CT4(ME3724
ࡸࡌࡿ㹑
High-Speed Orthogonal Robot
CT4
Instruction Manual
Sixth Edition
IAI America, Inc.
Please Read Before Use
Thank you for purchasing our product.
This Instruction Manual explains the handling methods, structure and maintenance of this product,
among others, providing the information you need to know to use the product safely.
Before using the product, be sure to read this manual and fully understand the contents explained
herein to ensure safe use of the product.
The DVD that comes with the product contains instruction manuals for IAI products.
When using the product, refer to the necessary portions of the applicable instruction manual by
printing them out or displaying them on a PC.
After reading the Instruction Manual, keep it in a convenient place so that whoever is handling this
product can reference it quickly when necessary.
[Important]
x This Instruction Manual is original.
x This product is not to be used for any other purpose from what is noted in this Instruction Manual.
IAI shall not be liable whatsoever for any loss or damage arising from the result of using the
product for any other purpose from what is noted in the manual.
x The information contained in this Instruction Manual is subject to change without notice for the
purpose of production improvement.
x If you have any question or finding regarding the information contained in this Instruction Manual,
contact our customer center or our sales office near you.
x Using or copying all or a part of this Instruction Manual without permission is prohibited.
x The company names, names of products and trademarks of each company shown in the
sentences are registered trademarks.
Table of Contents
Safety Guide............................................................................................................... 1
Caution in Handling .................................................................................................... 8
Names of the Parts ....................................................................................................11
1. Specifications Check .......................................................................................... 14
1.1
Checking the Product .....................................................................................................14
1.1.1
Components............................................................................................................14
1.1.2
Instruction Manuals Related to this Product, Which are Contained in the DVD. .....14
1.1.3
How to Read the Model Nameplate ........................................................................14
1.1.4
How to Read the Model Number .............................................................................15
1.2
Specification ...................................................................................................................17
1.2.1
Speed......................................................................................................................17
1.2.2
Maximum Acceleration and Transportable Mass.....................................................18
1.2.3
Driving System and Position Detector.....................................................................19
1.2.4
Positioning Accuracy ...............................................................................................20
1.2.5
Grip Force of Pick & Rotary Axis Equipped Type....................................................21
1.2.6
Duty of Pick & Rotary Axis.......................................................................................22
1.3
Operating Conditions of Pick & Rotary Axis ...................................................................23
1.4
Motor • Encoder Cables .................................................................................................27
1.4.1
Standard Type .........................................................................................................27
1.4.2
Rotary Axis Equipped Type .....................................................................................29
1.4.3
Pick & Rotary Axis Equipped Type ..........................................................................30
1.4.3
Pick & Rotary Axis Equipped Type ..........................................................................31
2. Installation .......................................................................................................... 33
2.1
Transportation ................................................................................................................33
2.1.1
Handling of the Robot .............................................................................................33
2.1.2
Handling of the Robot Mounted on Mechanical Equipment (System) .....................34
2.2
Installation and Storage/Preservation Environment........................................................35
2.3
How to Install..................................................................................................................36
2.3.1
Installation of the Main Body ...................................................................................36
2.3.2
Datum Surface ........................................................................................................37
2.3.3
Platform for Installation............................................................................................38
2.3.4
Attachment of Transported Objects .........................................................................39
2.3.5
Air Pipes on the Rotation Axis .................................................................................44
3. Connecting to the Controller ............................................................................... 45
4. Operation............................................................................................................ 49
4.1
4.2
4.3
Home Return of Pick & Rotary Axis................................................................................49
Home Position Angle of Gripper on Pick & Rotary Axis ..................................................49
Program of Pick & Rotary Axis (XSEL-PCT/QCT Controller)..........................................49
5. Maintenance Inspection...................................................................................... 50
5.1
Inspection Items and Inspection Schedule .....................................................................50
5.2
Visual Inspection ............................................................................................................51
5.3
Cleaning .........................................................................................................................51
5.4
Internal Inspection ..........................................................................................................52
5.5
Internal Cleanup .............................................................................................................54
5.6
Grease Supply ...............................................................................................................55
5.6.1
Grease Applied........................................................................................................55
5.6.2
How to Apply Grease ..............................................................................................55
5.7
Motor Replacement Process ..........................................................................................61
5.7.1
Motor Replacement for X1-Axis and X2-Axis ..........................................................61
5.7.2
Process to Replace the Motor for the Y-Axis ...........................................................69
5.7.3
Process to Replace the Motor for the Z-Axis...........................................................76
5.7.4
Motor Replacement of Pick & Rotary Axis...............................................................82
5.8
How to Replace Solenoid on Pick & Rotary Axis ............................................................86
5.9
How to Replace Spring on Pick & Rotary Axis................................................................89
5.10 How to Replace Belt on Pick & Rotary Axis....................................................................92
6. External Dimensions........................................................................................... 95
6.1
6.2
6.3
Standard Type ................................................................................................................95
Rotary Axis Equipped Type ............................................................................................96
Pick & Rotary Axis Equipped Type .................................................................................97
7. Life...................................................................................................................... 98
8. Warranty ............................................................................................................. 99
8.1
8.2
8.3
8.4
8.5
8.6
Warranty Period .............................................................................................................99
Scope of the Warranty....................................................................................................99
Honoring the Warranty ...................................................................................................99
Limited Liability...............................................................................................................99
Conditions of Conformance with Applicable Standards/Regulations, Etc., and
Applications..................................................................................................................100
Other Items Excluded from Warranty ...........................................................................100
Change History....................................................................................................... 101
Safety Guide
“Safety Guide” has been written to use the machine safely and so prevent personal injury or property
damage beforehand. Make sure to read it 1before the operation of this product.
Safety Precautions for Our Products
The common safety precautions for the use of any of our robots in each operation.
No.
1
Operation
Description
Model
Selection
Description
Ɣ This product has not been planned and designed for the application
where high level of safety is required, so the guarantee of the protection of
human life is impossible. Accordingly, do not use it in any of the following
applications.
1) Medical equipment used to maintain, control or otherwise affect human
life or physical health.
2) Mechanisms and machinery designed for the purpose of moving or
transporting people (For vehicle, railway facility or air navigation
facility)
3) Important safety parts of machinery (Safety device, etc.)
Ɣ Do not use the product outside the specifications. Failure to do so may
considerably shorten the life of the product.
Ɣ Do not use it in any of the following environments.
1) Location where there is any inflammable gas, inflammable object or
explosive
2) Place with potential exposure to radiation
3) Location with the ambient temperature or relative humidity exceeding
the specification range
4) Location where radiant heat is added from direct sunlight or other large
heat source
5) Location where condensation occurs due to abrupt temperature
changes
6) Location where there is any corrosive gas (sulfuric acid or hydrochloric
acid)
7) Location exposed to significant amount of dust, salt or iron powder
8) Location subject to direct vibration or impact
Ɣ For an actuator used in vertical orientation, select a model which is
equipped with a brake. If selecting a model with no brake, the moving part
may drop when the power is turned OFF and may cause an accident such
as an injury or damage on the work piece.
1
No.
2
2
Operation
Description
Transportation
3
Storage and
Preservation
4
Installation
and Start
Description
Ɣ When carrying a heavy object, do the work with two or more persons or
utilize equipment such as crane.
Ɣ When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
Ɣ When in transportation, consider well about the positions to hold, weight
and weight balance and pay special attention to the carried object so it
would not get hit or dropped.
Ɣ Transport it using an appropriate transportation measure.
The actuators available for transportation with a crane have eyebolts
attached or there are tapped holes to attach bolts. Follow the instructions
in the instruction manual for each model.
Ɣ Do not step or sit on the package.
Ɣ Do not put any heavy thing that can deform the package, on it.
Ɣ When using a crane capable of 1t or more of weight, have an operator
who has qualifications for crane operation and sling work.
Ɣ When using a crane or equivalent equipments, make sure not to hang a
load that weighs more than the equipment’s capability limit.
Ɣ Use a hook that is suitable for the load. Consider the safety factor of the
hook in such factors as shear strength.
Ɣ Do not get on the load that is hung on a crane.
Ɣ Do not leave a load hung up with a crane.
Ɣ Do not stand under the load that is hung up with a crane.
Ɣ The storage and preservation environment conforms to the installation
environment. However, especially give consideration to the prevention of
condensation.
Ɣ Store the products with a consideration not to fall them over or drop due to
an act of God such as earthquake.
(1) Installation of Robot Main Body and Controller, etc.
Ɣ Make sure to securely hold and fix the product (including the work part). A
fall, drop or abnormal motion of the product may cause a damage or
injury.
Also, be equipped for a fall-over or drop due to an act of God such as
earthquake.
Ɣ Do not get on or put anything on the product. Failure to do so may cause
an accidental fall, injury or damage to the product due to a drop of
anything, malfunction of the product, performance degradation, or
shortening of its life.
Ɣ When using the product in any of the places specified below, provide a
sufficient shield.
1) Location where electric noise is generated
2) Location where high electrical or magnetic field is present
3) Location with the mains or power lines passing nearby
4) Location where the product may come in contact with water, oil or
chemical droplets
No.
4
Operation
Description
Installation
and Start
Description
(2) Cable Wiring
Ɣ Use our company’s genuine cables for connecting between the actuator
and controller, and for the teaching tool.
Ɣ Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not
coil it around. Do not insert it. Do not put any heavy thing on it. Failure to
do so may cause a fire, electric shock or malfunction due to leakage or
continuity error.
Ɣ Perform the wiring for the product, after turning OFF the power to the unit,
so that there is no wiring error.
Ɣ When the direct current power (+24V) is connected, take the great care of
the directions of positive and negative poles. If the connection direction is
not correct, it might cause a fire, product breakdown or malfunction.
Ɣ Connect the cable connector securely so that there is no disconnection or
looseness. Failure to do so may cause a fire, electric shock or malfunction
of the product.
Ɣ Never cut and/or reconnect the cables supplied with the product for the
purpose of extending or shortening the cable length. Failure to do so may
cause the product to malfunction or cause fire.
(3) Grounding
Ɣ The grounding operation should be performed to prevent an electric
shock or electrostatic charge, enhance the noise-resistance ability and
control the unnecessary electromagnetic radiation.
Ɣ For the ground terminal on the AC power cable of the controller and the
grounding plate in the control panel, make sure to use a twisted pair cable
with wire thickness 0.5mm2 (AWG20 or equivalent) or more for grounding
work. For security grounding, it is necessary to select an appropriate wire
thickness suitable for the load. Perform wiring that satisfies the
specifications (electrical equipment technical standards).
Ɣ Perform Class D Grounding (former Class 3 Grounding with ground
resistance 100: or below).
3
No.
4
5
4
Operation
Description
Installation
and Start
Teaching
Description
(4) Safety Measures
Ɣ When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
Ɣ When the product is under operation or in the ready mode, take the safety
measures (such as the installation of safety and protection fence) so that
nobody can enter the area within the robot’s movable range. When the
robot under operation is touched, it may result in death or serious injury.
Ɣ Make sure to install the emergency stop circuit so that the unit can be
stopped immediately in an emergency during the unit operation.
Ɣ Take the safety measure not to start up the unit only with the power
turning ON. Failure to do so may start up the machine suddenly and
cause an injury or damage to the product.
Ɣ Take the safety measure not to start up the machine only with the
emergency stop cancellation or recovery after the power failure. Failure to
do so may result in an electric shock or injury due to unexpected power
input.
Ɣ When the installation or adjustment operation is to be performed, give
clear warnings such as “Under Operation; Do not turn ON the power!” etc.
Sudden power input may cause an electric shock or injury.
Ɣ Take the measure so that the work part is not dropped in power failure or
emergency stop.
Ɣ Wear protection gloves, goggle or safety shoes, as necessary, to secure
safety.
Ɣ Do not insert a finger or object in the openings in the product. Failure to do
so may cause an injury, electric shock, damage to the product or fire.
Ɣ When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
Ɣ When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
Ɣ Perform the teaching operation from outside the safety protection fence, if
possible. In the case that the operation is to be performed unavoidably
inside the safety protection fence, prepare the “Stipulations for the
Operation” and make sure that all the workers acknowledge and
understand them well.
Ɣ When the operation is to be performed inside the safety protection fence,
the worker should have an emergency stop switch at hand with him so
that the unit can be stopped any time in an emergency.
Ɣ When the operation is to be performed inside the safety protection fence,
in addition to the workers, arrange a watchman so that the machine can
be stopped any time in an emergency. Also, keep watch on the operation
so that any third person can not operate the switches carelessly.
Ɣ Place a sign “Under Operation” at the position easy to see.
Ɣ When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
* Safety protection Fence : In the case that there is no safety protection fence,
the movable range should be indicated.
No.
6
7
Operation
Description
Trial Operation
Automatic
Operation
Description
Ɣ When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
Ɣ After the teaching or programming operation, perform the check operation
one step by one step and then shift to the automatic operation.
Ɣ When the check operation is to be performed inside the safety protection
fence, perform the check operation using the previously specified work
procedure like the teaching operation.
Ɣ Make sure to perform the programmed operation check at the safety
speed. Failure to do so may result in an accident due to unexpected
motion caused by a program error, etc.
Ɣ Do not touch the terminal block or any of the various setting switches in
the power ON mode. Failure to do so may result in an electric shock or
malfunction.
Ɣ Check before starting the automatic operation or rebooting after operation
stop that there is nobody in the safety protection fence.
Ɣ Before starting automatic operation, make sure that all peripheral
equipment is in an automatic-operation-ready state and there is no alarm
indication.
Ɣ Make sure to operate automatic operation start from outside of the safety
protection fence.
Ɣ In the case that there is any abnormal heating, smoke, offensive smell, or
abnormal noise in the product, immediately stop the machine and turn
OFF the power switch. Failure to do so may result in a fire or damage to
the product.
Ɣ When a power failure occurs, turn OFF the power switch. Failure to do so
may cause an injury or damage to the product, due to a sudden motion of
the product in the recovery operation from the power failure.
5
No.
8
9
6
Operation
Description
Maintenance
and Inspection
10
Modification
and Dismantle
Disposal
11
Other
Description
Ɣ When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
Ɣ Perform the work out of the safety protection fence, if possible. In the case
that the operation is to be performed unavoidably inside the safety
protection fence, prepare the “Stipulations for the Operation” and make
sure that all the workers acknowledge and understand them well.
Ɣ When the work is to be performed inside the safety protection fence,
basically turn OFF the power switch.
Ɣ When the operation is to be performed inside the safety protection fence,
the worker should have an emergency stop switch at hand with him so
that the unit can be stopped any time in an emergency.
Ɣ When the operation is to be performed inside the safety protection fence,
in addition to the workers, arrange a watchman so that the machine can
be stopped any time in an emergency. Also, keep watch on the operation
so that any third person can not operate the switches carelessly.
Ɣ Place a sign “Under Operation” at the position easy to see.
Ɣ For the grease for the guide or ball screw, use appropriate grease
according to the Instruction Manual for each model.
Ɣ Do not perform the dielectric strength test. Failure to do so may result in a
damage to the product.
Ɣ When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
Ɣ The slider or rod may get misaligned OFF the stop position if the servo is
turned OFF. Be careful not to get injured or damaged due to an
unnecessary operation.
Ɣ Pay attention not to lose the cover or untightened screws, and make sure
to put the product back to the original condition after maintenance and
inspection works.
Use in incomplete condition may cause damage to the product or an
injury.
* Safety protection Fence : In the case that there is no safety protection
fence, the movable range should be indicated.
Ɣ Do not modify, disassemble, assemble or use of maintenance parts not
specified based at your own discretion.
Ɣ When the product becomes no longer usable or necessary, dispose of it
properly as an industrial waste.
Ɣ When removing the actuator for disposal, pay attention to drop of
components when detaching screws.
Ɣ Do not put the product in a fire when disposing of it.
The product may burst or generate toxic gases.
Ɣ Do not come close to the product or the harnesses if you are a person
who requires a support of medical devices such as a pacemaker. Doing
so may affect the performance of your medical device.
Ɣ See Overseas Specifications Compliance Manual to check whether
complies if necessary.
Ɣ For the handling of actuators and controllers, follow the dedicated
instruction manual of each unit to ensure the safety.
Alert Indication
The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the
warning level, as follows, and described in the Instruction Manual for each model.
Level
Degree of Danger and Damage
Symbol
Danger
This indicates an imminently hazardous situation which, if the product
is not handled correctly, will result in death or serious injury.
Danger
Warning
This indicates a potentially hazardous situation which, if the product is
not handled correctly, could result in death or serious injury.
Warning
Caution
This indicates a potentially hazardous situation which, if the product is
not handled correctly, may result in minor injury or property damage.
Caution
Notice
This indicates lower possibility for the injury, but should be kept to use
this product properly.
Notice
7
Caution in Handling
1. Ensure use of the product in the specified conditions, environments and ranges.
In case it is not secured, it may cause a drop in performance or malfunction of the product.
2. Do not conduct any treatment or operation that is not stated in this instruction
manual.
3. It is recommended to apply our products for the wiring between the actuator and
the controller.
4. Do not set speeds and accelerations/decelerations equal to or greater than the
respective ratings.
If the robot is operated at a speed or acceleration/deceleration exceeding the allowable value,
abnormal noise or vibration, failure, or shorter life may result.
5. Keep the load moment within the allowable value.
If the robot is operated under a load equal to or greater than the allowable load moment, abnormal
noise or vibration, failure, or shorter life may result. In an extreme case, flaking may occur.
6. Keep the overhang length to within the allowable value.
If the overhang length is equal to or greater than the allowable value, vibration or abnormal noise
may occur.
7. Back and forth operation in a short distance may cause wear of grease.
If the actuators are moved back and forth continuously over a short distance of 30 mm or less,
grease film may run out. As a guide, move the actuators back and forth repeatedly for around 5
cycles over a distance of 50 mm or more after every 5,000 to 10,000 cycles. Keep using the
actuators with the grease worn out may cause malfunction. If it is extreme, flaking may occur on
the guide.
8. Make sure to attach the High-Speed Orthogonal Robot CT4 properly by following
this instruction manual.
Danger: Without the High-Speed Cartesian Robot CT4 being solidly held or affixed, it may
not only cause abnormal noise, vibration, malfunction or shortened life, but it also
could cause such critical accidents as to destroy the peripherals including the
CT4 main body and work piece or to result in death because of the CT4 main
body being unstable.
8
9. Make an operation having acceleration/deceleration by S-shaped motion and
anti-vibration control.
(1) Setting for Acceleration/Deceleration by S-shaped Motion
Put SCRV Command in program and have a setting of the acceleration/deceleration by
S-shaped motion.
Set to 50% for the ratio.
Description: SCRV
50
[Refer to SEL language programming manual ME0224]
(2) Setting for Anti-Vibration Control
1) Have the setting done with the anti-vibration control.
The specific frequency for anti-vibration control is 40Hz.
40000 is set in Specific Frequency (Parameter Set 1) in Each Axis Parameter No. 153.
2) Put NTCH Command to the program and perform the anti-vibration operation.
The axis pattern should be set to all of the four axes. Set to 1101.
Parameter Set Number should be 1. Set to 1.
Description: NTCH 1101 1
[Refer to SEL language programming manual ME0224]
10. For the Rotary Axis, have an operation with the setting of the gain corresponding
to the moment of the load inertia indicated in the table below.
Driver
Driver
Driver
Driver
Parameter
Parameter
Parameter
Parameter
No. 46
No. 45
No. 43
No. 44
Speed Loop
Constant in
Load Inertia
Current Control Torque Filter
Velocity Loop
Proportional
Position Gain
Band Number Time Constant
[Kg㺃m2]
Gain
Integrated
0.000500 to 0.000491
24
1353
41
4
0
0.000400 to 0.000391
30
1353
33
4
0
0.000300 to 0.000291
40
1353
25
4
0
0.000200 to 0.000191
60
1353
17
4
0
0.000190 to 0.000181
63
1353
16
4
0
0.000180 to 0.000171
67
1353
15
4
0
0.000170 to 0.000161
71
1353
14
4
0
0.000160 to 0.000151
75
1353
13
4
0
0.000150 to 0.000141
80
1353
12
4
0
0.000140 to 0.000131
85
1353
11
4
0
0.000130 to 0.000121
92
1353
10
4
0
0.000120 to 0.000111
99
1353
9
4
0
0.000110 to 0.000101
108
1353
8
4
0
0.000100 to 0.000091
119
1353
8
4
0
0.000090 to 0.000081
125
1353
7
4
0
0.000080 to 0.000071
125
1353
6
4
0
0.000070 to 0.000061
125
1353
5
4
0
0.000060 to 0.000051
125
1353
5
4
0
0.000050 to 0.000041
125
1277
5
4
0
0.000040 to 0.000031
125
1036
5
4
0
0.000030 to 0.000021
125
796
5
4
0
0.000020 to 0.000011
100
555
5
4
0
0.000010 to 0.000001
100
314
5
4
0
0.000000
100
74
5
4
0
(Note) For safety, the gain is set low at the delivery.
(Note) In case of optimized selection of gain parameters not being made, it may cause an unexpected
operation error such as vibration or overshoot. Check the gain parameters carefully to have the settings
established.
XSEL-PCT/QCT
Axis-Specific
Parameter
No.60
9
11. For Pick & Rotary Axis, have an operation with the setting of the gain
corresponding to the moment of the load inertia indicated in the table below.
XSEL-PCT/QCT
Each Axis
Parameter
No.60
Load inertia [Kg㺃m2]
Position Gain
0.000040 ~0.000031
0.000030 ~ 0.000021
0.000020 ~ 0.000000
85
85
100
Driver Parameter
No.43
No.44
No.46
No.45
Velocity Loop
Speed Loop
Current Control Torque Filter
Proportional Integrated Time
Band Number Time Constant
Constant
Gain
525
8
4
50
396
8
4
50
226
8
4
0
(Note) For safety, the gain is set low at the delivery.
(Note) In case of optimized selection of gain parameters not being made, it may cause an
unexpected operation error such as vibration or overshoot. Check the gain parameters
carefully to have the settings established.
10
Names of the Parts
Ɣ Standard Type
Z-axis cover
Screw cover
X1-axis (master axis)
Y-axis
Table
Screw cover
Z-axis
Screw cover
X2-axis (slave axis)
Frame
Y direction
datum surface
Y-Z cable
X-Y cable
M cable
PG cable
Connector box
Connector Joint Details
Connector joint
X direction
datum surface
11
Ɣ Rotary Axis Equipped Type
X-Y cable (with built-in air pipes)
Y-Z cable (with built-in air pipes)
Air pipe c Joint
R-axis
Air pipe d Joint
Air pipe c (I4)
Air pipe d (I4)
M cable
PG cable
Air pipes and connector plugs
12
Detail of air pipes and
connector plugs
‫ە‬Pick & Rotary Axis Equipped Type
X-Y cable(dedicated for
model with PR axis)
X-Z cable(dedicated for
model with PR axis)
PR-axis
M cable
PG cable
Detail of Connector Plugs
Connector plugs
13
1. Specifications Check
1. Specifications Check
1.1
Checking the Product
If based on a standard configuration, this product consists of the items listed below.
Check the packed items against the packing specification. Should you find a wrong model or any
missing item, please contact your IAI dealer or IAI.
1.1.1
Components
No.
1
Name
ActuatorMain Body
Accessories
Model number
Refer to “How to Read the
Model Nameplate” and
“How to Read the Model
Number.”
Quantity
1 set
2
Motor • encoder cables
1 set
3
4
5
6
7
Eyebolt
In-house made seals
First Step Guide
Instruction Manual (DVD)
Safety Guide
3
1
1
1
1
1.1.2
Remarks
Refer to 1.3 “Motor
• Encoder Cables”.
Instruction Manuals Related to this Product, Which are Contained in the DVD.
The table below lists the related instruction manuals for each controller supported by this product,
which are included in the Instruction Manual (DVD).
No.
Name
Control No.
1
2
3
4
5
6
7
8
Instruction Manual for XSEL-P/Q/PCT/QCT Controller
Instruction Manual for XSEL-P/Q/PCT/QCT/PX/QX RC Gateway Function
Instruction Manual for PC Software IA-101-X-MW/IA-101-X-USBMW
Instruction Manual for Teaching Pendant SEL-T/TD/TG
Instruction Manual for Teaching Pendant IA-T-X/XD
Instruction Manual for DeviceNet
Instruction Manual for CC-Link
Instruction Manual for PROFIBUS-DP
ME0148
ME0188
ME0154
ME0183
ME0160
ME0124
ME0123
ME0153
1.1.3
14
How to Read the Model Nameplate
Model
MODEL
CT4-G1-A-40-40-30-10B-T2-3L
Serial number
SERIAL
No.000061910
MADE IN JAPAN
1.1.4
How to Read the Model Number
[1] Standard Type
C T 4 - G 1 - A - 4 0 - 4 0 - 3 0 - 1 0 B - T 2 - 3 L - A C - 㸨㸨
Identification for IAI use only
<Type>
<Option>
(Note 1)
AC : Air Pipe Equipped Type
<Encoder Type>
A
: Absolute
<Cable Length>
3L : 3m
<First Axis Stroke>
40
5L : 5m
: 400mm
<Applicable Controller>
<Second Axis Stroke>
40
T2 : XSEL-PCT/QCT
: 400mm
<Third Axis Stroke>
30
: 300mm
<Fourth Axis Stroke>
10B : 100mm with brake
Note 1 Identification for IAI use only : It may be displayed for IAI use. It is not a code to show
the model type.
[2] Rotary Axis Equipped Type (Option)
C T 4 - G 1 R T - A - 4 0 - 4 0 - 3 0 - 1 0 B - 3 6 L - T 2 - 3 L - 㸨㸨
Series Name
<Type>
(Note 1)
Identification for IAI use only
<Cable Length>
3L : 3m
<Encoder Type>
A
5L : 5m
: Absolute
<Applicable Controller>
<First Axis Stroke>
40
T2 : XSEL-PCT/QCT
: 400mm
<Second Axis Stroke>
40
: 400mm
<Third Axis Stroke>
30
: 300mm
<Fourth Axis Stroke>
10B : 100mm with brake
<Fifth Axis Sliding Angle>
36L : 360° with limit switch
Note 1 Identification for IAI use only : It may be displayed for IAI use. It is not a code to show
the model type.
15
1. Specifications Check
Series Name
[3] Pick & Rotary Axis Equipped Type (Option)
1. Specifications Check
C T 4 - G 1 P R - A - 4 0 - 4 0 - 3 0 - 1 0 B - 3 6 - T 2 - 3 L - 㸨㸨
Series Name
<Type>
<Encoder Type>
A
: Absolute
Identification for IAI use
only
<Cable Length>
3L : 3m
5L : 5m
<First Axis Stroke>
40
: 400mm
<Second Axis Stroke>
40
(Note 1)
<Applicable Controller>
T2
: XSEL-PCT/QCT
: 400mm
<Third Axis Stroke>
30
: 300mm
<Fourth Axis Stroke>
10B : 100mm with brake
<Fifth Axis Sliding Angle>
36 : 360°
Note 1 Identification for IAI use only : It may be displayed for IAI use. It is not a code to show
the model type.
16
1.2
1.2.1
Specification
Speed
Axis
Max. Speed
Motor Type [W]
Stroke [mm]
Max. Speed [mm/s]
X1-axis
400
400
2500
X2-axis
400
400
2500
Y-axis
400
300
2500
Z-axis
50
100
833
[2] Rotary Axis Equipped Type
Axis
Max. Speed
Motor Type [W]
Stroke [mm]
1. Specifications Check
[1] Standard Type
Max. Speed [mm/s]
X1-axis
400
400
2500
X2-axis
400
400
2500
Y-axis
400
300
2500
Z-axis
50
100
833
Axis
Motor Type [W]
Rotation Angle [° ]
Max. Speed [deg/s]
R-axis
60
Note 1 Multi-rotation available
360
(Note 1)
4500
[3] Pick & Rotary Axis Equipped Type
Axis
Max. Speed
Motor Type [W]
Stroke [mm]
Max. Speed [mm/s]
X1-axis
400
400
2500
X2-axis
400
400
2500
Y-axis
Z-axis
400
50
300
100
2500
833
Axis
Motor Type [W]
Rotation Angle [° ]
Max. Speed [deg/s]
PR-axis
12
Note 1 Multi-rotation available
360
(Note 1)
4500
17
1. Specifications Check
1.2.2
Maximum Acceleration and Transportable Mass
[1] Standard Type
Acceleration and Deceleration
3.2 G
Z-axis Transportable Mass
1.0 kg
[2] Rotary Axis Equipped Type
Acceleration and Deceleration
R-axis Transportable Mass
X1, X2, Y, Z-axis
3.2 G
R-axis
83300 deg/s2
(Note 1)
[3] Pick & Rotary Axis Equipped Type
Acceleration and Deceleration
X1, X2, Y, Z-axis
3.2 G
Note 1
Note 2
PR-axis
83300 deg/s2
(Note 1)
0.5 kg
PR-axis Transportable Mass (Note 2)
0.1 kg
Set it at 8.5G on a teaching tool such as the PC software.
(Conversion at 1G =9800deg/s2)
It is the maximum transportable mass. The profile of the gripping fingers,
coefficient of friction and grip force may make the weight available to grip 0.1kg or
less.
Caution: Do not have the settings of acceleration/deceleration exceeding the rated values.
It may cause vibration, malfunction or shortened life.
18
1.2.3
Driving System and Position Detector
[1] Standard Type
No. of Encoder
Pluses
16384
16384
16384
16384
Lead
[mm]
30
30
30
10
Ball Screw Type
Type
Diameter [mm]
Rolled
I16
Rolled
I16
Rolled
I16
Rolled
I8
[2] Rotary Axis Equipped Type
Motor
Axis
Type [W]
X1-axis
400
X2-axis
400
Y-axis
400
Z-axis
50
R-axis
60
No. of Encoder
Pluses
16384
16384
16384
16384
16384
Lead
[mm]
30
30
30
10
-
Ball Screw Type
Type
Diameter [mm]
Rolled
I16
Rolled
I16
Rolled
I16
Rolled
I8
-
[3] Pick & Rotary Axis Equipped Type
Motor
No. of Encoder
Axis
Type [W]
Pluses
X1-axis
400
16384
X2-axis
400
16384
Y-axis
400
16384
Z-axis
50
16384
PR-axis
12
16384
Lead
[mm]
30
30
30
10
-
Ball Screw Type
Type
Diameter [mm]
Rolled
I16
Rolled
I16
Rolled
I16
Rolled
I8
-
X1-axis
X2-axis
Y-axis
Z-axis
1. Specifications Check
Motor
Type [W]
400
400
400
50
Axis
19
1. Specifications Check
1.2.4
Positioning Accuracy
[1] Standard Type
Item
Specifications
X direction
±0.02 mm
Positioning Repeatability
Y direction
±0.02 mm
Z direction
±0.02 mm
X direction
0.05 mm or less
Lost Motion
Y direction
0.05 mm or less
The values shown above are the accuracy at the delivery from the factory.
It does not include the consideration of time-dependent change as it is used.
[2] Rotary Axis Equipped Type
Item
Specifications
X direction
±0.02 mm
Y direction
±0.02 mm
Positioning Repeatability
Z direction
±0.02 mm
R direction
±0.025°
X direction
0.05 mm or less
Lost Motion
Y direction
0.05 mm or less
The values shown above are the accuracy at the delivery from the factory.
It does not include the consideration of time-dependent change as it is used.
[3] Pick & Rotary Axis Equipped Type
Item
Specifications
X direction
±0.02 mm
Y direction
±0.02 mm
Positioning Repeatability
Z direction
±0.02 mm
R direction
±0.025°
X direction
0.05 mm or less
Y direction
0.05 mm or less
Lost Motion
R direction
0.1ror less
The values shown above are the accuracy at the delivery from the factory.
It does not include the consideration of time-dependent change as it is used.
20
1.2.5
Grip Force of Pick & Rotary Axis Equipped Type
1. Specifications Check
It grips with springs built in the gripping structure.
The grip force is the value of the gripping point at 0mm and overhang distance at 0mm.
The grip force could differ depending on the position on the stroke when the work piece is
gripped. (The grip force differs depending on the width of a work piece.) The following graph
shows the grip force on one side.Make the force double when considering both sides.
There is dispersion in the grip force. Take the graph below as a reference.
Stroke and Grip force
5.5
5.0
Grip force [N]
4.5
4.0
3.5
3.0
2.5
2.0
1.5
0.0
0.5
CLOSE
1.0
Stroke [mm]
1.5
2.0
OPEN
Grip force differs by the gripping point distance.
࣭The graph below shows the grip force at each gripping point distance when the maximum grip
force is determined as 100%.
There is dispersion in the grip force. Take the graph below as a reference.
࣭The gripping point distance shows the distance in vertical from the finger attachment surface to
the gripping point.
Grip Force Change in each Gripping Point Distance
120
Grip force [%]
100
80
60
40
20
0
0
5
10
15
20
Gripping Point Distance [mm]
21
1. Specifications Check
1.2.6
Duty of Pick & Rotary Axis
In case the ambient temperature around the controller exceeds 25degC, use it in the operational
condition that the duty of the open/close operation is in the range of “Safety Range” shown below.
In case the ambient temperature around the controller is 25degC or below, there is no limitation of
duty. It is available to operate in 100%.
ON time
Duty [%] =
Time of one cycle (ON time + OFF time)
Time of one cycle
ON
OFF
OFF time
ON time
ON time
: Duration of fingers open (shows the conducting time to the solenoid to release
the grip)
: Duration of fingers closed
OFF time
100
90
Prohibited Area
80
70
Duty
[%]
60
50
40
Safety Area
30
20
10
0
0.16 0.2
0.4
0.6
0.8
1.0
1.2
ON Time [Second]
22
1.4
1.5
1.6
1.8
1.3
Operating Conditions of Pick & Rotary Axis
1. Specifications Check
The weight of work piece can actually be transported may differ depending on the coefficient of
friction determined by the finger attachment (gripping fingers) and the material of a work piece.
Make a reference to see if transportation is available to conducting following calculation.
[Procedure 1] :Check for necessary grip force and transportable work piece weight
Ў
[Procedure 2] :Check for the vertical allowable load of the fingers and allowable moment
[Procedure 1] :Check for necessary grip force and transportable work piece weight
If a work piece is to be gripped on the fingers with the friction force created by the grip force,
the formula to calculate the necessary grip force is as follows;
F : Grip force [N]͐͐Sum of pressing force on each finger
ȝ : Coefficient of static friction between finger
attachment
and work piece
m : Mass of Work piece [kg]
g : Gravitational acceleration [=9.8m/s2]
The condition to grip the work piece statically and that the
work piece would not drop is;
Fȝ > W
F>
F/2
mg
ȝ
The Pick & Rotary Axis, High inertial force, in addition to
the gravity, will be applied to the work piece.
F/2
Coefficient
of Frictionȝ
W (mg)
Therefore, set the recommended safety ratio to 5, and the required grip force is;
mg
F> ×5
(safety factor)
ȝ
When coefficient of friction is ȝ 0.1 to 0.2;
mg
F>
× 5 = (25 to 50) × mg
0.1 to 0.2
Necessary grip force B 25 to 50 times or more of work piece weight
Transportable work piece mass B 1/25 to 1/50 or less of grip force
23
1. Specifications Check
[Procedure 2] : Check for the vertical allowable load of the fingers and allowable moment
Check the vertical load and the moment applicable to the finger. Figure out Fz, Ma, Mb and Mc
by referring to (1) to (3) described below, and considering not to exceed the allowable values.
MIa, MOa
Reaction force of work
MOc
piece gripping
LG
Finger
LC
FZ
FX
Finger attachment
Gripping point
FY
HC
Center of gravity for finger
HG
attachment and work piece
MIb, MOb
FX
FY
FZ
LG
HG
LC
HC
: External force in X direction applied to work piece and finger [N]
: External force in Y direction applied to work piece and finger [N]
: External force in Z direction applied to work piece and finger [N]
: Distance from finger attachment surface to gripping point (Gripping point) [mm] [Note 1]
: Distance from center of fingers to gripping point (Overhang) [mm] [Note 1]
: Distance from finger attachment surface to center of gravity for
work piece and finger attachment [mm]
: Distance from finger center to center of gravity for work piece
and finger attachment [mm]
MIa
MIb
MOa
MOb
MOc
Ma
Mb
Mc
: Moment in Ma direction generated on fingers due to grip force [N˜m]
: Moment in Mb direction generated on fingers due to grip force [N˜m]
: Moment in Ma direction generated on fingers due to external force [N˜m]
: Moment in Mb direction generated on fingers due to external force [N˜m]
: Moment in Mc direction generated on fingers due to external force [N˜m]
: All moment in Ma direction generated on fingers [N˜m]
: All moment in Mb direction generated on fingers [N˜m]
: All moment in Mc direction generated on fingers [N˜m]
Note 1 For LGHG, have the values below as the upper limit. Exceeding the allowable range may
generate excessive moment on the finger sliding mechanism, which may be a cause of a bad
impact to the product life.
24
Upper Limit for Gripping Point LG and Overhang HG
20
15
10
L
Gripping point L [mm]
25
5
0
0
5
10
15
20
25
30
Overhang amount H [mm]
1. Specifications Check
30
H
Allowable Load and Allowable moment on Fingers(Note 2)
Maximum allowable load moment [N˜m](Note 3)
Allowable Load in
Mamax
Mbmax
Mcmax
Vertical [N]
FZmax
14
0.04
0.04
0.07
Note 2
Note 3
The graphs show the values for allowable load and allowable moment in static on one
finger.
The values for the allowable moment are those when the load is applied in one
direction only.
The values become a half when load is applied from in two directions.
(1) Moment generated on fingers due to grip force
1) Moment in Ma direction [MIa]
MIa = LG 1.5F
G ×10-3
2
FG : Grip force of gripper [N]
2) Moment in Mb direction [MIb]
1.5F
MIb = HG G ×10-3
2
FG : Grip force of gripper [N]
Refer to “1.2.5 Grip Force of Pick & Rotary Axis Equipped Type” for grip force FG.
As the grip force is a reference value, it is multiplied by 1.5 for the safety margin in the
moment calculation.
25
1. Specifications Check
(2) Moment generated on fingers due to external force
External force as well as grip force will be applied to the work piece and the finger attachment
in the movements such as moving straight or turning in the condition of the gripper being
attached on a Cartesian Robot, Articulated Robot or other actuators.
Have the following calculation.
‹ External force applied on work piece and finger attachment [FX, FY, FZ]
Figure out the following types of external force in three directions, X, Y and Z, applied on the
work piece and finger attachment considering the condition of gripper use, and sum up all
the values.
a) Weight of work piece and finger attachment
F=mg m : Mass of work piece and finger attachment [kg],
g: Gravitational acceleration [=9.8m/s2]
b) Inertial force in gripper moving straight
F=ma a : Acceleration/deceleration during transportation [m/s2]
c) Centrifugal force in gripper turning
F=mr Ȧ 2 r : Radius of turning [m], Ȧ : Angular velocity [deg/s]
Confirm that Fz is below the allowable load vertical direction, Fzmax.
‹ Moment generated on fingers due to external force
Figure out the moment in each direction due to external force FX, FY and FZ.
1) Moment in Ma direction [MIa] [Moa]
Moa = LcFx × 10-3
2) Moment in Mb direction [Mob]
Mob = HcFx × 10-3
3) Moment in Mc direction [Moc]
Moc = LcFY × 10-3 + HcFz × 10-3
(3) All moment in each direction generated to fingers
Ma = MIa + Moa, Mb = MIb + Mob, Mc = Moc
Confirm that the value figured out in the calculation above is below the allowable load
moment.
(Note) Attempt to have the finger attachment minimized in size and weight even if it is in the
allowable range.
If the fingers are long and big in size and heavy in weight, the moment caused by an impact at
gripping may cause a performance drop or give a bad impact to the guide area.
26
1.4
1.4.1
Motor • Encoder Cables
Standard Type
CB-CT4-MAƑƑƑ
1. Specifications Check
[1] Motor Cable
ƑƑƑ shows the cable length. (Max 30m)
Example) 080 = 8m
[Minimum Bending Radius]
When used under moving condition: 51mm
When used in fixed condition:
34mm
4
3
2
1
CN3
4
3
2
1
CN4
4
3
2
1
CN5
B1
A1
B10
A10
M2
CN2
M1
4
3
2
1
CN1
M3
M4
L
CN1
Electric wire
color
CN2
Width
AWG18
Signal Name
Electric
wire color
PE
U
Pin No.
Pin No.
Signal Name
Green
1
A01
U
Red
Red
2
A02
V
White
V
White
3
B01
W
Black
W
Black
4
B02
PE
Green
A03
U
Red
Green
1
A04
V
White
CN3
PE
AWG18
U
Red
2
B03
W
Black
V
White
3
B04
PE
Green
Black
4
A05
U
Red
A06
V
White
1
B05
W
Black
Green
W
CN4
PE
AWG18
Green
U
Red
2
B06
PE
V
White
3
A07
U
Red
W
Black
4
A08
V
White
Green
1
CN5
PE
AWG18
U
Red
2
V
White
3
W
Black
4
B07
W
Black
B08
PE
Green
A09
NC
-
A10
NC
-
B09
NC
-
B10
NC
-
Width
AWG18
27
[2] Encoder Cable
1. Specifications Check
CB-CT4-PAƑƑƑ
ƑƑƑ shows the cable length. (Max 30m)䢢
Example) 080 = 8m
[Minimum Bending Radius]
When used under moving condition: 44mm
When used in fixed condition:
29mm
1
26
13
1
26
13
14
1
26
13
14
1
26
13
CN3
PG2
14
CN2
PG1
14
B1
A1
B25
A25
CN1
L
CN2
Electric
Width
Signal Name
Wire Color
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
AWG18
NC
(Soldered)
NC
NC
NC
NC
SRD+
Orange
SRDGreen
BAT+
Purple
BATGray
Vcc
Red
GND
Black
BKRBlue
BKR+
Yellow
The shield is clamped to the hood
Pin No.
10
11
12
13
26
25
24
23
9
18
19
1
2
3
4
5
6
7
8
14
15
16
17
20
21
CN3: Same as CN2
CN4: Same as CN2
CN5: Same as CN2
28
PG4
CN5
PG3
CN4
Pin No.
Signal Name
A01
A02
A03
A04
A05
B01
B02
B03
B04
B05
A06
A07
A08
A09
A10
B06
B07
B08
B09
B10
A11
A12
A13
A14
A15
B11
B12
B13
B14
B15
A16
A17
A18
A19
A20
B16
B17
B18
B19
B20
A21
A22
A23
A24
A25
B21
B22
B23
B24
B25
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
CN1
Electric Wire
Color
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
-
Width
AWG26
1.4.2
Rotary Axis Equipped Type
[1] Motor Cables
4
3
2
1
CN2
M1
4
3
2
1
CN3
M2
4
3
2
1
CN4
M3
4
3
2
1
CN5
M4
4
3
2
1
CN6
M5
1. Specifications Check
ƑƑƑ shows the cable length. (Max 30m)
Example) 080 = 8m
CB-CT4R-MAƑƑƑ
[Minimum Bending Radius]
When used under moving condition: 51mm
When used in fixed condition:
34mm
B1
A1
B10
A10
CN1
L
Width
Signal
Name
AWG18
PE
U
V
W
CN2
Electric Wire
Color
Green
Red
White
Black
Pin No.
Pin No.
1
2
3
4
Signal
Name
A01
A02
B01
B02
A03
A04
B03
B04
A05
A06
B05
B06
A07
A08
B07
B08
A09
A10
B09
B10
U
V
W
PE
U
V
W
PE
U
V
W
PE
U
V
W
PE
U
V
W
PE
CN3
AWG18
PE
U
V
W
Green
Red
White
Black
1
2
3
4
CN4
AWG18
PE
U
V
W
Green
Red
White
Black
1
2
3
4
CN5
AWG18
PE
U
V
W
Green
Red
White
Black
1
2
3
4
CN6
AWG18
PE
U
V
W
Green
Red
White
Black
1
2
3
4
CN1
Electric
Wire Color
Width
Red
White
Black
Green
Red
White
Black
Green
Red
White
Black
AWG18
Green
Red
White
Black
Green
Red
White
Black
Green
29
[2] Encoder Cable
CB-CT4R-PAƑƑƑ
1. Specifications Check
1
26
13
14
1
26
13
14
1
26
13
14
1
26
13
Width
AWG18
(Soldered)
Signal
Name
Orange
Green
Purple
Gray
Red
Black
Blue
Pin No.
10
11
12
13
26
25
24
23
9
18
19
1
2
3
4
5
6
7
8
14
15
16
17
20
21
CN4: Same as CN2
CN5: Same as CN2
CN6
Electric
Wire Color
NC
NC
E24V
0V
30
B25
A25
L
CN2
Electric
Wire Color
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
SRD+
SRDBAT+
BATVcc
GND
BKR-
CN3: Same as CN2
AWG18
(Soldered)
A1
CN1
BKR+
Yellow
The shield is clamped to the hood
Width
B1
[Minimum Bending Radius]
When used under moving condition: 54mm
When used in fixed condition:
36mm
PG5
CN6
14
ƑƑƑ shows the cable length. (Max 30m)䢢
Example) 080 = 8m
PG4
CN5
13
PG3
CN4
1
26
PG2
CN3
14
PG1
CN2
LS
CREEP
OT
RSV
NC
NC
NC
NC
NC
NC
NC
NC
NC
SRD+
SRDBAT+
BATVcc
GND
NC
Signal
Name
White /Blue
White /
Yellow
White / Red
Orange
Green
Purple
Gray
Red
Black
-
NC
The shield is clamped to the hood
Pin No.
10
11
12
13
26
25
24
23
9
18
19
1
2
3
4
5
6
7
8
14
15
16
17
20
21
Pin No.
Signal Name
A01
A02
A03
A04
A05
B01
B02
B03
B04
B05
A06
A07
A08
A09
A10
B06
B07
B08
B09
B10
A11
A12
A13
A14
A15
B11
B12
B13
B14
B15
A16
A17
A18
A19
A20
B16
B17
B18
B19
B20
A21
A22
A23
A24
A25
B21
B22
B23
B24
B25
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
LS
Vcc
GND
F.G
N
24V
CN1
Electric Wire
Color
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
White / Red
Red
Black
Ground
White / Yellow
White /Blue
Width
AWG26
1.4.3
Pick & Rotary Axis Equipped Type
[1] Motor Cable
1. Specifications Check
ƑƑƑ shows the cable length. (Max 30m)䢢
Example) 080 = 8m
CB-CT4R-MAƑƑƑ
[Minimum Bending Radius]
When used under moving condition: 51mm
When used in fixed condition:
34mm
CN2
M1
CN3
M2
B1
A1
B10
A10
CN4
M3
CN1
CN5
M4
CN6
M5
L
Width
Signal
Name
AWG18
PE
U
V
W
CN2
Electric Wire
Color
Green
Red
White
Black
Pin No.
Pin No.
1
2
3
4
Signal
Name
A01
A02
B01
B02
A03
A04
B03
B04
A05
A06
B05
B06
A07
A08
B07
B08
A09
A10
B09
B10
U
V
W
PE
U
V
W
PE
U
V
W
PE
U
V
W
PE
U
V
W
PE
CN3
AWG18
PE
U
V
W
Green
Red
White
Black
1
2
3
4
CN4
AWG18
PE
U
V
W
Green
Red
White
Black
1
2
3
4
CN5
AWG18
PE
U
V
W
Green
Red
White
Black
1
2
3
4
CN6
AWG18
PE
U
V
W
Green
Red
White
Black
1
2
3
4
CN1
Electric
Wire Color
Width
Red
White
Black
Green
Red
White
Black
Green
Red
White
Black
AWG18
Green
Red
White
Black
Green
Red
White
Black
Green
31
[2] Encoder Cable
ƑƑƑ shows the cable length. (Max 30m)䢢
Example) 080 = 8m
CN2
Width
AWG18
(Soldered)
1
26
13
14
1
26
13
14
1
26
13
14
1
26
13
CN2
Electric
Wire Color
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
SRD+
SRDBAT+
BATVcc
GND
BKR-
A1
B25
A25
CN1
L
Signal
Name
Orange
Green
Purple
Gray
Red
Black
Blue
BKR+
Yellow
The shield is clamped to the hood
Pin No.
10
11
12
13
26
25
24
23
9
18
19
1
2
3
4
5
6
7
8
14
15
16
17
20
21
CN3: Same as CN2
CN4: Same as CN2
CN5: Same as CN2
CN6: Same as CN2
32
B1
PG5
CN6
14
PG4
CN5
13
PG3
CN4
1
26
PG2
CN3
14
[Minimum Bending Radius]
When used under moving condition: 44mm
When used in fixed condition:
29mm
PG1
1. Specifications Check
CB-CT4PR-PAƑƑƑ
Pin No.
Signal Name
A01
A02
A03
A04
A05
B01
B02
B03
B04
B05
A06
A07
A08
A09
A10
B06
B07
B08
B09
B10
A11
A12
A13
A14
A15
B11
B12
B13
B14
B15
A16
A17
A18
A19
A20
B16
B17
B18
B19
B20
A21
A22
A23
A24
A25
B21
B22
B23
B24
B25
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
BAT+
BATSD
-SD
Vcc
GND
F.G
BKBK+
CN1
Electric Wire
Color
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
Red
Black
Ground
Blue
Yellow
Purple
Gray
Orange
Green
-
Red
Black
Ground
Blue
Yellow
Width
AWG26
2. Installation
2.1
Transportation
Handling of the Robot
[1] Handling of the Robot
Pay attention to the following when carrying the High-Speed Orthogonal Robot CT4. (described as
CT4 from now on)
(1)
When delivered with the axes attached at the IAI factory
It will be delivered in a package with an outer case fixed to a wooden base. The sliders are fixed so
they will not accidently move while in transportation.
x Do not damage or drop. The package is not applied with any special treatment that
enables it to resist an impact caused by a drop or crash.
x Consider an appropriate method for transportation.
x When suspending the package using ropes, pass the ropes from underneath the
reinforcement frames at the bottom of the base. When lifting with a forklift, also place the
forks underneath the base.
x Do not apply an impact on the package or let it bounce when putting it down.
x Do not step or sit on the package.
x Do not put any load that may cause a deformation or breakage of the package.
33
2. Installation
2.1.1
2. Installation
(2)
Handling after Unpackaged
Follow the instructions below to transport the unpackaged CT4 that was delivered from our factory
in assembled form.
x Secure the sliders to prevent sudden movement during transport.
x Do not apply an impact of 0.3G or more during transportation.
x When using a crane, attach the enclosed eyebolts at the positions shown in the figure
below (three points) to hang a string rope to pull up. Pay attention to the balance when
carrying. Do not apply vibration or impact.
Hanging hook with
locking feature
String’ rope, etc.
Eyebolt
Eyebolt
Eyebolt
Danger: Use the enclosed eyebolts to tighten the unit firmly.
It is extremely dangerous to use unspecified eyebolts or to have bolts not
tightened firmly enough since it may cause a drop of the product. Also, for
those tools such as a crane and hook, choose standardized ones with
enough stiffness.
x Be sure not to apply a load on any of the actuator brackets or covers or on the connector
box.
Also, avoid the cables being pinched or caused an excessive deformation.
2.1.2
Handling of the Robot Mounted on Mechanical Equipment (System)
The following are the cautions for when transporting the SCARA robots installed in the
machinery equipment (system) in the whole system.
x Carry the robot with stoppers attached on J1 and J2 axes.
x When suspending the mechanical equipment (system) with ropes, avoid applying force
to the SCARA robot, connector box, etc. Also, avoid the cables being pinched or caused
an excessive deformation.
34
2.2
Installation and Storage/Preservation Environment
[1] Installation Environment
x Where the robot receives radiant heat from strong heat sources such as heat treatment
furnaces
x Where the ambient temperature exceeds the range of 0 to 40qC
x Where the temperature changes rapidly and condensation occurs
x Where the relative humidity exceeds 85% RH
x Where the robot receives direct sunlight
x Where the robot is exposed to corrosive or combustible gases
x Where the ambient air contains a large amount of powder dust, salt or iron (at level exceeding
what is normally expected in an assembly plant)
x Where the robot is subject to splashed water, oil (including oil mist or cutting fluid) or chemical
solutions
x Where the robot receives impact or vibration
x Where the altitude is more than 2000m
If the robot is used in any of the following locations, provide sufficient shielding measures:
x Where noise generates due to static electricity, etc.
x Where the actuator is subject to a strong electric or magnetic field
x Where the actuator is subject to ultraviolet ray or radiation
[2] Storage/Preservation Environment
x The storage/preservation environment should be similar to the installation environment. In
addition, make sure condensation will not occur when the robot is to be stored or preserved
for a long period of time.
x Unless specified, we do not include drying agents when shipping the actuator. If you are
storing the robot in an environment where condensation might occur, you must treat the entire
shipping box, or treat the robot itself after unpacking, to prevent condensation.
x The unit can withstand temperatures up to 60ºC during a short storage/preservation period,
but only up to 50ºC if the storage/preservation period is longer than one month.
x The robot should be lying flat during storage/preservation.
If the robot is to be stored in a packed state, follow the specified robot position if indicated.
35
2. Installation
The robot should be installed in a location other than those specified below.
In general, the installation environment should be one in which an operator can work without
protective gear.
Also provide sufficient work space required for maintenance inspection.
2.3
How to Install
Shown below is how to install High-Speed Orthogonal Robot CT4.
2.3.1
Installation of the Main Body
2. Installation
Ɣ There are datum surfaces for attachment on the frame.
Ɣ There are through holes equipped on the base so the unit can be attached from the top of
the base on the frame.
Ɣ Also, consider enough space necessary for maintenance work such as replacement and
inspection.
A
30
A
280
3-M10
(for eyebolt attachment at transportation)
Through holes for installation
12-φ11 through
φ23 Counterbore, Depth 22
35
(100)
(35)
(100)
100
35
100
φ 11
φ 23
200
B
Datum
Surface
B
Datum Surface
20
200
350
200
Apply the socket head cap screw indicated in the table below suitable for the platform material.
Apply a high-tensile bolt with the performance of ISO-10.9 or more.
<When the platform material is steel>
Bolts to be used : M10×40 (Effective length of thread engagement 10 or more),
Washers to be used : M10 (10.5×18×2)
Tightening Torque : 60N • m
<When the platform material is aluminum>
Bolts to be used : M10×50 (Effective length of thread engagement 20 or more),
Washers to be used : M10 (10.5×18×2)
Tightening Torque : 60N • m
Danger: Use the specified bolts. Pay special attention when selecting the screw length.
Using an unspecified bolt or a bolt with inappropriate length may cause damage
to the tapped holes or inefficiency in the attachment strength, which may result
not only in abnormal noise, vibration, malfunction or drop in product life, but also
in such critical accidents as to destroy the peripherals including the CT4 main
body and work piece or in death because of the CT4 main body being unstable.
36
2.3.2
Datum Surface
Ɣ The side faces on the base is referred as the datum surface for the slider’s run.
Use these surfaces as the datum surfaces for mounting.
2. Installation
A
A
Datum Surface
Datum Surface
30
280
3-M10
(for eyebolt attachment at transportation)
35
(100)
(35)
(100)
100
35
100
φ 11
φ 23
200
B
Datum
Surface
B
Datum Surface
20
200
350
200
37
2.3.3
Platform for Installation
2. Installation
Ɣ The attachment surface should be a machined surface or a flat surface that possesses an
equivalent accuracy, and the flatness should be 0.05mm/m or less.
Ɣ The platform should possess a structure that the robot can be installed in the horizontal
orientation.
Ɣ The platform to mount the robot on receives large reaction forces. Shown in the table below
is the transient maximum reaction force (reference) applied to each axis when 1kg is loaded
assuming the robot moves at the maximum speed and acceleration.
Prepare a platform that is stiff enough. Affix the robot with items such as anchor bolts to
install it solidly so the CT4 would not move with the movement of the robot.
Axis
X-axis
Y-axis
Z-axis
Reaction Force
660N
235N
85N
Ɣ Prepare a platform with its specific frequency at 75Hz or more.
[Example for Installation Platform]
Shown in the figure below is an example for an installation platform.Build an installation
platform by referring to it.
0.05/1000
25 or more
□100 x 100 x t6.0
(Steel Squares)
800 or less
900
38
500 or less
2.3.4
Attachment of Transported Objects
[1] Standard Type: Attachment to Z-Axis
Table
φ5H7 depth 5
40
6
5
40
+ 0.012
depth
0
5 H7
(194)
Tapped Hole
6-M5 depth 6
Oblong Hole
Reamed Hole
24
50
55
Tapped Hole
3-M6 depth 10
14
6.5
29
Tightening screws
x For attaching using male screws, use a hex socket head cap screw.
x Use of high-tension bolts meeting at least ISO-10.9 is recommended.
x Have the length of thread engagement approximately 1.8 times the nominal diameter.
39
2. Installation
x There are tapped holes on the table and the end of the Z-axis. Affix the transported object
here.
x The way to affix follows the installation of the main unit.
x There are reamed holes and slotted holes on the top surface of the table. Use these reamed
holes and slotted holes if repeatability of attaching and detaching is required. Also, if small
readjustment such as the perpendicularity is required, use one of the reamed holes on the
table for the readjustment.
x Refer to the figure below for the screwing depth and reamed depth. Screwing further down
than indicated in the figure may destroy the tapped hole or lower the reinforcement of the
attachment of the work part, result not only in the drop of the accuracy, vibration or abnormal
noise, but in unexpected accidents.
There are restrictions in the moment and load overhang length when attaching a load on the table.
Allowable Overhang Length
Load length L [mm]
X, Y, Z directions 50
2. Installation
Dynamic Allowable Moment[N㺃m]
Ma
Mb
Mc
6.4
9.2
14.2
ᵫᶁ
ᵫᶀ
40
ᵫᵿ
[2] Rotary Axis Equipped Type: Attachment to R-Axis
Ɣ Use such tools as split cramp or locking assemblies when attaching such a thing as an arm or
a tool on the rotary axis.
Power lock, etc.
2. Installation
Tool attachment
plate
To attach a tool such as
a gripper to the end
Ɣ There is a limitation on the moment of inertia and the moment to the attachment.
Item
Performance
0.0002kg㺃m2 (2kg㺃cm2)
Allowable Moment of Inertia
1.2N㺃m
Allowable moment
(Note) The cables and air pipes on the tool can also be a load depending on the layout.
Consider also the load of cables and pipes for the moment of inertia and the moment
on the attached tool and have them not to exceed the allowable values. Also, pay
attention to how the cables and air pipes are fixed.
Ɣ Attach the work on the end of the rotary axis with care that the center of its gravity would not
offset from the output axis.
Ɣ The angle of the two parallel surfaces on the output axis is adjusted to
come to ±10deg or less after home-return operation is complete in the
setting at the delivery.
In case that the use with precise facing is necessary, adjust the angle
with Each Axis Parameter No. 12 (Home Preset Value) on
XSEL-PCT/QCT Controller.
(The repeatability of the width between two faces is ±0.025deg)
41
[3] Pick & Rotary Axis Equipped Type : Attachment to PR Axis
Please prepare the finger attachment separately.
[Dimensions on Finger Attachment]
2. Installation
8.4
8.4
2.7
3
1.5
1
8.3
8.4
2
2
2- 1.5 h7
5.4 (Pin distance when closed)
home position of gripping
9.4 (Pin distance when open)
Nominal
thread size
M3
M2 depth 3
11.4 (M2 distance when closed)
34
Tightening Torque
In the case that steel is used for
In the case that aluminum is used for
the screw seating surface
the screw seating surface
1.54N㺃m
0.83N㺃m
(0.16kgf㺃m)
(0.09kgf㺃m)
About Tightening Screws
• Use a hex socket head cap screw for the attachment to the base.
• It is recommended to use high-tensile screws with ISO-10.9 or more.
• Make sure to have the effective length of screw engagement described below or more for the
tightening of a screw and a female screw.
When female screw is on steel ĺ Thread length same as nominal diameter
When female screw is on aluminum ĺ Thread length 1.8 times longer them nominal diameter
Caution: Pay special attention when selecting the screw length. In case that an inappropriate
length of a bolt is applied, it may cause a drop in the operation accuracy or an
unexpected accident due, insufficient strength of actuator attachment or an
interference with the operating area.
42
[Positioning of Finger Attachmentin Open/Close and Perpendicular Direction
For improvement of finger attachment accuracy and the repeatability of the attachment, it is
recommended to have a positioning by attaching at two points, positioning pin and two sides
of the finger, as shown below.
Open/close direction
2. Installation
Positioning pin (Finger fixing)
Positioning in
open/close direction
φ1.5
Finger attachment
Fixing screw
M2
Perpendicular
direction
One side hitting surface
Positioning in
perpendicular direction
Finger
Caution: When attaching or detaching the finger attachment to the finger, hold the finger
attachment with a tool such as a wrench to tighten the attachment screw to avoid
load being applied to the guide area.
43
2.3.5
Air Pipes on the Rotation Axis
2. Installation
The air tube (I4) is laid inside the Z cover through inside the cables via the joint on the back side of
the frame. Join it to the piping on the Z cover. Also, the T-slot on the Z-axis and rotation axis can
be utilized to fix the air pipes. When piping, pay attention to the interference with the moving parts
when operating the Z-axis, and also pay attention not to pinch the pipes.
Air pipe: 2 points of φ4 are
provided along Z-axis
Partition plug (φ4 × 2)
for air pipe connection
44
M cable
PG cable
3. Connecting to the Controller
For the controller, those other than the controller dedicated for CT4 cannot be used.
Using other controllers may cause a problem such as burning the product, ignition or generating
heat.
Use the dedicated cables enclosed in the package when connecting of the CT4 and the controller.
CT4 Actuator
Dedicated Connection Cables
(Connect the CT4 with the dedicated controller)
Regenerative
Resistor Unit
2 Units
Dedicated Controller
XSEL-PCT, QCT
Standard Type
y Motor Cable
CB-CT4-MAƑƑƑ
y Encoder Cable
CB-CT4-PAƑƑƑ
Rotary Axis Equipped Type
y Motor Cable
CB-CT4R-MAƑƑƑ
y Encoder Cable
CB-CT4R-PAƑƑƑ
Pick & Rotary Axis Equipped Type
y Motor Cable
CB-CT4R-MAƑƑƑ
y Encoder Cable
CB-CT4PR-PAƑƑƑ
Standard Type and
Pick & Rotary Axis Equipped Type
r = 51mm or more (Movable Use)
r = 34mm or more (Fixed Use)
Rotary Axis Equipped Type
r = 54mm or more (Movable Use)
r = 36mm or more (Fixed Use)
ƑƑƑ shows the cable length.
The max. length should be 30m.
Example) 080 = 8m
45
3. Connecting to the Controller
[XSEL-PCT/QCT Connecting to the Controller]
Warning: For wiring, please follow the warnings stated below. When constructing a
system as the machinery equipment, pay attention to the wiring and
connection of each cable so they are conducted properly. Not following them
may cause not only a malfunction such as cable breakage or connection
failure, or an operation error, but also electric shock or electric leakage, or
may even cause a fire.
3. Connecting to the Controller
• Use dedicated cables of IAI indicated in this instruction manual. Contact us if you
wish to have a change to the specifications of the dedicated cables.
• Make sure to turn the power off in the process of power line or cable connection or
disconnection.
• Do not attempt to cut a dedicated cable with connectors on both ends to extend,
shorten or re-joint it.
• Hold the dedicated cable to avoid mechanical force being applied to the terminals and
connectors.
• Use a cable pipe or duct to have an appropriate protection when there is a possibility
of mechanical damage on a dedicated cable.
• In case a dedicated cable is to be used at a moving part, make sure to lay out the
cable without applying any force to pull the connector or extreme bend on the cable.
Do not attempt to use the cable with a bending radius below the allowable value.
• Make certain that the connectors are plugged properly. Insufficient connection may
cause an operation error, thus it is extremely risky.
• Do not lay out the cables to where the machine runs over them.
• Pay attention to the cable layout so it would not hit peripherals during an operation. In
case it does, have an appropriate protection such as a cable track.
• When a cable is used hanging on the ceiling, prevent an environment that the cable
swings with acceleration or wind velocity.
• Make sure there is not too much friction inside the cable storage equipment.
• Do not apply radiated heat to power line or cables.
• Have a sufficient radius for bending, and avoid a bend concentrating on one point.
Steel Strap
(Piano Wire)
Tie them up softly.
• Do not let the cable bend, kink or twist.
46
• Do not pull the cable with a strong force.
3. Connecting to the Controller
• Pay attention not to concentrate the twisting force to one point on a cable.
• Do not pinch, drop a heavy object onto or cut the cable.
• When a cable is fastened to affix, make sure to have an appropriate force and do not
tighten too much.
Do not use spiral tube in any
position where cables are bent
frequently.
• PIO line, communication line, power and driving lines are to be put separately from
each other and do not tie them together. Arrange so that such lines are independently
routed in the duct.
Power Line
Duct
I/O Line
(Flat Cable, etc.)
47
3. Connecting to the Controller
Follow the instructions below when using a cable track.
• If there is an indication to the cable for the space factor in a cable track, refer to the
wiring instruction given by the supplier when storing the cable in the cable track.
• Avoid the cables to get twined or twisted in the cable track, and also to have the
cables move freely and do not tie them up. (Avoid tension being applied when the
cables are bent.)
Do not pile up cables. It may cause faster abrasion of the sheaths or cable breakage.
48
4. Operation
4.1
4.3
Unlike other rotary axes of IAI, the revolution axis of Pick & Rotary Axis does not conduct the
mechanical end search in home-return operation.
It goes to the home position without having a reversing operation from the stop position.
Home Position Angle of Gripper on Pick & Rotary Axis
4. Operation
4.2
Home Return of Pick & Rotary Axis
The gripper after the home-return operation is adjusted in our factory to be +/- 1deg.
(The repeatability of the orientation of the gripper is +/-0.025deg)
Program of Pick & Rotary Axis (XSEL-PCT/QCT Controller)
(1) Revolution Part
It is the same as the existing operation programs. Set the rotation angle to the 5 th axis in the
position table, and run with operation commands such as MOVP.
(2) Gripper
It opens when Virtual Output Port 7305 (5th Gripper Release output) is ON and closes when
it is OFF.
BTON 7305 : Open
BTOF 7305 : Close
[Refer to the instruction manuals of XSEL-P/Q/PCT/QCT controller for details]
49
5. Maintenance Inspection
5.1
Inspection Items and Inspection Schedule
Have maintenance inspections following the intervals below.
8 hours per day is assumed as the operation condition
Have inspections more frequently if the operation frequency is high for night and day continuous
operation, etc.
Visual inspection
Internal Check
Grease supply*1
except for PR Axis
gripper
Grease supply*2
on PR axis
gripper
5. Maintenance Inspection
At startup
ż
inspection
1 month after
start of
ż
ż
operation
6 months after
start of
ż
ż
ż
ż
operation
1 year after
start of
ż
ż
ż
ż
operation
Every 6
months
ż
ż
ż
ż
thereafter
*1 In case the distance to run reaches 3,000km within 6 months, supply grease in every
3,000km.
*2 In case the times to open and close the gripper on PR Axis reaches two million times within
six months, supply grease in every two million times.
Caution: If the actuators are operated back and forth repeatedly over a distance of the
30mm or less at X1, X2, Y, and Z axes, the oil film created by the grease may be
broken. To keep operating in this condition may cause abnormal noise and
vibration, resulting in a malfunction to cause flaking. It is recommended to have 5
cycles of back and forth operation in a distance more than 50mm after every
5,000 to 10,000 rounds of the short distance operation. A layer of the grease will
recover.
[Period for Replacement of Replacement Parts (Reference)]
Refer to the following table for the period to replace the parts for Pick & Rotary Axis.
Replacement Parts
Period for Replacement (Reference)
Solenoid
Spring
Belt
50
4 million times of open and close, abrasion on solenoid plunger,
drop in open force
4 million times of open and close, drop in open force
When the gear and belt area show obvious friction.
When swelling occurs as a result of oil adhesion.
When damages such as a crack occurs on the belt gear and back
side.
When the belt breaks.
5.2
Visual Inspection
For the visual inspection, check the appearance following items.
Main Body
Looseness of attachment screws
Cables
Scratches, proper connection of connectors
Overall
Vibration or abnormal noise
x For Z-axis, it can be considered that the grease applied to the guide may drop depending on
the environment. Clean it up and have a grease supply when necessary.
5.3
Please clean the external body at any time.
When cleaning, wipe with a soft cloth to remove dust and dirt.
Do not blow compressed air so dust would not get in from gaps.
Do not apply petroleum solvent since it may damage the resin or painted surfaces.
When extremely dirty, wipe it off firmly with cloth that neutral detergent or alcohol is applied
on.
51
5. Maintenance Inspection
x
x
x
x
x
Cleaning
5.4
Internal Inspection
Turn OFF the power, remove the screw cover and have a visual inspection.
Include the items below in the internal check.
Main Body
5. Maintenance Inspection
Ball Screw
Guide
Looseness of attachment
screws
Condition and dirt of
lubricant
In the inspection, check if dust is involved inside and the condition of the lubricant.
Even if the grease looks brown, it will be fine as long as the sliding area seems wet and shiny.
If the grease is mixed with dust and dirty or has no shiny appearance, or if the grease has lost its
efficacy due to prolonged use, clean the applicable area and then replenish the grease.
Described below is how to check inside.
[X1-axis, X2-axis, Y-axis]
1) Detach the four screws holding the screw cover (at the points where circled) and remove the
screw cover.
Screw Cover
Y-axis
X1-axis
X2-axis
Tool to use: Hex Wrench 2.5mm-sized
2) Check inside.
3) After the work is finished, attach the screw cover and tighten the screws.
Tightening Torque:88.7N㺃cm
52
[Z-axis]
1) Remove the four screws holding the Z-axis cover. Detach the Z-axis cover.
5. Maintenance Inspection
Z-axis
Tool to use: Hex Wrench 2.5mm-sized
2) Turn ON the controller, put the brake switch up (to RLS side) to release the brake and move
the table down. Turn OFF the controller.
BrakeSwitch
Table
53
3) Detach the four screws holding the screw cover (at the points where circled) and remove the
screw cover.
5. Maintenance Inspection
Screw Cover
Tool to use: Hex Wrench 2.5mm-sized
4) Check inside.
5) After the work is finished, attach the screw cover and tighten the screws.
Tightening Torque : 83N㺃cm
6) Attach the Z-axis cover.
Caution: Be careful in case a hand or a work piece is attached and the Z-axis brake is
released. It may cause an injury or may damage the hand or work piece by
dropping it.
5.5
Internal Cleanup
x When cleaning, wipe with a soft cloth to remove dust and dirt.
x Do not blow compressed air so dust would not get in from gaps.
x Do not use oil type solvent, neutral detergent or alcohol.
54
5.6
Grease Supply
5.6.1
Grease Applied
The following grease is applied when the product is shipped out from IAI factory.
Ball Screw
Guide
Bearing
Kyodo Yushi
Maltemp ET-R
No.2
(Urea-based)
5.6.2
How to Apply Grease
[1] X1, X2-axis
1) Turn OFF the power to the controller and slide the Y-axis manually with hands to the
direction shown with an arrow below to move it away a little from the motor side. You will be
able to see the grease nipples for X1-axis and X2-axis.
Y-axis
Grease Nipple
(Note) Make sure to use a grease gun that is applicable
for the grease nipple inlet diameter shown below.
Nipple inlet diameter [mm]
I6.0
2) Supply grease to the grease nipple either on the right or left by using a grease gun.
Grease supply volume (reference)
3cc to 4cc
Recommended grease gun
MG70
Nozzle
N model
Supplier
THK
55
5. Maintenance Inspection
Warning: Do not attempt to apply any other type of grease than described above. It may not
only impact the performance of the grease, but also may damage the CT4.
3) Move the X1, X2-axis several times with hand.
5. Maintenance Inspection
Caution: Ɣ Applying too much grease will increase the stirring resistance and may make
the ball screw easy to generate heat or make the excess grease on the ball
screw splash around with the rotation and dirt the surrounding. Do not supply
grease more than three or four times with a grease gun.
Ɣ In case the grease got into your eye, immediately go to see the doctor to get
an appropriate care.
After finishing the grease supply work, wash your hands carefully with water
and soap to rinse the grease off.
[2] Y-axis
1) For the Y-axis, there is a grease nipple on the back side.
Y-axis
Grease Nipple
(Note) Make sure to use a grease gun that is applicable
for the grease nipple inlet diameter shown below.
Nipple inlet diameter [mm]
I6.0
2) Supply grease to the grease nipple either on the right or left by using a grease gun.
Grease supply volume (reference)
3cc to 4cc
Recommended grease gun
MG70
Nozzle
N model
Supplier
THK
3) Turn OFF the controller and move the Y-axis with hand for several rounds.
Caution: Ɣ Applying too much grease will increase the stirring resistance and may make
the ball screw easy to generate heat or make the excess grease on the ball
screw splash around with the rotation and dirt the surrounding. Do not supply
grease more than three or four times with a grease gun.
Ɣ In case the grease got into your eye, immediately go to see the doctor to get
an appropriate care.
After finishing the grease supply work, wash your hands carefully with water
and soap to rinse the grease off.
56
[3] Z-axis
1) Remove the four screws holding the Z-axis cover. Detach the Z-axis cover.
5. Maintenance Inspection
Z-axis
Tool to use: Hex Wrench 2.5mm-sized
2) Turn ON the controller, put the brake switch up (to RLS side) to release the brake and move
down the table. Turn OFF the controller.
BrakeSwitch
Table
57
3) Detach the four screws holding the screw cover (at the points where circled) and remove the
screw cover.
5. Maintenance Inspection
Screw Cover
Tool to use: Hex Wrench 2.5mm-sized
4) Apply grease to the ball screw with finger. Wipe off the excess grease.
Ball Screw
5) Move the table several times with hand.
6) After the work is finished, attach the screw cover and tighten the screws.
Tightening Torque: 83N㺃cm
7) Attach the Z-axis cover.
Caution: Ɣ Be careful in case a hand or a work piece is attached and the Z-axis brake is
released. It may cause an injury or may damage the hand or work piece by
dropping it.
Ɣ In case the grease got into your eye, immediately go to see the doctor to get
an appropriate care.
After finishing the grease supply work, wash your hands carefully with water
and soap to rinse the grease off.
58
[4] PR-axis
1)
Remove the three screws holding the pulley cover. Detach pulley cover.
Pulley cover
Tools to use : Precision Phillips Screwdriver
2)
Remove the two screws holding the side plate. Detach the side cover.
(Note) There is a spring inside on one side. Pay attention not to drop it.
Hex socket head cap screws M2×5
Tool to use: Hex Wrench 1.5mm-sized
Side cover
3)
Push the grease along the guide (points with arrows) with using a spatula, or supply it with
using a grease injector and move the guide back and forth to spread over the grease.
Wipe away the excess grease and splashed grease at last.
59
5. Maintenance Inspection
Cross recessed screw for precision instrument M2.6×4
5. Maintenance Inspection
4)
Supply the grease to the link part (points with arrows) with using a spatula, a rolling pin or a
grease injector and spread it over.
Wipe away the excess grease and splashed grease at last.
Please work of 4) Remove the side plate of the other side at the same.
5)
Attach the side plate and fix it with the two screws.
Hex socket head cap screws M2×5
Tool to use: Hex Wrench 1.5mm-sized
Tightening Torque : 25.4N㺃cm
6)
Attach the pulley cover and fix it with the three screws.
Thin-head small screw M2×6
Pulley cover
Tool to use: Hex Wrench 1.5mm-sized
Cross recessed screw for precision instrument M2.6×4
Tools to use : Precision Phillips Screwdriver
60
5.7
Motor Replacement Process
Shown in the description below is how to replace the motor in such a case that it gets a wire
broken.
The screws and other components detached for the replacement will be necessary when rebuild
the product. Prepare a storage box beforehand to keep the components in it.
Caution: It is necessary to have the controller turned ON and operate the servo to turn it
ON and OFF for the operation of the brake (Z-axis) when replacing the motor.
Pay special attention when working with the power supply ON.
Motor Replacement for X1-Axis and X2-Axis
5. Maintenance Inspection
5.7.1
[Items Required for Replacement Work]
x Motor Unit for Replacement
Model No. : M-CGXY-TMA400-TA-CO
Model No. : HDS-1
x Heat Radiation Sheet (Note 1): Two pieces
x Hex Wrench: 2.5mm, 3mm and 4mm-sized
Note 1
Prepare it because it is likely to be torn in motor replacement work.
[Procedure]
(1)
Detaching the Motor Cover
Turn OFF the power to the controller and disconnect the motor cable and encoder cable.
Y-axis and Z-axis can be at any position.
Detach the four screws affixing motor cover with a hex wrench. Detach the motor cover.
X1-axis
X2-axis
Tool to use: Hex Wrench 2.5mm-sized
61
5. Maintenance Inspection
(2)
Detaching the Screw Cover
Detach the four screws holding the screw cover (at the points where circled) and remove the
screw cover.
Screw Cover
Tool to use: Hex Wrench 2.5mm-sized
(3)
Detaching the Motor
1) Detach the four screws holding the plate at the back and remove the plate.
Tool to use: Hex Wrench 4mm-sized
2) There are connectors of the motor cable and encoder cable stored inside.
Pull the connectors out and unplug them.
62
3) Detach the two screws (at the points where circled) holding the plate of the heat radiation
sheet at the bottom of the motor.
Tool to use: Hex Wrench 3mm-sized
4) Turn OFF the controller and move the Y-axis to the direction shown with an arrow below
so you can see the coupling tightening screws (at the points where circled).Loosen the
coupling screw with the hex wrench.
Y-axis
Coupling
Tool to use: Hex Wrench 2.5mm-sized
63
5. Maintenance Inspection
5. Maintenance Inspection
5) Detach the four screws holding the motor (at the points where circled and two places at
the bottom) and remove the motor together with the plate on the bottom of the motor.
Tool to use: Hex Wrench 4mm-sized
6) It is likely that the heat radiation sheet attached on the plate at the bottom of the motor is
torn when removing the motor. In such a case, attach a new heat radiation sheet.
Plate on Motor Bottom
64
Heat Radiation Sheet
(4) Attaching the New Motor
1) Adjust the coupling on the new motor so the screw on it faces up.
Screw
Y-axis
Slider with the Y-axis mounted
7mm
65
5. Maintenance Inspection
2) Move the Y-axis and adjust it to the position where the clearance gets to 7mm as shown in
the figure.
5. Maintenance Inspection
3) Insert the motor together with the plate at the bottom of the motor, and temporarily tighten
the screws to hold the motor (at the circled places and 2 places on the bottom) with a hex
wrench.
Tighten the coupling tightening screw (at the circled places).
Coupling
Tool to use: Hex Wrench 4mm-sized
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 83N•cm
4) Tighten the four screws holding the motor (at the circled places and 2 places on the bottom).
66
Tool to use: Hex Wrench 4mm-sized
Tightening Torque : 342N•cm
5) Attach the two screws (at the points where circled) to hold the plate on the bottom of the
motor.
Tool to use: Hex Wrench 3mm-sized
Tightening Torque : 176N•cm
6) Joint the connectors and store the cables inside.
7) Tighten the four screws to hold the plate at the back to affix the plate.
Tool to use: Hex Wrench 4mm-sized
Tightening Torque : 207N•cm
67
5. Maintenance Inspection
5. Maintenance Inspection
(5)
(6)
(7)
68
Attaching the Screw Cover
Tighten the four screws holding the screw cover (at the points where circled) and remove the
screw cover.
Screw Cover
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 88.7N•cm
Attaching the Motor Cover
Attach the four screws to hold the motor cover to affix it.
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 88.7N•cm
Connection to the controller
Connect the connectors on the motor cable and encoder cable to match the connector
numbers on the connectors to those indicated on the controller.
5.7.2
Process to Replace the Motor for the Y-Axis
[Items Required for Replacement Work]
x Motor Unit for ReplacementModel No. : M-CGXY-TMA400-TA-CO
x Hex Wrench: 2.5mm, 3mm and 4mm-sized
[Procedure]
(1) Detaching the Motor Covers 1 and 2
Turn OFF the power to the controller and disconnect the motor cable and encoder cable.
X1-axis, Y2-axis and Z-axis can be at any position.
5. Maintenance Inspection
Detach the four screws holding the cable clamps on the top of Motor Cover 1, and remove
the cable clamps.
Y-axis
Motor Cover 1
Tool to use: Hex Wrench 2.5mm-sized
Detach the four screws holding Motor Cover 2, then another four holding Motor Cover 1 next,
and remove Motor Cover 1 and 2.
Motor Cover 1
Tool to use: Hex Wrench 3mm-sized
Motor Cover 2
Tool to use: Hex Wrench 2.5mm-sized
69
5. Maintenance Inspection
(2) Detaching the Motor
1) Detach the connectors of the motor cable and encoder cable.
2) Detach the four screws holding the screw cover (at the points where circled) and remove the
screw cover.
Screw Cover
Tool to use: Hex Wrench 2.5mm-sized
3) Move the Z-axis to a position where the coupling tightening screw can be seen.
Loosen the coupling tightening screw (at the circled places).
Z-axis
Coupling
Tool to use: Hex Wrench 2.5mm-sized
70
4) Detach the four screws holding the motor (at the points where circled and two places at the
bottom) and pull out the motor unit and the coupling to the direction indicated below with an
arrow.
Tool to use: Hex Wrench 4mm-sized
71
5. Maintenance Inspection
5. Maintenance Inspection
(3)
1)
2)
Attaching the New Motor
Adjust the coupling on the new motor so the screw on it faces up.
Screw
Move the Z-axis and adjust it to the position where the clearance gets to 7mm as shown in
the figure.
Z-axis
Slider with Z-axis mounted
7mm
72
3)
Slide in the motor to the main body and temporarily tighten the four screws to hold the motor
(at the circled places and 2 places on the bottom).
Tighten the coupling screw (at the circled places).
Tool to use: Hex Wrench 4mm-sized
Coupling
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 83N•cm
4)
Tighten the four screws affixing the motor (at the circled places and 2 places on the bottom).
Tool to use: Hex Wrench 4mm-sized
Tightening Torque : 342N•cm
73
5. Maintenance Inspection
5. Maintenance Inspection
5)
Join the connectors.
6)
Tighten the four screws holding the screw cover (at the points where circled) and attach the
screw cover.
74
Screw Cover
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 88.7N•cm
(4)
Attaching the Motor Covers 1 and 2
Attach the four screws to hold Motor Cover 1, then another four to hold Motor Cover 2 next,
to affix Motor Cover 1 and 2.
Motor Cover 1
Tool to use: Hex Wrench 3mm-sized
Tightening Torque : 207N•cm
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 88.7N•cm
Attach the cable clamps and tighten the four screws affixing the cable clamps on the top of
Motor Cover 1.
Motor Cover 1
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 88.7N•cm
(5)
Connection to the controller
Connect the connectors on the motor cable and encoder cable to match the connector
numbers on the connectors to those indicated on the controller.
75
5. Maintenance Inspection
Motor Cover 2
5.7.3
Process to Replace the Motor for the Z-Axis
[Items Required for Replacement Work]
x Motor Unit for ReplacementModel No.: M-CGZ-TMA050-TA-B-CO
x Cable Band
x Hex Wrench: 2mm, 2.5mm and 3mm-sized
[Procedure]
5. Maintenance Inspection
(1)
Detaching the Z-axis Cover
Turn OFF the controller. X1-axis, X2-axis and Y-axis can be at any position.
Remove the four screws holding the Z-axis cover.
Z-axis
76
Tool to use: Hex Wrench 2.5mm-sized
(2)
Detaching the Motor
1) Cut and remove the cable bands clamping the cables. Disconnect the motor cable
connector from the ribbon cable.
Cable Bands
Brake Switch
Detach the screws holding the screw cover and remove the screw cover.
Screw Cover
Table
Tool to use: Hex Wrench 2.5mm-sized
77
5. Maintenance Inspection
2) Turn ON the controller, put the brake switch up (to RLS side) to release the brake and move
down the table.
3) Move the table to a position where the coupling tightening screw can be seen(at the circled
places). Loosen the coupling screw.
5. Maintenance Inspection
Coupling
Tool to use: Hex Wrench 2mm-sized
Caution: Be careful of the table dropping down.
Hold the table (and/or work piece) so it would not drop down before loosening the
coupling screw.
4) Remove the motor fixing screws and pull out the motor unit and the coupling from the body.
78
Tool to use: Hex Wrench 3mm-sized
(3)
1)
Attaching the New Motor
Adjust the coupling on the new motor so the screw on it faces below.
Screw
5. Maintenance Inspection
2)
Locate the table at a point of 2mm from the mechanical end.
Hold the slider so it would not drop down.
3)
Slide in the motor to the main body and temporarily tighten the screws to affixing the motor.
Tighten the coupling tightening screw (at the circled places).
Coupling
Tool to use: Hex Wrench 2mm-sized
Tightening Torque : 45.8N•cm
Tool to use: Hex Wrench 3mm-sized
79
5. Maintenance Inspection
4)
Tighten the screws affixing the motor (at the circled places).
Tool to use: Hex Wrench 3mm-sized
Tightening Torque : 176N•cm
5)
Plug in the motor cable and ribbon cable, and clamp them with cable bands.
Cable Band
6)
80
Tighten the screws holding the screw cover and remove the screw cover.
Screw Cover
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 88.7N•cm
(4)
(5)
5. Maintenance Inspection
Attaching the Z-axis Cover
Tighten the four screws holding the Z-axis Cover and remove the Z-axis Cover.
Tool to use: Hex Wrench 2.5mm-sized
Tightening Torque : 88.7N•cm
Connection to the controller
Connect the connectors on the motor cable and encoder cable to match the connector
numbers on the connectors to those indicated on the controller.
81
5.7.4
Motor Replacement of Pick & Rotary Axis
5. Maintenance Inspection
[Items required for replacing the motor]
y Replacement motor unit
y Hex Wrench
1.5mm-sized, 2.5mm-sized
y Precision phillips screwdriver
y Tension gauge
y Strong string or long tie-band
[Procedure]
1) Remove the four screws holding the top cover. Detach top cover.
Remove the three screws holding the pulley cover. Detach the pulley cover.
Top Cover
Thin-Head Small Screw M2×6
Pulley Cover
2)
Cross Recessed Screw for Precision Instrument
M2.6×4
There are connectors on the motor power lines and the encoder signal lines (PG lines)
stored inside.
Disconnect the connectors.
PG Lines Stored
· Connector
· Cables
for Power Lines Stored
82
3)
Remove the four screws holding the cable attachment bracket. Detach the cable
attachment bracket.
Cable Attachment Bracket
Ground line Terminal
Hex Socket Head Cap Screws : M3×6
Washer : M3
Shielded line Terminal
4)
5. Maintenance Inspection
Washer㸸M3
Hex Socket Head Cap Screws : M3×6
Remove the two screws holding the motor to detach the motor.
Motor
Timing Belt
Solenoid Attachment Base
Washer : M3
Hex Socket Head Cap Screws : M3×12
5)
Attach a new motor for replacement, hang on the timing belt, and tighten the two screws
temporarily.
New Motor
Solenoid Attachment Base
Timing Belt
Washer : M3
Hex Socket Head Cap Screws : M3×12
83
6)
After attaching the motor, set the alignment mark on the pulley to the PR axis as shown in
the figure below. Set the alignment mark in the range of ± 10deg.
90 deg
Alignment mark
within ± 10°
Front
Pulley
PR axis
5. Maintenance Inspection
7)
With a tough string or long cable band, keep the motor pulled at 5N of force, and tighten
the two screws. At this moment, pay attention to the alignment mark of the pulley to avoid it
being moved.
Driving line
Tension Gauge
Tension Force : 5N
Strong String or Long Tie-Band
Hex Socket Head Cap Screws : M3×12
8)
Tightening Torque : 83.0N㺃cm
Attach the cable attachment bracket and fix it with the four screws.
Tighten the ground line terminal on the screw close to the cable.
Cable Attachment Bracket
Ground line Terminal
Washer : M3
Shielded Line Terminal
Washer : M3
Hex Socket Head Cap Screws : M3×6
84
9)
Join the connectors on the motor power lines and store them inside the cable attachment
bracket.
Join the connectors on the motor power lines and store them inside the cable attachment
bracket.
PG Lines Stored
Solenoid Drive
⥺
Encoder Signal
· Connector
· Cables
for Power Lines Stored
Cable Attachment Bracket
10) Attach the pulley cover and fix it with the three screws.
Attach the top cover and fix it with the four screws.
Top Cover
Thin-Head Small Screw M2×6
Pulley Cover
Cross Recessed Screw for Precision Instrument M2.6×4
85
5. Maintenance Inspection
Storage of Power
Line Connectors
5.8
How to Replace Solenoid on Pick & Rotary Axis
[Reference for Replacement]
4 million times of open and close, abrasion on solenoid plunger, drop in open force
5. Maintenance Inspection
[Items required for replacing the motor]
y Solenoid for replacement
y Hex Wrench
1.5mm-sized, 2.5mm-sized
y Precision phillips screwdriver
[Procedure]
1) Remove the four screws holding the top cover. Detach top cover.
Remove the three screws holding the pulley cover. Detach the pulley cover.
Top Cover
Thin-Head Small Screw M2×6
Pulley Cover
2)
Cross Recessed Screw for Precision Instrument M2.6×4
Disconnect the connectors on the solenoid power lines
Solenoid Drive
Encoder Signal
⥺
Storage of Power Line Connectors
86
3)
Remove the six screws holding the solenoid fixing plate.
Solenoid Fixing Plate
Hex Socket Head Cap
Screws : M3×6
Washer : M3
4)
Hex Socket Head Cap Screws : M3×6
5. Maintenance Inspection
Washer : M3
Detach the solenoid fixing plate and rubber sheet.
Detach the solenoid
Attach the bushing cap.
Solenoid Fixing Plate
Rubber Sheet
Solenoid
Cable Ejection Direction
Datum Surface to
Fix Solenoid
Bushing Cap
As the solenoid generates dust, wipe it away inside with cloth.
87
5)
Attach the new solenoid for replacement.
Attach the solenoid fixing plate and the rubber sheet.
Solenoid Fixing Plate
Solenoid
Rubber Sheet
5. Maintenance Inspection
Cable Ejection Direction
Datum Surface to
Fix Solenoid
Bushing Cap
6)
Join the solenoid power line connectors.
Solenoid Drive
Encoder Signal
Storage of Power Line Connectors
7)
Attach the pulley cover and fix it with the three screws.
Attach the top cover and fix it with the four screws.
Top Cover
Thin-Head Small Screw M2×6
Pulley Cover
Cross Recessed Screw for Precision Instrument M2.6×4
88
5.9 How to Replace Spring on Pick & Rotary Axis
[Reference for Replacement]
4 million times of open and close, drop in open force
[Items required for replacing the motor]
y Spring for Replacement, Samini 12-0640
y Hex Wrench
1.5mm-sized, 2.5mm-sized
y Precision phillips screwdriver
y Tension gauge
Pulley Cover
2)
5. Maintenance Inspection
[Procedure]
1) Remove the three screws holding the pulley cover. Detach pulley cover.
Cross recessed screw for precision instrument M2.6×4
Remove the two screws holding the side plate. Detach the side plate.
Hex Socket Head Cap Screws : M2×5
Side Cover
89
3)
There is a spring inside of the gripper of either side. Take it out.
Hex Socket Head Cap Screws : M2×5
Gripper
Side Plate
Side Plate
5. Maintenance Inspection
Hex Socket Head Cap
Screws : M2×5
Spring
4)
Put in the spring for replacement without any tilt, to face along the side surface of the
finger.
Hex Socket Head Cap Screws : M2×5
Gripper
Side Surface of Finger
Side Plate
Side Plate
Hex Socket Head Cap
Screws : M2×5
Spring
Set the spring certainly in the attachment hole at the back of the side plate.
Attachment Hole for Spring
Side Plate
90
5)
Attach the side plate and fix it with the two screws.
Hex socket head cap screws : M2×5
Side Cover
5. Maintenance Inspection
6)
Tightening Torque : 25.4N㺃cm
Attach the pulley cover and fix it with the three screws.
Pulley Cover
Cross Recessed Screw for Precision Instrument M2.6×4
91
5.10
How to Replace Belt on Pick & Rotary Axis
5. Maintenance Inspection
[Reference for Replacement]
When the gear and belt area show obvious friction.
When swelling occurs as a result of oil adhesion.
When damages such as a crack occurs on the belt gear and back side.
When the belt breaks.
[Items required for replacing the motor]
y Belt for replacement, Mitsuboshi Belting 40S2M138GB
y Hex Wrench
1.5mm-sized, 2.5mm-sized
y Precision phillips screwdriver
y Tension gauge
y Strong string or long tie-band
[Procedure]
1) Remove the four screws holding the top cover. Detach top cover.
Remove the three screws holding the pulley cover. Detach the pulley cover.
Top Cover
Thin-Head Small Screw M2×6
Pulley Cover
92
Cross Recessed Screw for Precision Instrument M2.6×4
2)
Loosen the two screws holding the motor, and slide the motor.
Detach the timing belt.
Motor
Timing Belt
Solenoid Attachment Base
Washer : M3
3)
Hang a new belt for replacement, and tighten the two screws temporarily.
Motor
Timing Belt
Solenoid Attachment Base
Washer : M3
Hex Socket Head Cap Screws : M3×12
After attaching the belt, set the alignment mark on the pulley to the PR axis as shown in
the figure below. Set the alignment mark in the range of ± 10deg.
90 deg
Alignment mark
within ± 10°
Front
PR axis
Pulley
93
5. Maintenance Inspection
Hex Socket Head Cap Screws : M3×12
4)
With a tough string or long cable band, keep the motor pulled at 5N of force, and tighten
the two screws. At this moment, pay attention to the alignment mark of the pulley to avoid
it being moved.
Driving line
5. Maintenance Inspection
Tension Gauge
Tension Force : 5N
Strong String or Long Tie-Band
Hex Socket Head Cap Screws : M3×12
5)
Tightening Torque : 83.0N㺃cm
Attach the pulley cover and fix it with the three screws.
Attach the top cover and fix it with the four screws.
Top Cover
Thin-Head Small Screw M2×6
Pulley Cover
94
Cross Recessed Screw for Precision Instrument M2.6×4
Attachment
Datum Surface
680.5
245
130
60
C
Y : STROKE
300
B
60
130
E
164
X : XTROKE
400
Detail B
Scale 1 : 2
Attachment Datum Surface
Sectional view E-E
Scale 1 : 2
100
100
3-M6 Depth 10
Mass [kg]
Scale 1 : 2
Drawing view C
29
55
24
50
φ 5H7 Depth 5
+0.012
Depth 5
0
6-M5 Depth 6
5 H7
350
280
200
3-M10
φ 23 Counterbore, Depth 5
(For eyebolt)
Attachment hole (12 locations) and
Eyebolts the position to apply (3 locations)
20
200
Attachment Datum Surface
35
E
200
40
40
φ 23
φ 11
Attachment hole size
30
s
6
6.5
14
194
Z : STROKE
100
82.0
190
400
571
164
Attachment
Datum Surface
M Cable
PG Cable
311
6.1
95
6. External Dimensions
790
6. External Dimensions
Standard Type
(680.5)
Attachment
Datum Surface
30
245
130
60
C
820
Y : STROKE
300
B
790
(60)
130
E
Scale 1 : 2
Drawing view C
Detail B
Scale 1 : 2
Sectional view E-E
Scale 1 : 2
Attachment Datum Surface
30
100
100
35
29
±10°
15
E
190.5
X :STROKE
400
175
Attachment hole size
50
55
200
.5
(4)
Mass [kg]
3-M6 Depth 10
Detail H
Scale 1 : 1
C0
φ8 h7
7 (width across flat section)
(φ8 h7)
(φ8 h7)
83.0
(19.5)
(400)
200
3-M10
φ23 Counterbore, Depth 5
(For eyebolt)
Air pipe: 2 points of φ4 are
provided along Z-axis
350
280
6. External Dimensions
Attachment hole (12 locations) and
Eyebolts the position to apply (3 locations)
200
20
Attachment Datum Surface
6.5
14
(209)
8
Z : STROKE
100
96
175
571
(190.5)
Attachment
Datum Surface
H
311
Partition Plug (φ4 × 2)
for air pipe connection
M Cable
PG Cable
6.2
Rotary Axis Equipped Type
φ 23
φ 11
97
(680.5)
Attachment
Datum Surface
15
130
C
B
Y:STROKE
300
805
790
(60)
130
240
E
2
for
n
2
200
29
48.8
H
9.4 (Pin Distance when Open)
2- φ1.5 h7
5.4 (Pin Distance when Closed)
Home Position of Gripping
Scale 1 : 2
8.4
20
200
Mass [kg]
3-M6 depth 10
350
280
3
83.0
(400)
M Cable
PG Cable
Detail H
Scale 2 : 1
571
(240)
Attachment
Datum Surface
Home Position
Angle of Gripper
M2 depth 3
11.4 (M2 Distance when Closed)
34
2.7
8.4
200
3-M10
φ23 Counterbore, depth 5 (For eyebolt)
Attachment hole (12 locations) and
Eyebolts the position to apply (3 locations)
Attachment Datum Surface
Drawing View C
er φ36
Re .5
vo
lut
io
ipp
Gr
8.4
Sectional view E-E
Scale 1 : 2
Attachment Datum Surface
Detail B
Scale 2 : 1
ter
me
Dia
X:STROKE
400
E
Ø23
Ø11
1
1.5
100
35 100
30
Z:STROKE
100
Attachment hole size
76
6.5
14
8.3
6. External Dimensions
188
±1°
311
Back panel
6.3
Pick & Rotary Axis Equipped Type
7. Life
7. Life
The mechanical life of the High-Speed Orthogonal Robot CT4 is represented by the guide that
receives the moment load mostly.
One of the elements determining the operation life is “rated load”.
There are two types of “rated load”, one is the “static rated load” and the other is the “dynamic
rated load”.
x “Static rated load”
: it is a load that makes a small dent mark on the interface when a load is
applied in a stopped condition
x “Dynamic rated load” : it is a load that the remaining rate of the guide not being broken and is
assumed constant after an operation for a certain distance is carried out
with a load being applied.
The guide supplier shows the dynamic rated load assuming the remaining rate of the guide not
being broken after 50km of operation is 90% for the life of the guide.
However, it is important to know the specific product life for the general-purposed industrial
machines also from the view of maintenance.
The life of the guide is sufficient for the radial load, and is mostly influenced by the moment load
caused by the offset from the center of the guide.
The operation life is set assuming 1.2 times of the load coefficient (safety margin) under the
allowable load moment.
X1, X2 and Y-axis are set as 20,000km. 5,000km set for Z-axis. [For the dynamic allowable load
moment, refer to 1.2. Specifications.]
 The formula of the dynamic allowable load moment when the operation life of X1, X2 and
Y-axis is 20,000km is as shown below:
CIA = M50
fw
×
50km
20000km
1
3
CIA : Allowable Dynamic Load Moment
fw : Load factor (=1.2)
M50 : Dynamic rated moment when run for 50km and
remaining rate is 50%
The life with the applied moment can be calculated with the following formula.
L=
CIA
P
3
× 20000km
L
: Operating life (Remaining Probability 90%)
CIA : Dynamic allowable moment
P
: Applied moment
 The formula of the dynamic allowable load moment when the operation life of the Z-axis is
5,000km is as shown below:
CIA : Allowable Dynamic Load Moment
1
fw : Load factor (=1.2)
3
50km
CIA = M50 ×
M50 : Dynamic rated moment when run for 50km and
fw
5000km
remaining rate is 50%
The life with the applied moment can be calculated with the following formula.
L=
98
CIA
P
3
× 5000km
L
: Operating life (Remaining Probability 90%)
CIA : Dynamic allowable moment
P
: Applied moment
8. Warranty
8.1
Warranty Period
One of the following periods, whichever is shorter:
y 18 months after shipment from IAI
y 12 months after delivery to the specified location
y 2,500 hours of operation
8.2
Scope of the Warranty
Note that breakdowns due to any of the following reasons are excluded from the scope of warranty:
[1] Anything other than our product
[2] Modification or repair performed by a party other than us (unless we have approved such
modification or repair)
[3] Anything that could not be easily predicted with the level of science and technology available
at the time of shipment from our company
[4] A natural disaster, man-made disaster, incident or accident for which we are not liable
[5] Natural fading of paint or other symptoms of aging
[6] Wear, depletion or other expected result of use
[7] Operation noise, vibration or other subjective sensation not affecting function or maintenance
Note that the warranty only covers our product as delivered and that any secondary loss arising from a
breakdown of our product is excluded from the scope of warranty.
8.3
Honoring the Warranty
As a rule, the product must be brought to us for repair under warranty.
8.4
(1)
(2)
Limited Liability
We shall assume no liability for any special damage, consequential loss or passive loss such as a
loss of expected profit arising from or in connection with our product.
We shall not be liable for any program or control method created by the customer to operate our
product or for the result of such program or control method.
99
8. Warranty
Our products are covered by warranty when all of the following conditions are met. Faulty products
covered by warranty will be replaced or repaired free of charge:
(1) The breakdown or problem in question pertains to our product as delivered by us or our
authorized dealer.
(2) The breakdown or problem in question occurred during the warranty period.
(3) The breakdown or problem in question occurred while the product was in use for an
appropriate purpose under the conditions and environment of use specified in the instruction
manual and catalog.
(4) The breakdown of problem in question was caused by a specification defect or problem, or
by a quality issue with our product.
8.5
(1)
(2)
8. Warranty
(3)
8.6
Conditions of Conformance with Applicable Standards/Regulations,
Etc., and Applications
If our product is combined with another product or any system, device, etc., used by the customer,
the customer must first check the applicable standards, regulations and/or rules. The customer is
also responsible for confirming that such combination with our product conforms to the applicable
standards, etc. In such a case we will not be liable for the conformance of our product with the
applicable standards, etc.
Our product is for general industrial use. It is not intended or designed for the applications
specified below, which require a high level of safety. Accordingly, as a rule our product cannot be
used in these applications. Contact us if you must use our product for any of these applications:
[1] Medical equipment pertaining to maintenance or management of human life or health
[2] A mechanism or mechanical equipment intended to move or transport people (such as a
vehicle, railway facility or aviation facility)
[3] Important safety parts of mechanical equipment (such as safety devices)
[4] Equipment used to handle cultural assets, art or other irreplaceable items
Contact us at the earliest opportunity if our product is to be used in any condition or environment
that differs from what is specified in the catalog or instruction manual.
Other Items Excluded from Warranty
The price of the product delivered to you does not include expenses associated with programming, the
dispatch of engineers, etc. Accordingly, a separate fee will be charged in the following cases even
during the warranty period:
[1] Guidance for installation/adjustment and witnessing of test operation
[2] Maintenance and inspection
[3] Technical guidance and education on operating/wiring methods, etc.
[4] Technical guidance and education on programming and other items related to programs
100
Change History
Revision Date
Description of Revision
First edition
2012.11
Second edition
Caution in Handling
(2) 1) The No.158 of control parameter was corrected to 153.
2013.01
Third edition
1.2.4 Positioning Accuracy
Lost Motion X direction 0.1mm or less ĺ Corrected to 0.05mm or less.
Lost Motion X direction 0.1mm or less ĺ Corrected to 0.05mm or less.
2013.09
Fourth edition
Rotary Axis Equipped Type is added.
2014.01
Fifth edition
Pg.34
“In case the distance to run reaches 3,000km within 6 months, supply
grease in every 3,000km.” is added.
2014.06
Sixth edition
Pick & Rotary Axis Type has added.
2015.06
Edition 6C
Pg.55, 56 Grease supply volume, Recommended grease gun added.
Change History
2012.08
101
Manual No.: ME3724-6C (June 2015)
Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan
TEL +81-54-364-5105 FAX +81-54-364-2589
website: www.iai-robot.co.jp/
Technical Support available in USA, Europe and China
Head Office: 2690 W. 237th Street, Torrance, CA 90505
TEL (310) 891-6015 FAX (310) 891-0815
Chicago Office: 110 East State Parkway, Schaumburg, IL 60173
TEL (847) 908-1400 FAX (847) 908-1399
Atlanta Office: 1220 Kennestone Circle, Suite 108, Marietta, GA 30066
TEL (678) 354-9470 FAX (678) 354-9471
website: www.intelligentactuator.com
Ober der Röth 4, D-65824 Schwalbach am Taunus, Germany
TEL 06196-88950 FAX 06196-889524
SHANGHAI JIAHUA BUSINESS CENTER A8-303, 808, Hongqiao Rd. Shanghai 200030, China
TEL 021-6448-4753 FAX 021-6448-3992
website: www.iai-robot.com
825, PhairojKijja Tower 12th Floor, Bangna-Trad RD., Bangna, Bangna, Bangkok 10260, Thailand
TEL +66-2-361-4458 FAX +66-2-361-4456
The information contained in this document is subject to change without notice for purposes of
product improvement.
Copyright © 2015. Jun. IAI Corporation. All rights reserved.
15.06.000
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