Denso VP-G SERIES Installation & Maintenance Manual
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Denso VP-G SERIES Installation & Maintenance Manual

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ROBOT
Vertical articulated
VP-G SERIES
INSTALLATION & MAINTENANCE GUIDE

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Summary of Contents for Denso VP-G SERIES

  • Page 1 ROBOT Vertical articulated VP-G SERIES INSTALLATION & MAINTENANCE GUIDE...
  • Page 2 Copyright © DENSO WAVE INCORPORATED, 2005-2011 All rights reserved. No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher. Specifications are subject to change without prior notice. All products and company names mentioned are trademarks or registered trademarks of their...
  • Page 3 Preface Thank you for purchasing this high-speed, high-accuracy assembly robot. Before operating your robot, read this manual carefully to safely get the maximum benefit from your robot in your assembling operations. Robot series and/or models covered by this manual Series Model Mini-sized, vertical articulated VP-6242G (6-axis type)
  • Page 4 How this book is organized This book is just one part of the robot documentation set. This book consists of SAFETY PRECAUTIONS, chapters one through three. Chapter 1 Installing Robot Components Provides information about physical site planning, installation procedures, and engineering-design notes for hands.

  • Page 5: Table Of Contents

    Contents Chapter 1 Installing Robot Components ........................1 1.1 Preparing a Proper Environment for Installation....................1 1.1.1 Ambient Temperature and Humidity ......................1 1.1.2 Vibration................................. 1 1.1.3 Connecting the Robot Unit and Robot Controller ..................2 1.1.4 Installation Environment of the Robot Unit ....................2 1.2 Mounting the Robot Unit ............................
  • Page 6 Chapter 3 Maintenance and Inspection ........................27 3.1 Maintenance & Inspection Intervals and Purposes ..................... 27 3.2 Daily Inspections..............................28 3.2.1 Check Items..............................28 3.3 Quarterly Inspections ............................29 3.3.1 Check Items..............................29 3.3.2 Cleaning the Air Intake Filter in the Robot Controller ................. 29 3.4 Biennial Inspections ............................

  • Page 7: Chapter 1 Installing Robot Components

    Chapter 1 Installing Robot Components Preparing a Proper Environment for Installation Before installing the robot unit and robot controller, confirm that the operating environment is in conformity with each item of SAFETY PRECAUTIONS, "Installation Precautions". Also, take proper measures to protect the components from vibration. In an inappropriate environment, the robot will not operate to its full capacity or performance, components may not last long, and unexpected failure may result.

  • Page 8: Connecting The Robot Unit And Robot Controller

    1.1.3 Connecting the Robot Unit and Robot Controller Before delivery, the robot unit and the robot controller are configured as a set. If you purchase two or more robot systems, take care not to mistake each set when connecting robot units and controllers. Caution: The robot unit and robot controller in a set are given the same serial number.
  • Page 9 100  100 pipe 500 or more Caution (1) When the robot operates at high speed, the robot mount undergoes large reaction forces. The mount must be rigid enough so that it will not vibrate or be displaced due to reaction forces. It is also advisable to mechanically join the robot mount with heavy equipment.

  • Page 10: Mounting The Robot Unit

    Mounting the Robot Unit Caution Before handling or installing the robot unit, be sure to read SAFETY PRECAUTIONS, "Installation Precautions." 1.2.1 Transporting the Robot Unit An arm fixing plate is used to secure the robot arms during transportation from the factory and should be removed after installation. Caution: The robot unit should only be moved prior to installation if the arm fixing plate is in place.

  • Page 11: Securing The Robot Unit

    (4) Set the robot unit into place on the robot mount. (5) Secure the robot unit to the mount with four bolts and plain washers. Bolt: M8 30 mm (strength class: 12.9) Tightening torque: 35 7 Nm Bolt Positions for Securing the Robot Unit (VP-G series)

  • Page 12: Grounding The Robot Unit

    For the installing procedures of the robot controller, refer to the RC7M CONTROLLER MANUAL, Section 6.2 "Installing the Robot Controller." Cautions for Designing the Robot Hand Refer to the GENERAL INFORMATION ABOUT ROBOT for VP-G SERIES, Chapter 3, Section 3.5 "Precautions When Designing the End-effectors."...

  • Page 13: Locking Out The Power Switch

    Locking Out the Power Switch Lock out the power switch during maintenance and inspection jobs using a commercially available padlock, according to the following procedure. Step 1 Check that the power switch of the robot controller is turned OFF. Step 2 Remove the lockout bar provided on the robot controller.

  • Page 14: Chapter 2 Customizing Your Robot

    Chapter 2 Customizing Your Robot What Is Customization? You may customize your robot by modifying or setting the following: - Software motion limits for defining motion space - Mechanical ends for defining restricted space - Control set of motion optimization - Robot installation conditions You are recommended to define new motion space and restricted space in order to prevent interference with other devices or entanglement of the end-effector wiring and...

  • Page 15: Modifying Software Motion Limits To Define New Motion Space

    Software Motion Limits and Mechanical Ends 2.2.2 Factory Defaults of Software Motion Limits The table below lists the software motion limits that are set at the time of delivery. Factory Defaults of Software Motion Limits (VP-G series) Robot model 1st axis 2nd axis...

  • Page 16: Changing Software Motion Limits

    2.2.3 Changing Software Motion Limits If the robot interferes with any other device, change the software motion limits to make the motion space smaller as shown in the upper figure on this page. If the air piping or wiring of the end-effector becomes taut as the robot runs, then change the software motion limits to make the motion space smaller as shown in the lower figure on this page.

  • Page 17: Precautions When Changing The Software Motion Limits

    2.2.4 Precautions When Changing the Software Motion Limits (1) The software motion limits are invalid until CAL is completed. (2) Confirm the operating space of the robot in the actual working environment. Set the software motion limits using the correct unit of measurement. If the operating space is too small, the robot may seem to become inoperable.
  • Page 18 Press the SHIFT key and then press [F12 Maint.]. STEP 4 The Maintenance Functions (Arm) window will appear. Press [F1 M Space] on the Maintenance Functions (Arm) window. STEP 5 The Motion Space window will appear as shown below.
  • Page 19 Select the item to be modified, then press [F5 Change]. STEP 6 The numeric keypad will appear as shown below. Enter a desired value using the numeric keys, then press OK. The new value will be set on the line of the item selected in the Motion Space window.

  • Page 20: Changing The Mechanical End

    Regarding to the additional mechanical stopper installation, you may need to prepare and install the stopper on your own. Please contact your DENSO representative for more details. CAUTIONS AT CHANGING THE MECHANICAL ENDS 1. When changing the mechanical ends, design the mechanical stoppers according to your usage and manufacture them.

  • Page 21: Calset

    (2) When CALSETing, move the axis to be CALSET in the vicinity of the mechanical stop, release the brake, and bring the axis into contact with the mechanical stop. In the VP-G series, each of all axes has a brake. (3) When performing CALSET, be careful with the robot motion. The execution of the CALSET command releases motor brakes so that the robot arms will move by its own weight.

  • Page 22: Mounting The Calset Jig

    2.4.3 Mounting the CALSET Jig To CALSET the 6th axis having no mechanical stop, you need to mount the CALSET jig on the axis. Mounting the CALSET jig on the 6th axis Fit a stopper pin in the CALSET jig. STEP 1 Release the brake of the 6th axis.
  • Page 23 Install the CALSET jig on the 6th axis flange as shown in the figure below. STEP 3 TIP: The CALSET position of the 6th axis refers to the point where the stopper pin (shown in the figure below) comes into contact with bolt (A) by turning the flange of the 6th axis.

  • Page 24: What Is A Calset Position

    2.4.4 What Is a CALSET Position? The limit position of an arm to be CALSET is called a CALSET position. Each axis has a mechanical end in each of the positive and negative directions. The mechanical ends shown in the figure below are the CALSET positions. <VP-6242G>...

  • Page 25: Calset Procedure

    2.4.5 CALSET Procedure 2.4.5.1 CALSETing a Single Axis CALSETing a specified single axis only is called single-axis CALSET. Perform single-axis CALSET if the motor of an axis is replaced so that the axis must be CALSET, or if some axes cannot be moved to the CALSET positions (mechanical stop positions) at any given time because of interference between the robot unit and its surrounding facilities.
  • Page 26 Press the SHIFT key and [F12 Maint.]. STEP 7 Press [F3 Brake.]. STEP 8...
  • Page 27 Confirm that there is no danger even if the arms fall as a result of released STEP 10 brakes. CAUTION: In the VP-G series, the brake of the specified axis is released. Press OK. STEP 11 The system message appears asking you whether you want to change the...
  • Page 28 Press OK. STEP 12 The system message appears informing that the brake is released and warning against drop of arms. CALSET.] STEP 13 Press the axis to be CALSET against the mechanical stop by hand. Press [F6 CALSET.]. STEP 14 The Set CALSET window appears.
  • Page 29 Press the axis number to be CALSET to select CALSET (green display). STEP 15 Deselect CALSET (black display) for the other axes that are not required to be CALSET. Press OK. STEP 16 The system message appears asking whether you want to carry out CALSET and showing a caution that the robot reference position will change.
  • Page 30 Press the EMERGENCY STOP button. STEP 18 The robot brake becomes activated. Turn the EMERGENCY STOP button to cancel robot stop. STEP 19 Press the MOTOR to turn ON the power to the motor. STEP 20 Caution: A "motor lock overload" error may occur just after the power to the motor is turned ON.

  • Page 31: Setting Control Set Of Motion Optimization

    Setting Control Set of Motion Optimization The optimum speed or acceleration will vary depending upon the payload and center of gravity of an end-effector or workpiece that is to be set at the end of the robot flange. Set the payload and center of gravity position of the end-effector or workpiece and the control set of motion optimization according to the payload and robot posture.

  • Page 32: Setting Robot Installation Conditions

    Y-axis positive direction (orientation vector) Z-axis positive direction (approach vector) X-axis positive direction (normal vector) Right Hand Coordinate System Setting Robot Installation Conditions The optimum operating conditions will differ depending on whether the robot is floor-mounted or overhead-mounted. When the robot leaves the factory, it is set for floor-mount. If you overhead-mount your robot, you need to change the installation settings.

  • Page 33: Chapter 3 Maintenance And Inspection

    Chapter 3 Maintenance and Inspection Maintenance & Inspection Intervals and Purposes Carry out the maintenance and inspection jobs show in the table below. Caution: Maintenance and inspection must be carried out by a trained worker who possesses the ability to perform these tasks safely.

  • Page 34: Daily Inspections

    Daily Inspections 3.2.1 Check Items Before starting operation every day, check the items listed in the table below. Daily Inspections Table Controller What to do: Check: How to check: Criterion Power (Note 1) Connectors (CN1 to Engage the CN10 on the robot No looseness, parts properly Visually...

  • Page 35: Quarterly Inspections

    Quarterly Inspections 3.3.1 Check Items Check the items listed in the table below every three months. Quarterly Inspections Table Controller Check: How to check: Criterion What to do: Power Robot base Measure the tightening No looseness. Tighten the bolts to the mounting bolts torque with a torque specified torque.

  • Page 36: Biennial Inspections

    Replace the two types of backup batteries listed below and inspect the timing belts every two years. Please contact your DENSO representative to inspect timing belts and to adjust them. Caution (1) The battery used in this device may present a risk of fire or chemical burn if mistreated.

  • Page 37: Replacing The Encoder Backup Battery

    3.4.2 Replacing the Encoder Backup Battery Replace the encoder backup battery according to the procedure below. STEP 1 Prepare a new set of 3 backup batteries for replacement. STEP 2 Turn the controller power ON. Note: When replacing the encoder backup battery, do not turn the controller power OFF.
  • Page 38 Remove the cover from the robot unit. STEP 4 Replace an old battery with new one, one by one. STEP 5 Note: Do not disconnect all old batteries at the same time before connecting a new one. If you do so, the encoder positional data may be lost.

  • Page 39: Replacing The Memory Backup Battery

    3.4.3 Replacing the Memory Backup Battery For the replacing procedures of the memory backup battery, refer to the RC7M CONTROLLER MANUAL, Section 6.5 "Replacing the Memory Backup battery.” 3.4.4 Setting the Next Battery Replacement Date After replacing the memory backup battery, set the next battery replacement date from the teach pendant, according to the following procedure.

  • Page 40: Supplies And Tools For Maintenance

    Supplies and Tools for maintenance The table below shows the supplies and tools for maintenance. Supplies and Tools for Maintenance Name Part No. Remarks 410053-0100 For standard type of controllers (FS-1705W) Air filter set 410053-0110 For global type of controllers (FS-1705) Memory backup battery 410076-0260 For RC7M controller...

  • Page 41: Checking The Odometer And Trip Meter

    Checking the Odometer and Trip Meter You may check the odometer and trip meter which count traversed distance of each axis in the Odometer window of the teach pendant. The access to the Odometer window is [F6 Set]—[F6 Maint.]—[F5 Odometer]. The Odometer window shows the following items: [Odometer] Shows the total distance of each axis traversed after the robot leaves the factory.
  • Page 42 STEP 4 The Maintenance menu appears as shown below. Press [F5 Odometer]. STEP 5 The Odometer window appears as shown below. In the above Odometer window, the J1 through J6 are expressed in rpm. If the Trip meter count exceeds the Interval value, the oil change prompt message will appear.

  • Page 43: Resetting The Trip Meter To Zero

    3.7.2 Resetting the Trip Meter to Zero STEP 1 Display the Odometer window as shown below. Access: [F6 Set]—[F6 Maint.]—[F5 Odometer] from the top screen. Press [F6 Reset]. STEP 2 The following message appears. Press the OK button. The trip meter has been reset to zero.

  • Page 44: Checking The Controller On-Time And The Robot Running Time And Resetting Their User Counters

    Checking the Controller ON-Time and the Robot Running Time and Resetting Their User Counters You may check the robot controller ON-time and the robot running time in the Total hours window of the teach pendant. The Total hours window shows the following items: [Total operation] Shows the grand total of the robot controller ON-time counted after the controller leaves the factory.
  • Page 45 STEP 2 The Total hours window appears as shown below. [Total operation] Shows the grand total of the robot controller ON-time counted after the controller leaves the factory. [Total running] Shows the grand total of the robot running time counted after the robot leaves the factory.

  • Page 46: Resetting The User Counters Of The Controller On-Time And The Robot Running Time

    3.8.2 Resetting the User Counters of the Controller ON-Time and the Robot Running Time STEP 1 Display the Total hours window as shown below. Access: [F6 Set]—[F6 Maint.]— [F1 Total h] from the top screen To reset the user counter of the controller ON-time (Cumu.operation), for example, press [F4 Cumu.
  • Page 47 STEP 3 The user counter of the controller ON-time has been reset to zero as shown below.

  • Page 48: Resetting Encoders

    Resetting Encoders You need to reset encoders and perform CALSET if: - Error 641* occurs due to run-down encoder backup batteries, or - Error 677* occurs due to a great impact applied to the robot when the power is off. (* is any of 1 to 6 denoting the object axis.) This section describes how to reset encoders.

  • Page 49: 3.10 Backing Up Projects

    - after performing CALSET - after changing RANG values - after replacement of a motor DENSO preserves arm data configured at the time of shipment for 10 years. If your arm data is lost, contact your DENSO representative. Note Arm data refers to CALSET and RANG values in project data, which is unique to individual robots and determines the position of each joint.
  • Page 50 STEP 1 Create a new project in WINCAPSIII. STEP 2 Choose "Get information from the controller for creating a new project." STEP 3 Following the project wizard, enter the IP address and the desired backup file name. STEP 4 Select "Receive data from the controller after creating the project." STEP 5 Close the project.

  • Page 51: 3.10.2 Transfer Arm Data

    STEP 1 Loading the arm data (***.wam) into the WINCAPSIII project This step is necessary when only arm data is supplied by DENSO. When project data has been backed up, open the project data in WINCAPSIII and proceed to STEP 2.
  • Page 52 STEP 3 Transferring arm data to the robot controller Choose Connect | Transfer data to display the Transfer data window. Select Parameters | Arm parameters and Configuration | CALSET, then press Send. Upon completion of transfer of the CALSET-related arm data, restart the robot controller.
  • Page 53 Please feel free to send your comments regarding any errors or omissions you may have found, or any suggestions you may have for generally improving the manual. In no event will DENSO WAVE INCORPORATED be liable for any direct or indirect damages resulting from the application of the information in this manual.

This manual is also suitable for:

Vp-6242gVp-5243g

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