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Chapter 4 Maintenance of Mechanical Components

Document Version V1.0.1 (09-21-2022)

4.3

Cover

Be sure to make replacement after powering off the controller and

related devices and unplugging the power plug, otherwise safety

accidents and robot failures may occur.

Figure 4-5 Diagram of robot covers

4.3.1

Robot cover

Tools: a set of Allen wrench, a straight screwdriver

Robot cover

Base connector panel

Base side door

Summary of Contents for AH20

Page 1: ......

Page 2: ...Maintenance Manual AH20 Robot AH20 0850 0204 2000 AH20 0850 0204 4000 AH20 1050 0204 2000 AH20 1050 0204 4000 Document version V1 0 1 Issued on September 21 2022 QKM Technology Dongguan Co Ltd...

Page 3: ...e maintenance of mechanical and electrical components so that users can better use AH20 Robot this manual can serve as a reference for system integrators to design user workstation systems by using ou...

Page 4: ...tes that a dangerous situation would occur and cause serious personal injury or death if it is not avoided It indicates that a potentially dangerous situation would occur and cause personal injury or...

Page 5: ...rocess and use this product and related parts Caution The contents of this document are subject to change any time due to product upgrade or other reasons QKM reserves the right to change the contents...

Page 6: ...loss or liability due to improper use of this product QKM Technology Dongguan Co Ltd Headquarters Tower A Building 17 Headquarters 1 No 4 Xinzhu Road Songshan Lake High tech Industrial Development Zon...

Page 7: ...on each update of the document and the latest version of the document includes the updates in all previous versions of the document Version Time Change Content V1 0 0 June 10 2022 The first version of...

Page 8: ...apter 1 Safety Precautions 1 1 1 Precautions for operation 1 1 2 Precautions for electrical safety 2 1 3 Warning sign 3 Chapter 2 Safety Maintenance 5 2 1 Use of robot in accordance with regulations 5...

Page 9: ...Components 14 4 1 Lubrication of spline screw shaft 14 4 1 1 Standard type 14 4 1 2 Protective type 19 4 2 Removal and installation of protective cover 19 4 2 1 Removal of protective cover 20 4 2 2 In...

Page 10: ...otor fan 51 5 2 Replacement and maintenance of encoder battery 53 5 3 Replacement and maintenance of controller assembly 56 5 4 Replacement and maintenance of IO free distribution PCBA 58 5 5 Replacem...

Page 11: ...nt Version V1 0 1 09 21 2022 IX 5 11 Replacement and maintenance of the fan assembly of the mechanical arm 2 77 5 12 Replacement and maintenance of brake PCBA 79 Chapter 6 Technical service 83 6 1 Con...

Page 12: ...moval of fastening screws 34 Figure 4 7 Lift the cover 35 Figure 4 8 Removal of fastening screws 36 Figure 4 9 Take out the side door of the base 37 Figure 4 10 Remove the fastening screws from the co...

Page 13: ...14 Removal of fastening screws 63 Figure 5 15 Filter 65 Figure 5 16 Removal of fastening screws 66 Figure 5 17 QBUS module 68 Figure 5 18 Removal of QBUS module 69 Figure 5 19 QBUS fuse 71 Figure 5 20...

Page 14: ...arning signs 3 Table 3 1 Routine cleaning and maintenance schedule 10 Table 3 2 Handling of common exceptions 12 Table 4 1 Selection of lubricating grease 15 Table 4 2 Accessories 21 Table 4 3 Accesso...

Page 15: ...to inspection and other operations and related laws and regulations prescribed by laws and regulations of relevant countries for workers engaged in services related to industrial robots Make sure tha...

Page 16: ...o the power plug when using the robot Do not connect directly to the factory power supply Be sure to make replacement after turning off the controller and the related equipment and unplugging the powe...

Page 17: ...take sufficient care when operating In order to operate and maintain the robot system safely be sure to observe the cautions and contents on the warning signs Table 1 1 Warning signs SN Labeling Note...

Page 18: ...ce Manual 4 Document Version V1 0 1 09 21 2022 D Non professionals are not allowed to open it E A sign for protection from residual voltage F Warning Hot surface G Beware of collisions Figure 1 1 Posi...

Page 19: ...ly maintain it in accordance with the contents of this manual Common situations involving illegal use use beyond specified operating range unsafe use of electricity non use of additional protective de...

Page 20: ...The dangerous area includes any position where the robot body and the robot arms may stay in their motion trajectories which can be protected by isolated protective devices to avoid personal injury o...

Page 21: ...cing the system speed and then gradually increasing the speed Fault occurrence Steps for operation when a fault occurs Turn off the control system of the robot to prevent any unexpected restart withou...

Page 22: ...operly When teaching the robot check whether its work area is reasonable and remove other objects from the work area Stop running Precautions when the robot stops running Reduce the speed of the robot...

Page 23: ...ressed air Check whether air supply is normal and whether air pressure is stable Check whether there are obvious impurities in compressed air and whether there is accumulated water in air pipe Check w...

Page 24: ...ing maintenance and checks The cycle for routine inspection is based on the normal working conditions For the normal working environment please refer to the section of environment requirements in AH20...

Page 25: ...outine disinfectant and cleaning liquid Do not use acidic cleaning liquid to perform routine maintenance on the robot 3 4 Safety inspection Safety system test cycle generally six months depending on t...

Page 26: ...e Handling Abnormal E stop Failure in robot E stop line Ensure that the E stop switch is not pressed Check whether the E stop switch is damaged Replace the E stop switch Unable to connect robot Failur...

Page 27: ...perly connect the plug Improper parameter configuration Reconfigure parameters of communication connector I O communication connector fails I O plug is damaged Check whether the I O line is properly c...

Page 28: ...se is used up The use of lubricating oil or grease can effectively extend the life of the robot Running out of grease may cause abnormal wear noise etc Check the grease on the spline screw shaft regul...

Page 29: ...Micro vibration Long life resistance to micro vibration Spline shaft Non food industry AZ food machinery grease Micro vibration Stable nonhazardous Spline shaft Food industry Accessories special oil...

Page 30: ...end of the screw then press the brake button and do not release it until the spline screw shaft is pushed down to the lowest end as shown in Figure 4 2 Figure 4 2 Push down the spline screw shaft Step...

Page 31: ...Document Version V1 0 1 09 21 2022 17 Figure 4 3 Apply lubricating grease Step 3 Hold the end of the screw then press the brake button and push the spline screw shaft up to the top as shown in Figure...

Page 32: ...tributed on the surface of the screw the replenishment is completed Wipe the excess grease off the upper and lower gears of the screw with dust free paper Note Hold the end of the screw before pressin...

Page 33: ...grease and disposable protective gloves Step 1 Refer to Section 4 2 1 Removal of protective cover to remove the protective cover from the robot Step 2 Refer to Section 4 1 1 Standard robot to replace...

Page 34: ...ep groove ball bearing 1 Fixed cover 1 Jackscrew 2 Accessories of screw lower protective cover Connecting fastener 1 Deep groove ball bearing 1 Bearing fixing ring 1 Circlip for hole 1 Telescopic prot...

Page 35: ...ws Step 1 Check whether the robot is equipped with a protective cover Step 2 Remove the protective cover at the upper end of the screw Use 2 5 mm Allen wrench to remove the 4 M3 fastening screws from...

Page 36: ...tective cover at the upper end of the screw remove the protective cover and the coupling in upward direction and place them properly as shown in the figure below Step 3 Remove the protective cover at...

Page 37: ...move the end flange in downward direction and properly place it as shown in the figure below Use the flat nose pliers to remove the flat key from the screw Use 4 mm Allen key to loosen the fastening s...

Page 38: ...move the protective cover and the coupling in upward direction and place them properly Step 4 Reinstall the end flange Place the flat key into the keyway install the flange by aligning with the keyway...

Page 39: ...the other side alternately perform the operation for 2 3 times until all the screws are tightened firmly do not tighten up the fastening screws on one side at one time The robot whose protective cover...

Page 40: ...ls Qty Spare parts 1 set Allen wrench 1 Straight screwdriver 1 Protective gloves 1 Step 1 Install the protective cover at the lower end of the screw Use 4 mm Allen wrench to loosen the fastening screw...

Page 41: ...g screws of the coupling after completely applying it to the top of the protective cover as shown in the figure below Install the bearing fixing ring and the connecting fastener loosen the fastening s...

Page 42: ...ighten the fastening screws of the flange after the bottom of the screw completely fits the contact surface of the flange ii Move the connecting fastener down along the screw until it is in full conta...

Page 43: ...stening screws of the bearing fixing ring Use 2 5 mm Allen key to install the protective cover and the connecting fastener Do not screw in the bolt at one time when fixing Use an Allen wrench to tight...

Page 44: ...2022 Install the protective cover Step 2 Install the protective cover at the upper end of the screw Install the coupling and the protective cover and tighten the fastening screws of the coupling afte...

Page 45: ...1 2022 31 Use 5 mm Allen wrench to install the extension rod assembly of the protective cover as shown in the figure below Lock the protective cover in the protective cover extension rod assembly and...

Page 46: ...ersion V1 0 1 09 21 2022 cover extension rod assembly as shown in the figure below The robot equipped with the protective cover is shown in the figure below The Z axis stroke of the robot equipped wit...

Page 47: ...ake replacement after powering off the controller and related devices and unplugging the power plug otherwise safety accidents and robot failures may occur Figure 4 5 Diagram of robot covers 4 3 1 Rob...

Page 48: ...21 2022 Step 1 Lower the spline screw shaft to the lowest point Step 2 Use 2 5 mm Allen wrench to remove the fastening screws from the robot cover as shown in Figure 4 6 Figure 4 6 Removal of fastenin...

Page 49: ...cal Components Document Version V1 0 1 09 21 2022 35 Figure 4 7 Lift the cover 4 3 2 Base side door Tool Allen wrench Step 1 Use 2 5 mm Allen wrench to loosen the anti off screws from the side door of...

Page 50: ...AH20 Robot Maintenance Manual 36 Document Version V1 0 1 09 21 2022 Figure 4 8 Removal of fastening screws Step 2 Take out the side door of the base as shown in Figure 4 9...

Page 51: ...nents Document Version V1 0 1 09 21 2022 37 Figure 4 9 Take out the side door of the base 4 3 3 Connector panel Tool Allen wrench Step 1 Use 2 5 mm Allen wrench to remove the fastening screws from the...

Page 52: ...21 2022 Figure 4 10 Remove the fastening screws from the connector panel Step 2 Gently take the connector panel out by holding its upper end Be careful not to break off the cables when taking it out a...

Page 53: ...operation or power outage When installing the connector panel do not clasp the cables or forcibly bend them to press in 4 4 Timing belt tension measurement 4 4 1 Measuring instrument Instrument name s...

Page 54: ...ght automatically turns on and the screen shows the data used at the previous shutdown Function Key Name Notes POWER Power switch MEASURE Measuring key MASS Belt mass WIDTH Belt width SPAN Span UP Pre...

Page 55: ...rements can be set via PC and the data will be displayed directly on the PC screen upon measurement 4 4 2 Parameter setting Refer to the U 508 Tension Meter User Manual the tension meter user manual i...

Page 56: ...flashing until the probe receives a signal then the LED light automatically turns off and a curve graph appears on the screen Step 5 After the signal is received the measured tension will be displayed...

Page 57: ...the desired unit by pressing the SELECT button Press and hold the POWER button again until the meter is turned off then turn on the meter for normal operation all data entered must be in millimeters...

Page 58: ...e belt with too low tension If a tension value cannot be obtained the belt may be too weak to produce a clear frequency signal In order to get an accurate tension value the belt should be a little ten...

Page 59: ...irregular belt teeth will affect the tension of the belt when it is running 5 000 Hz maximum frequency Automatic shutdown if there is no operation within 5 minutes Manual shutdown by pressing the pow...

Page 60: ...oduct in areas with potential for sparks as this may cause explosions Do not use this product outdoors during thunderstorms Turn off the power and use it in a safe place or you may be struck by lightn...

Page 61: ...e to do so may cause abnormal action of the robot which is very dangerous and may also cause electric shock or malfunction Do not allow foreign objects to enter the robot If the power is turned on whe...

Page 62: ...contact 5 1 Replacement and maintenance of 1 axis motor fan 5 1 1 Replacement of 1 axis motor fan The position of the 1 axis motor fan is shown in the figure Figure 5 1 1 axis motor fan Tools and acce...

Page 63: ...warning sign Step 2 Use the Allen wrench to remove the fastening screws from the protective cover and take out the protective cover as shown in the figure Figure 5 3 Take out the protective cover Ste...

Page 64: ...screw the waterproof connecting plug from the fan cable then take out the fan assembly to be replaced as shown in the figure Figure 5 5 Take out the fan assembly Step 5 Replace with a new fan assembly...

Page 65: ...nd its service life the 1 axis motor fan of AH20 Series Robot needs to be cleaned and maintained regularly Tools and accessories Allen wrench diagonal pliers anti static gloves Step 1 Remove the fan a...

Page 66: ...ed and work normally with ARM If the robot can work normally it indicates that the test signals of all fans are normal If the robot cannot work properly find out the cause and solve the fault The robo...

Page 67: ...Inspection content Notes Replacement Cleaning 5 2 Replacement and maintenance of encoder battery The encoder is equipped with a 3 6 V disposable Li SOCl2 battery with a normal voltage of not less than...

Page 68: ...uction operation It is recommended to make a preventive replacement Tools and accessories Allen wrench cable tie diagonal pliers encoder battery assembly anti static gloves Figure 5 6 Encoder battery...

Page 69: ...d encoder battery Fix the cable of the new encoder battery with a cable tie Step 6 Install the connector panel and base side door of the robot as they are Step 7 After the battery of the robot is repl...

Page 70: ...d locations 5 3 Replacement and maintenance of controller assembly The controller is located in the robot base To replace the controller remove the back and side door of the base The position of the c...

Page 71: ...emove the base side door from the robot Step 2 Refer to Section 4 3 3 to remove the connector panel from the robot Step 3 Unplug all cables connected to the controller unscrew the four M4 10 hexagon s...

Page 72: ...r assembly At the time of installation users shall check whether the connectors match the line labels as shown in the figure below Step 5 Restore the back and side panels of the base 5 4 Replacement a...

Page 73: ...for aviation plug cable tie diagonal pliers anti static gloves Step 1 Refer to Section 4 3 3 Connector panel to remove the connector panel from the robot Step 2 Unplug all the cables connected to the...

Page 74: ...12 Removal of IO free distribution PCBA Step 5 Install a new IO free distribution PCBA on the base connector panel and tighten the screws Connect all the cables to the new IO free distribution PCBA A...

Page 75: ...e robot 5 5 Replacement and maintenance of surge suppressor The surge suppressor is located on the connector panel of the robot To replace it it s required to remove the connector panel The position o...

Page 76: ...re 5 13 Surge suppressor Step 1 Refer to Section 4 3 3 to remove the connector panel from the robot Step 2 Unplug all cables from the surge suppressor Step 3 Use the cross screwdriver to remove the sc...

Page 77: ...a new surge suppressor on the part in the base and tighten the screws then connect all the cables to the new surge suppressor At the time of installation users shall check whether the connectors match...

Page 78: ...and connector panel of the robot 5 6 Replacement and maintenance of filter The filter is located on the connector panel of the robot To replace it it s required to remove the connector panel of the r...

Page 79: ...2022 65 Figure 5 15 Filter Step 1Refer to Section 4 3 3 to remove the connector panel from the robot Step 2Unplug all cables connected to the filter Step 3Use the cross screwdriver to unscrew the fas...

Page 80: ...stall a new filter on the connector panel and tighten the screws Connect all cables to the new filter At the time of installation users shall check whether the connectors match the line labels and avo...

Page 81: ...5 7 Replacement and maintenance of QBUS module The QBUS module is located in the base of the robot To replace it the connector panel and side door of the robot need to be pulled out The position of t...

Page 82: ...side door and connector panel from the robot Step 2Refer to Section 5 3 to remove the controller assembly Step 3Use the straight screwdriver to remove the terminals from the connector Unplug all the c...

Page 83: ...l of the robot The lower end of the QBUS module is close to the filter terminal block Be careful not to hit other cables when removing the screws When installing the connection terminals make sure tha...

Page 84: ...ch the line labels and avoid damage to the controller due to wrong connection The line labels corresponding to each connector are shown below 5 8 Replacement and maintenance of QBUS fuse There are two...

Page 85: ...se Step 3 After installing a new fuse tighten the cover and restore the robot after replacement The burning of the QBUS fuse indicates that the main circuits of the QBUS and the drive Cell may burn ou...

Page 86: ...fuse separately without troubleshooting as this may cause secondary damage 5 9 Replacement and maintenance of 24 V switching power supply The 24 V switching power supply is located in the base of the...

Page 87: ...nd connector panel from the robot Step 2 Unplug the 24 V power plug and 220 V power plug from the switching power supply The line labels of the 24V power plug include 24V 1 G24 24V 3 and G24 3 The lin...

Page 88: ...et and tighten the screws Connect the 24 V power plug and 220 V power plug to the new switching power supply Step 5 Install the side door and panel of the robot as they are 5 10 Replacement and mainte...

Page 89: ...and connector panel from the robot Step 2 Use diagonal pliers to remove the cable tie along the fan cable Step 3 Refer to Section 5 4 Definition of pins on IO free distribution PCBA to locate the Fan...

Page 90: ...e tie Connect the connector of the new fan assembly to the connector of the switch fan Step 6 Install the connector panel and base side door of the robot as they are This cooling fan is installed in a...

Page 91: ...he cables in the control cabinet to prevent them from damage disconnection or poor contact 5 11 Replacement and maintenance of the fan assembly of the mechanical arm 2 The mechanical arm 2 fan is loca...

Page 92: ...the screws from the mechanical arm 2 shell of the robot and gently pull out the second mechanical arm shell Step 2 Unplug all the cables connected to the fan of the mechanical arm 2 Step 3 Use 3 Allen...

Page 93: ...nd tighten the screws then connect the fan cables 5 12 Replacement and maintenance of brake PCBA The brake PCBA is located in the mechanical arm 2 of the robot To replace it the mechanical arm 2 shell...

Page 94: ...efer to Section 4 3 1 to remove the screws from the mechanical arm 2 shell of the robot and gently pull out the mechanical arm 2 shell Step 2 Unplug all cables connected to the brake PCBA Step 3 Use t...

Page 95: ...2 Step 4 Install a new brake PCBA in the original position and tighten the screws then connect all the cables to the new brake PCBA At the time of installation users shall check whether the connector...

Page 96: ...sion V1 0 1 09 21 2022 Step 5 Reinstall the mechanical arm 2 shell of the robot J6 Brake button J5 Brake button J8 24V power supply J3 3 axis controller power J15 3 axis motor modification J4 4 axis c...

Page 97: ...service department and provide information below as much as possible Model and serial number of the robot nameplate on the back of the robot base Model and serial number of the control system contact...

Page 98: ...AH20 Robot Maintenance Manual 84 Document Version V1 0 1 09 21 2022...

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