Robo cylinde actuator slider dust-proof/splash-proof type (2 pages)
Summary of Contents for IAI ROBO Cylinder RCP5-BA4
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ROBO Cylinder RCP5 Actuator Belt Type Instruction Manual First Edition BA4/BA4U BA6/BA6U BA7/BA7U IAI America, Inc.
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This product is not to be used for any other purpose from what is noted in this instruction manual. IAI shall not be liable whatsoever for any loss or damage arising from the result of using the product for any other purpose from what is noted in the manual.
Table of Contents Safety Guide......................1 Caution in Handling ....................8 International Standards Compliances ..............9 Names of the Parts ....................10 1. Specifications Check..................11 1.1 Checking the Product ......................11 1.1.1 Parts ........................11 1.1.2 Related Instruction Manuals for the Each Controller Supported by This Product.........................
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4.8 Procedure for Belt Replacement and Tuning ..............48 4.8.1 Tension Adjustment ..................... 48 4.8.2 Replacement of the Belt..................51 4.9 Replacement Process ....................... 60 5. External Dimensions..................73 5.1 RCP5-BA4/BA4U ......................73 5.2 RCP5-BA6/BA6U ......................74 5.3 RCP5-BA7/BA7U ......................75 6.
Safety Guide “Safety Guide” has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it 1before the operation of this product. Safety Precautions for Our Products The common safety precautions for the use of any of our robots in each operation. Operation Description Description...
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Operation Description Description Transportation When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.
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Operation Description Description Installation (2) Cable Wiring and Start Use our company’s genuine cables for connecting between the actuator and controller, and for the teaching tool. Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around.
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Operation Description Description Installation (4) Safety Measures and Start When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. When the product is under operation or in the ready mode, take the safety measures (such as the installation of safety and protection fence) so that nobody can enter the area within the robot’s movable range.
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Operation Description Description Trial Operation When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation.
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Operation Description Description Maintenance When the work is carried out with 2 or more persons, make it clear who is and Inspection to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Perform the work out of the safety protection fence, if possible.
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Alert Indication The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, and described in the instruction manual for each model. Level Degree of Danger and Damage Symbol This indicates an imminently hazardous situation which, if the product Danger Danger is not handled correctly, will result in death or serious injury.
Caution in Handling 1. Make sure to follow the usage condition, environment and specification range of the product. In case it is not secured, it may cause a drop in performance or malfunction of the product. 2. Do not attempt to have any handling or operation that is not stated in this Instruction manual.
International Standards Compliances This actuator complies with the following overseas standard. Refer to Overseas Standard Compliance Manual (ME0287) for more detailed information. RoHS Directive CE Marking...
Names of the Parts See figure below for BA4/BA6/BA7 (Motor upper mount). For BA4U/BA6U/BA7U, the motor unit is mounted facing the lower side. In this manual, the right and left sides of the actuator are expressed in the way it is placed horizontally as shown in the figure below, and is looked at from the motor side.
1.1 Checking the Product The standard configuration of this product is comprised of the following parts. See the component list for the details of the enclosed components. If you find any fault or missing parts, contact your local IAI distributor. 1.1.1 Parts...
<Stroke> [Refer to 1.2 Specifications] Note 1 Identification for IAI use only: It may be displayed for IAI use. It is not a code to show the model type. Note 2 It is necessary to select either of CJT (Top), CJR (Right), CJL (Left) or CJB (Bottom) for the...
1.2.2 Speed and Payload [When high-output setting is effective] Payload [kg] Max. Acceleration Type Motor Type Lead [mm] Speed Speed [mm/s] 0.5G 48 or BA4U equiv. 1000 1200 48 or BA6U equiv. 1000 1500 48 or 1000 BA7U equiv. 1400 1600...
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[Speed and Payload] Speed-Payload (Horizontal) Speed [mm/s] BA4/BA4U Speed-Payload (Horizontal) Speed [mm/s] BA6/BA6U Speed-Payload (Horizontal) Speed [mm/s] BA7/BA7U Caution: Do not attempt to establish the settings for the acceleration/deceleration above the allowable range. It may cause vibration, malfunction or shortened life. Setting of acceleration/deceleration above the ratings may cause creeping.
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[When high–output setting is ineffective] Payload [kg] Max. Acceleration Type Motor Type Lead [mm] Speed Speed [mm/s] 0.5G 48 or equiv. BA4U 1000 1200 48 or equiv. BA6U 1400 48 or equiv. BA7U 1200...
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[Speed and Payload] Speed-Payload (Horizontal) 1000 1200 Speed [mm/s] BA4/BA4U Speed-Payload (Horizontal) 1000 1200 1400 1600 Speed [mm/s] BA6/BA6U Speed-Payload (Horizontal) 1000 1200 1400 1600 Speed [mm/s] BA7/BA7U Caution: Do not attempt to establish the settings for the acceleration/deceleration above the allowable range.
1.2.3 Driving System • Position Detector No. of Encoder Type Motor Type Lead Pulses 48 or BA4U equiv. 48 or BA6U equiv. 48 or BA7U equiv. 1.2.4 Positioning Precision Type Lead Item Tolerance Positioning repeatability ±0.08mm 48 or BA4U equiv. Lost motion 0.1mm or less 48 or...
(Note) The home position is adjusted at the factory before shipment. If you wish to change the home after the delivery of your actuator, you must return the actuator to IAI for adjustment. 1.3.3 Cable Eject Direction Changed (Model: CJT, CJR, CJL, CJB) If a change in the cable ejection direction is made, the direction of cable ejection will be changed.
1.4.2 Motor • Encoder Integrated Cables Robot Type CB-CAN-MPA indicates the cable length L (Example. 030 = 3m). Max.20m Actuator side Controller side Connector: DF62B-24S-2.2C Connector: PADP-24V-1-S Contact: DF62-2428SCFA (AWG26) Contact: DF62-22SCFA (AWG22) SPND-002T-C0.5 (AWG26) SPND-001T-C0.5 (AWG22) Connection diagram Actuator side Controller side Electric Signal...
2. Installation Transportation [1] Handling of Robot (1) Handling the Packed Unit Unless otherwise specified, the actuator is shipped with each axis packaged separately. Do not damage or drop. The package is not applied with any special treatment that enables it to resist an impact caused by a drop or crash.
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[2] Handling in the Assembled Condition This is the case when the product is delivered from our factory under a condition that it is assembled with other actuators. The combined axes are delivered in a package that the frame is nailed on the lumber base.
2.2 Installation and Storage • Preservation Environment [1] Installation Environment The actuator should be installed in a location other than those specified below. In general, the installation environment should be one in which an operator can work without protective gear. Also provide sufficient work space required for maintenance inspection.
How to Install This chapter explains how to install the actuator on your mechanical system. 2.3.1 Installation Orientation Follow the information below when installing the actuator, as a rule. Do pay attention to these items (except with custom-order models). : Possible : Possible for stroke 1,000mm or less : Not possible Horizontally...
2.3.2 Installation The surface to mount the main unit should be a machined surface or a plane that possesses an equivalent accuracy and the flatness should be within 0.05mm/m. Also, the platform should have a structure stiff enough to install the unit so it would not generate vibration or other abnormality. Also consider enough space necessary for maintenance work such as actuator replacement and inspection.
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Tightening Screws Use hexagonal socket head bolts for the male threads for installing the base. Use of high–tension bolts meeting at least ISO 10.9 is recommended. For the effective engagement length between the bolt and female thread, provide at least the applicable value specified below: Female thread is made of steel material Same length as the nominal diameter...
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[2] Attachment of the Transported Object There are tapped holes on the top surface of the slider. Affix the transferred work piece on them. The way to affix follows the installation of the main unit. There are two reamed holes on the top surface of the slider. Use them in case it is necessary to have repeatability of attaching and detaching.
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[Distance between slider center and motor cover at mechanical end: A] Type BA4/BA4U BA6/BA6U 66.5 BA7/BA7U 68.5...
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[3] Installation Surface Make sure the platform to install the actuator possesses a structure with sufficient stiffness, so vibration would not be generated. The surface where the actuator will be mounted should be a machined surface or that with an accuracy equivalent to it, and the flatness should be 0.05mm or below.
3. Connecting with the Controller As the connection cable for the controller and RCS3 (this actuator), use the IAI-dedicated controller and dedicated connection cable. This section explains the wiring method for a single axis. • If the dedicated connection cable cannot be secured, reduce the load on the cable by allowing it to deflect only by the weight of the cable or wire it in a self-standing cable hose, etc., having a large...
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• Use dedicated cables of IAI indicated in this instruction manual. Contact us if you wish to have a change to the specifications of the dedicated cables.
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• Have a sufficient radius for bending, and avoid a bend concentrating on one point. Steel Strap (Piano Wire) Tie them up softly. • Do not let the cable bend, kink or twist. • Do not pull the cable with a strong force. •...
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• When a cable is fastened to affix, make sure to have an appropriate force and do not tighten too much. Do not use spiral tube in any position where cables are bent frequently. • PIO line, communication line, power and driving lines are to be put separately from each other and do not tie them together.
4. Maintenance and Inspection Inspection Items and Schedule Follow the maintenance inspection schedule below. It is assumed that the equipment is operating 8 hours per day. If the equipment is running continuously night and day or otherwise running at a high operating rate, inspect more often as needed.
External Visual Inspection An external visual inspection should check the following things. Main Unit Loose actuator mounting bolts, other loose items Cables Scratches, proper connections Stainless steel sheet Scratches Overall Irregular noise, vibration • The life of the stainless steel sheet should be 5,000km of driving distance as a reference. However, replace the stainless steel sheet when it is necessary depending on the condition of use.
If the condition of attachment changes, it may impact the sheet position misalignment or its life. In such cases, contact the sales technical department in IAI. Also, there is a risk of getting hurt on the edge of the stainless sheet. Make sure to...
4.4.2 Inspection of the Belt After checking the lubrication and dirtiness on the guide part, check the belt visually. As the durability of the belt gets influenced widely by the operation time, the period for replacement cannot be easily determined. As the time of operation goes, degradation such as abrasion proceeds.
• Do not use oil-based solvents, neutral detergent or alcohol. 4.6 Grease Supply 4.6.1 What Grease to Use IAI uses the following grease in our plant. Guide Kyodo Yushi Multitemp LRL 3 Other companies also sell similar types of grease. For more detailed information, ask the supplier to find an equivalent for you by telling them the name of the grease.
4.6.2 How to Apply Grease Remove the attachment screws (at arrows) on the side cover to detach the side cover on one side. Screws: M2.5, M3 (BA4/BA4U), M3 (BA6/BA6U, BA7/BA7U) For some stroke patterns, there is another attachment screw on the side cover between two screws on right and left ends.
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After grease supply is finished on one side, put back the side cover. Hitting it on the edge of the stainless steel sheet when attaching may cause the sheet damaged or meandered, which may result in earlier degradation or wear-out of the sheet. Therefore, to avoid a touch to the sheet edge, insert a shim (approx.
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T Use a spatula to push the grease in between the slider and the base, or supply grease with a grease injector and move the slider to spread the grease out evenly. • Confirm the ball feeding surface on the guide is glossy with oil of the grease. Do the same work again and again till the grease gets spread out enough.
4.7 Procedures for Replacement and Adjustment of Stainless Steel Sheet Described below explains how to replace and adjust the stainless steel sheet. Replacement of the stainless steel sheet can be conducted without detaching the side covers. 4.7.1 Preparation (1) Required Items Replacement stainless steel sheet Phillips Screwdriver Adhesive tape...
4.7.2 Procedure for Replacement and Tuning Remove the screws (4 places) holding the stainless steel sheet and stainless steel sheet retainer plates (2 pieces) with using a Phillips screwdriver. Pull the old stainless steel sheet Adhere cellophane tape on one end of the new stainless steel sheet. Adhesive tape Stainless steel sheet Stainless steel sheet...
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With the stainless steel sheet being held, move the slider to put through the stainless steel sheet.. After the stainless steel sheet passes through the slider, pull one end of the stainless steel sheet out to the position of the stainless steel retainer plate. Take off the adhesive tape once positioning is finished.
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Affix the two stainless steel sheet retainer plates with screws (4 places). To affix them, use a Phillips driver. There are two slits on the body as a guide for stainless steel attachment. Allocate the stainless steel sheet so it comes in the center between two slits.
4.8 Procedure for Belt Replacement and Tuning 4.8.1 Tension Adjustment [Required Items] Tension adjustment wire (provide a commercially available wire like the one shown in the photograph at right) Hex wrench BA4/BA4U Opposite side 2.5mm, Opposite side 3 mm BA6/BA6U, Opposite side 3mm, BA7/BA7U Opposite side 4 mm...
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Loosen the M3 (for BA4/BA4U) or M3 (for BA6/BA6U, BA7/BA7U) hex socket flange head cap screw holding the pulley unit. Pulley unit Hex socket flange head cap screw Adjust the belt tension. Hang a wire on the pulley unit and pull it evenly by applying tension described in the table below with a tension gauge.
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Attach the pulley cover and tighten the four M2.6 (for BA4/BA4U) or M3 (for BA6/BA6U, BA7/BA7U) screws. Pulley cover Screws Type Tightening Torque BA4/BA4U 45.8N•cm BA6/BA6U 83.0N•cm BA7/BA7U Affix the stainless steel sheet retaining plate with screws (2 places in circles) with using a Philips screwdriver.
4.8.2 Replacement of the Belt [Required Items] Belt for replacement Model IAI Maintenance Part Code Manufacturer Model Code BA4/BA4U LB-RCP5-BA4- (Stroke) 3GT width 6 BA6/BA6U LB-RCP5-BA6- (Stroke) GATES UNITTA ASIA 3GT width 9 LB-RCP5-BA7- (Stroke) BA7/BA7U Tension adjustment wire (provide a commercially available wire like the...
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Remove the four attachment screws (4 places in circles) holding the stainless steel sheet, and detach the stainless steel sheet and stainless steel retaining plate. Motor side Opposite side of the motor Stainless steel sheet retainer plate Stainless steel sheet Stainless steel sheet retainer plate Caution:...
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Remove the side cover attachment screws (at arrows) to detach the side covers on the both ends. Screw size: M2.5, M3 (BA4/BA4U), M3 (BA6/BA6U, BA7/BA7U) Do not remove the one in red circle. Detach the side covers with the sheet plate remained on. For some stroke patterns, there is another attachment screw on the side cover between two screws on right and left ends.
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Remove the M3 (for BA4/BA4U) or M4 (for BA6/BA6U, BA7/BA7U) hex socket flange head cap screws holding the pulley unit to detach the pulley unit. Pulley unit Hex socket flange head cap screw Remove the M3 screw holding the belt under the slider with using a hex wrench. Slide away the belt and the belt retainer appears.
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Attach the replacement belt through the slider, pulley (motor end) and pulley (tip end). (Note) Make sure the belt is not twisted. Next, put the both ends of the belt and the belt retainer through the hole on the slider and affix them with M3 screws.
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Loosely tighten the M3 (for BA4/BA4U) or M4 (for BA6/BA6U, BA7/BA7U) hex socket flange head cap screws holding the pulley unit for temporary to attach the pulley unit. Pulley unit Hex socket flange head cap screws Adjust the belt tension. Hang a wire on the pulley unit and pull it evenly by applying tension described in the table below with a tension gauge.
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10) Attach the pulley cover, tighten up with the four M2.6 (for BA4/BA4U) or M3 (for BA6/BA6U, BA7/BA7U) screws with using a hex wrench. Pulley cover Screws Type Tightening Torque BA4/BA4U 45.8N•cm BA6/BA6U 83.0N•cm BA7/BA7U 11) Put on the side covers on the both sides, and tighten the attachment screws (at arrows) for the side covers.
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12) Put on the stainless steel sheet and stainless steel sheet retaining plate, and tighten the four M3 attachment screws (4 places in circles). Motor side Opposite side of the motor Stainless steel sheet retaining plate Stainless steel sheet Stainless steel sheet retaining plate There are two slits on the body as a guide for stainless steel attachment.
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13) Put on the slider cover, and tighten the two attachment screws with using a Philips screwdriver. Scerws Slider cover Type Bolt Diameter Tightening Torque BA4/BA4U M2.6 cross recessed flat-head machine screw 43.1N•cm BA6/BA6U M3 cross recessed flat-head machine screw 76.8N•cm BA7/BA7U M4 cross recessed flat-head machine screw...
4.9 Replacement Process [Required Items] Motor Unit for Replacement W/O Brake With Brake Tension adjustment wire (provide a commercially available wire like the one shown in the photograph at right) Hex wrench BA4/BA4U opposite side 2.5mm, opposite side 3mm BA6/BA6U opposite side 3mm, BA7/BA7U opposite side 4mm...
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Remove the four attachment screws (4 places in circles) holding the stainless steel sheet, and detach the stainless steel sheet and sheet retaining plate. Motor side Opposite side of the motor Stainless steel sheet retaining plate Stainless steel sheet Stainless steel sheet retaining plate Caution: Pay attention not to have the stainless steel sheet bent forcefully or damaged when...
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Remove the side cover attachment screws (at arrows) to detach the side covers on the both ends. Screw size: M2.5, M3 (BA4/BA4U), M3 (BA6/BA6U, BA7/BA7U) Do not remove the one in red circle. Detach the side covers with the sheet plate remained on. For some stroke patterns, there is another attachment screw on the side cover between two screws on right and left ends.
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Remove the M3 (for BA4/BA4U) or M4 (for BA6/BA6U, BA7/BA7U) hex socket flange head cap screws holding the pulley unit to detach the pulley unit. Pulley unit Hex socket flange head cap screws Remove the M3 screw holding the belt under the slider with using a hex wrench. Slide away the belt and the belt retainer appears.
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Remove the four attachment screws holding the motor cover and end cover with using a Philips screwdriver to detach the motor cover and end cover. Pull off the motor and encoder connector. Connector Connector For BA7/BA7U, the motor can be taken off in the condition that the motor cover is detached. For BA4/BA4U and BA6/BA6U, turn around the actuator if it is a type with the motor unit mounted on the top, remove the screws shown in the figure below (4 places in circles), and take off the motor.
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10) To reuse the pulley, remove the two M4 (BA4/BA4U, BA6/BA6U) or M5 (BA7/BA7U) hex socket set screws holding the pulley with using a hex wrench to detach the pulley. Hex socket set Pulley screws holding 11) Attach the detached pulley to the replacement motor with keeping gap of Dimension G. Tighten the four M4 (BA4/BA4U, BA6/BA6U) or M5 (BA7/BA7U) hex socket set screws holding the pulley with using a hex wrench to affix the pulley.
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12) For BA4/BA4U and BA6/BA6U, attach the motor for replacement as shown in the figures below, and tighten the four screws of M3 (BA4/BA4U and BA6/BA6U) to hold the motor. For BA7/BA7U, tighten the motor from the top with four M4 screws. Motor Screws Type...
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14) Put on the motor cover, and tighten the four attachment screws holding the motor cover and end cover with using a Philips screwdriver.
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15) Attach the replacement belt through the slider, pulley (motor end) and pulley (tip end). (Note) Make sure the belt is not twisted. Next, put the both ends of the belt and the belt retainer through the hole on the slider and affix them with M3 screws.
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16) Loosely tighten the M3 (for BA4/BA4U) or M4 (for BA6/BA6U, BA7/BA7U) hex socket flange head cap screws holding the pulley unit for temporary to attach the pulley unit. Pulley unit Hex socket flange head cap screws 17) Adjust the belt tension. Hang a wire on the pulley unit and pull it evenly by applying tension described in the table below with a tension gauge.
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18) Attach the pulley cover and tighten the four M2.6 (for BA4/BA4U) or M3 (for BA6/BA6U, BA7/BA7U) screws. Pulley cover Screws Type Tightening Torque BA4/BA4U 45.8N•cm BA6/BA6U 83.0N•cm BA7/BA7U 19) Put on the side covers on the both sides, and tighten the attachment screws (at arrows) for the side covers.
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20) Put on the stainless steel sheet and stainless steel sheet retaining plate, and tighten the four M3 attachment screws (4 places in circles). Motor side Opposite side of the motor Stainless steel sheet retaining plate Stainless steel sheet Stainless steel sheet retaining plate There are two slits on the body as a guide for stainless steel attachment.
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21) Put on the slider cover, and tighten the two attachment screws with using a Philips screwdriver. Screw Slider cover Type Bolt Diameter Tightening Torque BA4/BA4U M2.6 cross recessed flat-head machine screw 43.1N•cm BA6/BA6U M3 cross recessed flat-head machine screw 76.8N•cm BA7/BA7U M4 cross recessed flat-head machine screw...
6. Life The mechanical life of the actuator is represented by the guide that receives the moment load mostly. Operation life of the linear guide is to be determined by the total driving distance which can reach without having 90% flaking (peeling on rail surface). Operation life can be figured out with the calculation method shown below.
[Load coefficient f t is a coefficient to consider the life drop due to operational conditions. Load coefficient Reference for Operational Conditions acceleration/deceleration 1.0 to 1.5 Small vibration or impact in slow operation 0.5G or less [Attachment coefficient f ] Attachment coefficient f is a coefficient to consider the life drop due to the condition of actuator attachment.
7. Warranty Warranty Period One of the following periods, whichever is shorter: 18 months after shipment from IAI 12 months after delivery to the specified location 2,500 hours of operation Scope of the Warranty Our products are covered by warranty when all of the following conditions are met. Faulty products...
Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications (1) If our product is combined with another product or any system, device, etc., used by the customer, the customer must first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such combination with our product conforms to the applicable standards, etc.
Pg. 12, 18 Note added to state option to change direction for cable ejection has to be selected Pg. 13, 14 Note added that it is performance when high-output setting is effective Pg. 49 IAI maintenance part codes added for belt for replacement October 2015 1E edition Pg. 15 Correction made...
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