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CMA Dishmachines GR Series Maintenance Manual

Painting robot
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GR Painting Robot Series
Mechanical Maintenance Manual
Version No.：ZL-GR6150-002-V1
Issue Date：January 2020
The copyright is reserved for CMA (WUHU) Robotics Company Limited
For customer use only and any unauthorized use of this manual is strictly prohibited
CMA (WUHU) Robotics Company Limited
No.96, East Wanchun Road, Jiujiang Economic Development District, Wuhu, Anhui Province
TEL：400-052-8877
CMA
CMA (WUHU) Robotics Company Limited
Supplier of Intelligent Painting Robots

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  • Page 1 GR Painting Robot Series Mechanical Maintenance Manual Version No.：ZL-GR6150-002-V1 Issue Date：January 2020 The copyright is reserved for CMA (WUHU) Robotics Company Limited For customer use only and any unauthorized use of this manual is strictly prohibited CMA (WUHU) Robotics Company Limited No.96, East Wanchun Road, Jiujiang Economic Development District, Wuhu, Anhui Province TEL：400-052-8877 CMA (WUHU) Robotics Company Limited...
  • Page 2 Mechanical Maintenance Manual ZL-GR6150-002-V1 Statement Thank you for purchasing the painting robots designed by CMA (WUHU) Robotics Company Limited (CMA, in short). The contents stated in the manual are directly related to your safety, lawful rights and responsibilities. Please ensure to read through the manual and correctly set the operation parameters before use.
  • Page 3 Mechanical Maintenance Manual ZL-GR6150-002-V1 About the Manual The target readers of the manual include professionals involved in robot operation, maintenance and technical service. This manual intends to explain the mechanical maintenance during use for all the GR6150 painting robots designed by CMA. In order to effectively draw the attention of the users of the manual to a specific subject or aspect, the following symbols will be used, each with the following meanings.
  • Page 4 Mechanical Maintenance Manual ZL-GR6150-002-V1 renewed.  If you need to order the manual due to damage, loss, etc., please contact our agent or the nearest sales office on the back cover of the manual, and order according to the data number on the cover.

  • Page 5: Table Of Contents

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Content Chapter One: Safety ..............................1 1.1 Instruction for Safe Use of Robots ....................... 1 1.1.1 Safety Precautions during Adjustment,Operation,Mainteance ............1 1.1.2 Safety Countermeasures of Robot Body ..................3 1.2 Shift,Transfer, and Sale of Robots ........................ 7 1.3 Abandonment of Robots ..........................
  • Page 6 Mechanical Maintenance Manual ZL-GR6150-002-V1 4.4.1 The Oil Supply Quantity of Lubricant ................... 34 4.4.2 Space Orientation of Lubrication ....................34 4.4.3 Lubricant Replacement Steps for J1~J4 Axis Reducer and Wrist Parts ........34 4.4.4 Release the Residual Pressure in Lubricating Oil Cavity .............. 37 4.5 Robot Maintenance and Use Area ......................

  • Page 7: Chapter One Safety

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Chapter One Safety 1.1 Instructions for Safe Use of Robots Before performing installation, operation, maintenance, and overhaul operations, please be sure to read this manual and other attached documents thoroughly and use this product correctly. Please fully grasp the equipment knowledge, safety information and all precautions before using this product.
  • Page 8 Mechanical Maintenance Manual ZL-GR6150-002-V1 Most robot accidents are as follows: 1、The automatic operation was performed without confirming whether there is anyone in the robot's motion range. 2、It enters the robot's motion range in the automatic operation state, and the robot Danger starts suddenly during the operation.

  • Page 9: Safety Countermeasures Of Robot Body

    Mechanical Maintenance Manual ZL-GR6150-002-V1 During the operation of the robot, please configure a monitor (the third party) who can immediately press the emergency stop button to monitor the safety status. Danger During the operation of the robot, the operation should be carried out in a state where the emergency stop button can be pressed immediately.
  • Page 10 Mechanical Maintenance Manual ZL-GR6150-002-V1 When designing and manufacturing the end effector, it is controlled within the allowable payload range of the robot wrist. Attention The fail-safe protection structure should be adopted, even if the power supply or compressed air supply of the end effector is cut off, the installation object will not be released or fly out, and the corner or protruding part should be treated to prevent damage to people and objects.
  • Page 11 Mechanical Maintenance Manual ZL-GR6150-002-V1 Industrial robot gesture method (example) 1. Connect: Do the work related to the connection 2. No way! Disconnect: Raise your right hand and wave vigorously left and right 3. Is that confirm):Raise your right hand up high forward Attention 4.
  • Page 12 Mechanical Maintenance Manual ZL-GR6150-002-V1 According to the setting place and operating content, the relevant operation regulations and checklists such as starting method, operation method, solution in case of abnormality, etc. of the robot should be compiled. And carry out the operation according to the operating regulations.

  • Page 13: Shift,Transfer, And Sale Of Robots

    Mechanical Maintenance Manual ZL-GR6150-002-V1 1.2 Shift, Transfer, and Sale of Robots When the robot is shifted, transferred, or sold, it is necessary to ensure that the auxiliary documents of the robot, such as the mechanical operation manual, electrical maintenance manual, and robot programming manual, are transferred to the new user.
  • Page 14 Mechanical Maintenance Manual ZL-GR6150-002-V1 When carrying out abandoned work, please pay full attention not to be pinched or injured. Attention Waste products should be discarded in a safe state. Attention CMA (WUHU) Robotics Company Limited...

  • Page 15: Chapter Two Basic Description

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Chapter Two Basic Description Robot System Composition The industrial robot is composed of the following components, See Figure 2-1: Robot body   Robot electric control cabinet  Explosion-proof control cabinet  Teach pendant  Connection (power supply) cables, etc. ...
  • Page 16 Mechanical Maintenance Manual ZL-GR6150-002-V1 GR6150 Robot Packing List Name Configuration type Quantity Unit Remarks robot body standard configuration robot electric control standard configuration cabinet explosion-proof control standard configuration cabinet code cable Connecting cable from power cable robot body to electric control cabinet Ground cable piece...

  • Page 17: Machine Body Nameplate

    Mechanical Maintenance Manual ZL-GR6150-002-V1 The body color is green; Fuses (in the robot electric control cabinet: two in each 5A and 10A glass tube fuse; five 2A glass tube fuses; two other in each 2A and 32A fuse cores ); Attached an electrical schematic diagram and three backup circular connector boards Note: The above is the standard configuration list, excluding the case of customized models.
  • Page 18 Mechanical Maintenance Manual ZL-GR6150-002-V1 Fig. 2-2 Robot Body Nameplate CMA (WUHU) Robotics Company Limited...

  • Page 19: Body Part Composition And Identification Of Each Axis

    Mechanical Maintenance Manual ZL-GR6150-002-V1 2.4 Body Part Composition and Direction Identification of Each Axis The robot mechanical body is mainly composed of base part , rotating part, upper arm part, functional forearm part, and wrist part. The joints of the machine body are driven by servo motors, and the joints cooperate with each other to realize the adjustment of the position and posture of the robot end in space.

  • Page 20: Robot Axis Range Limit And Home Position

    Mechanical Maintenance Manual ZL-GR6150-002-V1 2.5 Robot Axis Range Limit and Home Position Each axis of the robot body has a home position and range limit.When the robot system is running normally, each axis of the robot is controlled to move within the allowable range. In addition, in order to ensure further safety, mechanical end stops are provided on some axes(see Fig.
  • Page 21 Mechanical Maintenance Manual ZL-GR6150-002-V1 Note: Special instructions about mechanical end stop position and home position. (1) Mechanical end stop and home position of axis 1: Due to the symmetrical structure design of this robot, the mechanical end stop and home position of axis 1 installation position can be installed and adjusted according to the actual usage (see Figure 2-5).

  • Page 22: Robot Performance Parameters

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Rotate －90° (3) Working Home Position (1)Calibration Position (2)Axis 3 Rotate －90° of Axis 3 of Axis 3 Fig.2-6 Home Position Calibration of Axis 3 2.6 Robot Performance Parameters (1)Robot Performance Parameter Table Performance Parameter Table Model GR6150 Action type...
  • Page 23 Mechanical Maintenance Manual ZL-GR6150-002-V1 J4 axis ±540° J5 axis ±540° J6 axis ±540° Maximum radius of activity 2900mm Diameter of hollow wrist thread hole Φ65mm Maximum payload on wrist 15 kg Wall installation, ground installation、inclined Installation conditions installation、suspended installation Protection level IP65(wrist part) / IP65(body part) Repeat accuracy ±0.25mm...

  • Page 24: Allowable Value Of Wirst Payload

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Fig.2-7 Robot Motion Range Diagram Note: The workspace shown in this figure is the maximum that can be reached theoretically. It will change due to the influence of the installation method in actual operation. In actual use, please consider the influence of the installation method on the working space.

  • Page 25: Allowable Maximum Of Moment Of Inertia

    Mechanical Maintenance Manual ZL-GR6150-002-V1 GR6150 44.2 Nm 28.8 Nm 15.1Nm 2.7.3 Allowable Maximum of Moment of Inertia Allowable moment of inertia Robot model J4 axis rotation J5 axis rotation J6 axis rotation GR6150 1.17 kgm 0.87 kgm 0.15 kgm 2.7.4 Allowable Payload Curve Diagram Fig.2-8 Wrist Axis Torque Diagram of GR 6150 CMA (WUHU) Robotics Company Limited...

  • Page 26: Chapter Three Handling And Installation

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Chapter Three Handling and Installation 3.1 Robot Handling 3.1.1 Handling Precautions The following are precautions for robot handling operations. Please work safely after fully understanding the following: The handling of robots and control devices must be carried out by qualified personnel for hook, lifting operation, forklift, etc.
  • Page 27 Mechanical Maintenance Manual ZL-GR6150-002-V1 （2） Handling method two Set the robot to the posture shown in Fig.3-2 and use a forklift to carry it. The angles of each axis of the handling posture are set as follows: position J1 axis J2 axis J3 axis J4 axis...

  • Page 28: Robot Installation

    Mechanical Maintenance Manual ZL-GR6150-002-V1 When transporting, be sure to install a fixed fixture for transport! When using other handling methods instead of cranes and forklifts, please note that the robot's arms and motors cannot be subjected to external forces! After unpacking and installation, be sure to remove the fixed fixture for transport and rubber pad! Attention The fixed fixture will be used for robot handling in the future, please keep it properly!

  • Page 29: Ground Mounting

    Mechanical Maintenance Manual ZL-GR6150-002-V1 wall-mounted installation ground installation Through-hole Through-hole Fig.3-3 Robot Base Size 3.2.3 Ground Mounting First, fix the bottom plate on the ground. We recommend that the thickness of the bottom plate should be more than 30mm. Use 8 chemical bolts of M20 or more to fix the bottom plate on the ground. The base of the robot is firmly fixed on the bottom plate with M16 hexagon socket screws of strength grade 12.9 through the four mounting holes (the length of the screw must ensure that the screw thread length reaches 1.5 times the nominal diameter of the thread).

  • Page 30: Supporter Installation

    Mechanical Maintenance Manual ZL-GR6150-002-V1 chemical bolt groups eight groups(more than M20) Fig.3-4 “Robot Installation Example” Too long or too short screws for fixing the base of the robot will cause bad fixing accidents! The connection strength of chemical bolts depends on the strength of concrete. When the strength of concrete is insufficient, it can be strengthened by the following methods: Increase the number of chemical bolt groups;...

  • Page 31: Installation Site And Environment

    Mechanical Maintenance Manual ZL-GR6150-002-V1 wall-mounted installation suspended installation Wall-mounted/ Suspended Installation Fig.3-5 Please ensure that the flatness of the installation plane of the robot base is ≤0.5mm, otherwise the robot may be damaged. Attention 3.3 Installation Site and Environment The robot should be able to keep normal when used, transported and stored under the specified environmental conditions, and its performance should meet the requirements.

  • Page 32: Intergrated Application Installation Interface

    Mechanical Maintenance Manual ZL-GR6150-002-V1 For the robot to be used, if there is strong vibration, a lot of dust, cutting oil splashing, or other objects in the use environment, please contact our service personnel to use a robot cover or other methods to protect the robot parts. Attention 3.4 Integrated Application Installation Interface 3.4.1 Tool installation at the End of the Robot Wrist...
  • Page 33 Mechanical Maintenance Manual ZL-GR6150-002-V1 Table of Screws". mounting screws tool parts meshing length depth of the screw hole mounting flange Fig. 3-7 Schematic Diagram of End Load Mounting Screws If the fastening screw is too long, the fastening screw will hit the bottom, causing the tool to not to be installed safely on the flange, which will interfere with the rotation of the 6-axis.

  • Page 34: Other Auxiliary Interfaces

    Mechanical Maintenance Manual ZL-GR6150-002-V1 1、As calculated above, if the total cross-sectional area of the air pipe exceeds 25% of the cross-sectional area of the inner hole of the wrist, the life of the air pipe will be shortened. Even if the FAR is less than 25%, the life span of the air pipe will be shortened to varying degrees with the posture angle of the wrist.Therefore, before starting the operation, please check and inspect the air pipe and its arrangement thoroughly.
  • Page 35 Mechanical Maintenance Manual ZL-GR6150-002-V1 size dimensions of the external Fig.3-12 internal component installation component installed on the upper size Dimension drawing of reserved Fig.3-13 reserved opening size opening for motor base two sides two sides Fig.3-8 Fig.3-9 Dimensions of the External Component Installed Dimensions of the External Component on the Upper Arm Installed on the Motor Base...
  • Page 36 Mechanical Maintenance Manual ZL-GR6150-002-V1 Fig.3-12 Dimensions of the External Component Installed on the Upper Arm reserved opening 1 for motor base reserved opening 2 for motor base two sides (Note: The reserved openings of the motor base are sealed with cover plates. The opening cover can be designed, processed and used according to actual use.

  • Page 37: Chapter Four Overhaul And Maintenance

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Chapter Four Overhaul and Maintenance Overhaul is divided into daily overhaul and regular overhaul. Inspectors must prepare overhaul plans and carry out overhaul. Please refer to the table below for overhaul items and overhaul periods. In addition, the overhaul must be carried out every 40,000 hours of work or every 8 years (the principle of choosing which way to reach the deadline first).

  • Page 38: Annual Inspection

    Mechanical Maintenance Manual ZL-GR6150-002-V1 of various components deal with it tightening of external tighten the end effector screws and external main screws main screws Annual Inspection 4.1.3 Table 4.3 Annual Inspection Table Number Inspection items Inspection positions cleaning and overhaul of various Check whether there is a problem with the components component and deal with it...

  • Page 39: Lubricant Inspection

    Mechanical Maintenance Manual ZL-GR6150-002-V1 To tighten and replace the screws, you must use a torque wrench to tighten with the correct torque, and then paint to fix it. In addition, it should be noted that bolts that are not loose should not be tightened with a torque higher than the required torque.

  • Page 40: Change The Lubricant

    Mechanical Maintenance Manual ZL-GR6150-002-V1 The robot maintenance needs to be regularly lubricated and overhauled in accordance with the following regulations to ensure efficiency. Attention 4.4 Change the Lubricant 4.4.1 The Oil Supply Quantity of Lubricant Table 4.6 Oil Supply Table of Changing the Lubricant Amount of The position Name for the lubricant...
  • Page 41 Mechanical Maintenance Manual ZL-GR6150-002-V1 （5）Install the hexagon socket screw plug on the lubricant filling and drain port. （6）After the oil is supplied, follow the steps in item 4.4.4 to release the residual pressure in the lubricant chamber. If the lubrication operation is not performed correctly, the internal pressure of the lubrication cavity may suddenly increase, which may damage the sealing part, resulting in lubricant leakage and abnormal operation.
  • Page 42 Mechanical Maintenance Manual ZL-GR6150-002-V1 J3 oil drain port (the high) J3 oil filling port (the low) J2 oil filling port (the low) J2 oil drain port (the high) J1 oil drain port (the high) J1 oil filling port (the low) oil filling port of wrist holder oil filling port of...

  • Page 43: Release The Residual Pressure In Lubricating Oil Cavity

    Mechanical Maintenance Manual ZL-GR6150-002-V1 The tools required are as follows: Number Specification Remarks lubricant gun with the function of checking and counting oil oil supply joint[M10x1] one piece oil supply hose[φ8x1m] one strip weight meter measure the weight of lubricant sealing tape gas source 4.4.4 Release the Residual Pressure in Lubricating Oil Cavity...

  • Page 44: Home Position Calibration

    Mechanical Maintenance Manual ZL-GR6150-002-V1 door with safety latch safety fence Fig. 4-2 Maintenance and Use Area 4.6 Home Position Calibration Home position calibration refers to an operation performed to associate the angle of each robot axis with the encoder count value. The purpose of the home position calibration operation is to obtain the encoder count value corresponding to the home position.

  • Page 45: Mechanical Home Position Calibration Of Each Axis

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Rotate the marking line of the home block to the fully aligned state, that is, the home position. 4.6.2 Mechanical Home Position Calibration of Each Axis When re-calibrating the mechanical home position of each axis of the robot, operate the robot in the jog mode to make each axis of the robot run to the home position alignment mark of each axis, use home calibration tooling to zero, and then enter the home position information interface of the robot teaching box to record the coordinates of each axis.
  • Page 46 Mechanical Maintenance Manual ZL-GR6150-002-V1 rotate -90˚ home position of axis-3 home position calibration tooling home position of axis-4 home position of axis-6 home position of axis-5 Fig.4-3 Robot Home Position Map CMA (WUHU) Robotics Company Limited...

  • Page 47: Appendix

    Mechanical Maintenance Manual ZL-GR6150-002-V1 Appendix A Tightening Torque Table of Screws Note: Due to the special material of the motor flange, the tightening torque cannot be too large, please refer to the note in the table to add. Tightening torque (cast aluminum) Screw 12.9 grade Tightening torque (cast iron)（Nm）...
  • Page 48 Mechanical Maintenance Manual ZL-GR6150-002-V1 gear of axis-1 reducer and input 11200011800 gear of axis-2 reducer and input 11200011801 gear of axis-3 Table 3 Hollow Wrist Name Material code Unit per Remarks robot hollow wrist wrist part 11500010715 Table 4 Sealant and others Name Model specification Application area...
  • Page 49 Mechanical Maintenance Manual ZL-GR6150-002-V1 O-ring rubber seal installation of J3 axis reducer 10300001368 O-ring rubber seal RV sleeve of J1/J2 axis 10300001340 O-ring rubber seal RV sleeve of J3 axis 10300001322 O-ring rubber seal motor installation of axis-3 10300013877 double-sided J1 axis pipeline 10300016064 dust-proof coil...
  • Page 50 Mechanical Maintenance Manual ZL-GR6150-002-V1 CMA (WUHU) Robotics Company Limited Efort Intelligent Equipment Company Limited No. 96 Wanchun East Road, Jiujiang District, No. 96 Wanchun East Road, Jiujiang District, Wuhu City, Anhui Province Wuhu City, Anhui Province www.cmarobot.com.cn www.efort.com.cn service hotline：400-052-8877 service hotline：400-052-8877 CMA (WUHU) Robotics Company Limited...

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