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Epson ProSix S5 Series, Manual

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Maintenance    6. Joint #3 (Replacing the Reduction Gear Unit) 

 

130

 

S5    Rev.5

 

 

6.2    Replacing the Joint #3 Reduction Gear Unit 

 

 

WARNING 

■

 

Before  performing  any  replacement  procedure,  turn  OFF  the  Controller  and 

related  equipment,  and  then  pull  out  the  power  plug  from  the  power  source.   

Performing  any  replacement  procedure  with  the  power  ON  is  extremely 

hazardous  and  may  result  in  electric  shock  and/or  malfunction  of  the  robot 

system. 

■

 

Do not insert or pull out the motor connectors while the power to the robot system 

is turned ON.    Inserting or pulling out the motor connectors with the power ON is 

extremely hazardous and may result in serious bodily injury as the Manipulator 

may move abnormally, and also may result in electric shock and/or malfunction of 

the robot system. 

■

 

Be sure to connect the AC power cable to a power receptacle.    DO NOT connect 

it directly to a factory power source.    To shut off power to the robot system, pull 

out  the  power  plug  from  the  power  source.    Performing  any  work  while 

connecting the AC power cable to a factory power source is extremely hazardous 

and may result in electric shock and/or malfunction of the robot system. 

 

 

CAUTION 

■

 

Be careful not to apply excessive shock to the motor shaft during replacement 

procedures.    The shock may shorten the life cycle of the motors and encoder 

and/or damage them.

 

■

 

Carefully  use  alcohol,  liquid  gasket,  and  adhesive  following  respective 

instructions and also instructions below.    Careless use of alcohol, liquid gasket, 

or adhesive may cause a fire and/or safety problems.   

-

  Never put alcohol, liquid gasket, or adhesive close to fire. 

-

  Use alcohol, liquid gasket, or adhesive while ventilating the room. 

-

  Wear protective gear including a mask, protective goggles, and oil-resistant 

gloves. 

-

  If  alcohol,  liquid  gasket,  or  adhesive  gets  on  your  skin,  wash  the  area 

thoroughly with soap and water. 

-

  If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your 

eyes or wash out your mouth with clean water thoroughly, and then see a 

doctor immediately. 

■  Wear  protective  gear  including  a  mask,  protective  goggles,  and  oil-resistant 

gloves during grease up.    If grease gets into your eyes, mouth, or on your skin, 

follow the instructions below. 

If grease gets into your eyes  : Flush them thoroughly with clean water, and 

then see a doctor immediately. 

If grease gets into your mouth : If swallowed, do not induce vomiting.    See a 

doctor immediately. 
If grease just gets into your mouth, wash out 

your mouth with water thoroughly. 

If grease gets on your skin 

:  Wash  the  area  thoroughly  with  soap  and 

water. 

 

Summary of Contents for ProSix S5 Series

Page 1: ...Rev 5 EM133R2483F EPSON ProSix S5 series MANIPULATOR MANUAL ...

Page 2: ...Manipulator manual S5 series Rev 5 ...

Page 3: ...S5 Rev 5 i EPSON ProSix S5 series Manipulator Manual Rev 5 Copyright 2010 2013 SEIKO EPSON CORPORATION All rights reserved ...

Page 4: ...nty period information However customers will be charged for repairs in the following cases even if they occur during the warranty period 1 Damage or malfunction caused by improper use which is not described in the manual or careless use 2 Malfunctions caused by customers unauthorized disassembly 3 Damage due to improper adjustments or unauthorized repair attempts 4 Damage caused by natural disast...

Page 5: ...are subject to change without notice Please notify us if you should find any errors in this manual or if you have any comments regarding its contents INQUIRIES Contact the following service center for robot repairs inspections or adjustments If service center information is not indicated below please contact the supplier office for your region Please prepare the following items before you contact ...

Page 6: ... info robots epson com Europe EPSON DEUTSCHLAND GmbH Factory Automation Division Otto Hahn Str 4 D 40670 Meerbusch Germany TEL 49 0 2159 538 1391 FAX 49 0 2159 538 3170 E MAIL robot infos epson de China EPSON China Co Ltd Factory Automation Division 7F Jinbao Building No 89 Jinbao Street Dongcheng District Beijing China 100005 TEL 86 0 10 8522 1199 FAX 86 0 10 8522 1120 Taiwan EPSON Taiwan Technol...

Page 7: ...96 FAX 65 0 6271 3182 Korea EPSON Korea Co Ltd Marketing Team Robot Business 27F DaeSung D Polis A 606 Seobusaet gil Geumcheon gu Seoul 153 803 Korea TEL 82 0 2 3420 6692 FAX 82 0 2 558 4271 Japan EPSON SALES JAPAN CORPORATION Factory Automation Systems Department Nishi Shinjuku Mitsui Bldg 6 24 1 Nishishinjuku Shinjuku ku Tokyo 160 8324 JAPAN TEL 81 0 3 5321 4161 ...

Page 8: ...e retailer where you purchased this product Use of the chemical symbols Pb Cd or Hg indicates if these metals are used in the battery This information only applies to customers in the European Union according to DIRECTIVE 2006 66 EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and accumulators and repealing Directive 91 157 EEC...

Page 9: ...ntrol Unit Drive Unit EPSON RC 6 0 For details on commands refer to EPSON RC User s Guide or Online Help Turning ON OFF Controller When you see the instruction Turn ON OFF the Controller in this manual be sure to turn ON OFF all the hardware components For the hardware components see the table above Photos and Illustrations Used in This Manual The appearance of some parts may differ from those on ...

Page 10: ...viii S5 Rev 5 ...

Page 11: ... 2 2 Model Number 19 2 3 Appearance 20 2 4 Specifications 25 2 4 1 Table 25 2 4 2 Option Table 26 2 5 How to Set the Model 27 3 Environment and Installation 28 3 1 Environmental Conditions 28 3 2 Unpacking Transportation and Relocation 30 3 2 1 Using a Crane 31 3 2 2 Using a Forklift 32 3 2 3 Removing Attaching the Shipping Bolts and Jigs 32 3 2 4 Relocating 33 3 3 Mounting Dimensions 34 3 4 Insta...

Page 12: ...nation 67 5 3 Coordinate System 69 5 4 Setting the Cartesian Rectangular Range in the XY Coordinate System of the Manipulator 69 Maintenance 1 Safety Maintenance 73 2 Periodic Inspection 75 2 1 Schedule for Maintenance Inspections 75 2 2 Inspection Tasks 76 2 3 Grease Replenishment 78 2 3 1 Joint 1 Reduction Gear Unit 80 2 3 2 Joint 1 Gear 81 2 3 3 Joint 2 Reduction Gear Unit 82 2 3 4 Joint 3 Redu...

Page 13: ...he Reduction Gear Unit 133 6 3 Replacing the Joint 3 Timing Belt 140 7 Joint 4 142 7 1 Replacing the Joint 4 Motor 142 7 2 Replacing the Joint 4 Reduction Gear Unit 145 7 2 1 Greasing the Reduction Gear Unit 146 7 2 2 Replacing the Reduction Gear Unit 147 7 3 Replacing the Joint 4 Timing Belt 153 8 Joint 5 Joint 6 155 8 1 Replacing the Joint 5 Joint 6 Motor 155 8 2 Replacing the Joint 5 Joint 6 Ti...

Page 14: ...xii S5 Rev 5 12 Calibration 188 12 1 Overview 188 12 2 Calibration Procedure 190 12 3 Calibration Jig 193 13 Maintenance Parts List 195 13 1 Standard 195 13 2 Option 197 ...

Page 15: ...Setup Operation This volume contains information for setup and operation of the Manipulators Please read this volume thoroughly before setting up and operating the Manipulators ...

Page 16: ......

Page 17: ...ations are indicated throughout the manual by the following symbols Be sure to read the descriptions shown with each symbol WARNING This symbol indicates that a danger of possible serious injury or death exists if the associated instructions are not followed properly WARNING This symbol indicates that a danger of possible harm to people caused by electric shock exists if the associated instruction...

Page 18: ...rements before designing and or constructing the robot system Designing and or constructing the robot system without understanding the safety requirements is extremely hazardous and may result in serious bodily injury and or severe equipment damage to the robot system and may cause serious safety problems The Manipulator and the Controller must be used within the environmental conditions described...

Page 19: ...whenever the Manipulator moves abnormally while the robot system is operated Continuing the operating the robot system while the Manipulator moves abnormally is extremely hazardous and may result in serious bodily injury and or severe equipment change to the robot system WARNING Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source To shut...

Page 20: ...h unnecessarily while the Manipulator is operating Pressing the switch during the operation makes the brakes work This will shorten the life of the brakes due to the worn friction plates Normal brake life cycle About 2 years when the brakes are used 100 times day Before using the Emergency Stop switch be aware of the followings The Emergency Stop E STOP switch should be used to stop the Manipulato...

Page 21: ... of the end effector and work piece WEIGHT SPEED ACCEL settings operating pose etc The free running time angle distance of the Manipulator are shown below Conditions of Measurement ACCEL Setting 100 SPEED Setting 100 Load kg 5 WEIGHT Setting 5 RC180 RC620 S5 A701 S5 A901 Free running time second Arm 1 0 4 Arm 2 0 4 Arm 3 0 4 Arm 4 0 4 Arm 5 0 4 Arm 6 0 1 Free running angle degree Arm 1 80 70 Arm 2...

Page 22: ...rake Follow either method to release the electromagnetic brake and move the arms manually 1 5 1 Moving the Arm Using the Brake Release Unit Follow the method when you just unpack the delivered boxes or when the Controller does not start up yet 1 5 2 Moving the Arm Using the Software Follow the method when you can use the software Arm Motion J1 J1 J2 J2 J3 J4 J4 J5 J5 J6 J6 J3 Joint 1 Arm 2 Lower A...

Page 23: ...ne by one If you need to release some brakes at a time take a great care Because when some joints are released at a time the arms may fall to unintended directions This is extremely dangerous and may break the manipulator or catch your hand fingers Take care of the arm downward motion when the brake is released While you are pressing the brake release switch the arm moves downward by its own weigh...

Page 24: ...ed If you turn ON the brake release unit without the connector it may lead to the short for the male pin used in the connector Before turning ON the brake release unit make sure that the connector is connected When you purchased several S5 series Manipulators and use the brake release unit in the manipulator without the connection cable you need to change the connection cable inside the manipulato...

Page 25: ...ide Connect the connection cable to the connector plate 2 M4 10 Connection cable Connector plate 5 Take out the connector of internal cable SW1 Internal short connector 6 Disconnect the internal short connector Keep the short connector to the inside of base or somewhere not to lose 7 Connect the connection cable and internal cable SW1 Connector SW1 Connection cable 8 Mount the connector plate Be c...

Page 26: ...t the brake release unit to the connector of the connection cable Connector of the connection cable Remove the brake release unit 1 Turn OFF the brake release unit 2 Remove the power cable of the brake release unit 3 Disconnect the brake release unit from the connector of connection cable 4 Connect the external short connector to the connector of connection cable ...

Page 27: ...it described in the previous page 2 Plug the power cable into the brake release unit 3 Plug the power cable into the power supply plug 4 Turn ON the brake release unit When the brake release unit is enabled the power lamp lights up 5 Press the arm switch J1 J6 you want to move and then move the arm Press the switch again then the brake will be released The brake will be enabled by pressing the swi...

Page 28: ... may cause hands and fingers to be caught and or may cause equipment damage to or malfunction of the Manipulator Before releasing the brake be sure to keep the Emergency Stop switch handy so that you can immediately press the Emergency Stop switch If you cannot immediately press the Emergency Stop switch you have no means to stop the arms urgently when a wrong operation causes the arm to fall The ...

Page 29: ...paratively high joint torque may be generated Be careful not to get hands or fingers caught during operations The Manipulator may also collide with peripheral equipment and it may cause equipment damage to or malfunction of the Manipulator Max Joint Torque in Low Power Status Unit N m Joint 1 2 3 4 5 6 S5 A701 121 80 135 82 56 59 12 72 19 21 8 01 S5 A901 167 06 169 78 70 74 12 72 19 21 8 01 CAUTIO...

Page 30: ... the labels to operate and maintain the Manipulator safely Do not tear damage or remove the labels Use meticulous care when handling those parts or units to which the following labels are attached as well as the nearby areas Location of Labels Labels Location of Labels Labels 1 NOTE Hazardous voltage exists while the Manipulator is ON To avoid electric shock do not touch any internal electric part...

Page 31: ...Setup Operation 1 Safety S5 Rev 5 17 Location of Labels 1 1 1 3 2 5 4 6 7 Back View Lateral View Left side Lateral View Right side Front View ...

Page 32: ... 2 High accuracy trajectory control The accuracy of CP trajectory control has been improved so that you can operate the Manipulator with more flexibility while taking advantage of six degrees of freedom 3 Available for large payloads Large allowable moment of inertia has made it possible to support relatively large payloads Optimal control for payload by using the WEIGHT and INERTIA commands make ...

Page 33: ...17 cm3 1cft sample air around the center of the motion rang 10 particles or less Exhaust System Exhaust port diameter Inner diameter ø12 mm Outer diameter ø16 mm Exhaust tube Polyurethane tube Outer diameter ø12 mm Inner diameter ø8 mm or Inner diameter ø16mm Recommended exhaust flow rate Approx 1000 cm3 s Normal Protection model IP65 The Protection model Manipulators operate under adverse conditi...

Page 34: ...Arm 6 The wrist rotates Joint 1 Arm 2 Lower Arm Arm 3 Arm 4 Joint 6 Joint 3 Joint 4 Arm 1 Joint 5 Arm 6 Base Joint 2 LED Lamp This lamp lights up while the motors are ON Upper Arm Arms 3 to 6 Arm 5 Details of Connector Plate View A E F A B C D Standard model Protection model G Cleanroom model A Grease Supply Opening B User Cable Connector 15 pin D sub connector C Air Supply Opening D Air Supply Op...

Page 35: ...5 A701 Unit mm 87 298 59 114 330 310 100 305 88 109 109 2 2 M4 Tap P0 7Depth 8 mm Front Back 40 66 199 150 2 70 25 623 2 55 423 473 90 or more 40 110 80 752 4 M8 Tap P1 25 Depth 16mm 2 M4 Tap P0 7 Depth 8mm Air Supply Opening M5 Tap with cover plug Space for cables ...

Page 36: ...Unit mm 87 398 114 330 400 100 405 88 109 109 40 66 199 150 2 70 25 723 2 55 523 573 40 110 80 842 2 2 M4 Tap P0 7Depth 8 mm Front Back 90 or more 4 M8 Tap P1 25 Depth 16mm 2 M4 Tap P0 7 Depth 8mm Air Supply Opening M5 Tap with cover plug Space for cables ...

Page 37: ... 15 225 40 310 330 156 179 752 948 246 51 233 114 277 203 246 239 Joint 1 0 pulse position 170 Arm 1 170 Arm 1 P point Joint 2 0 pulse position Joints 3 5 0 pulse position Motion range of P point P point Intersection of the rotation centers for Joints 4 5 and 6 Joints 4 6 0 pulse position Front View Top View Lateral View P point Motion range of P point ...

Page 38: ...00 330 97 317 842 1137 423 14 341 132 400 209 251 198 Joint 1 0 pulse position 170 Arm 1 170 Arm 1 P point Joint 2 0 pulse position Joints 3 5 0 pulse position Motion range of P point P point Intersection of the rotation centers for Joints 4 5 and 6 Joints 4 6 0 pulse position Front View Top View Lateral View P point Motion range of P point ...

Page 39: ...0 deg 65 deg Arm 3 70 deg 190 deg 72 deg 190 deg Arm 4 190 deg Arm 5 135 deg Arm 6 360 deg Max pulse range Arm 1 5920402 pulse Wall mounting 1044777 pulse 8120639 pulse Wall mounting 1433054 pulse Arm 2 2524350 pulse 5825423 pulse 3155438 pulse 7281778 pulse Arm 3 6149057 pulse 2265442 pulse 7686321 pulse 2912712 pulse Arm 4 5534152 pulse Arm 5 3932160 pulse Arm 6 6553600 pulse Resolution Arm 1 0 ...

Page 40: ...ection Restrictions on payload exceeding 5 kg more than 5 kg and less than or equal to 7 kg in the Setup Operation 4 3 1 WEIGHT Setting 3 In the case where the center of gravity is at the center of each arm If the center of gravity is not at the center of each arm set the eccentric quantity using INERTIA command 4 For details of the environmental requirements refer to the Setup Operation 3 1 Envir...

Page 41: ...erly Improper setting of the Manipulator model may result in abnormal or no operation of the Manipulator and or cause safety problems If an MT label is attached to the rear of a Manipulator the Manipulator has custom specifications If the Manipulator has custom specifications the methods for setting the model may differ from those described below Please contact us with the number on the MT label T...

Page 42: ...0 to 80 no condensation First transient burst noise 2 kV or less Power wire 1 kV or less Signal wire Electrostatic noise 4 kV or less Environment Install indoors Keep away from direct sunlight Keep away from dust oily smoke salinity metal powder or other contaminants Keep away from flammable or corrosive solvents and gases Keep away from water Keep away from shock or vibration Keep away from sourc...

Page 43: ...revent dust water etc from the outside Follow the precautions in use environment described below The surface of the Manipulator has general oil resistance However if your requirements specify that the Manipulator must withstand certain kinds of oil please consult your distributor Rapid change in temperature and humidity can cause condensation inside the Manipulator If your requirements specify tha...

Page 44: ... CAUTION When removing the anchor bolts support the Manipulator to prevent falling Removing the anchor bolts without supporting the Manipulator may get hands fingers or feet caught as the Manipulator will fall Do not remove the wire tie securing the arm until you finish the installation You may get your hands caught in the Manipulator when the wire tie is removed before completing the installation...

Page 45: ...tor After transporting the Manipulator remove the eyebolts and keep them for future use When transporting the Manipulator for a long distance secure it to the delivery equipment so that the Manipulator cannot fall If necessary pack the Manipulator in the same way as it was delivered When condensation occurs on the Manipulator during transport or storage turn ON the power only after the condensatio...

Page 46: ...he Manipulator must be performed slowly in order to avoid overturning or slippage Transporting Posture Pallet Bolt 4 M10 Inset here the forklift claws Controller 3 2 3 Removing Attaching the Shipping Bolts and Jigs The shipping bolts and jigs are attached to the Manipulator as shown the figure below points A B for protecting the Manipulator from various external forces during transportation The ji...

Page 47: ... shipping jigs at the point A with the bolts 6 M5 14 hexagon socket head cap bolts with plain washers and disc spring washers 3 2 4 Relocating Follow the procedures described below when relocating the Manipulator 1 Turn OFF the power for all devices and unplug the cables Remove the mechanical stops if using them to limit the motion range For details on the motion range refer to the Setup Operation...

Page 48: ...ipment Space for teaching points Space for maintenance and inspections Space for cables The minimum bend radius of the power cable is 90 mm When installing the cable be sure to maintain sufficient distance from obstacles In addition leave enough space for other cables so that they are not bent forcibly Mounting Dimensions Unit mm A 90 105 100 0 05 194 160 138 160 194 100 0 05 Power Cable View A 4 ...

Page 49: ...d may result in serious bodily injury and or severe equipment damage to the robot system as the Manipulator may fall down Before installing and operating the Manipulator make sure that all parts of the Manipulator are in place and have no external defects Missing or defective parts may cause improper operation of the Manipulator Improper operation of the Manipulator is extremely hazardous and may ...

Page 50: ...0 N Max Vertical rotating torque 800 N m 900 N m Max Vertical reaction force 3000 N 3500 N There are 4 threaded holes for the Manipulator base Use M10 mounting bolts conforming to the strength ISO898 1 property class 12 9 For the dimensions refer to the Setup Operation 3 3 Mounting Dimensions The plate for the Manipulator mounting face should be 30 mm thick or more and made of steel to reduce vibr...

Page 51: ... to withstand maximum torque and reaction force of the Manipulator refer to the table in Setup Operation 3 4 1 Base Table Mounting As a rough standard when there is a concrete floor with thickness of 150 mm or more the base of the Manipulator can be secured directly to the floor with M10 anchor bolts However before mounting the Manipulator check that the floor is level and that all cracks etc are ...

Page 52: ...be ø 8 mm to the exhaust port 3 4 4 Protection model Refer to the installation procedure of each Manipulator model and install the Manipulator When the Manipulator is a Protection model be aware of the followings WARNING Connect the power cable connection and the signal cable connector to the Manipulator immediately after the Manipulator installation The Manipulator without connecting them may res...

Page 53: ...bend or pull the cables forcibly The unnecessary strain on the cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock and or improper function of the robot system Before wiring turn OFF the Controller and related equipment and then pull up a warning sign e g DO NOT TURN O...

Page 54: ...ator is a Protection model be aware of the followings WARNING Connect the power cable connection and the signal cable connector to the Manipulator immediately after the Manipulator installation The Manipulator without connecting them may result in electric shock and or malfunction of the robot system as it cannot ensure IP65 CAUTION When operating the Manipulator under special environmental condit...

Page 55: ...nding electrodes may result in electric shock and or malfunction of the robot system When using metal ducts metallic conduits or distributing racks for cable ground in accordance with national and local electric equipment technical standards Grounding that dose not meet the standards may result in electric shock and or malfunction of the robot system Follow local regulations for grounding It is re...

Page 56: ...a How to set the reference points for calibration 1 Decide the reference points The reference points should be two or more around the points poses where your Manipulator moves frequently Also Arms 2 3 and 5 should not form a straight line at these reference points the Manipulator should not stretch completely Be sure that the Manipulator moves to the reference points without problems 2 Attach the ...

Page 57: ...he Setup Controller dialog Select Robot Calibration and Hofs values are indicated EPSON RC 6 0 RC620 Select menu Setup System Configuration Robot Robot Calibration To save the Hofs value to a file click the Save button 6 Remove the calibration jigs When using the jigs explained in the Maintenance 12 3 Calibration Jig remove the jig attached to the end effector after setting the reference points an...

Page 58: ...the connectors on both ends of the cables are connected Pneumatic Tubes Max Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter Inner Diameter 0 49 MPa 5 kgf cm2 71 psi 2 ø 6 mm ø 4 mm Fittings for ø 6 mm outer diameter pneumatic tubes are supplied on the both ends of the pneumatic tubes When the Manipulator is a Protection model be aware of the followings CAUTION Be sure to use IP65 complian...

Page 59: ...le tube outside diameter φ 6 mm View A View B Numbers of Pins in Use Pin JAZ 15S 3 Female pin JAZ 15P 3 Male pin B side A side The same pin number 1 15 of two connectors is connected in the lead line of single 0 2 mm2 When the Manipulator is a Protection model be aware of the followings CAUTION Be sure to attach the cap on the user cable connector when not using the connector Using the Manipulator...

Page 60: ...c tubes may damage the robot system and or work piece as the work piece is released when the Emergency Stop switch is pressed I O outputs are configured at the factory so that they are automatically shut off 0 by power disconnection the Emergency Stop switch or the safety features of the robot system Wrist Flange Ø12H7 45 P C D 31 5 5 Fitting depth 4 M5 Tap P0 8 Depth 9 mm ø5H7 hole Depth 7mm degr...

Page 61: ...P0 7 Depth 8 mm Front Back 4 M8 P1 25 Depth 16 mm 4 3 WEIGHT and INERTIA Settings The WEIGHT and INERTIA commands are for setting the load parameters of the Manipulator These settings optimize the Manipulator motion WEIGHT Setting The WEIGHT command is for setting the load weight The more the load weight increases the more the speed and acceleration deceleration for the Manipulator movement are re...

Page 62: ...eries Manipulators When the load of the Manipulator is more than 5 kg and less than or equal to 7 kg refer to the section Setup Operation 4 3 1 WEIGHT Setting Restriction on payload exceeding 5 kg more than 5 kg and less than or equal to 7 kg Allowable Moment and Moment of Inertia for S5 series Manipulators Arm Allowable Moment N m kgf m 1 GD 2 4 Allowable Moment of Inertia kg m 2 4 12 1 22 0 3 5 ...

Page 63: ...ound down m 244 mm c mm Distance from the Arm 5 rotation center mm 80 mm c 244 mm 80 mm 164 mm Moment A moment is a necessary torque holding torque to counteract the gravity affecting the load Design an end effector so that the eccentric quantity at the position where the load is attached is within the allowable moment A maximum torque T is calculated by the following formula T m kg L m g m s2 m W...

Page 64: ...he Manipulator and or shorten the life cycle of parts mechanisms The acceptable weight capacity end effector and work piece for S5 series Manipulators is 2 kg nominal rating and 5 7 kg maximum When the load weight of the end effector and work piece exceeds the rating change the setting of the Weight parameter After the setting of the Weight parameter is changed the maximum acceleration deceleratio...

Page 65: ...eight assuming that the equipment is attached to the end of the Arm 6 Then this equivalent weight added to the load will be a Weight parameter Calculate the Weight parameter by following the formula below and enter the value Weight Parameter Formula Weight parameter Mw Wa Mw Wa Load on the fore end of Arm 6 kg Equivalent weight of the upper arm deck kg Wa ma La L ma L La Weight of the equipment on...

Page 66: ...p Mw Wa 1 0 04 1 04 Enter 1 04 for the Weight parameter Automatic speed setting by Weight parameter Speed Acceleration Deceleration Weight Parameter The percentage in the graph is based on the speed at rated weight 2 kg as 100 When the payload of the Manipulator is more than 5 kg and less than or equal to 7 kg refer to the section Restrictions on payload exceeding 5 kg more than 5 kg and less than...

Page 67: ...rm pose restriction of the Arm 5 is equivalent to the tilt restriction of working plane A2 In the case of eccentric load the restricted angle is an angle B forming with a vertical line and a straight line passing through the center of gravity of load and the rotation center of Arm 5 The eccentric quantity of load should be within the allowable moment and the allowable moment of inertia of Arms 4 5...

Page 68: ...tia Setting a value that is smaller than the actual moment of inertia may cause errors excessive shock insufficient function of the Manipulator and or shorten the life cycle of parts mechanisms The acceptable moment of inertia of load in S5 series Manipulator is 0 1 kg m2 nominal rating and 0 1 kg m2 maximum When the moment of inertia of load exceeds the rating change the setting of the moment of ...

Page 69: ... the parameter enter the larger value of a or b Eccentric Quantity Eccentric quantity of load on Arm 6 The eccentric quantity of load weight of the end effector and work piece on Arm 6 can be set by the eccentric quantity parameter of the INERTIA command Enter the larger value of a or b in the figure above to the Eccentricity text box The method for setting the parameter varies with the software u...

Page 70: ... entire load is calculated by the sum of each part a b and c Work Piece b Work Piece c End Effector a Rotation Center Moment of Inertia of End Effector a Moment of Inertia of Work Piece b Moment of Inertia of Work Piece c Whole Moment of Inertia The methods for calculating the moment of inertia for a b and c are shown on this page or the next page Find the whole moment of inertia using the basic f...

Page 71: ...L Weight m Rectangular Parallelepiped s Center of Gravity Rotation Center m m L 2 b 2 h 2 12 b Moment of inertia of a cylinder m m L 2 r 2 2 Weight m L r Cylinder s Center of Gravity Rotation Center c Moment of inertia of a sphere m r 2 m L 2 2 5 Sphere s Center of Gravity r Weight m L Rotation Center ...

Page 72: ...he acceleration deceleration of Arm 6 are controlled according to the moment of inertia set by the INERTIA command The acceleration deceleration of the whole Manipulator are controlled according to the eccentricity set by the INERTIA command The more the moment of inertia and eccentricity of the load increase the more the acceleration deceleration are reduced Auto Acceleration Deceleration Accordi...

Page 73: ...Motion Range in the Setup Operation 2 3 Appearance This is the maximum motion range of the Manipulator There are three methods for setting the motion range described as follows 1 Setting by pulse range for all arms 2 Setting by mechanical stops 3 Setting the Cartesian rectangular range in the X Y coordinate system of the Manipulator Mechanical Stop Rectangular Range Setting Pulse Range Motion Rang...

Page 74: ... 3 5 1 4 Max Pulse Range of Arm 4 5 1 5 Max Pulse Range of Arm 5 5 1 6 Max Pulse Range of Arm 6 CAUTION Do not set and or use the Arm 4 with pulse range beyond the maximum value The Arm 4 does not have a mechanical stop The used of Arm 4 in motion exceeding the maximum pulse range may cause inner wiring damage to and or malfunction of the Manipulator Once the Manipulator receives an operating comm...

Page 75: ...gure below Counterclockwise pulse values are positive and clockwise pulse values are negative S5 A701 Top View 170 170 5920402 pulse 5920402 pulse 30 30 1044777 pulse 1044777 pulse Arm 1 0 pulse position Arm 1 S5 A901 Top View 170 170 8120639 pulse Arm 1 8120639 pulse 30 30 1433054 pulse 1433054 pulse Arm 1 0 pulse position ...

Page 76: ...rm 2 is shown in the figure below Counterclockwise pulse values are positive and clockwise pulse values are negative S5 A701 Lateral View 150 deg 65 deg Arm 2 0 pulse position 2524350 pulse Arm 2 5825423 pulse S5 A901 Lateral View 150 deg 65 deg 3155438 pulse 7281778 pulse Arm 2 0 pulse position Arm 2 ...

Page 77: ...rm 3 is shown in the figure below Counterclockwise pulse values are positive and clockwise pulse values are negative S5 A701 Lateral View 70 deg 190 deg Arm 3 0 pulse position 6149057 pulse Arm 3 2265442 pulse S5 A901 Lateral View 72 deg 190 deg Arm 3 0 pulse position 7686321 pulse Arm 3 2912712 pulse ...

Page 78: ...nt View 190 deg Arm 4 0 pulse position 5534152 pulse 190 deg Arm 4 5534152 pulse S5 A901 Front View 190 deg Arm 4 0 pulse position 5534152 pulse 190 deg Arm 4 5534152 pulse CAUTION Do not set and or use the Arm 4 with pulse range beyond the maximum value The Arm 4 does not have a mechanical stop The used of Arm 4 in motion exceeding the maximum pulse range may cause inner wiring damage to and or m...

Page 79: ...m 5 is shown in the figure below Counterclockwise pulse values are positive and clockwise pulse values are negative S5 A701 Lateral View 135 deg Arm 5 0 pulse position 135 deg Arm 5 3932160 pulse 3932160 pulse S5 A901 Lateral View 135 deg Arm 5 0 pulse position 135 deg Arm 5 3932160 pulse 3932160 pulse ...

Page 80: ...Arm 6 is shown in the figure below Clockwise pulse values are positive and counterclockwise pulse values are negative S5 A701 Front View 360 deg Arm 6 0 pulse position 360 deg 6553600 pulse Arm 6 6553600 pulse S5 A901 Front View 360 deg Arm 6 0 pulse position 360 deg 6553600 pulse Arm 6 6553600 pulse ...

Page 81: ... operation is restricted in the specified motion range according to the joint angle combination of the Arm 2 3 and 4 The Manipulator operation is restricted and the Manipulator stops when the joint angles of the Arm are within the gray areas in the following figure Combination of Joint 2 and 3 S5 A701 Joint 2 Angle degree Joint 3 Angle degree S5 A901 Joint 2 Angle degree Joint 3 Angle degree ...

Page 82: ...led During CP motion command execution You attempt to execute the motion command for moving the Manipulator to a target point or pose in the specified motion range The restriction to the Manipulator operation is disabled The Arms of the Manipulator momentarily go through the specified motion range during the PTP motion command execution even though the joint angles of the Arms are in the gray area...

Page 83: ...rea is defined so that the end effector does not interfere with the rear side of the Manipulator The XYLim setting is that you can set the upper and lower limits of the X and Y coordinates The limited Manipulator operation area and XYLim setting apply only to the software Therefore these settings do not change the physical range The maximum physical range is based on the position of the mechanical...

Page 84: ...Setup Operation 5 Motion Range 70 S5 Rev 5 ...

Page 85: ...71 Maintenance This volume contains maintenance procedures with safety precautions for Manipulators ...

Page 86: ...S5 Rev 5 72 ...

Page 87: ...re to check it while you are outside of the safeguarded area Checking the operation of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the Manipulator may move unexpectedly Before operating the robot system make sure that both the Emergency Stop switches and safeguard switches function properly Operating the robot system when the switches do not fu...

Page 88: ...ea thoroughly with soap and water If alcohol liquid gasket or adhesive gets into your eyes or mouth flush your eyes or wash out your mouth with clean water thoroughly and then see a doctor immediately Wear protective gear including a mask protective goggles and oil resistant gloves during grease up If grease gets into your eyes mouth or on your skin follow the instructions below If grease gets int...

Page 89: ... inspections in accordance with the schedule 2 1 Schedule for Maintenance Inspections Inspection tasks are divided into five stages daily 4 months 24 months 48 months and 96 months Move up the regular checks when the Manipulator has been used for the following amount of time Inspection Interval between Inspections Accumulated Operating Time Daily Inspect every day 4 month 4 months 1000 hours 24 mo...

Page 90: ...eplenishment 3 2 3 1 Joint 2 reduction gear unit 24 month Grease gun Check for malfunction Replace if necessary Perform grease replenishment 3 2 3 2 Joint 3 reduction gear unit 24 month Grease gun Check for malfunction Replace if necessary Perform grease replenishment 3 2 3 3 Joint 4 reduction gear unit 24 month Grease gun Check for malfunction Replace if necessary Perform grease replenishment 3 2...

Page 91: ...elated Details Arm 1 4 Oil Seals Daily Visual Keep the oil seals clean removing any dust such as metal powders Drain plug Drain cover 4 month Screw driver Wrench Remove the condensation if it presents in manipulator 4 2 5 4 When the manipulator is used in the environment where rapid changes in temperature and humidity occur perform the inspection more often than specified above ...

Page 92: ...and may result in electric shock and or malfunction of the robot system CAUTION Ensure that there is sufficient grease in the Manipulator Operating the Manipulator with insufficient grease will damage sliding parts and or result in insufficient function of the Manipulator Once the parts are damaged a lot of time and money will be required for the repairs Wear protective gear including a mask prote...

Page 93: ...5 79 Grease Gun Lubrication Nozzle Shape Use a commercially available grease gun We recommend the use of a grease gun with a nozzle shaped like that shown in the figure below and an outer diameter øD 13 mm or less Straight Chuck Hose øD øD øD ...

Page 94: ... cap plug PT1 8 Be sure to remove the plug from the air vent When grease is being added while the plug is in the air vent the internal pressure increases Increasing internal pressure may cause malfunction of the robot system 4 Pump grease into the reduction gear unit from the grease inlet using a grease gun Grease Grease for reduction gear SK 1A Quantity 25 g 5 Operate the Manipulator at low power...

Page 95: ... plug PT1 8 Be sure to remove the plug from the air vent When grease is being added while the plug is in the air vent the internal pressure increases Increasing internal pressure may cause malfunction of the robot system 4 Pump grease into the reduction gear unit from the grease inlet using a grease gun Grease Grease for reduction gear SK 1A Quantity 25 g 5 Operate the Manipulator at low power mod...

Page 96: ...m the air vent Plug LP M5 Be sure to remove the plug from the air vent When grease is being added while the plug is in the air vent grease will go inside the motor and may cause malfunction of the robot system 4 Pump grease into the reduction gear unit from the grease inlet using a grease gun Grease Grease for reduction gear SK 1A Quantity 30 g 5 Operate the Manipulator at low power mode speed for...

Page 97: ...from the air vent Plug LP M5 Be sure to remove the plug from the air vent When grease is being added while the plug is in the air vent grease will go inside the motor and may cause malfunction of the robot system 4 Pump grease into the reduction gear unit from the grease inlet using a grease gun Grease Grease for reduction gear SK 1A Quantity 20 g 5 Operate the Manipulator at low power mode speed ...

Page 98: ...ternal pressure may cause malfunction of the robot system 3 Remove the plug from the grease inlet Plug LP M5 4 Attach a grease nipple to the grease inlet The grease nipple is supplied with the Manipulator Grease nipple M5 5 Pump grease into the reduction gear unit from the grease inlet using a grease gun Grease Grease for reduction gear SK 1A Quantity 7 g 6 Operate the Manipulator at low power mod...

Page 99: ...function of the robot system 2 Remove the plug from the grease inlet Plug LP M5 3 Attach a grease nipple to the grease inlet The grease nipple is supplied with the Manipulator Grease nipple M5 4 Pump grease into the reduction gear unit from the grease inlet using a grease gun Grease Grease for reduction gear SK 1A Quantity 5 g 5 Operate the Manipulator at low power mode speed for one hour to run i...

Page 100: ...lug from the air vent Plug LP M5 Be sure to remove the plug from the air vent When grease is being added while the plug is in the air vent the internal pressure increases Increasing internal pressure may cause malfunction of the robot system 4 Pump grease into the reduction gear unit from the grease inlet using a grease gun Grease Grease for reduction gear SK 1A Quantity 5 g 5 Operate the Manipula...

Page 101: ...es as shown below Bolt Tightening Torque M3 245 N cm 25 kgf cm M4 490 N cm 50 kgf cm M5 980 N cm 100 kgf cm M6 1 760 N cm 180 kgf cm M8 3 720 N cm 380 kgf cm M10 7 350 N cm 750 kgf cm M12 12 740 N cm 1 300 kgf cm We recommend that the bolts aligned on circumference should be fastened in a crisscross pattern as shown in the figure below 1 5 3 7 2 6 4 8 Bolt hole Do not fasten all bolts securely at ...

Page 102: ...the bolt Detach the drain cover and the gasket of the No 1 drain vent Replace the gasket with a new one if it is damaged 2 Remove the drain plug of the No 2 drain vent Drain plug PT1 8 3 Incline the Arm 3 slightly toward the No 2 drain vent side 4 Drain the condensation water 5 Put the gasket between the drain cover and arm and then secure the cover of the No 1 drain vent with the bolt Bolt Apply ...

Page 103: ...lfunction of the robot system When installing the cover be careful not to allow the cables to interfere with the cover mounting and do not bend these cables forcibly to push them into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock a...

Page 104: ...l Remove the gasket with the cover Installation Attach the gasket between the cover and manipulator You can t reuse the gasket Be sure to use a new gasket For protection model Liquid gasket R13B031201 is applied Removal Remove caked on liquid gasket residue with a scraper or similar tool Installation Apply liquid gasket on the contact surfaces of the cover and manipulator Wipe off any excess liqui...

Page 105: ...t is attached S5 A701C R13B031271 S5 A901C R13B031272 Removal Remove the gasket with the cover Installation Attach the gasket between the cover and manipulator You can t reuse the gasket Be sure to use a new gasket For protection model Liquid gasket R13B031201 is applied Removal Remove caked on liquid gasket residue with a scraper or similar tool Installation Apply liquid gasket on the contact sur...

Page 106: ...Removal Remove the gasket with the cover Installation Attach the gasket between the cover and manipulator You can t reuse the gasket Be sure to use a new gasket For protection model Liquid gasket R13B031201 is applied Removal Remove caked on liquid gasket residue with a scraper or similar tool Installation Apply liquid gasket on the contact surfaces of the cover and manipulator Wipe off any excess...

Page 107: ...m model A gasket R13B031274 is attached Removal Remove the gasket with the cover Installation Attach the gasket between the cover and manipulator You can t reuse the gasket Be sure to use a new gasket For protection model Liquid gasket R13B031201 is applied Removal Remove caked on liquid gasket residue with a scraper or similar tool Installation Apply liquid gasket on the contact surfaces of the c...

Page 108: ... between the cover and the body Removal Remove the gasket together with the cover Installation Install the gasket between the cover and the body Do not reuse the gasket Replace it with a new one For Protection model Liquid gasket R13B031201 is applied Removal Scrape off the old liquid gasket with a scraper or a similar tool Installation Apply liquid gasket to the contacting face of the cover and t...

Page 109: ...ats 3 mm Hexagon socket head cap bolts 4 M4 10 Tightening torque 1 4 N m 0 14 kg m For Protection model Remove the bolts and then remove the Connector Sub Plate Remove the gasket the spacer and the seal washer together with the cover Tool Hexagonal wrench width across flats 3 mm Hexagon socket head cap bolts 4 M4 15 Tightening torque 1 4 N m 0 14 kg m ...

Page 110: ...ng any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder Disassembled...

Page 111: ...d water After parts have been replaced motors reduction gear units timing belts etc the Manipulator cannot perform positioning properly because a mismatch exists between the origin stored in each motor encoder and its corresponding origin stored in the Controller After replacing the parts it is necessary to match these origins The process of aligning the two origins is called Calibration Refer to ...

Page 112: ...on bolt 6 M4 10 3 Connect the backup battery to the Joint 1 motor cables 4 Remove the Joint 1 motor cables from the cables inside the manipulator 5 Remove the hexagon socket head cap bolts a 2 M4 25 with disc spring b 2 M4 14 with disc spring 6 Remove the Joint 1 motor with the motor plate Use the hexagon socket head cap bolts as a removal tap 7 Remove the Joint 1 input gear from the Joint 1 motor...

Page 113: ...Maintenance 4 Joint 1 Replacing the Motor S5 Rev 5 99 8 Remove the Joint 1 motor plate from the Joint 1 motor 9 Remove caked on liquid gasket residue with a scraper or similar tool ...

Page 114: ...et head cap bolt 1 M5 16 with disc spring 2H 5 Apply the liquid gasket Tightening torque 10 N m 1 02 kgf m Hold the Joint 1 input gear as shown in the picture while removing the bolt to prevent the gear from turning Wipe excess adhesive from other parts of the motor with a wiping cloth treated with alcohol 4 Apply the liquid gasket on surfaces of the Joint 1 motor plate and the Base Apply the grea...

Page 115: ...ance 4 Joint 1 Replacing the Motor S5 Rev 5 101 7 Remove the backup battery 8 Mount the Bottom Cover Button bolt 6 M4 10 Tightening torque 1 4 N m 0 14 kgf m 9 Put the manipulator in the installation position ...

Page 116: ...to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safety problems Never put alcohol liquid gasket or adhesive...

Page 117: ...the structure details of the reduction gear refer to Maintenance 13 Maintenance Parts List Joint 1 Reduction Gear Unit 4 2 1 Greasing the Reduction Gear Unit CAUTION Wear protective gear including a mask protective goggles and oil resistant gloves during grease up If grease gets into your eyes mouth or on your skin follow the instructions below If grease gets into your eyes Flush them thoroughly w...

Page 118: ...ear Proper quantity SK 1A R13ZA00330100 Grease for oil seal Proper quantity MP 1 R13B030306 Liquid gasket Proper quantity 1206C R13B031201 Material Wire tie Joint 1 Reduction Gear Unit Removal 1 Turn OFF the Controller 2 Remove the cables from inside the manipulator For details refer to Maintenance 9 1 Replacing the Cable Unit 3 Remove the Joint 1 motor For details refer to Maintenance 4 1 Replaci...

Page 119: ...4 10 7 Remove the Joint 1 output gear Hexagon socket head cap bolt 6 M3 30 with disc spring 8 Detach the Base and Arm 1 Hexagon socket head cap bolt 16 M5 30 with disc spring If the Base and Arm 1 are not easily detached tap the corner of the Base using a plastic hammer or similar tool 9 Remove the waveform generator and bearing from the Arm 1 ...

Page 120: ...t 12 M5 40 with disc spring 11 Remove the bearing from the waveform generator using a hand press or similar tool 12 Remove the bearing from the Joint 1 output gear 13 Remove the oil seal from the Arm 1 14 Remove caked on liquid gasket residue with a scraper or similar tool 15 Repair scratches incurred during tap use with a sharpening stone or similar tool ...

Page 121: ...y liquid gasket to contact surfaces of the circular spline flexspline and Arm 1 2 Mount the circular spline flexspline on the Arm 1 Hexagon socket head cap bolt 12 M5 40 with disc spring 2H 5 Tightening torque 8 4 N m 0 86 kgf m 3 Press the bearing into the waveform generator using a hand press or similar tool 4 Apply grease on the bearing of the waveform generator Grease for reduction gear SK 1A ...

Page 122: ...d flexspine of the Base 7 Mount the circular spline and flexspline to the Base Press the bearing into the Joint 1 output gear Put a seal side of the bearing to the gear side Base side and the other side to the Arm side 8 Mount the spacer to the Joint 1 output gear 9 Mount the Joint 1 output gear to the Base Hexagon socket head cap bolt 6 M3 30 with disc spring 2H 3 Tightening torque 2 25 N m 0 23 ...

Page 123: ...on the Base GT SA bolt 7 M4 16 Tightening torque 2 8 N m 0 29 kgf m 14 Mount the shaft to on the flange GT SA bolt 4 M4 12 Apply liquid gasket Tightening torque 2 8 N m 0 29 kgf m Apply grease for the oil seal on the contact surfaces of the O ring and oil seal Grease MP 1 Treat the O ring and oil seal with extra care and prevent from curing up 15 Mount the Joint 1 motor For details refer to Mainte...

Page 124: ...ing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder Disassemble...

Page 125: ...ts timing belts etc the Manipulator cannot perform positioning properly because a mismatch exists between the origin stored in each motor encoder and its corresponding origin stored in the Controller After replacing the parts it is necessary to match these origins The process of aligning the two origins is called Calibration Refer to Maintenance 12 Calibration and follow the steps that pertain to ...

Page 126: ...starting the replacement Joint 2 Motor Removal 1 Remove the Arm 2 Cover For details refer to the Maintenance 3 2 Arm 2 Cover 2 Connect the backup battery to the Joint 2 motor cable 3 Remove the Joint 2 motor cable from inside the manipulator 4 Remove the Joint 2 motor and the motor plate from the Arm 2 GT SA bolt 2 M4 16 with M4 washer 5 Remove the Joint 2 motor plate from the Joint 2 motor Hexago...

Page 127: ... bolt 3 M4 16 with disc spring 2H 4 M4 washer Tightening torque 2 8 N m 0 29 kgf m 3 Place the timing belt around the Joint 2 input pulley and mount the Joint 2 motor to the Arm 2 GT SA bolt 2 M4 16 with M4 washer Tightening torque 2 8 N m 0 29 kgf m Make sure the Arm 2 touches the radiation sheet on the motor side surface It is necessary for the heat radiation of the motor Adjust the belt tension...

Page 128: ...to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safety problems Never put alcohol liquid gasket or adhesive...

Page 129: ...necessary to match these origins The process of aligning the two origins is called Calibration Refer to Maintenance 12 Calibration and follow the steps that pertain to the software you are using to perform the calibration A reduction gear unit consists of the three parts described below When replacing the reduction gear unit be sure to always replace the waveform generator flexspline and circular ...

Page 130: ...iately If grease gets into your mouth If swallowed do not induce vomiting See a doctor immediately If grease just gets into your mouth wash out your mouth with water thoroughly If grease gets on your skin Wash the area thoroughly with soap and water When greasing the reduction gear unit use only the grease specified for the reduction gear unit While greasing the reduction gear unit be careful not ...

Page 131: ...er quantity SK 1A R13ZA00330100 Liquid gasket Proper quantity 1206C R13B031201 Bearing 1 6000ZZ R13B030805 1 6916DDU R13B030806 1 6913ZZ R13B030807 Material Wire tie We recommend folding the upper structure Arms 2 to 6 to the stop side before the replacement Structure of the reduction gear unit for the Joint 2 and Joint 3 are almost same The replacement procedure below uses pictures of Joint 3 Joi...

Page 132: ...t 2 output pulley Hexagon socket head cap bolt 1 M5 20 with disc spring 2H 5 6 From the waveform generator remove the housing 7 From the housing remove the bearing 8 From the waveform generator remove the bearing 9 Remove the circular spline from the Arm 2 Hexagon socket head cap bolt 29 M4 12 with disc spring 2H 4 ...

Page 133: ...are detached Therefore hold the Arm 2 while removing the housing 11 Remove the bearing and oil seal from the Arm 1 12 Remove the flexspline from the Arm 1 Hexagon socket head cap bolt 30 M4 16 with disc spring 2H 4 13 Remove caked on liquid gasket residue with a scraper or similar tool 14 Repair scratches incurred during tap use with a sharpening stone or similar tool NOTE ...

Page 134: ...ocket head cap bolt 30 M4 16 with disc spring 2H 4 Apply liquid gasket Tightening torque 2 8 N m 0 29 kgf m 2 Press the bearing into the Arm 1 Apply adhesive to the contact surface with the Arm 2 Apply liquid gasket to the outer periphery of the bearing Spread flat the adhesive and liquid gasket using a spatula Be careful to keep the liquid gasket out of the bearing 3 Apply grease to the inside an...

Page 135: ...id gasket on the Arm 1 The height of the oil seal surface and Arm 1 surface should be the same 5 Apply grease for the reduction gear unit on the teeth of the flexspline Grease for reduction gear unit SK 1A 6 Press bearing into the waveform generator 7 Apply liquid gasket to the inside of the bearing 8 Press the bearing into the waveform generator NOTE ...

Page 136: ...p bolt 1 M5 20 with disc spring 2H 5 Tightening torque 10 N m 1 02 kgf m 12 Apply grease for the reduction gear unit to the teeth of circular spline Grease for reduction gear unit SK 1A 13 Insert the bearing into the opposite side of the Arm 1 s reduction gear unit mounting surface 14 Pass the circular spline through the Arm 1 and Arm 2 and joint the arms Hexagon socket head cap bolt 29 M4 12 with...

Page 137: ... flexspline Grease for reduction gear unit SK 1A 17 Apply grease to the bearing of waveform generator Grease for the reduction gear unit SK 1A 18 Apply liquid gasket to the surfaces of the housing with the waveform generator mounted and circular spline 19 Mount the housing and circular spline 20 Mount the Joint 2 motor unit to the manipulator For details refer to Maintenance 5 1 Replacing the Join...

Page 138: ...cycle of the motors and encoder and or damage them Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safety problems Never put alcohol liquid gasket or adhesive close to fire Use alcohol liquid gasket or adhesive while ventilating the room Wear protective gear incl...

Page 139: ...he manipulator will lose its posture Therefore hold the Arm 2 to prevent it from turning while replacing the belt Joint 2 Timing belt Installation 1 Set the timing belt on the pulley and loosely secure the motor plate with the bolts GT SA bolt 2 M4 16 with M4 washer 2 Apply the specified tension to the timing belt and secure the motor plate firmly Tightening torque 2 8 N m 0 29 kgf m Belt tension ...

Page 140: ...ing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder Disassemble...

Page 141: ...ts timing belts etc the Manipulator cannot perform positioning properly because a mismatch exists between the origin stored in each motor encoder and its corresponding origin stored in the Controller After replacing the parts it is necessary to match these origins The process of aligning the two origins is called Calibration Refer to Maintenance 12 Calibration and follow the steps that pertain to ...

Page 142: ...3 motor cable from inside of the manipulator 4 Remove the Joint 3 motor and the Joint 3 motor plate from the Arm 2 GT SA bolt 2 M4 16 with M4 washer 5 Remove the Joint 3 motor plate from the Joint 3 motor Hexagon socket head cap bolt 3 M4 16 with disc spring 2H 4 M4 washer 6 Remove the Joint 3 input pulley from the Joint 3 motor Hexagon socket head cap bolt 1 M4 18 with disc spring 2H 4 WARNING Al...

Page 143: ... head cap bolt 3 M4 16 with disc spring 2H 4 M4 washer Tightening torque 2 8 N m 0 29 kgf m 3 Place the Joint 3 timing belt around the Joint 3 input pulley and mount the Joint 3 motor to the Arm 2 GT SA bolt 2 M4 16 with M4 washer Tightening torque 2 8 N m 0 29 kgf m Make sure the Arm 2 touches the radiation sheet on the motor side surface It is necessary for the heat radiation of the motor Adjust...

Page 144: ...to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safety problems Never put alcohol liquid gasket or adhesive...

Page 145: ... When replacing the reduction gear unit be sure to always replace the waveform generator flexspline and circular spline all together as one set For the structure details of the reduction gear refer to Maintenance 13 Maintenance Parts List Joint 3 Reduction Gear Unit 6 2 1 Greasing the Reduction Gear Unit CAUTION Wear protective gear including a mask protective goggles and oil resistant gloves duri...

Page 146: ... use only the grease specified for the reduction gear unit While greasing the reduction gear unit be careful not to allow any foreign substances in the grease Location for applying grease on the teeth of flexspline and circular spline and the waveform generator Circular Spline Flexspline Waveform Generator ...

Page 147: ...nance Parts Reduction gear unit 1 S5 A701 R13B010034 S5 A901 R13B010035 Grease for reduction gear Proper quantity SK 1A R13ZA00330100 Liquid gasket Proper quantity 1206C R13B031201 Adhesive Proper quantity Loctite 242 R13B031701 Bearing 1 6913ZZ R13B030807 1 6000ZZ R13B030805 1 6913DDU R13B030808 Material Wire tie We recommend folding the upper structure Arms 3 to 6 to the stop side before the rep...

Page 148: ...ousing remove the bearing 6 From the waveform generator remove the bearing 7 Remove the circular spline from the Arm 2 Hexagon socket head cap bolt 6 M4 12 8 Remove the housing from the Arm 2 GT SA bolt 6 M4 10 When the housing is removed the Arm 1 and Arm 2 are detached Make sure to hold the Arm 2 while removing the housing NOTE ...

Page 149: ...ing and oil seal from the Arm 3 10 Remove the flexspline from the Arm 3 Hexagon socket head cap bolt 32 M3 10 with disc spring 2H 3 11 Remove caked on liquid gasket residue with a scraper or similar tool 12 Repair scratches incurred during tap use with a sharpening stone or similar tool ...

Page 150: ...ly adhesive to the contact surface with the Arm 3 Apply liquid gasket to the outer periphery of the bearing Spread flat the adhesive and liquid gasket using a spatula Be careful to keep the liquid gasket out of the bearing 3 Apply grease to the inside and lip of the oil seal Grease MP 1 4 Press the oil seal into the Arm 3 Before mounting the oil seal wipe off any liquid gasket on the Arm 3 The hei...

Page 151: ... gasket to inside of the bearing 8 Press the bearing into the waveform generator 9 Apply liquid gasket to inside of the housing 10 Press the waveform generator into the housing 11 Mount the Joint 3 output pulley to the waveform generator Hexagon socket head cap bolt 1 M4 18 with disc spring 2H 4 Tightening torque 4 8 N m 0 49 kgf m ...

Page 152: ...htening torque 2 8 N m 0 29 kgf m 15 Insert the housing into the Arm 2 and bearing GT SA bolt 6 M4 10 Tightening torque 2 8 N m 0 29 kgf m If the housing is not easily inserted tap the housing using a plastic hammer or similar tool 16 Apply 5 mm thick grease for the reduction gear unit to the inner periphery of the flexspline Grease for reduction gear unit SK 1A 17 Apply grease to the bearing of w...

Page 153: ...9 19 Mount the housing and circular spline 20 Mount the Joint 3 motor unit to the manipulator For details refer to Maintenance 6 1 Replacing the Joint 3 Motor 21 Mount the cables to inside of the manipulator For details refer to Maintenance 9 1 Replacing the Cable Unit ...

Page 154: ...uring replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safety problems Never put alcohol liquid gasket or adhesive close to fire Use alcohol liquid gasket or a...

Page 155: ...anipulator will lose its posture Therefore hold the Arm 3 to prevent it from turning while replacing the belt Joint 3 Timing belt Installation 1 Set the timing belt on the pulley and loosely secure the motor plate with the bolts GT SA bolt 2 M4 16 with M4 washer 2 Apply the specified tension to the timing belt and secure the motor plate firmly Tightening torque 2 8 N m 0 29 kgf m Belt tension 57 9...

Page 156: ...s The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and encoder will cause a positional gap and cannot be used again Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safet...

Page 157: ...Note Maintenance Parts AC servo motor 1 50W R13B000628 Grease for reduction gear Proper quantity SK 1A R13ZA00330100 Liquid gasket Proper quantity 1206C R13B031201 Adhesive Proper quantity Loctite 242 R13B031701 Material Wire tie Joint 4 Motor Removal 1 Remove the Arm 3 Cover For details refer to Maintenance 3 3 Arm 3 Cover 2 Remove the LED lamp 3 Remove the bolts that secure the supporting plate ...

Page 158: ...e the grooves of the pulley to prevent the motor from turning 2 Set the belt around the pulley and mount the Joint 3 motor to the Arm 3 GT SA bolt 2 M3 12 with M3 washer Tightening torque 1 4 N m 0 14 kg m From the Arm 3 side surface confirm that the timing belt is properly set on the pulley 3 Mount the Joint 4 motor cable to the lead line 4 Remove the backup battery 5 Mount the supporting plate o...

Page 159: ...to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safety problems Never put alcohol liquid gasket or adhesive...

Page 160: ... refer to Maintenance 13 Maintenance Parts List Joint 4 Reduction Gear Unit 7 2 1 Greasing the Reduction Gear Unit CAUTION Wear protective gear including a mask protective goggles and oil resistant gloves during grease up If grease gets into your eyes mouth or on your skin follow the instructions below If grease gets into your eyes Flush them thoroughly with clean water and then see a doctor immed...

Page 161: ...13ZA00330100 Liquid gasket Proper quantity 1206C R13B031201 Adhesive Proper quantity Loctite 242 R13B031701 Bearing 1 6806ZZ R13B030810 1 6808ZZ NS7 R13B030809 Material Wire tie Joint 4 Reduction Gear Unit Removal 1 Pull out the lead line toward the Arm 2 side For details refer to Maintenance 9 1 Replacing the Cable Unit 2 Remove the bolts and then remove the pipe GT SA bolt 2 M3 12 3 Remove he bo...

Page 162: ...rator GT SA bolt 3 M3 10 7 Remove the bolts and then remove the Joint 4 reduction gear unit using the removal tap Hexagon socket head cap bolt 16 M3 20 with disc spring 2H 3 8 Remove the bearing from the housing 9 Remove the bearing from the waveform generator 10 Remove caked on liquid gasket residue with a scraper or similar tool 11 Repair scratches incurred during tap use with a sharpening stone...

Page 163: ...to the spacer Hexagon socket head cap bolt 12 M3 30 with disc spring 2H 3 Apply liquid gasket 1206C Tightening torque 1 4 N m 0 14 kgf m 3 Apply liquid gasket to inner periphery of the bearing Press the bearing into the waveform generator Bearing 6806ZZ Liquid gasket 1206C 4 Apply liquid gasket to the inner periphery of the bearing Press the bearing into the waveform generator Bearing 6808ZZ NS7 L...

Page 164: ...phery of the bearing Bearing 6808ZZ NS7 Liquid gasket 1206C 9 Apply liquid gasket to contact surfaces of the housing circular spline and flexspline Liquid gasket 1206C 10 Mount the housing to the circular spline and flexspline Hexagon socket head cap bolt 16 M3 20 with disc spring 2H 3 Tightening torque 1 4 N m 0 14 kgf m 11 Mount the pulley and washer to the waveform generator GT SA bolt 3 M3 10 ...

Page 165: ...orque 10 N m 1 02 kgf m 15 Apply liquid gasket to the contact surfaces of the spacer and Arm 3 Liquid gasket 1206C 16 Mount the spacer to the Arm 3 Hexagon socket head cap bolt 4 M6 16 with disc spring 2H 6 Tightening torque 10 N m 1 02 kgf m 17 Set the belt around the belt and mount the Joint 4 motor to the Arm 3 GT SA bolt 2 M3 12 with M3 washer Tightening torque 1 4 N m 0 14 kg m From the Arm 3...

Page 166: ...fied tension is applied to the belt Belt tension 19 6 26 5 N 2 0 2 7 kgf 19 Mount the pipe to the Arm 3 GT SA bolt 2 M3 12 Tightening torque 1 4 N m 0 14 kgf m Be careful of the pipe direction See the photo 20 Mount the lead line For details refer to Maintenance 9 1 Replacing the Cable Unit NOTE ...

Page 167: ...n the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder Disassembled motor and encoder will cause a positional gap and cannot be used again Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safety problems Never put alc...

Page 168: ... 2 Remove the timing belt Follow the removal steps 1 to 4 in Maintenance 7 2 2 Replacing the Joint 4 Reduction Gear Unit Timing belt Joint 4 Timing belt Installation 1 Mount the timing belt Follow the installation steps 17 to 21 in Maintenance 7 2 2 Replacing the Joint 4 Reduction Gear Unit 2 Mount the Arm 3 Cover For details refer to Maintenance 3 3 Arm 3 Cover ...

Page 169: ...lacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and encoder will cause a positional gap and cannot be used again Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a...

Page 170: ...l disengage the brake which may cause the Manipulator to fall and may result in serious bodily injury and or severe equipment damage Joint 5 6 Motor Removal 1 Remove the Arm 4 Cover For details refer to Maintenance 3 4 Arm 4 Cover 2 Connect the backup battery to the motor cable 3 Remove the motor cable from the lead line 4 Remove the bolts and then remove the motor plate and motor from the Arm 4 G...

Page 171: ...and then remove the bracket Hexagon socket head cap bolt 2 M2 6 5 GT SA bolt 2 M3 12 7 Remove the electromagnetic brake 8 Remove the bolts and then remove the motor plate GT SA bolt 2 M3 12 with M3 washer 9 Remove the set screws and then remove the rotor hub Hexagon socket head cap set screw 2 M2 ...

Page 172: ...pacer or similar tool to secure the rotor hub at 2 mm from the motor edge surface 2 mm 2 Mount the motor plate to the motor GT SA bolt 2 M3 12 with M3 washer Tightening torque 1 4 N m 0 14 kgf m 3 Insert the electromagnetic brake into the rotor hub 4 Mount the bracket using the brake centering jig The processed spacer as shown in the photo does not need the brake centering jig Hexagon socket head ...

Page 173: ...alfunction 6 Mount the pulley and then secure the brake cable with a wire tie Hexagon socket head cap bolt M3 30 with disc spring 2H 3 Apply adhesive Tightening torque 2 25 N m 0 23 kgf m 7 Mount the motor plate and motor to the Arm 4 GT SA bolt 2 M4 16 with M4 washer 8 Set the timing belt on the pulley and adjust the belt tension For details refer to Maintenance 8 2 Replacing the Joint 5 Joint 6 ...

Page 174: ...l not to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life cycle of the motors and encoder and or damage them Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Careless use of alcohol liquid gasket or adhesive may cause a fire and or safety problems Never put alcohol liquid gasket or ad...

Page 175: ...e timing belt from the pulley GT SA bolt 2 M4 16 with M4 washer Joint 5 6 Timing Belt Installation 1 Insert the motor unit to its original position in the Manipulator 2 Set the timing belt on the pulley and loosely fasten the motor plate with the bolts GT SA bolt 2 M4 16 with M4 washer 3 Apply the specified tension to the timing belt and firmly fasten the motor plate Tightening torque 2 8 N m 0 29...

Page 176: ...ough 9 in Maintenance 8 1 Replacing the Joint 5 Joint 6 Motor Joint 5 Joint 6 Electromagnetic brake Installation 1 Mount the electromagnetic brake For details refer to Installation Steps 1 through 11 in Maintenance 8 1 Replacing the Joint 5 Joint 6 Motor Name Quantity Note Maintenance Parts Electromagnetic brake Joint 5 1 R13B030508 Electromagnetic brake Joint 6 1 R13B030510 Adhesive Proper amount...

Page 177: ... the cables Do not put heavy objects on the cables Do not bend or pull the cables forcibly The unnecessary strain on the cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock and or improper function of the robot system 9 1 Replacing the Cable Unit If the power and signa...

Page 178: ...room Wear protective gear including a mask protective goggles and oil resistant gloves If alcohol liquid gasket or adhesive gets on your skin wash the area thoroughly with soap and water If alcohol liquid gasket or adhesive gets into your eyes or mouth flush your eyes or wash out your mouth with clean water thoroughly and then see a doctor immediately Wear protective gear including a mask protecti...

Page 179: ...aintenance 3 Covers for details on removing covers 3 Cut the wire ties that bind six connector packs power system signal system of the motors of the Joints 1 2 3 4 5 and 6 4 Connect the motor encoder backup battery for the Joint 1 2 3 4 5 and 6 motor to the each motor If you unplug the power cable and signal cable without connecting the backup batteries for the motor encoders the position data in ...

Page 180: ...Cut off the wire ties and pull out the lead line toward the Arm 3 To pull out the lead line smoothly bind the connectors with a tape as shown in the picture below 13 Remove the connectors of power cable and signal cable Connector For Joint 2 L For Joint 3 U 14 Cut off all wire ties that secure the lead line inside the Arm 2 15 Remove the saddle Hexagon socket head cap bolt 2 M4 8 with disc spring ...

Page 181: ... 4 M4 washer and rubber plate 17 Pull out the lead line toward the Arm 2 18 Remove the supporting plate GT SA bolt 2 M4 12 19 Remove the saddle GT SA bolt 2 M5 10 with M5 washer 20 Remove the connectors of power cable and signal cable Connector For Joint 1 S 21 Pull out the lead line by pulling the connector plate ...

Page 182: ...nd Arm 1 to Arm 4 2 Connect the Joint 1 motor connector to the lead line Remove the backup battery 3 Press the lead line into the Base and mount the Connector Plate Hexagon socket button head bolt 8 M4 10 Tightening torque 1 4 N m 0 14 kgf m Be careful not to catch the cables between the Base and the Connector Plate 4 Put the lead line around the Arm 3 as shown in the picture 5 Pass a wire tie thr...

Page 183: ...4 10 Tightening torque 2 8 N m 0 29 kgf m 8 Secure the cables to the supporting plate as shown in the picture 9 Loosely secure the cables in the Arm 3 with a wire tie 10 Secure the supporting plate to the Arm 3 GT SA bolt 2 M4 10 Tightening torque 2 8 N m 0 29 kgf m 11 Mount the saddle to the spring some winds from the end of the lead line ...

Page 184: ...onnect the connector to the lead line Remove the backup battery Connector For Joint 2 L For Joint 3 U 15 Mount the rubber plate and saddle to the spring some winds from the end of the lead line 16 Secure the saddle to the Arm 2 Hexagon socket head cap bolt 2 M4 6 with disc spring 2H 4 M4 washer Tightening torque 2 8 N m 0 29 kgf m ...

Page 185: ...Hexagon socket head cap bolt 2 M4 8 with disc spring 2H 4 M4 washer Tightening torque 2 8 N m 0 29 kgf m 19 Set a wire tie in the area marked in white 20 Bind the signal connectors with a wire tie as shown in the picture Connector For Joint 2 L For Joint 3 U 21 Bind the power connectors with a wire tie as shown in the picture Connector For Joint 2 L For Joint 3 U ...

Page 186: ...emove the backup battery Connector For Joint 5 B For Joint 6 T 24 Bind the signal connectors with a wire tie as shown in the picture Connector For Joint 5 B For Joint 6 T 25 Bind the power connectors with a wire tie as shown in the picture Connector For Joint 5 B For Joint 6 T 26 Put the connector of the signal cable in the position shown in the picture 27 Pass the wire tie through the cable fixin...

Page 187: ...two air hoses to the Arm 4 Air Hose A Black B Blue Make sure to mount the air hoses in the right position Otherwise the air lines change inside the manipulator and the equipment such as the hand cannot function normally 31 Press the power connectors into the Arm 4 32 Connect the connector to the lead line Remove the backup battery Connector For Joint 4 R 33 Mount the LED lamp to the Arm 3 NOTE ...

Page 188: ...le Unit 174 S5 Rev 5 34 Mount the connector of the LED lamp to the lead line 35 Remove the following covers Arm 1 Cover Arm 2 Cover Arm 3 Cover Arm 4 Cover Base Connector Plate For details refer to Maintenance 3 Covers ...

Page 189: ... Cable Unit S5 Rev 5 175 9 2 Wiring Diagrams 9 2 1 Signal Cable Cable color Azure Black Brown Green Gray Blue Orange Red Violet White Yellow Code A B BR G GR L O R V W Y Resolver Board Gyro Board Brake Switch Brake ...

Page 190: ...Maintenance 9 Cable Unit 176 S5 Rev 5 9 2 2 Power Cable Cable color Azure Black Brown Green Gray Blue Orange Red Violet White Yellow Code A B BR G GR L O R V W Y ...

Page 191: ...Maintenance 9 Cable Unit S5 Rev 5 177 9 2 3 User Cable Code Cable color A Azure B Black BR Brown G Green GR Gray L Blue O Orange R Red V Violet W White Y Yellow ...

Page 192: ...y hazardous and may result in electric shock and or malfunction of the robot system CAUTION When disconnecting the connectors during the replacement of the cable unit be sure to reconnect the connectors to their proper positions by referring to the connector pin assignments Improper connection of the connectors may result in improper function of the robot system For details on the connections refe...

Page 193: ...2 Disconnect the following connectors from the controller Power cable connector Signal cable connector 3 Remove the connector sub plate For details refer to Maintenance 3 Covers Do not pull the sub plate forcibly Do not disconnect the M C cable from the connector sub plate 4 Remove the connectors Connectors X010 X011 X020 X12 X30 X13 X040 X14 X050 LEDA BR010 BR020 BR030 BR040 Each connector is num...

Page 194: ...nnectors to the controller Power cable connector Signal cable connector 4 Turn ON the controller power 5 Check operation to see if the manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 6 If the battery connector BT1 was disconnected calibrate the Joint 1 For details refer to Maintenance 12 Calibration 7 If the Manipula...

Page 195: ... source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Use meticulous care when handling the lithium battery Improper handling of the lithium battery as mentioned below is extremely hazardous may result in heat generation leakage explosion or inflammation and may cause serious safety problems Improper Handling Attempting to charge Disassembli...

Page 196: ...der occurs When the motor or gears are removed from the robot for parts replacement You cannot recover by 10 3 Data Recovery Procedure For calibration after parts replacement refer to Maintenance 12 Calibration 10 2 Replacing the Battery Unit Name Quantity Note Maintenance Parts Battery unit 1 R13B060005 Liquid Gasket Proper quantity R13B031201 Battery Unit Removal 1 Turn OFF the power for the Con...

Page 197: ...ery unit If you disconnect the old battery unit without connecting new one all position data for each arm will be lost and all arms need to be calibrated again Make sure to use our specified battery unit Code R13B060005 7 As shown in the picture use wire ties to secure the battery unit 8 Mount the grease supply tube for the Joint 1 reduction gear unit 9 Mount the connector plate Button bolt 8 M4 1...

Page 198: ...n to match the home position of the joint accurately Make sure to match the home position of the joint as accurate as possible visually CAUTION The Arm 4 does not have a mechanical stop The used of Arm 4 in motion exceeding the maximum pulse range may cause inner wiring damage to and or malfunction of the Manipulator 6 Reset the encoder again by the procedure in step 2 7 Restart EPSON RC 5 0 EPSON...

Page 199: ... 6 Joint 2 out of home position in direction Hofs Hofs 1 Hofs 2 131072 Hofs 3 Hofs 4 Hofs 5 Hofs 6 Joint 6 out of home position in direction Hofs Hofs 1 Hofs 2 Hofs 3 Hofs 4 Hofs 5 Hofs 6 131072 Joint 6 out of home position in direction Hofs Hofs 1 Hofs 2 Hofs 3 Hofs 4 Hofs 5 Hofs 6 131072 10 Move to 0 pulse position again Go Pulse 0 0 0 0 0 0 11 Be sure to check that all joints have moved to thei...

Page 200: ...ory power source To shut off power to the robot system pull out the power plug from the power source Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Carefully use alcohol liquid gasket and adhesive following respective instructions and also instructions below Car...

Page 201: ...Mount the LED lamp connector 3 Mount the Arm 3 Cover For details refer to the Maintenance 3 3 Arm 3 Cover For protection model When the Manipulator is a protection model liquid gasket R13B031201 was applied on the LED mounting surface Removal The LED lamp is secured with liquid gasket There is a risk that the LED lamp gets broken in removal Replace the LED lamp with great caution Installation Befo...

Page 202: ...uarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly For EPSON RC a coordinate point including the arm pose is defined as point The data is called point data There are two methods to move the Manipulator during calibration Releasing the electromagnetic brake and moving the arms manually For details refer to the Setup Operation...

Page 203: ...usly it will be more difficult to verify their origins and obtain the origin positions However joint 5 cannot be calibrated alone according to the structure of the Manipulator Make sure you calibrate joint 6 at the same time Calibration Flowchart 4 Temporary Calibration Yes Start 1 Basic Pose Confirmation 2 Part Replacement 3 Encoder Initialization 6 Accuracy Testing Re calibrate End No Calibrate ...

Page 204: ...rn ON the Controller when all joints are in the motion range The message Encoder alarm has occurred Check robot battery EPSON RC must be restarted is displayed Initialize the encoder at the current position and reset the error Initialize the encoder using one of the following procedures Execute the following command at the Monitor Window Encreset The joint number 1 to 6 corresponding to the encode...

Page 205: ...r the currently registered point data that makes it easy to verify the accuracy of the joint whose origin you want to calibrate Move the Manipulator to the selected point while avoiding interference with peripheral equipment To perform temporary calibration input the pulse value of the specified point data For example when the specified point data is P1 execute the following command Calpls Ppls P1...

Page 206: ...oint 5 and 6 to the position when calibrating Joint 5 Select the Joint jog mode from the Jog Teach to execute the jog motion Perform the calibration Input one of the following commands according to the joint being calibrated Joint 1 Calib 1 Joint 2 Calib 2 Joint 3 Calib 3 Joint 4 Calib 4 Joint 5 Calib 5 6 Joint 6 Calib 6 6 Accuracy Testing Move the Manipulator into a different point to verify the ...

Page 207: ... 12 3 Calibration Jig Jigs such as the one described in this section are necessary in order to set the reference points for calibration when installing the Manipulator In practice there are instances where your end effector can be used B A C ...

Page 208: ...bration 194 S5 Rev 5 Unit mm deg 50 11 28 15 20 25 ø12H7 60 8 20 28 14 40 5 14 4 C1 ø20 4 C3 25 ø12H7 2 M4 4 ø5 5 ø31 5 40 20 45 ø5H7 ø70 Ø12h6 3 8 PCD20 2 ø4 5 ø8 depth5 14 7 ø28 ø12h6 3 6 24 10 ø12h6 B 1 A 1 C 2 2 ø5 5 ...

Page 209: ...S5 A901 For Joint 3 R13B010034 S5 A701 6 2 2 R13B010035 S5 A901 For Joint 4 R13B010036 7 2 2 For Joint 5 R13B010037 For Joint 6 R13B010038 Electromagnetic Brake For Joints 5 R13B030508 8 3 For Joints 6 R13B030510 8 3 Timing Belt For Joint 2 R13B030228 5 3 For Joint 3 R13B030229 S5 A701 6 3 R13B030230 S5 A901 For Joint 4 R13B030231 7 3 For Joints 5 6 R13B030232 8 2 Grease Reduction gear For ALL Joi...

Page 210: ...031262 R13B031268 For Cleanroom model 8 O ring For Joint 1 R13B031255 4 2 For Joint 6 R13B031263 Gasket Base R13B031269 For Cleanroom model R13B031275 2 5 Arm 1 R13B031270 For Cleanroom model 3 1 Arm 2 S5 A701C R13B031271 For Cleanroom model 3 2 S5 A901C R13B031272 For Cleanroom model Arm 3 R13B031273 For Cleanroom model 3 3 Arm 4 R13B031274 For Cleanroom model 3 4 Radiating sheet For Joint 1 2 3 ...

Page 211: ...A rigid ring shaped body with gear teeth on the inner circumference The circular spline has two more teeth than the flexspline does 2 Battery for backing up motor encoder The battery for backing up a motor encoder is only used for retaining the motor position data during maintenance cable replacement etc It is not used for the Manipulator itself Even storing a battery consumes battery power When t...

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