CMA Dishmachines GR 6160 Maintenance Manual Download

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GR 6160

Industrial Robot

工业机器人

6 axis GR series

轴

系列

Mechanical useand maintenance manual

机械使用维护手册

The first edition

第一版

CMA (WuHu) Robotics CO.,LTD

希美埃（芜湖）机器人技术有限公司

Summary of Contents for GR 6160

Page 1: ...GR 6160 Industrial Robot 6 axis GR series 6 GR Mechanical useand maintenance manual The first edition CMA WuHu Robotics CO LTD...

Page 2: ...is located in National Robots Industry Park Wuhu City 2015 CMA CMA Robotics spa is established in 1994 and the headquarter is located in North Italy Udine City As the first supplier that has proposed...

Page 3: ...t year continued development currently has been an advanced manufacturer of national Robots The company has leaded some important scientific and technological projects of national class and has accumu...

Page 4: ...15 2 2 MECHANICAL SYSTEM 16 2 2 16 2 3 THE MECHANICAL PERFORMANCE PARAMETERS 17 2 3 17 2 3 1 The definition of performance parameters 17 2 3 1 17 2 3 2 The performance parameters of the robot 19 2 3...

Page 5: ...ation of lubricate grease 34 3 4 2 34 3 4 3Procedure of grease replacement in reducer of J1 J2 J3 J4 and gear box of motor base 35 3 4 3 J1 J2 J3 J4 35 3 4 4 Procedure of grease replacement in wrist 3...

Page 6: ...1 HANDLING ROBOT 69 5 1 69 5 1 1Handling Precautions 69 5 1 1 69 5 1 2 TransportMethod 70 5 1 2 70 5 2 INSTALLATION 71 5 2 71 5 2 1External Interface Dimensions 71 5 2 1 71 5 3 INSTALLATION SPECIFICA...

Page 7: ......

Page 8: ...eration manual Case where a mistake made in handling is likely to cause the user to be exposed to the dangerof death or serious injury and where the degree of the urgency imminence of the warning Give...

Page 9: ...emergencystop button The other person must work quickly and carefully within the robot operatingarea Always allocate confirm and know an escape route prior to beginning work 4 2 1 1 1 5 Ensure payload...

Page 10: ...arize the above as unsafe activities caused by human error such as careless mistakes and not following the established procedures Workers not be ableto take appropriate actions such as emergency stop...

Page 11: ...y other unexpected robot motion patterns It may beimpossible to stop a robot or escape from a robot that started unexpectedly The best way to avoid such accidents is Do not get near the robot as much...

Page 12: ...he environment for which it was designed and has fail safeconstruction to minimize damage or accidents during operation The robot maintains a good levelof safety because various safety functions exist...

Page 13: ...stopper blocks mounted on the moving tip of thearticulations The arm may fall under its own weight when motors are removed or brakes arereleased Therefore take action to prevent dropping and check th...

Page 14: ...m may drop or move forward orbackward PROPERLY SUPPROT THE ARM BEFORE REMOVING THE MOTOR To prevent the arm from dropping use a wooden block nylon sling crane or other means tosupport the arm securely...

Page 15: ...s and injuries When fabricating the end effecter set its weight static torque and the moment of inertia withinthe range of the permissible load levels of the robot wrist Provide a failsafe constructio...

Page 16: ...erating and while thepower is ON follow the precautions to be observed during operation In some cases electromagnetic waves other forms of noise or defective circuit boards may erase the recordedwork...

Page 17: ...t at all times and never work with your back toward therobot An operator may not notice the start of robot if he she is not facing it resulting in anaccident Press the emergency stop button immediatel...

Page 18: ...due to forgetfulness and error of operators if relying onmemory alone Proceed with work with the robot s power OFF when operation or manipulation of the robot isnot necessary It can never run with its...

Page 19: ...o stumbling Cleaning the workplace is a step toward safety 1 2 Movement alienation and selling of the robot 1 2 Hand over all manuals and documents received when purchasing the robot to the new ownerw...

Page 20: ...s not transferable to the new owner unless a special agreement has been concluded Theuser must conclude a new agreement with the new owner 1 3 Abandon the robot 1 3 Do not disassemble heat or burn bat...

Page 21: ...urther than disconnecting wiring fromconnectors or terminal blocks Disassembled pieces e g conductors etc may cause injury tohands or eyes Use extreme care when scrapping so as to avoid accidents and...

Page 22: ...ional features Robot ontology model ST standard edition HW for hollow arm omit on behalf of the standard version ST HW Robot load a total of three take 0 to reserve said the unit is kg 0 Kg Robot axis...

Page 23: ...sists of the base station the big arm forearm forearm extended part wrist components and ontology of package parts a total of six motor can drive the six joints movement for different forms of exercis...

Page 24: ...1 The definition of performance parameters 2 3 1 The performance parameters of robot mainly includes working space the robot load the robot movement speed the robot s maximum motion range and repeat...

Page 25: ...ximum rate of movement joint robot the maximum speed of single joint movement 3 GB T 12645 4 The maximum operating range of the robot Reference GB industrial robot acceptance rules JB T 8896 define th...

Page 26: ...parameters of the table 2 1 Robot model GR6160 Action type Joint type Degrees of freedom 6 Axis Placement Mounted Maximum operating speed axis J1 140 sec axis J2 140 sec axis J3 165 sec axis J4 500 s...

Page 27: ...ics CO LTD 20 2 The robot working space diagram as shown in figure 2 2 2 2 2 Fig 2 2 the robot working space 2 2 Protection grade IP65 Dust proof drip proof IP65 Repeat positioning accuracy 0 15mm Rob...

Page 28: ...me shape as that of the standard stopper makes it possible to adjust the operating angle of the J1 axis in steps of 30 In this case a maximum operating range of the J1 axis comes to 180 J1 180 J1 30 F...

Page 29: ...the following cases you need to perform home position adjustment 1 Replace the motor 2 Replace the encoder 3 Replacing reducer 4 Replace the cable 1 2 3 4 2 4 1Home position adjustment method 2 4 1 H...

Page 30: ...CMA WuHu Robotics CO LTD 23 professional engineers 1 2 Mechanical zero revision The dial calibration Labelled zero block scale line turn to completely align the zero point 2...

Page 31: ...djustmentof all axes 2 4 2 Fig 2 6 Home position of J1 J2 J4 2 6 J1 J2 J4 Fig 2 7 Home position of J3 J5 J6 2 7 J3 J5 J6 Home position of J4 J4 Home position of J5 J5 Home position of J3 J3 Home posit...

Page 32: ...static load torque Around J4 axis J4 Around J5 axis J5 Around J6 axis J6 GR6160 41N M Not more than 41N M 41 N M Not more than 41 N M 23 N M Not more than 23 N M A load fixed to the tip of the robot...

Page 33: ...4 Allowable maximum inertia moment 2 4 Robot Model Allowable inertia moment Around J4 axis J4 Around J5 axis J5 Around J6 axis J6 GR6160 1 6kg m2 Not more than 1 6kg m2 1 6kg m2 Not more than1 6kg m2...

Page 34: ...ement the inspection program Furthermore perform overhauls every 40 000 operating hours or every eight years whichever comes earlier The inspection periods have been examined for Spraying For high fre...

Page 35: ...ase Visual check of lubrication port for grease leak 3 1 1 2 3 4 5 6 3 1 2 Quarterly inspection 3 1 2 Table 3 2 Quarterly inspection Items No inspection Item Inspection method 1 Cables in teaching box...

Page 36: ...3 1 4 Inspection every two years 3 1 4 2 Table 3 4 Inspection Items every two years No inspection Item Inspection method 1 2 Replace reducer gear box oil Wrist replacement parts Lubricants Replace the...

Page 37: ...J5 2 Fix the motor of J1 7 Fix the motor of J6 3 Fix the motor of J2 8 Fix the wrist 4 Fix the motor of J3 9 Fix the end actuator 5 Fix the motor of J4 3 5 1 6 J5 2 J1 7 J6 3 J2 8 4 J3 9 5 J4 Please...

Page 38: ...dust meter Recommended grease steel dust meter OM 810 Idemitsu Kosan Ltd Grease gun Lubrication amount counter function A nozzle of less than 17 mm in diameter Seal tape OM 810 17mm If the grease leak...

Page 39: ...grease canbefore after the lubrication work to confirm the amount Immediately after removing the drain plug grease may splash because internalpressure is still high for example soon after robot stops...

Page 40: ...t J1 J2 J3 J4 20 000 4 10 000 2 3 6 Table 3 6 grease and Lubricationamount Replacement point Lubricati on amount Applicablegreas e comment J1 axisreduction gear 3400cc MolyWhiteRE No 00 Lubricating gr...

Page 41: ...he following table Table 3 7 Robot orientation of lubricate grease Replacement point Robot orientation J1 J2 J3 J4 J5 J6 J1 axisreducer unbending unbending unbending unbending unbending unbending J2 a...

Page 42: ...rease according to chapter 3 4 5 1 3 7 2 3 M10X1 3 1 3 3 4 5 6 3 4 5 3 4 4 Procedure of grease replacement in wrist 3 4 4 1 Move robot for lubrication to orientation according to table 3 7 2 Turn off...

Page 43: ...ubricating oil 2 If the quantity of oil supply not up to par available supply with precision regulator to oil gas during extrusion cavity pressure regulator control should be used under the maximum 0...

Page 44: ...O LTD 37 J1 J1 axis gear grease for port 2 0 025MPa 3 4 5 6 3 4 5 Fig3 1Oil change J1 J2 axis reducer 3 1 J1 J2 J2 axis gear grease discharge port J2 J1 J1 axis gear grease discharge port J2 axis gear...

Page 45: ...cement parts lubricants wrist 3 3 J4 J3axis gear grease for port J3 J3axis gear grease discharge port J3 J4 Wrist body J5 J6 axis for fat mouth J5 J6 Wrist connector J5 J6 axis the fat mouth J5 J6 Gea...

Page 46: ...chamber 3 4 5 After the oil supply in order to release the residual oil cavity pressure should be appropriate operating robot At this point for lubricating oil in import and export the installation wi...

Page 47: ...e to the situation around should take the robot run the same frequency for example takes only half of the cases the axis Angle should take the robot run 2 times after the end of the action would be in...

Page 48: ...me and can restore operation failure 3 even if the failure happens as long as the electricity again after power off and can run the fault 4 Not the robot itself but the side of the system fault lead t...

Page 49: ...grasp the phenomenon and determine what is abnormal due to problems caused by parts 1 Step 1 what is a shaft appeared abnormal Must first understand what a shaft appear abnormal phenomenon If there i...

Page 50: ...ent components lead Therefore in order to ascertain which component is damaged refer to the contents shown in this table 4 1 Table 4 1 fault phenomenon and reason Faultdescription The reasonparts redu...

Page 51: ...ovement and position deviation 1 Inspection method Check the oil amount of fe powder increase the amount of iron powder in thelubricating oil concentration around for more than 1000 PPM has the possib...

Page 52: ...mponents overall see 4 4 1 2 J5 J6 4 4 1 4 3 2Motor 4 3 2 Motor abnormalities stop shaking and vibration during operation action occurs anomaly In addition there will be abnormal fever and abnormal so...

Page 53: ...weight J1 J2 J3 J4 J5 J6 GR6160 43kg 19 6kg 3 8kg 18 13kg 4 2 J1 J2 J3 J4 J5 J6 GR6160 43kg 19 6kg 3 8kg 18 13kg Maintenance tools Dial gauge1 100 mm used to measure the positioning accuracy reverse...

Page 54: ...lator wrist part translation 1 2 4 2 3 4 1 3 Assembly 1 Remove the installation surface impurities scrape off with tools apply glue in with the plane the fitting surface with cleaner dry cleaning Net...

Page 55: ...BOND1110F 3 J5 J6 4 2 3 73 5 3 43Nm 5 6 Fig 4 1Replace the wrist parts in figure 4 1 Table 4 3 replacement wrist parts list Name Specifications Model Quantity Torque Nm 1 Arm extension rodassembly 1 2...

Page 56: ...st fixed mechanical arm and then remove the motor After inserting zeros point bolt with wood or crane fixed mechanicalarm to prevent falling then dismantle the motor zero point bolt and the block is u...

Page 57: ...ar 4 1 2 J1 1 3 J1 2 3 4 5 J1 6 5 6 J1 4 Assembly 1 Remove the motor flange surface impurities ensure clean 2 Install the gear 4 to the J1 shaft on the motor 3 With screw 6 and washer 5 will be a fixe...

Page 58: ...he motor set screw 2 coated in thread sealant LOCTITE 577 and washer 3 6 Install the J1 shaft connection cable of the motor 7 Proofreading operation 1 2 4 J1 3 6 5 4 THREEBOND1110F J1 5 2 LOCTITE577 3...

Page 59: ...sembly 1 The robot placed in position shown in Figure 4 4 attitude As shown in Figure 4 4 with rope hanging from the robot can also be made in diameter bolt 25 is inserted into the arm and J2 axis bas...

Page 60: ...shaft 4 Coated on the surface of the motor flange THREEBOND 1110 f planar sealant 5 Horizontal motor 1 at the same time should be careful not to damage the gear surface 6 Use the screw 2 coated in thr...

Page 61: ...0 1 2000 12 9 4 LOCTITE 577 128 4 6 37 3 Spring washer 12 GB T93 1987 4 4 O ring seal 170 3 55 GB T3452 1 2005 1 5 2 axis input gear 1 6 Spring washer 8 GB T93 1987 1 7 Hexagon socket head cap screws...

Page 62: ...ate location with a sling hanging from it 2 Power dump 3 Removing the motor 1 of the connection cable 4 Removing the motor mounting screws 2 and the washer 3 O ring seal 7 out of the motor 5 Pull moto...

Page 63: ...rizontally mounted motor 1 Flat top coat sealant installation THREEBOND 1110F At the same time be careful not to damage the surface of the gear 5 With screws 2 The threads coated with thread sealant L...

Page 64: ...t gear 1 5 Spring washer 8 GB T93 1987 1 6 Hexagon socket head cap screws M8 45 GB T70 1 2000 12 9 1 37 2 1 86 7 O ring seal 122 2 65 GB T3452 1 1992 1 4 6 J3 1 140201115 1 2 M10 25 GB T70 1 2000 12 9...

Page 65: ...the bearing and the elastic ring to the correct position Then bearing gear connected with the body and the mounting plate install rubber O ring 3 Horizontally mounted motor 1 Flat top coat sealant in...

Page 66: ...replacement and spare partslist see below chart J4 J5 Fig 4 6 J4 axis motor replacement 4 6 J4 Table 4 7 Replace the J4 axis motor parts list Name Standard Quantity Torque N M 1 Motor 140201042 1 2 S...

Page 67: ...rews M5 45 GB T93 1987 1 9 01 0 49 4 7 J4 1 140201042 1 2 5 GB T70 1 2000 4 3 M5 20 GB T93 1987 4 9 01 0 49 4 O 53 2 65 GB T3452 1 1992 1 5 4 ER16L C20 03 01A 1 6 O 87 5 2 65 GB T3452 1 1992 1 7 M8 25...

Page 68: ...5 GB T70 1 2000 4 3 M5 20 GB T93 1987 4 9 01 0 49 4 O 53 2 65 GB T3452 1 1992 1 5 5 ER16L C20 03 02A 1 6 O 87 5 2 65 GB T3452 1 1992 1 7 M8 25 GB T70 1 2000 4 37 2 1 86 8 8 GB T93 1987 4 9 30 GB T894...

Page 69: ...5 The installation process to ensurethat rubber O ring 4 in the correct position With screws 10 and spring washers 11 fixed gear 9 and motor 1 The installation process to ensurethat rubber O ring 8 i...

Page 70: ...T93 1987 4 4 O ring seal 87 5 2 65 GB T3452 1 1992 1 5 6 axis input gear 1 6 Spring washer 5 GB T70 1 2000 1 7 Hexagon socket head cap screws M5 16 GB T93 1987 1 9 01 0 49 4 9 J6 1 140201042 1 2 M5 2...

Page 71: ...the surface waiting for the sealant to soften about 10 minutes Use spatula spread evenly softened sealant 2 1 2 10 3 Assembly 1 In order to prevent dust from falling part sealant applied after sealan...

Page 72: ...plitude is small and the big arm and motor connection this part with the movement of the robot pipeline package has the relative motion and ontology if piping bag and ontologies periodically contact f...

Page 73: ...me specifications of the pipeline also be mark in the same position the purpose is to convenient installation 4 will wear all cables into the pipeline of new replacement 5 to wear into the cable line...

Page 74: ...ch sounds alarm to allow the robot stop movement in order to ensure the safety of the operator 3 Height of Securityfenceshould be not less than 2 meters 1 1 2 3 2 2 Qualification requirements of maint...

Page 75: ...CMA WuHu Robotics CO LTD 68 4 9 Fig 4 9 maintenance area...

Page 76: ...linked to the lifting operation forklifts and other job qualifications By not master the correct implementation of the skills of workers handling operations may result in tipping falling and other ac...

Page 77: ...e fork legs were moving 1 5 1 Fig 5 1 forklift robot posture 5 1 When handling and installation operations should be taken to avoid damage to the wiring In addition after the end of the device is moun...

Page 78: ...Interface Dimensions 5 2 1 In figure 5 3 shows the robot base installation size load is given in figure 5 4 5 5 installed flange size figure 5 6 5 9 is part of the installation size chart for externa...

Page 79: ...CMA WuHu Robotics CO LTD 72 Fig 5 4 end load mounting flange dimensions 5 4 Fig 5 5 end load mounting flange dimensions 5 5...

Page 80: ...Hu Robotics CO LTD 73 Fig 5 6 the base part of J2 shaft assembly base on external dimensiondrawing 5 6 J2 Fig 5 7 big arms are installed on the external size chart 5 7 2 M8 through 6 M8 depth12 4 M8 d...

Page 81: ...g 5 8 motor block installed on the external size chart 5 8 Fig 5 9 lower lever installed on the external dimension drawing 5 9 Fig 5 10 forearm extension rod is installed on the external size chart 5...

Page 82: ...on the external size chart Figure 5 10 External mounting dimensions 5 1 5 3 5 4 5 5 J2 5 6 5 7 5 8 5 9 5 10 Remark 1 Robots have the two interfaces one is the base installation interface the second is...

Page 83: ...N1 min 600KG 0 5G 4 9m s2 5 3 1Environment and climate adaptation should meet the requirements of Table 2 5 3 1 2 Robots at ambient conditions specified in Table 5 2 1 of use transport and storage sho...

Page 84: ...robot parts Appendix A Screw tightening torque table A Note Due to the special motor flange material tightening torque cannot be too large please refer to the table annotation applied N m M3 2 0 18 M...

Page 85: ...10900018807 1 J3 10900018808 1 J4 J5 J6 10900018809 3 Table 2Seals and plugs etc Name Model Specifications Number of single Use the site Rubber O ring 170 3 55 1 J2 axis motor Rubber O ring 122 2 65 1...

Page 86: ...J2 SN65AE107AA0 1 J3 SN60AN107AA0 1 J4 ER16LA C20 03 04A 1 J5 ER16LA C20 03 05A 1 J6 ER16LA C20 03 06A 1 Table 4Part Name Drawing No Number of single Use the site Wrist parts ER16LA C20 04 1 Wrist par...

Page 87: ...5 1 The base unit J2 axis Reducer 10800000006 1 The base unit J3 axis Reducer 10800000007 1 Arm parts J4 axis Reducer 10800000008 1 Arm parts J5 axis Reducer 10800010475 1 Wrist parts J6 axis Reducer...

Page 88: ...CMA WuHu Robotics CO LTD 96 No 96 East Wanchun Road Jiujiang Zone Wuhu Anhui China TEL 86 0 553 5670660 400 052 8877 WWW CMAROBOTICS COM...

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