Cat. No. I201E-EN-01 Delta Robot ZX-T Series CR_UGD4_XXL1300H Series Delta Robot XXL USER´S MANUAL CONTENTS CR_UGD4_XXL1300H 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 Installationandoperatingconditions S-2 3.5 Residualrisks S-2 3.5.1 Releasedevice S-3 3.5.2 Transport S-3 3.5.3 Assemblyandstart-up S-3 3.5.4 Maintenanceandrepair S-3 3.5.5 Systemintegrator S-4 Chapter 1 Introduction 1. Introduction 1-1 1.1 Descriptionoftherobot 1-1 1.2 Typecodeexplanation 1-1 2. Identification 1-1 3. Part names 1-2 Chapter 2 Model overview 1. Overview Chapter 3 2-1 Installation 1. Unpacking 3-1 1.1 Unpackingtheshippingbox 3-1 1.2 Checkthedamage 3-1 1.3 Liftingandtransportation 3-1 2. Mounting the robot 3-3 3. Mounting the motors and cabling 3-4 3.1 Mountingthemotors 3-4 3.2 Connectingthecables 3-4 T-1 CONTENTS User's Manual 3.3 Mountingthemotorcovers 3-5 3.4 Mountingtherotationmotororgearboxwithhisadaptorring 3-6 4. Assembling the secondary arms 3-7 4.1 Makeanassembly 3-7 4.2 Mountthearmassemblyontherobot 3-8 5. Mounting the rotational axis on the gearbox shaft 6. Calibration Chapter 4 3-9 3-10 Maintenance 1. Periodic maintenance 4-1 1.1 Springs 4-1 1.2 Ballbearingcups 4-2 1.3 Rotationalaxis 4-2 2. Cleaning the robot 4-4 3. Spare parts 4-4 Chapter 5 Robot settings 1. Kinematics 5-1 2. Workspace 5-2 3. Software limits 5-3 Chapter6 Specifications 1. Basicspecifications 1.1 Cycletime 6-1 6-1 2. External view and dimensions 6-2 3. Designspecifications 6-3 3.1 Occupationareaofrobot 6-3 3.2 Gripperinterface 6-3 3.2.1 Withrotationalaxis 6-3 3.2.2 Withoutrotationalaxis 6-4 3.3 Softwaredesign 3.3.1 T-2 CR_UGD4_XXL1300H Dimensionsandlimits 6-5 6-6 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 Releasedevice Transport Assemblyandstart-up Maintenanceandrepair Systemintegrator S-3 S-3 S-3 S-3 S-4 1. Attention Informationinthisdocumentcanchangewithoutpriornotice. Nopartofthismanualandaddeddocumentationmaybecopied,reproducedortranslatedintoanotherlanguagewithout priorwrittenapproval. Readandunderstandthematerialcontainedinthisuser'smanualbeforeyouworkontheCR_UGD4_XXL1300Hrobot forthefirsttime.Thisuser'smanualissupposedtohelpyouusethecapabilitiesoftheCR_UGD4_XXL1300Hrobot safelyandproperly. 2. Explanation of warnings and notes Thismanualusesthefollowingsafetyalertsymbolsandsignalwordstoprovidesafetyinstructionsthatmustbe observedandtodescribehandlingprecautions,prohibitedactions,andcompulsoryactions.Makesureyouunderstand themeaningofeachsymbolandsignalwordandthenreadthismanual. DANGER THISINDICATESANIMMEDIATELyHAzARDOUSSITUATIONWHICH,IfNOTAVOIDED,WILLRESULTINDEATHOR SERIOUSINjURy. WARNING THISINDICATESAPOTENTIALLyHAzARDOUSSITUATIONWHICH,IfNOTAVOIDED,COULDRESULTINDEATHOR SERIOUSINjURy. NOTE Explainsthekeypointintheoperationinasimpleandclearmanner. S-1 Safety Instructions OMRONEUROPEB.V.cannotbeholdresponsibleforanydamagetotheenvironment,tothemachineortothe functioningofthemachineoccurredbyerrorsormissingdataintheillustrations,drawingorspecifications. 3. Safety information 3.1 General Safety Instructions This´3. Safety information´subchaptercontainsinformationregardingworkingwiththeCR_UGD4_XXL1300H robot.QualifiedpersonnelworkingwiththeCR_UGD4_XXL1300HrobotmusthavereadandunderstoodtheCR_ UGD4_XXL1300Hrobotdocumentation,includingthesafetyinformationchapter. 3.2 Qualified personnel Thesearepeoplewho,duetherespecialisttraining,knowledgeandexperience,andtheirfamiliarizationwiththe relevantstandards,areabletoassesstheworktobecarriedoutanddetectanypotentialhazards. 3.3 Liability TheCR_UGD4_XXL1300Hrobotisbuildusingstate-of-the-arttechnologyandinaccordancewiththerecognized safetyrules.Nevertheless,misuseoftheCR_UGD4_XXL1300Hrobotmayconstitutearisktolifeandlimborcause damagetotheCR_UGD4_XXL1300Hrobotandtoothermaterialproperty. 3.4 Installation and operating conditions youmayonlyusethecomponentsinaccordancewiththeinstallationandoperatingconditionsdescribedinthe documentation.Theoperatingconditionsattheinstallationlocationmustbecheckedandmaintainedinaccordance withtherequiredtechnicaldata.WithinthemeaningoftheMachineryDirectivetheCR_UGD4_XXL1300Hrobotis anincompletemachine.CommissioningisprohibiteduntiltheusablemachineorsysteminwhichtheCR_UGD4_ XXL1300HrobotisinstalledmeetsallrequirementsoftheMachinedirective2006/42/EC. fortheCR_UGD4_XXL1300Hrobotyouhavetoobservethefollowingstandards,directivesandregulations: • ENISO10218-1:2011Robotsandroboticdevices-Safetyrequirementsforindustrialrobots-Part1:Robots. • ENISO10218-1:2011Robotsandroboticdevices-Safetyrequirementsforindustrialrobots-Part2:Robotsystems andintegration. 3.5 Residual risks Safetyandhealthrisksarisingfromtherobotmechanicshavebeenreducedbymeansofsafetytechnologyanddesign engineering.Howeveraresidualriskremains,sincetherobotmechanicswillbemovebyanautomatedcontrolsystem. Thefollowingaretypicalwarningsconcerningresidualriskswhichcannotbeassignedtoaspecificaction.The expressionofsafetylabelsisidenticaltothesafetyinformation. S-2 3.5.1 Release device Therobotmechanicsarenotsuppliedwithanreleaseswitchtocontrolthebrakesofthemotors. 3.5.2 Transport Theprescribedtransportpositionoftherobotmustbeobserved.Transportationmustbecarriedoutinaccordancewith thetransportationinstructionsorassemblyinstructionsoftherobot. WARNING • ONLyUSEAUTHORIzEDHANDLINGEQUIPMENTWITHASUffICIENTLOAD-BEARINGCAPACITyTOTRANSPORT THEROBOT. • WEARSUITABLEPROTECTIVECLOTHINGIfNECESSARy. 3.5.3 Assembly and start-up Beforestartingupsystemsanddevicesforthefirsttime,acheckmustbecarriedouttoensurethatthesystemand devicesarecompletedandoperational,thattheycanbeoperatedsafelyandthatanydamageisdetected. Thevalidnationalorregionalworksafetyregulationsmustbeobservedforthischeck.Thecorrectfunctioningofall safetycircuitsmustalsobetested. Thefollowingtestsmustbecarriedoutbeforestart-upandrecommissioning.Itmustbeensuredthat: • Therobotiscorrectlyinstalledandfastenedinaccordancewiththespecificationsintheassemblyinstructions. • Therearenoforeignbodiesorloosepartsontherobot. • Allrequiredsafetyequipmentiscorrectlyinstalledandoperational. WARNING • AWRONGINSTALLEDROBOTMAyTHROWOffHISARMS. • WEARSUITABLEPROTECTIVECLOTHINGIfNECESSARy. 3.5.4 Maintenance and repair Aftermaintenanceandrepairwork,checksmustbecarriedouttoensuretherequiredsafetylevel.Thevalidnational orregionalworksafetyregulationsmustbeobservedforthischeck.Thecorrectfunctioningofallsafetycircuitsmust alsobetested. Thepurposeofmaintenanceandrepairworkistoensurethatthesystemiskeptoriginalor,intheeventofafault,to returnthesystemtoanoperationalstate.Repairworkincludestroubleshootinginadditiontotheactualrepairitself. Thefollowingsafetymeasuresmustbecarriedoutwhenworkingontherobot: • Switchofthemachine(system)wheretherobotisbuilt-in(e.g.withapadlock)topreventitfrombeingswitchedon again • Labelthemachine(system)withasignindicationthatworkisinprogress.Thissignmustremaininplace,even duringtemporaryinterruptionstothework. • Theemergencystopfromthemachine(system)mustremainactive.Ifsafetyfunctionsorsafeguardsaredeactivated duringmaintenanceorrepairwork,theymustbereactivatedimmediatelyaftertheworkiscompleted. S-3 Safety Instructions WARNING • MOUNTARELEASESWITCHONTHEMACHINESOTHEARMS(MOTOR)OfTHEROBOTCOULDBEMANUALLy moved. • MOVINGANAXISWITHANIMPROPERLyWORkINGRELEASESWITCHCANDAMAGETHEMOTORBRAkE.THIS CANRESULTINPERSONALINjURyANDMATERIALDAMAGE. • BEfORERELEASINGTHEBRAkE,yOUHAVETOBESURETHATNOONEISINTHEHAzARDAREAOfTHEROBOT. 3.5.5 System integrator Therobotissafelyintegratedintoacompletesystembythesystemintegrator.Thesystemintegratorisresponsiblefor thefollowingtasks: 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 CongratulationswiththepurchaseofyourhighspeedDeltarobotXXL.Thisisahighspeedpickandplacerobotwhich usesstate-of-the-artcarboncompositematerialsandthelatestservodrivetechnologytobeputinuseinthemost demandingpickandplaceapplications. ThismanualdescribesthemainversionsoftheCR_UGD4_XXL1300Hrobot,andalloptions.Whereapplicablecheck theappropriatedataforyourrobottype,thetypecanbefoundontheidentificationtagoftherobot. 1.1 Description of the robot TheCR_UGD4_XXL1300HDeltarobotisahighspeedpickandplacerobotwhichusesstate-of-the-artcarbon compositematerialsandthelatestservodrivetechnologytobeputinuseinthemostdemandingpickandplace applications.Therobotisdesignedasa3-axis(optional4throtationalaxis)Deltakinematicsystem. Characteristicsoftherobot: • Requiresverylowmaintenance • 3+1(rotationalaxisoptional)degreesoffreedom • Compactdesignformountinginamachine • Lownoiselevel<68dB(A) 1.2 Type code explanation CR_UGD4_XXL1300H_R:3+1axes(withrotationalaxis),1300mmworkingrange,max.payload:8kg CR_UGD4_XXL1300H_NR:3axes(withoutrotationalaxis),1300mmworkingrange,max.payload:8kg 2. Identification Ontherobotbaseplateanidentificationtagismounted,importantdataonthisplate: • Robottype • Totalweightoftherobot • yearofproduction • Serialnumber,importantfororderingspareparts 1-1 Introduction Thismanualshouldbereadbeforethecommissioningoftherobot.Bymechanicalengineersinthedesignphaseduring theintegrationoftherobotinthemachineandbysoftwareengineerstochecktheperformanceenvelopeoftherobot. 1 3. 1 Part names CR_UGD4_XXL1300H Introduction Cable entry plate Rotary servo motor Motor cover Primary arm Rotational axis Secondary arm TCP (Tool Center Point) TheCR_UGD4_XXL1300HrobotconsistsofthreeradiallyplacedaxiswhichgivetheTCPfreedomtomoveinthree directions,X,yandz.Anoptionalfourthaxiscantakecareoftherotation,Rz,oftheTCP. Theprimaryandsecondaryarmsoftherobotareconstructedfromanodizedaluminumendsandcarboncomposite material;theyaredirectlymountedonadouble-stagegearboxtoguaranteehighstiffness.Thesecondaryarmsare mountedwithhardenedstainlesssteelballjointbearingstotheprimaryarmsandtheTCP,thisguaranteeslowwear andfrictionandisveryeasytoservice. Optionallytherobotisequippedwithanextraservomotorfortherotationalaxis,theslidingshaftisconstructedof titaniumtomaintainthehighlydynamiccharacteroftherobot. 1-2 Chapter 2 Model overview Contents 1. Overview 2-1 1. Overview TheCR_UGD4_XXL1300Hhasaworkingrangeof1300mm.Thespecificationsaregiveninthebelowfigure,if specificationsdifferformodels,forinstancewith-orwithoutrotationaxis,itisindicatedinthespecificationlist.The Deltarobotisdeliveredstandardwithsanitarysecondaryarms,thismeanstheyarefullyclosedtopreventany contaminationontheinsideofthesecondaryarms. 2 CR_UGD4_XXL1300H (1300 mm) 150 300 900 Model overview 780 1300 NOTE Notethattherotationservomotor,onthetopoftherobot,isoptional. 2-1 Chapter 3 Installation Contents 1. Unpacking 3-1 1.1 Unpacking the shipping box 3-1 1.2 Check the damage 3-1 1.3 Lifting and transportation 3-1 2. Mounting the robot 3-3 3. Mounting the motors and cabling 3-4 3.1 Mounting the motors 3-4 3.2 Connecting the cables 3-4 3.3 Mounting the motor covers 3-5 3.4 Mounting the rotation motor or gearbox with his adaptor ring 3-6 4. Assembling the secondary arms 3-7 4.1 Make an assembly 3-7 4.2 Mount the arm assembly on the robot 3-8 5. Mounting the rotational axis on the gearbox shaft 6. Calibration 3-9 3-10 1. Unpacking 1.1 Unpacking the shipping box Therobotcomesinaspecialshippingbox. Thefollowingstepmustbecarriedouttoremovetheshippingbox: • Unscrewthescrewsfromthecoverofthewoodenbox • Nowremovethecover 1.2 3 Check the damage • 1xTCP-ToolCenterPoint(incaseofCR_UGD4_XXL1300H_NRmodel) • 6xsecondaryarms • 6xspringpackage(12xspringbracketsand6xspring) Checkallthecomponentsandtherobotfortransportationdamage. 1.3 Lifting and transportation Beforetherobotislifted,itmustbeensuredthatitisfreefromobstructions. Removeallthescrewswheretherobotismountedwithinthebox. 1 No. 1 Description 3xscrewswithprotectionmaterial Therobotmustbeliftedandtransportedbyusingliftingtackleorforklifttruck.Twoliftingstrapshastobeattached intotwoeyeboltsthatarescrewedintothebaseplate.Theliftingstrapshastobelongenoughandmustberoutedin suchawaythattherobotisnotdamaged. 3-1 Installation firsttakeouttheindividualcomponentsfromthepackageandcheckthateverythingiscompleteaccordingtothe followinglist: • 1xrotationalaxis(incaseofCR_UGD4_XXL1300H_Rmodel) • 1xadaptorringfortherotationalaxisgearormotor(incaseofCR_UGD4_XXL1300H_Rmodel) WARNING • THEROBOTMAyTILTDURINGTRANSPORTATION. • ADDITIONALSAfEGUARDINGMEASUREMUSTBETAkEN. • WEARSUITABLEPROTECTIVECLOTHINGIfNECESSARy. • WHENUSINGAfORkLIfTTRUCk,DRIVEEXTREMELySLOWLyANDCAREfULLy. 1 3 2 Installation 3 No. 3-2 Description 1 Liftingtackle 2 2xliftingstraps 3 2xeyebolts 2. Mounting the robot Themountingsurfacefortherobotmustbemachinedandofanappropriatequality.It'salsopossibletousealevelling elementtoaligntherobot. ThreeM20boltsareneededtomountingtherobottotheframe,exactboltlengthdependsonframelayout.The tighteningtorqueofaM206.8boltis300Nm. Thebelowfigureshowsthemountingpatternfromtherobot. 0RXQWLQJKROHV [0 3 Installation [PRXQWLQJSDWWHUQ NOTE Itisadvisabletoputonemotoroftherobotinlinewiththedirectionofthetransportbelttomakeprogrammingeasier. 3-3 3. Mounting the motors and cabling 3.1 Mounting the motors Whenyourrobotisdeliveredwithoutmotors,youhavetomountthembyyourself.firstofall,youhavetoremovethe threemotorcoversfromtherobot. Thefollowingstepsmustbecarriedouttoremovethemotorcoversfromtherobot.Pleaseseealsothefollowing picture: • RemovetheM6Allenbolt 3 Installation 1 2 No. Description 1 1xM6Allenbolt 2 Motorcover • Removethemotorcover • Repeattheprocessfortheothertwomotorcovers 3.2 Connecting the cables Therobotisdeliveredwith3cableentryplates.Theyaremountedaboveeveryprimaryarmmotortofeedhiscables through. Thefollowingstepsmustbecarriedouttofeedthecablesthroughtheentryplates.Pleaseseealsothebelowpictures: • Removethe4boltsofthecableentryplates • Removethecableentryglands 1 2 3 3-4 No. Description 1 4xM5Allenbolt 2 Cableentryglands 3 Blindthule • Insertthecablesintotheopeningofthemotorcover • Connectthecables 3 3.3 Mounting the motor covers • Mountthecoverinthemachinedgroove • InstalltheAllenM6boltinthecoverbracketandtighten • Repeattheprocessfortheothertwomotorcovers • Themotorcoversarenowmounted 1 2 No. Description 1 Coverbracket 2 Machinedgroove 3-5 Installation • Clampthecableentryglandsaroundthecableandslideitbackintothecableentryplate.Afterwardsalsoslidethe blindthulebackintothecableentryplate • Mountthecableentryplateonthebaseplate,usingthe4M5Allenbolts 3.4 Mounting the rotation motor or gearbox with his adaptor ring ThissectionisapplicableonlytotheCR_UGD4_XXL1300H_Rmodel(withrotationalaxis). Dependentonthetypeofrotationmotororgearboxwithrotationmotor,aspecialadaptorringformountingis included. 3 1 2 Installation No. Description 1 Gearboxormotor 2 Adaptorring Nowmounttheadaptorring(withthemotororgearbox)onthelowersideofthebaseplatefromtherobotwiththe includedboltsandrings. 1 2 No. 3-6 Description 1 Lowersideofthebaseplate 2 Rotationadaptorringwithmotororgearbox 4. Assembling the secondary arms 4.1 Make an assembly Beforemountingthesecondaryarmsontherobot,wehavetopre-assemblethemasshownonthebelowfigure,sothat wegetanarmassembly. 3 3 1 2 Installation No. Description 1 Sanitarycupholderincl.ballbearingcup 2 Springpackage 3 Secondaryarm Repeatthisactionfortheother2armsets. WARNING • INCORRECTMOUNTEDSPRINGSCANjUMPAWAy. • WEARSUITABLEPROTECTIVECLOTHINGANDSAfETyGLASSES. • NEVERPULLTHESPRINGSfURTHERAPARTTHANNECESSARyWHENMOUNTINGTHEARMASSEMBLyONTHE PRIMARyARMORTCPBALLjOINTS. • REPLACESPRINGSAfTEROVERSTRETCHING. 3-7 4.2 Mount the arm assembly on the robot formounting,pullasecondaryarmwithhiscupholderovertheballjointoftheprimaryarm.Nowpullthearmsapart withtheincluded"secondaryarmexpander"againsttheforceofthespringinordertoputthesecondarmoverthe secondballjointoftheprimaryarm. ThenrepeatthisactionfortheTCP(seebelowpicture). 3 Installation 1 No. 1 Description TCP-ToolCenterPoint(withorwithoutrotationalaxis) Repeatthisactionfortheother2secondaryarmassembly's. Nowyourrobotmechaniciscompletelyinstalled. 3-8 5. Mounting the rotational axis on the gearbox shaft ThissectionisapplicableonlytotheCR_UGD4_XXL1300H_Rmodel(withrotationalaxis). Pleaseperformthefollowingstepsfirst. • Extendtherotationalaxistoitsentirelength,thenretractthesameandcheckwhetheritiseasytooperateorwhether someresistanceoccurs NOTE Alightirregularresistanceisnormalandcausedbythemanufacturingtolerancesofthetubes.Theaxisisruninduringthefirst150 hoursofoperation.Incaseofproblems,pleasechecktheaxisfordamageorcontactyourOMRONrepresentative. 3 1 Installation 2 No. Description 1 Clampingbushwithbolts 2 Rotationalaxis ReleasethetwoM5Allenboltswhicharemountedintotheclampingbush(seeabovepicture). Indeliverycondition,anextrafillbushislocatedintheclampingbush. Measureyourmotor/gearboxaxisanddetermineifyouneedtheextrafillbush. 1 2 3-9 No. Description 1 Motororgearshaft 2 Topconnectorrotationalaxis Nowpushthetopconnectorintotheshaftuntilthetopconnectorcomesintoitsstoppositionontheshaft.Tightenthe twoM5Allenboltswith7Nm. Therotationalaxisisnowmounted. 3 6. Calibration Installation Noteveryrobotthatisdeliverediscalibrated. Ifyouwanttocalibratetherobotbyyourself,acalibrationkitwithaspecialtoolisavailable(showninthebelow picture). ThecalibrationsetcanbeorderedasCR_ART.1098 No. 1 Description Calibrationtool Thefollowingstepsmustbecarriedouttoputthethreeupperarmsfromtherobotinthezeroposition.Please,seethe belowpictures: • Makesureallthesecondaryarmsaredisassembled • Releasethemotorbrakeandmakesurealltheprimaryarmsarerotateddownfarenough,sothecalibrationtool couldbemounted • Slidethecalibrationtoolonthebaseplateasshowninthenextpicture • Nowtightenthestarnutuntilthetoolisfixed 3-10 • Releasethemotorbrakefromtheselectedmotorandpushtheupperarmwithhisballjointagainstthecalibrationas shownintheabovepicture • Nowfixthemotorbrakefromtheselectedmotor • Repeatthecalibrationstepsfortheothertwoprimaryarms • Removethetool • Nowalltheprimaryarmsareinzeropositionfromthekinematicmodel • Nowputtheencodervaluesfromtheservomotorsin0º • Checkthattheangleindicatedforthethreemotorsis0º(±0.1°) • yourrobotisnowcalibrated 3-11 Installation WARNING • CALIBRATINGTHEROBOTMUSTBECARRIEDOUTByQUALIfIEDPROGRAMMINGPERSONNELONLy,ASTHIS REQUIRESANEXCELLENTLEVELOfkNOWLEDGEOfTHECONTROLSySTEM. • WHENCARRyINGOUTTHEHOMINGyOURSELf,THISMUSTBECARRIEDOUTEXACTLyINTHEWAyANDTHE ORDERTHATTHEyAREDESCRIBED. 3 Chapter 4 Maintenance Contents 1. Periodic maintenance 4-1 1.1 Springs 4-1 1.2 Ball bearing cups 4-2 1.3 Rotational axis 4-2 2. Cleaning the robot 4-4 3. Spare parts 4-4 1. Periodic maintenance Beforeworkingontherobot,pleasebeensuredthatthemachinewheretherobotisbuiltin,istotallyswitchedoff. DANGER • SWITCHOffTHEMACHINE(SySTEM)WHERETHEROBOTISBUILTIN(E.G.WITHAPADLOCk)TOPREVENTIT fROMBEINGSWITCHEDONAGAIN. • LABELTHEMACHINE(SySTEM)WITHASIGNINDICATIONTHATWORkISINPROGRESS.THISSIGNMUST REMAININPLACE,EVENDURINGTEMPORARyINTERRUPTIONSTOTHEWORk. • THEEMERGENCySTOPfROMTHEMACHINE(SySTEM)MUSTREMAINACTIVE.IfSAfETyfUNCTIONSOR SAfEGUARDSAREDEACTIVATEDDURINGMAINTENANCEORREPAIRWORk,THEyMUSTBEREACTIVATED IMMEDIATELyAfTERTHEWORkISCOMPLETED. 1.1 Springs 4 WARNING • INCORRECTMOUNTEDSPRINGSCANjUMPAWAy. • WEARSUITABLEPROTECTIVECLOTHINGANDSAfETyGLASSES. • NEVERPULLTHESPRINGSfURTHERAPARTTHANNECESSARyWHENMOUNTINGTHEARMASSEMBLyONTHE PRIMARyARMORTCPBALLjOINTS. Howtodisassemblethesprings: • Disassemblethesecondaryarmsfromtherobotwiththe"secondaryarmexpander" • Replacethesprings • forre-assemblingthesecondaryarms,seeSection 4 Assembling the secondary armsinChapter3 4-1 Maintenance Howtomaintainthesprings: • Thespringshastobereplacedevery3800workinghoursoronceayear • Whentherobotisfallapart,checkthespringsondamages • OnlyusespringsdeliveredbyOMRON,otherwisetheguaranteewillexpire • Replacespringsafteroverstretching • forspareparts,seeSection 3 Spare partsinthischapter 1.2 Ball bearing cups Theballbearingcupshasthesamelifetimeasthesprings.Werecommendtoexchangetheseatthesametimeasthe springs. Howtomaintaintheballbearingcups: • Theballbearingcupshastobereplacedevery3800workinghoursoronceayear • Whentheballbearingcupsmakesqueakingnoises,takeofthesecondaryarmassembly’sandcleanthecupswith pressedair • Do not lubricate the ball bearing cups! forinstructionstoreplacetheballbearingcups,seebelowpicture: 4 1 Maintenance No. 1 Description M6bolt • ScrewanM6boltinthebacksidefromthecupholder • Nowtheballbearingcupwillcomeout 1.3 Rotational axis Theplainbearingsontherotationalaxiswearwithtimesothatbacklashstartstooccurontherotationalaxis.Howfast theplainbearingsbecomeworndependsstronglyonthefollowingfactors: • Theworkingpath • Thepayload • Thespeedoftherobot • Therotationactions WhendoIhavetoexchangetheplainbearings? • Ifthereisalotofplayontherotationalaxis • Every3000workinghoursoronceayear forinstructionstoreplacetheplainbearings,seethebelowpicture: 1 2 4-2 No. Description 1 Sliderblock 2 M6boltwithwasher • UnscrewthetwoM6boltswithwasherandtakeofthebolts 4 1 No. 1 Description Plainbearing • Exchangetheoldplainbearingswiththenewones • Putbackthetwotubesontherotationalaxis • MountthetubeswiththetwoM6boltsincludingwashers WARNING • PLAINBEARINGSHASTOBEMOUNTEDVERyCAREfULLy. • WRONGMOUNTEDPLAINBEARINGSMAyDAMAGE. • EXTENDTHEROTATIONALAXISTOITSENTIRELENGTH,THENRETRACTTHESAMEANDCHECkWHETHERITIS EASyTOOPERATEORWHETHERSOMERESISTANCEOCCURS. 4-3 Maintenance • Removethetwotubes(sometimesthetubeswillclampinsidethesliderblock,useasmallplastichammertorelease them) 2. Cleaning the robot Cleantherobotbywashingwithsoftclothorsponge.Usesoapormilddetergentandwarmwaterfollowedbyclear waterrinse. foroilandgreasestainsusealcoholwithsoftcloth. Donotuseahighpressurewatercleaner,oranyotherhighpressurecleaningdevice. 3. Spare parts Description 4 OMRON Part No. Maintenance Calibrationtool CR_ART.1098 Springpackage CR_ART.1123 Ballbearingcups CR_ART.1124 Cardancoupling CR_ART.1126 Hingerollers CR_ART.1127 Plainbearing CR_ART.1128 Gearboxfortherotationalaxis CR_ART.1154 Primaryarmset CR_ART.1239 Secondaryarmset CR_ART.1240 Splinepartrotationalaxis CR_ART.1241 Gearboxfortheprimaryarm CR_ART.1268 TCP-ToolCenterPoint CR_ART.1269 4-4 Chapter 5 Robot settings Contents 1. Kinematics 5-1 2. Workspace 5-2 3. Software limits 5-3 1. Kinematics ThekinematicsparametersfortheCR_UGD4_XXL1300Hrobotareshownbelow.Settheseparameterscorresponding tothecontrollersettings. WARNING IfTHEkINEMATICSPARAMETERSARENOTSETPROPERLy,THISMAyCAUSETHEROBOTTOMALfUNCTION.SO, BESURETOSETTHESEPARAMETERSCORRECTLy. .LQHPDWLFVSDUDPHWHUV 5I /I 5 Robot settings /P 5P PP 5I PP'LVWDQFHUDGLXVIURPWKHFHQWHURIWKHIL[HGIUDPHWRWKHPRWRURIWKHD[LV 5PPP'LVWDQFHUDGLXVIURPWKHFHQWHURIWKHPRYLQJIUDPHWRWKHFRQQHFWLRQSRLQWRI/LQN /I PP/HQJWKRI/LQN /P PP/HQJWKRI/LQN 5-1 2. Workspace TheworkspaceparametersfortheCR_UGD4_XXL1300Hrobotareshownbelow.Settheseparameterscorresponding tothecontrollersettings. WARNING IfTHEWORkSPACEPARAMETERSARENOTSETPROPERLy,THISMAyCAUSETHEROBOTTOMALfUNCTION.SO, BESURETOSETTHESEPARAMETERSCORRECTLy. Workspace parameters Zu 5 Rcy Rcy Robot settings Hcy Hco Rco Zu: -731 mm Distance from the Z-axis origin position Rcy: 650 mm Radius of the cylinder Hcy: 300 mm Height of the cylinder Rco: 390 mm Radius of the frustum cone of underside Hco: 150 mm Height of the frustum cone 5-2 3. Software limits ThesoftwarelimitsfortheCR_UGD4_XXL1300Hrobotareshownbelow. WARNING IfTHEα-,β- or γ-AXISSOfTLIMITISSETINCORRECTLy,THEARMMAyCOLLIDEWITHTHEROBOTBASEORBASE PREPAREDByTHEUSER,CAUSINGBREAkAGE.SO,BESURETOSETTHESOfTLIMITSCORRECTLy. Minus direction soft limit [-30°] 5 Robot settings Plus direction soft limit [88°] 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 Gripper interface 6-3 3.2.1 3.2.2 Withrotationalaxis Withoutrotationalaxis 6-3 6-4 3.3 Software design 6-5 3.3.1 Dimensionsandlimits 6-6 1. Basic specifications Robot model Workingvolume CR_UDG4_XXL1300H_R CR_UDG4_XXL1300H_NR X,yaxis Stroke Ø 1300mm zaxis Stroke 300mm(max.Ø1300mm)/450mm(centerØ780mm) θaxis Rotationrange ±180°(defaultsetting,itcanbe changed) Arm1,2,3 3000W Servomotor Rotationalaxis4 Repeatability *1 Maximumthrough-put 1000W X,y,zaxis ±1mm θaxis ±0.3° *2 90CPM Maximumpayload *4 8kg θaxistolerablemomentofinertia *3 Accordingtotheservomotor Ø8 Usertubing(outerdiameter) *5 Travellimit Softlimit Noiselevel <68dB(A) Ambienttemperature 5ºCto45ºC Relativehumidity Max.90% IP65 Weight 90kg Specifications Protectionclass *1: *2: *3: *4: *5: 6 Thisisthevalueataconstantambienttemperature. With0.1kgpayload.Whenreciprocating305mminhorizontaland25mminverticaldirections. Therearelimitstoaccelerationcoefficientsettings. CPM:Cycleperminutes.Checkthenote2forthecycledefinition. Onlyfortheairsuctioning.Theairinjectionisnotallowed. 1.1 Cycle time Y Z1 P&P path Z2 Payload 25x300x25mm(z1xyxz2) Cycle time 0.90s 8kg 200x1000x200mm(z1xyxz2) 1.5s 6-1 2. External view and dimensions 0RXQWLQJKROHV [0 Specifications 6 31,5 G3/8 depth 15 8 x M6 STC 50 63 Gripper dimensions 6-2 3. Design specifications 3.1 Occupation area of robot Iftherobotisintegratedintothemachineitmustbeconsideredwhatthereachisofallrobotpartstopreventcollision withotherpartsinthemachine. WhentheTCPmovestoitsouterpositions,theprimaryandsecondaryarmscanriseabovethebaseplate,takecarethat nomechanicalobstructionsareintheareasindicatedinthebelowpicture. 600 420 400 100 200 6 3.2 Gripper interface 3.2.1 With rotational axis ThebelowfigureshowsthegripperconnectionsizesfortheCR_UGD4_XXL1300H_Rrobot(withrotationalaxis) accordingtoISO9409-1-A31,5. 31,5 G3/8 depth 15 8 x M6 STC 50 63 6-3 Specifications WARNING IfMECHANICALOBSTRUCTIONSAREINTHEINDICATEDAREA,THEROBOTORTHEOTHERMACHINEPARTS couLd be damaGed. 3.2.2 Without rotational axis ThebelowfigureshowsthegripperconnectionsizesfortheCR_UGD4_XXL1300H_NRrobot(withoutrotational axis). Thedesignofthegripperthatismountedundertherobothavegreatinfluenceontheperformanceoftherobot.Both theweightofthegripperandthedistanceofthecenterofgravityofthegrippertotheTCPbasepointhavenegative influenceonthefinalperformanceoftherobot. 6 Ifyouneedtoinstallcablingforthegripper,pleasefollowthefollowingsteps: • Mountthecablesonthebaseplateorframe,neartheturningpointfromtheprimaryarmonthegearbox • Mountthecablesontheprimaryarm,withty-rapsorclampingparts • keepabigloopatthehingepointfromtheprimaryandsecondaryarm • Mountthecablesonthesecondaryarm,withty-rapsorclampingparts • keepabigloopfromthelowestmountingpointatthesecondaryarmtilltheconnectiononthegripper Specifications 6-4 3.3 Software design Thearmlengthsandpitchcirclesoftherotationpointsareshowninthebelowpicture. Upper arm rotation points circle diameter 295 mm Upper arm length 440 mm Lower arm length 950 mm Lower arm rotation points circle diameter 140 mm 6 Specifications 6-5 3.3.1 Dimensions and limits Description Value Negativesoftwarelimit -30º Positivesoftwarelimit 88º Tb-z(topbaseplatetozeroposition) 210mm z-tw(zeropositiontotopworkarea) 690mm Neg.° Top mounting bracket 0° Tb-z Primary arm Z-tw 6 Pos.° Specifications Top work area 6-6 Revision history Amanualrevisioncodeappearsasasuffixtothecatalognumberonthefrontcovermanual. Cat. No. I201E-EN-01 Revision code Thefollowingtableoutlinesthechangesmadetothemanualduringeachrevision. Revision code Date 01 july2015 Description Originalproduction Authorized Distributor: Cat. No. I201E-EN-01 Note: Specifications subject to change without notice. Printed in Europe
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