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6 Maintenance
6.3 Weld Ground Brush Replacement – Type I

6-2

162068-1CD

MH-SERIES
POSITIONER

6.3

Weld Ground Brush Replacement – Type I

6.3.1

MH95/185/505/1605

To replace the grounding brush(s) proceed as follows:
1. Shut down cell using main disconnect.

2. Use a flathead screwdriver to disconnect the brush cable(s) from the

ground post (

Figure 6-1

Fig. 6-1: Brush Cable Removal

3. Release the spring tensioner on the back of the brush by squeezing

both black spring levers and pulling away from the faceplate.

4. Reach in and steady the brush case with one hand.

GROUND POST

GROUND BRUSH

CABLE

64/101

Содержание MH SIGMA-5 Series

Страница 1: ...ceipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN INSTRUCTIONS DX100 INSTRUCTIONS DX100OPERATOR S MANU...

Страница 2: ...ct YASKAWA may modify this model without notice when necessary due to product improvements modifications or changes in specifications If such a modification is made the manual number will also be revi...

Страница 3: ...mportant items WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to personnel CAUTION Indicates a potentially hazardous situation which i...

Страница 4: ...or unexpected positioner motion Figure 2 Release of EMERGENCY STOP Button TURN Observe the following precautions when performing teaching operations within the working envelope of the positioner View...

Страница 5: ...ing has been performed Check for problems in positioner movement Check for damage to insulation and sheathing of external wires Always return the Programming Pendant to the hook on the cabinet of the...

Страница 6: ...vi 162068 1CD 162068 1CD MH SERIES POSITIONER 6 101...

Страница 7: ...on 3 1 3 2 MH Series SIGMA 5 Positioner Assembly Type I 3 1 3 2 1 MH Series SIGMA 5 Positioner Type I Specifications 3 2 3 3 MH Series SIGMA 5 Positioner Assembly Type II 3 3 3 3 1 MH3105 Series SIGMA...

Страница 8: ...18 4 4 7 Tooling Fixture Removal 4 21 4 5 MotoMount Installation 4 22 4 5 1 Preparation 4 22 4 5 2 Unpack and Assemble 4 22 4 5 3 Securing MotoMount Drive Components onto Faceplate 4 24 4 5 4 Retrofi...

Страница 9: ...Position 6 7 6 5 1 Homing 6 7 6 6 Maintenance Schedule 6 11 6 6 1 MH Series SIGMA 5 Positioner 6 11 6 6 2 MotoMount 6 11 6 7 Troubleshooting 6 12 6 7 1 MH Series SIGMA 5 Positioner 6 12 6 7 2 MotoMoun...

Страница 10: ...R 3 DESCRIPTION OF EQUIPMENT Provides a description of the major components CHAPTER 4 INSTALLATION This chapter provides installation procedures CHAPTER 5 TOOLING RECOMMENDATIONS This chapter provides...

Страница 11: ...ate single or multiple external axis control packages to provide a complete positioner kit 1 3 System Layout The two major components of a typical headstock and tailstock positioner assembly MHT are M...

Страница 12: ...ut Type I Fig 1 2 MHT System Layout Type II DRIVE ASSEMBLY MotoMount ASSEMBLY HS AC SERVO MOTOR MotoMount ASSEMBLY TS TAILSTOCK COLUMN STANDARD TOOL RADIUS LEVELING SCREW TYP HEADSTOCK COLUMN MotoMoun...

Страница 13: ...l output bearing faceplate and a cast iron housing It also includes dual integral position switches and weld ground brushes 1 3 1 1 Drive Assembly with MotoMount The Drive Assembly combined with the M...

Страница 14: ...sembly with a column that is designed to be floor mounted or mounted to a machine base as required for use in cantilevered stand alone applications The standard configuration provides connectors in th...

Страница 15: ...tem This system is designed to be floor mounted or mounted to a machine base Span between the headstock and tailstock is determined by the application The standard configuration provides a 815 mm tool...

Страница 16: ...our issue along with complete contact information Please allow approximately 24 to 36 hours for a response to your inquiry Please have the following information ready before calling techsupport motoma...

Страница 17: ...e recommend approved Motoman training courses for all personnel involved with the operation programming or repair of the robot system This training is designed to familiarize personnel with the safe a...

Страница 18: ...ks Emergency stop palm buttons located on operator station robot controller and programming pendant Check all safety equipment frequently for proper operation Repair or replace any non functioning saf...

Страница 19: ...before program changes are made To avoid loss of information programs or jobs a backup must always be made before any service procedures are done and before any changes are made to options accessorie...

Страница 20: ...ot perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual Use proper replacement parts Improper connections can damage the robot All connec...

Страница 21: ...ion Holes in the faceplate provide for mounting MotoMount drive components or parts fixtures in stand alone cantilevered applications 3 2 MH Series SIGMA 5 Positioner Assembly Type I The design of the...

Страница 22: ...95 Headstock Speed rpm 23 8 12 4 9 8 10 8 180 Degree Sweep Time sec 1 56 2 72 3 36 3 28 Rated CG Off Center mm 152 152 152 152 Rated CG Overhang mm 500 250 331 0 Load 500 mm CG Overhang kgf 75 75 168...

Страница 23: ...sitioner Assembly Type II 3 3 MH Series SIGMA 5 Positioner Assembly Type II The MH3105 head stock utilizes a Type II drive assembly similar to that used in the MSR505 MSR1005 and MotoSweep O 20 50 pro...

Страница 24: ...s Type Rotation Rated Load kgf 3105 Max MHT Load CG Off Center kgf mm 6300 90 Headstock Speed rpm 6 7 180 Degree Sweep Time sec 4 95 Rated CG Off Center mm 152 Rated CG Overhang mm 58 Load 500 mm CG O...

Страница 25: ...uired for use with all Motoman MHT series headstock tailstock positioners The MotoMount drive components are mounted onto the headstock faceplate while the tailstock components replace earlier tailsto...

Страница 26: ...9 MotoMount HD Layout FACEPLATE WELD GROUND CABLE TAILSTOCK TOOLING ADAPTER DRIVE BUSHING TAILSTOCK COLUMN FACEPLATE WELD GROUND CABLE AUXILARY MOUNTING HOLES AUXILARY MOUNTING HOLES PRIMARY MOUNTING...

Страница 27: ...ed This section identifies customer supplied items and tools required to complete installation 4 1 1 Customer Supplied Items Servo motion control unit Incoming power supply Two earth ground cables wit...

Страница 28: ...otective plastic wrapping from equipment 2 Inspect equipment for shipping damage 3 Unbolt the equipment from the shipping skid see Fig 4 10 Fig 4 10 Unbolting the Drive Assembly 4 Attach a lifting dev...

Страница 29: ...s for positioners The following figures show the mounting hole patterns Fig 4 11 shows the mounting hole pattern for the MH95 185 Fig 4 12 shows the mounting hole pattern for the MH505 Fig 4 13 shows...

Страница 30: ...0 1 20 350 0 70 0 210 0 400 0 76 2 SWITCHES BRACKETS NOT SHOWN FOR CLARITY 2X M10 x 1 5 THRU HOLES FOR ADDITIONAL MOUNTING SUPPORT AS REQUIRED FOR SPECIFIC APPLICATIONS 0 5 0 0 4X 11 0 THRU 0 018 0 0...

Страница 31: ...eed as follows 1 Set the column assembly in desired position 2 Use the leveling bolt holes as a guide and transfer the hole locations to the concrete 3 Remove column assembly 4 Install the anchors per...

Страница 32: ...lace a level on top of the housing perpendicular to the faceplate 2 Use the two leveling bolts beneath the faceplate A and B and a third beneath the motor C to level axially If the faceplate side need...

Страница 33: ...g connections can be found in the system manual See separate documentation specific to your system 4 2 5 2 Ground Cables Type I Two locations are provided for attaching weld ground cables see Figure 4...

Страница 34: ...ipment proceed as follows 1 Carefully remove protective plastic wrapping from equipment 2 Inspect the equipment for shipping damage 3 Unbolt headstock from the shipping skid using a 3 4 inch socket 4...

Страница 35: ...itioner Type II 4 3 3 Unbolting the Drive Assembly Floor Mounting Type II Figure 4 17 provides dimensions for accurately floor mounting the MH3105 headstocks Fig 4 17 MH3105 Floor Mounting SHIPPING BO...

Страница 36: ...adstock The headstock must be leveled in two directions Parallel to the faceplate Perpendicular to the faceplate Since it only takes three points to define a plane use only three of the six leveling b...

Страница 37: ...ng the Cables Do not connect the encoder power and ground cables until after the drive assembly is securely in place 4 3 4 1 Connection to Motoman Controller When the MH Series SIGMA 5 Positioner asse...

Страница 38: ...on the floor from the edge of the headstock base toward the location of the tailstock Fig 4 20 Strike a Chalk Line 3 Set the tailstock in its approximate position on the floor using the chalk line Th...

Страница 39: ...n the tailstock on the floor across from the headstock 4 Use the chalk line and the center line of each component as guides for placement of the tailstock column on the floor 5 To position the tailsto...

Страница 40: ...ck assembly axially proceed as follows 1 Place a level on top of the tailstock column in the axial direction 2 Use the leveling bolts A B and C to adjust the axial level Adjust bolts A and B equally T...

Страница 41: ...sembly axially proceed as follows 1 Place a level on top of the tailstock column in the axial direction 2 Use the leveling bolts A B and C to adjust the axial level Adjust bolts A and B equally To lev...

Страница 42: ...Mount HD allows for a misalignment between the tailstock and the tooling fixture without affecting performance A misalignment of 0 5 degrees is allowed If the tailstock is out of alignment more than 0...

Страница 43: ...tock assemblies 3 Slowly lower tooling fixture while aligning with the headstock and tailstock locating pins Fig 4 27 Tooling Fixture Installation Headstock Tailstock 4 Continue lowering the tooling u...

Страница 44: ...the MotoMount drive components A tooling fixture must be installed to align the system 4 4 6 1 Horizontal Alignment Check the horizontal alignment by measuring the gap see Figure 4 23 between the moun...

Страница 45: ...lar to the tailstock adapter within 1 2 degree a visual check with a square is acceptable Repeat this process until the gap at both positions is within 1 mm If moving the bearing housing cannot provid...

Страница 46: ...bottom 2 Using calipers measure the alignment gap 3 Rotate the positioner 180 degrees until the drive bushing is at the top 4 Measure the alignment gap at the second position If the gaps are differen...

Страница 47: ...rizontal alignment Insure ground cable is installed and properly secured When horizontal and vertical alignment is complete ensure all bolts are tightened to the appropriate torque including tailstock...

Страница 48: ...it is part of a larger system MotoMount drive components Dowel pins 2 Mounting hardware Weld ground cable Carefully remove plastic wrapping from components and inspect them for shipping damage 4 5 2...

Страница 49: ...wel pins into the appropriate dowel pin hole in the mounting block It is important that the dowel pin is pressed in as far as possible 4 Relocate the spacer behind the other dowel hole and install the...

Страница 50: ...er holes in the faceplate and push fixture block in as far as possible 3 Insert both mounting bolts through the fixture block and tighten into the faceplate holes Torque bolts to 76 N m 56 lbf ft 4 In...

Страница 51: ...al Center Position Side View 4 6 1 Allowable Misalignment The flexibility of MotoMount allows for misalignment between the tailstock and the tooling fixture without affecting performance A total misal...

Страница 52: ...wer tooling fixture onto the tailstock using the locating pin 6 Install the M16 tool mounting bolts and washers onto the tailstock customer supplied grade 8 8 bolts and torque the bolts to 190 N m 140...

Страница 53: ...e tailstock adapter until a suitable position is acquired These two processes do not effect MotoMount s performance It is important that a minimum distance is maintained between the tailstock adapter...

Страница 54: ...stock with MotoMount To ensure optimal performance from the MH SERIES POSITIONER tooling system Yaskawa Motoman makes the following recommendations for each configuration 5 1 Headstock Only Tooling Re...

Страница 55: ...ing fixture please read the following recommendations Use all bolt holes on the faceplate to mount the tooling fixture Use the dowel pins 5 1 1 2 Mounting Holes Faceplate The customer supplied tooling...

Страница 56: ...25 MM 2 X SLIP FIT FOR M12 DOWEL 4 X M12 x 1 75 100 MM 100 MM CAUTION To proper secure fixture rated loads required the use of all M16 mounting holes 0 0 30 MM OD X 6 ID THRU PILOT 1 8 28 BSPT M16 X 2...

Страница 57: ...mmendations Fig 5 42 Mounting Holes on Faceplate MH3105 0 0 0 0 DIA 120 THRU M16 X 2 THRU 225 0 MM 274 5 MM 30 MM TYP TYP 12 5 MM 4 X M10 1 5 THRU 2 X M12 THRU 225 0 MM 194 9 MM 194 9 MM 112 5 MM 112...

Страница 58: ...s Some applications require multiple tooling fixtures that are switched in and out of the positioner as production needs change To prepare these extra fixtures to work with MotoMount the following spa...

Страница 59: ...following hole pattern Figure 5 44 Fig 5 44 Tooling Template MotoMount 5 2 3 3 Hole Pattern on MotoMount HD The tooling fixture flange that attaches to MotoMount HD must have the following hole patter...

Страница 60: ...Clearance MotoMount Fig 5 47 Drive Component Clearance MotoMount HD 5 2 3 5 Tailstock Flange Specifications Figure 5 48 shows the specifications for the tooling fixture flange that is secured to the...

Страница 61: ...mmendations 5 2 Headstock Tailstock with MotoMount MotoMount HD tailstock adapter Fig 5 48 Tailstock Adapter MotoMount Fig 5 49 Tailstock Adapter MotoMount HD 36 5 7 MM MINIMUM TOOLING FIXTURE FLANGE...

Страница 62: ...only Do not use the auxiliary mounting holes for the primary tooling support Center shaft clearance required on the tooling fixture when using auxiliary mounting holes on the headstock are shown in Fi...

Страница 63: ...ommended spare parts with Yaskawa Motoman part numbers Motoman recommends the following parts be kept on hand 6 2 Servomotor The AC servomotor has no wear parts i e brushes so a simple daily inspectio...

Страница 64: ...proceed as follows 1 Shut down cell using main disconnect 2 Use a flathead screwdriver to disconnect the brush cable s from the ground post Figure 6 1 Fig 6 1 Brush Cable Removal 3 Release the spring...

Страница 65: ...6 Lower the case below the retaining edge and slowly pull the brush holder out of the housing Figure 6 3 Fig 6 3 Brush removal MH95 185 505 1605 NOTE When pulling the brush holder out identify and sec...

Страница 66: ...nto nut plate Thread the screws into nut plate loosely 10 Push the brush holder up in front of the retaining edge and hold steady 11 Squeeze the brush retaining spring and push the brush against the f...

Страница 67: ...cell using main disconnect 2 Remove the back panel of the drive assembly 3 Use a flathead screwdriver to disconnect the brush cable s from the ground post Figure 6 4 Fig 6 4 Brush Cable Post 4 Release...

Страница 68: ...e case Fig 6 5 Brush Assembly 7 Lower the case below the retaining edge and slowly pull the brush holder out of the housing Figure 6 6 Fig 6 6 Brush Removal 3105 NOTE When pulling the brush holder out...

Страница 69: ...Home Position The home position on the drive assembly is set in the controller by the operator Any position of the headstock can be programmed as home The factory setting of home position is found us...

Страница 70: ...o the Home position install the homing pin through the hole in the faceplate The pin may need to be tapped in with a hammer 4 Slowly jog the drive assembly until the plastic pin just touches the home...

Страница 71: ...To reset each a MH3105 headstock proceed as follows 1 Make sure robot s is in home position 2 Locate the headstock homing hole Using the programming pendant in TEACH MODE jog the faceplate slowly unt...

Страница 72: ...amming pendant Cursor to ROBOT and press SELECT Cursor to HOME POSITION and press SELECT Press the PAGE OVER key to the desired station indicated in the top right corner Make sure the headstock is in...

Страница 73: ...tment at 937 847 3200 Weld Brushes First Week Check for dirt and ensure full contact with faceplate Weekly Check for dirt and ensure full contact with faceplate Cleaning As required Clean with dry clo...

Страница 74: ...stem has been wired correctly Overload Reduce load or reduce unbalanced load Unstable operation Incorrect wiring Inspect and correct wiring across motor terminals L1 L2 L3 and PE Motor overheats Exces...

Страница 75: ...215 220 135 202 240 127 191 260 120 181 280 114 171 300 109 163 HTS Applications assume 1 2 load on Note headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum lo...

Страница 76: ...350 97 146 375 92 138 400 88 131 425 84 125 450 80 120 475 76 115 500 73 110 HTS Applications assume 1 2 load on Note headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment...

Страница 77: ...284 450 182 273 475 174 262 500 168 252 Note HTS Applications assume 1 2 load on headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum load based upon 75 maximum...

Страница 78: ...48 260 734 1101 280 705 1058 300 679 1018 Note HTS Applications assume 1 2 load on headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum load based upon 75 maximu...

Страница 79: ...750 1018 1527 800 971 1456 850 928 1392 900 889 1333 950 852 1279 Note 1 HTS Applications assume 1 2 load on headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum...

Страница 80: ...ttached parts which lose their identity by being welded soldered riveted etc to other parts or assemblies B 1 2 Parts List This form is divided into four columns as follows 1 Figure Item Number Column...

Страница 81: ...Symbols and Abbreviations The following is a list of symbols and abbreviations used in the parts list amp ampere AC alternating current cyl cylinder DC direct current fig figure hex hexagon ID inside...

Страница 82: ...ction B 3 162068 1CD 162068 1CD Fig B 1 MH95 M185 Head Stock 24 27 19 1 22 23 6 29 20 19 19 3 5 6 4 7 25 26 30 2 11 12 14 15 16 10 9 13 18 17 32 6 31 33 34 26 38 TORQUE TO 40 0 Nm TORQUE TO 6 0 Nm TOR...

Страница 83: ...148 5 WASHER_LOCK_M8 1 16 479147 5 WASHER_FLAT_M8 1 17 158342 1 SCREW PPH M4x0 7 X 8 MACHINE 4 18 479154 4 TIE MOUNT 4 19 479281 105 FITTING PLUG 1 8BSPT BLACK 3 20 158941 9 LABEL PRODUCT ID 1 21 1339...

Страница 84: ...B 1 Introduction B 5 162068 1CD 162068 1CD Fig B 2 MSR205 MH505 Head Stock 4 37 9 10 1 34 33 28 36 5 4 3 24 15 23 22 25 38 15 35 2 27 28 29 7 6 30 31 32 21 20 19 18 16 17 15 16 17 39 20 19 15 18 16 17...

Страница 85: ...1 BRACKET MTG LIMIT SWITCH 2 21 145896 1 PIN HOMING 1 22 144371 1 BRUSH GROUND METAL GRAPHITE 2 23 130235 6 SCREW HHC 1 4 20 X 1 ZP GR5 4 24 130443 15 WASHER FLAT 1 4 SAE 4 25 144372 1 BRUSH HOLDER 1...

Страница 86: ...B 3 MH1605 Head Stock TORQUE TO 29 5 Nm TORQUE TO 6 Nm 5 6 3 15 24 16 23 17 18 19 25 26 27 11 29 30 39 31 32 20 6 13 34 35 37 36 22 23 7 38 28 14 4 12 11 10 TORQUE TO 3 6 Nm TORQUE TO 3 6 Nm TORQUE T...

Страница 87: ...RV RV 320E 185 1 15 152538 1 ADAPTER FLYWHEEL MRM2 250 750 M3X 1 16 151593 7 GEAR INPUT PINION 185 1 17 145428 2 WASHER FLAT M8 X 16 OD X 3 THK 1 18 470617 1 WASHER CONICAL SPRING M8 1 19 407248 21 S...

Страница 88: ...B Illustrated Parts list MH SERIES POSITIONER B 1 Introduction B 9 162068 1CD 162068 1CD Fig B 4 Type II Drive Assembly Components 1 2 3 4 5 6 7 8 21 20 18 13 11 10 10 22 19 15 16 17 9 88 101...

Страница 89: ...X 35 6 16 470602 1 WASHER CONICAL SPRING M6 18 17 130060 12 SCREW SHC 1 4 20 X 2 1 2 GR8 6 18 130444 5 WASHER LOCK 1 4 6 19 130443 15 WASHER FLAT 1 4 SAE 6 20 144371 1 BRUSH GROUND METAL GRAPHITE 3 21...

Страница 90: ...B Illustrated Parts list MH SERIES POSITIONER B 1 Introduction B 11 162068 1CD 162068 1CD Fig B 5 MotoMountTM Tailstock Components 95 185 505 7 12 13 14 15 3 2 90 101...

Страница 91: ...R 1 3 148135 1 SCREW SET CONE PT M8X6 1 4 148124 1 PIN LOCATOR 16MM 1 5 155870 1 ADAPTER BLOCK TAILSTOCK GEN2 1 6 156164 1 RETAINER TAILSTOCK BEARING 2 7 146953 3 RING RETAINING EXTERNAL 55 1 8 407249...

Страница 92: ...B Illustrated Parts list B 1 Introduction B 13 162068 1CD 162068 1CD MH SERIES POSITIONER Fig B 6 MotoMountTM Tailstock Components 1605 3105 2 3 4 5 6 7 9 10 11 12 13 14 15 8 92 101...

Страница 93: ...120 4 3 146951 1 CLAMP SHAFT 1 4 148124 1 PIN LOCATING DIA16 1 5 146950 4 SHAFT SQUARE 1 6 148136 1 BEARING SPHERICAL ROLLER 1 7 146940 4 RING RETAINING INTERNAL 1 8 146965 3 ADAPTER TAILSTOCK 1 9 14...

Страница 94: ...trated Parts list MH SERIES POSITIONER B 1 Introduction B 15 162068 1CD 162068 1CD Fig B 7 MotoMount Components 2 1 19 17 16 3 4 6 28 31 11 7 8 9 10 7 8 18 24 20 23 22 21 12 13 14 15 30 29 26 25 27 5...

Страница 95: ...11 146503 1 PLATE SIDE BLOCK 1 12 130887 11 CABLE WELD 4 0 1FT 2 13 131272 1 SCREW HHC M12X25 ZP CLASS 8 8 3 14 479148 7 WASHER LOCK M12 3 15 147462 1 WASHER M12 HIGH STRENGH 5 16 145848 1 SEAL O RING...

Страница 96: ...B Illustrated Parts list MH SERIES POSITIONER B 1 Introduction B 17 162068 1CD 162068 1CD Fig B 8 MotoMount HD Drive Components 7 9 10 8 5 3 2 4 6 11 96 101...

Страница 97: ...00 2 ADAPTER ASSY MOTOMOUNT HD Ref 2 149227 1 HUB MOUNTING 1 3 146195 3 BLOCK GUIDE 1 4 149768 1 BEARING CAM FOLLOWER 1 5 148124 1 PIN LOCATING DIA 16 MM HEAD 1 6 146196 3 BLOCK MOUNTING FIXTURE 1 7 1...

Страница 98: ...B Illustrated Parts list B 1 Introduction B 19 162068 1CD 162068 1CD MH SERIES POSITIONER Fig B 9 Slip Ring Components 2 3 4 5 6 7 8 98 101...

Страница 99: ...Title Qty B 9 148634 1 ACCESSORY SLIP RING MOTOMOUNT HD Ref 2 148636 1 SUPPORT GUARD SLIP RING 1 3 148635 1 GUARD SLIP RING 1 4 148848 1 SLIP RING ASSY MOTOMOUNT HD 1 5 146913 2 FITTING NIPPLE PIPE B...

Страница 100: ...B Illustrated Parts list B 1 Introduction B 21 162068 1CD 162068 1CD MH SERIES POSITIONER 100 101...

Страница 101: ...0 162068 1CD MANUAL NO Specifications are subject to change without notice for ongoing product modifications and improvements MH SERIES SIGMA 5 POSITIONER MANUAL 101 101...

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