Sony Desktop Robot OPERATION MANUAL CAST-AU4/B2521E GA
About this Operation Manual This Operation Manual is intended as a guide for users of the Sony Desktop Robot ROBOKIDS. Before operating this system, you should first throughly read this manual. You may not understand all of the explanations the first time through, but be on the lookout for any special directions. It should be used in conjuction with the RK card manual for your specifications.
How to Use this Operation Manual First Time Users Read this manual form chapter 1 through chapter 4 before starting any operation. The manual describes the procedures required in setting up ROBOKIDS for users who have little experience with FA (Factory Automation) equipment. Routine Assembly Follow the respective application manuals for routine assembly task operations. Replacing the Unit or Memory Card Remove the existing unit. Attach the new unit and replace the memory card.
Manual Configuration This operation manual describes the procedures required to operate the desktop robot ROBOKIDS Various types of applications such as dispensing and soldering may be accomplished by exchanging the memory cards (RK card) which stores the programs required to run an application. The semi-programmable specification allows the user to modify an operation program and peripheral task program to perform a specific work.
Contents Safety Instruction ............................................................................................................... S-1 Unpacking ........................................................................................................................... U-1 1. Outline 1-1 Nomenclature .................................................................................................................... 1-2 1-2 Outline Drawings ..........................................................
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.
Definition of warning symbols Pay particular attention to the following symbols and conventions shown on the machine and on the Operation Manual. Fully understand the contents of symbols and conventions before reading the Operation Manual. 《Machine Symbols》 Indicates a protective terminal of mechanical parts to which an external protective earth wire is connected. When the part with this mark is removed, the high voltage appears. Check the operation manual before using the part with this mark.
Safety Instruction ■ Important Safeguards ◆ The tool driving mechanism are subject to unexpected movement. Pay attention to safety measures. ◆ Turn off the main power prior to performing maintenance or inspections. Failure to observe this may result in severe injury through electric shocks or unexpected movement of the machine. ◆ Mistakes during maintenance and inspections may result in accidents. Observe the followings prior to starting maintenance or inspections: 1.
Precautions on Usage Operate on the specified voltage Operate the ROBOKIDS only on AC power voltage as specified on the label of the machine. The power cord must be directly connected to the electrical output, and grounded. The ROBOKIDS conforms with the safety requirements of the target country to which it is shipped. When a machine will not be used for extended period of time If the machine is not in use for a long period, unplug the power cord from the electrical output. To unplug, pull on the plug.
Safety Instruction Precaution on memory cards Before inserting or removing a memory card, always turn the power off. The data stored in the memory card may be damaged if a memory card is inserted or removed while the power is on. Precaution on the teaching pendant ROBOKIDS uses a teaching pendant for the CAST-PRO or SRX. The CAST-U teaching pendant and CAST-PRO teaching pendant are not compatible. Do not use the CAST-U teaching pendant with the ROBOKIDS.
On handling batteries The following battery is used in the base machine controller. 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. (1) Shorting Do not short the batteries.
Unpacking 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. NOTE Be sure to use the packaging material specified by Sony Corporation when transporting the machine. Accsesory box Remove by holding hands at the bottom as shown by the arrows.
When the machine is unpacked, make sure the following items are in the package. Base machine Operation Manual U-2 Power cable (For AC 200V to 240 V) Operation box USER I/O connector PCR-E68FS (connector) PCS-E68LA (connector cover) (Honda Communications Company) External supply power connector for USER I/O MC 1.5/2-ST-3.81 (Phoenix Contact Inc.
1. Outline 1. Outline ROBOKIDS is a desktop assembly tool designed to automate cell production systems saving a significant amount of power consumed by assembly lines. It may be used in a variety of applications by simply exchanging the work unit and memory card. The basic operation procedures are common throughout the applications enabling a smooth migration from one work to another. • The programs required for an application are stored in the memory card “RK Card”.
1-1 Nomenclature Front View X-axis Unit or tool mounting bracket Work table mounting bracket (Y-axis) X-axis stand TECH. PEN.
1. Outline Rear View Internal/external selecting switch for I/O (Upper : OUTSIDE, Lower : INSIDE) INLET (power) POWER switch Fan Z- and ZR-axis connector OPERATION BOX connector DC24V INPUT (I/O power) connector (Up to maximum 1.5 A) SAFETY connector CAST-PRO Teaching Pendant 88 SRX Teaching pendant 8 CAST-P06 (option) CAST-AU4/B2521E USER INPUT/OUTPUT connector (External I/O connector) RS232C connector (Used only when the full open programmable specification is used.
1-2 Outline Drawings ■ ROBOKIDS Standard Type (CAST-AU4/B2521E) 320 (35) 250 (Stroke) φ4 + 0.03 0 4-M4 (40) 26 4 (7) A 203 (300) + 0.03 0 2 (6) 48 (60) (69) 40 105 Detailed view of "A" 18 105 (250) (78) 90 (6) (52) 210 210 (Stroke) 10 110 (4.
1. Outline Height Adjustable Type (CAST-AU4/BT2521E) 320 (35) (300) 18 A 203 250 (Stroke) 105 105 (250) (6) (78) 90 (69) 40 230 (440) A (52) (4.
■ 3-Axes Model Z-unit 162 70 10 (13) 5 (202) 179 76 26 97 45 68 58 26 14 11 48 4-M4 ■ 4-Axes Model ZR-unit 162 97 144.
1. Outline Service Tapped-Hole Position 20 10 (250) (1.
Service Tapped-Hole Position (Tall Model) φ 4- 1-8 22 CAST-AU4/B2521E
1. Outline 1-3 Specifications 1-3-1 Machine Specifications Item Two axes specification Three axes specification with Z-axis Four axes specification with ZR-axis X-axis 250 mm 250 mm 250 mm Y-axis 210 mm 210 mm 210 mm Z-axis R-axis – – 70 mm – 70 mm 0° to 360° X-axis 300 mm/s (*1) 300 mm/s (*2) 300 mm/s (*3) Y-axis(*4) 300 mm/s 300 mm/s 300 mm/s Z-axis – 100 mm/s (*2) 70 mm/s (*3) R-axis – – 550°/s (*3) Pose-repeatability X-axis Y-axis ±0.05 mm ± 0.05 mm ±0.05 mm ± 0.
1-3-2 Control Specifications Drive method Movement method Pulse motor drive (open loop control) PTP, CP Control axis count Up to four axes (all axes simultaneous control) Interpolation function CP control speed 3-dimensional linear interpolation and 3-dimensioal circular interpolation 1 to 100 mm/s Direct teaching via teaching pendant (option) Teaching method Point program Direct data input Program capacity Full open : Total 176 Kbytes RK card : Maximum 20 work programs for one operation program.
2. Preparation 2. Preparation 2-1 Attaching the Units 2-1-1 Attaching the Z-unit 1. Fix the supplied mounting plate to the work table. (Two positions) 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) Determine the fixing position using the positioning pin that is supplied with the equipment.
4. Attach the removed front cover. (Four positions) Tightening torque 8 kgfcm 5. Connect the connectors to the Z-/ZRunit connectors. Be sure to fix the connector by tightening the screws. 6. Attach the cable holder supplied, to the post.
2. Preparation 7. Fix the cable clamp of the cable to the cable holder.
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. Hexagon socket head cap screw M4 × 6, 4 pieces Spring washer SW4, 4 pieces Flat washer W4, 4 pieces Tightening torque 15 kgfcm 3. Attach the front cover.
2. Preparation 4. Connect the connectors to the Z-/ZRunit connectors. Be sure to fix the connector by tightening the screws. 5. Attach the cable holder supplied, to the post.
5. Fix the clamp of the cable on the cable holder.
2. Preparation 2-2 Connecting the External Signal The base machine is equipped with the following connectors for external signal communication.
Connector for external switch (SAFETY) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Contents 24 V SA RETURN OUT SA EMG OUT Stop RELAY OUT (C) Stop RELAY OUT (NO) Stop RELAY OUT (NC) 0V FG SA RETURN IN SA Stop IN (C) SA Stop IN (NC) BAR (C) BAR (NC) SA Stop ENABLE 0V Safety box Max 0.1 A Connect shield of the cable RETURN indicator Stop indicator These lines can be freely used by users because these lines are prepared for independent relay to be energized at the time of stop.
2. Preparation 2. Connect the external signals to the USERl I/O connector by soldering. Connect the wires to the corresponding pins of the USER I/O connector. For the signal names and pin numbers of the respective pins, refer to the I/O connector input/output specifications, Operation Manual (or Operation Manual of Full Open Programmable in the case of the full open programmable specifications) of memory card (RK card).
■ Input Circuit USER I/O power supply source selector slide switch Up position: Externally supplied 24V Down position: Internal 24V (default setting) User external power supply connector PC board side: MC1.5/2-G-3.81 (Phoenix Contact Inc.) S1 24V 0V Note1) 24V 24V IN 0V 0V IN Pin No. 1 35 I/O connector PC board side PCR-E68LMDA (Honda communication) 0V 2 36 TLP280 Direction of current SW1 SI1 operates when SI1 SW1 is ON. Maximum 7mA (SYSRUN) 37 SI2 (Reservation input ) 4 SI3 470Ω 680pF 3 3.
2. Preparation ■ Output Circuit USER I/O power supply source selector slide switch Up position: Externally supplied 24V Down position: Internal 24V (default setting) User external power supply connector PC board side: MC1.5/2-G-3.81 (Phoenix Contact Inc.) S1 24V 0V 24V IN Note1) 24V 0V 0V IN 0V TLP127 I/O connector PC board side PCR-E68LMDA (Honda communication) Direction of current 20 SO1 Maximum (EMC-OUT) 0.
2-3 Connecting to an Electrical Outlet Prepare the power cable for AC 200 V to 240 V referring to the following connection diagram. The user must provide and wire an AC power plug to connect to the AC outlet.
2. Preparation 2-4 Starting Up the Base Machine Make sure that the main power is turned off. Connect the operation box. 2-4-1 Full-open Programmable Specification Turn on the power switch on the rear panel. Subsequent operating procedure changes depending on the application created by user. 2-4-2 When Using Memory Card “RK card” Before operation ensure that an application memory card (RK card) is inserted in the memory card slot.
3. Turn the base machine on. About five seconds later, the white indicator of START button starts flashing in green. POWER switch · · · ON 4. Press the START button. The machine starts returning home. The green indicator of the START button turns on and changes to slow flashing after completing home return. (About 30 seconds later) 5. Press the START button again. The green indicator of START button turns on and the machine starts assembling work. The START indicator lights in green.
3. Maintenance 3. Maintenance 3-1 Maintaining the Machine Clean the surfaces of the machine with a soft dry cloth. If the stain is difficult to remove, use cloth moistened with a mild detergent solution, followed by using a dry cloth. 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. Move the work table and the work unit to the ends by hand, remove the X-axis and Y-axis covers by pulling them, then remove the fallen materials such as screws. Remove the front cover of the Z-unit and ZRunit also. NOTE If the work table and the work unit are not moved to the ends as indicated, they may cause damage to the covers. 4. Wipe of the old grease and apply grease at the center of each side of the X-axis and Y-axis guide rails. Apply about 0.2 g of grease.
3. Maintenance 6. Apply grease to the Z unit and the ZR unit as shown in the same manner. 4 axes specification model 3 axes specification model 7. Attach the covers of the X-axis, Y-axis, Z unit and ZR unit to their original positions. NOTE ◆ Be careful not to damage the covers when they are reinstalled. ◆ After the covers are attached, move the respective axes using the teaching pendant until grease covers all necessary part.
3-3 Cleaning and Replacing the Air Filter Air is circulated in the controller of the base machine to cool the controller. The cooling air is introduced through the air filter on the rear of the machine. Dust may be accumulated choking the air filter which decreases the cooling power causing serious damage such as thermal breakdown of ICs if the air filter is not properly maintained. Clean the air filter once every six months. If the air filter is heavily clogged, replace the air filter.
3. Maintenance 3. Replace the media (filter). 4. Reinstall the front cover as before. Replacement media Sony Order No. .........
3-4 Replacing the Battery 1. Turn off the POWER switch and unplug the AC power cord from the AC outlet. The battery is located in the recess at the bottom on the rear of the Z-axis. 2. Exchange the battery with the new lithium battery. lithium battery NOTE Battery replacement must be completed within eight hours after the main power is turned off. If not, internal data can be damaged. Replacement lithium battery (primary battery) Sony Order No. .........
4. Troubleshooting 4. Troubleshooting 4-1 Common Items 4-1-1 Stepping Out (Note 1) The machine performs open loop servo control using a pulse motor (stepping motor) without positional feedback. The machine thus continues to operate with positional error even if it steps out due to overloading of the retaining torque of the motor. When the base machine steps out, or when it operates with positional errors, check the following items first. (1) Overloaded The base machine has a limited carrying loading.
(4) Synthesis of movements in the same direction In some programs, the machine is operated by synthesizing two movements (the FOS and PFOS with the AWAKE instruction of LUNA). When the teaching points to be synthesized are aligned on the same line, the machine can step out. When such a movement is experienced, the application program must be modified. (5) Eccentric loading When a load (tool, work, etc.
4. Troubleshooting 4-1-2 External Noise External electrical noise is a difficult problem because it is invisible. Take the following remedial measures. If the symptom disappears, electrical noise was probably the cause of the trouble. (1) Earthing the power supply Always connect the earth of the AC output to ground (Class 3 ground). If the earth is not connected, the equipment is susceptible to electrical noise.
4-2 Full-open Programmable Specifications Connect the SRX teaching pendant via a debug station and check the error codes and error history using the following procedure. 1 Connect a debug station. 2 Connect the SRX teaching pendant. 3 Press the MANAGEMENT key and select “Error History” with the F4 key by scrolling the cursor using the ↑ ↓ key. MANAGE ↑↓ sHOME RETURN CONSTANT ❙ SELECT F1 F2 F3 F4 4 The error history is displayed.
4. Troubleshooting 5 Check the error code number E*** on display and find out causes and countermeasures referring to the following table. When the machine does not operate normally, check the error contents referring to the following table. For the contents that are unique to the respective applications, refer to the Operation Manual of the memory card (RK card), and take the appropriate measures. Error No.
Error No. 4-6 Causes Solutions Correct the speed so as not to exceed the range. Replace the sensor Correct the speed so as not to exceed the range. Replace the sensor E301 X-axis limit sensor error E302 Y-axis limit sensor error E303 Z-axis limit sensor error E304 R-axis limit sensor error E314 X-axis command position error Correct the speed so as not to exceed the range. Correct the target point E315 Y-axis command position error Correct the speed so as not to exceed the range.
4. Troubleshooting 4-3 When Memory Card (RK Card) is Used The operational flow starting from turning on the main power of the machine until the programmed operation or teaching is started, is shown as follows. Causes and countermeasures when trouble occurs in the respective state from 1) to 9) are shown on the next page. Use these tables for troubleshooting. There may be a case when an error number is displayed on the teaching pendant.
Fault-Finding Chart of 1) Symptoms The simple operation teaching pendant keeps displaying “666” “E01” appears on the simplified TP. “E02” appears on the simplified TP. The main power cannot be turned on.
4.
Trouble Check Sheet If a trouble occurs, check the following items before contacting your Sony dealer or the nearest Sony FA offices. 1) 5) Name of dealer from which you purchased the ROBOKIDS Company name : Person in charge : Tel: What is the serial number of your ROBOKIDS? (It is marked on the sticker of the rear cover.) M No. R No. What type of memory card are you using ? (It is marked on the memory card.) TYPE NAME When did the trouble occur? 1.
5. Repair Parts Lists 5. Repair Parts Lists 5-1 ROBOKIDS Body Descriptions Part No.
5-3 Z/R-axis Unit Descriptions 5-2 Part No.
6. Appendix 6. Appendix ■ User Input/Output Specifications of USER I/O Connector Input Contents I/O names in terms Connector pin No. RK card specification of software (including semi-programmable specification) 3 SI1 SYSRUN Full-open programmable specification 37 SI2 Reserved by system (User cannot use it.) 4 SI3 Reserved by system (User cannot use it.) 38 SI4 Reserved by system (User cannot use it.) 5 SI5 Reserved by system (User cannot use it.
Output Contents I/O names in terms Connector pin No. RK card specification of software (including semi-programmable specification) Full-open programmable specification 20 54 SO1 SO2 EMG-OUT, stop switch, stop status output ERROR, robot error signal 21 SO3 Reserved by system (User cannot use it.) 55 SO4 Drive servo ON signal 22 SO5 ONLINE signal 56 SO6 Reserved by system (User cannot use it.
6. Appendix ■ Specifications of the Connected I/O (Used only in the semi-programmable specifications and the full open programmable specifications) Input I/O names in terms of software Contents I23 I24 START button (White button of operation box) RETURN button (To be connected from the rear SAFETY connector by user) I25 Work program No. 1 (First digit of the PROGRAM switch of the operation box (1)) I26 Work program No.
■ Connector for Debug Station Pin No.
6. Appendix ■ Connector for Operation Box I/O names in terms of software Contents 1 I25 Work program No. 1 (First digit of the PROGRAM switch (1)) 2 3 L23 L24 START LED Stop LED 4 – 0V 5 I32 Application program No. 8 (Second digit of the PROGRAM switch (8)) 6 I23 START button 7 – Stop button 8 9 – – Stop button 24 V 10 I31 Application program No. 4 (Second digit of the PROGRAM switch (4)) 11 I26 Work program No.
■ SAFETY Connector Pin No. Signal Contents 1 24V +24 V 2 3 SA START OUT SA STOP OUT RETURN indicator Stop indicator 4 STOP RELAY OUT (C) Stop output common 5 STOP RELAY OUT (NO) Stop output (NO) 6 STOP RELAY OUT (NC) Stop output (NC) 7 0V – 8 FG FG (Shielded wire, etc.) 9 SA RETURN IN RETURN switch 10 SA Stop IN (C) 11 SA Stop IN (NC) 12 BAR (C) Barrier (safety door, etc.) 13 BAR (NC) Barrier (safety door, etc.
6. Appendix ■ Connector for ZR-axis Cable Pin No.
Supply Period of Repair Parts The functional repair parts (parts needed to maintain product performance) of this machine will be supplied for up to seven years in principle after production is discontinued. 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.
1st Edition 3rd Edition November, 1998 October, 2001
Sony Manufacturing Systems Corporation Printed in Japan © 2001.
