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Manipulator Manual of AIR20-A Industrial Robot

Safety Protection Measures before Use

Before running the manipulator and peripheral equipment and the whole

system, be sure to fully study the safety protection measures of operator and

system. Safe operation of industrial robot is as shown in Fig.1

。

Fig.1 The figure

of safe operation of industrial robot Schematic Diagram of Safety

Operation of Industrial Robot

Definition of operating personnel

Manipulator operation personnel consist of operator, teacher and maintenance

engineer who shall satisfy the following conditions:

Operator



Switch on/off the power supply of manipulator.



Start the manipulator program via the operating panel.



have no right to operate within the safety barrier

Teacher



Execute the functions of operator

。



Perform the manipulator teaching, etc. outside the safety barrier.

Maintenance Engineer



Execute the functions of teacher.

Summary of Contents for AIR20-A

Page 1: ...Manipulator Manual of AIR20 A Industrial Robot Sign I Peitian Robot AIR20 A Manipulator Manual ...

Page 2: ...ious reasons that do not have to be done and are not possible we have not described it for a variety of reasons Therefore for those situations that are not described in the manual the impossible can be regarded as the case The products described in this specification are subject to the limitations of the Foreign Trade Law of the People s Republic of China The export of the product from China to ot...

Page 3: ...ructions will cause an accident cause serious or fatal injury to the person or serious damage to the item Warning Failure to follow the instructions may result in an accident causing the severe or fatal injury or the great losses of property Caution Prompt for the environmental conditions and important things or shortcuts you shall pay attention to Prompt Prompt for additional literature and instr...

Page 4: ...ation When considering its security the operator should not be considered independently but should be considered in the system environment When using the operating machine it is important to take corresponding measures to the safety fence WARNING CAUTION AND PROMPTS This specification includes matters needing attention to ensure the personal safety of operators and prevent damage to operators Acco...

Page 5: ...e operator in the situation shown below Otherwise it will not only have a negative impact on operators and peripherals but also cause casualties 1 Used in flammable environments 2 Used in explosive environments 3 Used in environments where there is a lot of radiation 4 Used in water or in high humidity environments 5 Used for the purpose of transporting people or animals 6 Use as a foot e g on or ...

Page 6: ... the operator Warning When using the operator for the first time after installation be sure to do so at a low speed and then gradually accelerate the speed and confirm that there are any anomalies Matters needing attention in operation Warning When using the operator be sure to make sure there are no personnel in the safety fence before carrying out the operation At the same time check to see if t...

Page 7: ...ort 1 Check the safety fence carefully and make sure it is not dangerous before entering the fence 2 The emergency stop button can be pressed at any time 3 The operating machine shall be operated at low speed 4 The operation should be carried out after confirming the state of the whole system so as to avoid the operator falling into a dangerous situation due to the remote control instructions or a...

Page 8: ...hould be pressed and then the operation should be carried out Warning Please consult our company when you need to replace the parts The replacement of parts by the client may result in unexpected accidents which may cause the operator to be damaged and the operator is injured Warning When entering the security fence check the whole system carefully and make sure it is not dangerous If there is a d...

Page 9: ...any time when you need it Warning The auxiliary equipment such as the crane shall be used when the moving motor and the speed reducer and the like have certain weight parts so as to avoid the excessive work load for the operators At the same time it is necessary to avoid the wrong operation otherwise the operation and death of the operation may be caused Warning Be careful not to fall because of t...

Page 10: ...hould be correctly loaded back to their original parts and if the parts are found to be insufficient or surplus they should be reconfirmed and installed correctly Warning During the maintenance of the pneumatic system and hydraulic system it is important to release the internal pressure to zero and operate again Warning After replacing the parts be sure to carry on the test operation according to ...

Page 11: ...r operations must receive the training of the company and pass the relevant assessment Warning When carrying out maintenance operations appropriate lighting appliances should be equipped but care should be taken not to make the lighting appliances a source of new danger Warning Be sure to refer to this specification for regular maintenance if not regular maintenance will affect the service life of...

Page 12: ...ration of industrial robot Schematic Diagram of Safety Operation of Industrial Robot Definition of operating personnel Manipulator operation personnel consist of operator teacher and maintenance engineer who shall satisfy the following conditions Operator Switch on off the power supply of manipulator Start the manipulator program via the operating panel have no right to operate within the safety b...

Page 13: ...opped the manipulator is possibly waiting for the start signal and is about to act The manipulator shall be regarded as operating at this state To ensure the safety of operation personnel it is necessary to confirm that the manipulator is in the operating state via the audible and visual alarms such as the warning lamp Be sure to set the safety barrier and safety door around the system so that the...

Page 14: ...vent the unrelated personnel from entering the range of manipulator or to prevent operators from entering a hazardous location Emergency stop button shall be set within the reach of operators Prompt Manipulator controller is designed to be connected to an external emergency stop button With this connection the manipulator will stop when the external emergency stop button is pressed Safety of Teach...

Page 15: ...operator operates automatically Safety of Repair Engineer To ensure the safety of repair engineer full attention shall be paid to the following items Never enter the range of manipulator while the manipulator is running Perform the repair operation while the controller is powered off if possible Main circuit breaker shall be locked if necessary to prevent other personnel from turning on the power ...

Page 16: ...firmed in advance that there is no people in the range of manipulator and the manipulator and peripheral equipment are in a normal status Safety of Peripheral Equipment Precautions in terms of procedures The detection devices such as the limit switch shall be used to detect the dangerous status and the manipulator shall be stopped as needed according to the signals of detection device In case of a...

Page 17: ... is operated in slow feed mode the operators shall be highly vigilant regardless of the circumstances and quickly respond to various problems Precautions in terms of procedures If the ranges of multiple manipulators overlap care shall be taken to avoid the interference between manipulators Be sure to specify an operation origin for the manipulator program and create a program that starts and ends ...

Page 18: ...2 3 BASIC SPECIFICATIONS 5 2 4 ENVIRONMENTAL REQUIREMENTS FOR OPERATION 6 3 THE LABEL NAME AND MEANING OF AIR20 A 8 3 1 SAFETY SIGN OF MANIPULATOR 8 3 2 MANIPULATOR NAMEPLATE 8 3 3 DIRECTION SIGN OF EACH AXLE 9 4 AIR20 A TRANSPORT AND HANDING 10 4 1 HANDING DIMENSIONS 10 4 2 HANDING POSTURE 12 4 3 HANDING WITH FORKLIFT 13 4 4 HANDING WITH SWINGING RING 13 5 AIR20 A PREPARATION BEFORE INSTALLATION ...

Page 19: ...TION OF EACH JOINT 35 11 GENERAL PRINCIPLES OF MAINTENANCE 38 12 MAINTENANCE ITEMS 39 12 1 DAILY MAINTENANCE 39 12 2 FIRST MAINTENANCE 39 12 3 REGULAR MAINTENANCE 41 13 PROJECT MAINTENANCE PROCESS 45 13 1 CLEANING OF MANIPULATOR 45 13 2 CHECK AND REPAIR OF CABLE 45 13 3 BATTERY REPLACEMENT 49 13 4 REPLACE GREASE 50 13 5 REPLACEMENT OF SYNCHRONOUS BELT 56 14 COMMON FAULTS AND TREATMENT 59 15 CONDIT...

Page 20: ...n release number software or file version The relevant information of the product is shown in Table 1 1 Table 1 1 Product related information Product name AIR20 A robot manipulator Manual Product num BJM SS UG 02 021 Product version V2 4 0 1 3 Product use objects Operator Teacher Service 1 4 Relevant documentation information The contents of this article may involve the following documents please ...

Page 21: ...netic compatibility regulations of member states 2014 2014 68 EU Pressure facility directive Electromagnetic compatibility directive 2014 68 EU directive issued by European Parliament and Council on May 15 2014 to balance the pressure facility regulations of member states It is only suitable for the robot with hydraulic balance weight 2014 ISO 13850 Safety of machinery Emergency stop function Prin...

Page 22: ...nts 2005 61000 6 4 A1 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments 2011 60204 1 A1 Safety of machinery Electrical equipment of machines Part 1 General requirements 2009 IEC 60529 IP rating provided by enclosures IP Code This standard applies to the IP rating for the electrical equipment with enclosures and the rated voltage exceeding 72...

Page 23: ...ystem Fig 2 1 shows an example of industrial robot system in which 1 Manipulator 2 Manipulator 3 Teach pendant 4 Connecting power supply cable 2 2 Basic Structure Manipulator refers to the mechanism of robot system to grab or move the objects tools or workpieces also known as the robot body This manipulator is the 6 DOF tandem industrial robot that consists of three swing axes and three rotating a...

Page 24: ...control axes 6 axes J1 J2 J3 J4 J5 and J6 Mounting mode Ground mounting lift mounting Range upper limit lower limit J1 170 170 J2 95 155 J3 95 170 J4 185 185 J5 135 135 J6 400 400 Max speed J1 175 s J2 175 s J3 170 s J4 360 s J5 360 s J6 600 s Transport capacity Wrist 20kg Elbow 12kg Drive mode Electrical servo drive with AC servo motor Repeated positioning accuracy 0 03mm Robot weight 260kg Noise...

Page 25: ... Table 2 2 Temperature Limits Requirement Value C Min temperature 5 Max temperature 45 CAUTION When the ambient temperature is lower than 10 it is recommended to heat the engine for a few minutes before use to avoid robot alarm or performance degradation caused by changes in viscosity of grease Humidity The humidity in the installation environment of manipulator shall not be more than 95 as specif...

Page 26: ...e to vibration Robot manipulator shall be used in an environment where there is no vibration The limit frequency of ambient vibration is 22 Hz and the amplitude shall not exceed 0 15 mm Special environment requirements Do not operate this manipulator in the flammable explosive and corrosive environments ...

Page 27: ...s shown in Fig 3 1 Fig 3 1 No Approaching Sign of Manipulator Danger It is so easy or may cause unnecessary personal injury and even death if you do not comply with this regulation 3 2 Manipulator nameplate The nameplate of the manipulator can be seen on the base of the manipulator The nameplate contains the corresponding model version number weight serial number production date and other informat...

Page 28: ... at the rotating or swinging joints of axes 1 6 of manipulator as shown in Fig 3 3 to indicate the moving direction of each Joint J1 in sign represents the axle 1 other axes are represented by the corresponding numbers indicates the positive direction and indicates the negative direction Fig 3 3 Direction Sign of Each joint on Manipulator ...

Page 29: ...ns of this manual Precautions for manipulator during handing as shown in Fig 4 1 Fig 4 1 Precautions for manipulator during handing During handing the following points should be noted Do not pull eyebolt sideways Do not use forklift and other grippers to apply impact force to the delivery support Do not put chains on delivery support 4 1 Handing Dimensions Three views of manipulator during the han...

Page 30: ...or Manual of AIR20 A Industrial Robot AIR20 A Transport and Handing 11 Fig 4 2 Dimensions of AIR20 A Manipulator during the Handling Process Fig 4 3 Dimensions of AIR20 A Manipulator during the Handling Process ...

Page 31: ... Manipulator during the Handling Process 4 2 Handing Posture One to six axis posture of AIR20 A manipulator during handling shall be posed as shown in Table 4 1 and Fig 4 5 Table 4 1 Angle Values of Axes for Robot during Handling A1 A2 A3 A4 A5 A6 0 65 165 0 80 0 Fig 4 5 Handling posture of AIR20 A Manipulator ...

Page 32: ...f manipulator and handling device is about 260kg Fig 4 6 Schematic Diagram of AIR20 A Handling with Forklift Caution Manipulator shall be equipped with the matching handling bracket The incorrect handling method may cause the damage to manipulator Manipulator posture during handling is subject to the description in Chapter 4 2 Handing Posture of this manual 4 4 Handing with Swinging Ring Handling ...

Page 33: ...handled with swinging ring insert a soft object between the sling and manipulator to avoid the scratching on the manipulator body by sling Manipulator may turn over when transported with swinging ring During the handling please take special care to keep the manipulator steady Do not pull the swinging ring to the side to avoid the damage to the manipulator and the unpredictable failure ...

Page 34: ... Operation Make sure that the installation site can withstand the pressure or pull from the manipulator and its load 5 2 Installation Tool and Required Connectors The following tools may be required to install the manipulator more tools may be required depending on the installation method A set of Internal hexagonal wrench Adjustable wrench Torque wrenches of different specifications etc The follo...

Page 35: ...tallation ground inclination shall be less than 5 for manipulator Table 6 1 The force applied to foundation by AIR20 A manipulator Load type Force torque mass Vertical force Fv 4215N Horizontal force Fh 4215N Overturning torque Mk 3853Nm Rotary torque Mr 3195Nm Manipulator quality 260kg Total weight of load 57kg 20kg 12kg 25kg Dimensions of AIR20 A manipulator base are as shown in Fig 6 1 Fig 6 1 ...

Page 36: ...ixing Fixing screw Four M20x40 Grade 12 9 Chemical bolt Eight M20 not less than Grade 4 8 Fixing plate of robot 25 mm 1 piece Mounting bracket 25mm 4 piece Prompt There shall be no insulating materials between the fixing plate and mounting bracket of robot and the manipulator and concrete Mark means that the part is in need Bracket shall be firmly installed on the ground with the strength not less...

Page 37: ...nipulator base on the fixing plate with four M20x40 bolts Grade 12 9 a b Fig 6 2 The fixed mode 1 for manipulator Prompt Fixing plate surface shall meet certain roughness and flatness requirements as detailed in Fig 6 2 Manipulator base M20X40 bolts Robot fixed plate M20 chemical bolts Concrete 0 3 6 3 ...

Page 38: ...face and secure it with eight M20 chemical bolts strength not less than Grade 4 8 2 Install the manipulator base on the fixing plate with four M20x40 bolts Grade 12 9 a b Fig 6 3 The fixed mode 2 for manipulator Prompt Fixing plate surface shall meet certain roughness and flatness requirements as detailed in Fig 6 3 Manipulator base M20X40 bolts Robot fixed plate M20 chemical bolts Concrete 0 3 6 ...

Page 39: ...rackets with 8 M20 chemical bolts strength grade not less than 4 8 2 Install the manipulator base on the bracket with eight M20x40 bolts Grade 12 9 a b Fig 6 4 The fixed mode 3 for manipulator Prompt Mounting surface of bracket shall meet certain flatness requirements as shown in Fig 6 4 Manipulator base M20X40 bolts Mounting bracket M20 chemical bolts Concrete 0 5 ...

Page 40: ...ew M20 of manipulator shall not be shorter than 40 mm and the insufficient length will cause the poor fixing and other accidents When installing the manipulator ceiling the length of fixing screws for manipulator shall be increased to 45 mm and the thickness of mounting plate shall be not less than 30 mm ...

Page 41: ...of Heavy duty Interfaces of Manipulator Heavy duty interface of AIR20 A manipulator is defined as shown in Table 7 1 and Table 7 2 Table 7 1 Pin definition of Heavy duty power line Pin number Definition Internal cables Use the pin A1 GND black 2 J1 black 2 J2 CDM 1 0 A2 A3 PE yellow and green J3 CDM 0 5 A4 U3 black 1 J3 CDM 0 5 A5 V3 black 2 J3 CDM 0 5 A6 W3 black 3 J3 CDM 0 5 A7 A1 A2_BR_24V blac...

Page 42: ...6 gray J6 CDM 0 37 C7 A3 A4_BR_24V black 4 J3 brown J4 CDM 0 75 C8 A5 A6_BR_24V brown J5 brown J5 CDM 0 5 C9 PE yellow J4 CDM 0 37 C10 U4 pink J4 CDM 0 37 C11 V4 green J4 CDM 0 37 Table 7 2 Pin definition of Heavy duty encoder line Pin number Definition Internal cables Use the pin D1 J1_5V pink J1 CAM 08 D2 J1_0V gray J1 CAM 08 D3 J1_PS green J1 CAM 08 D4 J1_PS yellow J1 CAM 08 D5 J2_5V pink J2 CA...

Page 43: ...9 J5_0V gray J5 CAM 08 D20 J5_PS green J5 CAM 08 D21 J5_PS yellow J5 CAM 08 D22 J6_5V pink J6 CAM 08 D23 J6_0V gray J6 CAM 08 D24 J6_PS green J6 CAM 08 D25 J6_PS yellow J6 CAM 08 Caution When the robot is connected attention should be paid to the one to one correspondence between the Heavy duty on the body and the Heavy duty on the control cabinet ...

Page 44: ...ples of accessory types The accessory equipment of the operator mainly includes mechanical grab Fig 8 1 hydraulic pressure sucker Fig 8 2 welding gun welder Fig 8 3 infrared identification equipment visual identification equipment cutting machine other special equipment etc Fig 8 1 Industrial robot grab Fig 8 2 Suction cups for industrial robots Fig 8 3 Arc welding gun for industrial robot ...

Page 45: ...tion between operator and control cabinet As described in Chapter 7 2 Definitions of Heavy duty Interfaces of Manipulator of this manual the heavy duty connector on the operator body is connected to the control cabinet through three cables The definition of heavy duty connector on the control cabinet of AIR20 A manipulator is shown in Fig 8 4 below For more details please refer to the correspondin...

Page 46: ...motion range of each axis of AIR20 A manipulator is shown in Table 9 1 as follows Table 9 1 motion range of each axis of AIR20 A manipulator axis number motion range J1 170 170 J2 85 150 J3 95 170 J4 180 180 J5 135 135 J6 360 360 Prompt If the mechanical limit of J1 axis is removed the range of motion can reach 180 180 See Fig 9 1 for the motion range of the manipulator During the installation of ...

Page 47: ...each Joint Robot is limited to the movable range except that the origin position is lost due to the servo system abnormality and system error In addition an optional mechanical brake is also available on Joint 1 to limit the movable range in order to further ensure the safety A sliding limit device is arranged inside the mechanical body of Joint 4 as its mechanical brake Fig 9 2 shows the position...

Page 48: ...m angular speed of each axis of the manipulator is shown in Table 9 2 Table 9 2 maximum angular speed of each axis of the manipulator axis number Maximum angular velocity s J1 175 J2 175 J3 170 J4 360 J5 360 J6 600 9 5 Output flange size The Table 9 3 and Fig 9 3 show output flange specification and connection size of AIR20 A Tightening torque of screws is shown in Appendix B ...

Page 49: ...hen installing the fixture the depth of the threaded hole and pin hole shall be fully considered for the screws and locating pins used It is forbidden to install the length beyond the depth of the threaded hole 10 5mm and the depth of the pin hole 4mm otherwise the wrist of the operator will be damaged 9 6 Load and installation method Wrist load installation of manipulator The wrist load line diag...

Page 50: ...4kgm that of 5 axis is less than 1 04kgm and that of 6 axis is less than 0 28kgm Please refer to Table 2 1 for specific values a b Fig 9 4 location of wrist load center of AIR20 A Manipulator Installation of elbow equipment of axis 3 of manipulator The specification and size of the installation hole of J3 axis elbow of AIR20 A manipulator are shown in Fig 9 5 ...

Page 51: ...fied torque and apply thread glue on the thread otherwise the long term operation may lead to looseness or even fracture resulting in accidents Warning Since it may cause adverse effects on the safety and function of the manipulator it is absolutely not allowed to add machining holes and screw holes to the Manipulator body When installing the equipment the screw used shall fully consider the depth...

Page 52: ... follows 1 Fixed position of manipulator jib See Fig 9 6 for the specification and size of the installation hole of the manipulator jib Fig 9 6 interface dimension drawing of AIR20 A manipulator jib 2 Fixed position of the manipulator boom and the j1axis body See Fig 9 7 for the specification and size of the installation hole of the manipulator jib Fig 9 7 interface dimension drawing of AIR20 A bo...

Page 53: ...e internal components or cables of the operator will be damaged The above parts are designed for cable fixation If equipment is needed to be installed it should be guaranteed that 1 Arm load wrist load 20kg 2 Shoulder load arm load elbow load 37kg When installing the equipment the reliability of installation shall be fully considered It is recommended to use 12 9 grade screws to install according ...

Page 54: ...librated when the following situations occur Repair such as motor replacement or belt pulley removal Replace the encoder battery The encoder wire of the motor is loose or reinstalled The manipulator has a strong collision Replace the control cabinet or control system e g industrial personal computer 10 3 Calibration position of each Joint The position of each axis of the manipulator is shown inFig...

Page 55: ...position shown in Fig 10 1 the naked eye shall be used to make the zero point position of each shaft to be aligned as shown inFig 10 2 Fig 10 2 Calibration method of naked eye observation zero Warning In the calibration process of the manipulator the speed should be reduced as much as possible and the operator should not enter the working range of the robot After each time the robot stops moving t...

Page 56: ...ator should not enter the working range of the robot After each time the robot stops moving the alignment of the zero scale on the axis position should be observed Caution When the calibration block is used for calibration of the manipulator the basic alignment of the calibration slot shall be observed with the naked eye the operating speed of the manipulator is reduced to the manual lowest gear a...

Page 57: ... the downtime of the device it is unnecessary to maintain and cause waste Robot systems are designed to work under rather demanding conditions and require minimal maintenance Nevertheless daily inspection and regular maintenance must be carried out according to a given interval cycle The time interval in the maintenance table is the recommended value and the time interval actually required by the ...

Page 58: ...e operation of the operator and the peripherals are consistent with the instructions 12 2 First maintenance The operation machine shall run for the first time 320 hours or 1 month whichever is shorter and the following items shall be inspected and maintained As shown in Table 12 2 Table 12 2 Operating Machine First Maintenance Project Ordinal Inspection item Main points of inspection 1 Whether the...

Page 59: ... Maintenance site Internal cable and cable sheath inside the manipulator base with the electrical mounting plate removed Big arm of manipulator and internal cable and cable sheath of J1 axle body Connecting cable of manipulator grounding terminal user cable joint Confirmation Check the cable sheath for crack and wear and if so replace it Check if the lubricating grease on the surface of internal c...

Page 60: ... possible Note 4 About the Maintenance of Synchronous Belt After disassembling the manipulator cover plate check whether the synchronous belt is worn or damaged For the details see Chapter 13 4 Replace grease in this manual Check the inside of synchronous belt teeth for white hair the belt side for wear belt teeth for crush the belt body for breakage and elongation pre tightening force is decreasi...

Page 61: ...Whether the synchronous belt is worn or not Check the synchronous belt for wear elongation and fracture 3840 hours 1 year regular maintenance For every 3840 hours or 1 year whichever is the shorter time the operator needs to carry out the inspection and maintenance of the following items As shown in Table 12 5 Table 12 5 Operation machine 3840 hours 1 year maintenance project Ordinal Inspection it...

Page 62: ...hours 3 years regular maintenance The operation machine shall be operated for 3 years or 11520 hours whichever is less and the following items shall be inspected and repaired As shown in Table 12 7 Table 12 7 operator 11520 hours 3 years maintenance project Ordinal Inspection item Main points of inspection 1 Replacement of synchronous tape See Chapter 12 2 First maintenance 15360 hours 4 years per...

Page 63: ... or 19200 hours whichever is the shorter time the operator needs to be overhauled and many parts need to be replaced Please contact us As shown in Table 12 9 Table 12 9 operator 19200 hours 5 years maintenance project Ordinal Inspection item Main points of inspection 1 Overhaul of operating machine Please consult our company ...

Page 64: ...ces connected to the robot 3 Clean the manipulator with the vacuum cleaner or wipe it with a cloth 4 After all safety conditions are met conduct the follow up work of manipulator Warning Do not apply the water jet on the manipulator especially the joints and seals Do not clean the manipulator with compressed air Do not remove any protector of manipulator Do not clean the manipulator with solvent 1...

Page 65: ...ables for wear or damage 4 Check all the cables connector for wear or damage 5 Check all the bracket and Tie down straps are fixed on the operation 6 Check the fixation between the cable and bracket for wear or damage 7 In case of crack wear or damage please contact us for replacement timely Check and Overhaul Process for Internal Cables of J1 Joint Body check and repair process as follows 1 Remov...

Page 66: ...so it shall be replenished timely 8 The cable in the base to keep the shape U type like the figure Fig 13 2 9 Install the cover plate and coat the joint surface between the cover plate and base with sealant Fig 13 2 Check and Repair for Internal Cables of J1 Joint Body Check and Repair Process for Internal Cables of Big Arm Check and Repair Process as follows 1 Remove elbow cable retaining plate a...

Page 67: ...pears it should be replaced in time 8 Put the cable inside the elbow 9 Install cable fixed plate Fig 13 3 Check and Repair for Internal Cables of Big Arm Warning Replace the manipulator cable please consult with us Using unqualified cables may cause the robot to not work properly Check and Repair Process for Internal Cables of the wrist Check and Repair Process as follows 1 Remove the cover plate ...

Page 68: ...department of the company to replace the internal cables of the operator The use of substandard cables may result in the robot not working properly 13 3 Battery Replacement The data on the positions of manipulator axes is saved with the encoder battery The battery shall be replaced according to the following process every 7 860 h or 2 years whichever comes first or in case of A2 alarm from drive R...

Page 69: ...conditions are met and then perform the calibration and testing of manipulator Fig 13 5 Remove operator electrical installation panel 13 4 Replace grease Operation machine J1 axis to J6 axis reducer every 11520 hours or 3 years whichever is shorter need to replace the internal grease Grease type and grease quantity please refer to Table 13 1 Table 13 1 type and quantity of operator grease13 1 Oper...

Page 70: ...ced after cooling Wear gloves to prevent allergic reactions Open the drain carefully and slowly to prevent oil spatter J1 axis reducer replacement grease process Fig 13 6 replace the lubricating grease of J1 axis reducer13 1 The replacement process is as follows 1 Run the manipulator as shown in Table 13 2 2 To prevent danger turn off the power hydraulic and pneumatic sources connected to the robo...

Page 71: ...arge volume is greater than the injection volume From the fat injection port injection lack of quantity can be 9 Remove the grease injector install the M10x1 plug on the grease outlet and grease injector and apply the sealing tape sealant Caution When injecting fat from the fat injection port into the inner part of the operation machine the fat injection speed by hand pump is less than 8g s and th...

Page 72: ...ank 6 Remove the grease injection port M10x1 plug install the grease injection nozzle and use manual grease injection gun to inject grease until the new grease is discharged from the outlet 7 Release the grease pressure inside the reducer as shown in Table 13 3 8 The amount of oil discharged by weighing shall be equal to the amount of oil injected If the discharge amount is less than the injection...

Page 73: ...her and the grease may cause damage to the motor oil seal and the grease enters the motor J3 axis reducer replacement grease process Fig 13 8 replace the lubricating grease of J3 axis reducer The replacement process is as follows 1 Run the manipulator as shown inTable 13 2 2 To prevent danger turn off the power hydraulic and pneumatic sources connected to the robot 3 Place the sump tank for collec...

Page 74: ...an 0 3mpa In order to ensure the smooth elimination of the old oil inside the reducer after a period of oil injection take a rest for a while such as the oil outlet no old oil discharge to continue the oil injection When the oil filling speed is too fast the instantaneous pressure inside the reducer becomes higher and the grease may cause damage to the motor oil seal and the grease enters the moto...

Page 75: ... releasing the internal pressure as shown in Table 13 3 5 Thoroughly remove grease from floor and operating machine to avoid slipping 13 5 Replacement of Synchronous Belt Synchronous belt of J5 and J6 axes shall be replaced every 11520h or 13year whichever comes first For the model of synchronous belt please see Table 13 4 Table 13 4 Synchronous Belt Model for Manipulator Manipulator Model Positio...

Page 76: ...e the motor pulley remove the old synchronous belt and install the new one 6 Initially tighten the screw M4 of motor base 7 Adjust the screw position adjust the synchronous belt to the appropriate pre tightening force and installation deflection The recommended pre tightening force and installation deflection are respectively 14 6 N and 2 6 mm 8 Install the motor base screw M4 according to the spe...

Page 77: ...onous Belt Fig 13 11 Installation Deflection of Synchronous Belt Warning After the replacement of synchronous belt the J5 and J6 axes of manipulator shall be calibrated For details see Chapter 10 Calibration of the axes of the AIR20 A manipulato of this manual Motor Mounting screw of motor Synchronous belt ...

Page 78: ... base is not firmly fixed on the workshop pedestal 2 The base floats from the workshop pedestal and generates the vibration when the manipulator acts due to the screw looseness insufficient flatness of base and the foreign objects 1 When the screw is loose tighten it with the torque wrench according to the proper torque 2 Trim the base flatness in accordance with the tolerance 3 Check if the forei...

Page 79: ...acement of lubricating grease for a long time 1 Mechanical transmission system is subjected to excessive external force due to collision or overload causing the damage to the gear surface or rolling surface of the gear bearing reducer or the peeling due to fatigue 2 The gear surfaces or rolling surfaces of gear bearing and reducer are damaged due to the foreign matters trapped in the gear bearing ...

Page 80: ...hether it vibrates 3 Check the cables of the manipulator body between the manipulator body and control cabinet and inside the controller for damage and if so replace the cable 4 Check whether the cable joint is in good contact In case of the poor contact or looseness re tighten or take appropriate measures to ensure the good contact 5 Check whether the action control parameters are correct and if ...

Page 81: ...olts between arms 6 Fixing bolts of shell 7 Fixing bolts of end effector Turn off the power of manipulator and confirm that the screws are tightened and shake the entire head of manipulator manually 1 Large backlash is resulted from the wear or damage of internal gears of manipulator due to the overload collision etc 1 If you need to replace the internal gear please consult with us Motor overheati...

Page 82: ...nd excessive load 2 Failure of motor body to perform its functions causes the excessive current to flow through the motor 1 Please rectify the mechanical fault by reference to the instructions of vibration abnormal noise and looseness 2 Please confirm whether the brake is released when the motor is powered on 3 After the motor is replaced the overheating of motor disappears It is confirmed that th...

Page 83: ...ng accuracy keeps stable after the deviation the joint surface of pedestal surface Joint casting and reducer may slide due to the excessive load such as the collision 3 Abnormality of motor encoder 1 In case of the unstable repeated positioning accuracy please rectify the mechanical fault by reference to the instructions for the vibration abnormal noise and shaking 2 If the repeated positioning ac...

Page 84: ...ture without condensation Max vibration condition Frequency 22 Hz amplitude 0 15 mm 15 2 Precautions for Storage of Manipulator In addition to Chapter 2 4 Environmental Requirements for Operation of this manual the following shall be paid with attention for the long term storage of manipulator 1 Before the long term storage of manipulator it shall be posed for handling and placed on the horizontal...

Page 85: ... be cleaned regularly for dust and pollutant with the specific cleaning cycle depending on the storage environment of manipulator 5 When the storage period is over and the manipulator is put into the operation again the manipulator shall be checked in accordance with Chapter 5 1 Check item of this manual ...

Page 86: ...ection cable of manipulator and control cabinet 5m standard 10m 15m 20m 25m Length of connection cable of power supply and control cabinet 5m standard 10m 15m 20m 25m Length of connecting cable of teach pendant and control cabinet 3 5m ARCCxP standard 5m inCubex standard 10m 15m 20m Options of Robot Body Color of robot body Bright yellow standard Others______ Logo of robot body AE standard Others_...

Page 87: ...ard without nameplate Specification of inCube10 connecting cable of power supply and control cabinet 16A standard 10A Options of control cabinet Is it necessary to perform the absolute positioning accuracy calibration No standard Yes Is it necessary to option other functions No standard Welding function Palletizer function metal bending nonsupport ARCCxP Hand guiding function Currently supported o...

Page 88: ...Manipulator Manual of AIR20 A Industrial Robot Conditions of Storage 69 AE standard without AE Logo ...

Page 89: ...onth s 8 640 h 30 month s 9 600 h 33 month s 10 560 h 3 year 11 520 h 39 month s 12 480 h 42 month s 13 440 h 45 month s 14 400 h 4 year 15 360 h 51 month s 16 320 h 54 month s 17 280 h 57 month s 18 240 h 5 year 19 200 h 1 Cleaning of manipulat or 0 5h 〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇 2 Cleaning of control cabinet vent 0 1h 〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇〇 3 Is the synchrono us ...

Page 90: ... 10 560 h 3 year 11 520 h 39 month s 12 480 h 42 month s 13 440 h 45 month s 14 400 h 4 year 15 360 h 51 month s 16 320 h 54 month s 17 280 h 57 month s 18 240 h 5 year 19 200 h pendant control cabinet and manipulat or for damage 7 Check the connector s of motor etc for looseness 0 2h 〇〇〇〇〇〇 8 Tighten the end effector screws 0 2h 〇〇〇〇〇〇 9 Tighten the external main screws 1h 〇〇〇〇〇〇 1...

Page 91: ...month s 5 760 h 21 month s 6 720 h 2 year 7 680 h 27 month s 8 640 h 30 month s 9 600 h 33 month s 10 560 h 3 year 11 520 h 39 month s 12 480 h 42 month s 13 440 h 45 month s 14 400 h 4 year 15 360 h 51 month s 16 320 h 54 month s 17 280 h 57 month s 18 240 h 5 year 19 200 h Synchrono us Belt 13 Battery Replacem ent 0 5h 〇〇 14 Replace the internal cables of manipulat or 8h 〇 15 Manipulat or overh...

Page 92: ...2 78 104 125 M14 113 165 195 M16 195 250 305 M20 370 500 600 Prompt All screws must be tightened with proper torque Except for the torque specified in the text the corresponding tightening torque shall be selected according to the screw performance level Remove foreign matters in screws and threaded holes Torque for lightly lubricated screws Screws shall be tightened evenly and symmetrically Accor...

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AE AIR20-A, Manipulator Manual

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