EFORT ER10-3-900 Operation And Maintenance Manual Download

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ER10-3(4)-900 Mechanical Operation and
Maintenance Manual for Industrial Robot

EFORT INTELLIGENT EQUIPMENT CO.,LTD

Hotline(Tel):400-0528877

Summary of Contents for ER10-3-900

Page 1: ...ER10 3 4 900 Mechanical Operation and Maintenance Manual for Industrial Robot EFORT INTELLIGENT EQUIPMENT CO LTD Hotline Tel 400 0528877 ...

Page 2: ...ound you or property damage to the robot or other objects around you This announcement and manual are the latest version of this batch of products before delivery Please visit www efort com cn for updated information This manual is only used as a guide for the normal operation of the product During the use of the product EFT will not be liable for personal injury and property loss caused by other ...

Page 3: ...ximum of Static Payload Torque 18 2 7 3 Allowable Maximum of Moment of Inertia 15 2 7 4 Allowable Payload Curve Diagram 15 Chapter Three Handling and Installation 16 3 1 Robot Handling 16 3 1 1 Handling Precautions 16 3 1 2 Auxiliary Handling Tooling 16 3 1 3 Handling Method 18 3 2 Robot Installation 24 3 2 1 Setting of Safety Fence 24 3 2 2 Robot Installation Method 25 3 2 3 Ground Mounting 25 3 ...

Page 4: ...the Residual Pressure in the Lubricating Oil Cavity 35 4 4 Robot Maintenance and Use Area 36 4 5 Home Position Calibration 36 4 5 1 Home Position Calibration Method 37 4 5 2 Mechanical Home Position Calibration of Each Axis 37 4 6 Battery Replacement 38 Chapter Five Common Faults and Treatment Measures 35 Appendix 44 A Screw Tightening Torque Table 44 B Backup List 44 ...

Page 5: ...ork clothes safety helmets safety shoes etc 2 When turning on the power make sure that there are no workers within the robot s operating range 3 The power must be cut off before entering the robot s range of motion for work 4 When overhaul maintenance and other operations must be carried out under the power on state two persons should work in a team at this time One person maintains a posture that...

Page 6: ...nts Emergency situations generally have the following types 1 Low speed action suddenly becomes high speed action 2 Other operators performed the operation 3 A different program was started due to an abnormality or program error in the peripheral equipment 4 Abnormal operation due to noise malfunction defect etc 5 Misoperation 6 Originally planned to regenerate at low speed to perform the action b...

Page 7: ...revent the danger of the robot when the peripheral equipment is abnormal so as to ensure safe operation Attention The main body of the robot is a multi joint manipulator structure and the angle of each joint in the movement is constantly changing When you must approach the robot for teaching and other tasks be careful not to get caught by the joints Each joint action end is equipped with a mechani...

Page 8: ...mal operations malfunctions damage and other dangerous situations Attention Although electromagnetic interference is related to its type or intensity there is no perfect countermeasure with current technology When the robot is in operation or when the power is on the operation precautions and regulations should be followed Due to electromagnetic waves other noises and substrate defects the recorde...

Page 9: ...nnect Raise your right hand up high forward Use your thumb and index finger to form a circle 3 Is that OK to confirm 4 OK Raise your right hand and wave vigorously left and right Raise your right hand up high forward The right hand is facing the opponent Straight up arms 5 Wait a moment 6 Leave Stretch your right arm horizontally and weave to the left ...

Page 10: ...his requirement must be thoroughly implemented Attention According to the setting place and operating content the relevant operation regulations and checklists such as starting method operation method solution in case of abnormality etc of the robot should be compiled And carry out the operation according to the operating regulations Operation only based on the memory and knowledge of the operator...

Page 11: ...on or unsafe operation which may lead to accidents Attention When the robot is shifted transferred or sold abroad if there are no special provisions in the contract terms at the time of the initial sale the security related terms shall not be inherited by the new recipient The original customer and the new recipient must sign a new contract Attention When it is not necessary to make the robot move...

Page 12: ...ard and components of the control device before discarding it Sharp parts such as cracks or cuts wires etc may cause injury Attention After the cables and external wiring are removed from the connector and junction box do not disassemble them further and then discard them Otherwise it may cause injury to hands or eyes due to conductors etc Attention When carrying out abandoned work please pay full...

Page 13: ...ion 2 2 Unpacking Check Attention 1 Before unpacking please confirm whether the outer packaging of the product is intact 2 After unpacking please confirm whether all parts of the robot are complete and whether the model is consistent with the order If you find missing or wrong parts please contact the supplier in time Table 2 1 Unpacking List of ER10 3 4 900 Name Model Number Unit Remarks robot bo...

Page 14: ...of the operator can be seen on the robot body which contains the corresponding model type weight voltage production number manufacturing date and other information As shown in Figure 2 2 below Fig 2 2 Robot Body Nameplate 2 4 Body Part Composition and Direction Identification of Each Axis The robot mechanical body is mainly composed of the base part the rotating part the big arm part the small arm...

Page 15: ...he robot body has a home position and range limit When the robot system is running normally each axis of the robot is controlled to move within the allowable range In addition in order to ensure further safety mechanical end stops are provided on some axes to prevent the robot from operating beyond the allowable range when the robot control system is abnormal the small arm part the big arm part th...

Page 16: ...t installation inversion Drive method AC Servo Drive Robot model ER10 3 900 ER10 4 900 Maximum speed of motion axis J1 axis 300 sec axis J2 axis 320 sec axis J3 axis 380 sec axis J4 axis 600 sec Maximum range of motion axis J1 axis 130 axis J2 axis 250 69 axis J3 axis 130 axis J4 axis 360 Maximum payload on wrist 10 kg J3 axis mechanical end stop J1 axis home position J1 axis mechanical end stop J...

Page 17: ...ial Robot ER10 3 4 900 Fig2 7 Robot Workspace Diagram of ER10 3 900 Maximum arm span 860mm Repeat accuracy 0 08mm Protection level IP54 Ambient temperature 0 45 Relative Humidity 40 90 Atmospheric pressure 86KPa 106KPa Body weight 30kg P point P point range ...

Page 18: ...allation payload at the front end of the robot wrist is affected by the allowable weight of the wrist the allowable payload torque value and the allowable moment of inertia The allowable payload torque value changes according to the actual payload moment of inertia The wrist payload should be strictly controlled within each allowable value When using the robot with a wrist payload other than the a...

Page 19: ...model Allowable moment of inertia J3 axis rotation J4 axis rotation ER10 3 900 1 5 kg ER10 4 900 1 5 kg 0 8 kg 2 7 4 Allowable Payload Curve Diagram Fig 2 9 Wrist Axis Torque Diagram of ER10 3 900 Fig 2 10 Wrist Axis Torque Diagram of ER10 4 900 Distance from end flange axis Distance from the center of rotation of J3 axis m Distance from end flange axis Distance from the center of rotation of J3 a...

Page 20: ...ibed in the manual and confirm the weight and steps before proceeding If the operation cannot be performed in accordance with the specified method the robot and the control device may tip over or fall during the handling process resulting in accidents Attention When carrying out transportation and installation operations care should be taken to avoid damaging the wiring In addition after the devic...

Page 21: ...echanical Operations and Maintenance Manual for Industrial Robot ER10 3 4 900 Fig 3 1 Packing and Fixing Bracket Diagram Fig 3 2 Packing and Fixing Bracket Installation Diagram of ER10 3 900 M6 10 M5 10 ...

Page 22: ... with 2 soft slings The recommended sling length is 2m Rubber hoses etc should be put on the part where the steel cable is in contact with the robot body for protection The handling fixed workpiece should not be disassembled during the handling process otherwise it may cause damage to the robot body The angles of each axis of the handling posture are set as follows position J1 axis J2axis J3 axis ...

Page 23: ...g Attention When handling please note that the robot s arms and motors cannot be subjected to external forces After unpacking and installation be sure to remove the fixed fixture for transport and rubber pad Fig 3 4 Schematic Diagram of Lifting and Handling of ER10 3 900 4 soft slings 50Kg 2m 2 M6 10 chrome plated flat washers grade C 6 2 M5 10 chrome plated flat washers grade C 5 packing bracket ...

Page 24: ...tion method it should be fixed on the ceiling and wall with sufficient strength and the treatment plan to prevent falling should also be considered Otherwise accidents such as personal injury and equipment damage may occur 3 2 1 Setting of Safety Fence It is necessary to comply with the national standard of the People s Republic of China GB11291 2 2013 that is Safety Requirements for Robots and Ro...

Page 25: ...the foundation can withstand the dynamic load of the robot during acceleration and deceleration and the static weight of the robot and fixtures In addition if the installation surface of the robot is not flat the robot may deform and its performance may be affected Please ensure that the flatness of the robot installation is less than 0 5mm The dimensions of the base installation interface are sho...

Page 26: ...mical bolts of M16 or more to fix the bottom plate on the ground The base of the robot is firmly fixed on the bottom plate with M16 hexagon socket screws of strength grade 12 9 through the four mounting holes the length of the screw must ensure that the screw thread length reaches 1 5 times the nominal diameter of the thread If there is no loosening during operation please fully fix and prevent lo...

Page 27: ... is higher than that of chemical bolt components 3 2 5 Suspended Installation Suspended Installation robot base bottom plate Refer to the ground installation specifications as shown in Table 3 1 Attention In order to ensure safety the following precautions should be taken when implementing upside down and wall mounted installations 1 Install the anti fall safety device as shown in Figure 3 8 2 The...

Page 28: ...ns storage and transportation conditions ambient temperature 0 45 40 55 relative humidity 80 40 93 40 atmospheric pressure 86 106 kPa vibration less than0 5G 4 9m s2 others no corrosive gas Note Note For the robot to be used if there is strong vibration a lot of dust cutting oil splashing or other objects in the use environment please contact our after sales service department to use a robot cover...

Page 29: ... end load installation size dimensions of the external component installed on the big arm Fig 3 10 external component installation size dimensions of the external component installed on the small arm Fig 3 11 external component installation size dimensions of external component installed on the wrist Fig 3 12 external component installation size uniform distribution uniform distribution ...

Page 30: ...900 Fig 3 10 Dimensions of the External Component Installed on the Boom of ER10 3 4 900 a ER10 3 900 b ER10 4 900 Fig 3 11 Dimensions of the External Component Installed on the Small Arm a ER10 3 900 b ER10 4 900 Fig 3 11 Dimensions of External Component Installed on the Wrist ...

Page 31: ...noise inspection check whether the transmission mechanism has abnormal noise 2 interference inspection check whether the transmission mechanism is running smoothly and whether there is abnormal vibration 3 air cooling inspection check whether the fan behind the control cabinet is well ventilated 4 pipeline accessories inspection check whether it is complete whether it is worn or not whether there ...

Page 32: ...ubricant of the wrist parts replace according to lubrication requirements Attention Note 1 Regarding cleaning parts mainly at the oil seal of the mechanical wrist cleaning chips and splashes 2 Regarding the fastening parts tighten the end effector installing screws robot body installing screws and screws that have been removed for overhaul All screws exposed to the outside of the robot should be t...

Page 33: ...e department promptly 4 3 1 The Oil Supply Quantity of Lubricant Table 4 6 Oil Supply Table of Changing the Lubricant of ER10 3 900 The position Amount of oil Name for the lubricant Remarks J1 axis reducer 220cc MOLYWHITE RE No 00 Rapid oiling will cause the pressure in the oil tank to rise the crack of sealing ring and the leakage of lubricating oil The oil supply speed should be controlled below...

Page 34: ...y increase which may damage the sealing part resulting in lubricant leakage and abnormal operation Therefore when performing lubrication operations please observe the following 1 Before performing the lubrication operation open the oil drain port remove the oil drain plug or screw plug 2 Slowly provide lubricant the oil supply speed should be controlled below 40cc 10 seconds do not use too much fo...

Page 35: ...ealing tape 6 gas source 4 3 4 Release the Residual Pressure in the Lubricating Oil Cavity After the oil is supplied in order to release the residual pressure in the lubrication tank the robot should be properly operated At this time install a recovery bag under the lubricant inlet and outlet to avoid the spilled lubricating oil from scattering In order to release the residual pressure when the oi...

Page 36: ...e safety gate 2 A safety carpet or photoelectric switch should be installed on the floor so that when the operator enters the robot s range of motion an alarm will be issued through the buzzer and photoelectric switch to stop the robot from moving to ensure the safety of the operator 3 The height of the safety fence is not less than 2 meters 2 Qualification requirements and precautions for mainten...

Page 37: ...olve these problems 1 Software Home position Calibration The laser tracker needs to be used to establish the coordinate system of each joint of the robot and the system encoder s reading is set to zero The software calibration is more complicated and needs to be operated by professionals of our company 2 Mechanical Home position Calibration Line Calibration Rotate the marking line of the zero bloc...

Page 38: ...Remove the rear cover of the robot base and remove the battery pack as shown in Figure 4 6 Remove the old battery from the battery box and put the new battery into the battery box paying attention to the positive and negative polarity of the battery Reconnect the battery cable and fix the battery pack After installation follow the steps to fix the rear cover of the base After ensuring that all saf...

Page 39: ... The mounting base and the foundation are not firmly fixed 1 The ground installation conditions do not meet the requirements resulting in insufficient foundation rigidity 2 The specifications and strength of chemical bolts do not meet the requirements Refer to the 3 2 3 Ground Installation section of this manual to make the concrete foundation and chemical bolt set meet the installation requiremen...

Page 40: ... does not improve after running at low speed for 1 2 days the internal parts may be damaged Please consult our after sales service department for replacement Fault Fault classification Possible cause of fault Treatment measures Vibratio n and abnorm al noise Other faults that may cause vibration and abnormal noise 1 The connection cable between the robot body and the control cabinet is abnormal re...

Page 41: ...ause the motor to work in an abnormal state the average current value increases and overheating occurs Please set the parameters and program instructions reasonably according to the operation manual and the load should be controlled within the allowable range Other faults that may cause the motor to overheat 1 The joints of the robot are abnormal causing the motor to be overloaded and overheating ...

Page 42: ...osition accuracy cannot be guaranteed due to loose screws and abnormal connection of the main body structure 2 Due to impact or long term overload the joint position is shifted and even parts are damaged 1 Tighten the screws and check the joint connection 2 Adjust and restore the shifted joint position If any parts are damaged replace them in time Position shift occurs when connecting peripheral d...

Page 43: ...he robot body are removed other parts may lose support resulting in unpredictable movements and causing damage to personnel and equipment Therefore the replacement and maintenance of parts requires professionals to use professional tools to operate If necessary please contact our company s after sales service department ...

Page 44: ...educer 10800010478 one J2 axis reducer 10800000124 one J3 axis reducer 10800000125 one The following spare parts are exclusive to ER10 4 900 J4 axis motor 10900026048 one J4 axis reducer 10800012777 one Table 2 ER10 3 4 900 Sealing Ring and Screw Plug etc Name Material code Unit per robot Application area hexagon socket screw plug M10x1 three overall combined sealing washer 10 three overall Screw ...

Page 45: ...900 Sealant and others Name Model specification Unit per robot Application area flat sealant THREEBOND 1110F one screw tightening agent THREEBOND 1374 one grease MOLYWHITE RENO 00 According to refueling volume detergent THREEBOND 6602T one thread sealant LOCTITE577 one battery pack 10900025475 one ...

Page 46: ...ifications and external dimensions of this product are subject to change without prior notice The technical data and illustrations are for reference only and we reserve the right to change them EFORT INTELLIGENT EQUIPMENT CO LTD No 96 Wanchun Road Jiujiang Economic Development Zone Wuhu Anhui China Website http www efort com cn ...

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