Mitsubishi Electric CR800-D Series User Manual
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Mitsubishi Electric CR800-D Series User Manual

Industrial robot, controller, predictive maintenance function
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Mitsubishi Electric Industrial Robot
CR800-D/R/Q series controller
Predictive Maintenance Function
User's Manual
BFP-A3663

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Summary of Contents for Mitsubishi Electric CR800-D Series

  • Page 1 Mitsubishi Electric Industrial Robot CR800-D/R/Q series controller Predictive Maintenance Function User’s Manual BFP-A3663...
  • Page 3 Safety Precautions Always read the following precautions and the separate "Safety Manual" before starting use of the robot to learn the required measures to be taken. CAUTION All teaching work must be carried out by an operator who has received special training.
  • Page 4 The points of the precautions given in the separate "Safety Manual" are given below. Refer to the actual "Safety Manual" for details. DANGER When automatic operation of the robot is performed using multiple control devices (GOT, programmable controller, push-button switch), the interlocking of operation rights of the devices, etc.
  • Page 5 CAUTION Never carry out modifications based on personal judgments, or use non- designated maintenance parts. Failure to observe this could lead to faults or failures. WARNING When the robot arm has to be moved by hand from an external area, do not place hands or fingers in the openings.
  • Page 6 CAUTION Make sure there are no mistakes in the wiring. Connecting differently to the way specified in the manual can result in errors, such as the emergency stop not being released. In order to prevent errors occurring, please be sure to check that all functions (such as the teaching box emergency stop, customer emergency stop, and door switch) are working properly after the wiring setup is completed.
  • Page 7 ■ Revisions Revision Date Instruction Manual No. Revision Details • First print 2019-04-25 BFP-A3663...
  • Page 8 This specifications is original. • Company names and product names described in this document are trademarks or registered trademarks of each company. • and TM are omitted in the text of this guide. Copyright(C) 2019 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVED...

  • Page 9: Table Of Contents

    Contents Before starting use ..........................9 1.1. Contents of the instruction manual ..................... 9 1.2. Compatible products ......................... 10 1.3. Related manuals ..........................11 1.4. Maintaining the robot ........................12 1.4.1. Type of maintenance and inspection ..................12 1.4.2. Inspecting/replacing timing belt ....................13 1.4.3.
  • Page 10 13.1.2. Abnormality detection function ....................97 13.1.3. MELFA Smart Plus ........................99 13.2. Consumption degree calculation function ..................100 13.2.1. Serial number .......................... 100 13.2.2. Operating information ......................102 13.2.3. Maintenance Log ........................108 13.2.4. Consumption degree....................... 120 13.2.5. Consumption status ........................ 129 13.2.6.

  • Page 11: Before Starting Use

    1. Before starting use 1.1. Contents of the instruction manual This function can be used with the RT ToolBox3 Predictive maintenance screen, parameters, status variables, and dedicated input/output signals. In this manual, the following structure is used to explain how the predictive maintenance function using examples of the RT ToolBox3 Predictive maintenance screens.

  • Page 12: Compatible Products

    1.2. Compatible products The following products are compatible with this function. Item Description Remarks RV-2FR series, RV-4FR series, Vertical multi-joint Standard model RV-7FR series, type RV-FR series 6-axis robot only RV-13FR series, RV-20FR series Robot arm RH-3FRH series, RH-6FRH series, Horizontal multi-joint RH-12FRH series, Standard model only...

  • Page 13: Related Manuals

    1.3. Related manuals The following manuals are related to the predictive maintenance function. Manual name Description Explains the procedures required to operate the robot arm Robot Arm Setup & Maintenance (unpacking, transportation, installation, confirmation of operation), and the maintenance and inspection procedures. Explains details on the functions and operations such as each Detailed explanations of functions function and operation, commands used in the program,...

  • Page 14: Maintaining The Robot

    1.4. Maintaining the robot This function supports maintenance and inspection so that the robot can be used for a long time without trouble. Efficient maintenance is supported though early detection of abnormalities or deterioration of robot components and notification of the time of maintenance parts replacement or overhaul based on the actual operating status of the robot.

  • Page 15: Inspecting/Replacing Timing Belt

    1.4.2. Inspecting/replacing timing belt This robot uses a timing belt for the drive conveyance system. Compared to gears and chains, the timing belt does not require lubrication and has a low noise. However, if the belt usage method and tension adjustment are inadequate, the life could drop and noise could be generated.

  • Page 16: Lubrication

    1.4.3. Lubrication Grease is used for the reduction gears of the robot. Grease has various roles, such as suppressing of wear of reduction gears, removal of frictional heat, and prevention of burn-in. If you use a robot for a long period of time, the grease will deteriorate due to loads during operation (operating speed, operation frequency, heat generation condition, and others.).

  • Page 17: Replacing The Battery

    1.4.4. Replacing the battery An absolute encoder is used for the position detector, so while power of controller is turned off the position must be saved by the backup battery. These batteries are installed when the robot is shipped from the factory, but as these are consumable parts, they must be replaced periodically by the customer.

  • Page 18: About Overhaul

    1.4.5. About Overhaul Robots which have been in operation for an extended period of time can suffer from wear and other forms of deterioration. In regard to such robots, we define overhaul as an operation to replace parts running out of specified service life or other parts which have been damaged, so that the robots may be put back in shape for continued use.

  • Page 19: Basic Specifications

    2. Basic specifications 2.1. Overview of basic specification of the predictive maintenance function The predictive maintenance function roughly consists of the following three functions. Information on predictive maintenance by each function can be checked on the Predictive maintenance screen, status variables, and parameters of RT ToolBox3. The following features are also available. •...

  • Page 20: Maintenance Simulation

    2.1.1. Maintenance simulation Using the real machine (online) or simulations on RT ToolBox3, this function estimates the parts replacement time or the recommended maintenance time when specific motion patterns (robot programs) are repeated. Maintenance simulation estimates the following items. 1) Number of years up to the time of replenishing grease 2) Number of years up to the time of timing belt replacement 3) Recommended number of years up to the maintenance time for overhauling parts (Of reduction gear, bearing, ball screw, and ball spline, the part for which there is the shortest...
  • Page 21 When RT ToolBox3 mini is used, simulation on RT ToolBox3 cannot be used. Caution The recommended number of years up to the replacement/maintenance time output by this function is the value calculated when the specified operation is repeated. Also, the result may vary depending on the performance of the personal computer used and the load status.

  • Page 22: Consumption Degree Calculation Function

    2.1.2. Consumption degree calculation function This function calculates the consumption degree [%] of robot components based on the actual operating status (motor speed, load status, and others), and calculates the period up to maintenance/inspection or overhaul. Consumption Degree [%] is calculated based on the recommended maintenance time of each part as 100 [%].
  • Page 23 Operation method RT ToolBox3 Predictive maintenance screen (Refer to 11.1 Warning Pause 11.2 Maintenance Reset.) [Parameters] (Refer to 14.2 Consumption degree calculation function 14.2.3 Operation parameters .) [I/O Signal] (Refer to 15 Dedicated input/output signals 15.1 Consumption degree calculation function.) Notification Notification content ·...
  • Page 24 [About the robot controller] Caution • When using this function by upgrading from a non-compatible controller software version to a compatible controller software version, the consumption degree during the period of the non-compatible software version is not added up, thus the result of consumption degree calculation function cannot be the correct value.
  • Page 25 <<MEMO>> Basic specifications 23...

  • Page 26: Abnormality Detection Function

    2.1.3. Abnormality detection function This function detects abnormalities or deterioration of robot reduction gear components early. Before the robot exhibits behavior that is a sign of an abnormality, the function can detect reduction gear or encoder abnormalities. Without adding sensors or an analysis personal computer, the robot controller alone can detect abnormalities in reduction gear or the encoder.
  • Page 27 • The score output by the reduction gear abnormality detection function is calculated Caution based on motor feedback data and is a reference value for detecting abnormalities that leads to a failure. It does not guarantee to certainly detect abnormalities before part failure.

  • Page 28: Target Models/Target Axes

    2.1.4. Target models/target axes (1) Consumption degree calculation function/maintenance simulation The table below shows the joint axes for which target parts of the consumption degree calculation function of each robot type are used. (Compatible robots are the standard models only.) ...
  • Page 29 (5) RH-3FRHR Joint axis J1axis J2 axis J3 axis J4 axis    Grease Maintenance parts     Timing belt   Reduction gear    Bearing Overhaul parts  Ball screw  Ball spline *3：The RH-3FRHR series uses a ball screw/spline but this function assumes that the J3 axis uses a ball screw and the J4 axis uses a ball spline.

  • Page 30: How To Utilize The Predictive Maintenance Function

    2.2. How to utilize the predictive maintenance function The predictive maintenance function assumes the following usages. (1) At system startup It is possible to estimate the replacement time of maintenance parts or the recommended maintenance time of overhaul parts when an operation pattern of the robot is repeated using "Maintenance Simulation". This function can be used for planning a maintenance schedule when starting up a system.
  • Page 31 << MEMO >> Basic specifications 29...

  • Page 32: Startup And Initial Settings

    3. Startup and initial settings This section describes the procedure to start the predictive maintenance function. Validation of the predictive maintenance function (3.1) 1. Turn off the power of the robot controller. 2. Insert the "MELFA Smart Plus Card" or "MELFA Smart Plus Card Pack"...

  • Page 33: Enabling The Predictive Maintenance Function

    3.1. Enabling the predictive maintenance function Insert the "MELFA Smart Plus Card" into the robot controller and set parameters. Turn off the power of the robot controller. CR800-D type Switch 1) Turn off the switch of the earth leakage circuit breaker. CR800-R/Q type 1) Turns off the power of the robot CPU system.
  • Page 34 Turn on the power of the robot controller. CR800-D type Switch 1) Turn on the switch of the earth leakage circuit breaker. 2) The POWER lamp of the robot controller lights. CR800-R/Q type 1) Turn on the switch of the earth leakage circuit breaker. Earth leakage circuit breaker 2) The POWER lamp of the robot controller lights.
  • Page 35 Restart the robot controller. CR800-D type 1) Turn off the switch of the earth leakage circuit breaker. 2) Turn on the switch of the earth leakage circuit breaker. CR800-R/Q type 1) Turns off the power of the robot CPU system. 2) Turn off the switch of the earth leakage circuit breaker.

  • Page 36: Initial Setting Of The Predictive Maintenance Function

    3.2. Initial setting of the predictive maintenance function Set how to notify when consumption or abnormality of a part is detected. Specify such as the detection level for warning occurrence, and the notification method (presence of warning/signal output, notification day). If you have not set the notification method, upon starting the predictive maintenance function, the [Setting] - [Synthesis] screen appears.

  • Page 37: Setting Detection Level

    4) Abnormality detection notification method: Set how to notify the score. You can select Warning Occurrence or Signal Output, or both. (Setting of Warning Occurrence and Signal Output are the same as with the abnormality detection notification method.) 5) Level setting: You can set the levels at which warnings occur for each joint axis.
  • Page 38 Detection level setting method (1) Reduction gear The detection level of the reduction gear abnormality detection for each joint axis is "-1" (detection disabled) as a factory default. Since the score varies depending on the operating speed and operating conditions such as the hand load by the hand and workpiece, set the detection level according to the actual operating conditions.
  • Page 39 Example of robot failure: The graph below shows data resulting from reduction gear failure. The numerical value 1 of the horizontal axis (Log No.) represents the day that a robot stopped due to wear of the reduction gear. The detection level had been set to 191 which was 10 points higher than the maximum score (180.08) from 7 days worth of log data after starting operation.
  • Page 40 (2) Encoder data/communication abnormality Encoder data abnormality error or communication abnormality error occurs when miscount of the certain number of times or communication failure occurs, respectively, and the robot will stop by the error. This function uses 100 as the error occurrence condition and outputs miscount and communication failure, which did not reach an error, as the score, and notifies that an abnormality has occurred before the robot stops due to the error.
  • Page 41  Checking scores with the real-time monitor oscillograph The scores of the fault detection function can be monitored with the real-time monitor oscillograph.This section explains how to start the oscillograph real time monitor. For details of the oscillograph function and how to use the real time monitor, refer to the separate "RT ToolBox3/RT ToolBox3 mini User's Manual".
  • Page 42 (3) Start the Communication Setting screen of the Oscillograph screen of the predictive maintenance function. 1) In Data#1 to Data#4, from the data list, select the score item to be monitored. 2) Click the "Set" button to close the "Communication Setting" screen. 1) Click List of data that can be displayed Predictive maintenance score...
  • Page 43 (5) Adjust display points on the graph. 1) Change "Display Points" on the lower right side of the Oscillograph screen. 2) When you move the slider on the bottom to the right direction, the value on the right side changes. Display points are points to be displayed on graph.
  • Page 44 The Oscillograph cannot be used when the communication method is set to High speed. If you see the message "It can not communicate with the controller", please change so that the RT ToolBox3 (MELFA_RT.exe) is allowed to receive in the Windows Firewall settings. Check item or cause 1) Show the following screen by selecting [Control panel] ->...

  • Page 45: Setting Signals

    3.2.3. Setting signals Set signal numbers when you wish to use signal input/output to implement notification when consumption or abnormality of parts is detected, reset the abnormality detection status/consumption degree, or pause warning occurrence/signal output. For dedicated input/output signals of the predictive maintenance function, refer to "15. Dedicated input/output signals".

  • Page 46: Setting Of Maintenance Simulation

    3.3. Setting of maintenance simulation In order to use "Maintenance Simulation" for the simulation of RT ToolBox3, the function code and parameter of the MELFA Smart Plus card need to be set to RT ToolBox3. This section explains the procedure for setting the function code of the MELFA Smart Plus card to RT Toolbox3, which is not connected to the robot controller where the MELFA Smart Plus card has been installed.
  • Page 47 Set the function code of the MELFA Smart Plus card. Next, enter the function code obtained in Step 1 to the RT ToolBox3 that performs the maintenance simulation. 1) Start RT ToolBox3 that performs the maintenance simulation. At that time, click the right button of the mouse on the desktop icon of RT ToolBox3 and select "Implement as administrator"...
  • Page 48 Check that the predictive maintenance function is enabled. 1) Change the operation mode to <Simulation>. If parameter setting in Step 3 is performed using <Simulation>, start up Simulation once again. (The "PMENA" parameter requires rebooting.) 2) From the project tree, expand [Maintenance] and check that [Predictive Maintenance] is displayed.
  • Page 49 << MEMO >> Startup and initial settings 47...

  • Page 50: Basic Screen Structure

    4. Basic screen structure This screen displays the status of reduction gear, the encoder, and battery (normal, warning, abnormalities), and the total evaluation result of the consumption degree calculation function. RT ToolBox3 project tree 1) Predictive Maintenance [Predictive Maintenance] is displayed under [Maintenance] of the project tree.
  • Page 51 (1) Total score This screen displays the total evaluation result of the abnormality detection function and consumption degree calculation function, and maintenance messages. For details, refer to "5. Total score". (2) Consumption degree calculation The screen indicates the consumption degree of each part and each joint axis of maintenance parts and overhaul parts calculated by the consumption degree calculation function.

  • Page 52: Total Score

    5. Total score This screen displays the status of reduction gear, the encoder, and battery (normal, warning, abnormalities), and the total evaluation result of the consumption degree calculation function. Total score 1) Consumption degree 4) Save calculation 2) Abnormality detection (3) Predictive maintenance message (1) Consumption degree calculation The Consumption Degree area indicates the total score (Consumption Degree [%] and Up to...
  • Page 53 (2) Abnormality detection This area of the screen indicates the score status obtained using the abnormality detection function. The display also includes the status (normal, fault) of reduction gear, the status (normal, fault) of the encoder, and the status (normal, warning, fault) of the battery. You can check details of each joint axis on the Abnormality Detection screen.

  • Page 54: Consumption Degree Calculation Function

    6. Consumption degree calculation function This function calculates the consumption degree [%] of robot components based on the actual operating status (motor speed, load status, and others), and calculates the period up to maintenance/inspection or overhaul. The screen indicates the consumption degree of each joint axis of maintenance parts and overhaul parts calculated by the consumption degree calculation function.
  • Page 55 (1) Consumption degree This area of the screen indicates the consumption degree of each part of the target axis and each joint axis in a graph and numeric value [%]. (For target axis, refer to "2.1.4 Target models/target axes".) (2) Predictive maintenance message This field displays predictive maintenance messages according to the part status.
  • Page 56 [About the robot controller] Caution • When using this function by upgrading from a non-compatible controller software version to a compatible controller software version, the consumption degree during the period of the non-compatible software version is not added up, thus the result of consumption degree calculation function cannot be the correct value •...
  • Page 57 <<MEMO>> Consumption degree calculation function 55...

  • Page 58: Abnormality Detection Function

    7. Abnormality detection function This function detects abnormalities or deterioration of robot reduction gear components early. Before the robot exhibits behavior that is a sign of an abnormality, the function can detect reduction gear or encoder abnormalities. The screen that indicates the score calculated by the abnormality detection function. The display also includes the current score of the reduction gear including reduction gears, encoder data abnormality, and encoder communication abnormality.
  • Page 59 (3) Predictive maintenance message This field displays predictive maintenance messages according to the part status. When an abnormality is detected, an appropriate predictive maintenance message is displayed; check the message content and take measures. For predictive maintenance messages and measures, refer to "10. When consumption occurred/abnormality detected 10.2 Abnormality detection".
  • Page 60 • The score output by the reduction gear abnormality detection function is calculated Caution based on motor feedback data and is a reference value for detecting abnormalities that leads to a failure. It does not guarantee to certainly detect abnormalities before part failure.
  • Page 61 How to check the motor speed with the RT ToolBox3 monitor function 1) From the RT ToolBox3 project tree, click [Monitor] - [Servo] and then double-click [Speed] to display the [SPEED] screen. 2) You can monitor data related to the speed of each axis motor of the robot in action. RT ToolBox3 project tree 1) Speed monitor screen 1) [Servo]...

  • Page 62: Operating Information

    8. Operating information The Operating Information screen is used to manage and display the integration time and accumulation count from the time when the previous overhaul was carried out. The integration time and accumulation count data are reset when "Reset operation at overhaul implementation"...
  • Page 63 << MEMO >> Operating information 61...

  • Page 64: Maintenance Simulation

    9. Maintenance simulation This function estimates the parts replacement time or the recommended maintenance time when a specific motion pattern (robot program) is repeated using a real machine (online) or simulations on RT ToolBox3. Maintenance simulation estimates the following items. 1) Number of years up to the time of replenishing grease 2) Number of years up to the time of timing belt replacement 3) Recommended number of years up to the recommended maintenance time for overhauling parts...
  • Page 65 Caution When RT ToolBox3 mini is used, simulation on RT ToolBox3 cannot be used. The recommended number of years up to the replacement/maintenance time output by this function is the value calculated when the specified operation is repeated. Also, the result may vary depending on the performance of the personal computer used and the load status.

  • Page 66: Cycle" Operation

    9.1. "1 Cycle" operation This operation is performed in the simulation mode of the RT ToolBox3. Specify the start line and end line of the robot program to estimate the parts replacement/ the recommended maintenance time based on its 1 Cycle operation pattern. [Note] When an actual machine is connected, the "1 Cycle"...
  • Page 67 Move the current position of the robot to the robot operation start position of 1 Cycle operation. If the current position of the robot is not at the start position of 1 Cycle operation, if 1 Cycle operation starts, the robot moves to the operation start position first. Since that operation is included in the calculation by the maintenance simulation, calculation cannot give the correct 1 Cycle operation result.
  • Page 68 Select "1 Cycle". 1) Select "1 Cycle" on the Maintenance Simulation screen. Maintenance Simulation screen 1 Cycle Select the execution program. 1) Click [Program Selection] on the Maintenance Simulation screen. 2) The "Select Robot Program" screen opens; select the program to run the simulation and click the "OK"...
  • Page 69 Select the start line and end line of the program. 1) The Select Program Line Number Select Program Line Number screen screen appears. 2) Select the start line and end line. <Selection method> Enter the line number in the input Click to input box at the right side of Start Line line numbers.
  • Page 70 The simulation results are displayed. The simulation results are displayed when operation from the start line to end line specified in Step 5 is repeated. 1) When program operation ends, the maintenance simulation results are displayed. The displayed results are estimated results based on the value of "Operation Time of a Day" and "Working Days in a Month".
  • Page 71 [Tact time calculation] Caution • The calculated tact time varies with the performance and load status of the computer used and will not completely match the actual robot operating time (tact time). • Use this function as a rough yardstick for tact time study. Under correct conditions, the results of tact time calculation with this software have an error of about ±3% compared to the actual robot operating time (tact time).

  • Page 72: Program Operation

    9.2. Program operation Run a program online or in the simulation mode of RT ToolBox3. While running a robot program automatically, the pats replacement/ the recommended maintenance time is estimated for operation from when the start button is pressed to when the end button is pressed is repeated.
  • Page 73 Select the "Program" for the estimation method. (Simulation only) 1) When running a program in simulation mode, select "Program" on the Maintenance Simulation screen. [Note] When an actual machine is connected, the "1 Cycle" button and "Program" button are not displayed.
  • Page 74 End the maintenance simulation. 1) When a series of operations for performing maintenance simulation have been executed, click the "End" button on the Maintenance Simulation screen. The maintenance simulation ends and the Maintenance Simulation result screen appears. (Even though the "End" button is clicked, the robot continues operation.) Maintenance Simulation screen Maintenance simulation 72...
  • Page 75 The simulation results are displayed. The maintenance simulation result displayed is when the operation from clicking the "Start" button in Step 4 to clicking the "End" button in Step 5 is repeated. 1) When program operation ends, the maintenance simulation results are displayed. The displayed results are estimated results based on the value of "Operation Time of a Day"...

  • Page 76: When Consumption Occurred/Abnormality Detected

    10. When consumption occurred/abnormality detected When the consumption status of the target part exceeded the notification day you specified or when the score of the abnormality detection exceeded the detection level, an error number and error message corresponding to the status are displayed. Predictive maintenance message is also displayed in the maintenance message field on the RT ToolBox3 Predictive maintenance screen.

  • Page 77: Overhaul Parts

    (2) Timing belt Error number C.713n Error message Timing belt replacement period RT ToolBox3 predictive The timing belt (Jn axis) consumption degree exceeded the warning number of maintenance message days remaining. Please check the details and prepare for timing belt replacement. Measures Replace the timing belt.
  • Page 78 (2) Bearing Error number C.715n Error message Overhaul period (bearing) RT ToolBox3 predictive The bearing (Jn axis) consumption degree exceeded the warning number of days maintenance message remaining. Please check the details and prepare for overhaul. Measures Perform overhaul of the robot body. For selection of replacement parts and overhaul implementation timing, consult with our service affiliated company.

  • Page 79: Servo On Time

    10.1.3. Servo ON time (* n in the table indicates the axis numbers (1 to 6). Error number C.7110 Error message Overhaul period (servo on time) RT ToolBox3 predictive The servo on time exceeded the warning number of days remaining. maintenance message Please check the details and prepare for overhaul.

  • Page 80: Abnormality Detection

    10.2. Abnormality detection 10.2.1. Reduction gear (* n in the table indicates the axis numbers (1 to 6).) Error number C.717n Error message Abnormality detection (reduction gear) RT ToolBox3 predictive The warning of the reduction gear (Jn axis) failure was detected. maintenance message Check the details and perform maintenance and inspection of reduction gear.

  • Page 81: Battery

    10.2.3. Battery Error number C.7510 Error message Battery voltage low (robot) RT ToolBox3 predictive Battery voltage is low. maintenance message Early battery replacement is recommended. Measures Replace the battery as soon as possible. For the battery replacement procedure and home position setting procedure, refer to the separate volume, "Instruction Manual/Robot Arm Setup &...

  • Page 82: Maintenance

    11. Maintenance On the maintenance screen, you can reset the consumption degree, or can specify backup/restore and pausing of warning occurrence/warning signal output during maintenance. In addition, you can check the maintenance log. 1) Start predictive maintenance. 2) Click [Maintenance] to expand the menu; the maintenance functions are displayed. 3) Click [Warning Pause], [Maintenance Reset], [Backup], or [Maintenance Log], to switch the main screen.

  • Page 83: Warning Pause

    11.1. Warning Pause Displays the list of warning and warning signals that are occurring or paused. Usually, the alarm of consumption degree calculation is notified at the intervals you set. If you desire to stop notification (alarm, dedicated output signal), you can temporarily disable at this stage. Note that the alarm of abnormality detection cannot be reset while it exceeds the notification level.

  • Page 84: Maintenance Reset

    11.2. Maintenance Reset When part replacement, grease replenishing, or overhaul was performed, the information of the axes for which maintenance was performed accumulated in the controller needs to be reset. On the Maintenance Reset screen, you can reset the information held by the controller such as the consumption degrees calculated by the consumption degree calculation function or the information related to score calculated by the abnormality detection function.

  • Page 85: Backup And Restore

    11.3. Backup and restore You can back up or restore predictive maintenance information held in the controller. To replace the robot body or robot controller only, you need to perform backup/restore of the predictive maintenance information to migrate the predictive maintenance information. For backup/restore of the predictive maintenance information, click [Maintenance] - [Backup] of the predictive maintenance function.
  • Page 86 • The predictive maintenance information of the robot body is saved in the robot Caution controller; it is necessary to use the correct combination of the robot body and robot controller. To replace the robot body or robot controller only, perform backup/restore of predictive maintenance information to migrate the predictive maintenance information.

  • Page 87: Backup (Robot  Personal Computer)

    11.3.1. Backup (robot  personal computer) Save the predictive maintenance information in the robot controller to a file on a personal computer. When clicking the [Backup] button, a time stamp folder (folder name: "YYmmdd-HHMMSS") is automatically created in the [Maintenance] - [PMBackup] folder directly under the project and the backup data is saved in that folder.

  • Page 88: Restore (Personal Computer  Robot)

    11.3.2. Restore (personal computer  robot) Transfer the information backed up on the personal computer to the robot controller. To restore predictive maintenance information, from the folder selection dialog box, select the folder you wish to restore. If there is missing backup data, an error message is displayed and restore is interrupted. The following describes how to restore predictive maintenance information.

  • Page 89: Maintenance Log

    11.4. Maintenance Log Display the recorded maintenance log. 11.4.1. Maintenance Log screen The predictive maintenance function stores 10 maintenance log items of the past. Upon executing maintenance reset, item, date & time, consumption degree [%] and accumulation count are recorded. On the Maintenance Log screen, the recorded log is displayed.

  • Page 90: Data To Be Recorded In The Maintenance Log

    11.4.2. Data to be recorded in the maintenance log After performing grease replenishing, timing belt replacement, or robot overhaul, upon resetting the consumption degree of each part, the reset date & time, consumption degree [%] at the time of reset, and reset count are recorded in the maintenance log.
  • Page 91 << MEMO >> Maintenance 89...

  • Page 92: Batch Management Of Maintenance Information

    12. Batch management of maintenance information Explains how to collectively manage maintenance information of the entire production line with the host system. Robots in the factory 12.1. Functional overview Maintenance information used in the predictive maintenance function is compatible with the data output in communication protocol MelfaRXM.ocx, SLMP.

  • Page 93: Output Data

    12.2. Output data Output data Target Unit Robot status variable Parameter Robot body serial number Character C_RBSerial RBSERIAL string Power ON time h (hours) M_PowOnTime TIMPOWON Servo ON time h (hours) M_SrvOnTime TIMSRVON Basic data Operation time h (hours) M_PrgTime TIMPRG Actual operation time h (hours)
  • Page 94 Output data Target Unit Robot status variable Parameter − − Specify data to get LOGPMNO − Piece M_PMLogGrs Grease Character C_PMLogGrs LOGPMGRS string − Piece M_PMLogBlt Timing belt Character C_PMLogBlt LOGPMBLT string − Piece M_PMLogDec Reduction gear Character C_PMLogDec LOGPMDEC string Maintenance Log −...

  • Page 95: Request Id (Melfarxm.ocx) Specified By Requestservice

    12.3. Request ID (MelfaRXM.ocx) specified by RequestService You can get robot status variables and parameter values related to the predictive maintenance function using the existing request ID. ID value Function name Get variable value Get parameter value (consider open level) Write parameter value Batch management of maintenance information 93...

  • Page 96: Robot (System) Status Variables

    13. Robot (system) status variables 13.1. Robot (system) status variable list 13.1.1. Consumption degree calculation function *1) Attributes in the table, R: Read only *2) Mechanism No..1 to 3, Specifies a mechanism number corresponding to the multitask processing function <Serial number>...
  • Page 97 <Consumption degree> Variable name Array Details Attribute Data type, Page designation Unit M_PMCsmMnt None Consumption degree Single-precision real number (mechanism total type, % (maintenance parts)) M_PMCsmOH None Consumption degree Single-precision real number (mechanism total type, % (overhaul parts)) M_PMCsmGrs Axis No.(1 to 8) Consumption degree Single-precision real number...
  • Page 98 <Notification> Variable name Array Details Attribute Data type, Page designation Unit Axis No.(1 to 8) Notification pause status Integer type M_PMRptGrs (grease) Axis No.(1 to 8) Notification pause status Integer type M_PMRptBlt (timing belt) Axis No.(1 to 8) Notification pause status Integer type M_PMRptDec (reduction gear)

  • Page 99: Abnormality Detection Function

    13.1.2. Abnormality detection function *1) Attributes in the table, R: Read only <Abnormality detection log> Variable name Array Details Attribute Data type, Page designation Unit M_PMLogScr None Log data count of Integer type abnormality detection log M_PMLogD Log No.(1 to 365) Abnormality detection log Single-precision Axis No.(1 to 9)
  • Page 100 <Detection level> Page Variable name Array Details Attribute Data type, designation Unit M_PMWngDrv Axis No.(1 to 8) Integer type Detection level (reduction gear abnormality detection) M_PMWngEnc1 Axis No.(1 to 8) Detection level Integer type (encoder data abnormality detection) M_PMWngEnc2 Axis No.(1 to 8) Detection level Integer type (encoder communication...

  • Page 101: Melfa Smart Plus

    13.1.3. MELFA Smart Plus <MELFA Smart Plus card> Page Variable name Array Details Attribute Data type, designation Unit Integer type M_SmartPlus MELFA Smart Plus function － usage status Character string － C_SmartPlus MELFA Smart Plus function name type *1) Attributes in the table, R: Read only *2) For the Robot (system) status variable of MELFA Smart Plus card, refer to the separate volume, "Instruction Manual/MELFA Smart Plus".

  • Page 102: Consumption Degree Calculation Function

    13.2. Consumption degree calculation function 13.2.1. Serial number C_RBSerial: Robot body serial number [Function] Returns the serial number of the robot body. [Format] Example) <String variable> = C_RBSerial(<Mechanism number>) [Terminology] <String variable> Specify the string variable to assign. <Mechanism number> Set the mechanism number.
  • Page 103 C_RCSerial: Controller serial number [Function] Returns the serial number of the robot controller. [Format] Example) <String variable> = C_RCSerial [Terminology] <String variable> Specify the string variable to assign. [Sample] 1 C1$ = C_RCSerial 'The serial number of the robot controller is set in C1$. [Explanation] (1) Returns the serial number of the robot controller.

  • Page 104: Operating Information

    13.2.2. Operating information M_PowOnTime: Power ON time [Function] Returns the cumulative time of power supply ON of robot controller from a last overhaul. [hour] [Format] Example) <Numeric variable> = M_PowOnTime [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PowOnTime 'The cumulative time of power ON of the robot controller is set in M1.
  • Page 105 M_SrvOnTime: Servo ON time [Function] Returns the cumulative time of servo ON of the robot body from a last overhaul. [hour] [Format] Example) <Numeric variable> = M_SrvOnTime [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_SrvOnTime 'The cumulative servo ON time of the robot body (mechanism 1) is set in M1. [Explanation] (1) Returns the cumulative time of servo ON of the robot body (mechanism 1).
  • Page 106 M_PrgTime: Operation time [Function] Returns the cumulative time of the operating time of the robot controller from a last overhaul. [hour] [Format] Example) <Numeric variable> = M_PrgTime [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PrgTime 'The operation time of the robot controller is set in M1.
  • Page 107 M_MovTime: Actual operation time [Function] Returns the cumulative time of the moving time of the robot body from a last overhaul. [hour] [Format] Example) <Numeric variable> = M_MovTime [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_MovTime 'The actual operation time of the robot body (mechanism 1) is set in M1.
  • Page 108 M_SrvOnNum: Servo ON count [Function] Returns the cumulative count of the servo ON of the robot body from a last overhaul. [Format] Example) <Numeric variable> = M_SrvOnNum [Terminology] <Numeric variable> Specify the joint type variable to assign. [Sample] 1 M1 = M_SrvOnNum 'The servo ON count of the robot body (mechanism 1) is set in M1. [Explanation] (1) Returns the servo ON count of the robot body (mechanism 1).
  • Page 109 M_MtRotNum: Motor cumulative rotation count [Function] Returns the cumulative number of rotations of the motor of the robot body from a last overhaul of the specified axis. [Format] Example) <Numeric variable> = M_MtRotNum(<Axis number>) [Terminology] <Numeric variable> Specify the joint type variable to assign. <Axis number>...

  • Page 110: Maintenance Log

    13.2.3. Maintenance Log M_PMLogGrs: Maintenance count (grease) [Function] Returns the maintenance count (reset count) of the grease of the specified axis. [Format] Example) <Numeric variable> = M_PMLogGrs(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis for which to get a log. (1 to 6) When omitted, 1 is used.
  • Page 111 M_PMLogBlt: Maintenance count (timing belt) [Function] Returns the maintenance count (reset count) of the timing belt of the specified axis. [Format] Example) <Numeric variable> = M_PMLogBlt(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis for which to get a log. (1 to 6) When omitted, 1 is used.
  • Page 112 M_PMLogDec: Maintenance count (reduction gear) [Function] Returns the maintenance count (reset count) of the decelerator of the specified axis. [Format] Example) <Numeric variable> = M_PMLogDec(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis for which to get a log. (1 to 6) When omitted, 1 is used.
  • Page 113 M_PMLogBrg: Maintenance count (bearing) [Function] Returns the maintenance count (reset count) of the bearing of the specified axis. [Format] Example) <Numeric variable> = M_PMLogBrg(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis for which to get a log. (1 to 6) When omitted, 1 is used.
  • Page 114 M_PMLogBss: Maintenance count (ball screw/ball spline) [Function] Returns the maintenance count (reset count) of the ball screw / ball spline of the specified axis. [Format] Example) <Numeric variable> = M_PMLogBss(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number>...
  • Page 115 M_PMLogOH: Maintenance count (overhaul (servo ON time)) [Function] Returns the maintenance count (reset count) of the overhaul. [Format] Example) <Numeric variable> = M_PMLogOH [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMLogOH 'The maintenance count of overhaul is set in M1. [Explanation] (1) Returns the maintenance count (reset count) of overhaul for the robot body (mechanism 1).
  • Page 116 C_PMLogGrs: Maintenance log (grease) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the grease. [Format] Example) <String variable> = C_PMLogGrs(<Log number>, <Axis number>) [Terminology] <String variable> Specify the string variable to assign. <Log number>...
  • Page 117 C_PMLogBlt: Maintenance log (timing belt) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the timing belt. [Format] Example) <String variable> = C_PMLogBlt(<Log number>, <Axis number>) [Terminology] <String variable> Specify the string variable to assign. <Log number>...
  • Page 118 C_PMLogDec: Maintenance log (reduction gear) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the decelerator. [Format] Example) <String variable> = C_PMLogDec(<Log number>, <Axis number>) [Terminology] <String variable> Specify the string variable to assign. <Log number>...
  • Page 119 C_PMLogBrg: Maintenance log (bearing) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the bearing. [Format] Example) <String variable> = C_PMLogBrg(<Log number>, <Axis number>) [Terminology] <String variable> Specify the string variable to assign. <Log number>...
  • Page 120 C_PMLogBss: Maintenance log (ball screw/ball spline) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the ball screw / ball spline. [Format] Example) <String variable> = C_PMLogBss(<Log number>, <Axis number>) [Terminology] <String variable> Specify the string variable to assign.
  • Page 121 C_PMLogOH: Maintenance log (overhaul (servo ON time)) [Function] Returns the maintenance log data (the reset date and time, the cumulative time of servo ON when resetting) of the overhaul. [Format] Example) <String variable> = C_PMLogOH(<Log number>) [Terminology] <String variable> Specify the string variable to assign. <Log number>...

  • Page 122: Consumption Degree

    13.2.4. Consumption degree M_PMCsmMnt: Consumption degree (mechanism total (maintenance parts)) [Function] Returns the overall consumption degree of the maintenance part (grease and timing belt). [%] [Format] Example) <Numeric variable> = M_PMCsmMnt [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMCsmMnt 'The overall consumption degree of the maintenance parts is set in M1.
  • Page 123 M_PMCsmOH: Consumption degree (mechanism total (overhaul parts)) [Function] Returns the overall consumption degree of the overhaul part (decelerator, bearing and ball screw / ball spline). [%] [Format] Example) <Numeric variable> = M_PMCsmOH [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMCsmOH 'The overall consumption degree of the overhaul parts is set in M1.
  • Page 124 M_PMCsmGrs: Consumption degree (grease) [Function] Returns the consumption degree of the grease of the specified axis. [%] [Format] Example) <Numeric variable> = M_PMCsmGrs(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 125 M_PMCsmBlt: Consumption degree (timing belt) [Function] Returns the consumption degree of the timing belt of the specified axis. [%] [Format] Example) <Numeric variable> = M_PMCsmBlt(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 126 M_PMCsmDec: Consumption degree (reduction gear) [Function] Returns the consumption degree of the decelerator of the specified axis. [%] [Format] Example) <Numeric variable> = M_PMCsmDec(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 127 M_PMCsmBrg: Consumption degree (bearing) [Function] Returns the consumption degree of the bearing of the specified axis. [%] [Format] Example) <Numeric variable> = M_PMCsmBrg(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 128 M_PMCsmBss: Consumption degree (ball screw/ball spline) [Function] Returns the consumption degree of the ball screw / ball spline of the specified axis. [%] [Format] Example) <Numeric variable> = M_PMCsmBss(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count.
  • Page 129 M_PMRmnMnt: Remaining time (mechanism total (maintenance parts)) [Function] Returns the remaining time until maintenance of the maintenance part (grease and timing belt). [hour] [Format] Example) <Numeric variable> = M_PMRmnMnt [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMRmnMnt 'The remaining time up to the maintenance of the maintenance part is set in M1. [Explanation] (1) Returns the remaining time up to the maintenance of the maintenance parts (grease, timing belt) of the robot body (mechanism 1).
  • Page 130 M_PMRmnSrv: Remaining time (servo ON time) [Function] Returns the remaining time until specified time of an overhaul of the cumulative time of servo ON. [hour] [Format] Example) <Numeric variable> = M_PMRmnSrv [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMRmnSrv 'The remaining time up to overhaul of the overhaul part is set in M1.

  • Page 131: Consumption Status

    13.2.5. Consumption status M_PMStsMnt: Consumption status (mechanism total (maintenance parts)) [Function] Returns the consumption status of the maintenance part (grease and timing belt). [Format] Example) <Numeric variable> = M_PMStsMnt [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMCsmMnt 'The overall consumption degree of the maintenance parts is set in M1. [Explanation] (1) Returns the consumption status of the maintenance part (grease, timing belt) of the robot body (mechanism 1).
  • Page 132 M_PMStsOH: Consumption status (mechanism total (overhaul parts)) [Function] Returns the consumption status of the overhaul part (decelerator, bearing and ball screw / ball spline). [Format] Example) <Numeric variable> = M_PMStsOH [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMStsOH 'The consumption status of the overhaul part is set in M1.
  • Page 133 M_PMStsGrs: Consumption status (grease) [Function] Returns the consumption status of grease of the specified axis. [Format] Example) <Numeric variable> = M_PMStsGrs(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 134 M_PMStsBlt: Consumption status (timing belt) [Function] Returns the consumption status of timing belt of the specified axis. [Format] Example) <Numeric variable> = M_PMStsBlt(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 135 M_PMStsDec: Consumption status (reduction gear) [Function] Returns the consumption status of decelerator of the specified axis. [Format] Example) <Numeric variable> = M_PMStsDec(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 136 M_PMStsBrg: Consumption status (bearing) [Function] Returns the consumption status of bearing of the specified axis. [Format] Example) <Numeric variable> = M_PMStsBrg(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 137 M_PMStsBss: Consumption status (ball screw/ball spline) [Function] Returns the consumption status of ball screw / ball spline of the specified axis. [Format] Example) <Numeric variable> = M_PMStsBss(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 138 M_PMStsSrv: Consumption status (servo ON time) [Function] Returns the arrival status to the specified time of an overhaul of the cumulative time of servo ON. [Format] Example) <Numeric variable> = M_PMStsSrv [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMStsSrv 'The arrival status to the specified overhaul time is set in M1.

  • Page 139: Notification

    13.2.6. Notification M_PMRptGrs: Notification pause status (grease) [Function] Returns the stop status of warning / signal output, of grease consumption of the specified axis. [Format] Example) <Numeric variable> = M_PMRptGrs<Axis number> [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number>...
  • Page 140 M_PMRptBlt: Notification pause status (timing belt) [Function] Returns the stop status of warning / signal output, of timing belt consumption of the specified axis. [Format] Example) <Numeric variable> = M_PMRptBlt<Axis number> [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number>...
  • Page 141 M_PMRptDec: Notification pause status (reduction gear) [Function] Returns the stop status of warning / signal output, of decelerator consumption of the specified axis. [Format] Example) <Numeric variable> = M_PMRptDec<Axis number> [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis for which to get a log.
  • Page 142 M_PMRptBrg: Notification pause status (bearing) [Function] Returns the stop status of warning / signal output, of bearing consumption of the specified axis. [Format] Example) <Numeric variable> = M_PMRptBrg<Axis number> [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis for which to get a log.
  • Page 143 M_PMRptBss: Consumption status (ball screw/ball spline) [Function] Returns the stop status of warning / signal output, of ball screw / ball spline consumption of the specified axis. [Format] Example) <Numeric variable> = M_PMRptBss<Axis number> [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number>...
  • Page 144 M_PMRptSrv: Notification pause status (servo ON time) [Function] Returns the stop status of warning / signal output, of arrival status to the specified time of an overhaul of the cumulative time of servo ON. [Format] Example) <Numeric variable> = M_PMRptSrv [Terminology] <Numeric variable>...

  • Page 145: Abnormality Detection Function

    13.3. Abnormality detection function 13.3.1. Abnormality detection log M_PMLogScr: Log data count of abnormality detection log [Function] Returns the number of log data of the abnormality detection log (the reduction gear and encoder). [Format] Example) <Numeric variable> = M_PMLogScr [Terminology] <Numeric variable>...
  • Page 146 M_PMLogD：Abnormality detection log data (reduction gear) [Function] Returns the score from the abnormality detection log (reduction gear) of the specified axis. [Syntax] Example) <Numeric variable> = M_PMLogDrv(<Log number>, <Axis number>) [Term] <Numeric variable> Specify the numeric variable to assign. <Log number> Specify the number of the log to retrieve. (1 to 365) The greater the number, the older the log data.
  • Page 147 M_PMLogE1：Abnormality detection log data (encoder data abnormality) [Function] Returns the score from the abnormality detection log data (encoder data abnormality) of the specified axis. [Syntax] Example) <Numeric variable> = M_PMLogEnc1(<Log number>, <Axis number>) [Term] <Numeric variable> Specify the numeric variable to assign. <Log number>...
  • Page 148 M_PMLogE2：Abnormality detection log data (encoder communication abnormality) [Function] Returns the score from the abnormality detection log (encoder communication abnormality) of the specified axis. [Syntax] Example) <Numeric variable> = M_PMLogEnc2(<Log number>, <Axis number>) [Term] <Numeric variable> Specify the numeric variable to assign. <Log number>...

  • Page 149: Score

    13.3.2. Score M_PMScrDrv: Score (reduction gear) [Function] Returns the score of reduction gear of the specified axis. [Format] Example) <Numeric variable> = M_PMScrDrv(<Axis numbe>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 150 M_PMScrEnc1: Score (encoder data abnormality) [Function] Returns the score of encoder data error of the specified axis. [Format] Example) <Numeric variable> = M_PMScrEnc1(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 151 M_PMScrEnc2: Score (encoder communication abnormality) [Function] Returns the score of encoder communication error of the specified axis. [Format] Example) <Numeric variable> = M_PMScrEnc2(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.

  • Page 152: Abnormality Detection Status

    13.3.3. Abnormality detection status M_PMStsDrv: Abnormality detection status (reduction gear) [Function] Returns the abnormality detection status of reduction gear of the specified axis. [Format] Example) <Numeric variable> = M_PMStsDrv(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count.
  • Page 153 M_PMStsEnc1: Abnormality detection status (encoder data abnormality) [Function] Returns the abnormality detection status of encoder data error of the specified axis. [Format] Example) <Numeric variable> = M_PMStsEnc1(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 154 M_PMStsEnc2: Abnormality detection status (encoder communication abnormality) [Function] Returns the abnormality detection status of encoder communication error of the specified axis. [Format] Example) <Numeric variable> = M_PMStsEnc2(<Axis number>) [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 155 M_PMStsBat: Abnormality detection status (battery voltage status) [Function] Returns the abnormality detection status of battery voltage. [Format] Example) <Numeric variable> = M_PMStsBat [Terminology] <Numeric variable> Specify the numeric variable to assign. [Sample] 1 M1 = M_PMStsBat 'The battery voltage status is set in M1. [Explanation] (1) Returns the battery voltage status of the robot body (mechanism 1).

  • Page 156: Notification

    13.3.4. Notification M_PMRptDrv: Notification pause status (reduction gear) [Function] Returns the stop status of warning / signal output, of abnormality detection of reduction gear of the specified axis. [Format] Example) <Numeric variable> = M_PMRptDrv<Axis number> [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number>...
  • Page 157 M_PMRptEnc1: Notification pause status (encoder data abnormality) [Function] Returns the stop status of warning / signal output, of abnormality detection of encoder data error of the specified axis. [Format] Example) <Numeric variable> = M_PMRptEnc1<Axis number> [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number>...
  • Page 158 M_PMRptEnc2: Notification pause status (encoder communication abnormality) [Function] Returns the stop status of warning / signal output, of abnormality detection of encoder communication error of the specified axis. [Format] Example) <Numeric variable> = M_PMRptEnc2<Axis number> [Terminology] <Numeric variable> Specify the numeric variable to assign. <Axis number>...

  • Page 159: Detection Level

    13.3.5. Detection level M_PMWngDrv：Detection level (reduction gear abnormality detection) [Function] Returns the detection level (reduction gear abnormality detection) of the specified axis. [Syntax] Example) <Numeric variable> = M_PMWngDrv<Axis number> [Term] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to retrieve the detection level (reduction gear abnormality detection) from.
  • Page 160 M_PMWngEnc1：Detection level (encoder data abnormality detection) [Function] Returns the detection level (encoder data abnormality detection) of the specified axis. [Syntax] Example) <Numeric variable> = M_PMWngEnc1<Axis number> [Term] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to retrieve the detection level (encoder data abnormality detection) from.
  • Page 161 M_PMWngEnc2：Detection level (encoder communication abnormality detection) [Function] Returns the detection level (encoder communication abnormality detection) of the specified axis. [Syntax] Example) <Numeric variable> = M_PMWngEnc2<Axis number> [Term] <Numeric variable> Specify the numeric variable to assign. <Axis number> Specify the joint axis to retrieve the detection level (encoder communication abnormality detection) from.

  • Page 162: Parameter

    14. Parameter 14.1. Common to predictive maintenance functions (*1 Attributes in the table, R: Read only, W: Write only, R/W: Read/write) Parameter Number of Factory Attribute Parameter Details explanation name elements setting Pause method of PMSTPWAY Integer 1 Specify the pause method of warning warning occurrence occurrence or warning signal output of the predictive/preventive maintenance...

  • Page 163: Consumption Degree Calculation Function

    14.2. Consumption degree calculation function 14.2.1. Setting parameters (*1 Attributes in the table, R: Read only, W: Write only, R/W: Read/write) Parameter Number of Factory Attribute Parameter Details explanation name elements setting Warning PMWNGDAY Integer 2 Specify the warning remaining number (30, 16) remaining of days and operation time of a day of...
  • Page 164 Parameter Number of Factory Attribute Parameter Details explanation name elements setting Notification PMRPTMNT Integer 2 Specify the notification method of the 0, 0 predictive/preventive maintenance method of function. (Maintenance part maintenance consumption) part Specify the behavior when the warning consumption occurrence detection level by the predictive/preventive maintenance function exceeded the remaining time...

  • Page 165: Data Acquisition Parameters

    14.2.2. Data acquisition parameters The following operations are possible using the data acquisition parameters of the consumption degree calculation function. Get the integration time and accumulation count from the previous overhaul. (Total) Get the consumption degree [%] of the target part. (Total/for each joint axis) Get the remaining time [h] to the recommended maintenance time of the target part.
  • Page 166 Parameter Number of Attribute Parameter Details explanation name elements Consumption degree of the Consumption degree of the CSMPMGRS Real predictive/preventive predictive/preventive maintenance function number 8 maintenance function (grease) (grease) (Up to three decimal places) * "-1" when the predictive/preventive maintenance function is disabled, and "0" when the axis does not exist.
  • Page 167 <Getting consumption status> Parameter Number of Attribute Parameter Details explanation name elements Consumption status of the STSPMMNT Integer 1 Consumption status of the predictive/preventive predictive/preventive maintenance function maintenance function (mechanism total (maintenance parts)) (mechanism total -1: The predictive/preventive maintenance (maintenance parts)) function is disabled 0: The remaining time exceeded the warning occurrence remaining time.
  • Page 168 Parameter Number of Attribute Parameter Details explanation name elements Consumption status of the STSPMSRV Integer 1 Consumption status of the predictive/preventive predictive/preventive maintenance function maintenance function (servo ON time (at overhaul implementation)) (servo ON time (at overhaul The meaning of the value is the same as that implementation)) of the mechanism total (maintenance parts) (STSPMMNT).

  • Page 169: Operation Parameters

    14.2.3. Operation parameters The following operations are possible using the parameters for operation of the consumption degree calculation function. Reset consumption degree reset of the target part. (For each joint axis) Pause occurrence of warnings until consumption degree reset of the target part. (For each joint axis) Get the consumption degree warning occurrence status or pause status of the target part.
  • Page 170 Parameter Number of Attribute Parameter Details explanation name elements Resets total accumulated data related to the Operating information RSTPMOH Integer 1 operating information (integration time, (integration time, accumulation count) of the accumulation count) total accumulated data reset predictive/preventive maintenance function. (Used at the time of overhaul.) In order to prevent mis-operation, the value upon reading is [-1] (out of setting range).
  • Page 171 Parameter Number of Attribute Parameter Details explanation name elements Consumption degree Specifies pause of warning RPTPMDEC Integer 8 (reduction gear) occurrence/warning signal output of the consumption degree (reduction gear) of Specifying pause of each joint axis. warning occurrence/warning * The meaning of reading and writing is the signal output same as that of grease (RPTPMGRS).
  • Page 172 <Maintenance log> Parameter Number of Attribute Parameter Details explanation name elements Specifying data to get LOGPMNO Integer 2 Specifies the data to get the maintenance log maintenance log of the predictive/preventive maintenance function. It is possible to get specified data (log number, joint axis number) for each part using the following virtual parameters.
  • Page 173 Parameter Number of Attribute Parameter Details explanation name elements Getting maintenance log LOGPMOH Character Gets maintenance log (overhaul) data. (overhaul) data string 6 Element 5: Servo ON time [h] at reset (integer) * If a log number with which there is no recorded data or nonexistent joint axis number is specified, the output becomes as follows:...

  • Page 174: Abnormality Detection Function

    14.3. Abnormality detection function 14.3.1. Setting parameters (*1 Attributes in the table, R: Read only, W: Write only, R/W: Read/write) Attribute Parameter Number of Factory Parameter Details explanation name elements setting Detection level PMWNGDRV Integer 6 Specify the detection level of the -1, -1, -1, (reduction gear predictive maintenance function...

  • Page 175: Data Acquisition Parameters

    14.3.2. Data acquisition parameters The following operations are possible using the data acquisition parameters of the abnormality detection function. Get the score of the target part (For each joint axis) Get the abnormal status of the target part (For each joint axis) (*1 Attributes in the table ...
  • Page 176 Parameter Number of Attribute Parameter Details explanation name elements Abnormality detection status of the predictive Abnormality STSPMBAT Integer 1 maintenance function (battery voltage) detection status (battery voltage) -1: The predictive maintenance function is disabled 0: Normal 1: Battery voltage low 2: Battery voltage has run out Parameter 174...

  • Page 177: Operation Parameters

    14.3.3. Operation parameters The following operations are possible using the operation parameters of the abnormality detection function. Score maximum value reset (encoder data abnormality, encoder communication abnormality) (For each joint axis) Pauses occurrence of a warning until maintenance of the target part. (For each joint axis) Gets the warning occurrence status or pause status of the target part.
  • Page 178 Attribute Parameter Number of Details explanation Parameter name elements Encoder data RPTPMEN1 Integer 8 Specify pause of warning occurrence/warning signal abnormality output of the abnormality detection (encoder data detection abnormality) of each joint axis. Pause of * The meaning of reading and writing is the same as that warning of the reduction gear (RPTPMDRV).
  • Page 179 Attribute Parameter Number of Parameter Details explanation name elements Getting LOGPMDRV Character Gets the abnormality detection log (reduction gear) abnormality string 10 data. detection log Element 1: Log number (1 to 365) (reduction gear) Element 2: Date (YYYY/MM/DD) data Element 3: The maximum score value of the specified day (J1 axis) (Up to three decimal places) Element 4: The maximum score value of the specified...

  • Page 180: Dedicated Input/Output Signals

    15. Dedicated input/output signals This section describes dedicated input/output signals related to the predictive maintenance function. To use those signals, from the Predictive Maintenance screen, click the [Setting] - [Signal] screen and (Note 1) assign a signal number to the respective parameter. For the setting procedure for signal numbers, refer to "3 Startup and initial settings, 3.2.3 Setting signals".
  • Page 181 Signal number at factory Parameter Signal Category Function default name level CR800-R/Q CR800-D -1 (No -1 (No − − Input meaning), meaning), Maintenance warning of predictive/preventive maintenance PMSIGGRS (grease) − Output Outputs the effect that the remaining time (remaining recommended maintenance time) of the grease exceeded the warning occurrence detection level.
  • Page 182 <Consumption degree reset> Signal number at factory Parameter Signal default Category Function name level CR800-R/Q CR800-D Consumption degree reset of predictive/preventive maintenance (grease) − Input Resets the grease consumption degree information. PMRSTGRS * The reset target axis is specified in IODATA or DIODATA using the axis bit pattern.
  • Page 183 <Pausing warning occurrence/signal output> Signal number at factory Parameter Signal default Category Function name level CR800-R/Q CR800-D Pause of warning and warning signal output (grease) − Input * The pause target axis is specified in IODATA or PMSTPGRS DIODATA using the axis bit pattern. Pause of unspecified axes is canceled.

  • Page 184: Abnormality Detection Function

    15.2. Abnormality detection function This function allows you to check the abnormality detection status using dedicated output signals. (Use parameters to specify the detection level or presence of signal output.) • The signal changes only when Element 2 of the PMRPTSCR parameter is "1" Caution (output).
  • Page 185 <Pausing warning occurrence/signal output> Signal number at factory Parameter Signal Category Function default name level CR800-R/Q CR800-D Pause of warning and warning signal output (reduction gear abnormality detection) − Input * The axis bit pattern is specified by the IODATA or PMSTPDRV DIODATA parameter.

  • Page 186: Troubleshooting

    16. Troubleshooting 16.1. Error number list This section describes the cause and countermeasure to take for the error numbers when errors related to the predictive maintenance function occurs. In event of an error, refer to this chapter and take appropriate action.

  • Page 187: Consumption Degree Calculation Function

    16.1.2. Consumption degree calculation function In case the remaining time up to the recommended replacement/maintenance time of each part or the remaining time up to the specified overhaul time exceeded the remaining time of warning occurrence specified by the "PMWNGDAY" parameter, or the setting of the dedicated output signal is incorrect, the following warnings will occur.
  • Page 188 Error number Causes of the error and its countermeasures Upper four Lower five digits digits Error Illegal parameter (PMSIGGRS) message Cause The parameter setting is illegal Correct the parameter Measures Error Illegal parameter (PMSIGBLT) message The parameter setting is illegal Cause Correct the parameter Measures...
  • Page 189 Error number Causes of the error and its countermeasures Upper four Lower five digits digits Error Illegal parameter (PMRSTNEW) message The parameter setting is illegal Cause Correct the parameter Measures Error Illegal parameter (PMSTPGRS) message The parameter setting is illegal Cause Correct the parameter Measures...

  • Page 190: Abnormality Detection Function

    16.1.3. Abnormality detection function If the score exceeded the detection level specified by the parameter "PMWNGDRV", "PMWNGEN1", or "PMWNGEN2", or if the setting of the dedicated output signal is incorrect, the following warnings will occur. However, the score warning is limited to those permitted to occur by the "PMRPTSCR" parameter. "Score"...
  • Page 191 Error number Causes of the error and its countermeasures Upper four Lower five digits digits Error Illegal parameter (PMSTPEN1) message Cause The parameter setting is illegal Measures Correct the parameter H.6640 99000 Error Illegal parameter (PMSTPEN2) message Cause The parameter setting is illegal Measures Correct the parameter Error...

  • Page 192: Melfa Smart Plus Card

    16.1.4. MELFA Smart Plus card Indicates the error number related to the MELFA Smart Plus card. Error number Error cause and measures Error message Cannot use the MELFA Smart Plus. L3780 Cause Invalid MELFA Smart Plus. Measures Check the MELFA Smart Plus card or parameter. Error message Cannot use the MELFA Smart Plus.
  • Page 193 Troubleshooting 191...
  • Page 194 Apr., 2019 MEE Printed in Japan on recycled paper. Specifications are subject to change without notice.

This manual is also suitable for:

Cr800-r seriesCr800-q series

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