolts loose 3 Are the positions of the jigs other than the robot deviated 4 If the positional deviation ca
26. on the teaching pendant display screen 3 Recording the origin data Write the origin data displayed on the teaching pendant to the origin data label attached to the back of the battery cover Refer to Fig 2 10Origin data label on page 13 and Fig 2 11Correspondence of origin data label and axis on page 16 for details on the origin data label 4 Installing the cover Install the battery cover removed in step 1 Confirming the origin data label above Refer to 5 3 5Replacing the backup battery on page 51 and replace the battery cover This completes the recording of the origin data Resetting the origin 5 69 5Maintenance and Inspection 5 70 Resetting the origin 6Appendix 6 Appendix Appendix 1 Configuration flag The configuration flag indicates the robot posture For the 6 axis type robot the robot hand end is saved with the position data configured of X Y Z A and However even with the same position data there are several postures that the robot can change to The posture is expressed by this configuration flag and the posture is saved with FL1 in the position constant X Y Z A B C FL1 FL2 The types of configuration flags are shown below 1 RIGHT LEFT This means in which side the J5 axis Q is in comparison with the plane through the J2 axis vertical to the ground RIGHT LEFT RIGHT Rotation center a Rotation center x amp BOOOO 1 1O
27. p 5 type 2Unpacking to Installation Press the MOVE TOOL keys to select the tool jog mode TOOL will appear at the upper left of the screen Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH gt 3 5 10 30 50 70 100 When the MOVE 7 keys are pressed the override will decrease in the reverse order The currently set speed will appear on the upper right of the screen Set the override to 10 here for confirmation work 6 axis type The direction of the frange will not move When the MOVE X J1 keys are pressed the robot will move along the X axis plus direction of the tool coordinate system When the MOVE X J1 keys are pressed Move along the minus direction When the MOVE Y J2 keys are pressed the robot will move along the Y axis plus direction of the tool coordinate system When the MOVE Y J2 keys are pressed Move along the minus direction 6 axis type only When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction of the tool coordinate system When the MOVE Z J3 keys are pressed Move along the minus direction When the robot is in the transportation posture gt There are directions from which linear movement is not possible from the transportation posture In this case will appear the
28. press INP Next a confirmation 1 DEF 0 screen will appear Designate the origin setting axis Resetting the origin 5 61 5Maintenance and Inspection lt MECHA gt 9 Press the 1 and INP keys SET ORIGIN The origin posture will be set OK 1 1 EXECUTE B _ J5 1 Set the origin lt MECHA gt 12345678 10 Setting of the origin is completed BRAKE 00000100 SET AXIS 00000100 11 Refer to 5 5 4Recording the origin data on ORIGIN COMPLETED page 69 in this manual and record the origin data on the origin data seal Releasing the brakes To release the brakes move the cursor to the Brake axis No with the lt or key The brakes can be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately O Origin setting axis designation lt gt Move the cursor to the Axis Designation axis No in the origin setting with the lt or key The origin is set only for the axis for which a 1 is displayed the screen If the origin is not to be set press the 0 key and display a 0 5 62 Resetting the origin 5Maintenance and Inspection 8 All axis origin setting 1 First refer to
29. 1 Daily inspection items uai eoe eei eei ten 5 38 9 22 Periodic inspection RTT 5 39 5 3 Maintenance and inspection procedures 40 5 40 53 Robot arm 5 40 5 3 2 Installing removing the cover 5 42 5 3 3 Inspection maintenance and replacement of timing belt 5 44 1 Timing belt replacement period 0001000 5 44 2 Inspection adjustment and replacement of the J5 axis timing belt 5 45 Timing Delt COM SION A LA Sol eM aa 5 47 9 94 LuDFIG AOL ct eo neni ena e ita lie b a 5 48 1 Lubrication position and specifications e meremeenavaenaeaemennavaenanaemaenanaamavaamaenamaememaemaemanaa 5 48 2 L brication method si Ge vaala 5 50 5 3 5 Replacing the backup battery ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 5 51 1 Replacing the robot arm battery sescenti toss tts 5 51 5 4 Maintenance parts Ri
30. 5 64 Resetting the origin 5 5 2 Jig method 5Maintenance and Inspection The reference dimension drawing of the calibration jig 1E INST used with this method is shown in Fig 5 11 This jig is the same option as the Mitsubishi RV EN Series 4 5 5 drill through equal circumference divisions 11X 7 counterbore from rear surface oT EA PAUS T 002 5H7 45 reaner through 174 94 0 05 410 122 0 05 T t 40H7 m x 11 72 0 05 Fig 5 11 1E INST calibration jig reference dimension drawing The procedure of setting the origin with the calibration jig is shown below This operation is carried out with the teaching pendant Set the MODE switch on the front of the controller to TEACH and set the ENABLE DISABLE switch the teaching pendant to ENABLE to enable the teaching pendant The following operation is carried out while lightly pressing the deadman switch on the teaching pendant lt MENU gt lt MAINT gt 1 TEACH 2 RUN 1 PARAM 2 INIT 3 FILE 4 MONI 3 BRAKE 4 ORIGIN 5 MAINT 6 SET 5 POWER Select the maintenance screen lt MAINT gt 1 PARAM 2 INIT 1 DATA 2 MECH JIG 4 ABS 3 BRAKE 4 ORIGIN 5 POWER 5 USER J2 4 MNO Select the Origin Setting screen lt ORIGIN gt 1 DATA 2 MECH 3 JIG 4 ABS 9 USER n
31. 6 SET 5 STU lt MAINT gt E rade 2 Press the 4 key the maintenance screen and display the origin setting 3 ORIG J6 method selection screen 5 POWER 5 STU lt ORIGIN gt 1 DATA 2 MECH B INP 3 Press the 1 key on the origin setting method selection screen and select oum 4 ABS EXE the data input method DEF The origin data input method will be selected and the screen for turning OFF the servo power will appear lt ORIGIN gt EE 4 Press the 1 and INP keys to turn OFF the servo power The screen for ok4 B INP id 05 inputting the origin data will appear 1 EXECUTE Ee lt DATA gt D 000000 1 000000 000000 3 000000 000000 5 000000 000000 Q Selecting a menu The menu can be selected with one of the following methods A Press the numeral key for the No of the item to be selected B Using the and f 1 keys etc move the cursor to the item to be selected and then press the INP key Setting the origin 2 15 2Unpacking to Installation 5 Inputting the origin data Origin data label D J1 J2 J3 J4 J DATA DC D 5 46 1 Ji _J2 T B screen 3 J3 J4 9 JO J6 Input the value confirmed in section 1 Confirming the origin data on page 13 The correspondence of the origin data label value and axis to be input is shown in Fig 2 11 For the 5 axis robot the J4 axis is meaningless Fig 2 11 Correspondence
32. C J6 keys are pressed Rotate in the minus direction When alarm No 5150 occurs If alarm No 5150 ORIGIN NOT SET occurs the origin has not been set correctly Reconfirm the value input for the origin data lt gt Tool length OC The default tool length is Omm and the control point is the center of the end axis After installing the hand set the correct tool length in the parameters Refer to the separate manual Detailed Explanation of Functions and Operations for details 2 26 Confirming the operation 2Unpacking to Installation 4 3 axis XYZ jog operation Select the 3 axis XYZ jog mode XYZ456 LOW Press the MOVE XYZ keys and then X 134 50 xyz xyz press only the XYZ key XYZ456 will appear 220 00 move 2 _ at the upper left of the screen Z 280 00 3 axis orthognal jog mode Each time the MOVE keys pressed the override will increase in the order of LOW Set the jog speed HIGH gt 3 5 10 30 50 70 gt XYZA56 LOW 100 When the MOVE keys are pressed X 134150 the override will decrease in the reverse order Y 220 00 ETER The currently set speed will appear on the Z 280 00 Set the soeed upper right of the screen Set the override to 10 here for confirmation work Moving along the XYZ coordinate 5 axis type 6 flange position does change When the MOVE X J1
33. Installation of safety fence Establish a set signaling method to the related operators for starting work and follow this method Signaling of operation start As a principle turn the power OFF during maintenance work Place a sign indicating that maintenance work is in progress on the start switch etc Indication of maintenance work in progress Before starting work inspect the robot emergency stop switch and other related devices etc and confirm that there are no errors Inspection before starting work N CAUTION N CAUTION N CAUTION N CAUTION N CAUTION N CAUTION N WARNING WARNING N CAUTION N WARNING NCAUTION N CAUTION NCAUTION NCAUTION N WARNING N CAUTION The points of the precautions given in the separate Safety Manual are given below Refer to the actual Safety Manual for details Use the robot within the environment given in the specifications Failure to do so could lead to a drop or reliability or faults Temperature humidity atmosphere noise environment etc Transport the robot with the designated transportation posture Transporting the robot in a non designated posture could lead to personal injuries or faults from drop ping Always use the robot installed on a secure table Use in an instable posture could lead to positional deviation and vibration Wire the cable as far away from noise sources as possible If placed near a noise source positio
34. MITSUBISHI Mitsubishi Industrial Robot RV 4A 5AJ 3AL 4AJL Series INSTRUCTION MANUAL ROBOT ARM SETUP amp MAINTENANCE MIZLI A BFP A8034 B N Safety Precautions Always read the following precautions and the separate Safety Manual before starting use of the robot to learn the reguired measures to be taken N CAUTION N CAUTION WARNING N CAUTION N WARNING NCAUTION NCAUTION NCAUTION All teaching work must be carried out by an operator who has received special training This also applies to maintenance work with the power source turned ON Enforcement of safety training For teaching work prepare a work plan related to the methods and procedures of oper ating the robot and to the measures to be taken when an error occurs or when restart ing Carry out work following this plan This also applies to maintenance work with the power source turned ON Preparation of work plan Prepare a device that allows operation to be stopped immediately during teaching work This also applies to maintenance work with the power source turned ON Setting of emergency stop switch During teaching work place a sign indicating that teaching work is in progress on the start switch etc This also applies to maintenance work with the power source turned ON Indication of teaching work in progress Provide a fence or enclosure during operation to prevent contact of the operator and robot
35. ORG 1st element 135 40 9 0 95 45 50 3 When completed changing the parameters turn the controller power OFF and ON Move the waist axis to the motion range limit with joint jog operation and confirm that the limit over occurs and the robot stops at the angle changed for both the sides This completes setting the parameters and the changing of the motion range 3 34 Changing the motion range 4Basic operations 4 Basic operations The basic operations from creating the program to automatic operation are explained in section 4 Basic operations in the From Controller Setup to Maintenance manual Refer that manual as necessary 4 35 4Basic operations 4 36 5Maintenance and Inspection 5 Maintenance and Inspection The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are described in this chapter The types and replacement methods of consumable parts are also explained 5 1 Maintenance and inspection interval Maintenance and inspection are divided into the inspections carried out daily and the periodic inspections carry out at set intervals Always carry these out to prevent unforeseen trouble to maintain the product for a long time and to secure safety 1 Inspection schedule In addition to the monthly inspection add the following inspection items every three months estimated at 500 Hr operation hours
36. XIS 00000000 SET AXIS 11111100 deadman switch on the teaching pendant press ORIGIN NOT DEF ORIGIN NOT DEF the STEP MOVE and X key The brakes will be released only while these keys are held down B J5 M DEF Designate the brakes release axis N CAUTION When the brakes are released the robot arm could drop by its own weight depending on the posture If the deadman switch only P7TB T or T B X W key is released the brakes will be applied immediately 8 Set the robot posture with the brakes released Contact the calibration Jig against the machined surface on the front and side of the base as bellow 1 Calibration Jig 1 Calibration Jig 5 type 6 axis type 5 66 Resetting the origin 5Maintenance and Inspection 5 axis type 6 axis type et the origin c IDEE ut Press the key and move the cursor to SET AXIS 11101100 SET AXIS 11111100 Axis Designation To set the origin set 1 Set 0 for the axis for which the origin is not to ORIGIN NOT DEF ORIGIN NOT DEF ELE When 0 5 set the previously set data will be saved lt JIG gt 12345678 CHANGES TO ORIGIN 10 Press the 1 and INP keys OK The origin posture will be set 1 EXECUTE INP Set the origin 1 DEE 5 axis type 6 axis type 12345678 lt JIG gt 12345678 11 Setting of the origin 15 completed BRAKE 11101100 BRAKE 11111100 SET AXIS 11101100 SET AXIS 11111100 2 ORIGIN
37. cidents do not hold the robot from the left right sides or hold covers that have no grips 2 8 Installation 2 2 4 Installation procedures 4 M8 x 40 hexagon socket bolt Clean SA type is 4 M8 x 100 Four positions Spring washer Plain washer Blower base Clean SA type only co N Robot front 5 Installation o 5 ER reference 58 surface ER E 4 9 installation hole So S Base bottom Fig 2 5 Installation dimensions 2Unpacking to Installation 1 The robot installation surface has been machine finished Use the installation holes 4 18 holes opened at the four corners of the base and securely fix the robot with the enclosed installa tion bolts M16x60 hexagon socket bolts 2 Install the robot on a level surface 3 It is recommended that the surface roughness of the table onto which the robot is to be installed by 6 3a or more If the installation surface is rough the contact with the table will be poor and positional deviation could occur when the robot moves 4 When installing use a common table to prevent the position of the devices and Jigs subject to robot work from deviating 5 The installation surface must have sufficient strength to withstand the arm reaction during operation and resistance against deformation and vibration caused by the static dynamic load of the robot arm and peripheral devices etc 6 Remove the fixt
38. d L1 100 will appear on the STATUS NUMBER display on the front of the controller Setting the origin 2 13 2Unpacking to Installation 3 Preparing the T B Next prepare to use the T B 1 Set the MODE switch on the front of the controller to TEACH 2 Set the ENABLE DISABLE switch to ENABLE The menu selection screen will appear The following operations are carried out with the T B DISABLE ENABLE 2 Q Operating from the T B O Always set the MODE switch mode selection key switch the front of the controller to TEACH and then set the T B ENABLE DISABLE switch to ENABLE When the T B is valid only operations from the T B are possible Operations from the controller or external signals will not be accepted When T B operations are mistaken The displayed screen will return to the menu selection screen when the MENU key is pressed Carry out the operations again from this screen Operations can also be carried out again by setting the T B ENABLE DISABLE switch to DISABLE once and then setting to ENABLE 2 14 Setting the origin 2Unpacking to Installation 4 Selecting the origin setting method lt T B screen gt Keys used lt MENU gt 1 2 RUN 1 Press the 5 key on the menu screen and display the maintenance 3FILE Go sereen 5 MAINT
39. e conveyance system of the pitch axis Compared to gears and chains the timing belt does not require lubrication and has a low noise However if the belt usage method and tension adjustment are inadequate the life could drop and noise could be generated Sufficient aging to remove the initial elongation of the belt and adjustment of the belt tension have been carried out before shipment from the factory However depending on the robot working conditions elongation will occur gradually over a long time The tension must be confirmed during the periodic inspection The timing belt must be replaced in the following cases 1 Timing belt replacement period The timing belt life is greatly affected by the robot working conditions so a set time cannot be given However if the following symptoms occur replace the belt 1 When cracks from at the base or back of the belt teeth 2 When the belt expands due to adherence of oil etc 3 When the belt teeth wear to approx half of the tooth width 4 When the belt teeth jump due to belt teeth wear 5 When the belt snaps N CAUTION Due to the manufacturing of the timing belt initial wear will occur Wear chips may accumulate in the cover after approx 300 Hr of operating the robot but this is not a fault If the wear chips appear soon after wiping them off replace the belt N CAUTION When the belt is replaced the machine system origin may deviate In this case the position data must be reviewed
40. e product The standard configuration of the robot arm part of the purchased product is shown inTable 2 1 Confirm the parts Users who have purchased optional products should refer to the separate RP 4A 5AJ 3AJ AAJL Series Standard Specifications Table 2 1 Standard configuration mee 9 Robot arm RV 4A RV 5AJ RV 3AL or RV 4AL series Wemews vase Mee ae smeek dme ETE N dme Pee E _ NE we am Confirming the product 2 5 2Unpacking to Installation 2 2 Installation 2 2 1 Unpacking Pull off 1 Tape 2 lid 3 Cushioning material a b Pull off 3 Cushioning material CAUTION Always unpack the Robot arm robot at a flat place The robot could tilt over if unpacked at an unstable place Note The cushioning material will be required if the robot is transported again so save it in a safe place Fig 2 1 Unpacking the robot arm AN CAUTION The robot is shipped from the factory in cardboard packaging Always refer to Fig 2 1 and unpack the robot Handle the robot arm according to 2 2 2 Transportation procedures transporting with a crane 1 Using a knife etc slit the tape 1 fixing the upper lid 2 of the cardboard box Fig 2 1 a 2 Pull the upper lid 2 of the cardboard box off with both hands Fig 2 1 b 3 Pull the cushioning material 3 off with both hand
41. e set 1 EXECUTE 5 Set the origin 1 DEF lt MECHA gt 12345678 9 Setting of the origin is completed BRAKE 00100000 SET AXIS 00100000 10 Refer to 5 5 4Recording the origin data on ORIGIN COMPLETED page 69in this manual and record the origin data on the origin data seal Releasing the brakes To release the brakes move the cursor to the Brake axis No with the lt or key The brakes be released only for the axis for which 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately Origin setting axis designation lt gt Move the cursor to the Axis Designation axis No in the origin setting with the lt or key The origin is set only for the axis for which a 1 is displayed the screen If the origin is not to be set press the 0 key and display a 0 Resetting the origin 5 57 5Maintenance and Inspection 5 J4 axis origin setting Only 6 axis type lt MECHA gt 12345678 1 Before moving the twist axis move the J3 axis BRAKE 00100000 to prevent arm interference SET AXIS 11101000 Press the 0 key twice and then press the 1 ORIGIN NOT DEF key 717 will display at the 3 position to set the brake release 2 Confirm the axis for
42. ear 2 16 6 Installing the battery cover c csccccecesseccecessecescescecessecessesceccesecceseececceseecesessescessecesssseseeseseessesestesessereeeeeees 2 17 2 4 Confirming the operation ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 2 18 CD JolntJo ODOFBLIOE VR cm cem dei rictu rtc sac cele 2 21 2 XYZ jog operating u mA A A A AM 2 23 9 Tool oz ODBFALOl zie trt EE 2 25 4 3 axis She een nee 2 27 5 Cylindrical jog operation 000 ee ee 2 29 3 Installing the option devices a 3 31 3 1 Installing the solenoid valve set 1E VD01 VD02 VDO3 2 0 010000010000 3 31 3 2 Ghanging the motion A E 3 33 T M 4 35 9 Maititenance and Inspection sa 5 37 5 1 Maintenance and inspection interval 5 37 9 2 Inspection items ee aaa m 5 38 5 2
43. en the MOVE X J1 keys are pressed Rotate in the minus direction J2 axis jog operation 5 type 6 type When the MOVE Y J2 keys are pressed the J2 axis will rotate in the plus direction When the MOVE Y J2 keys are pressed Rotate in the minus direction Confirming the operation 2 21 2Unpacking to Installation lt gt When the robot is in the transportation posture gt The axes may be outside the movement area Move these axes toward the inner side of the movement area If moved outward an 4 will appear on the screen and the robot will not move J3 axis jog operation 5 type 6 axis type When the MOVE Z J3 keys are pressed the J3 axis will rotate in the plus direction When the MOVE Z J3 keys are pressed Rotate in the minus direction J4 J5 and J6 axis jog DAS C mn sad ee Cove Ne ST STEP J4 axis MOVE 5 type 6 axis type When the MOVE A J4 keys are pressed the J4 axis will rotate in the plus direction When the MOVE A J4 keys are pressed Rotate in the minus direction 6 axis type only When the MOVE J5 keys are pressed the J5 axis will rotate in the plus direction When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE C J6 keys are pressed the J6 axis will rotate in the plus direction When the MOVE C J6 key
44. enance and Inspection lt USER gt CUSER 12345678 ap TO ORIGIN pangu sree 9 Press the 1 key and then the INP key The 1 EXECUTE ORIGIN NOT DEF SIA will be set 05 1 DEF Set the origin This completes the setting of the origin with the user origin method 5 5 4 Recording the origin data When the origin has been set with the jig method record that origin data on the origin data label With this the origin can be set with the origin data input method the next time Confirm the origin data on the teaching pendant screen origin data input screen The origin data label is enclosed with the arm or attached on the back of the battery cover The teaching pendant operation method and battery cover removal method for confirming the origin data is the same as the methods for setting the origin with the origin data input method Refer to 2 3 2Setting the origin with the origin data input method on page 13 and write the origin data displayed on the teaching pendant onto the origin label 1 Confirming the origin data label Remove the battery cover Refer to 5 3 5Replacing the backup battery on page 51 and remove the battery cover 2 Confirming the origin data Confirm the value displayed on the teaching pendant s Origin Data Input screen Refer to 2 3 2Setting the origin with the origin data input method Inputting the origin data on page 16 and display the Origin Data Input screen
45. er designated origin parameter USRORG The parameter details and input methods are described in the separate Instruction Manual Detailed Explanation of Functions and Operations Refer to that manual and input the user designated origin position MENU lt MAINT gt 4 Next set the origin 1 TEAGH 2 RUN 1 PARAM 2 INIT Press the MENU key to display the Menu 3 FILE 4 MONI 3 BRAKE 4 ORIGIN screen 5 MAINT 6 SET 5 POWER 5 Press the 5 key to display the Maintenance screen 06 5 STU Display the maintenance screen 6 Press the 4 key to select the Origin Setting lt ORIGIN gt screen 1 PARAM 2 INIT 1 DATA 2 MECH 3 BRAKE 4 ORIGIN 4 3 JIG 4 ABS 5 9 USER lt MAINT gt Y J2 Display the origin setting method selection scree 4 MNO 7 Press the 5 key to select the user origin lt ORIGIN gt method 1 DATA2 MECH Then press 1 key and INP key to turn OFF 3 JIG4 ABS the servo 9 USER 1 EXEGUTE C E J5 Select the origin method and servo OFF 9 1 DEF lt USER gt 12345678 lt USER gt BRAKE 00000000 CHANGES TO ORIGIN 8 Press the key and input 1 for the axis for which the origin is to be set Press the INP key to display the Confirmation screen OK 1 EXECUTE SET AXIS 11110000 ORIGIN NOT DEF RPL B INP J5 EXE Designate the origin setting axis 1 DEF 5 68 Resetting the origin 5Maint
46. he text this refers to a key on JOINT the teaching pendant This indicates to press the B key while holding down the A key 7 FORWD X In this example the Forward key is pressed while holding down the X A B Y key This indicates to hold down the A key press and release the B key and then press the C key In this example the Step Move key is held down the Condition key is pressed and released and the Replace key is pressed STEP MOVE CONDI IRPL B C TAB This indicates the teaching pendant 1 2 Using the instruction manuals 1 2 Safety Precautions 1Before starting use Always read the following precautions and the separate Safety Manual before starting use of the robot to learn the reguired measures to be taken N CAUTION NCAUTION NWARNING NCAUTION N DANGER NCAUTION NCAUTION NCAUTION All teaching work must be carried out by an operator who has received special training This also applies to maintenance work with the power source turned ON Enforcement of safety training For teaching work prepare a work plan related to the methods and procedures of oper ating the robot and to the measures to be taken when an error occurs or when restart ing Carry out work following this plan This also applies to maintenance work with the power source turned ON Preparation of work plan Prepare a device that allows opera
47. he timing pulleys 4 and 5 when adjusting the tension 6 Securely tighten the four motor installation screws 1 after adjusting the tension If insecurely fixed the motor could loosen due to vibration Replacement method 1 The timing belt replacement method is shown in Fig 5 6 2 Move the robot posture with the teaching pendant so that the J5 axis is facing downward Move in the same direction as the specific gravity 3 Make sure that the pulleys do not move during the belt replacement 4 If the positional relation of pulley 4 and pulley 5 deviates positional deviation could occur 5 Make a mark with a felt tip marker on timing belt 2 and timing pulleys 4 and 5 as shown in Fig 5 6 so that the engagement of the timing belt 2 and timing pulleys 4 and 5 teeth does not deviate 6 Loosen the four motor installation screws 1 and remove the belt 7 Copy the marks onto the new timing belt Tense both belts when doing this 8 Set the marks of the new timing belt to the timing pulleys 4 and 5 and install the belt 9 Refer to steps 3 to 6 in the adjustment method and the section on the 3 Timing belt tension to adjust the tension 10 The position may be deviated after the belt is replaced Check whether positional deviation has occurred 11 If the position has deviated refer to 5 5Resetting the origin on page 53 and reset the origin position 5 46 Maintenance and inspection procedures 5Maintenance and Inspection
48. ith the installation install the shoulder cover 1 at its original position Make sure that the cables do not get caught at this time The connection correspondence after installation is as shown in Table 3 1 Table 3 1 Solenoid valve ports and hoses Correspondence of couplings and hand ports Fore arm Robot arm back Solenoid valve Solenoid valve Hand Hand port coupling No side coupling No AIR OUT AIR IN d OPEN 1 1 A Hand 1 1st row CLOSE 2 2 B OPEN 3 3 A Hand 2 2nd row CLOSE 4 4 B OPEN 5 5 A Hand 3 3rd row CLOSE 6 6 B 3 32 Installing the solenoid valve set 1E VD01 VD02 VD03 Slnstalling the option devices 3 2 Changing the motion range The motion range of the J1 axis can be changed to the range shown in Table 3 2 Option Table 3 2 Motion range alternative range Axis Standard Alternative angle Angle 160 135 90 45 One of the points shown t Insertion position None A B C on the left d Angle 160 135 90 45 One of the points shown Insertion position None a b on the left Note The insertion position given in the table indicates the insertion position for the movement range change stopper Refer to Fig 3 2 The motion range is changed with robot arm settings and parameter settings 1 Setting the robot arm 1 Tilt the robot arm with a crane until the bottom of the base is visible as shown in Fig 3 2
49. keys are pressed the robot will move along the X axis plus direction When the MOVE X J1 keys are pressed Move along the minus direction When the MOVE Y J2 keys are pressed the robot will move along the Y axis plus direction When the MOVE Y J2 keys are pressed Move along the minus direction When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed Move along the minus direction Jog mode will change when only XYZ key is pressed again O When the MOVE XYZ keys are pressed and then only the XYZ key is pressed the upper left display will change in the order of XYZ 3 5 XYZ CYLINDRICAL Each jog mode can be selected Q Q The flange surface end axis posture cannot be maintained with 3 axis XYZ jog With 3 axis XYZ jog the flange surface end axis posture orientation is not maintained when moving linearly in the X Y or Z axis direction Use XYZ jog to maintain the posture Confirming the operation 2 27 2Unpacking to Installation EA axis J6 axis 5 axis type 6 axis type The flange position changes This is the same as the J4 J5 and J6 axis joint jog operation When the MOVE A J4 keys are pressed the J4 axis will rotate in the plus direction When the MOVE A J4 keys are pressed Rotate in the minus direction
50. lled when the robot is shipped from the factory but as these are consumable parts they must be replaced periodically by the user The guideline for replacing the battery is one year but this will differ according to the robot s usage state When the battery life nears the Battery cumulative time over alarm Alarm No 7520 will occur Once the alarm occurs replace all batteries in the robot arm and controller as soon as possible Lithium batteries type AGBAT and ER6 are used in both the controller and robot arm The battery replacement procedures are as follow 1 Replacing the robot arm battery N CAUTION Don t disconnect connector etc While replacing the battery the encoder position data is saved by the power supplied from the controller Thus if the cable connection is incomplete the encoder position data will be lost when the controller power is turned OFF Several batteries are used in the robot arm but replace all old batteries with new batteries at the same time Battery 2 Truss screw Read connector E O 3 Connecta box Section A Setails of section A Fig 5 10 Replacing the battery 1 Check that the cable between the robot unit s connector box and controller is securely connected 2 Turn the controller power ON While replacing the battery the position data is saved by the power supplied from the controller Thus if the cable connection is incomplete or if the controller power is OFF the
51. n is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 7 J6 axis origin setting 1 Install the hand option or bolt two M5 bolts lt MECHA gt 12345678 prepared by user at opposing positions on the BRAKE 00000100 mechanical interface SET AXIS 00000100 ORIGIN NOT DEF B 2 Press the 0 key five times and then press the ipi 1 key 1 will display at the 5 position to set Designate the origin setting axis 7 the brake release 3 Confirm the axis for which the brakes are to released 4 One worker must securely support the upper arm with both hand 5 While holding down the deadman switch hold down the MOVE X keys The brakes will be released while the keys are held down 6 Hold onto the hand or bolt installed in step 1 and slowly rotate the mechanical interface to the match marks Bolt M5 2 bolts Prepared by user N CAUTION The wrist roll axis does not have a dmm mechanical stopper When setting the origin position do not rotate the axis more than the motion range 200deg RPL l 7 Press the key The cursor will move to Move the cursor 2 AXIS DESIGNATION lt MECHA gt 12345678 V BRAKE 00000100 8 Designate the axis for which the origin is to be SET AXIS 00000100 see ORIGIN NOT DEF s Set 1 for the 6 axis and set 0 for the other 55 KA axes Then
52. n of the frange will not move Assuming that the current position is on an arc centering on the 4 axis the robot moves along that arc When the MOVE Y J2 keys are pressed the robot will move along the arc in the plus direction When the MOVE Y J2 keys are pressed Move in the minus direction When the MOVE X J1 keys are pressed the robot will expand in the radial direction When the MOVE X J1 keys are pressed Contract in the radial direction When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed Move along the minus direction Confirming the operation 2 29 2Unpacking to Installation Changing the flange surface orientation 2 E ES ES S DEDI jas S 7 117 9 lt 2 2 vl Ge E Es A X STEP B Ea UIN EI X Contro in EJ point Contro ms I 2 point a Y STEP STEP dE 94 05 4 T 2 GH MOVE EP C US gt 5 type 6 axis type The flange position does not change This is the same as the A B and C axis XYZ jog operation When the MOVE A J4 keys are pressed 6 axis type The X axis will rotate in the plus direction 5 type Z axis will rotate in the plus direction of the tool coordinate system When the MOVE A J4 keys are pressed Rotates in
53. nal deviation or malfunction could occur Do not apply excessive force on the connector or excessively bend the cable Failure to observe this could lead to contact defects or wire breakage Make sure that the workpiece weight including the hand does not exceed the rated load or tolerable torque Exceeding these values could lead to alarms or faults Securely install the hand and tool and securely grasp the workpiece Failure to observe this could lead to personal injuries or damage if the object comes off or flies off during operation Securely ground the robot and controller Failure to observe this could lead to mal functioning by noise or to electric shock accidents Indicate the operation state during robot operation Failure to indicate the state could lead to operators approaching the robot or to incorrect operation When carrying out teaching work in the robot s movement range always secure the priority right for the robot control Failure to observe this could lead to personal inju ries or damage if the robot is started with external commands Keep the jog speed as low as possible and always watch the robot Failure to do so could lead to interference with the workpiece or peripheral devices After editing the program always confirm the operation with step operation before starting automatic operation Failure to do so could lead to interference with periph eral devices because of programming mistakes etc Make sure tha
54. nnot be corrected refer to Troubleshooting check and remedy 2 Is there any abnormal motion or abnormal noise Follow the troubleshooting section Visual 5 38 Inspection items 5Maintenance and Inspection 5 2 2 Periodic inspection Carry out periodic inspection with the procedures given in Table 5 2 Table 5 2 Periodic inspection items details Procedure Inspection item details Remedies Monthly inspection items Are any of the bolts or screws on the robot arm loose Securely tighten the bolts Are any of the connector fixing screws or terminal block terminal Securely tighten the screws screws loose Remove the cover at each section and check the cables for wear Check and eliminate the cause damage and adherence of foreign matter If the cables are severely damaged contact the Mitsubishi Service Department 3 month inspection items BEN Is the timing belt tension abnormal If the timing belt is loose or too tense adjust it 6 month inspection items Is the friction at the timing belt teeth severe If the teeth are missing or severe friction is found replace the timing belt Yearly inspection items Lubricate the grease at the harmonic reduction gears for each axis Inspection items 5 39 5Maintenance and Inspection 5 3 Maintenance and inspection procedures The procedures for carrying out the periodic maintenance and inspection are described in this section Thoroughly read the contents
55. osition to set the brake release SET AXIS 11101000 B ORIGIN NOT DEF J5 2 Confirm the axis for which the brakes are to be Designate the origin setting axis Loe released 3 One worker must securely support the fore arm with both hands 4 While holding down the deadman switch hold down the MOVE X keys The brakes will be released while the keys are held down 5 With both hands slowly move the J3 axis in plus direction and contact the axis against the mechanical stopper N CAUTION For safety purposes the step for releasing the brakes must be carried out by two workers One worker must operate the T B and the other must support the arm When the brakes are released the robot arm could drop by its own weight depending on the posture AN CAUTION If the T B X key or the deadman switch is released the brakes will be applied immediately JG Front of base m 5 type 6 axis type 5 56 Resetting the origin 5Maintenance and Inspection 6 Press the key The cursor will move to Move the cursor AXIS lt MECHA gt 12345678 BRAKE 00100000 7 Designate the axis for which the origin is to be set xi 2 1 e NB Set 1 for the 3 axis and set 0 for the other i J5 KAS EXE axes Then press INP Next a confirmation 0 ABC screen will appear Designate the origin setting axis ai 8 Press the 1 and INP keys 0K 1 The origin posture will b
56. ounding screw section 2Unpacking to Installation 2 2 6 Connecting with the controller Controller Robot arm Motor signal cable 5m Motor power cable 5m Fig 2 8 Connecting the machine cables Carry out the following procedure after installing the controller referring to the separate Controller Setup Basic Operation and Maintenance manual 1 Make sure that the power switch on the front of the controller is turned OFF 2 Connect the machine cable to the robot arm and the corresponding connector on the control AN CAUTION The machine cable connectors are dedicated for the controller side and robot arm side so take special care when connecting If connected incorrectly the connector pins could bend or break Thus even if connected correctly the robot will not operate correctly creating a dangerous situation N CAUTION Take special care to the leading of the connection cable If the cable is pulled with force or bent excessively wires could break or the connector could be damaged Installation 2 11 2Unpacking to Installation 2 3 Setting the origin The origin is set so that the robot can be used with a high accuracy After purchasing the robot always carry out this step before starting work This step must also be carried out if the combination of robot and controller being used is changed There are several methods for setting the origin but the origin data input method will be explained he
57. play a 0 5 54 Resetting the origin 5Maintenance and Inspection 3 J2 axis origin setting lt MECHA gt 12345678 BRAKE 01000000 1 Press the 0 key and then press the 1 key 1 will display at the 2 position to set the brake release SET AXIS 11101000 ORIGIN NOT DEF 43 2 Confirm the axis for which the brakes are to be 1 DEF released Designate the origin setting axis 3 One worker must securely support the upper arm with both hands 4 While holding down the deadman switch hold down the MOVE X keys The brakes will be released while the keys are held down 5 With both hands slowly move the J1 axis in minus direction and contact the axis against the mechanical stopper N CAUTION For safety purposes the step for releasing the brakes must be carried out by two workers One worker must operate the T B and the other must support the arm When the brakes are released the robot arm could drop by its own weight depending on the posture AN CAUTION If the T B X key or the deadman switch is released the brakes will be applied immediately Front of mp base 6 axis type j 6 Press the key The cursor will move to Move the cursor AXIS lt MECHA gt 12345678 BRAKE 01000000 set SET AXIS 01000000 Set 1 for the 2 axis and set 0 for the other C B INP 1 ORIGIN NOT DEF KA 35 axes Then press INP Next a confirmation 0 ABC 1 DEF sc
58. position data will be lost 3 Press the emergency stop button to place the robot in the emergency stop state This must be carried out for safety purposes 4 Remove the installation screws 2 shown in Fig 5 10 and remove the connector box cover 1 5 There is a battery holder in the connector box 3 Remove the old battery from the holder and disconnect the lead connector 6 Insert the new battery into the holder and connect the lead connector Make sure to replace all batteries with new ones 7 Install the connector box cover 1 with the above steps in reverse 8 Initialize the battery consumption time Always carry out this step after replacing the battery and initialize the battery usage time Refer to the separate Instruction Manual Detailed Explanation of Functions and Operations for details on the operation methods Maintenance and inspection procedures 5 51 5Maintenance and Inspection 5 4 Maintenance parts The consumable parts that must be replaced periodically are shown in Table 5 6 and spare parts that may be required during repairs are shown in Table 5 7 Purchase these parts from the designated maker when required Some Mitsubishi designated parts differ from the 5 standard parts Thus confirm the part name robot arm and controller serial No and purchase the parts from the dealer Table 5 6 Consumable part list No Pa
59. procedures required to operate the controller unpacking transportation installation confirmation of operation basic operation from creating the program to automatic operation and the maintenance and inspection procedures Explains details on the functions and operations such as each function and operation commands used in the program connection with the external input output device and parameters etc Explains the causes and remedies to be taken when an error occurs Explanations are given for each error No Using the instruction manuals 1 1 1Before starting use 1 1 2 Symbols used in instruction manual The symbols and expressions shown in Table 1 1 are used throughout this User s Manual Learn the meaning of these symbols before reading this instruction manual Table 1 1 Symbols in instruction manual Precaution indicating cases where there is a risk of operator fatality or seri AN D AN G E R ous injury if handling is mistaken Always observe these precautions to safely use the robot Precaution indicating cases where the operator could be subject to fatalities AN W ARNIN G or serious injuries if handling is mistaken Always observe these precautions to safely use the robot Precaution indicating cases where operator could be subject to injury or N C AUTIO N physical damage could occur if handling is mistaken Always observe these precautions to safely use the robot If a word is enclosed in brackets or a box in t
60. re Refer to 5 5 Resetting the origin on page 52 for the other methods The teaching pendant is reguired for this operation 2 3 1 Installing the teaching pendant T B By using the REMOVE T B switch the T B can be installed and removed while the controller s control power is ON However in this procedure the teaching pendant will be installed with the control power OFF Refer to the separate From Controller Setup to Maintenance for details on installing the teaching pendant with the control power ON 1 Installing with the control power OFF 1 Confirm that the controller s power supply switch is OFF Display LCD ENABLE DISABLE switch salm 2 Connect the T B connector to the RS 422 T B O connector on the controller IG gt 3 Fix the connector with the top and bottom screws so that it K will not come off mergency stop switch e 5 4 Do not pull the cable with force or bend it excessively as gt Seem keys the cable could break or the connector could be damaged 22 Appearance af teaching pendant 5 Confirm that the REMOVE T B switch on the side of the T controller is not depressed is projected REMOVE T B switch Connector 6 Set the ENABLE DISABLE switch to DISABLE did S Teaching pendant T B Fig 2 9 Installing the T B control power OFF REMOVE T B switch gt When using the robot with the T B this switch
61. rect O O If the origin input data is incorrect the alarm No 1760 origin setting data illegal will occur when origin data input In this case reconfirm the value input for the origin data Setting the origin 2 17 2Unpacking to Installation 2 4 Confirming the operation In this section the robot will be moved manually using the T B to confirm that the operation is correct Moving the robot manually is called jog operation This operation includes the Joint jog that moves each axis the XYZ jog that moves along the XYZ coordinate system and the Tool jog that moves along the tool coordinate system This operation is carried out while pressing the deadman switch on the back of the T B N CAUTION N CAUTION N CAUTION The robot will move during this operation Make sure that there are no operators near the robot and that there are no obstacles such as tools in the robot operation range To immediately stop the robot release the deadman switch on the back of the T B The servo power will turn OFF and the robot will stop The robot will also stop if the EMG STOP switch emergency stop switch on the front of the T B or the EMG STOP switch emergency stop on the front of the controller is pressed Confirm that the origin has been set If the origin has not been set will appear at the current position display on the teaching pendant the joint jog operation will take place in any jog mode selected
62. reen will appear Designate the origin setting axis 7 Designate the axis for which the origin is to be ian 8 Press the 1 and INP keys 0 1 The origin posture will be set INP 1 EXECUTE Set the origin 1 DEF lt MECHA gt 12345678 9 Setting of the origin is completed BRAKE 01000000 SET AXIS 01000000 10 Refer to 5 5 4Recording the origin data on ORIGIN COMPLETED page 69 in this manual and record the origin data on the origin data seal Resetting the origin 5 55 5Maintenance and Inspection Releasing the brakes To release the brakes move the cursor to the Brake axis No with the lt or key The brakes can be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately O Origin setting axis designation lt gt Move the cursor to the Axis Designation axis No in the origin setting with the lt or key The origin is set only for the axis for which a 1 is displayed the screen If the origin is not to be set press the 0 key and display a 0 4 J3 axis origin setting lt MECHA gt 12345678 BRAKE 00100000 1 Press the 0 key twice and then press the 1 key 17 will display at the 3 p
63. rrying out teaching work in the robot s movement range always secure the priority right for the robot control Failure to observe this could lead to personal inju ries or damage if the robot is started with external commands Keep the jog speed as low as possible and always watch the robot Failure to do so could lead to interference with the workpiece or peripheral devices After editing the program always confirm the operation with step operation before starting automatic operation Failure to do so could lead to interference with periph eral devices because of programming mistakes etc Make sure that if the safety fence entrance door is opened during automatic opera tion the door is locked or that the robot will automatically stop Failure to do so could lead to personal injuries Never carry out modifications based on personal judgments or use non designated maintenance parts Failure to observe this could lead to faults or failures When the robot arm has to be moved by hand from an external area do not place hands or fingers in the openings Failure to observe this could lead to hands or fingers catching depending on the posture Do not stop the robot or apply emergency stop by turning the robot controller s main power OFF If the robot controller main power is turned OFF during automatic operation the robot accuracy could be adversely affected 2Unpacking to Installation 2 Unpacking to Installation 2 1 Confirming th
64. rt name Type Usage place Supplier 1 Grease SK 1A Reduction gears of An needed each axis 2 Lithium battery AGBAT kata ype d In battery cover 6 axis type 5 Table 5 7 Spare parts list No Part name Type Usage place Q ty Supplier 1 Timing belt S2M 320 U J5 axis 2 AC servo motor J1 axis J2 axis 2 3 J3 axis 1 4 5 axis type J5 J6 2 6 axis type J5 J6 3 5 Reduction gears J1 axis 1 Mitsubishi Electric 6 J2 axis 1 7 J3 axis 1 8 5 axis type J5 1 6 axis type J4 J5 2 9 J axis 1 Note Confirm the robot arm serial No and contact the Mitsubishi Service Department for the type Table 5 8 Spare parts option list No Part name Type Usage place Supplier 5 52 Maintenance parts 5Maintenance and Inspection 5 5 Resetting the origin The origin is set so that the robot can be used with a high accuracy After purchasing the robot always carry out this step before starting work The origin must be reset if the combination of robot and controller being used is changed or if the motor is changed causing an encoder area The types of origin setting methods are shown in Table 5 9 Table 5 9 Origin setting method No Method Explanation Remarks 1 Origin data input The origin data set as the default is input from The setting method is explained in 2 3Setting the method the T B origin on page 12 2 Mechanical stopper This origin posture is set by con
65. s are pressed Rotate in the minus direction Q O When an on the T B screen display If the robot is moved outside the movement area an will appear In this case move the axis in the opposite direction JOINT LOW Edw 160 00 In the example on the left the J1 axis is at the limit of the plus side movement area S 20 00 E 80 00 2 22 Confirming the operation 2Unpacking to Installation 2 XYZ jog operation Select the XYZ jog mode XZ LOW Press the MOVE XYZ keys to select X 134 50 XYZ the orthogonal jog mode X Y Z will appear 22000 move A at the upper left of the screen Z 280 00 XYZ jog mode Set the jog speed Each time the MOVE keys are pressed the override will increase in the XYZ LOW order of LOW gt HIGH gt 3 gt 5 gt 10 30 X 13450 gt 50 70 100 When the MOVE 5 OT keys are pressed the override will decrease in the reverse order The currently set speed will appear on the upper right of the screen Set the override to 10 here for confirmation work Moving along the XYZ coordinate TZ GAAF SPACE POR 5 axis type 6 axis type The direction of the frange will not move When the MOVE X J1 keys are pressed the robot will move along the X axis plus direction When the MOVE X J1 keys are pressed Move along the minus direction When the MOVE Y J2 ke
66. s to complete the unpacking process Fig 2 1 c 2 6 Installation 2Unpacking to Installation 2 2 2 Transportation procedures transporting with a crane M6 X 16 2 bolts Arm fixing plate Fig 2 2 Transportation procedures transporting with a crane 1 Attach the suspension fittings to the left and right sides of the shoulder section and securely fix with bolts M6 x 16 2 bolts At this time fix two of the suspension fitting s three holes at the side closest to the robot front 2 Catch wires in the eye bolts installed on the suspension fittings and quietly suspend the arm 3 At this time make sure that the wires etc do not interfere with the robot arm or covers Always place cloth etc at interfering places 4 When transferring to the installation place take care not to apply vibration or impact 5 After installing at the installation place remove the above suspension fittings 6 Always follow the above procedures and methods to transport the robot for secondary transportation such as when changing the installation position If the arm is directly suspended without using the specified suspension fittings or if it is suspended in the work posture the configuration devices could be damaged and the transportation workers will be subject to risk due to an inadequate center of gravity position Installation 2 7 2Unpacking to Installation 2 2 3 Transportation procedures Forearm
67. selection screen lt ORIGIN gt 1 DATA 2 MECH 3 Press the 2 key and select the jig method 3 JIG 4 ABS Then press the 1 key and the INP key to 5 USER 1 EXECUTE turn the servo OFF Securely fix the transportation jig A to the base A B INP with the fixing bolts M4 X 12 2 bolts in this 2 GHI 1 DEF state Select the jig method When setting the origin all axes can be set or only random axes can be set The methods corresponding to the axes to be set are described below so select the corresponding explanation and set the origin The brakes are released here and the arm is moved with both hands N CAUTION For safety purposes the brakes must be released by two workers Resetting the origin 5 53 5Maintenance and Inspection 2 J1 axis origin setting lt MECHA gt 12345678 BRAKE 10000000 SET AXIS 11101000 ORIGIN NOT DEF B Release the brakes Move the cursor lt MECHA gt 12345678 BRAKE 10000000 SET AXIS 10000000 ORIGIN DEF Designate the origin setting axis lt MECHA gt SET ORIGIN 0K 1 TE TE 1 EXEGUTE 1 DEF Set the origin lt MECHA gt 12345678 BRAKE 10000000 SET AXIS 10000000 ORIGIN COMPLETED Releasing the brakes OH Q B C INP 05 46 1 DEF ABC 1 Press the 1 key 1 will display at the 1 position to set the brake release 2 Confirm the axis for which the brakes are to be released
68. sor lt MECHA gt 12345678 BRAKE 00010000 SET AXIS 00010000 ORIGIN NOT DEF B C INP 5 46 EXE Designate the origin setting axis V DE 0 0 NO lt MECHA gt SET ORIGIN OK 1 B INP EXECUTE 5 Set the origin 1 DEE lt MECHA gt 12345678 BRAKE 00010000 SET AXIS 00010000 ORIGIN COMPLETED Releasing the brakes OH gt 11 Press the key The cursor will move to AXIS 12 Designate the axis for which the origin is to be set Set 1 for the 4 axis and set 0 for the other axes Then press INP Next a confirmation screen will appear 13 Press the 1 and INP keys The origin posture will be set 14 Setting of the origin is completed 15 Refer to 5 5 4Recording the origin data on page 69 in this manual and record the origin data on the origin data seal To release the brakes move the cursor to the Brake axis No with the lt or key The brakes be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately Origin setting axis designation Move the cursor to the Axis Designation axis No in the origin setting with the lt or key The origin is set only for the a
69. ssed 6 axis type The X axis will rotate in the plus direction 5 type The Z axis will rotate in the plus direction of the tool coordinate system When the MOVE A J4 keys are pressed Rotate in the minus direction When the MOVE J5 keys are pressed 6 axis type The Y axis will rotate in the plus direction 5 type The Y axis will rotate in the plus direction of the tool coordinate system When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE J6 keys are pressed 6 axis type The Z axis will rotate in the plus direction 5 type There is no operation When the MOVE C J6 keys are pressed Rotate in the minus direction O When alarm No 5150 occurs If alarm No 5150 ORIGIN NOT SET occurs the origin has not been set correctly Reconfirm the value input for the origin data Tool length OO The default tool length is Omm and the control point is the center of the end axis After installing the hand set the correct tool length in the parameters Refer to the separate manual Detailed Explanation of Functions and Operations for details 2 24 Confirming the operation 3 Tool jog operation Select the tool jog mode TOOL LOW 22000 Z 280 00 Set the jog speed TOOL LOW X 134 50 t se E pere Set the speed Moving along the tool coordinate system X J1 MOVE
70. step 6 J5 axis origin setting on page 60 and set the origin of the J5 axis 2 To prevent impacts of the J5 axis on the robot arm move the J5 axis to near degrees with joint jog operation refer to 1 Joint jog operation page 21 in this manual Flange direction J5 axis Flange direction J5 axis 5 type 6 axis type 3 For the 6 axis robot refer to 5 J4 axis origin setting Only 6 axis type page 58 and set the J4 axis origin position The following steps are carried out simultaneously with the other axes so they can be skipped here For the 5 axis robot proceed to step 4 4 Refer to 2 J1 axis origin setting on page 54 and 3 92 axis origin setting page 55 4 J3 axis origin setting on page 56 7 96 axis origin setting on page 61 and set the origin positions of the J1 axis J2 axis J3 axis and J6 axis The following steps for setting each axis are carried out simultaneously with the other axes so they can be skipped here 5 When completed with all work the robot posture should be as bellow Front of robot Front of robot 5 axis type 6 axis type Resetting the origin 5 63 5Maintenance and Inspection Move the cursor JG 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN NOT DEF B INP 05 SEXES 1 DEF 0 ABC Designate the origin setting axis JG SET ORIGIN OK 1 m B 1 EXECUTE 1 DEF Se
71. t if the safety fence entrance door is opened during automatic opera tion the door is locked or that the robot will automatically stop Failure to do so could lead to personal injuries Never carry out modifications based on personal judgments or use non designated maintenance parts Failure to observe this could lead to faults or failures When the robot arm has to be moved by hand from an external area do not place hands or fingers in the openings Failure to observe this could lead to hands or fingers catching depending on the posture Do not stop the robot or apply emergency stop by turning the robot controller s main power OFF If the robot controller main power is turned OFF during automatic operation the robot accuracy could be adversely affected Revision history Date of Instruction Point Manual No 2000 07 12 BFP A8052 B Spare parts option list was added Error in writing correction Revision Details Instruction Point Manual No Revision Details Introduction Thank you for purchasing the Mitsubishi industrial robot This instruction manual explains procedures to be taken for unpacking installing servicing and inspecting the robot arm Always read through this manual before starting use to ensure correct usage of the robot No part of this manual may be reproduced by any means or in any form without prior consent from Mitsubishi The details of this manual are subject
72. t the origin JG 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN NOT DEF Q Releasing the brakes OH Q 6 Press the key The cursor will move to AXIS 7 Designate the axis for which the origin is to be set The origin setting of the 5 axis has been completed with the first operation so set the 5 axis to 0 and set all of the other axes to 17 Then press INP The 5 axis robot does not have the 4 axis so set O Next a confirmation screen will appear 8 Press the 1 and INP keys The origin posture will be set 9 Setting of the origin is completed 10 Refer to 5 5 4Recording the origin data on page 69 in this manual and record the origin data on the origin data seal To release the brakes move the cursor to the Brake axis No with the lt or key The brakes can be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately O Origin setting axis designation lt gt Move the cursor to the Axis Designation axis No in the origin setting with the lt or key The origin is set only for the axis for which a 1 is displayed the screen If the origin is not to be set press the 0 key and display a 0
73. tacting each axis The setting method is explained in 5 5 1Mechanical method against the mechanical stopper stopper method on page 53 3 Jig method The origin posture is set with the calibration jig The setting method is explained in 5 5 2Jig method installed page 65 4 User origin method A randomly designated position is set as the Before using this method the origin must be set with the origin posture origin data input method or Mechanical stopper method or jig method The setting method is explained in 5 5 3User origin method on page 68 5 5 1 Mechanical stopper method The method for setting the origin with the transportation jig is explained below This operation is carried out with the T B Set the MODE switch on the front of the controller to TEACH and set the T B ENABLE DISABLE switch to ENABLE to validate the T B Move the J4 axis to the upper end with jog operation beforehand 1 Select the T B MENU lt MAINT gt 1 TEACH 2 RUN 1 PARAM 2 INIT 1 Press the 5 key on the menu screen and 3 FILE 4 MONI 99 3 BRAKE 4 ORIGIN display tie Maintenance Screen 5 MAINT 6 SET 5 POWER 5 STU Display the maintenance screen lt MAINT gt lt ORIGIND 1 PARAM 2 INIT 1 DATA 2 MECH 2 Press the 4 key on the maintenance screen 2 BRAKE 4 ORIGIN 3 JIG 4 ABS and display the origin setting method selection 5 POWER 5 USER screen Y J2 MNO Display the method
74. the minus direction When the MOVE J5 keys are pressed 6 axis type The Y axis will rotate in the plus direction 5 type The Y axis will rotate in the plus direction of the tool coordinate system When the MOVE B J5 keys are pressed Rotates in the minus direction When the MOVE J6 keys are pressed 6 axis type The Z axis will rotate in the plus direction 5 type There is no operation When the MOVE C J6 keys are pressed Rotates in the minus direction 2 30 Confirming the operation Slnstalling the option devices 3 Installing the option devices 3 1 Installing the solenoid valve set 1E VD01 VD02 VD03 1 Shoulder cover B 2 Socket bolt 11 port 6 port 7 port 10 A port 4 P round head screw M3 25 5 No 1 solenoid valve 3 Plate 9 No 2 solenoid valve Details of section A GR3 GR5 GR2 GR4 GR6 EE seo ma When using one row When using two row solenoid valve solenoid valve Fig 3 1 Solenoid valve installation procedures When using three row solenoid valve Fig 3 1 shows the solenoid valve installation procedures and the solenoid valve connector connection procedures The installation procedures are as follow This work must be carried out with the controller power turned OFF 1 Remove the bolts 2 five M4 X 8 bolts that are fixing the shoulder cover 1 and then remove
75. the shoulder cover 2 Using the screw hole in the plate 3 located at the middle of the robot arm install the solenoid valve with the enclosed screws 4 two M3 X 25 screws 3 Of the two air hoses 6 stored in Section A connect the one marked as AIR IN to the quick coupling P port 8 of the No 1 solenoid valve 6 The primary air can be supplied from the air 1 port at the base 4 Connect the hose marked with 1 to the A port 6 of the No 1 solenoid valve 5 Connect the hose marked with 2 to the B port 7 of the No 1 solenoid valve 5 For the two row valve 1E VD02 Installing the solenoid valve set 1E VD01 VD02 VD03 3 31 Slnstalling the option devices Connect the hose marked with 3 to the A port 10 of the No 2 solenoid valve 9 Connect the hose marked with 4 to the port 11 of the No 2 solenoid valve 9 Connect in the same manner for the three row valve 1E VD03 VDO3E 5 Disconnect the plug from the forearm connected to the connectors GR1 to GR6 Connect the GR1 connector to the GR1 plug protruding from the No 1 solenoid valve 5 Connect the GR2 connector to the GR2 plug protruding from the No 1 solenoid valve 5 For the two row valve 1E VD02 VDO2E Connect the GR3 connector to the GR3 plug protruding from the No 2 solenoid valve 6 Connect the GR4 connector to the GR4 plug protruding from the No 2 solenoid valve 6 Connect in the same manner for the three row valve 1E VD03 VDO3E 6 When completed w
76. tion to be stopped immediately during teaching work This also applies to maintenance work with the power source turned ON Setting of emergency stop switch During teaching work place a sign indicating that teaching work is in progress on the start switch etc This also applies to maintenance work with the power source turned ON Indication of teaching work in progress Provide a fence or enclosure during operation to prevent contact of the operator and robot Installation of safety fence Establish a set signaling method to the related operators for starting work and follow this method Signaling of operation start As a principle turn the power OFF during maintenance work Place a sign indicating that maintenance work is in progress on the start switch etc Indication of maintenance work in progress Before starting work inspect the robot emergency stop switch and other related devices etc and confirm that there are no errors Inspection before starting work Safety Precautions 1 3 1Before starting use 1 2 1 Precautions given in the separate Safety Manual The points of the precautions given in the separate Safety Manual are given below Refer to the actual Safety Manual for details N CAUTION N CAUTION N CAUTION N CAUTION N CAUTION N CAUTION N WARNING N WARNING NCAUTION N WARNING NCAUTION N CAUTION NCAUTION N CAUTION N WARNING NCAUTION 1 4
77. to change without notice An effort has been made to make full descriptions in this manual However if any discrepancies or unclear points are found please contact your dealer Copyright C 1999 MITSUBISHI ELECTRIC CORPORATION CONTENTS t Before star UNE USS ai ala 1 1 1 1 Using AAA a 1 1 1 1 1 The details of each instruction manuals 22 ee ee ee ee ee ee ee ee Ge 1 1 1 1 2 Symbols used in instruction manual 2 0 4 1 ee ee ee ee ee ee 1 2 1 2 Safety I UL 1 3 1 2 1 Precautions given in the separate Safety Manual 2 1 4 2 Unpacking to Install all ON 14 4 rtr itor cec ete unde katk acra ndn En aa teda Uode tn kak E 2 5 2 1 Goertirming the Droduet oor eee Oo a o E E SEL 2 5 22 InetallatiO see ON neni area 2 6 2 2 U packIrig ase EE RE EE DEE GEE GE a a dI 2 6 2 2 2 Transportation procedures transporting with a crane 2 2 stone 2 7 2 2 3 Transportation procedures su Ee ee Ge ee Ge ei 2 8 2 24 Installation proc d r S
78. ures after installing the robot Installation 2 9 2Unpacking to Installation 2 2 5 Grounding procedures 1 Grounding methods Controller Robot arm an personal computer Controller Robot arm an Controller an personal Robot arm computer a Dedicated grounding b Common grounding Optimum Good personal computer c Common grounding Normal Fig 2 6 Grounding methods 2 Grounding procedures M4 x 10 SW PW Robot unit Robot grounding cable 2mm or more Prepared by user Fig 277 Gonnecting the grounding cable 2 10 installation 1 There are three grounding methods as shown in Fig 2 6 c but the dedicated grounding Fig 2 6 a should be used for the robot arm and con troller when possible Refer to the separate Controller Setup Basic Operation and Mainte nance for details on the controller grounding 2 Use Class D grounding grounding resistance 100 or less Dedicated grounding separated from the other devices should be used 3 Use a 2mm or more stranded wire for the grounding wire The grounding point should be as close to the robot arm and controller as possible and the length of the grounding wire should be short 1 Prepare the grounding cable 2mm or more and robot side installationscrew and washer 2 If there is rust or paint on the grounding screw section A remove it with a file etc 3 Connect the grounding cable to the gr
79. which the brakes are to be released 3 One worker must securely support the fore arm with both hands 4 While holding down the deadman switch hold down the MOVE X keys The brakes will be released while the keys are held down 5 With both hands slowly move the J3 axis in minus direction Stop at a position where the arm will not interfere even if the J4 axis is rotated and then apply the brakes Then set the J4 axis origin N CAUTION For safety purposes the step for releasing the brakes must be carried out by two workers One worker must operate the T B and the other must support the arm When the brakes are released the robot arm could drop by its own weight depending on the posture N CAUTION If the T B X key or the deadman switch is released the brakes will be applied immediately 4 6 Press the 1 keys 1 will display at the 4 SET AXIS 11101000 position to set the brake release 7 Confirm the axis for which the brakes are to be ORIGIN NOT DEF B J5 released PEL 8 One worker must securely support the fore arm Designate the origin setting axis with both hands 9 While holding down the deadman switch hold down the MOVE X keys The brakes will be released while the keys are held down 10 With both hands slowly move the J4 axis in plus direction and apply the brakes 5 58 Resetting the origin 5Maintenance and Inspection Move the cur
80. xis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 Resetting the origin 5 59 5Maintenance and Inspection 6 J5 axis origin setting lt MECHA gt 12345678 BRAKE 00001000 SET AXIS 11101000 ORIGIN NOT DEF J5 1 DEF Designate the origin setting axis 1 Press the 0 key and then press the 1 key 17 will display at the 5 position to set the brake release 2 Confirm the axis for which the brakes are to be released 3 One worker must securely support the wrist arm with both hands 4 While holding down the deadman switch hold down the MOVE X keys The brakes will be released while the keys are held down 5 With both hands slowly move the J5 axis in minus direction and contact the axis against the mechanical stopper N CAUTION For safety purposes the step for releasing the brakes must be carried out by two workers One worker must operate the T B and the other must support the arm When the brakes are released the robot arm could drop by its own weight depending on the posture AN CAUTION If the T B X key or the deadman switch is released the brakes will be applied immediately 5 type RPL Move the cursor lt MECHA gt 12345678 BRAKE 00001000 SET AXIS 00001000 ORIGIN NOT DEF B C INP 5 46 EXE Designate the origin setting axis DEP E ABO lt MECHA gt SET
81. xis reduction gears 8 arranged in the elbow block 5 J5 axis rotation section The rotation of the J5 axis motor 9 in the forearm is conveyed to the J5 axis reduction gears11 via the J5 axis timing belt 10 to rotate the wrist housing and following 6 J6 axis rotation section The J6 axis rotation is driven by the J6 axis motor 12 and J6 axis reduction gears 13 arranged in the wrist housing 5 40 Maintenance and inspection procedures 9 J5 axis motor 11 J5 axis timing belt 11 J5 axis harmonic reduction gears 12 J6 axis motor 13 J6 axis harmonic reduction gears 7 J4 axis motor 8 J4 axis harmonic reduction gears 9 J5 axis motor 11 J5 axis timing belt 11 J5 axis harmonic reduction gears 12 J6 axis motor 13 J6 axis harmonic reduction gears 5 J3 axis motor 5Maintenance and Inspection 4 J2 axis harmonic reduction gears 3 J2 axis motor 6 J3 axis harmonic reduction gears Elbow block Upper arm Shoulder a l 2 5 2 J1 axis harmonic reduction gears Forearm Wrist housing 4 J2 axis harmonic reduction gears 6 J3 axis harmonic reduction gears Elbow block Upper arm Shoulder 1 J1 axis motor 2 J1 axis harmonic reduction gears Forearm Wrist housing Fig 5 3 Outline structure drawing of robot arm 6 axis type Maintenance and
82. xis type and remove the required covers Caution The brands of grease given in Table 5 5 are those filled when the robot is shipped The lubrication time is a cumulative value of the operation at the maximum speed If the operation has been suspended or if the designated speed is slow the lubrication time can be lengthened in proportion The hours marked with a 1 are based on the yearly inspection Depending on the robot operation state the lubrication time will fluctuate so determine the time according to the state so that the grease does not run out The numbers in the above table correspond to the supply positions in Fig 5 8 and Fig 5 9 2 Lubrication method 1 Set the 5 axis type robot to the posture shown in Fig 5 8 6 axis type robot to the posture shown in Fig 5 9 2 Refer to the 5 3 2Installing removing the cover on page 42 and remove the covers 3 Remove the drain bolt 4 Insert the grease shown in Table 5 5 using a grease gun from the lubrication grease nipple 5 Install the drain bolt 6 Replace the covers with the removal procedure in reverse 5 50 Maintenance and inspection procedures 5Maintenance and Inspection 5 3 5 Replacing the backup battery An absolute encoder is used for the position detector so the position must be saved with the backup battery when the power is turned OFF The controller also uses a backup battery to save the program etc These batteries are insta
83. ys are pressed the robot will move along the Y axis plus direction When the MOVE Y J2 keys are pressed Move along the minus direction When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed Move along the minus direction When the robot is in the transportation posture O gt There are directions from which linear movement is not possible from the transportation posture In this case an will appear on the T B screen and the robot will not move Refer to section 1 Joint jog operation on page 217 and move the robot to a position where linear movement is possible and then carry out XYZ jog Confirming the operation 2 23 2Unpacking to Installation When an appears on the T B screen display gt If the robot is moved outside the movement area with any of the axes an will appear In this case move the axis in the opposite direction JOINT LOW In the example on the left further linear movement in the same direction is not possible MX 360 00 MY 280 00 MZ 170 00 Changing the flange surface orientation 2 EP 2 MOVE ES 7 RE E STEP R Move 5 yz MOVE Control point Tool qu m RE ES um RE B ES KON on MOVE MOVE SS K Js 65 5 type 6 axis type The flange position does not change When the MOVE A J4 keys are pre

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