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Mitsubishi MELFA RH-3SDHR3515 Instruction Manual
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Mitsubishi MELFA RH-3SDHR3515 Instruction Manual

Mitsubishi MELFA RH-3SDHR3515 Instruction Manual

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Mitsubishi Industrial Robot
RH-3SDHR3515/3512C/3512W
INSTRUCTION MANUAL
ROBOT ARM SETUP & MAINTENANCE
BFP-A8839-D

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Summary of Contents for Mitsubishi MELFA RH-3SDHR3515

  • Page 1 Mitsubishi Industrial Robot RH-3SDHR3515/3512C/3512W INSTRUCTION MANUAL ROBOT ARM SETUP & MAINTENANCE BFP-A8839-D...
  • 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. CAUTION Use the robot within the environment given in the specifications. Failure to do so could lead to a drop or reliability or faults. (Temperature, humidity, atmosphere, noise environment, etc.) CAUTION Transport the robot with the designated transportation posture.
  • Page 5 CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's main power OFF. If the robot controller main power is turned OFF during automatic operation, the robot accuracy could be adversely affected. Moreover, it may interfere with the peripheral device by drop or move by inertia of the arm. CAUTION Do not turn off the main power to the robot controller while rewriting the internal information of the robot controller such as the program or parameters.
  • Page 6 *S series: RH-6SH/12SH/18SH/20SH series/RH-3SHR series CAUTION Be careful of interference with peripheral equipment. Especially don't give a shock to the ball screw shaft (J3 axis). The ball screw shaft may be damaged. Collision detection function is valid condition for both of automatic and jog operation at shipping in RH- 3SHR series.
  • Page 7 Revision history Date of Point Instruction Manual No. Revision Details 2010-11-19 BFP-A8839 ・ First print 2010-12-02 BFP-A8839-A ・ Error in writing was corrected. (Reference figure number in "3.1 Installing the solenoid valve set") 2011-02-02 BFP-A8839-B ・ The note of installing the hand input cable was added. ・...
  • Page 8 ■ Introduction Thank you for purchasing the Mitsubishi industrial robot. This instruction manual explains the unpacking methods, installation, basic operation, maintenance and inspection of the robot arm. Always read through this manual before starting use to ensure correct usage of the robot.

  • Page 9: Table Of Contents

    CONTENTS Page 1 Before starting use ..................................1-1 1.1 Using the instruction manuals ............................1-1 1.1.1 The details of each instruction manuals ........................ 1-1 1.1.2 Symbols used in instruction manual ........................1-2 1.2 Safety Precautions ................................. 1-3 1.2.1 Precautions given in the separate Safety Manual ..................... 1-4 2 Unpacking to Installation ................................
  • Page 10 CONTENTS Page 5.3.3 Inspection, maintenance and replacement of timing belt ................5-68 (1) Timing belt replacement period ......................... 5-68 (2) Inspection and maintenance of J1 axis timing belt ..................5-69 (3) Inspection and maintenance of J2 axis timing belt ..................5-70 (4) Inspection and maintenance of J3 axis timing belt ..................

  • Page 11: Before Starting Use

    1Before starting use 1 Before starting use This chapter explains the details and usage methods of the instruction manuals, the basic terminology and the safety precautions. 1.1 Using the instruction manuals 1.1.1 The details of each instruction manuals The contents and purposes of the documents enclosed with this product are shown below. Use these documents according to the application.

  • Page 12: Symbols Used In Instruction Manual

    1Before starting use 1.1.2 Symbols used in instruction manual The symbols and expressions shown in Table 1-1 are used throughout this instruction manual. Learn the meaning of these symbols before reading this instruction manual. Table 1-1 ： Symbols in instruction manual Terminology Item/Symbol Meaning...

  • Page 13: Safety Precautions

    1Before starting use 1.2 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. (This also applies to maintenance work with the power source turned ON.) Enforcement of safety training CAUTION...

  • Page 14: Precautions Given In The Separate Safety Manual

    1Before starting use 1.2.1 Precautions given in the separate Safety Manual The points of the precautions given in the separate "Safety Manual" are given below. Refer to the actual "Safety Manual" for details. DANGER If the automatic operation of the robot is operated by two or more control equipment, design the right management of operation of each equipment of the customer.
  • Page 15 1Before starting use CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's main power OFF. If the robot controller main power is turned OFF during automatic operation, the robot accuracy could be adversely affected. CAUTION Do not turn off the main power to the robot controller while rewriting the internal information of the robot controller such as the program or parameters.

  • Page 16: Unpacking To Installation

    2Unpacking to Installation 2 Unpacking to Installation 2.1 Confirming the product The standard configuration of the robot arm, part of the purchased product, is shown in Table 2-1. Confirm the parts. Users who have purchased optional products should refer to the separate "Standard Specifications". Table 2-1 ：...

  • Page 17: Installation

    2Unpacking to Installation 2.2 Installation 2.2.1 Unpacking <3> Packing <2> Upper cover <1> Tape material (two) (Cardboard) Packing box <6> Tape (two) Cut the tape Remove the upper cover. Remove the packing material. Robot-arm base section <5> Packing material <4>hanging tools Open the vinyl.

  • Page 18: Transportation Procedures(Transporting With A Crane)

    2Unpacking to Installation 2.2.2 Transportation procedures(Transporting with a crane) Mass RH-3SDHR3515: Approx. 24kg RH-3SDHR3512C/3512W: Approx. 28kg <4> Hanging tools (two places) <7> Fixing plate Note) Install Hoisting Transport <9> Installation bolt, Nut <8> Installation stage (four places) Note) Be cautious of interference at the end of the shaft.

  • Page 19: Installation Procedures

    2Unpacking to Installation 2.2.3 Installation procedures The installation procedure of the robot arm is shown below. *1） General environment type 80mm Clean/Waterproof type: 200mm Maintenance space (Installation reference) 4-φ9 installation hole 2-M12 hole for hanging tools 4-M8 hole for the jack- Installation stage Maintenance space (example)
  • Page 20 2Unpacking to Installation 6) If you operate the robot at a high speed, reaction forces are applied to the installation stand by the robot's operation. Make sure that the installation stand on which the robot is placed has sufficient strength and rigidity.

  • Page 21: Grounding Procedures

    2Unpacking to Installation 2.2.4 Grounding procedures (1) Grounding methods 1) There are three grounding methods as shown in Fig. 2-4, but the dedicated grounding (Fig. 2-4 (a)) should be used for the robot arm and controller when possible. (Refer to the separate " Controller Controller Controller Controller...

  • Page 22: Connecting With The Controller

    2Unpacking to Installation 2.2.5 Connecting with the controller Robot arm base section ロボット本体ベース部 Controller ロボットコントローラ CR2DA-700 Motor signal cable (7m) モータ信号ケーブル（7m） (CN2) (CN2用) Motor power cable (7m) モータ電源ケーブル（7m） (CN1) (CN1用) Fig.2-6 ： Connecting the machine cables Carry out the following procedure after installing the controller referring to the separate "Controller Setup, Basic Operation and Maintenance"...
  • Page 23 2Unpacking to Installation CAUTION The machine cable connectors are dedicated for the controller side and robot arm side, so take special care when connecting. If connected incorrectly, the connector pins could bend or break. Thus, even if connected correctly, the robot will not operate correctly, creating a dangerous situation.

  • Page 24: Spare Wiring

    2Unpacking to Installation 2.3 Spare wiring As spare wiring four pairs of cab tire cables (AWG#27(0.1mm ), Total is eight cores both) are preinstalled between the base section and the No.2 arm rear section. Customer can utilize it. The cable clamp (customer preparation) is necessary to use.
  • Page 25 2Unpacking to Installation CAUTION When No.2 arm cover is installed, please keep too much load from being applied to the cables inside the robot, and the air hoses. If too much load is added, the breaking of a wire and the air hose break, and the robot cannot operate normally.

  • Page 26: Base Area

    2Unpacking to Installation 2.3.2 Base area 1) Remove the base cover B (R). Remove base cover B (R) ベースカバーB（R)を外す ベース部 Base section Cable tie 結束バンド (If length is short cut it.) （長さ不足時は解いてください） Grommet グロメット Spare wire (ADD) 予備配線（ADD） Spare wiring 予備配線...
  • Page 27 2Unpacking to Installation CAUTION When base cover B (R) is installed, please keep too much load from being applied to the cables inside the robot, and the air hoses. If too much load is added, the breaking of a wire and the air hose break, and the robot cannot operate normally.

  • Page 28: Setting The Origin

    2Unpacking to Installation 2.4 Setting the origin The origin is set so that the robot can be used with a high accuracy. After purchasing the robot, always carry out this step before starting work. This step must also be carried out if the combination of robot and controller being used is changed.

  • Page 29: Setting The Origin With The Origin Data Input Method

    2Unpacking to Installation 2.4.2 Setting the origin with the origin data input method (1) Confirming the origin data ● Origin data history table (Origin Data History) Serial No.ES804008 The origin data to be input is noted in the Date Default .

  • Page 30: Preparing The T/B

    2Unpacking to Installation (3) Preparing the T/B Next, prepare to use the T/B 1) Set the [MODE] switch on the front of the controller to "MANUAL". MODE MANUAL AUTOMATIC 2) Set the T/B [ENABLE] switch to "ENABLE". The menu selection screen will appear.

  • Page 31: Selecting The Origin Setting Method

    2Unpacking to Installation (4) Selecting the origin setting method <MENU> 1) Press the [4] key on the menu screen, and display the 1.FILE/EDIT 2.RUN ORIGIN/BRAKE screen. 3.PARAM. 4.ORIGIN/BRK 5.SET/INIT. 6.ENHANCED CLOSE <ORIGIN/BRAKE> 2) Press the [1] key on the ORIGIN/BRAKE screen, and 1.ORIGIN 2.BRAKE display the origin setting method selection screen.

  • Page 32: Inputting The Origin Data

    2Unpacking to Installation (5) Inputting the origin data T/B screen Origin data label Input the value confirmed in section Page 19, "(1) (D,J1,J2,J3,J4,J5,J6,J7,J8) Confirming the origin data". The correspondence of the origin data label value and axis <ORIGIN> DATA D:(■ to be input is shown in Fig.

  • Page 33: Installing The Base Cover B(L)

    2Unpacking to Installation <ORIGIN> DATA 5) After inputting all of the values, press the [EXE] key. The D:( V!%S29) origin setting confirmation screen will appear. J1( 06DTYY) J2( 2?HL9X) J3( 1CP55V) J4( T6!MSY) J5( Z21J%Z) J6( A12%Z0) ) J8( CLOSE 6) Press [F1] (Yes) to end the origin setting <ORIGIN>...

  • Page 34: Confirming The Operation

    2 Unpacking to Installation 2.5 Confirming the operation In this section, the robot will be moved manually using the T/B to confirm that the operation is correct. Moving the robot manually is called "jog operation". This operation includes the JOINT jog that moves each axis, the XYZ jog that moves along the base coordinate system, the TOOL jog that moves along the tool coordinate system, and the CYLNDER jog that moves along the circular arc.
  • Page 35 2 Unpacking to Installation ＋Z Base coordinate system reference orgin 直交座標系原点 ＋Y ＋X －X －Y ＋Z －Z End axis 先端軸 ＋Y * While maintaining the end axis posture, the axis ＋X moves straight along the base coordinate －X system. －Y Also, while maintaining the end axis position, the end axis posture changes..
  • Page 36 2 Unpacking to Installation ＋Z Base coordinate system reference orgin 直交座標系原点 ＋Y ＋X －X －Y ＋Z －Z End axis 先端軸 ＋Y ＋X * The axis moves straight along the base －X coordinate system. At this time, the end axis posture is not maintained. －Y J４軸...
  • Page 37 2 Unpacking to Installation ＋Z ＋Y ＋X －X －Y ＋Z WORK coordinate system －Z ＋Zw －Yw ＋Xw Tool length ツール長 * While maintaining the end axis posture, the axis moves straight along the work －Xw Controll coordinate system. point Also, while maintaining the end axis position, the end axis posture changes.

  • Page 38: Joint Jog Operation

    2 Unpacking to Installation (1) JOINT jog operation Select joint jog mode [JOG] Press the key and display the jog screen. ("JOG" is displayed on the screen bottom) <CURRENT> JOINT 100% M1 T0 Check that the "joint" in jog mode is displayed on +0.00 +0.00 the screen.
  • Page 39 2 Unpacking to Installation ・ When the [+Y (J2)] keys are pressed, the J2 axis will rotate in the plus direction. When the [-Y (J2)] keys are pressed, Rotate in the minus direction. ◇◆◇ When the robot is in the transportation posture ◇◆◇ The axes may be outside the movement area.

  • Page 40: Xyz Jog Operation

    2 Unpacking to Installation (2) XYZ jog operation Select XYZ jog mode [JOG] Press the key and display the jog screen. ("JOG" is displayed on the screen bottom) <CURRENT> JOINT 100% M1 T0 Check that the "XYZ" in jog mode is displayed on +0.00 +0.00 the screen.
  • Page 41 2 Unpacking to Installation ◇◆◇If the buzzer of T/B sounds and the robot does not move ◇◆◇ If it is going to move the robot across the operation range, the buzzer of T/B sounds and the robot does not move. In this case, please move to the counter direction. Changing the end axis posture ＋Z ＋Y...

  • Page 42: Tool Jog Operation

    2 Unpacking to Installation (3) TOOL jog operation Select TOOL jog mode [JOG] Press the key and display the jog screen. ("JOG" is displayed on the screen bottom) <CURRENT> JOINT 100% M1 T0 Check that the "TOOL" in jog mode is displayed +0.00 +0.00 on the screen.
  • Page 43 2 Unpacking to Installation ◇◆◇ When the robot is in the transportation posture ◇◆◇ There are directions from which linear movement is not possible from the transportation posture. In this case, the robot will not move. Refer to section "(1)JOINT jog operation" on page 28", and move the robot to a position where linear movement is possible, and then carry out XYZ jog.

  • Page 44: 3-Axis Xyz Jog Operation

    2 Unpacking to Installation (4) 3-axis XYZ jog operation Select XYZ456 jog mode [JOG] Press the key and display the jog screen. ("JOG" is displayed on the screen bottom) <CURRENT> JOINT 100% M1 T0 Check that the "XYZ456" in jog mode is +0.00 +0.00 displayed on the screen.
  • Page 45 2 Unpacking to Installation ◇◆◇ The flange surface end axis posture cannot be maintained with 3-axis XYZ jog. ◇◆◇ With 3-axis XYZ jog, the flange surface end axis posture (orientation) is not maintained when moving linearly in the X, Y or Z axis direction. Use XYZ jog to maintain the posture.

  • Page 46: Cylnder Jog Operation

    2 Unpacking to Installation jog operation CYLNDER Select cylindrical jog mode [JOG] Press the key and display the jog screen. ("JOG" is displayed on the screen bottom) <CURRENT> JOINT 100% M1 T0 Check that the "CYLNDER" in jog mode is +0.00 +0.00 displayed on the screen.
  • Page 47 2 Unpacking to Installation ＋Z ＋Y ＋X －Y －X Vertical 上下 －Z Radius 半径 円弧 － ＋ ＊ The position of the end axis will not change. ・ When the [+C (J6)] keys are pressed, The Z axis will rotate in the plus direction. When the [-C (J6)] keys are pressed, Rotates in the minus direction.

  • Page 48: Work Jog Operation

    2 Unpacking to Installation (6) Work jog operation Setting of the work coordinates system is necessary. By this jog operation, robot can be move along with the direction of work (or working table etc.), so teaching operations get easier. When jog operation, select by which work coordinates the robot moves The setting method of the work coordinates system using T/B (R32TB) is shown in the following.
  • Page 49 2 Unpacking to Installation 1) Select "6.ENHANCED" screen on the <MENU> screen. <MENU>　　 　 <EMHANCED>　　 　 1.FILE/EDIT 2.RUN 1.SQ DIRECT 2.WORK COORD. 3.PARAM. 4.ORIGIN/BRK 5.SET/INIT. 6.ENHANCED 　 123 CLOSE 　 123 CLOSE 2) Press the [2] keys in the menu screen and select "2. WORK COORD." <EMHANCED>　　...
  • Page 50 2 Unpacking to Installation Presses the function key corresponding to"Yes", the robot's current position is registered, and the registered coordinates value is displaye. Operation will be canceled if the [CLOSE] key is pressed. <WORK COORD> WORK NUMBER (2) <WORK COORD> WORK NUMBER (2) TEACHING POINT (WO) TEACHING POINT (WO)
  • Page 51 2 Unpacking to Installation Although setting of work coordinates is finishing above, confirmation of work coordinates can be done by press - ing the function key corresponding to "W GRID."([F2]) <WORK COORD> WORK NUMBER (2) <WORK COORD> WORK NUMBER (2) TEACHING POINT (WO) WORK COORDINATES DATA X: 214.12...
  • Page 52 2 Unpacking to Installation The jog movement based on work coordinates system ＋Z ＋Y ＋X －Y －X ＋Z Work coordinates system －Z ＋Zw －Yw ＋Xw Tool length ツール長 －Xw Controll point * The direction of the end axis will not change.
  • Page 53 2 Unpacking to Installation Changing the end axis posture ＋Z ＋Y ＋X －Y －X ＋Z Work coordinates system －Z ＋Zw －Yw ＋Xw Tool length ツール長 Controll point －Xw － ＋ * The position of the control point does not change. The end axis is －Z rotated.

  • Page 54: Installing The Option Devices

    3Installing the option devices 3 Installing the option devices 3.1 Installing the solenoid valve set Installation outline of the solenoid valve set of general environment specification is shown in Fig. 3-1 and is shown in Fig. 3-2 about clean / waterproof specification. <General environment type >...
  • Page 55 3Installing the option devices <Clean/ Waterproof type > (RH-3SDHR3512C/3512W) <7> P port <6> R port B port ４ ６ ８ １ ３ ５ ７ A port <1> Solenoid valve set <4> Hand output cable GR1,GR2 Solenoid valve set installation position 2-M5 Screw (for fixing) <13>...
  • Page 56 3Installing the option devices 1) Install the solenoid valve set <1> on the No.2 arm side. Fixing at the T slot on the No.2 arm side with two fixing screws and two nuts attached for T slots. Install in the position of 10mm from the arm end. 2) Connect the hand output cable within No.2 arm.
  • Page 57 3Installing the option devices *1） Screw (2-M5) and nut for T slots Nylon clamp Solenoid valve set (option) Air hose for secondary piping Air hose for secondary piping (customer preparation) (customer preparation) *1) Fixing the air hose (customer preparation) using the T slot by nylon clamp etc. Fig.3-4 ：...
  • Page 58 3Installing the option devices Table 3-1 ： Solenoid valve ports and hoses: Correspondence of couplings and hand ports Hand Hand port Solenoid valve port Solenoid valve used OPEN Hand 1 st row CLOSE OPEN Hand 2 nd row CLOSE OPEN Hand 3 rd row CLOSE...

  • Page 59: Installation Of Hand Tube

    3Installing the option devices 3.2 Installation of hand tube The installation procedure of the hand tube is as follows. In use of solenoid valve set and hand input cable optional, please operate with referring to the Page 44, "3.1 Installing the solenoid valve set" and the Page 53, "3.3 Installing the hand input cable"...
  • Page 60 3Installing the option devices 1) To protect the fixing place of the hand tube, roll the attached rubber sheet. If using the hand input cable, roll together. The hand tube and the hand input cable having the mark at the position which rolls the rubber sheet. The hand tube is the four places, a), b), c), and d) sequentially from the union side.
  • Page 61 3Installing the option devices 4) Install the union (φ 4 to φ3) side of the tube to secondary piping coupling (φ4 x 4 place) <2> on the No.2 arm inside motor cover <1>. The number of 1 to 4 is printed to the marking tube of the hand tube. Connect together with the number of coupling on 2nd arm.
  • Page 62 3Installing the option devices *On the Clean/ Waterproof specifica - tions seal the aperture of shaft end by liquefied gasket. Enlargement Hand flange Metal plate for tool Nylon clamp side fixing Rubber sheet Union (φ 4 to φ3) Tool Fig.3-8 ： Tool side fixing image of hand tube (example) 3-52 Installation of hand tube...

  • Page 63: Installing The Hand Input Cable

    3Installing the option devices 3.3 Installing the hand input cable The installation procedure of the hand input cable is as follows. In use of solenoid valve set and hand tube optional, please operate with referring to the Page 44, "3.1 Installing the solenoid valve set" and the Page 49, "3.2 Installation of hand tube"...
  • Page 64 3Installing the option devices 8) Align the top of hand input cable with the upper end of the piping fixing bracket <3> by the drawer side at the end of the shaft. 9) At the tool side of customer preparation should roll the rubber sheet (attachments) in the same way, and fix it by cable tie etc (attachments) with maintaining this adjustment position.

  • Page 65: Installing The Hand Output Cable

    3Installing the option devices 3.4 Installing the hand output cable The installation procedure of the hand output cable is as follows. Please operate with referring to the Page 44, "3.1 Installing the solenoid valve set" and the Page 55, "3.4 Installing the hand output cable" together.
  • Page 66 3Installing the option devices Note : Please see the hand output cable from the arm cover A (2) <4> side, and store it outside the bracket. If the cable enters within the bracket, it will rub to the timing belt and will become the cause of breaking down.

  • Page 67: Changing The Operating Range

    3Installing the option devices 3.5 Changing the operating range The operating range change optional installing method is shown below. The jog operation is necessary for this option installing. Installing this option after installing the robot and completing origin setting. The procedure is shown below. Note) Be sure to install the operating range change optional according to the procedure.
  • Page 68 3Installing the option devices Note : This operation is necessary for position adjustment of the mechanism stopper. Although it is not alteration visible especially, performs sure. Because to move correctly, move at 10% or less speed. a) First, move to +130 degree or more. <CURRENT>...

  • Page 69: Operating Range Change Of J2 Axis

    3Installing the option devices 3.5.2 Operating range change of J2 axis Upper face of No.1 arm Ａ Arm cover A <1> side Fixing with the Pin cover The hole for operating range change original fixing optional insertion (plus side) screw Fixing screw Note) The hole for operating range change...
  • Page 70 3Installing the option devices b) Next, move within -125 to -130 degree. <CURRENT> JOINT 100% M1 T0 B* +0.00 J2: -130.00 Within -125 to -130 degree J3: -560.00 +0.00 TOOL 3-XYZ CYLNDR ⇒ c) Finally stop within -5 to +5 degree. (Position adjustment of the mechanism stopper is completed now) <CURRENT>...

  • Page 71: Basic Operations

    4Basic operations 4 Basic operations The basic operations from creating the program to automatic operation are explained in section "4. Basic operations" in the "From Controller Setup to Maintenance" manual. Refer that manual as necessary. 4-61...

  • Page 72: Maintenance And Inspection

    5Maintenance and Inspection 5 Maintenance and Inspection The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are described in this chapter. The types and replacement methods of consumable parts are also explained. 5.1 Maintenance and inspection interval Maintenance and inspection are divided into the inspections carried out daily, and the periodic inspections carry out at set intervals.

  • Page 73: Inspection Items

    5Maintenance and Inspection 5.2 Inspection items The inspection items for the robot arm are shown below. Also refer to section "5. Maintenance and inspection" in the "Controller setup, basic operation, and maintenance" manual, and inspect the controller. 5.2.1 Daily inspection items Carry out the daily inspections with the procedures given in Table 5-1.

  • Page 74: Periodic Inspection

    Check and eliminate the cause. damage and adherence of foreign matter. If the cables are severely damaged, contact the Mitsubishi Service Department. 3-month inspection items Is the timing belt tension abnormal? If the timing belt is loose or too tense, adjust it.

  • Page 75: Maintenance And Inspection Procedures

    The procedures for carrying out the periodic maintenance and inspection are described in this section. Thoroughly read the contents, and follow the instructions. This work can be commissioned to the Mitsubishi Service Depart - ment for a fee. (Never disassemble, etc., the parts not described in this manual.) The maintenance parts, etc., required for the customer to carry out maintenance and inspection are described in...

  • Page 76: Installing/Removing The Cover

    5Maintenance and Inspection 5.3.2 Installing/removing the cover <3> No.1 Arm cover A <1> Base cover B (L) <4> Arm cover A (1) <2> Base cover B (R) <7> Motor cover J3 <9> Arm cover A (3) <5> No.1 Arm cover B <6>...
  • Page 77 5Maintenance and Inspection [Caution] When you remove the cover, don't remove other than the screw shown in Fig. 5-3 Table 5-3. (1) Referring to Fig. 5-3, remove the covers. (2) The names of the covers are given in Table 5-3, and a list of the cover installation screws is given in Table 5-3.

  • Page 78: Inspection, Maintenance And Replacement Of Timing Belt

    5Maintenance and Inspection 5.3.3 Inspection, maintenance and replacement of timing belt This robot uses a timing belt for the drive conveyance system of the J5 axis. 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 adjust - ment are inadequate, the life could drop and noise could be generated.

  • Page 79: Inspection And Maintenance Of J1 Axis Timing Belt

    5Maintenance and Inspection (2) Inspection and maintenance of J1 axis timing belt The reference figure at inspection and adjustment of the timing belt is shown in Fig. 5-4. <3>Tension adjustment screw <1> Idler fixing screw With the fixing nut (two places) Base cover B (R) side Idler Inside of the base...

  • Page 80: Inspection And Maintenance Of J2 Axis Timing Belt

    5Maintenance and Inspection (3) Inspection and maintenance of J2 axis timing belt The reference figure at inspection and adjustment of the timing belt is shown in Fig. 5-5. <5> Timing pulley <4> Timing pulley Inside of the No.1 arm Idler Upper face of No.1 arm <A>...

  • Page 81: Inspection And Maintenance Of J3 Axis Timing Belt

    5Maintenance and Inspection (4) Inspection and maintenance of J3 axis timing belt The reference figure at inspection and adjustment of the timing belt is shown in Fig. 5-6. <6> The hole for belt maintenance (Push the belt) <2> Timing belt No.2 arm Upper face of No.2 <A>...

  • Page 82: Inspection And Maintenance Of J4 Axis Timing Belt

    5Maintenance and Inspection (5) Inspection and maintenance of J4 axis timing belt The reference figure at inspection and adjustment of the timing belt is shown in Fig. 5-7. There are the two belts of the motor side and the shaft side, in the J4 axis. Perform inspection and adjustment of two belts simultaneously.
  • Page 83 5Maintenance and Inspection ■ Inspecting the J4 axis timing belt 1) Confirm that the robot controller power is OFF. 2) Refer to Page 66, "5.3.2 Installing/removing the cover", and remove the No.2 arm cover and the belt pulley cover J4. 3) Visually confirm that the symptoms indicated in "(1)Timing belt replacement period"...

  • Page 84: Timing Belt Tension

    5Maintenance and Inspection (6) Timing belt tension ｆ ： Pressing force ｓ ： Span ｄ ： Slack T ： Tension Pressing force Axis Belt type Sepang ： s mm Slack ： d mm Pressing force ： f (N) 340-5GT-20 363-3GT-12 297-3GT-9 J4 (Motor side) 345-3GT-6...

  • Page 85: Lubrication

    5Maintenance and Inspection 5.3.4 Lubrication (1) Lubrication position and specifications <1> J1 axis lubrication port Note) <1> J1 axis lubrication port 　 <2> J2 axis lubrica - tion port <3> Shaft lubrication Note) <2> J2 axis lubrication port 　 Note) With the grease nipple cover (yellow) Fig.5-9 ：...

  • Page 86: Lubrication Method

    5Maintenance and Inspection (2) Lubrication method 1) The positions of lubrication ports are shown in the Fig. 5-9. Move the robot to the posture in which it can supply the grease easy. 2) Refer to Page 66, "5.3.2 Installing/removing the cover", and remove the covers necessary.

  • Page 87: Replacing The Backup Battery

    5Maintenance and Inspection 5.3.5 Replacing the backup battery An absolute encoder is used for the position detector, so the position must be saved with the backup battery when the power is turned OFF. The controller also uses a backup battery to save the program, etc. 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 88: Replacing The Robot Arm Battery

    5Maintenance and Inspection (1) Replacing the robot arm battery Don't disconnect connector, etc. While replacing the battery, the encoder position CAUTION data is saved by the power supplied from the controller. Thus, if the cable connection is incomplete, the encoder position data will be lost when the controller power is turned OFF.

  • Page 89: About Overhaul

    5.4 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 speci - fied service life or other parts which have been damaged, so that the robots may be put back in shape for contin - ued use.

  • Page 90: Maintenance Parts

    Reduction gears of each axis An needed Lithium battery In base cover B(L) Note1)Confirm the robot arm serial No., and contact the dealer or service branch of Mitsubishi Electric Co., for the type. Table 5-6 ： Spare parts list Usage place...

  • Page 91: Resetting The Origin

    5 Maintenance and Inspection 5.6 Resetting the origin The origin is set so that the robot can be used with a high accuracy. After purchasing the robot, always carry out this step before starting work. The origin must be reset if the combination of robot and controller being used is changed or if the motor is changed causing an encoder area.

  • Page 92: Mechanical Stopper Method

    5 Maintenance and Inspection 5.6.1 Mechanical stopper method The method for setting the origin with the transportation jig is explained below. This operation is carried out with the T/B. Set the [MODE] switch on the front of the controller to "MANUAL", and set the T/B [ENABLE] switch to "ENABLE"...
  • Page 93 5 Maintenance and Inspection <ORIGIN> MECH ～ 5) Input "1" into the J1 axis. Set "0" to other axes. 6) Press the [EXE] key , and display Confirmation SPACE screen. CLOSE <ORIGIN> MECH 7) Press the [F1] key , and the origin position is set CHANGE TO ORIGIN.

  • Page 94: J2 Axis Origin Setting(Mechanical Stopper)

    5 Maintenance and Inspection (2) J2 axis origin setting(mechanical stopper) <MENU>　　 　 1) Press the [4] key on the menu screen, and dis - play the Origin/Break selection screen. 1.FILE/EDIT 2.RUN 3.PARAM. 4.ORIGIN/BRK 5.SET/INIT. 6.ENHANCED 　 123 CLOSE 2) With both hands, slowly move the J2 axis in + (plus) direction , and contact the axis against Ｊ2 the mechanical stopper.
  • Page 95 5 Maintenance and Inspection <ORIGIN> MECH 7) Press the [F1] key, and the origin position is set CHANGE TO ORIGIN. OK? 8) Setting of the origin is completed. <ORIGIN> MECH COMPLETED 9) Refer to Page 100, "5.6.5 Recording the origin data"...

  • Page 96: J3 And J4 Axis Origin Setting (Mechanical Stopper)

    5 Maintenance and Inspection (3) J3 and J4 axis origin setting (mechanical stopper) <MENU>　　 　 1) Press the [4] key on the menu screen, and dis - 1.FILE/EDIT 2.RUN play the Origin/Break selection screen. 3.PARAM. 4.ORIGIN/BRK 5.SET/INIT. 6.ENHANCED 　 123 CLOSE 2) Press the [2] key, and display the Break release <ORIGIN/BRAKE>...
  • Page 97 5 Maintenance and Inspection General environment type 7) Hold the J4 axis with your hand and rotate it slowly to match the alignment marks. *Move the J4 axis with maintaining the condition that the releasing brake of the J3 axis and the J3 axis contact to the mechanical stopper.
  • Page 98 5 Maintenance and Inspection <ORIGIN/BRAKE> 9) Press the [1] key , and display the Origin setting 1.ORIGIN 2.BRAKE selection screen. CLOSE <ORIGIN> 10) Press the [2] key , and display the Mechanical 1.DATA 2.MECH stopper selection screen. 3.TOOL 4.ABS 5.USER CLOSE <ORIGIN>...

  • Page 99: All Axis Origin Setting

    5 Maintenance and Inspection (4) All axis origin setting 1) Refer to the paragraphs from Page 82, "(1) J1 axis origin setting(mechanical stopper)" Page 86, "(3) J3 and J4 axis origin setting (mechanical stopper)" above for the description of how to adjust the origins of the J1 to J4 axes.

  • Page 100: Jig Method

    5 Maintenance and Inspection 5.6.2 Jig method This method is using the origin setting tool. If the origin setting tool is required, please ask nearby dealer. The reference figure of the origin setting tool is shown in Fig. 5-12. Fig.5-12 ： Reference dimension of origin setting tool The procedure of setting the origin with the origin setting tool is shown below.

  • Page 101: J1 Axis Origin Setting

    5 Maintenance and Inspection (1) J1 axis origin setting <MENU>　　 　 1) Press the [4] key on the menu screen, and dis - 1.FILE/EDIT 2.RUN play the Origin/Break selection screen. 3.PARAM. 4.ORIGIN/BRK 5.SET/INIT. 6.ENHANCED 　 123 CLOSE Select ORIGIN/BRK 　　　　　　　　　 2) Move the J1 axis slowly toward the front using both hands.
  • Page 102 5 Maintenance and Inspection ◇◆◇ Release the brake ◇◆◇ Do cursor movement into the parenthesis of each axis by the arrow key. The brakes can be released only for the axis for which a "1" is displayed on the screen. If the brakes are not to be released, press the [0] key and display a "0".

  • Page 103: J2 Axis Origin Setting

    5 Maintenance and Inspection (2) J2 axis origin setting <MENU>　　 　 1) Press the [4] key on the menu screen, and dis - play the Origin/Break selection screen. 1.FILE/EDIT 2.RUN 3.PARAM. 4.ORIGIN/BRK 5.SET/INIT. 6.ENHANCED 　 123 CLOSE No.1 arm 第1アーム 2) Slowly rotate the J2 axis 0 degree with both hands.

  • Page 104: J3 And J4 Axis Origin Setting

    5 Maintenance and Inspection ◇◆◇ Release the brake ◇◆◇ Do cursor movement into the parenthesis of each axis by the arrow key. The brakes can be released only for the axis for which a "1" is displayed on the screen. If the brakes are not to be released, press the [0] key and display a "0".

  • Page 105: All Axis Origin Setting

    5 Maintenance and Inspection (4) All axis origin setting 1) Refer to the paragraphs from Page 91, "(1) J1 axis origin setting" Page 94, "(3) J3 and J4 axis origin setting" above for the description of how to adjust the origins of the J1 to J4 axes. At this point, the robot will have the posture shown below.

  • Page 106: Abs Origin Method

    5 Maintenance and Inspection 5.6.3 ABS origin method When the origin setting of the robot is performed for the first time, this product records the angular position of the origin within one rotation of the encoder as the offset value. If the origin setting is performed according to the ABS origin method, this value is used to suppress variations in the origin setting operations and to reproduce the initial origin position accurately.

  • Page 107: Select The T/B

    5 Maintenance and Inspection The procedures for setting the origin with the ABS method are explained below. (1) Select the T/B <MENU>　　 　 1) Press the [4] key on the menu screen, and dis - 1.FILE/EDIT 2.RUN play the Origin/Break selection screen. 3.PARAM.

  • Page 108: User Origin Method

    5 Maintenance and Inspection 5.6.4 User origin method CAUTION Before using this method, the origin must be set with the other method. The setting method is explained in Page 81, "Table 5-7 ： Origin setting method". The procedure for setting the origin with the user origin method is explained below. This operation is carried out with the teaching pendant.
  • Page 109 5 Maintenance and Inspection <USER> 8) Input "1" into the axis to origin setting. Press J1:( )J2:( )J3:( the [EXE] key, and display Confirmation screen. J4:( )J5:( )J6:( ～ J7:( )J8:( REL. CLOSE → 9) Press the [F1] key, and the origin position is set <ORIGIN>...

  • Page 110: Recording The Origin Data

    5 Maintenance and Inspection 5.6.5 Recording the origin data When the origin has been set with the jig method, record that origin data on the origin data label. With this, the ori - gin can be set with the origin data input method the next time. Confirm the origin data on the teaching pendant screen (origin data input screen).

  • Page 111: 6Appendix

    6Appendix 6 Appendix Appendix 1 ： Configuration flag The configuration flag indicates the robot posture. For the 6-axis type robot, the robot hand end is saved with the position data configured of X, Y, Z, A, B and C. However, even with the same position data, there are several postures that the robot can change to. The posture is expressed by this configuration flag, and the posture is saved with FL1 in the position constant (X, Y, Z, A, B, C) (FL1, FL2).
  • Page 112 6Appendix Appendix-102 Configuration flag...
  • Page 114 HEAD OFFICE: TOKYO BUILDING, 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN NAGOYA WORKS: 5-1-14, YADA-MINAMI, HIGASHI-KU, NAGOYA 461-8670, JAPAN Authorised representative: MITSUBISHI ELECTRIC EUROPE B.V. GERMANY Gothaer Str. 8, 40880 Ratingen / P.O. Box 1548, 40835 Ratingen, Germany May., 2012 MEE Printed in Japan on recycled paper.

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