USER´S MANUAL - Omron Europe

Cat. No. I197E-EN-01A
Delta Robot
ZX-T Series
CR_UGD4_XXLH
Series
Delta Robot XXL
USER´S MANUAL
CONTENTS
CR_UGD4_XXLH
User's Manual
Safety Instructions
1. Attention
S-1
2. Explanation of warnings and notes
S-1
3. Safety information
S-2
3.1
General
S-2
3.2 Qualifiedpersonnel
S-2
3.3 Liability
S-2
3.4 Installation and operating conditions
S-2
3.5 Residual risks
S-2
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
Release device
Transport
Assembly and start-up
Maintenance and repair
System integrator
Chapter 1
Introduction
1. Introduction
1.1
S-3
S-3
S-3
S-3
S-4
1-1
Description of the robot
1.2 Type code explanation
1-1
1-1
2. Identification
1-1
3. Part names
1-2
Chapter 2
Model overview
1. Overview
2-1
2. Optional extensions
2-2
Chapter 3
Installation
1. Unpacking
3-1
2. Connecting the motor cables
3-1
3. Assembling the secondary arms
3-3
4. Mounting the rotational axis
3-5
5. Calibration
3-7
T-1
CONTENTS
Chapter 4
User's Manual
Maintenance
1. Periodic check, wear of springs
4-1
2. Cleaning the robot
4-1
3. Replacement of cups
4-1
4. Spare parts
4-2
Chapter 5
Robot settings
1. Kinematics
5-1
2. Workspace
5-2
3. Software limits
5-3
Chapter 6
Specifications
1. Basicspecifications
1.1 Cycletime
T-2
CR_UGD4_XXLH
6-1
6-1
2. Externalviewanddimensions
6-2
3. Designspecifications
6-3
3.1 Occupationareaofrobot
6-3
3.2 Mountingtherobottoitsframe
6-4
3.3 Armload
6-4
3.4 Gripperinterface
6-5
3.5 Softwaredesign
6-5
Safety Instructions
Contents
1.
Attention
S-1
2.
Explanation of warnings and notes
S-1
3.
Safety information
S-2
3.1
General
S-2
3.2
Qualified personnel
S-2
3.3
Liability
S-2
3.4
Installation and operating conditions
S-2
3.5
Residual risks
S-2
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
Release device
Transport
Assembly and start-up
Maintenance and repair
System integrator
S-3
S-3
S-3
S-3
S-4
1.
Attention
Information in this document can change without prior notice.
No part of this manual and added documentation may be copied, reproduced or translated into another language without
prior written approval.
Read and understand the material contained in this user's manual before you work on the CR_UGD4_XXLH robot for
the first time. This user's manual is supposed to help you use the capabilities of the CR_UGD4_XXLH robot safely and
properly.
2.
Explanation of warnings and notes
This manual uses the following safety alert symbols and signal words to provide safety instructions that must be
observed and to describe handling precautions, prohibited actions, and compulsory actions. Make sure you understand
the meaning of each symbol and signal word and then read this manual.
DANGER
THIS INDICATES AN IMMEDIATELy HAzARDOUS SITUATION WHICH, If NOT AVOIDED, WILL RESULT IN DEATH OR
SERIOUS INjURy.
WARNING
THIS INDICATES A POTENTIALLy HAzARDOUS SITUATION WHICH, If NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INjURy.
NOTE
Explains the key point in the operation in a simple and clear manner.
S-1
Safety Instructions
OMRON EUROPE B.V. cannot be hold responsible for any damage to the environment, to the machine or to the
functioning of the machine occurred by errors or missing data in the illustrations, drawing or specifications.
3.
Safety information
3.1
General
Safety Instructions
This ´3. Safety information´ subchapter contains information regarding working with the CR_UGD4_XXLH robot.
Qualified personnel working with the CR_UGD4_XXLH robot must have read and understood the CR_UGD4_XXLH
robot documentation, including the safety information chapter.
3.2
Qualified personnel
These are people who, due there specialist training, knowledge and experience, and their familiarization with the
relevant standards, are able to assess the work to be carried out and detect any potential hazards.
3.3
Liability
The CR_UGD4_XXLH robot is build using state-of-the-art technology and in accordance with the recognized safety
rules. Nevertheless, misuse of the CR_UGD4_XXLH robot may constitute a risk to life and limb or cause damage to
the CR_UGD4_XXLH robot and to other material property.
3.4
Installation and operating conditions
you may only use the components in accordance with the installation and operating conditions described in the
documentation. The operating conditions at the installation location must be checked and maintained in accordance
with the required technical data. Within the meaning of the Machinery Directive the CR_UGD4_XXLH robot is an
incomplete machine. Commissioning is prohibited until the usable machine or system in which the CR_UGD4_XXLH
robotisinstalledmeetsallrequirementsoftheMachinedirective2006/42/EC.
for the CR_UGD4_XXLH robot you have to observe the following standards, directives and regulations:
• ENISO10218-1:2011Robotsandroboticdevices-Safetyrequirementsforindustrialrobots-Part1:Robots.
• ENISO10218-1:2011Robotsandroboticdevices-Safetyrequirementsforindustrialrobots-Part2:Robotsystems
and integration.
3.5
Residual risks
Safety and health risks arising from the robot mechanics have been reduced by means of safety technology and design
engineering. However a residual risk remains, since the robot mechanics will be move by an automated control system.
The following are typical warnings concerning residual risks which cannot be assigned to a specific action. The
expression of safety labels is identical to the safety information.
S-2
3.5.1
Release device
The robot mechanics are not supplied with an release switch to control the brakes of the motors.
3.5.2
Transport
The prescribed transport position of the robot must be observed. Transportation must be carried out in accordance with
the transportation instructions or assembly instructions of the robot.
WARNING
• ONlyuSEAuthORIzEDhANDlINGEQuIPMENtwIthASuffICIENtlOAD-BEARINGCAPACItytOtRANSPORt
THE ROBOT.
• wEARSuItABlEPROtECtIvEClOthINGIfNECESSARy.
3.5.3
Assembly and start-up
Before starting up systems and devices for the first time, a check must be carried out to ensure that the system and
devices are completed and operational, that they can be operated safely and that any damage is detected.
The valid national or regional work safety regulations must be observed for this check. The correct functioning of all
safety circuits must also be tested.
The following tests must be carried out before start-up and recommissioning. It must be ensured that:
• therobotiscorrectlyinstalledandfastenedinaccordancewiththespecificationsintheassemblyinstructions.
• therearenoforeignbodiesorloosepartsontherobot.
• Allrequiredsafetyequipmentiscorrectlyinstalledandoperational.
WARNING
• AwRONGINStAllEDROBOtMAythROwOffhISARMS.
• wEARSuItABlEPROtECtIvEClOthINGIfNECESSARy.
3.5.4
Maintenance and repair
After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national
or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must
also be tested.
The purpose of maintenance and repair work is to ensure that the system is kept original or, in the event of a fault, to
return the system to an operational state. Repair work includes troubleshooting in addition to the actual repair itself.
The following safety measures must be carried out when working on the robot:
• Switchofthemachine(system)wheretherobotisbuilt-in(e.g.withapadlock)topreventitfrombeingswitchedon
again
• labelthemachine(system)withasignindicationthatworkisinprogress.thissignmustremaininplace,even during temporary interruptions to the work.
• theemergencystopfromthemachine(system)mustremainactive.Ifsafetyfunctionsorsafeguardsaredeactivated
during maintenance or repair work, they must be reactivated immediately after the work is completed.
S-3
Safety Instructions
WARNING
• MOuNtARElEASESwItChONthEMAChINESOthEARMS(MOtOR)OfthEROBOtCOulDBEMANuAlly MOVED.
• MOvINGANAxISwIthANIMPROPERlywORkINGRElEASESwItChCANDAMAGEthEMOtORBRAkE.thIS CAN RESULT IN PERSONAL INjURy AND MATERIAL DAMAGE.
• BEfORERElEASINGthEBRAkE,yOuhAvEtOBESuREthAtNOONEISINthEhAzARDAREAOfthEROBOt.
3.5.5
System integrator
The robot is safely integrated into a complete system by the system integrator. The system integrator is responsible for
the following tasks:
Safety Instructions
•
•
•
•
•
•
Installingtherobot
Performingriskassessment
Implementingtherequiredsafetyfunctionsandsafequards
Issuingthedeclarationofconformity
AttachingtheCEmark
Creatingtheoperatinginstructionsforthecompletesystem
S-4
Chapter 1 Introduction
Contents
1.
Introduction
1-1
1.1
Description of the robot
1-1
1.2
Type code explanation
1-1
2.
Identification
1-1
3.
Part names
1-2
1.
Introduction
Congratulations with the purchase of your high speed Delta robot XXL. This is a high speed pick and place robot which
uses state-of-the-art carbon composite materials and the latest servo drive technology to be put in use in the most
demanding pick and place applications.
This manual describes the main versions of the CR_UGD4_XXLH robot, and all options. Where applicable check the
appropriate data for your robot type, the type can be found on the identification tag of the robot.
1.1
Description of the robot
The CR_UGD4_XXLH Delta robot is a high speed pick and place robot which uses state-of-the-art carbon composite
materials and the latest servo drive technology to be put in use in the most demanding pick and place applications. The
robotisdesignedasa3-axis(optional4throtationalaxis)Deltakinematicsystem.
Characteristics of the robot:
• Requiresverylowmaintenance
• 3+1(rotationalaxisoptional)degreesoffreedom
• Compactdesignformountinginamachine
• lownoiselevel<70dB(A)
1.2
Type code explanation
CR_uGD4_xxlh_R:3+1axes(withrotationalaxis),1600mmworkingrange,max.payload:8kg
CR_uGD4_xxlh_NR:3axes(withoutrotationalaxis),1600mmworkingrange,max.payload:8kg
2.
Identification
On the robot base plate an identification tag is mounted, important data on this plate:
• Robottype
• totalweightoftherobot
• yearofproduction
• Serialnumber,importantfororderingspareparts
1-1
Introduction
This manual should be read before the commissioning of the robot. By mechanical engineers in the design phase during
the integration of the robot in the machine and by software engineers to check the performance envelope of the robot.
1
3.
1
Part names
CR_UGD4_XXLH
Introduction
Primary arm
Cable feed through
Rotary servo motor
Motor cover
Rotational axis
Secondary arm
TCP (Tool Center Point)
The CR_UGD4_XXLH robot consists of three radially placed axis which give the TCP freedom to move in three
directions, X, y and z. An optional fourth axis can take care of the rotation, Rz, of the TCP.
The primary and secondary arms of the robot are constructed from anodized aluminum ends and carbon composite
material; they are directly mounted on a double-stage gear box to guarantee high stiffness. The secondary arms are
mounted with hardened stainless steel ball joint bearings to the primary arms and the TCP, this guarantees low wear
and friction and is very easy to service.
Optionally the robot is equipped with an extra servo motor for the rotational axis, the sliding shaft is constructed of
titanium to maintain the highly dynamic character of the robot.
1-2
Chapter 2 Model overview
Contents
1.
Overview
2-1
2.
Optional extensions
2-2
1.
Overview
theCR_uGD4_xxlhhasaworkingrangeof1600mm.thespecificationsaregiveninthebelowfigure,if
specifications differ for models, for instance with- or without rotation axis, it is indicated in the specification list. The
Delta robot is delivered standard with sanitary secondary arms, this means they are fully closed to prevent any
contamination on the inside of the secondary arms.
2
CR_UGD4_XXLH (1600 mm)
200
350
1080
Model overview
815
1600
NOTE
Note that the rotation servo motor, on the top of the robot, is optional.
2-1
2.
Optional extensions
The CR_UGD4_XXLH robot can be delivered with several options:
• Rotationalaxis,anextramotorwithgearboxisplacedontopofthebaseplate,fourtitaniumtubes,capturedintwo
plastic parts, sliding over each other, are used to transfer a rotating motion to the TCP.
2
Model overview
2-2
Chapter 3 Installation
Contents
1.
Unpacking
3-1
2.
Connecting the motor cables
3-1
3.
Assembling the secondary arms
3-3
4.
Mounting the rotational axis
3-5
5.
Calibration
3-7
1.
Unpacking
The robot is delivered in a special crate, the secondary arms are not mounted yet, it is advised to mount them when the
robot is mounted in the machine frame.
The baseplate is fixed in a wooden frame. There are 2 lifting eyes on the baseplate, the baseplate can be lifted from the
box with an lifting machine.
The secondary arms are stored in the smaller boxes delivered in the shipping crate.
WARNING
THE ROBOT IS TOO HEAVy TO LIfT MANUAL, USE PROPER TOOLS TO LIfT THE ROBOT OUT Of THE CRATE.
2.
3
Connecting the motor cables
Now slide the feed through glands out of the cable feed through.
3-1
Installation
first remove the motor protection hoods from the robot after loosening the locking screw at the outside of the motor
hoods.
Remove the motor cover for the rotational axis motor on top of the robot.
Unscrew the cable feed through block on top of motor cover for the rotational axis.
feed the motor cables through the hole in the motor cover for the rotational axis and in the baseplate and connect them
to the servomotor.
See route through base plate showed in the below figure.
3
4
1
2
5
3
Installation
No.
Description
1
Cables to servomotor
2
Cable feed through
3
Baseplate
4
feedthrough gland
5
feedthrough gland blindstop
Clamp the feed through gland around the cable and slide it back into the cable feed through block. After sliding all
glands and cables into the block and screw the feed through block back on the motor cover.
3-2
3.
Assembling the secondary arms
WARNING
ASSEMBLING THE SECONDARy ARMS MUST BE DONE WITH THREE PERSONS.
Get two of the secondary arms and mount the assembled spring on the secondary arms.
3
2
Installation
1
No.
Description
1
Secondary arm
2
Spring package
Now put the two secondary arms on the primary arm by pulling the two secondary arms apart and fitting the ball cups
of the secondary arms over the ball joints of the primary arms. This should be performed by a minimum of 3 people.
3-3
Repeat the procedure for mounting the TCP joint to the primary arms.
3
Installation
Repeat this procedure for the three arms. Tip! After mounting the first and second arm you can put the TCP joint to rest
on a surface below the robot.
3-4
4.
Mounting the rotational axis
Intheshippingcrateseparateboxesareincludedwhichcontainthepartsfortherotationalaxis(option)andthe
secondary arms. first check if all components are available:
2
3
Installation
1
3
No.
Description
1
tCP-optionrotationaxis(1x)
2
Secondaryarm(6x)
3
Springpackage(6x)
If your robot is delivered with the optional rotational axis, shown below, it needs to be mounted separately.
3-5
Loose the two M5 bolts in the above cardan coupling and mount the cardan coupling on the motor shaft from the
rotationmotor(seebelowpicture).
3
Installation
Tighten the locking screw of the cardan shaft with a 5 mm Allen key.
3-6
5.
Calibration
Not every robot that is delivered is calibrated.
Ifyouwanttocalibratetherobotbyyourself,acalibrationkitwithaspecialtoolisavailable(showninthebelow
picture).
thecalibrationsetcanbeorderedasCR_ARt.1098
3
1
Installation
No.
Description
Calibration tool
1.
Slide the calibration tool on the base plate and tighten the star knob.
2.
Release the brake of the motor and put the ball joint at the calibration tool. Now calibrate the motor in your
software. Repeat this action for every arm
WARNING
• CAlIBRAtINGthEROBOtMuStBECARRIEDOutByQuAlIfIEDPROGRAMMINGPERSONNElONly,ASthIS REQUIRES AN EXCELLENT LEVEL Of KNOWLEDGE Of THE CONTROL SySTEM.
• whENCARRyINGOutthEhOMINGyOuRSElf,thISMuStBECARRIEDOutExACtlyINthEwAyANDthE ORDER THAT THEy ARE DESCRIBED.
3-7
Chapter 4 Maintenance
Contents
1.
Periodic check, wear of springs
4-1
2.
Cleaning the robot
4-1
3.
Replacement of cups
4-1
4.
Spare parts
4-2
1.
Periodic check, wear of springs
The wear of the springs cannot be checked, they must be replaced periodically. The exact period is dependent on factors
like, environmental conditions, number of running hours per day and speed of movements. Under normal conditions the
springsshouldlastatleast3800productionhours.
2.
Cleaning the robot
Clean the robot by washing with soft cloth or sponge. Use soap or mild detergent and warm water followed by clear
water rinse.
for oil and grease stains use alcohol with soft cloth.
Do not use a high pressure water cleaner, or any other high pressure cleaning device.
3.
4
Replacement of cups
2
1
3
No.
Description
1
Cup
2
M5 bolt
3
Cup holder
4-1
Maintenance
The cup holder have a threaded hole in the back of them, this is used to press the cups out of the cup holder, as is
shown in the below picture:
4.
Spare parts
Description
4
OMRON Part No.
Maintenance
Calibration tool
CR_ARt.1098
Primary arm set
CR_ART.1121
Secondary arm set
CR_ART.1122
Spring package
CR_ART.1123
Ball bearing cups
CR_ART.1124
Spline part rotational axis
CR_ART.1125
Cardan coupling
CR_ARt.1126
hingerollers(24pieces)
CR_ART.1127
Plain bearing
CR_ARt.1128
Gearbox for the primary arm
CR_ART.1143
Gearbox for the rotational axis
CR_ART.1154
4-2
Chapter 5 Robot settings
Contents
1.
Kinematics
5-1
2.
Workspace
5-2
3.
Software limits
5-3
1.
Kinematics
The kinematics parameters for the CR_UGD4_XXLH robot are shown below. Set these parameters corresponding to the
controller settings.
WARNING
If THE KINEMATICS PARAMETERS ARE NOT SET PROPERLy, THIS MAy CAUSE THE ROBOT TO MALfUNCTION. SO,
BE SURE TO SET THESE PARAMETERS CORRECTLy.
Kinematics parameters
Rf
Lf
5
Robot settings
Lm
Rm
Rf:
Rm:
Lf:
Lm:
(mm)
147.5 mm Distance (radius) from the center of the fixed frame to the motor of the axis
70 mm Distance (radius) from the center of the moving frame to the connection point of Link 2
525 mm Length of Link 1
1085 mm Length of Link 2
5-1
2.
Workspace
The workspace parameters for the CR_UGD4_XXLH robot are shown below. Set these parameters corresponding to the
controller settings.
WARNING
If THE WORKSPACE PARAMETERS ARE NOT SET PROPERLy, THIS MAy CAUSE THE ROBOT TO MALfUNCTION. SO,
BE SURE TO SET THESE PARAMETERS CORRECTLy.
Workspace parameters
Zu
5
Rcy
Rcy
Robot settings
Hcy
Hco
Rco
Zu:
-811 mm Distance from the Z-axis origin position
Rcy:
800 mm Radius of the cylinder
Hcy:
350 mm Height of the cylinder
Rco:
407 mm Radius of the frustum cone of underside
Hco:
200 mm Height of the frustum cone
5-2
3.
Software limits
The software limits for the CR_UGD4_XXLH robot are shown below.
WARNING
If THE α-, β- OR γ- AXIS SOfT LIMIT IS SET INCORRECTLy, THE ARM MAy COLLIDE WITH THE ROBOT BASE OR BASE
PREPARED By THE USER, CAUSING BREAKAGE. SO, BE SURE TO SET THE SOfT LIMITS CORRECTLy.
Minus direction
soft limit [-31°]
5
Robot settings
Plus direction
soft limit [90°]
5-3
Chapter 6 Specifications
Contents
1.
1.1
Basic specifications
Cycle time
6-1
6-1
2.
External view and dimensions
6-2
3.
Design specifications
6-3
3.1
Occupation area of robot
6-3
3.2
Mounting the robot to its frame
6-4
3.3
Arm load
6-4
3.4
Gripper interface
6-5
3.5
Software design
6-5
1.
Basic specifications
Robot model
Working volume
CR_UDG4_XXLH_R
CR_UDG4_XXLH_NR
X, y axis
Stroke
Ø 1600mm
z axis
Stroke
350mm(max.Ø1600mm)/550mm(centerØ815mm)
θaxis
Rotation range
±180°(defaultsetting,itcanbe
changed)
Arm 1, 2, 3
3000W
Servo motor
Rotational axis 4
Repeatability
*1
Maximum through-put
1000W
X, y, z axis
±1mm
θaxis
±0.3°
*2
80CPM
Maximum payload
*4
8kg
θaxistolerablemomentofinertia
*3
According to the servo motor
Ø8
usertubing(outerdiameter)
*5
Travel limit
Soft limit
Noise level
<70dB(A)
Ambient temperature
5ºC to 45ºC
Relative humidity
Max. 90%
IP65
Weight
Specifications
Protection class
*1:
*2:
*3:
*4:
*5:
6
115kg
This is the value at a constant ambient temperature.
With 0.1kg payload. When reciprocating 305mm in horizontal and 25mm in vertical directions.
There are limits to acceleration coefficient settings.
CPM: Cycle per minutes. Check the note 2 for the cycle definition.
Only for the air suctioning. The air injection is not allowed.
1.1
Cycle time
Y
Z1
P&P path
Z2
Payload
25x300x25mm(z1xyxz2)
Cycle time
1.00 s
200x500x200mm(z1xyxz2)
1.50 s
8kg
200x1000x200mm(z1xyxz2)
1.65s
200x1500x200mm(z1xyxz2)
1.77 s
6-1
2.
External view and dimensions
400
520
200
M20 (3 ×)
500
150
1600
680
100
12
0º
0º
12
50
0
50
180
1080
6
350
200
G1/4 depth 20
8 × 5 THRU ALL
M6-6H THRU ALL
50
63
6-2
0
M20x1.0 THRU ALL
0
31,5
40
63°
10
Specifications
0
20
3.
Design specifications
3.1
Occupation area of robot
If the robot is integrated into the machine it must be considered what the reach is of all robot parts to prevent collision
with other parts in the machine.
Maximum reach of robot arms for a CR_UGD4_XXLH robot without rotation axis are:
• themaximumreachoftheprimaryarmswhentheyareintheirhorizontalposition.
• themaximumreachofthesecondaryarmswhenthearmsareintheirouterposition.
• thelowestreachpositionofthetCP.
6
WARNING
If MECHANICAL OBSTRUCTIONS ARE IN THE INDICATED AREA, THE ROBOT OR THE OTHER MACHINE PARTS
COULD BE DAMAGED.
6-3
Specifications
When the TCP moves to its outer positions, the primary and secondary arms can rise above the baseplate, take care that
no mechanical obstructions are in the areas indicated in the below picture.
3.2
Mounting the robot to its frame
threeM206.8boltsareneededtofastentherobottotheframe,exactboltlengthdependsonframelayout.the
tighteningtorqueofaM206.8boltis250Nm.
WARNING
IT IS ADVISABLE TO PUT ONE MOTOR Of THE ROBOT IN LINE WITH THE DIRECTION Of THE TRANSPORT BELT TO
MAKE PROGRAMMING EASIER.
The CR_UGD4_XXLH has a circle bolt pattern for mounting the robot to its frame.
6
Specifications
Keep free a minimum of 200mm space area above the plastic motor cover for the rotational axis. for service access this
area might be needed to be able to remove the motor cover.
3.3
Arm load
The arms can be used to connect pneumatic hoses or small parts to, however this has a negative influence on robot
performance. Note that the influence is lower when the parts are connected higher up on the arms.
6-4
3.4
Gripper interface
In the below picture is shown the flange connection of the robot according to ISO 9409-1-A50.
3.5
Software design
WARNING
THE INPUT TORQUE Of THE ROBOT GEARBOX IS LIMITED TO 10 N·M, LIMIT THE MOTOR TORQUE IN THE SOfTWARE
TO PREVENT DAMAGE TO THE GEARBOX.
6
The arm lengths and pitch circles of the rotation points are shown in the below picture.
Specifications
Upper arm rotation points
circle diameter 295 mm
Upper arm length
525 mm
Lower arm length
1085 mm
Lower arm rotation points
circle diameter 140 mm
6-5
Offsets from rotation points to mounting points are shown in the below picture.
6
Specifications
6-6
Revision history
Amanualrevisioncodeappearsasasuffixtothecatalognumberonthefrontcovermanual.
Cat. No. I197E-EN-01
Revision code
The following table outlines the changes made to the manual during each revision.
Revision code
Date
01
May 2015
Description
Original production
Authorized Distributor:
Cat. No. I197E-EN-01A
Note: Specifications subject to change without notice.
Printed in Europe