ROBO Cylinder RCS2 Actuator ROBO Rotary

Transcription

1 ROBO Cylinder RCS2 Actuator ROBO Rotary [RT6/RT6R/RT7R Types] Operating Manual First Edition IAI America, Inc.

2 Safety Precautions (Please read before using the product.) Before installing, operating, maintaining or inspecting this product, please peruse this operating manual as well as the operating manuals and other related documentations for all equipment and peripheral devices connected to this product in order to ensure the correct use of this product and connected equipment/devices. Those performing installation, operation, maintenance and inspection of the product must have sufficient knowledge of the relevant equipment and their safety. The precautions provided below are designed to help you use the product safely and avoid bodily injury and/or property damage. In this operating manual, safety precautions are classified as Danger, Warning, Caution and Note, according to the degree of risk. Danger Warning Caution Note Failure to observe the instruction will result in an imminent danger leading to death or serious injury. Failure to observe the instruction may result in death or serious injury. Failure to observe the instruction may result in injury or property damage. The user should take heed of this information to ensure the proper use of the product, although failure to do so will not result in injury. It should be noted that the instructions under the Caution and Note headings may also lead to serious consequences, if unheeded, depending on the situation. All instructions contained herein provide vital information for ensuring safety. Please read the contents carefully and handle the product with due caution. Please keep this operating manual in a convenient place for quick reference whenever needed, and also make sure that the manual will get to the end-user. Danger [General] Do not use this product for the following applications: 1. Medical equipment used to maintain, control or otherwise affect human life or physical health 2. Mechanisms and machinery designed for the purpose of moving or transporting people 3. Important safety parts of machinery This product has not been planned or designed for applications requiring high levels of safety. Use of this product in such applications may jeopardize the safety of human life. The warranty covers only the product as it is delivered. [Installation] Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The product may ignite, burn, or explode. When installing the product, be sure to securely support and affix it (including the work). Failure to do so may cause the product to tip over, drop or malfunction, resulting in injury.

3 Avoid using the product in a place where the main unit or controller may come in contact with water or oil droplets. Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length. Doing so may result in fire. [Operation] Do not enter the machine s range of operation while the product is operating or standing by. The actuator may move suddenly, causing injury. Do not pour water onto the product. Spraying water over the product, washing it with water or using it in water may cause the product to malfunction, resulting in injury, electric shock, fire, etc. [Maintenance, Inspection, Repair] Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in injury, electric shock, fire, etc. Do not disassemble and reassemble the components relating to the basic structure of the product or its performance and function. Doing so may result in injury, electric shock, fire, etc. Warning [General] Do not use the product outside the specifications. Using the product outside the specifications may cause it to fail, stop functioning or sustain damage. It may also significantly reduce the service life of the product. In particular, observe the maximum loading capacity and speed. [Installation] If the machine will stop in the case of system problem such as emergency stop or power failure, design a safety circuit or other device that will prevent equipment damage or injury. Before supplying power to and operating the product, always check the operation area of the equipment to ensure safety. Supplying power to the product carelessly may cause electric shock or injury due to contact with the moving parts. Wire the product correctly by referring to the operation manual. Securely connect the cables and connectors so that they will not be disconnected or come loose. Failure to do so may cause the product to malfunction or cause fire. [Operation] Before operating the moving parts of the product by hand (for the purpose of manual positioning, etc.), confirm that the servo is turned off (using the teaching pendant or PC software). Failure to do so may result in injury. Do not scratch the cables. Scratching, forcibly bending, pulling, winding, crushing with heavy object, or pinching a cable may cause it to leak current or lose continuity, resulting in fire, electric shock, malfunction, etc. Turn off the power to the product in the event of power failure. Failure to do so may cause the product to suddenly start moving when the power is restored, thus resulting in injury or product damage. If the product is generating heat, smoke or a strange smell, turn off the power immediately. Continuing to use the product may result in product damage or fire. If noise or abnormally high vibration is detected, stop the operation immediately. Continuing to use the product may result in product damage, malfunction due to damage, runaway machine, etc. If any of the internal protective devices (alarms) of the product has actuated, turn off the power immediately. Continuing to use the product may result in product damage or injury due to malfunction. Once the power supply is cut off, investigate and remove the cause and then turn on the power again. Do not step on the product, use it as a footstool or place any object on it. You may lose your footing or the product may tip over, resulting in a fall and consequent injuries, product damage, malfunction due to damage, runaway machine, etc.

4 [Maintenance, Inspection, Repair] Before conducting maintenance/inspection, parts replacement, or other operations on the product, completely shut down the power supply. At this time, take the following measures: 1. Display a sign that reads, WORK IN PROGRESS. DO NOT TURN ON POWER at a conspicuous place, in order to prevent a person other than the operator from accidentally turning on the power while the operation is working. 2. When two or more operators are to perform maintenance/inspection together, always call out every time the power is turned on/off or an axis is moved in order to ensure safety. [Disposal] Do not throw the product into fire. The product may burst or generate toxic gases. Caution [Installation] Do not use the product under direct sunlight (ultraviolet ray), in a place exposed to dust, salt, iron powder, in a humid place, or in an atmosphere of organic solvent, phosphate-ester machine oil, etc. The product may lose its function over a short period of time, or exhibit a sudden drop in performance or its service life may be significantly reduced. Do not use the product in an atmosphere of corrosive gases (sulfuric acid or hydrochloric acid). Rust may form and reduce the structural strength of the product. When using the product in any of the places specified below, provide a sufficient shield. Failure to do so may result in malfunction: 1. Place where large current or high magnetic field is present 2. Place where welding or other operations are performed that cause arc discharge 3. Place subject to electrostatic noise 4. Place with potential exposure to radiation Do not install the product in a place subject to large vibration or impact. The product may malfunction if large vibration or shock is applied. Provide an emergency-stop device in a readily accessible position so the device can be actuated immediately upon occurrence of a dangerous situation during operation. Lack of such device in an appropriate position may result in injury. Provide sufficient maintenance space when installing the product. Routine inspection and maintenance cannot be performed without sufficient space, which will eventually cause the equipment to stop or the product to sustain damage. When transporting or installing the product, exercise due caution to prevent injury. For example, securely hold the product using a lift or support, or engage multiple operators to carry the product. Do not hold the moving parts of the product or its cables during installation. It may result in injury. Always use IAI s genuine cables for connection between the controller and the actuator. Also use IAI s genuine products for the key component units such as the actuator, controller and teaching pendant. Before installing or adjusting the product or performing other operations on the product, display a sign that reads, WORK IN PROGRESS. DO NOT TURN ON POWER. If the power is turned on inadvertently, injury may result due to electric shock or sudden activation of an actuator. [Operation] Turn on the power to individual equipment one by one, starting from the equipment at the highest level in the system hierarchy. Failure to do so may cause the product to start suddenly, resulting in injury or product damage. Do not insert a finger or object in the openings in the product. It may cause fire, electric shock, or injury. Do not step on the product, use it as a footstool or place any object on it. It may cause scoring, dents or deformation of the driving part, resulting in product damage, unintended stopping due to damage, or performance drop.

5 [Maintenance, Inspection, Repair] Wear protective goggles when applying grease to the actuator. Failure to do so may result in eye inflammation due to spattered grease. Note [Installation] Protection covers or other guards must be provided for the moving parts of the equipment to avoid direct contact with the operators. Do not configure a control circuit that will cause the work to drop in case of power failure. Configure a control circuit that will prevent the table or work from dropping when the power to the machine is cut off or an emergency stop is actuated. The following conditions must be met in order to ensure a smooth movement of mechanical parts: 1. Flatness of the mounting surface must be within 0.05 mm. 2. The mounting surface area must be large enough to ensure the rigidity of the actuator. [Installation, Operation, Maintenance] When handling the product, wear protective gloves, protective goggles, safety shoes, or other necessary gear to ensure safety. [Maintenance, Inspection, Repair] During maintenance, apply the specified grease to the ball screw. In particular, pay attention not to mix fluorine grease and lithium grease, because it may cause insufficient lubrication, higher resistance or other undesirable effects and eventually damage the machine. [Disposal] When the product no longer becomes usable or necessary, dispose of it properly as an industrial waste. Others IAI shall not be liable whatsoever for any loss or damage arising from a failure to observe the items specified in Safety Precautions.

6 Prohibited Handling of Cables When designing an application system using IAI actuators and controllers, incorrect wiring or connection of each cable may cause unexpected problems such as a disconnected cable or poor contact, or even a runaway system. This section explains prohibited handling of cables. Read the information carefully to connect the cables properly. Ten Rules for Handling Cables (Must be Observed!) 1. Do not let the cable flex at a single point. Steel band (piano wire) Bundle loosely. 2. Do not let the cable bend, kink or twist. 3. Do not pull the cable with a strong force. 4. Do not let the cable receive a turning force at a single point. 5. When fixing the cable, provide a moderate slack and do not tension it too tight. Use a curly cable. 6. Do not pinch, drop a heavy object onto or cut the cable. Do not use a spiral tube where the cable flexes frequently.

7 7. Notes on use of cable tracks The supplied cable is not a robot cable. Accordingly, never store the supplied cable in a cable track. If a relay cable is to be used, always use a robot cable. Bending radius r Use a cable track with its bending radius r set to 50 mm or greater. Do not let the cable get tangled or kinked in a cable track or flexible tube. When bundling the cable, keep a certain degree of flexibility (so that the cable will not become too taut when bent). Do not cause the cables to occupy more than 60% of the space in the cable track. Do not lay signal lines together with circuit lines that create a strong electric field. Cable track Cable Power line Signal lines (flat cable) Duct

8 Table of Contents 1. Introduction Safety Precautions Warranty Names of Actuator Parts RT RT6R RT7R Transportation and Handling Handling the Packed Actuator Handling the Unpacked Actuator Items to Check after Unpacking Installation Environment, Storage Environment Installation Environment Storage Environment Installation Method... 7 RT RT6R... 8 RT7R Cable Connection Connecting the Controller Checks after Installation... 9

9 9. Notes on Use Backlash and Positioning Repeatability Range of Operation and Home Return Range of Operation Home Return Direction Conditions for Loads Installable on the ROBO Rotary Actuator Maintenance/Inspection Inspection Items and Timings Visual Inspection of the Exterior Exterior Cleaning Specifications Specification List External Dimensions RT RT6R RT76R... 19

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11 1. Introduction Thank you for purchasing IAI s Robo Rotary actuator. This manual explains the correct handling of the actuator as well as its structure, maintenance and other items the user should know about the Robo Rotary. Before using the Robo Rotary, be sure to read this manual and ensure the correct handling of the actuator. 2. Safety Precautions 2.1 Basic handling precautions Any handling or operating method or any other operation not specified in this manual should be considered not permitted and should not be performed. Always use IAI genuine parts for wiring between the actuator and controller. To avoid danger, no one should ever enter the operating range of the machine while the machine is operating or receiving power. 2.2 Maintenance/Inspection Always turn off the controller power before commencing any maintenance/inspection work. Take sufficient precautions to prevent the power from accidentally being turned on by someone other than the operator performing inspection work. During maintenance/inspection, put a sign in a conspicuous place indicating that maintenance/inspection work is in progress. If maintenance/inspection is carried out by multiple operators, all operators should confirm the safety of themselves and others before carrying out each task. Particularly before turning on/off the power or conducting an operation check, each operator must call out and inform the others that the power can be turned on/off or machine can be started. (Notes) The information contained in this manual is subject to change without notice for the sake of improvement. If you have any question regarding any of the items explained herein, please contact IAI. Danger Failure to observe the cautionary instructions on installation may endanger the operators as well as bystanders. Incorrect installation may result in a serious accident or damage to the actuator. 1

12 3. Warranty 3.1 Warranty Period The warranty period expires upon elapse of one of the following periods, whichever occurs first. 18 months after shipment from IAI 12 months after delivery to the location specified by the user 2,500 hours after start of operation 3.2 Scope of Warranty IAI will repair, free of charge, any defects due to craftsmanship or material that may occur during the above warranty period. Note, however, that the following items are excluded from the scope of warranty. Aging, such as fading of exterior paint Wear of consumable parts Noises not affecting function or other perceived deviations Defects resulting from inappropriate handling or insufficient maintenance/inspection by the user Defects resulting from alteration not performed by IAI or IAI s agent Defects resulting from use of a controller not manufactured by IAI Defects resulting from an act of God, accident or fire Please note that the warranty covers only the product delivered. It will not cover any secondary losses arising from or in connection with a failure of the delivered product. The user must bring the product to our factory for repair. An additional fee will be chargeable for on-site repair, even during the warranty period. 2

13 4. Names of Actuator Parts The name of each part is shown below. 4.1 RT6 Drive shaft Body Motor cover End cover Motor bracket Actuator cable 4.2 RT6R Actuator cable Motor cover Flange Drive shaft Body Pulley cover 3

14 4.3 RT7R Actuator cable Motor cover Flange Drive shaft Body Pulley cover 4

15 5. Transportation and Handling 5.1 Handling the Packed Actuator When transporting the packed actuator, exercise due caution not to apply impact on the package by dropping it or hitting it against other object. A person should never attempt to carry a heavy package on his own. When setting down the package temporarily, keep it horizontal. Do not step onto the package. Do not place on the package a heavy object that may deform the package or article of a shape that allows the load concentrate. 5.2 Handling the Unpacked Actuator Once the actuator is unpacked, handle the actuator by its frame. When transporting the actuator, be careful not to hit it against other object. In particular, pay attention to the output shaft and cover. Do not apply an excessive force to the various parts of the actuator. Pay special attention to the cables. When unpacking the actuator, exercise due caution not to drop the actuator. It may cause injury or damage the machine. Should you find any part of the actuator missing or damaged during transportation, please contact an IAI Sales Engineering Representative immediately. 5.3 Items to Check after Unpacking After unpacking the box, check the condition of the product and the items contained in the package. Standard items Rotary actuator (including relay cables) Controller Rotary actuator operating manual Controller operating manual 1 unit 1 unit 1 copy 1 copy 5

16 6. Installation Environment, Storage Environment 6.1 Installation Environment Install the actuator in an environment meeting the conditions listed below. not be exposed to direct sunlight. be free from irradiating heat coming from a heat treatment furnace or other equipment that generates a large amount of heat. have surrounding air temperature of 0 to 40 C. have humidity of 85% or below (non-condensing). be free from corrosive or flammable gases. be free from excessive dust and suitable for normal assembly work. be free from oil mist or cutting oil. be free from impact or vibration. be free from strong electromagnetic field, ultraviolet light or radiation. Chemical resistance is not considered in the design of this product. In general, the actuator should be used in an environment where the operators can work without wearing any protective equipment or gear. 6.2 Storage Environment The storage environment should basically conform to the installation environment. If the actuator is to be stored for an extended period of time, provide appropriate measures to prevent dew condensation. The actuator is not packed with drying agent, unless otherwise specified by the user. If the actuator is to be stored in an environment where dew condensation may occur, take appropriate measures to protect the entire package, or the actuator itself (after unpacking it), from the detrimental effects of dew condensation. The actuator can withstand a storage temperature of up to 60 C for a short period. If the actuator must be stored for over a month, keep the storage temperature at 50 C or below. 6

17 7. Installation Method To install the actuator, use the tapped holes provided on the front face or bottom face of the actuator. The locations of tapped holes are shown below. RT6 4-M6, depth 12 7

18 RT6R 4-M6, depth 12 RT7R 9 through hole 4-M6, depth 12 2-M8, depth 12 8

19 8. Cable Connection 8.1 Connecting the Controller Plug the connector attached at the end of the actuator cable into the controller. Take note of the following points when connecting the actuator cable. If the actuator cable cannot be affixed, allow it to droop or wire it along a self-standing cable hose or along a large radius to minimize the load received by the cable. Do not cut the cable to extend or shorten its length or reconnect the cut cables together. Although the standard cables of medium and large types have sufficient flexibility, they are not robot cables. If the cable is to be stored in a movable cable duct (such as a cable track, etc.), use a robot cable. For details on how to connect other cables, such as the I/O cable, controller power cable and PC cable, refer to the operation manuals for the controller and PC software. 8.2 Checks after Installation Once the actuator is installed, check the following items. Visually examine the actuator, controller and cables for scratches, dents and other abnormalities. Confirm that the cables are connected correctly and the connectors are attached securely. Warning When connecting or disconnecting a cable, always turn off the controller power first. Connecting/disconnecting a cable while the controller is receiving power may cause the actuator to malfunction, resulting in a serious accident. Malfunction may result if the connector plugs are not inserted into the correct sockets. Loose connectors may cause the actuator to malfunction and create dangerous conditions. 9

20 9. Notes on Use 9.1 Backlash and Positioning Repeatability ROBO Rotary actuators have a backlash (play). Accordingly, the drive shaft may not move if the travel is smaller than the backlash. If the actuator moves in the same direction at all times, positioning can be performed within the positioning repeatability unless the reduction gears become free. However, the actuator may move by a dimension corresponding to the backlash in a standstill state, in which case the position may shift. If the rotating direction changes, the travel will become shorter by a dimension corresponding to the backlash. In this case, enter each position as a sum of the desired travel and the backlash. Backlash (play) and positioning repeatability Model Backlash (play) Positioning repeatability RT6 RT6R 0.1 or less ±0.02 RT7R 0.5 or less ±0.1 10

21 9.2 Range of Operation and Home Return Range of Operation The range of operation of ROBO Rotary actuators is 300 clockwise as viewed from the shaft. Since there is no stopper, the actuator may move beyond the range of operation if the shaft is turned by hand while the servo is off. Take note that if the range of operation is exceeded, the home return direction may be reversed. (Refer to 9.2.2, Home Return Direction. ) Use the supplied adhesive labels as rough visual guides for the range of operation. Note) On the RT7R, will be displayed when 300 is entered in the position data table. This is due to the resolution of the encoder. The actual position will also become

22 9.2.2 Home Return Direction With ROBO Rotary actuators, the rotating direction during home return operation will change depending on the standstill position of the shaft at the start of home return, as shown below. (1) The shaft was not detecting a sensor signal at the start of home return The actuator will rotate counterclockwise as viewed from the shaft ([1]) and upon detecting a sensor signal it will reverse its direction ([2]) and then subsequently stop when a Z phase signal is detected. (Refer to Fig. 1.) Sensor detection range Sensor reaction element Home [2] Shaft [1] Range of operation (300 ) Fig. 1 (2) The shaft was detecting a sensor signal at the start of home return (Ex. The shaft was turned by 300 or more while the servo was off) The actuator will rotate clockwise from the initial position ([3]) and subsequently stop upon detecting a phase Z signal. (Refer to Fig. 2.) Sensor detection range Sensor reaction element Home [3] Shaft Range of operation (300 ) Fig. 2 Although the range of operation is 300 with ROBO Rotary actuators, the actuator may rotate 360 depending on the situation, as explained above. Pay attention to possible contact between the ROBO Rotary actuator and structures or parts around it. 12

23 9.3 Conditions for Loads Installable on the ROBO Rotary Actuator Loads that can be installed on the ROBO Rotary actuator are limited by the specified limits of allowable load moment, rated torque and allowable inertial moment. If the specified limits are exceeded, the life of the actuator may become shorter or the actuator may fail. Exercise due caution. The table below lists the allowable load moments, rated torques and allowable inertial moments of different ROBO Rotary actuators. The concept of load moment is illustrated below. Conditions for loads installable on the shaft Model Allowable load moment Nm (kgfm) Rated torque Nm (kgfm) Allowable inertial moment kgm 2 (gfcms 2 ) RT6 RT6R 6.8 (0.694) 2.4 (0.25) 2.5 x 10-2 (0.25) RT7R 8.9 (0.907) (0.078) 1.25 x 10-3 (0.012) Load Load moment reference surface Load moment distance 13

24 10. Maintenance/Inspection Daily and periodic inspections are essential to making sure your actuator will operate safely and efficiently. Before carrying out each inspection, check the applicable maintenance/inspection items listed below Inspection Items and Timings Conduct visual inspection and add grease at the applicable timings specified below. The following schedule is based on eight hours of operation daily. If the actuator is operated at a higher utilization rate, including when it is operated continuously day and night, shorten the inspection intervals as necessary. Visual inspection At startup inspection 1 month after start of operation 6 months after start of operation 1 year after start of operation Every 6 months thereafter Every year thereafter * Any adjustments requiring the following operations must be carried out at our factory. Do not disassemble the actuator or cut any of its cables in the location where the actuator is installed. Disassemble the motor Disassemble the gear Disassemble the bearing Cut a cable If the user has disassembled any of the above components or cut any of the actuator s cables, IAI will not be responsible for any malfunction or problem that may occur thereafter. Warning Performing inspection or maintenance work without a thorough understanding of the specific tasks involved may result in a serial accident. If inspection is not carried out regularly, the drive part may reach its life prematurely or the actuator may suddenly start malfunctioning. 14

25 10.2 Visual Inspection of the Exterior In the visual inspection of the exterior, check the following items. Actuator Cables Overall Loosening of actuator mounting bolts, etc. Scratches, proper connection of connectors Noise, vibration 10.3 Exterior Cleaning Clean the exterior of the actuator as necessary. Use a soft cloth, etc., to wipe off dirt. Do not blow compressed air onto the actuator too strongly, in order to prevent dust from entering the actuator through small openings and gaps. Do not use petroleum solvent as it may damage the resin parts and coated surfaces. To clean stubborn soiling, moisten a soft cloth, etc., with neutral detergent and wipe gently. 15

26 11. Specifications 11.1 Specification List RT6 RT6R RT7R Gear ratio 1/18 1/4 Oscillation angle 300 Maximum speed 500 /s Rated torque 2.4 N-m N-m Allowable inertial moment 2.5 x 10-2 or less kg-m x 10-3 or less kg-m 2 Drive method Ball decelerator Ball decelerator + Timing belt Positioning repeatability ±0.02 mm Timing belt Backlash 0.1 or less 0.5 or less Allowable load moment 6.8 N-m or less 89 N-m or less Thrust load 100 N or less 16

27 11.2 External Dimensions RT6 4-M6, depth 12 Cable joint connector *1 Must be 40 or more *1 Connect the motor cable, encoder cable and limit switch cable. 17

28 RT6R 4-M6, depth 12 Cable joint connector *1 Must be 40 or more *1 Connect the motor cable, encoder cable and limit switch cable. 18

29 RT7R 9 through hole 4-M6, depth 12 2-M8, depth 12 Cable joint connector *1 Must be 40 or more *1 Connect the motor cable, encoder cable and limit switch cable. 19

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31 Catalog No.: ME3658-1A Head Office: 2690 W. 237th Street, Torrance, CA TEL (310) FAX (310) Chicago Office: 1261 Hamilton Parkway, Itasca, IL TEL (630) FAX (630) Atlanta Office: 1220-E Kennestone Circle, Marietta, GA TEL (678) FAX (678) website: Ober der Röth 4, D Schwalbach am Taunus, Germany TEL FAX The information contained in this document is subject to change without notice for the purpose of product improvement. Copyright SEP. IAI Corporation. All rights reserved.