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MITSUBISHI RV-2A/3AJ

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1. 2 armcover U Ti n ng pul e No 2 armcover L Fig 5 8 No 2 arm cover cleaning methods of clean specification Maintenance and inspection procedures 5 53 5Maintenance and Inspection 5 3 5 Lubrication 1 Lubrication position and specifications 5 axis type 3 J3 axis grease charge port lt 6 gt J6 axis grease charge port P 2 J2 axis grease lt 5 gt J5 axis grease charge port charge port X1 Spring shaft lt 1 gt J1 axis grease In the shoulder cover L charge port 6 axis type X4 axis grease lt 3 gt J3 axis grease charge port lt 6 gt J6 axis grease charge port 5 J5 axi charge pat 2 J2 axis grease charge port lt 1 gt J1 axis grease In the shoulder cover L charge port Fig 5 9 Lubrication positions 5 54 Maintenance and inspection procedures 5Maintenance and Inspection Table 5 5 Lubrication specifications Oiling Lubrication oil Default charge Lubrication Lubrication No Parts to be lubricated Cover to remove method maker amount interval amount X1 J1 axis reduction gears 70g 25g Shoulder cover B Grease 2 J2 axis reduction gears ea BIA 30 g 10 5 g Japan Harmonic Systems lt 3 gt J3 axis reduction gears Grease nip 30 g 10 5 g ple 4000Hr J4 axis reduction gears WA 610 17g 55g 6 axis type only Grease
2. T the robot nost be carri ed by tvo carri ed by tvo persons as persons as illustrated illustrated BU147D437H02 BU147D436H02 5 type 6 axis type Fig 2 2 Transportation of robot arm 1 When transporting with the grips one worker should hold the grip A at the waist and support the arm from the side with his body Lifting the sides of the robot or its covers that don t have any grips can be the cause of accidents such as the robot falling over damage to the cover or the dropping of the cover Therefore it should never be attempted 2 Make sure you do not apply any pressure to the covers when transporting the robot arm To prevent accidents You should not move any axis that does not have a brake 6 axis type J4 J6 axes 5 type J6 axis 3 When transporting the robot use a cart Carrying the robot arm by its grips should be limited to putting it on a cart or stand or to reposition it 4 When transporting the robot arm use an assistant and make it a 2 person job 5 Avoid applying any shock to the robot arm when transporting it AN CAUTION To prevent accidents do not hold the robot from the left right sides or hold covers that have no grips Installation 2 7 2Unpacking to Installation 2 2 3 Installation procedures 4 M3X30 Hexagon socket head bol t 4 ocati ons Spri ng washer Fl at washer LU T 2 E 43 Front of robot 5
3. 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 posi tion 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 opera tion on page 17 for details on the jog operation AN CAUTION Choose the user origin position as the position where it doesn t move by the gravity 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 user designated origin parameter USERORG The parameter details and input methods are described in the separate Instruction Manual Detailed Explana tion of Functions and Operations Refer to that manual and input the user designated origin position MEND MN gt 4 Next set the origin 1 TEACH 2 RUN 2 1 NT Press the MENU key to display th
4. 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 C J6 keys are pressed 6 axis type Rotate in the minus direction 5 axis type There is no operation 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 O Tool length O O The default tool length is 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 Confirming the operation 2 25 2Unpacking to Installation 4 3 axis XYZ jog operation Select the 3 axis XYZ jog mode XY2456 LOW Press the MOVE XYZ keys and then X 13450 xyz xvz press only the XYZ key XYZ456 will appear Y 22000 7 at the upper left of the screen Z 280 00 3 axis XYZ jog mode Each time the MOVE keys are pressed Set the jog speed the override will increase in the order of LOW HIGH gt 3 gt 5 gt 10 gt 30 gt 50 5 70 XYZ456 LOW 100 When the MOVE keys are pressed X 134 50 the override will decrease in the reverse order Y 220 00 ster t i The currently set speed will appear on the Z 280 00 Set
5. 12345678 BRAKE 01000000 set SET AX S 01 Set 1 for the 2 axis and set 0 for the other RAAN NO F C B INP G n DI a gt eE axes Then press INP Next a confirmation ABC n Designate the origin setting axis DEF screen will appear 7 Designate the axis for which the origin is to be 8 Press the 1 and INP keys SET AAN The origin posture will be set 1 B INP 1 EXEQUTE Set the origin 1 DEF MECH 12345678 9 Setting of the origin is completed BRAKE 01000000 SET AX S 01000000 10 Refer to 5 5 5Recording the origin data on CH GN CMLETED page 84 in this manual and record the origin data on the origin data seal Resetting the origin 5 69 5Maintenance and Inspection Releasing the brakes lt gt To release the brakes move the cursor to the BRAKE axis No with the lt or gt 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 Move the cursor to the SET AXIS axis No in the origin setting with the lt or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin
6. C are attached to clean specification The rubber packing and packing B are attached to protection specifica tion lt 14 gt Wrist cover S 2 2 lt 15 gt Elbow bushing 1 1 The silicone seal applies to clean specification Note The packing which showed in remarks is attached to protection and clean specification Refer to Table 5 7 Spare parts list on page 65 for type name of packing Table 5 4 Cover installation screw list No Installation screw name Qty Remarks a Socket bolt M3 x 8 nickel plated 27 b Truss screw M3 x 6 nickel plated 10 c Truss screw M3 x 8 nickel plated 8 d Socket bolt M3 x 6 nickel plated 2 6 axis type only The method of cover installation removal are all model commonness basically However to secure the cleanliness the packing and sealing are attached to clean specification Bi The elbow bushing lt 15 gt at the rear of the elbow cover The elbow section is sealed with a sealing agent silicon seal refer to Table 5 7 around the elbow bushing When removing and reinstalling the elbow cover apply silicon seal around the elbow bushing to seal it Wipe out the silicon seal which protruded after the installation The No 2 arm cover U L lt 10 gt lt 11 gt elbow cover U B L lt 7 gt lt 8 gt wrist cover U L lt 12 gt lt 13 gt Sponge packing is attached on the inner side of these covers So when removing installing these covers
7. Fig 2 14 CYLINDER jog operation Confirming the operation 2 19 2Unpacking to Installation 1 JOINT jog operation Select the JOINT jog mode JOINT LOW J1 734 50 STEP JOINT J2 20 00 d J3 8000 JOINT jog mode Set the jog speed JOINT LOW J1 3450 STEP J2 2000 J3 8000 Set the speed J1 axis jog operation STEP X STEP X UD H Qn MOVE SPACE MOVE run J1 axis 5 axis type Press the MOVE JOINT keys to select the JOINT jog mode JOINT 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 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 X H un J1 axis STEP X MOVE SPACE PQR 6 axis type When the MOVE X J1 keys are pressed the J1 axis will rotate in the plus direction When the MOVE X J1 keys are pressed Rotate in the minus direction J2 axis jog operation 5 axis type 6 axis 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 When the robot is in the transp
8. 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 4 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 20 and move the robot to a position where linear movement is possible and then carry out XYZ jog When an M appears on the T B screen display lt gt If the robot is moved outside the movement area with any of the axes will appear In this case move the axis in the opposite direction XYZ LOW In the example on the left further linear movement in the same direction is not possible WX 360 00 BAY 28000 Kaz 170 00 2 22 Confirming the operation 2Unpacking to Installation Changing the flange surface posture 5 axis type 6 axis type The control point does not change When the MOVE A J4 keys are pressed 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
9. J5 keys are pressed 6 axis type The Y axis will rotate in the plus direction 5 axis 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 axis type There is no operation When the MOVE C J6 keys are pressed 6 axis type Rotate in the minus direction 5 axis type There is no operation O When alarm No 5150 occurs lt gt If alarm No 5150 ORIGIN NOT SET occurs the origin has not been set correctly Reconfirm the value input for the origin data O Tool length O O The default tool length is 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 Confirming the operation 2 23 2Unpacking to Installation 3 TOOL jog operation Select the TOOL jog mode Press the MOVE TOOL keys to select the TOOL LOW TOOL jog mode TOOL will appear at the upper X 13450 TOOL left of the screen Y 220 00 as Z 280 00 TOOL jog mode Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH Set the jog speed gt 3 gt 5 gt 10 gt 30 gt 50 70 100 When the MOVE ke
10. 12 4 bolts uei the positioning com Tighten the bolt lt 3 gt in this state and securely fix the jig After fixing remove the pin lt 4 gt Pin NS ae 5 type 5 Designate the axis for which the brakes are to be 41G 12345678 41G 12345678 released BRAKE 00000000 BRAKE 11101000 Press the 1 key three times the 0 key once SET AX S 00000000 SET AX S 11101000 and the 1 key once CRI G N NOI DEF CRI GNNO DEF B e 05 6 Desi 1 DEF 0 ABC 6 One worker must hold the calibration jig handle esignate the brakes release axis or the robot arm 6 axis type 4jIG 12345676 4jIG 12345676 BRAKE 00000000 BRAKE 11101100 7 While the other worker is holding down the dead SET AXI S 00000000 SET AX S 11111100 man switch on the teaching pendant press the CRI G N NOT eee STEP MOVE and X key The brakes will be released only while these keys are held down B J5 1 DEF Designate the brakes release axis AN CAUTION When the brakes are released the robot arm could drop by its own weight depending on the posture If the deadman switch 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 lt gt Gli bration jig x Gli bration jig 5 type 6 axis type Rese
11. Fig 5 10 shows the procedures for J1 axis lubrication method 1 Remove the shoulder cover F B L 2 In the case of clean specification remove the air purging bolt 1 Take care not to lose the washer with seal at this time There is no air purging bolt except for the clean specification 3 Lubricate the grease shown in the Table 5 5 from grease nipple 2 4 In the case of clean specification tighten the air purging bolt 1 which removed with the above step 2 Do not forget to attach the washer with seal 5 Install the cover which removed with the above step 1 This completes the J1 axis lubrication Shoul cover R lt 2 gt G ease ni ppl e Shoul der cover B Bolt M8x6 washer wth seal Shoul der cover L Shoul der cover F Fig 5 10 J1 axis lubrication method 5 56 Maintenance and inspection procedures 5Maintenance and Inspection J2 axis lubrication method Fig 5 11 shows the procedures for J2 axis lubrication method 1 Remove the shoulder cover F B R 2 Remove the air purging bolt 1 Take care not to lose the washer with seal at this time There is air purging bolt in the J2 axis for all type 3 Lubricate the grease shown in the Table 5 5 from grease nipple lt 2 gt 4 Tighten the air purging bolt lt 1 gt which removed with the above step 2 Do not forget to attach the washer with seal 5 Install the cover which removed with the above
12. GN COMPLETED Releasing the brakes lt gt 1 Press the 1 key 1 will display at the 1 posi tion to set the brake release 2 Confirm the axis for which the brakes are to be released 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 SET AXIS 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 5Recording the origin data on page 84 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 gt 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 Origin setting axis designation lt gt Move the cursor to the SET AXIS
13. J6 5 STU Display the maintenance screen MN NI CH G N gt 1 PARAM 2 1 NT 1 DATA 2 2 Press the 4 key on the maintenance screen BRAKE 4 CH GN 3 IG 4 ABS and display the origin setting method selection 5 POMER 5 USER screen Y J2 4 MNO Display the method selection screen CH GN MECHA 1 DNA 2 SERVO CFF 3 Press the 2 key and select the jig method 3J IG 4 48S e Ecco 1 Then press the 1 key and the INP key to 5 USER turn the servo OFF B 5 KE m EXE 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 AN CAUTION The brakes are released here and the arm is moved with both hands For safety purposes the brakes must be released by two workers Resetting the origin 5 67 5Maintenance and Inspection 2 J1 axis origin setting MECHN 12345678 BRAKE 10000000 SET AXIS 11101000 CR GN NJI F B J5 1 DEF Release the brakes RPL Move the cursor lt gt 12345678 BRAKE 10000000 SET S 10000000 RAAN F B C INP 1 DEF 0 ABC Designate the origin setting axis MECHI SET CR GN B INP 1 EXEQUIE E 1 DEF Set the origin lt gt 12345678 BRAKE 10000000 SET AX S 10000000 R
14. JOINT jog operation Confirming the operation 2 17 2Unpacking to Installation 5 type 6 axis type While maintaining the flange surface posture the axis moves straight along the base coor dinate system Also while maintaining the flange surface position the flange surface posture changes Fig 2 11 XYZ jog operation 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 posture changes With the 5 axis type the axis moves only in the X and Y axis directions of the tool coordinates Fig 2 12 TOOL jog operation 2 18 Confirming the operation 2Unpacking to Installation 5 axis type 6 axis type The axis moves straight along the base coordinate system At this time the flange surface posture is not maintained Also the flange surface posture changes The flange surface position changes at this time Fig 2 13 3 axis XYZ jog operation 2 Redius 5 axis type 6 axis 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 posture changes
15. a J6 STU e o sre move NY wove 5 J6 axis 54 axi move step a Oo 5 J5 axis STEP B 99 MOVE 6 i 5 axis type 6 axis type The flange position changes Interpolate the joint taking care not to change the control point 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 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 J6 keys are pressed the J6 axis will rotate in the plus direction When the MOVE C J6 keys are pressed Rotate in the minus direction Confirming the operation 2 27 2Unpacking to Installation 5 CYLNDER jog operation Select the cylindrical jog mode MOVE CYLNDER jog mode MOVE 5 CYLNDER LOW 134 50 T 220 00 Z 28000 Set the jog speed CYLNDER LOW R 134 50 T 22000 see 0 ee 7 28000 esed MOVE FORWD BACKWD Moving along an arc centering on the Z axis STEP 2 se 2 MOVE Vertica Redius Control point 5 axis type Press the MOVE XYZ keys and then press only the XYZ key CYLNDER will appear at the upper left of the
16. and the separate Safety Manual before starting use of the robot to learn the required measures to be taken N CAUTION N CAUTION N WARNING N CAUTION N DANGER N CAUTION N CAUTION N CAUTION 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 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 durin
17. axis No in the origin setting with the lt or gt 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 display a 0 5 68 Resetting the origin 5Maintenance and Inspection 3 J2 axis origin setting MECHN 12345678 BRAKE 01000000 SET AX 5 11101000 1 Press the 0 key and then press the 1 key 1 will display at the 2 position to set the brake release RAN N EF J5 2 Confirm the axis for which the brakes are to be T 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 J2 axis in minus direction and contact the axis against the mechanical stopper AN 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 m Front of base 5 axi s type 6 axi s type RPL 6 Press the key The cursor will move to Move the cursor SET AXIS MECHN
18. axis is not required for the 5 axis type After inputting all of the values press the INP key The origin setting confirmation screen will appear 7 Press 1 B P and INP key to end the origin setting Setting the origin 2 15 2Unpacking to Installation O Moving the cursor Q Press the 1 1 1 e 1 and gt keys Inputting characters Hold down the CHAR key and press the key with the character to be input on the lower right Three characters wi scroll each time the character key is pressed O Correcting an input lt After returning one character by pressing the DEL key input the character again 6 Installing the shoulder cover B Return the shoulder cover B removed in section 1 Confirming the origin data on page 12 to its original position This completes the setting of the origin with the origin data input method Always remove and install the cover with the controller power turned OFF Failure AN WARNING to do so could lead to the robot moving because of incorrect operations or to physical damage or personal injury O If the origin input data is incorrect lt 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 2 16 Setting the origin 2Unpacking to Installation 2 4 Confirming the operation In
19. axis may be downward Turn it to the direc tion of gravity Make sure that the pulleys do not move while replacing the belt 3 If the pulley 4 and lt 5 gt position relation deviates the position could deviate 4 Make marks on the timing belt lt 2 gt and timing pulleys lt 4 gt and lt 5 gt with a felt tip pen as shown in Fig 5 6 so that the engagement of the timing belt 2 and timing pulleys lt 4 gt and lt 5 gt does not deviate 5 Loosen the four motor installation screws X1 and remove the belt 6 Copy the marks onto the new timing belt Make sure that both belts are tense when making the marks 7 Align the new timing belt with the marks on the timing pulleys 4 and lt 5 gt and install 8 Refer to steps 3 to 6 in W Adjusting the J5 axis timing belt and 3 Timing belt tension to adjust the tension 9 The position could deviate after the belt is replaced Confirm that the position has not deviated If deviated refer to 5 5Resetting the origin on page 66 and reset the origin position Maintenance and inspection procedures 5 51 5Maintenance and Inspection 3 Timing belt tension f Pressing force S Span d Slack Belt type Span s mm Slack d mm Pressing force f N B40S2M320U 120 1 9 0 7 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 bel
20. 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 AN CAUTION The brakes are released here and the arm is moved with both hands For safety purposes the brakes must be released by two workers Resetting the origin 5 83 5Maintenance and Inspection 5 5 5 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 ori gin 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 shoulder cover B The teaching pendant operation method and shoulder cover B 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 12 and write the origin data displayed on the teaching pendant onto the origin label 1 Confirming the origin data label Remove the shoulder cover B Refer to 5 3 2Installing removing the cover on page 48 and remove the shoulder cover B 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 i
21. 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 on 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 MEN MN 1 TEACH2 RUN 1 PARAM 2 INT 1 Press the 5 key on the Menu screen to select FILE 4 MN 3 BRAKE 4 CHGN the Maintenance screen 5 MN NT 6 SET 5 POMER J6 Select the maintenance screen 5 STU MN NT CH G N gt 1 PARAM 2 1 1 DATA 2 MECH 2 Press the 4 key to select the Origin Setting BRAKE 4 CH GN P 3 1G 4 5 screen 5 POMER 5 USER Y J2 Select the Origin Setting screen 4 CRI GN lt 1 gt SERVO CFF ma ABS X 1 3 Press the 3 key to select the jig method Then 5 USER f s press the 1 key and the INP key to turn the 2 servo OFF 1 EXECUTE Z B INP ia EXE Select the jig method 5 78 Resetting the origin 5Maintenance and Inspection 2 Mechanical interface lt 1 gt Calibration ji 4 Install the calibration jig lt 1 gt on the mechanical lt 3 gt Bolt interface 2 and insert the pin lt 4 gt to carry out M5 x
22. 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 that if the safety fence entrance door is opened during automatic oper
23. input is noted in the ate Default Nd origin data sheet enclosed with the arm D 529 or on the origin data history table J1 o6DTYY attached to the back side of the shoul J2 2 HL9X der cover B Refer to Fig 2 8 J 3 1CP55V J4 T6 M Y Referring to 5 3 2 Installing removing J 5 2210970 the cover on page 48 remove the J 6 12470 shoulder cover and confirm the Method E E N SP E N E N SP value SP AlphabetO Zero The value given in the default setting Note Meanings of symbols in method column Meanings of symbols in method column column is the origin settings set with the E Jig method calibration jig before shipment N Not used Note that the 5 axis type does not have SP Not used the J4 axis Fig 2 8 Origin data label an example AN WA RNING 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 AN 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 ON and L1 100 will appear on the STATUS NUMBER display on the front of the controller 2 12 Setting the origin 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 contr
24. move the axis the opposite direction JOINT LOW 921 160 00 J2 20 00 J3 80 00 In the example on the left the J axis is at the limit of the plus side movement area Confirming the operation 2 21 2Unpacking to Installation 2 XYZ jog operation Select the XYZ jog mode Press the MOVE XYZ keys to select the XYZ XYZ LOW jog mode XYZ will appear at the upper left of X 13450 XYZ the screen Y 220 00 Z 280 00 XYZ jog mode Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH Set the jog speed 3 5 10 gt 30 50 70 100 When the MOVE keys are pressed the override XYZ LOW will decrease in the reverse order The currently X 13450 STEP set speed will appear the upper right of the i Mere MOVE FORWD eackwo screen Set the override to 10 here for I et the speed confirmation work Moving along the base coordinate system wove ERA ES MNOJ TY 5 axis type Z i 6 axis type z X The direction of the frange will not change 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 keys are pressed the robot will move along the Y axis plus direction When the MOVE Y
25. step 1 This completes the J2 axis lubrication 2 Grease nipple Fig 5 11 J2 axis lubrication method E J3 axis lubrication method Fig 5 12 shows the procedures for J3 axis lubrication method 1 Remove the shoulder cover F B R and No 2 arm cover R 2 Remove the air purging bolt lt 1 gt Take care not to lose the washer with seal at this time There is air purging bolt in the J3 axis for all type 3 Lubricate the grease shown in the Table 5 5 from grease nipple 25 4 Tighten the air purging bolt lt 1 gt which removed with the above step 2 Do not forget to attach the washer with seal 5 Install the cover which removed with the above step 1 This completes the J3 axis lubrication lt gt Air purgi ng bolt Bolt MBx6 washer wth seal Fig 5 12 J3 axis lubrication method Maintenance and inspection procedures 5 57 5Maintenance and Inspection E J4 axis lubrication method for only 6 axis type Fig 5 13 shows the procedures for J4 axis lubrication method 1 Remove the elbow cover U Do not remove the elbow cover F B 2 In the case of clean specification remove the air purging bolt lt 1 gt Take care not to lose the washer with seal at this time There is no air purging bolt except for the clean specification 3 Lubricate the grease shown in the Table 5 5 from grease nipple 25 4 In the case of clean specification tighten the air purging bolt lt 1 gt which removed with th
26. 0 lt 00000 1 000000 000000 3 000000 000000 15 000000 000000 lt DATA gt D P000 1 000000 000000 3 000000 000000 15 000000 000000 _ lt pATA gt D VINbOO 1 000000 000000 3 000000 000000 15 000000 000000 _ lt DATA gt D V S29 1 000000 3 000000 000000 5 000000 000000 DATAPD VIS29 1 A B amp 8F G SY5 3 H 7 2H B HL U m 5 59A37 K8 86P _ lt DATA gt D V S29 CHANGES TO ORIGIN oco dB Execute EMI 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 VWX key once while holding down the CHAR key V will appear so release the CHAR key V will be set Inputting Press the key three times while holding down the CHAR key will appear so release the CHAR key will be set In the same manner while holding down the CHAR key press the key twice and the STU key once input S Release the CHAR key and press the 2 key input 2 and then the 9 key input 9 29 will appear at the D data on the teaching pendant screen Co Press the key and move the cursor to the J1 input position Input the J1 value in the same manner as above A Input the J2 J3 J4 J5 J6 values in the same manner Note that the J4
27. 0 key and display a 0 5 76 Resetting the origin 5Maintenance and Inspection 8 All axis origin setting 1 Refer to the one after 2 J1 axis origin setting on page 68 and set the origin positions of all axis The following steps for setting each axis are carried out simultaneously with the other axes so they can be skipped here 2 When completed with all work the robot posture should be as bellow 6 nark agrees 5 axis type RPL l Move the cursor 4I 12345678 BRAKE 00000000 SET AX S 11110000 CR G N B lt INP 05 6 2 Exe 0 ABC Designate the origin setting axis Pires SET CH GN INP B 1 EXECUTE m se Set the origin 1 DEF 4IG 12345678 BRAKE 00000000 SET AX S 11110000 CRI GN NOT 2 Q Releasing the brakes lt gt 6 axis type 3 Press the key The cursor will move to SET AXIS 4 Designate the axis for which the origin is to be set Set 1 to 6 of SET AXIS to 1 and then press the INP key The 5 axis robot does not have the 4 axis so set O Next a confirmation screen will appear 5 Press the 1 and INP keys The origin posture will be set 6 Setting of the origin is completed 7 Refer to 5 5 5Recording the origin data on page 84 in this manual and record the origin data on the origin data seal To release the brakes move the cursor to th
28. 0100 8 Designate the axis for which the origin is to be SET S 00000100 NR Deal CRI GN NOT F 5 5 in Set 1 for the 6 axis and set 0 for the other ws o xe axes Then press INP Next a confirmation 1 DEF 0 ABC screen will appear Designate the origin setting axis Resetting the origin 5 75 5Maintenance and Inspection MEHM 9 Press the 1 and INP keys SET AAN The origin posture will be set nD INP B 1 EXEQUIE Set the origin 1 DEF MECHA 12345678 10 Setting of the origin is completed BRAKE 00000100 SET AXI S 00000100 11 Refer to 5 5 5Recording the origin data on QR G N CCMLETED page 84 in this manual and record the origin data on the origin data seal Releasing the brakes lt gt 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 Move the cursor to the SET AXIS axis No in the origin setting with the 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
29. 122 2 160 a 5 6 1 nstal ati on standard si de Ee M ew frombottonm 4 9 installati on hol es Magni fi ed vi ew of C 122 pu A Fig 2 3 Installation dimensions 2 8 Installation 1 The robot installation surface has been machine finished Use the installation holes 4 9 holes opened at the four corners of the base and securely fix the robot with the enclosed installa tion bolts M8 x 30 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 2Unpacking to Installation 2 2 4 Grounding procedures 1 Grounding methods 1 There are three grounding methods as shown in Fig 2 4 but the dedicated grounding Fig 2 4 a should be used for the robot arm and controller when possible Refer to the separate Controller Setup Basic Operati
30. 5 1 Inspection schedule Maintenance and inspection interval 5 43 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 Controller setup basic operation and maintenance manual and inspect the controller 5 2 1 Daily inspection items Carry out the daily inspections with the procedures given in Table 5 1 Table 5 1 Procedure Daily inspection items details Inspection item details Remedies Before turning power ON Check the following items before turning the power ON 1 Are any of the robot installation bolts loose Securely tighten the bolts leaks drain clogging or hose damage Is the air source normal Visual Visual 2 Are any of the cover tightening screws loose Securely tighten the screws Visual 3 Are any of the hand installation bolts loose Securely tighten the bolts Visual 4 Is the power supply cable securely connected Securely connect Visual 5 Is the machine cable between the robot and controller securely Securely connect connected Visual 6 Are there any cracks foreign contamination or obstacles on the robot Replace with a new part or take remedial measures and controller cover 7 Is any grease leaking from the robot arm After cleaning replenish the grease Visual 8 Is there any abnormality in the pneumatic system Are t
31. 5678 BRAKE 00001000 SET AX S 00001000 E B C INP CRI G N NOT DEF Q9 gt Exe Designate the origin setting axis 1 IDEE D ABC lt gt SET CR GN 1 B INP 1 EXEQUIE _ t Set the origin 1 DEF MECHN 12345678 BRAKE 00001000 SET AX S 00001000 CR GN COMLETED 5 74 Resetting the origin J5 The J5 axis direction of 6 axis type in the drawing shows the case when the J4 axis is at the mechanical stopper position XQ lt Front of base 6 axis type 6 Press the key The cursor will move to SET 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 5Recording the origin data on page 84 in this manual and record the origin data on the origin data seal 5Maintenance and Inspection Releasing the brakes lt gt To release the brakes move the cursor to the BRAKE axis No with the lt or gt 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 releas
32. 6 axis type lt gt 12345678 BRAKE 00100000 SET AX S 11111000 CR G N 55 1 DEF Designate the origin setting axis J3 6 axis type 4m Front of base 1 Before moving the twist axis move the J3 axis to prevent arm interference Press the 0 key twice and then press the 1 key 1 will display at the 3 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 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 AN 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 MECH 12345678 BRAKE 00000000 SET AX S 11111000 CRI GN NOI zB Designate the origin setting axis 6 s type 5 72 Resetting the origin 6 With both hands sl
33. FA will appear on the T B screen and the robot will not move Refer to section 1 JOINT jog operation on page 20 and move the robot to a position where linear movement is possible and then carry out TOOL jog 2 24 Confirming the operation 2Unpacking to Installation When an M appears on the T B screen display lt gt If the robot is moved outside the movement area with any of the axes will appear In this case move the axis in the opposite direction TOOL LOW In the example on the left further linear movement in the same direction is not possible 360 00 280 00 WAZ 170 00 Changing the flange surface posture wee STEP C MOVE 0 ABC 5 type i 6 axis type The control point 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 The Z axis will rotate in the plus direction of the tool coordinate system When the MOVE A J4 keys are pressed 6 axis type Rotate in the minus direction 5 axis type Rotate in the minus direction When the MOVE J5 keys are pressed 6 axis type The Y axis will rotate in the plus direction of the tool coordinate system 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
34. MANDS 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 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 details on the MOVEMASTER commands used in the program For RV 1A 2AJ and RV 2A 3AJ series 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 I Before 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 t
35. MITSUBISHI Mitsubishi Industrial Robot RV 2A 3AJ INSTRUCTION MANUAL ROBOT ARM SETUP amp MAINTENANCE NT 1 3 S N Safety Precautions Always read the following precautions and the separate Safety Manual before starting use of the robot to learn the required measures to be taken N CAUTION N CAUTION NWARNING N CAUTION NWARNING N CAUTION N CAUTION N CAUTION 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 a
36. Make sure that if the safety fence entrance door is opened during automatic operation 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 C Precautions for the basic configuration are shown below When CR1 571 is used for the controller AN CAUTION Provide an earth leakage breaker that packed together on the primary power supply of the controller as protection against electric leakage Confirm the set ting connector of the input power supply voltage of the controller if the type which more than one power supply voltage can be used Then connect the power supply Failure to do so could lead to electric shock accidents Power supply RV 1A 2AJ series and RP 1AH 3AH 5AH series Single phase 90 132VAC 180 253VAC Except the above Single phase 180 253VAC Rear side of controller Earth leakage br
37. Open Half open Closed 1 General purposeinput 900 0 1 1 Corresponds to hand 1 2 General purposeinput 901 1 1 0 Open edge sensor 0 Q o e Q lt q Closed edge sensor General purpose input 901 E General purpose input 900 3 2 6 Confirming operability 1 Operate the teaching pendant to confirm that the hand opens and closes 2 To operate the teaching pendant refer to separate manual CR1 CR2 CR4 CR7 CR8 Controller INSTRUCTION MANUAL Detailed explanations of functions and operations 3 If the open close settings are reversed confirm the connection settings with Table 3 1 or Table 3 2 and reset the settings While operating the hand depending on the J5 axis and J6 axis the hand curl tube AN CAUTIO N and the hand check cable can get entangled with the hand adapter and forearm In this case temporarily remove the hand and reposition it to its correctly installed position as shown in Fig 3 3 This completes the installation of the pneumatic hand set 3 36 Installation the pneumatic hand set 4A HP02 HP02E 3 3 Installation the motorized hand set 4A HM02 Fig 3 4 shows the construction of the motorized hand set and the installation procedure and Table 3 5 shows the configuration equipment which correspond with the Fig 3 4 Mechani cal i nterface Hand adapter lt a gt H ket bolt Hexagon socket bolts SXagon socket Dots MBx 12 2 Mtori zed hand M ew fromA Fig 3 4 Motorized hand set installatio
38. S usados cea ORA ca mca idest d CRM em erii ota UU 5 Mamtenance and Ui eee iy accade adiac lic Rival or ires td cape estudia RE 5 1 and inspection interval 5 43 timing belt 3 Timing belt tension eene bd the cover of clean specification RV eduction gears lubrication m eal section lubrication method fo to lubricate the spring shaft area lacing the backup battery 1 Replacing the robot arm battery 5 6 6 8 0 0 1 2 SA SB RV 3AJC SA SB 5 53 iod 4 6 0 2 3 3 5 4 Maintenance parts 7 J6 8 All Appendix Appendix 1 1 Before 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 amp Maintenance Controller Setup Basic Operation and Maintenance Detailed Explanation of Functions and Operations xplanations of OVEMASTER COM
39. Set the origin META B INP J5 EXE 1 DEF MA gt 12345678 BRAKE 00100000 SET AX S 00100000 CR GN COMLETED Releasing the brakes 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 3 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 5Recording the origin data on page 84in 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 gt 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 Origin setting axis designation lt gt Move the cursor to the SET AXIS axis No in the origin setting with the lt or gt 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 display a 0 Resetting the origin 5 71 5Maintenance and Inspection 5 J4 axis origin setting Only
40. a 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 2 Unpacking to Installation 2 1 Confirming the product 2Unpacking to Installation The standard configuration of the robot arm part of the purchased product is shown in Table 2 1 Confirm the parts Users who have purchased optional products should refer to the separate Standard Specifications Table 2 1 Standard configuration No Part name Type Qty Remarks 1 Robot arm RV 2A RV 2AM RV 2AC SA SB Eith RV 3AJ RV 3AJM dara 1 unit or RV 3AJC SA SB 2 Guarantee card 1 copy 3 Installation bolts M8x30 4 pcs 4 Spring washer for installation bolts For M8 4 pcs For robot arm installation 5 Plain washer for installation bolts For M8 4 pcs 6 Marking seals 12 pcs Note The numbe
41. al position with the screws two M3x8 screws 9 Install the No 2 arm cover U and wrist cover S U to the original position In the case of clean specification take care not to damage the packing attached to the cover matching surface at this time This completes the lubrication to wrist housing end and between elbow block and forearm wist cover S Wth seal Wist cover U J6 axi s nator Wist cover L 2 gt R XC J6 axis nator cable Wist cover 5 Fig 5 17 Lubrication to wrist housing end and between elbow block and forearm Maintenance and inspection procedures 5 61 5Maintenance and Inspection 5 3 6 How to lubricate the spring shaft area This robot uses springs for gravity compensation for the J2 axis drive system The small power consumption of the motor is achieved by connecting spring hooks to the spring shafts set in the J2 axis motor area and J1 axis case thereby compensating for the gravity by the spring force Depending on the conditions under which the robot is used wear may occur due to lack of lubrication in the spring shaft areas If wear is detected during periodical inspections it is necessary to apply grease to the two areas shown in Fig 5 18 Use highly viscous grease water soluble types are not allowed Table 5 5 lists recommended types of grease Hand painting 1 n Hand painting Section of J2 axis motor Section of J1 axis Fig 5 18 Lubricated points in the spring shaft a
42. amage and adherence of foreign matter If the cables are severely damaged contact the Mitsubishi Service Department 4 It runs out of grease on the spring shaft for J2 axis Refer to 5 3 6How to lubricate the spring shaft area on page 62 and lublicate it 3 month inspection items 1 Is the timing belt tension abnormal If the timing belt is loose or too tense adjust it Is the inside of the arm dirty Wipe the dust with dry cloth or with alcohol 6 month inspection items 1 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 1 Replace the backup battery in the robot arm Exchange it referring to 5 3 7Replacing the backup battery on page 63 2 year inspection items 1 Lubricate the grease at the harmonic reduction gears for each axis Lublicate it referring to 5 3 5Lubrication on page 54 Inspection items 5 45 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 and follow the instructions This work can be commissioned to the Mitsubishi Service Depart ment 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 a
43. and remove the shoulder cover B lt 1 gt 2 Unfasten the two M3x8 bolts lt 11 gt holding the battery cover lt 12 gt and remove the cover 3 Install the solenoid valve by fastening it with the two attached M3x25 screws lt 5 gt to the screw holes on the plate lt 4 gt of the robot arm 4 Connect one of the two 6 pneumatic hoses in section the one marked AIR IN to the quick coupling port P lt 9 gt of the solenoid valve lt 6 gt The primary air flow can now be supplied from the pneumatic port at the base 5 Connect the hose marked 1 to port A lt 7 gt on the primary solenoid valve 65 Connect the hose marked 2 to port B 8 on the primary solenoid valve 65 If you are using the double type valves 1E VD02 VDO2E you need to do the following Connect the hose marked 3 to port A lt 11 gt on the secondary solenoid valve lt 10 gt Connect the hose marked 4 to port B lt 12 gt on the secondary solenoid valve lt 10 gt 6 Connect the GR1 plug protruding from the primary solenoid valve lt 6 gt to the connector GR1 Connect the GR2 plug protruding from the primary solenoid valve lt 6 gt to the connector GR2 If you are using double type valves 1E VD02 VD02E Connect the GR3 plug protruding from the secondary solenoid valve lt 10 gt to the connector GR3 Connect the GR4 plug protruding from the secondary solenoid valve lt 10 gt to the connector GR4 7 Store the newly attached connector
44. ation of the J6 axis is driven by the J6 axis motor lt 12 gt arranged in the wrist housing and the reduc tion gears lt 13 gt 5 46 Maintenance and inspection procedures 5Maintenance and Inspection lt gt axis reducti on gear bow bl ock Upper arm lt gt 5 axi s nator lt 10 gt 5 axi s ti ning belt 41 5 axi s reducti on gear lt 2 gt Jl ais re ducti on gear lt 42 gt 6 axis nator Shoul der Forearm Wist housi reducti on gear Fig 5 3 Outline structure drawing of robot arm 6 axis type Maintenance and inspection procedures 5 47 5Maintenance and Inspection 5 3 2 Installing removing the cover To renove the wist cover pushit up lt 14 gt Wi st_cover S lt 10 gt 2 armcover U lt 11 gt 2 armcover L A i a lt 12 gt Wist cover 5 lt 13 gt Wi st cover L 5 1 armcover Rear of d bow cover lt A gt Shoul der cover B lt 1 gt Shoul der_cover L p 0 a o Ts WE Fig 5 4 Installing removing the cover 5 axis type To renove lt 14 gt Wi st_cover S the wist cover push it up using a screw dri ver Screw dri ver Na 2 5 1 armcover dd Rear of bow cover lt 8 gt El bow cover B a lt Q gt El bow cover F lUi as S n 35 a a oon lt 6
45. 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 O Hr Monthly inspection Monthly inspection 500 H Monthly inspection 3 month inspection Monthly inspection Monthly inspection 1000H Monthly inspection 3 month inspection 6 month inspection Daily inspection Monthly inspection Monthly inspection 1500 H Monthly inspection 3 month inspection Monthly inspection Monthly inspection 2000Hmn Monthly inspection 3 month inspection 6 month inspection Yearly inspection Operating time lt 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 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
46. e BRAKE axis No with the lt or gt 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 Origin setting axis designation Move the cursor to the SET AXIS axis No in the origin setting with the 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 display a 0 Resetting the origin 5 77 5Maintenance and Inspection 5 5 2 Jig method The reference dimension drawing of the calibration jig 1E INST used with this method is shown in Fig 5 20 This jig is the same option as the Mitsubishi RV E RV EN RV 4A 5AJ 3AL 4AJL Series 9 CN 3a 4 5 5 drill through equal circumference divisions 11 X7 counterbore M from rear surface r gt 4 A nm 1 x CN AT 27 023 T 0 02 5H7 reamer through P The standard is in the center of the 40H7 174 94 0 05 163 410 ego 40 7 0045 110 04 632 6 3a d xiy Reamer through A A Fig 5 20 1E INST
47. e operation in clause 3 and change the installation position CAUTION There is no mechanical stopper for the J6 axis Do not manually rotate the J6 axis by more than the operation range 200 degrees when the servo is OFF If the axis is rotated by more than operation range when the servo is ON an encoder alarm occur 3 3 2 Installation the motorized interface Refer to the separate CR1 Controller Instruction Manual Controller setup basic operation and maintenance and install the motorized hand interface on the controller 3 3 3 Setting the parameters When using the motorized hand 1A HMO1 the tool data is 123mm Refer to separate manual CR1 CR2 CR4 CR7 CRS8 Controller INSTRUCTION MANUAL Detailed explanations of functions and operations and set the MEXTL parameters 3 3 4 Confirming operability 1 Operate the teaching pendant to confirm that the hand opens and closes 2 To operate the teaching pendant refer to separate manual CR1 CR2 CR4 CR7 CR8 Controller INSTRUCTION MANUAL Detailed explanations of functions and operations CAUTION While operating the hand depending on the J5 axis and J6 axis the hand curl tube and the hand check cable can get entangled with the hand adapter and forearm In this case temporarily remove the hand and reposition it to its correctly installed position as shown in Fig 3 4 AN CAUTION If the cable is incorrectly fixed and force is repeatedly applied on the connectors due to the
48. e Menu 3 FILE 4 3 BRE 4CRGN Ebra n 5 MA NT 6 SET 5 POWER 5 Press the 5 key to display the Maintenance screen J6 Display the maintenance screen 5 STU 6 Press the 4 key to select the Origin Setting MN gt CH GN screen 1 PARAM 2 INT 1 2 MECH 3 BRAKE 4 CRGN 3 IG 4 ABS 5 POMER 5 USER Y J2 Display the origin setting method selection screen 4 MNO 7 Press the 5 key to select the user origin RGN lt USER gt method 1 DATA2 MECH a SERVO OFF Then press 1 key and INP key to turn OFF 3 J G4 ABS X the servo 5 USER 1 EXEGUTE Resetting the origin 5 81 5Maintenance and Inspection 7 lt USER gt 12345678 lt UBER gt 8 Press the key and input 1 for the axis BRAKE 00000000 CANES TO AGN for which the origin is to be set Press the INP SET AX S 11111100 key to display the Confirmation screen QQ a N NOT DEF 1 EXEQUTE RPL B INP 09 Exe Designate the origin setting axis J 1 DEF 7 lt UBER gt lt LBER 12345678 9 Press the 1 key and then the INP key The CHANGES TO AGN um BRAKE 00000000 origin will be set OK 1 SET AX S 11111100 1 EXEQUTE CRI GN NOT DEF B INP J5 Set the origin 1 DEF This completes the setting of the origin with the user origin method 5 82 Resetting the origin 5Maintenance and Inspection 5 5 4 ABS origin method When t
49. e Model Quantity Description 1 Pneumatic hand 1E HP01 1 Hand input cable with pneumatic coupling 1E HPO1E 2 Pneumatic hand interface 2A RZ365 375 1 Interface board Install on the controller 3 Solenoid valve set 1E VD01 1 Comes with two M3x25 socket head bolts 1E VDO1E 4 Hand curl tube 1E ST0402C 1 2 tubes per set 5 Socket head bolts M5x16 4 lt 6 gt Socket head bolts M3x12 4 lt 7 gt Adapter BU144D697H01 1 This item is needed for installing lt 1 gt above Installation the pneumatic hand set 4A HP02 HP02E 3 35 3Installing the option devices 3 2 1 Installing the 1E HP01 1E HPO1E pneumatic hand Fig 3 3 shown the method for installing the pneumatic hand The installation steps are as folows 1 Use four M5x16 hexagon socket head bolts lt 5 gt to install the head adapter lt 7 gt to the robot arm s mechanical interface 2 Use four M3x12 hexagon socket head bolts 6 to install the pneumatic hand to the hand adapter Use Fig 3 3 to find the where the ends of the cables should be connected to the adapter 3 As shown in Fig 3 3 connect the hand curl tubes to coupling 1 and coupling 2 which protrudes from the cover of the forearm The opposite end of the tube connected to coupling 1 should be attached to the hand s OPEN coupling and the opposite end of the tube connected to coupling 2 should be attached to the hand s CLOSED coupling 4 As shown in Fig 3 3 connect t
50. e above step 2 Do not forget to attach the washer with seal 5 Install the cover which removed with the above step 1 In the case of clean specification take care not to damage the packing attached to the cover matching surface at this time This completes the J4 axis lubrication lt gt Ar purging bolt Bolt 8x6 washer wth seal El bow cover B Fig 5 13 J4 axis lubrication method J5 axis lubrication method Fig 5 14 shows the procedures for J5 axis lubrication method 1 Remove the No 2 arm cover U 2 In the case of clean specification remove the air purging bolt lt 1 gt Take care not to lose the washer with seal at this time There is no air purging bolt except for the clean specification 3 Lubricate the grease shown in the Table 5 5 from grease nipple lt 2 gt 4 In the case of clean specification tighten the air purging bolt lt 1 gt which removed with the above step 2 Do not forget to attach the washer with seal 5 Install the cover which removed with the above step 1 In the case of clean specification take care not to damage the packing attached to the cover matching surface at this time This completes the J5 axis lubrication No 2 armcover L 2 armcover U lt 1 gt Air purging bolt Bol 6 washer wth seal Pe Fig 5 14 J5 axis lubrication method 5 58 Maintenance and inspection procedures 5Maintenance and Inspection J6 ax
51. e battery and initialize the battery usage time Refer to the separate Instruction Manual Detailed Explanation of Functions and Operations for details on the opera tion methods oo 5 64 Maintenance and inspection procedures 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 dealer when required Some Mit subishi designated parts differ from the maker s standard parts Thus confirm the part name robot arm and con troller serial No and purchase the parts from the dealer Table 5 6 Consumable part list No Part name Type Usage place Q ty Supplier 1 Timing belt B40S2M320U J5 axis 1 2 Grease SK 1A Reduction gears of each axis An needed 3 BARRIERTA IMI V J4 J5 J6 of clean specification An needed Mitsubishi Electric 4 Shell Alvania Grease No 2 Spring shaft in base An needed 5 Lithium battery A6BAT 5 axis type 4 In battery cover 6 axis type 5 Table 5 7 Spare parts list Part name Type Usage place Q ty Supplier 1 AC servo motor J1 axis 1 2 J2 axis 1 3 J3 axis 1 4 6 axis type J4 axis 1 5 J5 axis 1 6 J6 axis 1 7 Reduction gears J1 J2 axis 2 8 J3 axis 1 9 J4 J5 axis J4 axis is for only 6 a
52. eaker NV Terminal cover Protective earth terminal PE Revision history Date of Point Instruction Manual No Revision Details 2001 09 11 BFP A8183Z First print 2001 09 25 BFP A8183 Formal style 2001 12 06 BFP A8183 A The explanation of the attached part of packing was added Error in writing correction 2002 04 23 BFP A8183 B Error in writing correction B 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 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 The information contained in this document has been written to be accurate as much as possible Please interpret that items not described in this document cannot be performed Please contact your nearest dealer if you find any doubtful wrong or skipped point Copyright C 2001 MITSUBISHI ELECTRIC CORPORATION CONTENTS 1 Before starting use instruction manua details of each instruc
53. ed the brakes will be applied immediately OS Origin setting axis designation Move the cursor to the SET AXIS axis No in the origin setting with the 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 display a 0 7 26 axis origin setting 1 Install the hand option or bolt two M5 bolts lt gt 12345678 prepared by user at opposing positions on the BRAKE 00000100 mechanical interface SET AX S 00000100 QA GN NOI B 2 Press the 0 key five times and then press the gs 1 key 1 will display at the 6 position to set Designate the origin setting axis the brake release 3 Confirm the axis for which the brakes are to be 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 customer AN CAUTION The J6 axis does not have a mechanical stopper When setting the origin position do not rotate the axis more than the motion range 200deg RPL 1 7 Press the key The cursor will move to Move the cursor SET AXIS MECH 12345678 BRAKE 0000
54. ed in 1 Timing belt replacement period have not occurred with the timing belt 4 Confirm that the belt tension is adjusted to slacken approx 1 9mm when the center of the belt is lightly pressed with a finger approx 0 7N as shown in Fig 5 7 Belt tension E Adjusting the J5 axis timing belt 1 Carry out steps 1 and 2 indicated in Bl Inspecting the J5 axis timing belt above 2 Lightly loosen the four motor installation bolts lt 1 gt Do not loosen too much 3 While confirming the tension of the timing belt 2 move the motor lt 3 gt in the direction of the arrow shown in the figure Move until the belt slackens approx 1 9mm when the center of the belt is lightly pressed with a fin ger approx 0 7N 4 The belt tension will increase when moved in the direction of arrow and will decrease when moved in the direction of arrow b 5 If the belt is loosened too much when adjusting the tension causing it to come off the timing pulleys lt 4 gt and lt 5 gt or if the belt and pulley teeth engagement is deviated the machine system s origin will deviate 6 After adjusting securely tighten the four motor installation bolts lt 1 gt Improper tightening can cause the belt to loosen with vibration Replacing the J5 axis timing belt 1 Fig 5 6 shows the methods for inspecting adjusting and replacing the timing belt 2 Move the robot posture with the teaching pendant so that the J5
55. en and select 1 DATA 2 MECH B INP the data input method 3 JIG 4 ABS EXE The origin data input method will be selected and the screen for turning USER OFF the servo power will appear A lt ORIGIN gt 4 Press the 1 and INP keys to turn OFF the servo power The screen for SERVO OFF inputting the origin data will appear OK ey en 1 NU 2 f DATA D 000000 1 000000 000000 3 000000 000000 9 000000 000000 O 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 1 keys etc move the cursor to the item to be selected and then press the INP key 2 14 Setting the origin 5 Inputting the origin data T B screen lt DATA gt D D tJi J2 3 J3 J4 5 Jo _ 6_ Origin data label 2Unpacking to Installation Input the value confirmed in section 1 Confirming the origin data on page 12 D J1 J2 J3 J4 J5 J6 The correspondence of the origin data label value and axis to be input is shown in Fig 2 9 For the 5 axis robot the J4 axis is meaningless Fig 2 9 Correspondence of origin data label and axis The method for inputting the origin data is explained below The value shown in Fig 2 8will be input as an example XT B screen DATA D 9boo00 1 000000 000000 3 000000 000000 15 000000 00000
56. g 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 I Before 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 CAUTION N WARNING N WARNING N CAUTION N WARNING N CAUTION N CAUTION ZS CAUTION ZS CAUTION ZS WARNING N CAUTION 1 4 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 envi ronment 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
57. gt 1 armcover L lt 2 gt Shoul cover B 99 gt Shoul der cover B 2 lt gt Shoul cover L e 5 D e put eg p 0 3 Shoul der cover F ens TM quU pe ae Dee Fig 5 5 Installing removing the cover 6 axis type 5 48 Maintenance and inspection procedures 5Maintenance and Inspection Table 5 3 Cover names Qty No Cover names 5 axis 6 axis Remarks type type lt 1 gt Shoulder cover L 1 1 X2 Shoulder cover R 1 1 lt 3 gt Shoulder cover F 1 1 lt 4 gt Shoulder cover B 1 1 lt 5 gt No 1 arm cover R 1 1 lt 6 gt No 1 arm cover L 1 1 lt 7 gt Elbow cover U 1 1 The packing C is attached to clean specification of 5 axis type The packing D is attached to clean specification of 6 axis type 8 Elbow cover B 0 1 The packing A and D are attached to clean specification Elbow cover L 1 0 The packing C is attached to clean specification X95 Elbow cover F 1 i lt 10 gt No 2 arm cover U 1 1 The packing C and D are attached to clean specification lt 11 gt No 2 arm cover L 1 1 The packing C and D are attached to clean specification The rubber packing is attached to protection specification lt 12 gt Wrist cover U 1 1 The packing B is attached to protection and clean specification lt 13 gt Wrist cover L 1 1 The packing B and
58. he hand check cable which is attached to the main unit of the hand to the connector which protrudes from the cover of the forearm This completes the installation of the hand 3 2 2 Installing the 1E VD01 1E VDO1E solenoid valve set To install the solenoid valve set refer to 3 1Installing the solenoid valve set 1E VD01 VD01E VD02 VD02E on page 31 in this manual 3 2 3 Installing the pneumatic hand interface To install the pneumatic hand interface refer to separate manual CR1 Controller INSTRUCTION MANUAL Controller setup basic operation and maintenance 3 2 4 Setting the parameters For the pneumatic hand 1E HP01 1E HPO1E the tool data is 107mm Refer to separate manual CR1 CR2 CR4 CR7 CR8 Controller INSTRUCTION MANUAL Detailed explanations of functions and operations and set the value of the MEXTL parameter to 107mm 3 2 5 Open close setting of the hand and settings for input signals The connections for the optional pneumatic hand sensor and the bit settings for input signals and for the hands open close setting are shown in Table 3 4 The hand connector numbers have been assigned numbers from the connector pins located at the end of the forearm Table 3 4 The hand s open close setting and input signal settings Hand check Setting pins for the open close setting of the hand connector Signal Comments numbers
59. he origin setting of the robot is performed for the first time this product records the angular position of the origin within one rotation of the encoder as the offset value If the origin setting is performed according to the ABS origin method this value is used to suppress variations in the origin setting operations and to reproduce the initial origin position accurately The procedures for setting the origin with the ABS method are explained below 1 Select the T B lt gt MN 1 2 RN 1 PARAM 2 1 Press the 5 key the menu screen and dis 3 FILE 4 MN 3 BRAKE 4 RAN play the maintenance screen 5 6 SET 5 PO R J6 5 STU Display the maintenance screen 2 Press the 4 key on the maintenance screen and display the origin setting method selection screen Y J2 4 MNO Display the method selection screen CH GN lt ABS gt 1 2 SERVO CFF 3 Press the 4 key and select the ABS method 3 16 4 48S 1 Then press the 1 key and the INP key to 5 USER 1 EXEQUTE turn the servo OFF a B a 2 GHI m 1 DEF Select the ABS method The origin of each axis can be set in the same manner as described in 5 5 1 Mechanical stopper method on page 67 2 J1 axis origin setting on page 68 and succeeding sections for how to set the origin for each axis When setting the origin all axes can
60. he 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 A 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 A CAUTION When the belt is replaced the machine system origin may deviate In this case the position data must be reviewed 5 50 Maintenance and inspection procedures 5Maintenance and Inspection 2 Inspection maintenance and replacement of J5 axis timing belt 3 Motor lt gt Mtor fixi ng screw NBx20 bolt wth hol e lt gt Ti ning belt pulle Fig 5 6 Inspection maintenance and replacement of J5 axis timing belt Inspecting the J5 axis timing belt 1 Confirm that the robot controller power is OFF 2 Refer to 5 3 2Installing removing the cover on page 48 and remove the No 2 arm cover U L 3 Visually confirm that the symptoms indicat
61. here any air Drain the drainage and remedy the air leaks replace the part After turning the power ON Turn the power ON while monitoring the robot 1 Is there any abnormal motion or abnormal noise when the power is turned ON Follow the troubleshooting section During operation try running with an original program 1 Check whether the movement points deviated 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 cannot be corrected refer to Troubleshooting check and remedy Follow the troubleshooting section Is there any abnormal motion or abnormal noise Visual Follow the troubleshooting section 5 44 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 1 Are any of the bolts or screws on the robot arm loose Securely tighten the bolts 2 Are any of the connector fixing screws or terminal block terminal Securely tighten the screws screws loose 3 Remove the cover at each section and check the cables for wear Check and eliminate the cause d
62. his instruction manual Table 1 1 Symbols in instruction manual Symbol Meaning Precaution indicating cases where there is a risk of operator fatality or seri AN DAN 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 WA RNIN 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 NCAUTIO 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 the text this refers to a key on JOINT the teaching pendant This indicates to press the B key while holding down the A key In this example the Forward key is pressed while holding down the X Y key 7 FORWD X A B 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 COND 5 RPL A B C TYB This indicates the teaching pendant 1 2 Using the instruction manuals 1 2 Safety Precautions I Before starting use Always read the following precautions
63. ignation Move the cursor to the SET AXIS axis No in the origin setting with the 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 display a 0 Resetting the origin 5 73 5Maintenance and Inspection 6 J5 axis origin setting MECHN 12345678 BRAKE 00001000 SET AX S 11101000 CRIGN NOT B J5 1 DEF Designate the origin setting axis 1 Press the 0 key four times and then press the 1 key 1 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 AN 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 axis type RPL 1 Move the cursor MECHN 1234
64. is lubrication method Fig 5 15 shows the procedures for J6 axis lubrication method 1 Remove the wrist cover S top and bottom of wrist 2 In the case of clean specification remove the air purging bolt lt 1 gt Take care not to lose the washer with seal at this time There is no air purging bolt except for the clean specification 3 Lubricate the grease shown in the Table 5 5 from grease nipple lt 2 gt 4 In the case of clean specification tighten the air purging bolt lt 1 gt which removed with the above step 2 Do not forget to attach the washer with seal 5 Install the cover which removed with the above step 1 In the case of clean specification take care not to damage the packing attached to the cover matching surface at this time This completes the J6 axis lubrication Wist cover S Wist block ae See 2 Gease nipple Ko Fig 5 15 J6 axis lubrication method Maintenance and inspection procedures 5 59 5Maintenance and Inspection 3 Oil seal section lubrication method for only clean specification The clean specification use the oil seal at between the wrist housing and forearm at the end of the wrist housing and between the elbow block and forearm Oil seal Refer to Table 5 6 Consumable part list on page 65 The oil seal section lubrication method is shown below AN CAUTION The grease used here will generate toxic decomposition gases at high temperatures exceeding 280 C Do no
65. is not to be set press the 0 key and display a 0 4 J3 axis origin setting 12345678 1 Press the 0 key twice and then press the 1 BRAKE 00100000 key 1 will display at the 3 position to set the SET AX 5 brake release CRGN NOT F J5 2 Confirm the axis for which the brakes are to be 1 DEF 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 and contact the axis against the mechanical stopper Designate the origin setting axis AN 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 base en Front of base 5 5 type 6 axi s type 5 70 Resetting the origin 5Maintenance and Inspection Move the cursor MECHN 12345678 BRAKE 00100000 SET AX S 00100000 NO CE B C 05 6 Designate the origin setting axis URED ues INP gt EXE SET CR GN OK 1 EXEQUIE
66. ket head bol t MB x 8 lt 5 gt Socket head bolt g NB x 8 Battery card mc Ue D EE Lead connector d m Rn Connect the battery connector e LT Battery card top draw ng Detail draw ng of section A Fig 5 19 Replacing the battery Maintenance and inspection procedures 5 63 5Maintenance and Inspection 1 Confirm that the robot arm and controller are connected with a cable 2 Turn the controller control power ON The position data is retained by the power supplied from the controller while replacing the battery Thus if the cable is not connected correctly or if the controller power is OFF the position data will be lost 3 Press the emergency stop button to set the robot in the emergency stop state This is a measure for safety and must always be carried out 4 Remove the shoulder cover B from the robot Refer to 5 3 2Installing removing the cover on page 48 Remove the installation screws lt 5 gt in section A of the robot arm and remove the battery cover lt 4 gt The battery holder is located in the battery cover lt 4 gt Remove the old battery from the holder and discon nect the lead connector Insert the new battery into the holder and connect the lead connector Replace all batteries with new ones at the same time 8 Carry out steps 4 to 5 in reverse to install the parts 9 Initialize the battery consumption time Always carry out this step after replacing th
67. l to the ground Rotation center of J1 axis Rotation center of J1 axis F L 1 Flag 1 amp BOOOO 1 70 RIGHT LEFT 5 type 6 axis type a Note amp B is shows the binary Fig 6 1 Configuration flag RIGHT LEFT 2 ABOVE BELOW Q is center of J5 axis rotation in comparison with the plane through both the J3 and the J2 axis 5 type 6 axis type FL 1 Flag 1 amp BOOOO OOOO T 1 70 ABOVE BELOW Note amp B is shows the binary Fig 6 2 Configuration flag ABOVE BELOW Configuration flag Appendix 85 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 Mechani cal i nterface F L 1 Flag 1 6 axis type 1 1YO NONFLIPY FLIP Note amp B is shows the binary Fig 6 3 Configuration flag NONFLIP FLIP Appendix 86 Configuration flag s MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100 8310 TELEX J24532 CABLE MELCO TOKYO NAGOYA WORKS 1 14 YADA MINAMI 5 HIGASHI KU NAGOYA JAPAN APR 2002 MEE Printed in Japan on recycled paper Specifications are subject to change without notice
68. lock and forearm Fig 5 17 shows the procedures for Lubrication to wrist housing end and between elbow block and forearm Refer to the 5 3 2Installing removing the cover on page 48 and remove the necessary covers 1 Remove the No 2 arm cover U and wrist cover S U 2 Remove the wrist cover L installation screw and shift the cover in the direction of the arrow The J6 axis motor cable is passed through the hole of ring lt 1 gt Make sure not to apply excessive force on the cable The ring lt 1 gt is fixed adhered to the wrist cover Make sure not to apply excessive force on the ring lt 1 gt 3 Apply grease BARRIERTA IMI V onto the surface that the seal ring lt 1 gt oil seal contacts using a brush etc 4 With the wrist cover L shifted move the ring X2 in the direction of the arrow and remove it The ring lt 2 gt is not adhered 5 Apply grease BARRIERTA IMI V onto the surface that the ring X2 oil seal contacts using a brush etc 6 Return the ring lt 2 gt to the original position Match the surface that the sponge is attached to the outer side and toward the wrist cover L side as shown in the Fig 5 17 7 While pressing the ring lt 2 gt in the arrow of the direction so that it matches the wrist cover L groove install the wrist cover L to the original position with the screws two M3x8 screws 8 While making sure that the ring X1 and ring lt 2 gt correctly match the groove install the wrist cover U to the origin
69. lt 5 gt J5 axis reduction gears Harmonie ipis SIUS 7g 15g Japan Harmonic Systems lt 6 gt J6 axis reduction gears 1ig 25g Wrist cover S Shell Alvania Grease when wear is lt 7 gt Spring shaft in the base Paint No 2 ig detected 1g Shoulder cover L Note1 Note1 If wear is detected during periodical inspections apply the grease The grease nipple position is shown in Fig 5 9 The lubrication specifications for each place are shown in Table 5 5 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 sus pended or if the designated speed is slow the lubrication time can be lengthened in proportion The Lubrication interval in Table 5 5 is usually based on the 2 year inspection 8Hr x 20 days x 24 months 4000Hr 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 Table 5 5 correspond to the supply positions in Fig 5 9 Maintenance and inspection procedures 5 55 5Maintenance and Inspection 2 Reduction gears lubrication method The reduction gears lubrication method is shown below Refer to the 5 3 2Installing removing the cover on page 48 and remove the covers Ji axis lubrication method
70. lve installation procedures RV 2A RV 3AJ 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 two M3x6 screws lt 2 gt and the two M3x8 bolts lt 3 gt and remove the shoulder cover B 15 2 Install the solenoid valve by fastening it with the two attached M3x25 screws lt 5 gt to the screw holes on the plate lt 4 gt of the robot arm Installing the solenoid valve set 1E VD01 VDO1E VD02 VD02E 3 31 3Installing the option devices 3 Connect one of the two 6 pneumatic hoses in section A the one marked AIR IN to the quick coupling port P lt 9 gt of the solenoid valve lt 6 gt The primary air flow can now be supplied from the pneumatic port at the base 4 Connect the hose marked 1 to port A X7 on the primary solenoid valve 65 Connect the hose marked 2 to port B lt 8 gt on the primary solenoid valve 65 If you are using the double type valves 1E VD02 VD02E you need to do the following Connect the hose marked 3 to port A lt 11 gt on the secondary solenoid valve lt 10 gt Connect the hose marked 4 to port B lt 12 gt on the secondary solenoid valve lt 10 gt 5 Connect the GR1 plug protruding from the primary solenoid valve lt 6 gt to the connector 1 Connect the GR2 plug protruding from the pri
71. make sure not to damage the packing The installing removing the cover procedures are shown below 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 and remove the cover 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 49 5Maintenance and Inspection 5 3 3 Inspection maintenance and replacement of timing belt This robot uses a timing belt for the drive conveyance system of the J5 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 adjust ment are inadequate the life could drop and noise could be generated Sufficient aging to remove the initial elon gation 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 T
72. mary solenoid valve lt 6 gt to the connector GR2 If you are using double type valves 1E VD02 VD02E Connect the GR3 plug protruding from the secondary solenoid valve lt 10 gt to the connector GR3 Connect the GR4 plug protruding from the secondary solenoid valve lt 10 gt to the connector GR4 6 When you have completed the installation reinstall the shoulder cover B lt 1 gt to its original position and be careful not to entangle the cables when you do so The connections after the installation appear as in Table 3 1 for single type valves hand 2 is not applicable Table 3 1 Solenoid valve ports and hoses Correspondence of couplings and hand ports Hand arm number Solenoid valve Solenoid valve coupling No port used OPEN 1 1 A Hand 1 First set CLOSE 2 2 B OPEN 3 3 A Hand 2 Second set CLOSE 4 4 B 3 32 Installing the solenoid valve set 1E VD01 VD01E VD02 VD02E 3Installing the option devices 3 1 2 RV 2AM RV 3AUM Protection specification GR3 GR4 C When using one row When using two row solenoid valve solenoid valve Connector connection P d lt 10 gt Secondary sol enoi d val ve lt 4 gt Plate Lead connector Detai ed draw ng of secti on A Fig 3 2 Solenoid valve installation procedures RV 2AM 3AJM 1 Remove the two M3x6 screws lt 2 gt and the two M3x8 bolts lt 3 gt
73. n procedures Table 3 5 Configurations for the motorized hand set 3Installing the option devices Number Part name Model type Quantity Notes lt 1 gt Motorozed hand 1A HMO1 1 lt 2 gt Motorozed hand curl cable 1E GHCD 1 1 lt 3 gt Motorozed hand interface 2A RZ364 1 Install on controller lt 4 gt Hexagon socket bolts M5x16 4 5 Hexagon socket bolts M3x12 2 6 Hand adapter BU144D697H01 1 Installation the motorized hand set 4 02 3 37 3Installing the option devices 3 3 1 Installing the motorized hand Fig 3 4 shows how to install the motorized hand 1 Install the hand adapter to the robot arm s mechanical interface with 4 hexagon socket bolts M5x16 2 Instal the motorized hand to the hand adapter with 2 hexagon socket bolts M3x12 Make sure that the position of the hand connector of the motorized hand and the position of the hand adapter are the same as that shown in Fig 3 4 3 Once the hand has been installed securely attach the hand curl cable to the hand s connector and to the robot s connector as shown in Fig 3 4 4 Move the J5 axis by JOG operation and confirm that the cable is not hindered CAUTION Install the O position the center of the operation range for the positions of the J5 axis and J6 axis If you set the installation position inappropriately the motorized hand curl cable and the hand adapter can get entangled In such a case repeat th
74. nd 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 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 ZS CAUTION CAUTION ZS CAUTION N CAUTION NWARNING NWARNING N CAUTION NWARNING N CAUTION N CAUTION ZS CAUTION N CAUTION NWARNING N CAUTION 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 environ ment 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 dropping 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 s
75. nput method 5b Inputting the origin data and display the Origin Data Input screen 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 shoul der cover B Refer to Fig 2 8Origin data label an example on page 12 and Fig 2 9Correspondence of origin data label and axis on page 15 for details on the origin data label 4 Installing the cover Install the shoulder cover B removed in step 1 Confirming the origin data label above Refer to 5 3 2Installing removing the cover on page 48 and replace the shoulder cover B This completes the recording of the origin data 5 84 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 B and C 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 P is center of flange in comparison with the plane through the J1 axis vertical to the ground Q is center of J5 axis rotation in comparison with the plane through the J1 axis vertica
76. nst the mechanical stopper stopper method on page 67 3 Jig method The origin posture is set with the calibration jig The setting method is explained in 5 5 2Uig method on installed page 78 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 81 5 ABS origin method This method is used when the encoder backup Before using this method the origin must be set with the data lost in the cause such as battery cutting other method with same encoder The setting method is explained in 5 5 4ABS origin method on page 83 5 66 Resetting the origin 5Maintenance and Inspection 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 MEND MN NI 1 TEACH 2 RN 1 2 1 Press the 5 key on the menu screen and dis 3 FILE 4 MN 3 BRAKE 4 RGN play the maintenance screen 5 MN 6 SET 5 PO ER
77. oller to TEACH 2 Set the T B ENABLE DISABLE switch to ENABLE The menu selection screen will appear The following operations are carried out with the T B Operating from the T B Always set the MODE switch mode selection key switch on 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 Q 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 Setting the origin 2 13 2Unpacking to Installation 4 Selecting the origin setting method XT B screen Keys used MENU j 1 TEACH 2 RUN 4MONI i 5 MAINT amp SET 5 1 Press the 5 key on the menu screen and display the maintenance screen p rete REL V EO ARM 2 Press the 4 key on the maintenance screen and display the origin setting PARAM 21 method selection screen 3 BRAKE 4 ORIGIN dei 9 POWER 4 ORIGIN 3 Press the 1 key on the origin setting method selection scre
78. on and Maintenance for Controller Controller Controller details on the controller grounding Robot arm and Robot arm and Robot arm and A gt personal personal personal 2 Use Class D grounding grounding resistance computer computer computer 100 or less Dedicated grounding separated from the other devices should be used 3 Use a AWG 14 2mmz2 or more stranded wire for p mm the grounding wire The grounding point should be Dedicated grounding bY Gommon grounding ey Common grounding as close to the robot arm and controller as possi Optimum Good Normal ble and the length of the grounding wire should be short Fig 2 4 Grounding methods 2 Grounding procedures Robot arm 1 Prepare the grounding cable AWG 14 2mm2 or more and robot side installation screw and washer 2 If there is rust or paint on the grounding screw section A remove it with a file etc M4 x 10 SW PW d 3 Connect the grounding cable to the grounding p d Screw section Robot grounding cable A W G 14 2mm or more Prepared by customer Fig 2 5 Connecting the grounding cable Installation 2 9 2Unpacking to Installation 2 2 5 Connecting with the controller Robot arm Controller Motor power cable 5m Motor signal cable 5m Fig 2 6 Connecting the machine cables Carry out the following procedure after installing the controller referring to the separa
79. ortation posture The axes may be outside the movement area Move these axes toward the inner side of the movement area If moved outward an will appear on the T B screen and the robot will not move 2 20 Confirming the operation 2Unpacking to Installation J3 axis jog operation Lr axis a 2 m move 5 axis 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 EC step 06 move A 5 STU J6 sis move 9 B J4 axis YZ Q5 ER axis MOVE J6 e move 1 DEF move ER sTEP E J4 J4 J5 and J6 axis jog operation J5 axis 5 axis 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 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 in the plus direction When the MOVE C J6 keys are pressed Rotate in the minus direction When an appears on the T B screen display If the robot is moved outside the movement area an KA will appear In this case
80. ource 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 malfunc tioning 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 pri ority right for the robot control Failure to observe this could lead to personal injuries 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 peripheral devices because of programming mistakes etc
81. owly move the J4 axis in minus direction and contact the axis against the mechanical stopper The J4 axis dose not have a brake 5Maintenance and Inspection RPL 7 Press the key The cursor will move to AXIS Move the cursor 12345678 8 Designate the axis for which the origin is to be BRAKE 00010000 set SET AX S 00010000 Set 1 for the 4 axis and set 0 for the other CRI G N Nor LEF us D e E axes Then press INP Next a confirmation Designate the origin setting axis 1 DEF 0 ABC screen will appear 9 Press the 1 and INP keys The origin posture will be set B INP J5 EXE Set the origin 1 DEF MECH 12345678 10 Setting of the origin is completed BRAKE 00010000 SET AX S 00010000 11 Refer to 5 5 5Recording the origin data on CRI G N COMLETED page 84 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 or gt 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 des
82. procedure the teaching pendant will be installed with the control power OFF Refer to the separate Controller setup basic operation and maintenance for details on installing the teaching pendant with the control power ON 1 Installing with the control power OFF Display LCD ENABLE DISABLE switch Emergency stop switch ES Operation keys Lu ps pE Appearance of teaching pendant Connector REMOVE T B switch Teaching pendant T B O REMOVE T B switch lt gt 1 Confirm that the controller s power supply switch is OFF 2 Connect the T B connector to the RS 422 T B connector on the controller 3 Do not pull the cable with force or bend it excessively as the cable could break or the connector could be damaged 4 Confirm that the REMOVE T B switch on the side of the controller is not depressed is projected 5 Set the T B ENABLE DISABLE switch to DISABLE Fig 2 7 Installing the T B control power OFF When using the robot with the T B this switch 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 Setting the origin 2 11 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 No ES804008 D The origin data to be
83. r 3 6 are in the plastic bag of the robot arm attachment Confirming the product 2 5 2Unpacking to Installation 2 2 Installation 2 2 1 Unpacking 1 2 Cushi oni ng naterial A Qushi oni ng naterial B DU Cushi oni n naterial B 3 4 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 The robot is shipped from the factory in cardboard packing Always refer to Fig 2 1 and unpack the robot Handle the robot arm according to 2 2 2 Transportation procedures Transportation by people The unpacking process is shown below 1 Open the top of the cardboard box 2 As shown in Fig 2 1 2 lay the box gently down so that the unpacking instructions on the top cover faces down 3 Pull the cushioning material A and B which encloses the robot arm out of the cardboard box as shown in Fig 2 1 3 4 Remove the cushioning material A 5 While keeping the robot enclosed in cushioning material B stand up the robot arm as shown in Fig 2 1 4 6 Remove the cushioning material B from the robot to complete the unpacking process 2 6 Installation 2Unpacking to Installation 2 2 2 Transportation procedures Transportation by people Forearm El bow cover Don t hold the resin cover when carryi ng the robot as this nay ead to breakage BUL47D428H02 NCAUTION a M prevent dropa ng
84. re described in 5 4Maintenance parts page 65 of this manual Always contact your dealer when parts are needed AN 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 lt 1 gt and reduction gears lt 2 gt arranged in the shoulder Non excitation magnetic brakes are mounted the Jlaxis motor lt 1 gt 2 The J2 axis rotation is driven by the J2 axis motor lt 3 gt and reduction gears lt 4 gt arranged in the shoulder Non excitation magnetic brakes are mounted in the J2 axis motor lt 3 gt 3 The J3 axis rotation is driven by the J3 axis motor lt 5 gt and reduction gears lt 6 gt arranged in the upper arm Non excitation magnetic brakes are mounted in the J3 axis motor lt 5 gt 4 The J4 axis rotation of 6 axis type is driven by the J4 axis motor lt 7 gt and reduction gears lt 8 gt arranged in the elbow block 5 The rotation of the J5 axis motor lt 9 gt arranged in the forearm is conveyed to the reduction gears lt 11 gt via the timing belt lt 10 gt to rotate the wrist housing and following parts Non excitation magnetic brakes are mounted in the J5 axis motor 9 6 The rot
85. rea 5 62 Maintenance and inspection procedures 5Maintenance and Inspection 5 3 7 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 installed 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 procedure of battery replacement of robot arm is explained below 1 Replacing the robot arm battery Don t disconnect connector etc While replacing the battery the encoder position AN CAUTION 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 lt 1 gt Shoul der cover B lt 2 gt Truss screw M x 8 lt 3 gt Soc
86. robot movement wire breakage could occur at the connector section This completes the installation of the motorized hand set 3 38 Installation the motorized hand set 4A HM02 3Installing the option devices 3 4 Hand output cable 1E GR35S This hand output cable is used by the customer to connect to the handle output connector on the shoulder sec tion of the robot arm Refer to section 3 1Installing the solenoid valve set 1E VD01 VD01E VD02 VD02E 4 Table 3 1 on page 32 for the connection methods 3 5 Installing the hand input cable 1E HC15C and hand curl tube 1E STO40 C The hand input cable and hand curl tube are used to connect to the hand and sensor manufactured by the customer Refer to section 3 2Installation the pneumatic hand set 4A HP02 HPO2E 5 and 6 on page 35 for the installation methods Hand output cable 1E GR35S 3 39 3Installing the option devices 3 40 Installing the hand input cable 1E HC15C and hand curl tube 1E STO40 C 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 41 4Basic operations 4 42 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
87. s in the battery cover lt 12 gt and reinstall the battery cover 8 When you have complered the installation reinstall the shoulder cover B lt 1 gt to its original position and be careful not to entangle the cables when you do so Installing the solenoid valve set 1E VD01 VDO1E VD02 VD02E 3 33 3Installing the option devices The connections after the installation appear as in Table 3 2 for single type valves hand 2 is not applicable Table 3 2 Solenoid valve ports and hoses Connection table for couplings and hand ports for the RV 2AM 3AJM F li Solenoid val Hand Hand port Hosenimber olenoid valve number port OPEN 1 i A Hand 1 First set CLOSE 2 2 B OPEN 3 A Hand 2 Second set CLOSE 4 4 B OPEN 5 5 Spare CLOSE 6 6 3 34 Installing the solenoid valve set 1E VD01 VD01E VD02 VD02E 3Installing the option devices 3 2 Installation the pneumatic hand set 4A HP02 HPO02E Table 3 1 shows the construction of the pneumatic hand set and the installation procedure and Table 3 1 shows the configuration equipment which correspond with the Table 3 1 Sol enoi d val ve set For eam Mechani cal interface lt gt Hand adapter lt 1 gt Pneanati c hand Hand check cabl e MewfromA Fig 3 3 Pneumatic hand set installation procedures Table 3 3 Configuration for the pneumatic hand set Number Part nam
88. screen Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH 3 gt 5 gt 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 MOVE 6 axis type The direction of the frange will not change Assuming that the current position is on an arc centering on the Z 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 2 28 Confirming the operation 2Unpacking to Installation Changing the flange surface posture 5 axis type 6 axis type Note The 5 axis type dose not have The flange position does not change this movement 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
89. t light cigarettes with this grease on the hands AN CAUTION Read the precautions enclosed with the grease before starting work Lubrication between wrist housing and forearm Fig 5 16 shows the procedures for Lubrication method between wrist housing and forearm Refer to the 5 3 2Installing removing the cover on page 48 and remove the necessary covers 1 Remove the elbow cover U 2 Make marks on the seal ring lt 1 gt and ring guide lt 2 gt with a felt tip pen so that the position is not deviated 3 Remove the bolts four M2x2 bolts and slide the seal ring lt 1 gt in the direction of the arrow 4 Apply grease BARRIERTA IMI V onto the surface that the seal ring lt 1 gt oil seal contacts using a brush etc 5 Apply grease onto the surface that the seal ring lt 1 gt and seal guide 2 and tighten the bolts lt 3 gt 6 Install the elbow cover U which removed with the above step 1 In the case of clean specification take care not to damage the packing attached to the cover matching surface at this time This completes the lubrication between wrist housing and forearm lt gt Seal ri Make a nark al so on opposi te si de ae El bow cover B Apply grease at shaded section 4 M x 2 Fig 5 16 Lubrication between wrist housing and forearm 5 60 Maintenance and inspection procedures 5Maintenance and Inspection Lubrication to wrist housing and between elbow b
90. t 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 5 52 Maintenance and inspection procedures 5Maintenance and Inspection 5 3 4 Cleaning inside the cover of clean specification RV 2AC SA SB RV 3AJC SA SB This robot has dust generating elements timing pully timing belt in the No 2 arm cover U L thus the inside must be cleaned periodically Clean these areas once every three months 500 hours 1 Refer to 5 3 2Installing removing the cover on page 48 and remove the No 2 arm cover U L 2 Wipe the dust sticking on the inside of cover with dry cloth or with alcohol Take care not to damage the sponge packing attached on the No 2 arm cover U L at this time 3 Wipe the dust sticking on the inside of forearm with dry cloth or with alcohol Take care not to damage the sponge packing attached on the forearm at this time 4 Install the No 2 arm cover which removed with the above step 1 Take care not to damage the above sponge packing at this time This completes the cleaning inside the cover
91. te 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 controller N 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 AN 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 2 10 Installation 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 here Refer to 5 5 Resetting the origin on page 66 for the other methods The teaching pendant is required 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
92. the E MOVE J Fore eon upper right of the screen Set the override to 10 here for confirmation work Moving along the base coordinate system Z X Y se f cz X 3 5 axis type 6 axis type The flange position does change 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 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 O Jog mode will change when only XYZ key is pressed again 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 XYZ456 CYLNDER Each jog mode can be selected 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 2 26 Confirming the operation 2Unpacking to Installation Changing the flange surface posture e
93. 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 base coordinate system the TOOL jog that moves along the tool coordinate system and the CYLNDER jog that moves along the circular arc This operation is carried out while pressing the deadman switch on the back of the T B AN 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 AN CAUTION 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 AN CAUTION 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 oper ation will take place in any jog mode selected Refer to 2 3 Setting the origin on page 11 for details on setting the origin PA J6 axis J2 axis J2 axis e 5 type 6 axis type Each axis moves independently The 5 axis type does not have the J4 axis Fig 2 10
94. tion manuals nbols used in instruction manual 1 1 Using 11 2 1 2 Safety Precautions 1 2 1 Precautions given in the smart Safety 2 Unpacking to Installation at ates i pde 24 the 2 2 3 Installation procedures 2 2 4 Grounding procedures D Foe met rods 1 Confirming the date bs Lied bud A control power 3 XYZ jog operation 4 3 axis XYZ jog op Yonne s MET 5 CYLINDER jog operation ssec enc ecd 3 Installing the option devices 311 Instal lli the solenoid inl 3 1 2 RV 2AM RV 3AJM specif ciot 3 2 Installation the pneumatic hand set 4A HP02 HF 3 2 1 Installing the 1E HP01 1E HP01E pneumatic Ard 3 2 2 Installing the 1E VD01 1E VDO1E solenoid valve set 3 2 3 Installing the pneumatic hand interfa 3 2 4 Setting the parameters 3 2 5 Open close setting of the han 3 2 6 Confirming operability nS 3 3 Installation the motorized land set 4A HM02 3 3 1 Installing the motorized hand 3 3 2 Installation the motorized interfac 3 3 3 Setting the parameters 3 3 4 Confirming operability 3 4 Hand output cable 1E GR3 3 5 Installing the hand input cable 1E HC15C and hand curl tube 1E STO40 O 3 39 A Bast Bera DI
95. tting the origin 5 79 5Maintenance and Inspection 5 type 6 axis type 9 Set the origin JIG 12345678 dios doo On Press the key and move the cursor to BRAKE 11101000 BRAKE 11101100 P s Buon P SET AXIS To set the origin set 1 Set 0 SET 5 11101000 for the axis for which the origin i ttob t CH G NNI CEF gin is no o be set When 0 is set the previously set data will be saved 4jIG 12345678 10 Press the 1 and INP keys GANGES The origin posture will be set ee 1 EXEQUIE B INP Set the origin 1 DEF 5 type 6 axis type 11 Setting of the origin is completed 4jIG 12345678 4jIG 12345678 BRAKE 11101000 BRAKE 11101100 E P SET ANS 11101000 SET 5 11111100 12 Refer to 5 5 5Recording the origin data CRI a N NOT EF CRI G NNI page 84 in this manual and record the origin data on the origin data seal This completes the setting of the origin with the jig method 5 80 Resetting the origin 5Maintenance and Inspection 5 5 3 User origin method N CAUTION Before using this method the origin must be set with the origin data input method or Mechanical stopper method or jig 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
96. will rotate in the plus direction 5 axis type There is no operation When the MOVE A J4 keys are pressed 6 axis type Rotates in the minus direction 5 axis type There is no operation When the MOVE B J5 keys are pressed 6 axis type The Y axis will rotate in the plus direction 5 axis type There is no operation When the MOVE B J5 keys are pressed 6 axis type Rotates in the minus direction 5 axis type There is no operation When the MOVE J6 keys are pressed 6 axis type The Z axis will rotate in the plus direction 5 axis type There is no operation When the MOVE C J6 keys are pressed 6 axis type Rotates in the minus direction 5 axis type There is no operation Confirming the operation 2 29 2Unpacking to Installation 2 30 Confirming the operation 3Installing the option devices 3 Installing the option devices 3 1 Installing the solenoid valve set 1E VD01 VD01E VD02 VD02E The following shows how to install the solenoid valve set Please note that the installation method differs depending on the robot arm type Refer to the item which corresponds to robot type being used 3 1 1 RV 2A RV 3AJ General environment lt 1 gt Shoul der cover B GR1 GR3 GR4 When using one row When using two row Detailed draw ng of solenoid valve solenoid valve secti on A Connector connection Fig 3 1 Solenoid va
97. xis type 2 10 J6 axis 1 Mitsubishi Electric 11 Packing A BU147D288H01 Clean specification elbow cover An needed 12 Packing B BU147D288H02 Protection and clean specification wrist An needed cover 13 Packing C BU147D600H01 Clean specification elbow cover No 2 An needed arm cover and wrist cover 14 Packing D BU147D600H02 Clean specification elbow cover and An needed No 2 arm cover 15 Rubber packing BU147D643H01 Protection specification No 2 arm cover An needed and wrist cover 16 Silicon seal KE 4898T Clean specification elbow bushing An needed Note Confirm the robot arm serial No and contact the dealer for the type Maintenance parts 5 65 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 8 Table 5 8 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 11 2 Mechanical stopper This origin posture is set by contacting each axis The setting method is explained in 5 5 1 Mechanical method agai
98. ys are pressed the override TOOL LOW will decrease in the reverse order The currently X 134 50 STEP set speed will appear the upper right of the Y 220 00 Set th id 10 h fi Z 28000 CES FORWD BAcKwD screen Set the override to 10 here for Set the spee confirmation work Moving along the tool coordinate system STEP at J MOVE SPACE XN SPACE ES move ca T Y 2 A ES Z TX 3 JD 5 type 6 axis type 7 ai MOVE e 2 move The direction of the frange will not change 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 There are directions from which linear movement is not possible from the transportation posture In this case an

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