1. Manuals
  2. Brands
  3. Sony Manuals
  4. Robotics
  5. CAST-AU4
  6. Operation manual

Sony CAST-AU4 Operation Manual

Sony robokids desktop robot operation manual
Hide thumbs
Table of Contents

Advertisement

Quick Links

Sony Desktop Robot
OPERATION MANUAL
GA
CAST-AU4/B2521E

Advertisement

Table of Contents
loading

Related Manuals for Sony CAST-AU4

Summary of Contents for Sony CAST-AU4

  • Page 1 Sony Desktop Robot OPERATION MANUAL CAST-AU4/B2521E...
  • Page 2 It should be used in conjuction with the RK card manual for your specifications. • This manual may not be replicated in whole or in part without the prior written authorization of Sony Corporation. •...
  • Page 3 Operation manual or the respective application manuals. This manual describes the ROBOKIDS base machine. Details for application unit installations may be found in the operation manuals that are attached when purchasing the application units. CAST-AU4/B2521E...
  • Page 4 The Operation Manual of each memory card (RK card) describes countermeasures for dispensing errors and soldering errors. 5. Replacement Parts Shows list of main replacement parts of the base machine. 6. Appendix Described input and output specifications of each connector. CAST-AU4/B2521E...

  • Page 5: Table Of Contents

    Abnormal Sound from Unit’s Motors ... 4-3 Full-open Programmable Specifications... 4-4 When Memory Card (RK Card) is Used ... 4-7 Trouble Check Sheet ... 4-10 Repair Parts Lists ROBOKIDS Body ... 5-1 Z-axis Unit ... 5-1 ZR-axis Unit ... 5-2 Appendix ... 6-1 CAST-AU4/B2521E...

  • Page 6: Safety Instruction

    Safety Instruction Sony Corporation designs and manufactures all its equipment with strict attention to safety. However, if the machine is operated or maintained without regard to the safety guidelines, damage or injury to the machine or operator may occur. To prevent accidents, those in charge of operation and maintenance must follow the safety work rules when using the machine.
  • Page 7 (of major injury). Warning Indicates that mis-handling may result in unexpected danger (electric shock, etc.,) and that the operator is at risk of injury or the equipment at risk of damage. Caution CAST-AU4/B2521E...
  • Page 8 N Connect the earth wiring (FG) to the tools. Electrical potential difference will occur with surrounding equipment if the electrical earth is not connected and may result in electrical shocks. N Be careful that motor gets very hot. CAST-AU4/B2521E Safety Instruction...
  • Page 9 Dropping any flammable liquid or metal, object into the machine can cause errors and trouble of the machine. Should any of them drop into the machine, unplug the power cord and contact your local Sony dealer. Do not place any obstacles in front of the fans.
  • Page 10 Be sure to check the operation of the fan attached to the controller before starting operation. Equipment can be seriously damaged by heat accumulated in ICs in certain operating environments in which equipment is used without sufficient heat dissipation. CAST-AU4/B2521E Safety Instruction...
  • Page 11 Lithium battery (primary battery) of type : CR17335SE-CN21 Manufactured by Sanyo Electric Co. Incorrect handling of the battery may result in dangerous situation. Do not perform the actions as listed below for safety. Sony Corporation is not responsible for the troubles related to the operation of the following precautions.

  • Page 12: Unpacking

    Transport it to the installation position while taking care not to drop or fall. Pay extra attention not to give any vibration or shock because the controller contains precision Caution electronic parts. Be sure to use the packaging material specified by Sony Corporation when transporting the NOTE machine. Accsesory box...
  • Page 13 When the machine is unpacked, make sure the following items are in the package. Base machine (For AC 200V to 240 V) Operation Manual External supply power connector for USER I/O MC 1.5/2-ST-3.81 (Phoenix Contact Inc.) Power cable Operation box USER I/O connector PCR-E68FS (connector) PCS-E68LA (connector cover) (Honda Communications Company) CAST-AU4/B2521E...

  • Page 14: Outline

    The external switch and connector enabling operation of the machine by two operators, must NOTE be prepared by the user. I Product Configuration The base machine consists of two axes X-axis and Y-axis. It may be upgraded to three and four axes by installing the optional Z-unit and ZR-unit respectively. CAST-AU4/B2521E 1. Outline...

  • Page 15: Nomenclature

    5. POWER ...Illuminates in green while power is on. Illuminates in red when a battery runs out. X-axis Unit or tool mounting bracket Memory card slot 5-gang LED display (POWER, TASK, ROBOT, PROGRAM switch ONLINE, ERROR indications from the left) X-axis stand START button Operation box STOP button CAST-AU4/B2521E...
  • Page 16 OPERATION BOX connector DC24V INPUT (I/O power) connector (Up to maximum 1.5 A) SAFETY connector CAST-PRO Teaching Pendant CAST-P06 (option) CAST-AU4/B2521E Internal/external selecting switch for I/O (Upper : OUTSIDE, Lower : INSIDE) INLET (power) USER INPUT/OUTPUT connector (External I/O connector)

  • Page 17: Outline Drawings

    1-2 Outline Drawings I ROBOKIDS Standard Type (CAST-AU4/B2521E) (35) (Stroke) (69) (250) + 0.03 φ4 4-M4 (60) Detailed view of "A" (78) (52) (Stroke) CAST-AU4/B2521E...
  • Page 18 Height Adjustable Type (CAST-AU4/BT2521E) (35) (Stroke) (69) CAST-AU4/B2521E (250) 1. Outline (78) (52) (Stroke)
  • Page 19 I 3-Axes Model Z-unit I 4-Axes Model ZR-unit 4-M4 φ12h7 CAST-AU4/B2521E...
  • Page 20 1. Outline Service Tapped-Hole Position Side A 6-M3 6-M3 (Side A only) (1.6) (250) CAST-AU4/B2521E...
  • Page 21 Service Tapped-Hole Position (Tall Model) CAST-AU4/B2521E...

  • Page 22: Specifications

    (round-off function) per every pulse that is theoretically calculated from the machine structure. This value changes especially when direction of movement or speed is changed. The resolution value can change depending on the card when the RK card is used. CAST-AU4/B2521E Three axes specification Two axes specification...

  • Page 23: Control Specifications

    Full open : Described by the machine language LUNA RK card : The standard software is supplied (option) 22 inputs and 22 outputs RS232C : One channel (general-purpose) Single-phase 100 to 240 V ±10% 50/60 Hz 300 VA Class 3 ground CAST-AU4/B2521E...

  • Page 24: Preparation

    Hexagon socket head cap screws M4 × 10, 2 pieces Tightening torque 15 kgfcm 2. Remove the Z-unit front cover. (The cover to which Sony logo mark is attached.) (Four positions) 3. Fix the Z-unit to the mounting plate. (Three positions)
  • Page 25 Be sure to fix the connector by tightening the screws. 6. Attach the cable holder supplied, to the post. Hexagon socket head cap screws M3 × 6, 2 pieces Spring washer SW3, 2 pieces Flat washer W3, 2 pieces Tightening torque 10 kgfcm Cable holder (supplied) CAST-AU4/B2521E...
  • Page 26 2. Preparation 7. Fix the cable clamp of the cable to the cable holder. CAST-AU4/B2521E...

  • Page 27: Attaching The Zr-Unit

    2-1-2 Attaching the ZR-unit 1. Remove the front cover. (The cover to which Sony logo mark is attached.) (Six positions) 2. Fix the ZR-unit to the mounting plate. (Four positions) Determine the fixing position using the positioning pin that is supplied with the equipment.
  • Page 28 5. Attach the cable holder supplied, to the post. Hexagon socket head cap screws M3 × 6, 2 pieces Spring washer SW3, 2 pieces Flat washer W3, 2 pieces Tightening torque 10 kgfcm CAST-AU4/B2521E 2. Preparation Cable holder (supplied)
  • Page 29 5. Fix the clamp of the cable on the cable holder. CAST-AU4/B2521E...

  • Page 30: Connecting The External Signal

    • Connect pin-14 to pin-15. (or to pin-7) How to control the RETURN : • Connect pin-9 and pin-7 (or pin-15) to the respective switches. Example of external Switch box stop switch Door switch Floor mat switch CAST-AU4/B2521E 2. Preparation...
  • Page 31 (Pins-4 and -6 are normally closed. In a stop, pins-4 and -5 are closed.) Connect shield of the cable Safety box RETURN indicator S top indicator RETURN button S top button Barrier switch, door switch, etc. CAST-AU4/B2521E...
  • Page 32 “F” when controlling the program selector from external location. If the second digit of the PROGRAM switch is set to “F”, the application program is set to external mode. CAST-AU4/B2521E Pin No.1 Connection Pin No.3 30 32 34 Connect a jumper wire with soldering...
  • Page 33 Maximum 7mA Reservation input Reservation input Reservation input I 21 I 22 COM1 Note1) When USER I/O power supply source selector slide switch Thermistor is set to 24V. (1A) Controller side User side SI1 operates when SW1 is ON. SW30 CAST-AU4/B2521E...
  • Page 34 N Be sure to use a shielded cable for I/O connection. The maximum length of a shielded cable is 1.0 m. Use the core conductor of the shielded cable. CAST-AU4/B2521E USER I/O power supply source selector slide switch Up position: Externally supplied 24V...

  • Page 35: Connecting To An Electrical Outlet

    The user must provide and wire an AC power plug to connect to the AC outlet. 2-12 To the three-pin electrical outlet Power cable (supplied) To the machine INLET Connection diagram of the AC power cable for 200 V to 240 V Brown Blue Green/Yellow Earth CAST-AU4/B2521E...

  • Page 36: Starting Up The Base Machine

    It may cause trouble. 2. Connect the USER I/O connector (in which SYSRUN is shorted) to the rear panel of the ROBOKIDS. (Refer to page 2-6.) CAST-AU4/B2521E 2. Preparation USER I/O connector Operation box Memory card slot...
  • Page 37 ◆ This operation does not load the point programs: such design prevents the internal point programs (created as a result of a teaching) from being overwritten by mistake. 2-14 POWER switch · · · ON The START indicator lights in green. CAST-AU4/B2521E...

  • Page 38: Maintenance

    Do not use volatile solvents such as alcohol, benzene or thinner, as they may mar the finish. Consult your local Sony dealer for the consumable parts, jigs and tools which are required for maintenance. 3-2 Greasing the Machine and Removing the Fallen Materials When shipped, the machine is greased along the guide rails of the X- and Y-axes.
  • Page 39 Wipe off extra grease at the ends of each rail with a cloth. (Extra grease will be solidified causing malfunction.) CAST-AU4/B2521E...
  • Page 40 N After the covers are attached, move the respective axes using the teaching pendant until NOTE grease covers all necessary part. N Be careful that the motors get very hot immediately after the operation is stopped. CAST-AU4/B2521E 4 axes specification model 3 axes specification model 3. Maintenance...

  • Page 41: Cleaning And Replacing The Air Filter

    2. Remove the front cover. Remove the bottom screws. While pulling the bottom of the cover to the front, raise the catches on the top. Front cover Air filter is inside the front cover. CAST-AU4/B2521E...
  • Page 42 3. Maintenance 3. Replace the media (filter). 4. Reinstall the front cover as before. Replacement media Sony Order No..4-761-607-01 CAST-AU4/B2521E...

  • Page 43: Replacing The Battery

    2. Exchange the battery with the new lithium battery. Battery replacement must be completed within eight hours after the main power is turned off. NOTE If not, internal data can be damaged. Replacement lithium battery (primary battery) Sony Order No..1-528-932-11 lithium battery CAST-AU4/B2521E...

  • Page 44: Troubleshooting

    This is called “stepping out”. This term is sometimes used incorrectly for tooth-skipping (between pulley and belt), but stepping out and tooth-skipping are actually entirely different phenomena. CAST-AU4/B2521E 4. Troubleshooting Example : Returning movement of the Z-axis operation...
  • Page 45 You can detect this trouble by listening for a rubbing sound or looking for scars. Check for these before use. (7) Belt tension If the belt tension becomes abnormal, contact your Sony dealer from which you purchased the machine, or contact Sony Max Corporation FA Service. (8) When the machine is operated at low temperature In early morning during winter, the room temperature may fall to 0°C or lower.

  • Page 46: External Noise

    These are the stepping out sound that is generated when the Z-axis is forcibly stopped by stepping it out in order to prevent the Z-axis from moving down during an emergency stop. These sounds cause no problem in terms of reliability. CAST-AU4/B2521E 4. Troubleshooting...

  • Page 47: Full-Open Programmable Specifications

    When an error occurs, it is registered in the top (the topmost line) and the oldest error is deleted. Date and time of occurrence Display is possible in a 1998/07/01 14:43:19 → format by scrolling right with the Program line number in which the error occurred Task name in which the error occurred Error number key. CAST-AU4/B2521E...
  • Page 48 When the Power lamp lights up in red, replace the battery. If it does not corresponds to any of the above contents, contact Sony sales or service office. Correct the program Correct the program of system task or peripheral task Correct the I/O number Load the point number.
  • Page 49 Correct the speed so as not to exceed the range. Correct the target point Correct the speed so as not to exceed the range. Correct the target point Correct the speed so as not to exceed the range. Correct the target point CAST-AU4/B2521E...

  • Page 50: When Memory Card (Rk Card) Is Used

    The robot errors which can occur in the ROBOKIDS are shown as follows. When any error number other than those listed below appears, consult your Sony dealer for more details. Application program "0"...
  • Page 51 Replace the START button Replace the external START button Causes Replace the START button Causes Start operation from the very beginning Confirm the sensor cable connection Correct the controller data from TP of the SRX Solutions Solutions Solutions Solutions CAST-AU4/B2521E...
  • Page 52 Dropped parts such as screws are choking. External unit is defective External noise is affecting The belt tension adjustment Consult your Sony dealer from which you purchased the machine or the nearest Sony FA offices for the actual adjustment of the belt tension. CAST-AU4/B2521E Causes...

  • Page 53: Trouble Check Sheet

    • The ROBOKIDS is still being used. 11) Customer Company name : Fill in the above items, and send this form to your Sony dealer or the nearest Sony FA offices by fax. 4-10 Person in charge : R No.

  • Page 54: Repair Parts Lists

    Descriptions Z-axis motor Z-axis home position sensor harness Z-axis linear guide Z-axis timing belt Z-axis relay cable harness Z-axis timing belt Bearing Mechanism block assembly CAST-AU4/B2521E Part No. Remarks A-8338-047-A Built-in board “Small” A-8338-048-A Built-in board “Large” 1-528-932-11 1-468-348-11 For DC 5 V...

  • Page 55: Zr-Axis Unit

    Z-axis home position sensor harness R-axis home position sensor harness Spline ball screw Z-axis timing belt R-axis timing belt Z/R-axis relay cable harness Bearing Mechanism block assembly Part No. Remarks 1-763-187-11 1-763-187-11 1-959-101-11 1-959-097-12 4-760-605-01 4-760-645-01 4-760-644-01 1-959-098-12 4-760-650-01 A-8336-314-A CAST-AU4/B2521E...

  • Page 56: Appendix

    The switch SI1 (SYSRUN) must always be connected. The ROBOKIDS cannot be operated NOTE unless the SI1 is turned on. Turn on or off SI1 as required. (Refer to page 2-6.) CAST-AU4/B2521E Contents RK card specification (including semi-programmable specification) SYSRUN Reserved by system (User cannot use it.)
  • Page 57 User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output CAST-AU4/B2521E...
  • Page 58 The barrier signal from the rear SAFETY connector becomes valid when the barrier is enabled. User cannot use it. User cannot use it. I User external power supply connector Power connector for I/O Pin No. Name 24 V CAST-AU4/B2521E 6. Appendix Contents Contents...
  • Page 59 Connector for SRX teaching pendant (Data set ready) Connector for program transfer (Transfer data) +5V for SRX teaching pendant Connector for program transfer (Data terminal ready) Signal ground +5V for SRX teaching pendant Manufacturer : JAE Manufacturer : JAE Manufacturer : JAE CAST-AU4/B2521E...
  • Page 60 Signal Type : CDS-3109-0122 Applicable plug : 17JE-23090-02 Applicable shell : 17JE-09H-1A CAST-AU4/B2521E Contents Work program No. 1 (First digit of the PROGRAM switch (1)) START LED Stop LED Application program No. 8 (Second digit of the PROGRAM switch (8))
  • Page 61 Stop output (NC) – FG (Shielded wire, etc.) RETURN switch Stop switch Stop switch Barrier (safety door, etc.) Barrier (safety door, etc.) External stop switch and barrier are enabled – Manufacturer : JAE Manufacturer : JAE Manufacturer : JAE CAST-AU4/B2521E...
  • Page 62 R_GND Z_A_C Z_/A R_A_C R_/A Model : DBLC-J25SAF-10L9 Applicable plug : DB-25PF-IN Applicable shell : DB-C4-J11 CAST-AU4/B2521E Contents Frame ground Unit signal common (GND) Z-unit signal ZR-unit signal DC 24 V for Z sensor Z-sensor signal Ground for Z-sensor Z-axis phase A signal...
  • Page 63 Because it may be possible to repair the machines depending upon the location of the problem even after this period, consult the service or sales representative from where you purchased the machine. 〔Singapore〕 Sony Electroncs (Singapore) Pte. Ltd TEL : 8615858 〔Europe〕 Sony Wega Produktions GmbH...
  • Page 64 1st Edition November, 1998 3rd Edition October, 2001...
  • Page 65 Sony Manufacturing Systems Corporation Printed in Japan © 2001.10 3-864-811-13...

This manual is also suitable for:

B2521eRobokids

Table of Contents