CKD INDEXMAN PPLX063 A Series Instruction Manual

ＳＭＢ−２０E
ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ
ＩＮＤＥＸＭＡＮ
ＰＩＣＫ＆ ＰＬＡＣＥ ＵＮＩＴ
ＰＰＬＸ Ｓｅｒｉｅｓ
● Please read this instruction manual
carefully before using this product,
particularly the section describing
safety．
● Retain this instruction manual with
the product for further consultation
whenever necessary．
Ver. 4
！ Ｔｏ Ｓａｆｅｌｙ Ｕｓｅ Ｔｈｉｓ Ｐｒｏｄｕｃｔ
Read this manual carefully before use.
The designer should confirm the safety of the mechanism and of the electric
control devices.
To ensure the safe use of this product, it is important to correctly select, use,
handle, and maintain the product.
The precautions indicated WARNING or CAUTIONS must be observed.
！
When a dangerous situation may occur if handling is mistaken
leading to fatal or serious injuries, or when there is a high degree
of emergency to a warning.
DANGER：
a dangerous situation may occur if handling is mistaken
！ WARNING：When
leading to fatal or serious injuries.
a dangerous situation may occur if handling is mistaken
！ CAUTION：When
leading to minor injuries or physical damage.
Note that some items described as "CAUTION" may lead to serious results
depending on the situation.
In any case, important information that must be observed is explained.
When custom specifications, product specifications may differ from descriptions
on this instruction manual. Refer to Drawing for Approval etc. per product.
[SMB-20E]
― 1 ―
！ WARNING :

Use the product within the range of specifications. A load
and/or r.p.m. exceeding the specifications may result in a
damage, a malfunction and/or accuracy deterioration of the
index unit.

Don't touch any moving part during the operation of the Pick
and Place unit.

Don't suddenly stop the input shaft revolution during the
output section is working.
① A sudden stop of the input shaft by clutch brake etc. will apply
the overload to the unit. This may cause an overrun of the dial
plate on the unit.
② If a torque saver is provided, a sudden stop will release the
torque saver. This may cause an overrun of the dial plate on
the unit.
③ If the emergency stop is necessary, install the safety measure
to prevent a sudden stop, and select the larger torque saver
enduring the overload.
！ CAUTION :

Shut off the power before maintenance or inspection. A
sudden movement caused by malfunction or control circuit
failure may result in personal injury.

Do not use the product in an explosive or ignitable
atmosphere.

The product must be assembled by a person with a basic
knowledge about the assembly.

Start and stop the Pick and Place unit at a dwell section. A
start or stop other than the dwell section will cause the
overload. This may result in a damage of the unit.

If a position detection cam is provided on the input shaft,
check the cam at the proper position periodically. A
misalignment of the cam caused by a loose set screw may
result in malfunction.

Don't use the product where wet or oily environment. The
product is not water-proof or drip-proof.
Where the product is subject to splashes of water or oil, it
must be protected with a cover or such.

The Pick and Place unit contains lubricant oil, which may
ooze out through the oil packing or another part during use.
Check the packing periodically, and install the oil pan if
necessary.
[SMB-20E]
― 2 ―
Terms of warranty
Conditions related to the warranty and scopes are as follows.
1) Period
The warranty period of the product is one year since the date of delivery.
(However, the period assumes eight hours of operation per day.
As well, if the durability limit is reached within one year, the period to the durability limit is the
warranty period.)
2) Scope
If failure is caused in the above warranty period due to poor workmanship of our product, we
will repair the product without charge without delay.
However, the scope of warranty shall not cover the following cases.
① Operation under the conditions or in the environment derailing from those specified in the
product specifications
② Failure caused by lack of attention or erroneous control
③ Failure caused by other than the delivered product
➃ Failure caused by operation derailing from the purposes for which the product is designed
➄ Failure caused by modification in the structure, performance, specification or other
features made by other than us after delivery, or failure caused by repairs done by other
than our designated contractor
➅ Loss in our product assembled to your machine or equipment, which would be avoided if
your machine or equipment were provided with general functions, structures or other
features common in the industry
➆ Failure caused by reason that is unforeseeable with technology put into practical use at
the time of delivery
➇ Failure caused by fire, earthquake, flood, lightning, or other acts of God, earth shock,
pollution, salt hazard, gas intoxication, excessive voltage, or other external causes
⑨ When it is caused by the part which is provided by a customer or a part used by the
appointment of the customer.
⑩ When the consumption parts such as bearing or the oil seal used for our product were
worn and deteriorated.
About optional parts (switch, drive parts etc.) we make the guarantee that followed the
guarantee ranges of each maker because life is different by driving condition.
The warranty mentioned here covers the discrete delivered product.
Only the scope of warranty shall not cover losses induced by the failure of the delivered product.
3) Warranty of product exported outside Japan
① We will repair the product sent back to our factory or company or factory designated by us.
Work and cost necessary for transportation shall not be compensated for.
② The repaired product will be packed according to the domestic packing specification and
delivered to a designated site inside Japan.
This warranty terms describe basic items.
Priority will be given to specification drawings and specification sheets if warranty description given on
such specification drawings or specification sheets is different from the warranty terms given herein
[SMB-20E]
― 3 ―
INDEX
Pick and Place Unit
PPＬX
Manual No. SMB-20E
INTRODUCTION ··········································································································５
１． UNPACKAGING ···································································································５
２． HOW TO ASSEMBLE AND INSTALL ······································· ５〜７
３． BEFORE OPERATION ····················································································７
４． ADEQUATE OPERATION ······························································ ８〜１１
５． MAINTENANCE ····························································································· １２
６． TROUBLE SHOOTING ·············································································· １３
７． WASTE ···················································································································· １３
８． PRODUCT SPECIFICATIONS ··············································· １４〜１６
９． INTERNAL STRUCTURE DRAWIND ······························ １７〜１８
１０．OTHERS ············································································································· １８
作成 2011.6.16
[SMB-20E]
― 4 ―
1
２
HOW
TO
ASSEMBLE
UNPACKAGING
AND INSTALL
INTRODUCTION
Thank you for choosing our Pick & Place unit.
This product is a composite unit that uses two cams for the horizontal and vertical directions to
output horizontal and vertical motions.
This manual shows precautions and service/inspection items below.
carefuly read this manual before use or maintenance.
1.
Please
UNPACKING
1)
2)
2.
Check that the product is as ordered
Model No.
Check for damage caused during transportation.
If any failure such as a missing screw, oil leak, or bent shaft is found, contact the
branch, sales office, or agency from which the product was purchased.
HOW TO ASSEMBLE AND INSTALL
product must be assembled by a person with a basic knowledge
！ CAUTION:The
about the assembly.
1)
Install the product as the attitude according to the specifications.
2)
Install the product so that it can be easily inspected, disassembled, and
assembled and grease can be added..
3)
Bolt a jig, if necessary, onto the output arm or output table in a position close to
the center of the traveling section of the output axis. If this operation is done in
the retention area of the output axis, force may be applied to the internal cam
follower, resulting in damage to the P & P unit.
4)
Do not apply an impact to the output arm or output table with a hammer or
another tool when mounting a jig on it.
Such an impact may cause damage to the P & P unit or lower accuracy.
5)
Key way are often used to secure the dial plate,
coupling, gear, sprocket, pulley, cam, boss, or
another part to the shaft. A chattering key way
always leads to shock or vibration The use of
standard key, JIS B 1301-1996 is recommended.
The methods fixing certainly should be conducted
for fixing important section not only using key but
using split model and friction fasteners, etc.
[SMB-20E]
― 5 ―
Key
Boss
Shaft
(split model)
２
HOW TO ASSEMBLE
AND INSTALL
6) The driveline from the motor to the index unit input shaft should be rigid and
nobacklash. A backlash may cause a shock during the dial plate rotation,
shorten the service life of the unit, and/or damage parts.
(1) Do not use another input shaft in series between the motor and the Pick and
Place Unit input shaft. If used, it should be sufficiently rigid.
Pick and Place unit
Pick and Place unit
Input shaft
Reduction
Gear
Reduction
Gear
Input shaft
Cam shaft
Cam shaft
Motor
Motor
Bad example (causes a shock)
Good example
(2) When directly connecting the Pick and Place unit input and reduction shafts
with a coupling, use a coupling of no backlash and easier to adjust alignment.
(If the space permits, a model that the Pick and Place unit and reducer are
integrated may be used.)
Pick and Place unit
Coupling
Reduction gear
Adjustment spacer
[SMB-20E]
― 6 ―
３
２
HOW TO ASSEMBLE
BEFORE
AND INSTALL
ＯＰＥＲＡＴＩＯＮ
(3)
Correctly install a tension adjuster for the timing belt or chain if used.
The lack of the tension adjuster may lead to shock or vibration.
Chain
Tension lever
An example of tension lever
7） Center the shafts.
Center the shafts when connected with a coupling.
broken.
Eccentric shafts may be
3. BEFORE OPERATION
Before operating the P & P unit, confirm the following:
1) Check if the bolts or screws for each part are firmly tightened.
2) Check if the input shaft is connected securely to the output arm or output table.
If the input shaft is loose, the table may rotate in an unstable manner and cause
a shock.
3) Check if the tension of the belt is proper.
A loose belt may run unsmoothly and cause residual vibration.
4) The PPLX uses a lubricating grease. A sufficient amount of grease is applied
before delivery, but add it periodically (semiannually). Apply a specified grease
to the sliding face of the cam and the direct-acting bearing under the front cover
of the PPLX.
5) Greases for the PPLX
Shown in the table below are the specified greases for the PPLX.
[SMB-20E]
Body
Linear way section
Manufacturer
Kyodo Yushi
Kyodo Yushi
Grease name
Citrax EP No.2
Multemp PS2
― 7 ―
４
ADEQUATE
OPERATION
ADEQUATE OPERATION
Explanation of operation
(1) Relative positions of the roller gear cam and turret w/cam follower are
illustrated below.
① Resting at a dwell
section of the cam
② Starts rotating upon the
③ Rotating
at
an
contact
section
indexing section
with
an
indexing
(2) Cam indexing angle
A cycle (360°) of the cam groove comprises a retention (straight) area and an
indexing (curved) area. In the retention section, the output section does not
travel even if the cam is rotating. It travels when the cam follower is in the
indexing area and the cam is rotating. The rotating angle of the cam
corresponding to this travel is called an indexing angle.
Center path of
cam follower
0°
90°
180°
Indexing section
Retention area
Indexing area
Cam width
1)
55°
4.
360°
Development (path of cam follower)
A development of cam
[SMB-20E]
― 8 ―
４
ADEQUATE
OPERATION
2) Adequate operation
Use the product within the range of specifications. A load and/or
！ WARNING:r.p.m. exceeding the specifications may result in a damage, a
malfunction and/or accuracy deterioration of the Pick and Place unit.
(1) Keep the load mass (carrying mass) below the dynamic rated carrying mass.
touch any moving part during the operation of the Pick and
！ WARNING:Don't
Place unit.
(2) Input shaft revolving speed
Use the r. p. m. of input shaft within the specifications.
Start and stop the Pick and Place unit at a dwell section. A start or
stop other than the dwell section will cause the overload. This may
result in a damage of the unit.
！ CAUTION:
[SMB-20E]
― 9 ―
４
ADEQUATE
OPERATION
(3)
Positional relationship between the timing chart and the key groove in the
input shaft
Start and stop the input shaft in the horizontal-direction and vertical-direction
retention zones ( a, b) according to the positional relationship between the
timing chart determined and the input shaft.
[Type A] Input shaft rotation
direction
Position where cam
index angle is 0 degrees
Stroke Lb
Stroke La
Input shaft rotation
direction
Position where cam
index angle is 0 degrees
Stroke Lb
Stroke La
Stroke La
150゜
0゜
360゜
Input shaft rotation angle(deg)
θa
Stroke Lb
[Type B]
θb
θa
50mm
0
360゜
Input shaft rotation angle(deg)
Timing Chart (Example)
[SMB-20E]
― 10 ―
４
ADEQUATE
OPERATION
！ WARNING:
Don't suddenly stop the input shaft revolution during the
output section is working.
① A sudden stop of the input shaft by clutch brake etc. will
apply the overload to the unit. This may cause an overrun
of the dial plate on the unit.
② If a torque saver is provided, a sudden stop will release
the torque saver. This may cause an overrun of the dial
plate on the unit.
③ If the emergency stop is necessary, install the safety
measure to prevent a sudden stop, and select the larger
torque saver enduring the overload.
(4) After emergency stop, manually rotate the shaft to the dwell section and start
again.
A handle should be provided with the driving system to permit the manual
rotation of the input shaft in such a case.
Input shaft pulley
Handle
Reduction gear
Output shaft
(5) Check for unusual sound.
If any unusual sound is heard during use, immediately stop the operation. The cam
follower or an internal part may have been failed. Contact the nearest sales agency or
factory.
！ WARNING : Do not use the product in an explosive or ignitable atmosphere.
！ CAUTION :
Don't use the product where wet or oily environment.
The product is not water-proof or drip-proof.
Where the product is subject to splashes of water or oil, it must be
protected with a cover or such.
(6) Prevention of water intrusion and corrosion
The Pick and Place unit input and output axis and mounting surfaces are not
protected from corrosion. They may be corroded depending on the storing
conditions or the operating atmosphere.
Always apply a coat of rust-preventive oil, grease, or rust proof paint over the
machined surfaces
.
[SMB-20E]
― 11 ―
５
MAINTENACE
5.
MAINTENANCE
Shut off the power before maintenance or inspection. A sudden
caused by malfunction or control circuit failure may result
！ WARNING: movement
in personal injury.
If a position detection cam is provided on the input shaft, check the
！ CAUTION:cam at the proper position periodically. A misalignment of the cam
caused by a loose set screw may result in malfunction.
The Pick and Place unit contains lubricant oil, which may ooze out
Check the
the oil packing or another part during use.
！ CAUTION:through
packing periodically, and install the oil pan if necessary.
[SMB-20E]
― 12 ―
6.
７
TROUBLE
SHOOTING
WASTE
TROUBLE SHOOTING
Phenomenon
No shock is produced by reducing
the speed of the input shaft.
Pick and Place unit
A shock is applied to
the output arm or
output table.
Driveline
The stop position is
incorrect.
Mounting of Pick
and Place unit body
Mounting of
subsidiary
table/arm
Unusual load
Overload protector
Pick and Place unit
does not rotate.
7.
６
Pick and Place unit
body or driveline
A shock remains although the
speed of the input shaft is reduced.
Measure to take
The carrying mass is excessive.
Reconsider using another P & P model.
There is something wrong with the
driving system or another. Please contact
us.
We will determine what measure to take
after consultation with you.
Internal damage is suspected. Contact us
for replacement of Pick and Place unit.
Internal Unusual sound or
temperature rise is suspected.
Input shaft has a backlash
between gear when driven.
Key chatters when driven by gear.
The timing belt is significantly
slack when it is running.
Input shaft angular position
sensor switch is out of place.
Faulty input shaft angular
position sensor.
Backlash at worm reduction gear
Overload on geared motor
reduction gear
Clutch release error
Frequent emergency stops
Overhaul worm reduction gear.
Reduce the carrying mass, or use a worm
speed reduction gear.
Check clutch.
Remove cause(s) of emergency stop.
Incomplete mounting or securing
Firmly secure.
The tightening torque is
insufficient, or the bolt is loose.
Check and tighten.
The P & P unit is used under a
load beyond the permissible
carrying mass.
Wrong torque setting
Poor repeatability
There is something wrong with the
Internal failure of Pick and Place
unit body
Faulty motor
Brake has been applied.
Grease has run out.
Reduce backlash between gear.
Replace key to reduce chatter.
Tighten with tension adjuster.
Relocate input shaft angular position
sensor switch.
Replace.
Recalculate the carrying mass, and
consult us about measures.
Adjust torque setting.
Replace.
Replace or contact us.
Replace.
Repair or replace.
Add grease.
WASTE
Metal, rubber and lubricant are used for this product. Since this product can not be burned,
this must be disposed as industrial waste.
[SMB-20E]
― 13 ―
８
PRODUCT
SPECIFICATIONS
8.
PRODUCT SPECIFICATIONS
1)
(Example)
How to order
(a)
(a) Model
060 030
PPLX 080
(b)
(c)
(c)Horizontaldirection stroke
(La)
(b) Size
(d)
A
1
X012345
(e)
(f)
(g)
(d) Verticaldirection stroke (e) Output axis type
(Lb)
A Type A: Arm type
10mm
005
5mm
200
200mm
060
60mm
1
(g) Special
specificatio
n No.
Six numbers
after "X"
～
010
～
40mm
50mm
63mm
80mm
～
2)
040
050
063
080
～
PPLX
(f) Installation orientation
B
Type B: Table type
2
Direction of
gravity
Characteristic chart
PPLX040 type A (arm type)
Item
Stroke La
Stroke Lb
Mass inside stroke La (moa)
Mass inside stroke Lb (mob)
Direction b
Output section
bending rigidity
Direction c
mm
mm
kg
kg
mm/N
mm/N
Lubrication method
Characteristic
value
max.80
max.30
0.5
1.0
0.004
0.015
Lubrication by
grease
Item
Permissible thrust force of input shaft
Permissible radial force of input shaft
Moment of inertia of input shaft
Internal frictional torque (Tin)
Repeated accuracy
Body mass
N
N
kg m2
Nm
mm
kg
Paint color
Characteristic
value
800
750
2.7×10-4
1.9
±0.02
10
Silver
PPLX050 type A (arm type)
Item
Stroke La
Stroke Lb
Mass inside stroke La (moa)
Mass inside stroke Lb (mob)
Direction b
Output section
bending rigidity
Direction c
Lubrication method
mm
mm
kg
kg
mm/N
mm/N
Characteristic
value
max.100
max.40
0.8
1.8
0.0035
0.0150
Lubrication by
grease
Item
Permissible thrust force of input shaft
Permissible radial force of input shaft
Moment of inertia of input shaft
Internal frictional torque (Tin)
Repeated accuracy
Body mass
Paint color
N
N
kg m2
Nm
mm
kg
Characteristic
value
1200
900
7.3×10-4
3.0
±0.02
15
Silver
[SMB-20E]
― 14 ―
８
PRODUCT
SPECIFICATIONS
PPLX063 type A (arm type)
Item
Stroke La
Stroke Lb
Mass inside stroke La (moa)
Mass inside stroke Lb (mob)
Direction b
Output section
bending rigidity
Direction c
mm
mm
kg
kg
mm/N
mm/N
Lubrication method
Characteristic
value
max.150
max.50
1.7
3.0
0.003
0.020
Lubrication by
grease
Item
Permissible thrust force of input shaft
Permissible radial force of input shaft
Moment of inertia of input shaft
Internal frictional torque (Tin)
Repeated accuracy
Body mass
N
N
kg m2
Nm
mm
kg
Paint color
Characteristic
value
2000
1600
2.4×10-3
4.8
±0.02
25
Silver
PPLX080 type A (arm type)
Item
Stroke La
Stroke Lb
Mass inside stroke La (moa)
Mass inside stroke Lb (mob)
Direction b
Output section
bending rigidity
Direction c
Item
Permissible thrust force of input shaft
Permissible radial force of input shaft
Moment of inertia of input shaft
Internal frictional torque (Tin)
Repeated accuracy
Body mass
Paint color
Bending rigidity (b)
Lubrication method
mm
mm
kg
kg
mm/N
mm/N
Characteristic
value
max.200
max.60
3.2
5.3
0.0025
0.0250
Lubrication by
grease
[SMB-20E]
― 15 ―
N
N
kg m2
Nm
mm
kg
Characteristic
value
2500
2700
8.6×10-3
7.8
±0.02
50
Silver
Bending
rigidity (c)
８
PRODUCT
SPECIFICATIONS
PPLX040 type B (table type)
Item
Stroke La
Stroke Lb
Mass inside stroke La (moa)
Mass inside stroke Lb (mob)
Body mass
mm
mm
kg
kg
kg
Lubrication method
Characteristic
value
max.80
max.30
0.6
1.2
10
Lubrication by
grease
Item
Permissible thrust force of input shaft
Permissible radial force of input shaft
Moment of inertia of input shaft
Internal frictional torque (Tin)
Repeated accuracy
N
N
kg m2
Nm
mm
Paint color
Characteristic
value
800
750
2.7×10-4
1.9
±0.02
Silver
PPLX050 type B (table type)
Item
Stroke La
Stroke Lb
Mass inside stroke La (moa)
Mass inside stroke Lb (mob)
Body mass
mm
mm
kg
kg
kg
Lubrication method
Characteristic
value
max.100
max.40
1.1
2.3
15
Lubrication by
grease
Item
Permissible thrust force of input shaft
Permissible radial force of input shaft
Moment of inertia of input shaft
Internal frictional torque (Tin)
Repeated accuracy
N
N
kg m2
Nm
mm
Paint color
Characteristic
value
1200
900
7.3×10-4
3.0
±0.02
Silver
PPLX063 type B (table type)
Item
Stroke La
Stroke Lb
Mass inside stroke La (moa)
Mass inside stroke Lb (mob)
Body mass
mm
mm
kg
kg
kg
Lubrication method
Characteristic
value
max.150
max.50
1.8
3.8
25
Lubrication by
grease
Item
Permissible thrust force of input shaft
Permissible radial force of input shaft
Moment of inertia of input shaft
Internal frictional torque (Tin)
Repeated accuracy
N
N
kg m2
Nm
mm
Paint color
Characteristic
value
2000
1600
2.4×10-4
4.8
±0.02
Silver
PPLX080 type B (table type)
Item
Stroke La
Stroke Lb
Mass inside stroke La (moa)
Mass inside stroke Lb (mob)
Body mass
Lubrication method
mm
mm
kg
kg
kg
Characteristic
value
max.200
max.60
3.6
6.9
50
Lubrication by
grease
Item
Permissible thrust force of input shaft
Permissible radial force of input shaft
Moment of inertia of input shaft
Internal frictional torque (Tin)
Repeated accuracy
Paint color
N
N
kg m2
Nm
mm
Characteristic
value
2500
270
8.6×10-4
7.8
±0.02
Silver
3) Others
 For the dynamic rated carrying mass, see the catalog.
 Refer to catalogs for dimensions.
[SMB-20E]
― 16 ―
９
INTERNAL
STRUCTURE
DRAWIND
９. INTERNAL STRUCTURE DRAWIND
1) Internal structural drawing of PPLX
[Type A]
26
21
14
22
19
10
24
15
9
25
16
12
1
6
20
7
13
2
23
5
3
18
4
17
11
8
Internal structure and part names
No.
1
2
3
4
5
6
7
8
9
Part name
Housing A
Base plate A
Plate A
Guide block A
Linear way A
Cover A
Guide block C
Linear way C
Matching spacer
[SMB-20E]
Quantity
1
1
1
1
1
1
1
1
1
No.
10
11
12
13
14
15
16
17
18
Part name
Spacer
Arm
Lift arm
Stand
Bearing retainer
Cam follower (X)
Cam follower (Y)
Cam follower
Cam follower
― 17 ―
Quantity
1
1
1
2
2
−
2
1
1
No.
19
20
21
22
23
24
25
26
27
Part name
Tapered roller bearings
Tapered roller bearings
Oil seal
O-ring
Nut
Cam (X)
Cam (Y)
Input shaft
Quantity
2
4
2
2
2
1
1
1
９
INTERNAL
STRUCTURE
DRAWIND
１０
OTHERS
2) Internal structural drawing of PPLX
[Type B]
29
24
17
25
22
13
27
18
12
28
19
15
1
8
23
9
16
2
7
26
3
6
4
20
5
11
14
21
10
Internal structure and part names
No.
1
2
3
4
5
6
7
8
9
10
Part name
Housing B
Base plate B
Plate B
Table
Guide block B
Linear way B
Cover B1
Cover B2
Guide block C
Linear way C
Quantity
1
1
1
1
1
1
1
1
1
1
No.
11
12
13
14
15
16
17
18
19
20
Part name
Linear way D
Matching spacer
Spacer
Arm
Lift arm
Stand
Bearing retainer
Cam follower (X)
Cam follower (Y)
Cam follower
Quantity
1
1
1
1
1
2
1
1
2
1
No.
21
22
23
24
25
26
27
28
29
30
Part name
Cam follower
Tapered roller bearings
Tapered roller bearings
Oil seal
O-ring
Nut
Cam (X)
Cam (Y)
Input shaft
Quantity
1
2
4
2
2
2
1
1
1
10. OTHERS
Please observe the matters mentioned above to maintain this product in normal
operation. When trouble occurs, please check model No. (refer to 8.1 ) and part
No. (refer to 9.) before contacting to your nearest business office or distributors to
ask replacement or to place order of repair part.
If you have any questions on handling, please consults with CKD.
[SMB-20E]
― 18 ―