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ZX-T Series
Cat. No. I201E-EN-01B
Delta Robot XXL
USER´S MANUAL
Delta RobotCR_UGD4_XXL1300H Series
CONTENTS CR_UGD4_XXL1300HUser's Manual
T-1
Safety Instructions
1. Attention S-1
2. Explanation of warnings and notes S-1
3. Safety information S-2
3.1 General S-23.2 Qualifiedpersonnel S-23.3 Liability S-23.4 Installationandoperatingconditions S-23.5 Residualrisks S-23.5.1 Releasedevice S-3
3.5.2 Transport S-3
3.5.3 Assemblyandstart-up S-3
3.5.4 Maintenanceandrepair S-3
3.5.5 Systemintegrator S-4
Chapter 1 Introduction
1. Introduction 1-1
1.1 Descriptionoftherobot 1-11.2 Typecodeexplanation 1-1
2. Identification 1-1
3. Part names 1-2
Chapter 2 Model overview
1. Overview 2-1
Chapter 3 Installation
1. Unpacking 3-1
1.1 Unpackingtheshippingbox 3-11.2 Checkthedamage 3-11.3 Liftingandtransportation 3-1
2. Mounting the robot 3-3
3. Mounting the motors and cabling 3-4
3.1 Mountingthemotors 3-43.2 Connectingthecables 3-4
CONTENTS CR_UGD4_XXL1300HUser's Manual
T-2
3.3 Mountingthemotorcovers 3-53.4 Mountingtherotationmotororgearboxwithhisadaptorring 3-6
4. Assembling the secondary arms 3-7
4.1 Makeanassembly 3-74.2 Mountthearmassemblyontherobot 3-8
5. Mounting the rotational axis on the gearbox shaft 3-9
6. Calibration 3-10
Chapter 4 Maintenance
1. Periodic maintenance 4-1
1.1 Springs 4-11.2 Ballbearingcups 4-21.3 Rotationalaxis 4-2
2. Cleaning the robot 4-4
3. Spare parts 4-4
Chapter 5 Robot settings
1. Kinematics 5-1
2. Workspace 5-2
3. Software limits 5-3
Chapter 6 Specifications
1. Basicspecifications 6-1
1.1 Cycletime 6-1
2. External view and dimensions 6-2
3. Designspecifications 6-3
3.1 Occupationareaofrobot 6-33.2 Gripperinterface 6-33.2.1 Withrotationalaxis 6-3
3.2.2 Withoutrotationalaxis 6-4
3.3 Softwaredesign 6-53.3.1 Dimensionsandlimits 6-6
Contents
1. Attention S-1
2. Explanation of warnings and notes S-1
3. Safety information S-23.1 General S-2
3.2 Qualified personnel S-2
3.3 Liability S-2
3.4 Installation and operating conditions S-2
3.5 Residual risks S-2
3.5.1 Releasedevice S-33.5.2 Transport S-33.5.3 Assemblyandstart-up S-33.5.4 Maintenanceandrepair S-33.5.5 Systemintegrator S-4
Safety Instructions
Sa
fety Instruc
tions
S-1
1. AttentionInformationinthisdocumentcanchangewithoutpriornotice.
OMRONEUROPEB.V.cannotbeholdresponsibleforanydamagetotheenvironment,tothemachineortothefunctioningofthemachineoccurredbyerrorsormissingdataintheillustrations,drawingorspecifications.
Nopartofthismanualandaddeddocumentationmaybecopied,reproducedortranslatedintoanotherlanguagewithoutpriorwrittenapproval.
Readandunderstandthematerialcontainedinthisuser'smanualbeforeyouworkontheCR_UGD4_XXL1300Hrobotforthefirsttime.Thisuser'smanualissupposedtohelpyouusethecapabilitiesoftheCR_UGD4_XXL1300Hrobotsafelyandproperly.
2. Explanation of warnings and notesThismanualusesthefollowingsafetyalertsymbolsandsignalwordstoprovidesafetyinstructionsthatmustbeobservedandtodescribehandlingprecautions,prohibitedactions,andcompulsoryactions.Makesureyouunderstandthemeaningofeachsymbolandsignalwordandthenreadthismanual.
DANGER THISINDICATESANIMMEDIATELYHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,WILLRESULTINDEATHORSERIOUSINJURY.
WARNING THISINDICATESAPOTENTIALLYHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,COULDRESULTINDEATHORSERIOUSINJURY.
NOTE Explainsthekeypointintheoperationinasimpleandclearmanner.
Sa
fety Instruc
tions
S-2
3. Safety information3.1 General
This´3. Safety information´subchaptercontainsinformationregardingworkingwiththeCR_UGD4_XXL1300Hrobot.QualifiedpersonnelworkingwiththeCR_UGD4_XXL1300HrobotmusthavereadandunderstoodtheCR_UGD4_XXL1300Hrobotdocumentation,includingthesafetyinformationchapter.
3.2 Qualified personnel
Thesearepeoplewho,duetherespecialisttraining,knowledgeandexperience,andtheirfamiliarizationwiththerelevantstandards,areabletoassesstheworktobecarriedoutanddetectanypotentialhazards.
3.3 Liability
TheCR_UGD4_XXL1300Hrobotisbuildusingstate-of-the-arttechnologyandinaccordancewiththerecognizedsafetyrules.Nevertheless,misuseoftheCR_UGD4_XXL1300HrobotmayconstitutearisktolifeandlimborcausedamagetotheCR_UGD4_XXL1300Hrobotandtoothermaterialproperty.
3.4 Installation and operating conditions
Youmayonlyusethecomponentsinaccordancewiththeinstallationandoperatingconditionsdescribedinthedocumentation.Theoperatingconditionsattheinstallationlocationmustbecheckedandmaintainedinaccordancewiththerequiredtechnicaldata.WithinthemeaningoftheMachineryDirectivetheCR_UGD4_XXL1300Hrobotisanincompletemachine.CommissioningisprohibiteduntiltheusablemachineorsysteminwhichtheCR_UGD4_XXL1300HrobotisinstalledmeetsallrequirementsoftheMachinedirective2006/42/EC.
FortheCR_UGD4_XXL1300Hrobotyouhavetoobservethefollowingstandards,directivesandregulations:
• ENISO10218-1:2011Robotsandroboticdevices-Safetyrequirementsforindustrialrobots-Part1:Robots.• ENISO10218-1:2011Robotsandroboticdevices-Safetyrequirementsforindustrialrobots-Part2:Robotsystems andintegration.
3.5 Residual risks
Safetyandhealthrisksarisingfromtherobotmechanicshavebeenreducedbymeansofsafetytechnologyanddesignengineering.Howeveraresidualriskremains,sincetherobotmechanicswillbemovebyanautomatedcontrolsystem.
Thefollowingaretypicalwarningsconcerningresidualriskswhichcannotbeassignedtoaspecificaction.Theexpressionofsafetylabelsisidenticaltothesafetyinformation.
Sa
fety Instruc
tions
S-3
3.5.1 Release device
Therobotmechanicsarenotsuppliedwithanreleaseswitchtocontrolthebrakesofthemotors.
WARNING • MOUNTARELEASESWITCHONTHEMACHINESOTHEARMS(MOTOR)OFTHEROBOTCOULDBEMANUALLY MOVED. • MOVINGANAXISWITHANIMPROPERLYWORKINGRELEASESWITCHCANDAMAGETHEMOTORBRAKE.THIS CANRESULTINPERSONALINJURYANDMATERIALDAMAGE. • BEFORERELEASINGTHEBRAKE,YOUHAVETOBESURETHATNOONEISINTHEHAZARDAREAOFTHEROBOT.
3.5.2 Transport
Theprescribedtransportpositionoftherobotmustbeobserved.Transportationmustbecarriedoutinaccordancewiththetransportationinstructionsorassemblyinstructionsoftherobot.
WARNING • ONLYUSEAUTHORIZEDHANDLINGEQUIPMENTWITHASUFFICIENTLOAD-BEARINGCAPACITYTOTRANSPORT THEROBOT. • WEARSUITABLEPROTECTIVECLOTHINGIFNECESSARY.
3.5.3 Assembly and start-up
Beforestartingupsystemsanddevicesforthefirsttime,acheckmustbecarriedouttoensurethatthesystemanddevicesarecompletedandoperational,thattheycanbeoperatedsafelyandthatanydamageisdetected.
Thevalidnationalorregionalworksafetyregulationsmustbeobservedforthischeck.Thecorrectfunctioningofallsafetycircuitsmustalsobetested.
Thefollowingtestsmustbecarriedoutbeforestart-upandrecommissioning.Itmustbeensuredthat:
• Therobotiscorrectlyinstalledandfastenedinaccordancewiththespecificationsintheassemblyinstructions.• Therearenoforeignbodiesorloosepartsontherobot.• Allrequiredsafetyequipmentiscorrectlyinstalledandoperational.
WARNING • AWRONGINSTALLEDROBOTMAYTHROWOFFHISARMS. • WEARSUITABLEPROTECTIVECLOTHINGIFNECESSARY.
3.5.4 Maintenance and repair
Aftermaintenanceandrepairwork,checksmustbecarriedouttoensuretherequiredsafetylevel.Thevalidnationalorregionalworksafetyregulationsmustbeobservedforthischeck.Thecorrectfunctioningofallsafetycircuitsmustalsobetested.
Thepurposeofmaintenanceandrepairworkistoensurethatthesystemiskeptoriginalor,intheeventofafault,toreturnthesystemtoanoperationalstate.Repairworkincludestroubleshootinginadditiontotheactualrepairitself.
Thefollowingsafetymeasuresmustbecarriedoutwhenworkingontherobot:
• Switchofthemachine(system)wheretherobotisbuilt-in(e.g.withapadlock)topreventitfrombeingswitchedon again• Labelthemachine(system)withasignindicationthatworkisinprogress.Thissignmustremaininplace,even duringtemporaryinterruptionstothework.• Theemergencystopfromthemachine(system)mustremainactive.Ifsafetyfunctionsorsafeguardsaredeactivated duringmaintenanceorrepairwork,theymustbereactivatedimmediatelyaftertheworkiscompleted.
Sa
fety Instruc
tions
S-4
3.5.5 System integrator
Therobotissafelyintegratedintoacompletesystembythesystemintegrator.Thesystemintegratorisresponsibleforthefollowingtasks:
• Installingtherobot• Performingriskassessment• Implementingtherequiredsafetyfunctionsandsafequards• Issuingthedeclarationofconformity• AttachingtheCEmark• Creatingtheoperatinginstructionsforthecompletesystem
Chapter 1 Introduction
Contents
1. Introduction 1-11.1 Description of the robot 1-1
1.2 Type code explanation 1-1
2. Identification 1-1
3. Part names 1-2
1-1
1
Introd
uctio
n
1. IntroductionCongratulationswiththepurchaseofyourhighspeedDeltarobotXXL.Thisisahighspeedpickandplacerobotwhichusesstate-of-the-artcarboncompositematerialsandthelatestservodrivetechnologytobeputinuseinthemostdemandingpickandplaceapplications.
Thismanualshouldbereadbeforethecommissioningoftherobot.Bymechanicalengineersinthedesignphaseduringtheintegrationoftherobotinthemachineandbysoftwareengineerstochecktheperformanceenvelopeoftherobot.
ThismanualdescribesthemainversionsoftheCR_UGD4_XXL1300Hrobot,andalloptions.Whereapplicablechecktheappropriatedataforyourrobottype,thetypecanbefoundontheidentificationtagoftherobot.
1.1 Description of the robotTheCR_UGD4_XXL1300HDeltarobotisahighspeedpickandplacerobotwhichusesstate-of-the-artcarboncompositematerialsandthelatestservodrivetechnologytobeputinuseinthemostdemandingpickandplaceapplications.Therobotisdesignedasa3-axis(optional4throtationalaxis)Deltakinematicsystem.
Characteristicsoftherobot:• Requiresverylowmaintenance• 3+1(rotationalaxisoptional)degreesoffreedom• Compactdesignformountinginamachine• Lownoiselevel<68dB(A)
1.2 Type code explanationCR_UGD4_XXL1300H_R:3+1axes(withrotationalaxis),1300mmworkingrange,max.payload:8kgCR_UGD4_XXL1300H_NR:3axes(withoutrotationalaxis),1300mmworkingrange,max.payload:8kg
2. IdentificationOntherobotbaseplateanidentificationtagismounted,importantdataonthisplate:• Robottype• Totalweightoftherobot• Yearofproduction• Serialnumber,importantfororderingspareparts
1-2
Introd
uctio
n
1 3. Part names
CR_UGD4_XXL1300H
Primary arm
TCP (Tool Center Point)
Cable entry plate Rotary servo motor
Motor cover
Secondary arm
Rotational axis
TheCR_UGD4_XXL1300HrobotconsistsofthreeradiallyplacedaxiswhichgivetheTCPfreedomtomoveinthreedirections,X,YandZ.Anoptionalfourthaxiscantakecareoftherotation,Rz,oftheTCP.
Theprimaryandsecondaryarmsoftherobotareconstructedfromanodizedaluminumendsandcarboncompositematerial;theyaredirectlymountedonadouble-stagegearboxtoguaranteehighstiffness.ThesecondaryarmsaremountedwithhardenedstainlesssteelballjointbearingstotheprimaryarmsandtheTCP,thisguaranteeslowwearandfrictionandisveryeasytoservice.
Optionallytherobotisequippedwithanextraservomotorfortherotationalaxis,theslidingshaftisconstructedoftitaniumtomaintainthehighlydynamiccharacteroftherobot.
Chapter 2 Model overview
Contents
1. Overview 2-1
2
Mo
de
l overview
2-1
1. OverviewTheCR_UGD4_XXL1300Hhasaworkingrangeof1300mm.Thespecificationsaregiveninthebelowfigure,ifspecificationsdifferformodels,forinstancewith-orwithoutrotationaxis,itisindicatedinthespecificationlist.TheDeltarobotisdeliveredstandardwithsanitarysecondaryarms,thismeanstheyarefullyclosedtopreventanycontaminationontheinsideofthesecondaryarms.
CR_UGD4_XXL1300H (1300 mm)
900
300
150
780
1300
NOTE Notethattherotationservomotor,onthetopoftherobot,isoptional.
Chapter 3 Installation
Contents
1. Unpacking 3-11.1 Unpacking the shipping box 3-1
1.2 Check the damage 3-1
1.3 Lifting and transportation 3-1
2. Mounting the robot 3-3
3. Mounting the motors and cabling 3-43.1 Mounting the motors 3-4
3.2 Connecting the cables 3-4
3.3 Mounting the motor covers 3-5
3.4 Mounting the rotation motor or gearbox with his adaptor ring 3-6
4. Assembling the secondary arms 3-74.1 Make an assembly 3-7
4.2 Mount the arm assembly on the robot 3-8
5. Mounting the rotational axis on the gearbox shaft 3-9
6. Calibration 3-10
3
Installa
tion
3-1
1. Unpacking1.1 Unpacking the shipping boxTherobotcomesinaspecialshippingbox.
Thefollowingstepmustbecarriedouttoremovetheshippingbox:• Unscrewthescrewsfromthecoverofthewoodenbox• Nowremovethecover
1.2 Check the damageFirsttakeouttheindividualcomponentsfromthepackageandcheckthateverythingiscompleteaccordingtothefollowinglist:• 1xrotationalaxis(incaseofCR_UGD4_XXL1300H_Rmodel)• 1xadaptorringfortherotationalaxisgearormotor(incaseofCR_UGD4_XXL1300H_Rmodel)• 1xTCP-ToolCenterPoint(incaseofCR_UGD4_XXL1300H_NRmodel)• 6xsecondaryarms• 6xspringpackage(12xspringbracketsand6xspring)
Checkallthecomponentsandtherobotfortransportationdamage.
1.3 Lifting and transportationBeforetherobotislifted,itmustbeensuredthatitisfreefromobstructions.Removeallthescrewswheretherobotismountedwithinthebox.
1
No. Description
1 3xscrewswithprotectionmaterial
Therobotmustbeliftedandtransportedbyusingliftingtackleorforklifttruck.Twoliftingstrapshastobeattachedintotwoeyeboltsthatarescrewedintothebaseplate.Theliftingstrapshastobelongenoughandmustberoutedinsuchawaythattherobotisnotdamaged.
3
Installa
tion
3-2
WARNING • THEROBOTMAYTILTDURINGTRANSPORTATION. • ADDITIONALSAFEGUARDINGMEASUREMUSTBETAKEN. • WEARSUITABLEPROTECTIVECLOTHINGIFNECESSARY. • WHENUSINGAFORKLIFTTRUCK,DRIVEEXTREMELYSLOWLYANDCAREFULLY.
1
2
3
No. Description
1 Liftingtackle
2 2xliftingstraps
3 2xeyebolts
3
Installa
tion
3-3
2. Mounting the robotThemountingsurfacefortherobotmustbemachinedandofanappropriatequality.It'salsopossibletousealevellingelementtoaligntherobot.ThreeM20boltsareneededtomountingtherobottotheframe,exactboltlengthdependsonframelayout.ThetighteningtorqueofaM206.8boltis300Nm.
Thebelowfigureshowsthemountingpatternfromtherobot.
NOTE Itisadvisabletoputonemotoroftherobotinlinewiththedirectionofthetransportbelttomakeprogrammingeasier.
3
Installa
tion
3-4
3. Mounting the motors and cabling3.1 Mounting the motorsWhenyourrobotisdeliveredwithoutmotors,youhavetomountthembyyourself.Firstofall,youhavetoremovethethreemotorcoversfromtherobot.
Thefollowingstepsmustbecarriedouttoremovethemotorcoversfromtherobot.Pleaseseealsothefollowingpicture:• RemovetheM6Allenbolt
1
2
No. Description
1 1xM6Allenbolt
2 Motorcover
• Removethemotorcover• Repeattheprocessfortheothertwomotorcovers
3.2 Connecting the cablesTherobotisdeliveredwith3cableentryplates.Theyaremountedaboveeveryprimaryarmmotortofeedhiscablesthrough.
Thefollowingstepsmustbecarriedouttofeedthecablesthroughtheentryplates.Pleaseseealsothebelowpictures:• Removethe4boltsofthecableentryplates• Removethecableentryglands
1
2
3
3
Installa
tion
3-5
No. Description
1 4xM5Allenbolt
2 Cableentryglands
3 Blindthule
• Insertthecablesintotheopeningofthemotorcover• Connectthecables
• Clampthecableentryglandsaroundthecableandslideitbackintothecableentryplate.Afterwardsalsoslidethe blindthulebackintothecableentryplate• Mountthecableentryplateonthebaseplate,usingthe4M5Allenbolts
3.3 Mounting the motor covers• Mountthecoverinthemachinedgroove• InstalltheAllenM6boltinthecoverbracketandtighten• Repeattheprocessfortheothertwomotorcovers• Themotorcoversarenowmounted
2
1
No. Description
1 Coverbracket
2 Machinedgroove
3
Installa
tion
3-6
3.4 Mounting the rotation motor or gearbox with his adaptor ringThissectionisapplicableonlytotheCR_UGD4_XXL1300H_Rmodel(withrotationalaxis).Dependentonthetypeofrotationmotororgearboxwithrotationmotor,aspecialadaptorringformountingisincluded.
1
2
No. Description
1 Gearboxormotor
2 Adaptorring
Nowmounttheadaptorring(withthemotororgearbox)onthelowersideofthebaseplatefromtherobotwiththeincludedboltsandrings.
1
2
No. Description
1 Lowersideofthebaseplate
2 Rotationadaptorringwithmotororgearbox
3
Installa
tion
3-7
4. Assembling the secondary arms4.1 Make an assemblyBeforemountingthesecondaryarmsontherobot,wehavetopre-assemblethemasshownonthebelowfigure,sothatwegetanarmassembly.
1
2
3
No. Description
1 Sanitarycupholderincl.ballbearingcup
2 Springpackage
3 Secondaryarm
Repeatthisactionfortheother2armsets.
WARNING • INCORRECTMOUNTEDSPRINGSCANJUMPAWAY. • WEARSUITABLEPROTECTIVECLOTHINGANDSAFETYGLASSES. • NEVERPULLTHESPRINGSFURTHERAPARTTHANNECESSARYWHENMOUNTINGTHEARMASSEMBLYONTHE PRIMARYARMORTCPBALLJOINTS. • REPLACESPRINGSAFTEROVERSTRETCHING.
3
Installa
tion
3-8
4.2 Mount the arm assembly on the robotFormounting,pullasecondaryarmwithhiscupholderovertheballjointoftheprimaryarm.Nowpullthearmsapartwiththeincluded"secondaryarmexpander"againsttheforceofthespringinordertoputthesecondarmoverthesecondballjointoftheprimaryarm.
No. Description
1 Secondaryarmexpander
ThenrepeatthisactionfortheTCP(seebelowpicture).
1
No. Description
1 TCP-ToolCenterPoint(withorwithoutrotationalaxis)
Repeatthisactionfortheother2secondaryarmassembly's.Nowyourrobotmechaniciscompletelyinstalled.
3
Installa
tion
3-9
5. Mounting the rotational axis on the gearbox shaftThissectionisapplicableonlytotheCR_UGD4_XXL1300H_Rmodel(withrotationalaxis).
Pleaseperformthefollowingstepsfirst.• Extendtherotationalaxistoitsentirelength,thenretractthesameandcheckwhetheritiseasytooperateorwhether someresistanceoccurs
NOTE Alightirregularresistanceisnormalandcausedbythemanufacturingtolerancesofthetubes.Theaxisisruninduringthefirst150hoursofoperation.Incaseofproblems,pleasechecktheaxisfordamageorcontactyourOMRONrepresentative.
1
2
No. Description
1 Clampingbushwithbolts
2 Rotationalaxis
ReleasethetwoM5Allenboltswhicharemountedintotheclampingbush(seeabovepicture).
Indeliverycondition,anextrafillbushislocatedintheclampingbush.Measureyourmotor/gearboxaxisanddetermineifyouneedtheextrafillbush.
1
2
3
Installa
tion
3-10
No. Description
1 Motororgearshaft
2 Topconnectorrotationalaxis
Nowpushthetopconnectorintotheshaftuntilthetopconnectorcomesintoitsstoppositionontheshaft.TightenthetwoM5Allenboltswith7Nm.
Therotationalaxisisnowmounted.
6. CalibrationNoteveryrobotthatisdeliverediscalibrated.Ifyouwanttocalibratetherobotbyyourself,acalibrationkitwithaspecialtoolisavailable(showninthebelowpicture).ThecalibrationsetcanbeorderedasCR_ART.1098
No. Description
1 Calibrationtool
Thefollowingstepsmustbecarriedouttoputthethreeupperarmsfromtherobotinthezeroposition.Please,seethebelowpictures:
• Makesureallthesecondaryarmsaredisassembled• Releasethemotorbrakeandmakesurealltheprimaryarmsarerotateddownfarenough,sothecalibrationtool couldbemounted• Slidethecalibrationtoolonthebaseplateasshowninthenextpicture• Nowtightenthestarnutuntilthetoolisfixed
3
Installa
tion
3-11
• Releasethemotorbrakefromtheselectedmotorandpushtheupperarmwithhisballjointagainstthecalibrationas shownintheabovepicture• Nowfixthemotorbrakefromtheselectedmotor• Repeatthecalibrationstepsfortheothertwoprimaryarms• Removethetool
WARNING • CALIBRATINGTHEROBOTMUSTBECARRIEDOUTBYQUALIFIEDPROGRAMMINGPERSONNELONLY,ASTHIS REQUIRESANEXCELLENTLEVELOFKNOWLEDGEOFTHECONTROLSYSTEM. • WHENCARRYINGOUTTHEHOMINGYOURSELF,THISMUSTBECARRIEDOUTEXACTLYINTHEWAYANDTHE ORDERTHATTHEYAREDESCRIBED.
• Nowalltheprimaryarmsareinzeropositionfromthekinematicmodel• Nowputtheencodervaluesfromtheservomotorsin0º• Checkthattheangleindicatedforthethreemotorsis0º(±0.1°)• Yourrobotisnowcalibrated
Chapter 4 Maintenance
Contents
1. Periodic maintenance 4-11.1 Springs 4-1
1.2 Ball bearing cups 4-2
1.3 Rotational axis 4-2
2. Cleaning the robot 4-4
3. Spare parts 4-4
4
Ma
intena
nce
4-1
1. Periodic maintenanceBeforeworkingontherobot,pleasebeensuredthatthemachinewheretherobotisbuiltin,istotallyswitchedoff.
DANGER • SWITCHOFFTHEMACHINE(SYSTEM)WHERETHEROBOTISBUILTIN(E.G.WITHAPADLOCK)TOPREVENTIT FROMBEINGSWITCHEDONAGAIN. • LABELTHEMACHINE(SYSTEM)WITHASIGNINDICATIONTHATWORKISINPROGRESS.THISSIGNMUST REMAININPLACE,EVENDURINGTEMPORARYINTERRUPTIONSTOTHEWORK. • THEEMERGENCYSTOPFROMTHEMACHINE(SYSTEM)MUSTREMAINACTIVE.IFSAFETYFUNCTIONSOR SAFEGUARDSAREDEACTIVATEDDURINGMAINTENANCEORREPAIRWORK,THEYMUSTBEREACTIVATED IMMEDIATELYAFTERTHEWORKISCOMPLETED.
1.1 SpringsHowtomaintainthesprings:• Thespringshastobereplacedevery3800workinghoursoronceayear• Whentherobotisfallapart,checkthespringsondamages• OnlyusespringsdeliveredbyOMRON,otherwisetheguaranteewillexpire• Replacespringsafteroverstretching• Forspareparts,seeSection 3 Spare partsinthischapter
WARNING • INCORRECTMOUNTEDSPRINGSCANJUMPAWAY. • WEARSUITABLEPROTECTIVECLOTHINGANDSAFETYGLASSES. • NEVERPULLTHESPRINGSFURTHERAPARTTHANNECESSARYWHENMOUNTINGTHEARMASSEMBLYONTHE PRIMARYARMORTCPBALLJOINTS.
Howtodisassemblethesprings:• Disassemblethesecondaryarmsfromtherobotwiththe"secondaryarmexpander"• Replacethesprings• Forre-assemblingthesecondaryarms,seeSection 4 Assembling the secondary armsinChapter3
4
Ma
intena
nce
4-2
1.2 Ball bearing cupsTheballbearingcupshasthesamelifetimeasthesprings.Werecommendtoexchangetheseatthesametimeasthesprings.
Howtomaintaintheballbearingcups:• Theballbearingcupshastobereplacedevery3800workinghoursoronceayear• Whentheballbearingcupsmakesqueakingnoises,takeofthesecondaryarmassembly’sandcleanthecupswith pressedair• Do not lubricate the ball bearing cups!
Forinstructionstoreplacetheballbearingcups,seebelowpicture:
1
No. Description
1 M6bolt
• ScrewanM6boltinthebacksidefromthecupholder• Nowtheballbearingcupwillcomeout
1.3 Rotational axisTheplainbearingsontherotationalaxiswearwithtimesothatbacklashstartstooccurontherotationalaxis.Howfasttheplainbearingsbecomeworndependsstronglyonthefollowingfactors:• Theworkingpath• Thepayload• Thespeedoftherobot• Therotationactions
WhendoIhavetoexchangetheplainbearings?• Ifthereisalotofplayontherotationalaxis• Every3000workinghoursoronceayear
Forinstructionstoreplacetheplainbearings,seethebelowpicture:
1
2
4
Ma
intena
nce
4-3
No. Description
1 Sliderblock
2 M6boltwithwasher
• UnscrewthetwoM6boltswithwasherandtakeofthebolts
• Removethetwotubes(sometimesthetubeswillclampinsidethesliderblock,useasmallplastichammertorelease them)
1
No. Description
1 Plainbearing
• Exchangetheoldplainbearingswiththenewones• Putbackthetwotubesontherotationalaxis• MountthetubeswiththetwoM6boltsincludingwashers
WARNING • PLAINBEARINGSHASTOBEMOUNTEDVERYCAREFULLY. • WRONGMOUNTEDPLAINBEARINGSMAYDAMAGE. • EXTENDTHEROTATIONALAXISTOITSENTIRELENGTH,THENRETRACTTHESAMEANDCHECKWHETHERITIS EASYTOOPERATEORWHETHERSOMERESISTANCEOCCURS.
4
Ma
intena
nce
4-4
2. Cleaning the robotCleantherobotbywashingwithsoftclothorsponge.Usesoapormilddetergentandwarmwaterfollowedbyclearwaterrinse.Foroilandgreasestainsusealcoholwithsoftcloth.Donotuseahighpressurewatercleaner,oranyotherhighpressurecleaningdevice.
3. Spare parts
Description OMRON Part No.
Calibrationtool CR_ART.1098
Springpackage CR_ART.1123
Ballbearingcups CR_ART.1124
Cardancoupling CR_ART.1126
Hingerollers CR_ART.1127
Plainbearing CR_ART.1128
Gearboxfortherotationalaxis CR_ART.1154
Primaryarmset CR_ART.1239
Secondaryarmset CR_ART.1240
Splinepartrotationalaxis CR_ART.1241
Gearboxfortheprimaryarm CR_ART.1268
TCP-ToolCenterPoint CR_ART.1269
Secondaryarmexpander CR_ART.1186
Gripperinterface (robotswithserialnumber1470orhigher)
CR_ART.1350
Gripperinterface (robotswithserialnumber1469orlower)
CR_ART.1363
Chapter 5 Robot settings
Contents
1. Kinematics 5-1
2. Workspace 5-2
3. Software limits 5-3
5
Rob
ot se
ttings
5-1
1. KinematicsThekinematicsparametersfortheCR_UGD4_XXL1300Hrobotareshownbelow.Settheseparameterscorrespondingtothecontrollersettings.
WARNING IFTHEKINEMATICSPARAMETERSARENOTSETPROPERLY,THISMAYCAUSETHEROBOTTOMALFUNCTION.SO,BESURETOSETTHESEPARAMETERSCORRECTLY.
5
Rob
ot se
ttings
5-2
2. WorkspaceTheworkspaceparametersfortheCR_UGD4_XXL1300Hrobotareshownbelow.Settheseparameterscorrespondingtothecontrollersettings.
WARNING IFTHEWORKSPACEPARAMETERSARENOTSETPROPERLY,THISMAYCAUSETHEROBOTTOMALFUNCTION.SO,BESURETOSETTHESEPARAMETERSCORRECTLY.
Zu
Rcy
Hcy
Hco
Rcy
Rco
Workspace parameters
Zu: -731 mm Distance from the Z-axis origin position Rcy: 650 mm Radius of the cylinder Hcy: 300 mm Height of the cylinder Rco: 390 mm Radius of the frustum cone of underside Hco: 150 mm Height of the frustum cone
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Rob
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3. Software limitsThesoftwarelimitsfortheCR_UGD4_XXL1300Hrobotareshownbelow.
WARNING IFTHEα-,β- OR γ-AXISSOFTLIMITISSETINCORRECTLY,THEARMMAYCOLLIDEWITHTHEROBOTBASEORBASEPREPAREDBYTHEUSER,CAUSINGBREAKAGE.SO,BESURETOSETTHESOFTLIMITSCORRECTLY.
Minus directionsoft limit [-30°]
Plus directionsoft limit [88°]
Chapter 6 Specifications
Contents
1. Basic specifications 6-11.1 Cycle time 6-1
2. External view and dimensions 6-2
3. Design specifications 6-33.1 Occupation area of robot 6-3
3.2 Gripper interface 6-3
3.2.1 Withrotationalaxis 6-33.2.2 Withoutrotationalaxis 6-4
3.3 Software design 6-5
3.3.1 Dimensionsandlimits 6-6
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1. Basic specifications
Robot model CR_UDG4_XXL1300H_R CR_UDG4_XXL1300H_NR
Workingvolume
X,Yaxis Stroke Ø1300mm
Zaxis Stroke 300mm(max.Ø1300mm)/450mm(centerØ780mm)
θaxis Rotationrange±180°(defaultsetting,itcanbe
changed)
ServomotorArm1,2,3 3000W
Rotationalaxis4 1000W
Repeatability*1X,Y,Zaxis ±1mm
θaxis ±0.3°
Maximumthrough-put*2 90CPM*4
Maximumpayload 8kg
θaxistolerablemomentofinertia*3 Accordingtotheservomotor
Usertubing(outerdiameter) Ø8*5
Travellimit Softlimit
Noiselevel <68dB(A)
Ambienttemperature 5ºCto45ºC
Relativehumidity Max.90%
Protectionclass IP65
Weight 90kg
*1: Thisisthevalueataconstantambienttemperature. *2: With0.1kgpayload.Whenreciprocating305mminhorizontaland25mminverticaldirections. *3: Therearelimitstoaccelerationcoefficientsettings. *4: CPM:Cycleperminutes.Checkthenote2forthecycledefinition. *5: Onlyfortheairsuctioning.Theairinjectionisnotallowed.
1.1 Cycle time
Z1
Y
Z2
P&P path Payload Cycle time
25x305x25mm(Z1xYxZ2) 1kg 0.47s
25x305x25mm(Z1xYxZ2)8kg
0.90s
200x1000x200mm(Z1xYxZ2) 1.5s
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2. External view and dimensions
NOTE Robotswithserialnumber1469orlowerhavedifferentgripperdimensions.Refertosection“3.2Gripperinterface”inthischapterformoredetailedinformationaboutdimensions.
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3. Design specifications3.1 Occupation area of robotIftherobotisintegratedintothemachineitmustbeconsideredwhatthereachisofallrobotpartstopreventcollisionwithotherpartsinthemachine.
WhentheTCPmovestoitsouterpositions,theprimaryandsecondaryarmscanriseabovethebaseplate,takecarethatnomechanicalobstructionsareintheareasindicatedinthebelowpicture.
400
100
200
420
600
WARNING IFMECHANICALOBSTRUCTIONSAREINTHEINDICATEDAREA,THEROBOTORTHEOTHERMACHINEPARTSCOULD BE DAMAGED.
3.2 Gripper interface
3.2.1 With rotational axisThebelowfigureshowsthegripperconnectionsizesfortheCR_UGD4_XXL1300H_Rrobot(withrotationalaxis)accordingtoISO9409-1-A31,5.
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3.2.2 Without rotational axisThebelowfigureshowsthegripperconnectionsizesfortheCR_UGD4_XXL1300H_NRrobot(withoutrotationalaxis).
Thedesignofthegripperthatismountedundertherobothavegreatinfluenceontheperformanceoftherobot.BoththeweightofthegripperandthedistanceofthecenterofgravityofthegrippertotheTCPbasepointhavenegativeinfluenceonthefinalperformanceoftherobot.
Ifyouneedtoinstallcablingforthegripper,pleasefollowthefollowingsteps:• Mountthecablesonthebaseplateorframe,neartheturningpointfromtheprimaryarmonthegearbox• Mountthecablesontheprimaryarm,withty-rapsorclampingparts• Keepabigloopatthehingepointfromtheprimaryandsecondaryarm• Mountthecablesonthesecondaryarm,withty-rapsorclampingparts• Keepabigloopfromthelowestmountingpointatthesecondaryarmtilltheconnectiononthegripper
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3.3 Software designThearmlengthsandpitchcirclesoftherotationpointsareshowninthebelowpicture.
Upper arm length440 mm
Lower arm length950 mm
Lower arm rotation pointscircle diameter 140 mm
Upper arm rotation pointscircle diameter 295 mm
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3.3.1 Dimensions and limits
Description Value
Negativesoftwarelimit -30º
Positivesoftwarelimit 88º
Tb-z(topbaseplatetozeroposition) 210mm
Z-tw(zeropositiontotopworkarea) 690mm
Top mounting bracket
Top work area
Tb-z
Z-tw
0°
Pos.°
Neg.°
Primary arm
Revision history
Amanualrevisioncodeappearsasasuffixtothecatalognumberonthefrontcovermanual.
Thefollowingtableoutlinesthechangesmadetothemanualduringeachrevision.
Revision code Date Description
01 July2015 Originalproduction
01A July2016 Secondaryarmexpanderwasincluded
01B October2016 Newgripperinterfacewasincluded
Cat. No. I201E-EN-01B Note: Specifications subject to change without notice.
Authorized Distributor:
Printed in Europe