EFORT ER180-4-3200 Operation And Maintenance Manual
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EFORT ER180-4-3200 Operation And Maintenance Manual

Industrial robot
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EFORT Intelligent Equipment Co., Ltd.
ER180-4-3200
Mechanical Operation and Maintenance
Manual for Industrial Robot
1

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Summary of Contents for EFORT ER180-4-3200

  • Page 1 EFORT Intelligent Equipment Co., Ltd. ER180-4-3200 Mechanical Operation and Maintenance Manual for Industrial Robot...
  • Page 2 Failure to follow the instructions and warnings in this manual may cause injury to you and the people around you, and damage to the EFORT Robot or other surrounding objects. The final interpretation right of this document and all related documents of EFORT robot belongs to EFORT.

  • Page 3: Table Of Contents

    2.7.2 Allowable Maximum Static Payload Torque ................. 16 2.7.3 Allowable Maximum Moment of Inertia ................16 2.7.4 Allowable Payload Curve .......................17 2.8 Stop time and stop distance of the ER180-4-3200 ................17 Chapter Three Handling and Installation ......................18 3.1 Robot Handling ..........................18 3.1.1 Handling Precautions ......................
  • Page 4 EFORT Intelligent Equipment Co., Ltd. 4.1.2 Quarterly Inspection .......................30 4.1.3 Annual Inspection ........................31 4.1.4 Inspect Every Two Years ......................31 4.2 Overhaul of Main Bolts ........................31 4.3 Checking the Grease ..........................32 4.4 Change the Grease ..........................33 4.4.1 The Oil Supply Quantity of Grease ..................33 4.4.2 Space Orientation of Lubrication ...................

  • Page 5: Chapter One Safety

    EFORT Intelligent Equipment Co., Ltd. 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 6 EFORT Intelligent Equipment Co., Ltd. Danger! 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 starts suddenly during the operation.

  • Page 7: Safety Countermeasures Of Robot Body

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 During the operation of the robot, the operation should be carried out in a state where the emergency stop button can be pressed immediately. In order to comply with these principles, it is necessary to fully understand the following precautions and follow them.
  • Page 8 EFORT Intelligent Equipment Co., Ltd. It is strictly forbidden to supply power, compressed air, and welding cooling water outside the specifications, which will affect the performance of the robot and cause abnormal operations, malfunctions, damage and other dangerous situations. Although electromagnetic interference is related to its type or intensity, there is no perfect countermeasure with current technology.
  • Page 9 Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Operators should also maintain awareness of escape at all times during operations. It must be ensured that in an emergency, you can escape immediately. Always pay attention to the actions of the robot, and do not work with your back to the robot.

  • Page 10: Robot Body Label Description

    EFORT Intelligent Equipment Co., Ltd. 1.2 Robot Body Label Description Safety warning labels will be pasted on the robot body. These labels are pasted on specific parts of the robot body to remind users of safety matters that need to be paid attention to when operating and maintaining the robot.

  • Page 11: Abandonment Of Robots And The Environmental Control Requirements

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 maintenance manual, robot programming manual, etc. in the appropriate language, modifying the display language, and ensuring compliance with local laws and regulations. Accidents can occur when new users perform incorrect or unsafe operations without reading the manual.
  • Page 12 EFORT Intelligent Equipment Co., Ltd. Waste products should be discarded in a safe state. The waste grease and oil-involved rags that appear in the robot maintenance process need to be transferred to the special disposal device for polluting flammable and dangerous goods, and handed over to the unit with the special hazardous waste qualification for collection, transportation, treatment and disposal.

  • Page 13: Chapter Two Basic Description

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Chapter Two Basic Description 2.1 Robot system composition The industrial robot is composed of the following components: Robot body  Control Cabinet  Teach pendant  Connection (power supply) cables, etc.

  • Page 14: Machine Body Nameplate

    EFORT Intelligent Equipment Co., Ltd. Standard Length: 8 m Control cabinet power Customized Length: 12 m/16 cable m/20 m Standard Length: 8 m Control cabinet encoder Customized Length: 12 m/16 cable m/20 m Standard Length: 8 m Control cabinet brake...

  • Page 15: Body Part Composition And Direction Identification Of Each Axis

    The names of the various components of the machine body and the identification of each axis direction are shown in Figure2-3: Fig. 2-3 Body Composition and Axis Direction of ER180-4-3200 Industrial Robot 2.5 Robot Axis Range Limit and Home Position Each axis of the robot body has a home position and range limit.

  • Page 16: Installation Diagram Of J1 Axis Adjustable Limit

    EFORT Intelligent Equipment Co., Ltd. Home position of axis J2 Mechanical end Mechanical end Mechanical end stop of J3 stop of J1 stop of J2 Home position of axis J1 Mechanical end stop of J4 Mechanical end stop of J3 Fig.

  • Page 17: Installation Diagram Of J2 Axis Adjustable Limit

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Fig 2-5 J1 axis adjustable limit diagram 2.5.2 installation diagram of J2 axis adjustable limit In the design of J2 axis, in order to adjust the motion range limit according to the actual movement needs, the components for controlling the motion range are added, and the adjustment range of a certain angle value (5) can be realized by optional J2 axis limit block, as shown in the figure.

  • Page 18: Robot Performance Parameters

    EFORT Intelligent Equipment Co., Ltd. Fig 2-7 J3 axis adjustable limit diagram 2.6 Robot Performance Parameters Table 2-2 Performance Parameter Table Model ER180-4-3200 Motion Type Joint Control Axes 4 Axis Axis J1 104°/sec Axis J2 104°/sec Maximum Motion Speed Axis J3 104°/sec...
  • Page 19 Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Fig 2-5 Motion Space of ER180-4-3200 Note: The working space shown in this figure is the theoretical maximum reachable range of point p. It will change due to the influence of the installation method in actual operation. In actual use, please consider the...

  • Page 20: Allowable Value Of Wrist Payload

    EFORT Intelligent Equipment Co., Ltd. 2.7 Allowable Value of Wrist Payload The installation load at the end of the wrist of the robot is affected by the allowable weight of the wrist, the allowable load torque value and the allowable moment of inertia value, and the allowable load torque value changes according to the actual load moment of inertia.

  • Page 21: Allowable Payload Curve

    Fig. 2-6 Wrist Axis Torque Diagram of ER180-4-3200 Stop time and stop distance of the ER180-4-3200 The following table shows the measured downtime distance and downtime when the ER180-4-3200 shutdown is triggered. These measurements correspond to the following configuration of the robot: Arm span: 100% Speed: 100% (The general speed of the robot is set to 100%, and the joint speed of J1 joint is 104°/s,...

  • Page 22: Chapter Three Handling And Installation

    EFORT Intelligent Equipment Co., Ltd. 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 23: Handling Method

    If you choose a forklift to carry the robot, you need to observe whether there are fork foot position near the base of the robot.The base of the ER180-4-3200 robot has no fork feet, and external fork feet need to be installed to assist forklift handling. After handling, remove the fork foot in time to avoid interference with the movement of the robot.
  • Page 24 EFORT Intelligent Equipment Co., Ltd. allowable weight is greater than the weight of the robot body). Rubber hoses should be placed on the cables to prevent from direct contact with the robot body. During hoisting, the angle of each axis should be adjusted to the value given in the table below, so as to ensure that the center of gravity is in the middle, which is convenient for hoisting.

  • Page 25: Robot Installation

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Fig. 3-4 Forklifting Sketch Map Corresponding Fixtures must be used in handling the robot. Ensure that no pressure is put on the robot arm or electric motor if neither lifting nor forklifting is applied.

  • Page 26: Setting Of Safety Fence

    In addition, the robot might be deformed or its performance is affected if the ground is uneven. Ensure that the ground flatness rate is within 0.5 mm. Figure 3-5 illustrates the size of base interface. Fig. 3-5 Size of Base Interface of ER180-4-3200...

  • Page 27: Ground Mounting

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 3.2.3 Ground Mounting The strength rate and maximum load of the concrete ground should meet the requirements of relevant quality regulations. The thickness of the concrete ground should be no less than the depth of the buried chemical bolts and the concrete ground should cover the entire base area to ensure the safety and reliability of installation.

  • Page 28: Supporter Installation

    EFORT Intelligent Equipment Co., Ltd. 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 29: Installation Site And Environment

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Fig. 3-7 Robot stress diagram Table 3-2 Force and moment values of base Force or Explain Numerical value moment Maximum overturning 44712(N.m) moment Maximum torsional 23680(N.m) moment Maximum vertical force 27216(N)

  • Page 30: Integrated Application Installation Interface

    EFORT Intelligent Equipment Co., Ltd. Robot Environmental Conditions storage and transportation environmental working conditions conditions conditions ambient temperature 0-45℃ -40~55 ℃ relative humidity ≤80%（40℃） ≤93%（40℃） atmospheric pressure 86~106 kPa (Under 1500m) （altitude） vibration less than0.5G，4.9m/s others no corrosive gas (Note)
  • Page 31 Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Fig. 3-9 Dimensions for Rotating Base Interface Fig. 3-10 Dimensions for Big Arm Interface...

  • Page 32: Io Line And Trachea Structure

    EFORT Intelligent Equipment Co., Ltd. Fig. 3-11 Dimensions for Small Arm Interface 3.5 IO line and trachea structure...
  • Page 33 Note: 1) There are two interfaces on the robot base, the base interface and the external interface. EFORT only offers the detailed dimensions and connection methods of these two interfaces. The connectors, screws and tools are to be equipped by an user.

  • Page 34: Chapter Four Overhaul And Maintenance

    EFORT Intelligent Equipment Co., Ltd. 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.

  • Page 35: Annual Inspection

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 tightening of external main tighten the end effector screws and external main screws screws 4.1.3 Annual Inspection Table 4-3 Annual Inspection Table Number Inspection items Inspection position cleaning and overhaul of various...

  • Page 36: Checking The Grease

    EFORT Intelligent Equipment Co., Ltd. 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 37: Change The Grease

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 4.4 Change the Grease 4.4.1 The Oil Supply Quantity of Grease Table 4-6 Oil Supply Table of Changing the Lubricant Amount of The position Name for the lubricant Remarks J1 axis...
  • Page 38 EFORT Intelligent Equipment Co., Ltd. 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 Grease leakage and abnormal operation. Therefore, when performing lubrication operations, please observe the following: 1）...
  • Page 39 Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Fig. 4-1 Distribution of Filling and Drain Ports Table 4-8 Tools Required for Changing Lubricant Tools Needed Specification Remarks lubricant gun with the function of checking and counting oil [M10x1] oil supply joint...

  • Page 40: Release The Residual Pressure In The Lubricating Oil Cavity

    EFORT Intelligent Equipment Co., Ltd. [φ8x1m] oil supply hose 1 piece weight meter Measure the weight of lubricant sealing tape gas source 4.4.4 Release the Residual Pressure in the Lubricating Oil Cavity After the oil is supplied, in order to release the residual pressure in the lubrication tank, the robot should be properly operated.

  • Page 41: Home Position Calibration

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Fig. 4-2 Maintenance and Calibration Areas 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 42: Mechanical Home Position Calibration Of Each Axis

    EFORT Intelligent Equipment Co., Ltd. Mechanical Home position Calibration (Line Calibration) Rotate the marking line of the zero block to the fully aligned state, that is, the zero point. 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...
  • Page 43 Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 attention to the positive and negative polarity of the battery. Reconnect the battery cable and fix the battery pack. After installation, follow the steps to fix the rear cover of the base.

  • Page 44: Chapter Five Common Faults And Treatment Measures

    EFORT Intelligent Equipment Co., Ltd. Chapter Five Common Faults and Treatment Measures When the robot body fails, please refer to this chapter for initial fault diagnosis. The conditions listed below cover the common faults that may occur on the robot body, the analysis of the fault causes, and the corresponding handling measures, which can help users to troubleshoot common faults.
  • Page 45 Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 collision; to avoid collision and long-term overload operation, and regularly （2）Long-term overload operation; replace the Grease according to the maintenance requirements of this （3）Long-term operation in the manual. absence of maintenance.
  • Page 46 EFORT Intelligent Equipment Co., Ltd. by hand following conditions to base and joint fixing screws, end flange cause shaking: connection screws, etc., use a torque （1）Loose screws at key wrench to tighten with the required connection parts; torque; （2）Damage to internal （2）If it can be determined that the...
  • Page 47 Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 influence of gravity. enters the motor brake, the seal failure, and then replace the causing the brake to fail. motor after solving the seal problem. (1)The joint parts are abnormal due to impact or...
  • Page 48 EFORT Intelligent Equipment Co., Ltd. （1）The position accuracy cannot be guaranteed due to loose screws and abnormal （1）Tighten the screws and check the The robot repeat Shift connection of the main joint connection; positioning accuracy command body structure; （2） Adjust and restore the shifted joint...

  • Page 49: Appendix

    Mechanical Operations and Maintenance Manual for Industrial Robot ER180-4-3200 Appendix A Screw Tightening Torque Table Tightening torque (cast Tightening torque (cast Screw 12.9 grade iron) aluminum) 2±0.18 2±0.18 4.5±0.33 4±0.33 9.01±0.49 7.35±0.49 15.6±0.78 12.4±0.78 37.2±1.86 30.4±1.86 73.5±3.43 59.8±3.43 128.4±6.37 104±6.37 204.8±10.2...
  • Page 50 EFORT Intelligent Equipment Co., Ltd. Motor gear of axis J3 ER180-C104-01-05 Base component Small arm Motor gear of axis J4 ER180-C104-04-02 component Table 4 Wrist Name Model Unit per robot Position Wrist ER180-C104-04 Wrist Table 5 Sealant and others Name...
  • Page 51 The technical data and illustrations are for reference only, and we reserve the right to change them. EFORT INTELLIGENT EQUIPMENT CO.,LTD No.96 East Wanchun Road, China(Anhui) Pilot Free Trade Zone Wuhu Area, Wuhu, Anhui Province, China website:http://www.efort.com.cn...

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