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IRB 6640
ABB IRB 6640 Manuals
Manuals and User Guides for ABB IRB 6640. We have
3
ABB IRB 6640 manuals available for free PDF download: Product Manual, Operating Manual
ABB IRB 6640 Product Manual (440 pages)
Brand:
ABB
| Category:
Robotics
| Size: 18.1 MB
Table of Contents
Table of Contents
5
Overview of this Manual
9
Product Documentation, M2004
13
How to Read the Product Manual
15
1 Safety
17
Introduction to Safety Information
17
General Safety Information
18
Safety in the Manipulator System
18
Safety Risks
19
Safety Risks During Installation and Service Work on Manipulators
19
CAUTION - Hot Parts May Cause Burns
21
Safety Risks Related to Tools/Workpieces
22
Safety Risks Related to Pneumatic/Hydraulic Systems
23
Safety Risks During Operational Disturbances
24
Risks Associated with Live Electric Parts
25
Safety Actions
26
Safety Fence Dimensions
26
Fire Extinguishing
27
Emergency Release of the Manipulator's Arm
28
Brake Testing
29
Risk of Disabling Function "Reduced Speed 250 MM/S
30
Safe Use of the Flexpendant
31
Work Inside the Manipulator's Working Range
32
Signal Lamp (Optional)
33
Safety Stops
34
What Is an Emergency Stop
34
Safety Related Instructions
36
Safety Signals in the Manual
36
Safety Symbols on the Manipulator Labels
38
DANGER - Moving Manipulators Are Potentially Lethal
42
DANGER - First Test Run May Cause Injury or Damage
43
WARNING - the Brake Release Buttons May be Jammed after Service Work
44
WARNING - the Unit Is Sensitive to ESD
45
WARNING - Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
46
2 Installation and Commissioning
49
Introduction
49
Design 1 and Design 2 of IRB 6640
50
Robot Transportation Precautions
51
Securing the Robot
58
Unpacking
60
Pre-Installation Procedure
60
Working Range and Type of Motion
62
Risk of Tipping/Stability
65
On-Site Installation
66
Lifting the Robot with Fork Lift
66
Lifting Robot with Roundslings
70
Manually Releasing the Brakes
73
Lifting the Base Plate
75
Securing the Base Plate
76
Orienting and Securing the Robot
80
Fitting Equipment on Robot
83
Installation of Cooling Fan for Motors, Axes 1 and 2 (Option)
90
Installation of Foundry Plus Cable Guard (Option No. 908-1)
97
Loads
98
Restricting the Working Range
99
Introduction
99
Mechanically Restricting the Working Range of Axis 1
100
Mechanically Restricting the Working Range of Axis 2
102
Mechanically Restricting the Working Range of Axis 3
104
Electrical Connections
107
Robot Cabling and Connection Points
107
Making Robot Ready for Operation (Foundry Prime)
109
Additional Installation Procedure
109
Commissioning (Foundry Prime)
112
Making Robotready for Operation, (Cleanroom)
113
Additional Installation Procedure, Clean Room
113
3 Maintenance
115
Introduction
115
Maintenance Schedule and Expected Component Life
116
Specification of Maintenance Intervals
116
Maintenance Schedule
117
Expected Component Life
122
Inspection Activities
124
Inspection, Oil Level Gearbox Axis 1
124
Inspection, Oil Level Gearbox Axis 2
126
Inspection, Oil Level Gearbox Axis 3
128
Inspection, Oil Level Gearbox Axis 4
130
Inspection, Oil Level, Gearbox Axis 5
132
Inspection, Oil Level Gearbox Axis 6
134
Inspection, Balancing Device
139
Inspection, Cable Harness
144
Inspection of Air Hoses (Foundry Prime)
149
Inspection of Surface Treatment (Foundry Prime)
150
Inspection, Information Labels
151
Inspection, Mechanical Stop Pin, Axis 1
154
Inspection, Additional Mechanical Stops
156
Inspection, Damper Axes 2-5
159
Inspection, Signal Lamp (Option)
161
Replacement / Changing Activities
163
Type of Oil in Gearboxes
163
Oil Change, Gearbox Axis 1
167
Oil Change, Gearbox Axis 2
170
Oil Change, Gearbox, Axis 3
173
Oil Change, Gearbox, Axis 4
176
Oil Change, Gearbox, Axis 5
179
Oil Change, Gearbox Axis 6
182
Replacement of SMB Battery
185
Lubrication Activities
188
Lubrication of Spherical Roller Bearing, Balancing Device
188
Rust Preventive Measures, Sealing Axis 4 (Foundry Prime)
190
Rust Preventive Measures, Support Bearing in Wrist (Foundry Prime)
193
Cleaning Activities
195
Cleaning, Robot
195
4 Repair
197
Introduction
197
General Procedures
198
Performing a Leak-Down Test
198
Mounting Instructions for Bearings
199
Mounting Instructions for Seals
201
Exchange of Parts on Clean Room Robots
203
Complete Robot
205
Replacement of Cable Harness, Axes 1-6
205
Replacement of Cabling, Axis 5 Motor
216
Fitting Cable Package Attachments (Cleanroom)
218
Replacement of Cable Harness, Cleanroom
226
Replacement of Cable Harness, Axes 1-4 IRB 6640ID
239
Replacement of Cable Harness, Axes 5-6 - IRB 6640ID
247
Replacement of Complete Arm System
252
Upper and Lower Arm
262
Replacement of Turning Disk
262
Replacement of Complete Wrist Unit
266
Replacement of Complete Wrist Unit, IRB 6640ID
271
Replacement of Upper Arm
274
Replacement of Complete Lower Arm
281
Frame and Base
287
Replacement of SMB Unit
287
Replacement of Brake Release Unit
290
Replacement of Spherical Roller Bearing, Balancing Device
294
Replacement of Balancing Device (Design 1)
299
Replacement of Balancing Device (Design 2)
308
Unloading the Balancing Device Using Distance Tool
319
Restoring the Balancing Device Using Distance Tool
322
Unloading the Balancing Device Using Hydraulic Press Tool
324
Restoring the Balancing Device Using a Hydraulic Press Tool
327
Motors
330
Replacement of Motor, Axis 1
330
Replacement of Motor Axis 2
334
Replacement of Motor, Axis 3
339
Replacement of Motor, Axis 4
344
Replacement of Motor, Axis 5 IRB 6640
348
Replacement of Motor, Axis 5, IRB 6640ID
353
Replacement of Motor, Axis 6, IRB 6640
356
Replacement of Motor, Axis 6, IRB 6640ID
360
Gearboxes
363
Replacement Gearbox Axis 1
363
Replacement Gearbox Axis 2
370
Replacement of Gearbox, Axis 3
378
Replacement of Gearbox, Axis 6
384
5 Calibration Information
389
Introduction
389
Calibration Methods
390
Calibration Scale and Correct Axis Position
392
Calibration Movement Directions for All Axes
393
Updating Revolution Counters
394
Checking the Calibration Position
397
6 Decommissioning
399
Introduction
399
Environmental Information
400
Decommissioning of Balancing Device
401
7 Reference Information
403
Introduction
403
Applicable Safety Standards
404
Unit Conversion
406
Screw Joints
407
Weight Specifications
410
Standard Toolkit
411
Special Tools
412
Dismounting and Mounting Tool 3HAC028920-001
415
Lifting Equipment and Lifting Instructions
430
8 Spare Parts
431
Spare Parts and Exploded Views
431
9 Circuit Diagrams
433
About Circuit Diagrams
433
Index
435
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ABB IRB 6640 Product Manual (443 pages)
Articulated robot
Brand:
ABB
| Category:
Robotics
| Size: 38.22 MB
Table of Contents
Table of Contents
5
Overview
9
Product Documentation, M2004
11
How to Read the Product Manual
13
1 Safety
15
Introduction
15
General Safety Information
16
Safety in the Robot System
16
Safety Risks
17
Safety Risks During Installation and Service Work on Robot
17
Safety Risks Related to Tools/Workpieces
19
Safety Risks Related to Pneumatic/Hydraulic Systems
20
Safety Risks During Operational Disturbances
21
Risks Associated with Live Electric Parts
22
Safety Actions
23
Safety Fence Dimensions
23
Fire Extinguishing
24
Emergency Release of the Robot's Arm
25
Brake Testing
26
Risk of Disabling Function "Reduced Speed 250 MM/S
27
Safe Use of the Flexpendant
28
Work Inside the Robot's Working Range
29
Signal Lamp (Optional)
30
Translate the Information on Safety and Information Labels
31
Safety Related Instructions
32
Safety Signals, General
32
DANGER - Moving Robots Are Potentially Lethal
34
DANGER - First Test Run May Cause Injury or Damage
35
WARNING - the Brake Release Buttons May be Jammed after Service Work
36
WARNING - the Unit Is Sensitive to ESD
37
WARNING - Safety Risks During Work with Gearbox Oil
38
2 Installation and Commissioning
39
Introduction
39
Robot Transportation Precautions
40
Securing the Robot
47
Unpacking
49
Pre-Installation Procedure
49
Working Range and Type of Motion
52
Risk of Tipping / Stability
55
On-Site Installation
56
Lifting the Robot with Fork Lift
56
Lifting Robot with Roundslings
60
Manually Releasing the Brakes
63
Lifting the Base Plate
65
Securing the Base Plate
66
Orienting and Securing the Robot
70
Fitting Cable Package Attachments (Cleanroom)
73
Fitting Equipment on Robot
81
Installation of Cooling Fan for Motors, Axes 1 and 2 (Option)
87
Loads
93
Restricting the Working Range
94
Introduction
94
Mechanically Restricting the Working Range of Axis 1
95
Mechanically Restricting the Working Range of Axis 2
97
Mechanically Restricting the Working Range of Axis 3
99
Electrical Connections
101
Robot Cabling and Connection Points
101
Making Robot Ready for Operation (Foundry Prime)
103
Additional Installation Procedure
103
Commissioning (Foundry Prime)
106
Making Robotready for Operation, (Cleanroom)
107
Additional Installation Procedure, Cleanroom
107
3 Maintenance
109
Introduction
109
Maintenance Schedule and Expected Component Life
110
Specification of Maintenance Intervals
110
Maintenance Schedule
111
Expected Component Life
116
Inspection Activities
117
Inspection, Oil Level Gearbox Axis 1
117
Inspection, Oil Level Gearbox Axis 2
119
Inspection, Oil Level Gearbox Axis 3
121
Inspection, Oil Level Gearbox Axis 4
123
Inspection, Oil Level, Gearbox Axis 5
125
Inspection, Oil Level Gearbox Axis 6
127
Inspection, Balancing Device
130
Inspection, Cable Harness
135
Inspection of Air Hoses (Foundry Prime)
140
Inspection, Information Labels
141
Inspection, Mechanical Stop, Axis 1
144
Inspection, Additional Mechanical Stops
146
Inspection, Damper Axes 2-5
148
Inspection, Signal Lamp (Option)
150
Replacement / Changing Activities
152
Type of Oil in Gearboxes
152
Oil Change, Gearbox Axis 1
156
Oil Change, Gearbox Axis 2
159
Oil Change, Gearbox, Axis 3
162
Oil Change, Gearbox, Axis 4
165
Oil Change, Gearbox, Axis 5
168
Oil Change, Gearbox Axis 6
171
Replacement of SMB Battery
174
Lubrication Activities
177
Lubrication of Spherical Roller Bearing, Balancing Device
177
Rust Preventive Measures, Bearing Axis 1 (Foundry Prime)
179
Rust Preventive Measures, Bearing Axis 4 (Foundry Prime)
182
Rust Preventive Measures, Support Bearing in Wrist (Foundry Prime)
185
Cleaning Activities
187
Cleaning, Robot
187
4 Repair
189
Introduction
189
General Procedures
190
Performing a Leak-Down Test
190
Mounting Instructions for Bearings
191
Mounting Instructions for Seals
193
Complete Robot
195
Replacement of Cable Harness, Axes 1-6
195
Replacement of Cabling, Axis 5 Motorirb 6640
207
Replacement of Cable Harness, Cleanroom
209
Replacement of Cable Harness, Axes 1-4- IRB 6640ID
222
Replacement of Cable Harness, Axes 5-6 - IRB 6640ID
230
Replacement of Complete Arm System
236
Replacement of Air Nipple and Hose (Foundry Prime)
244
Upper and Lower Arm
251
Replacement of Turning Disk
251
Replacement of Complete Wrist Unit
254
Replacement of Complete Wrist Unit, IRB 6640ID
259
Replacement of Upper Arm
262
Replacement of Complete Lower Arm
269
Frame and Base
275
Replacement of SMB Unit
275
Replacement of Brake Release Unit
279
Replacement of Spherical Roller Bearing, Balancing Device (Old and New)
283
Replacement of Balancing Device (Old and New)
287
Unloading the Balancing Device (Old and New)
296
Restoring the Balancing Device
299
Motors
302
Replacement of Motor, Axis 1
302
Replacement of Motor Axis 2
308
Replacement of Motor, Axis 3
315
Replacement of Motor, Axis 4
322
Replacement of Motor, Axis 5. IRB 6640
328
Replacement of Motor, Axis 5, IRB 6640ID
335
Replacement of Motor, Axis 6, IRB 6640, IRB 6620/Foundry Plus
338
Replacement of Motor, Axis 6, IRB 6640ID
344
Gearboxes
347
Replacement Gearbox Axis 1
347
Replacement Gearbox Axis 2
356
Replacement of Gearbox, Axis 3
363
Replacement of Gearbox, Axis 6
370
5 Calibration Information
375
Introduction
375
Calibration Methods
376
Calibration Scales and Correct Axis Position
378
Calibration Movement Directions for All Axes
379
Updating Revolution Counters
380
Checking the Calibration Position
383
6 Decommissioning
385
Introduction
385
Environmental Information
386
Decommissioning of Balancing Device
387
7 Reference Information
389
Introduction
389
Applicable Safety Standards
390
Unit Conversion
391
Screw Joints
392
Weight Specifications
395
Standard Toolkit
396
Special Tools
397
Lifting Equipment and Lifting Instructions
400
8 Spare Part List IRB 6640
401
Base Frame
401
Spare Parts - Balancing Device
403
Frame to Lower Arm
407
Lower Arm to Upper Arm
409
Upper Arm Including Wrist Unit, Motors Ax. 3- 6 (IRB 6640 and IRB 6640ID)
411
Cable Harness and SMB Unit
414
9 Circuitdiagrams
417
Introduction
417
Índice
419
ABB IRB 6640 Operating Manual (20 pages)
Brand:
ABB
| Category:
Robotics
| Size: 3.45 MB
Table of Contents
Table of Contents
5
Overview of this Manual
7
Emergency Safety Information
9
Stopping the Robot and Switching off the Power
9
Releasing a Person Trapped by the Robot Axes
10
Fire Extinguishing
16
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