Hyundai Robot HX300060301MME2 Manipulator Maintenance Manual - HX200L , HX200L-2000, - HX300 , HX300L, - HX400
The information presented in the manual is the property of HHI. Any copy or even partial is not allowed without prior written authorization from HHI. It may not be provided to the third party, nor used for any other purposes. HHI reserves the right to modify without prior notification. Printed in Korea - Oct. 2005. 1st Edition Copyright ⓒ 2005 by Hyundai Heavy Industries Co., Ltd.
Contents 1. 1. Safety Safety............................................................................................ 1-1 1.1. Introduction ............................................................................................ 1-2 1.2. Relevant Safety Regulations ................................................................. 1-4 1.3. Safety Training....................................................................................... 1-4 1.4. Safety Related Nameplate...........................
Contents 2.5. Axis Identification................................................................................. 2-11 2.6. Details of Wrist Axis Attachment Surface ............................................ 2-12 2.7. Details of Upper 1st ARM Attachment Surface..................................... 2-13 2.8. Application Wiring and Inspection Wiring Diagram .............................. 2-14 2.8.1. Details of Customer Application Connectors..................................... 2-15 2.9.
.1.8. A1 Frame - Gear Box........................................................................ 5-14 5.1.9. Wrist - Gear Box ............................................................................... 5-15 5.2. Battery Replacement ........................................................................... 5-16 5.2.1. Instructions for Battery Storage......................................................... 5-18 5.3. Internal Wiring.......................................................................
Contents List of Figures Figures List of Fig 1.1 Recommended Size for Fence and Gate Hole (Square Gate)......... 1-8 Fig 1.2 Recommended Size for Fence and Gate Hole (Slot Gate) .............. 1-8 Fig 1.3 Placement of Peripheral Equipment and Operator ........................ 1-10 Fig 1.4 Space for robot installation............................................................. 1-14 Fig 1.5 Robot’s Safety Circuit .................................................................... 1-24 Fig 1.
Fig 6.2 Encoder Reset Connector.............................................................. 6-18 Fig 8.1 Manipulator Configuration................................................................ 8-2 Fig 8.2 Motor and Brake wiring connection No.1 ......................................... 8-3 Fig 8.3 Motor and Brake wiring connection No.2 ......................................... 8-4 Fig 8.4 Encoder wiring Connection No.1 ..................................................... 8-5 Fig 8.
1. Safety 1.
1. Safety HX200/HX200L-2000/HX300/HX300L/HX400 1.1. Introduction The main purpose of this chapter is to describe the safety precautions for users and operators who repair and manipulate the industrial robot. This manual describes safety precautions for robot manipulator and controller, in comply with the requirement of ANSI/RIA R15.06-1999, Standard for Safety, Industrial Robots, and qualified with safety regulations.
1. Safety It is applied to the 6-axis industrial robot used by installing on the surface of wall or plane (axes addable). It is also appropriate for controlling operation in the dotted section or consecutive section. Major application is Spot welding Handling Assembly Application such as Sealing MIG/MAG welding Palletizing Grinding For the other use than the above emergency application, make a contact with our company to consult on the robot use and possible applications.
HX200/HX200L-2000/HX300/HX300L/HX400 1.2. Relevant Safety Regulations The robot is designed as per ISO10218.Jan. 1992 , safety standards for industrial robots, and furthermore in comply with ANSI/RIA 15.06-1999 regulations. 1.3. Safety Training All the personnel who intend to teach, operate or inspect the robot must be trained in an approved robotic operation and safety training course before start-up.
1. Safety 1.4. Safety Related Nameplate 1.4.1. Safety Marking For the purpose of effective safety instructions, the following safety symbols are used in this manual. Table 1-1 Safety marking Symbols Descrptions Warning Indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel and damage to equipment. The special attention must be paid to the operation and handling. Mandatory Indicate the compulsory measures that should be performed.
HX200/HX200L-2000/HX300/HX300L/HX400 1.4.2. Safety Nameplate Identification plates, warning label and safety symbols are attached to the robot and to the inside and outside of control panel. The designation labels and cable Mark for wire harness between the robot and control panel, and the cables inside/outside of control panel are provided. All of these plates, labels, symbols and marks constitute safety-relevant parts of the robot and the control panel.
1. Safety 1.5. Definition of Safety Functions Emergency Stop Function - IEC 204-1,10,7 There is one emergency stop button on the controller and teaching pendant respectively. If necessary, additional emergency buttons should be able to connected to the robot's safety chain circuit. The emergency stop function, which overrides all other robot controls, stops all moving parts by disconnecting power supply, and removes drive power to prevent the use of other dangerous functions controlled by the robot.
HX200/HX200L-2000/HX300/HX300L/HX400 1.6. Installation 1.6.1. Safety Fence 1.5m (60") Min 0.3m (12") Max Install safety fence against the possible collision between the robot and workers, so that no worker may approach the robot .When operators or other personnel enter the robot's working envelope by accident, it may cause an accident.
1. Safety ② The safety fence should be a fixed type in principle, using harmless materials that do not have any broken surface or projecting part. ③ Install the safety fence with an entrance gate, and register the safety plug at the gate so that it does not open unless pulling the plug out. Interlock the robot to be MOTORS OFF when the safety plug is pulled out., or wire the robot to be MOTORS OFF when the safety fence is open. (Refer to “11.
HX200/HX200L-2000/HX300/HX300L/HX400 1.6.2. Placement of Robot & Peripheral Equipment (1) Make sure that the power supply is off before operating, when connecting the primary power of controller or peripheral equipment. There is a possible danger of electric shock because the high voltage such as 220V and 440V is used as its primary power. (2) Post a sign [No enter during operation] up the safety fence gate, and inform the operators of its purport.
1. Safety (5) Make sure that the robot manipulator and the wiring and piping of controller, interlock panel, and timer should not be placed in the way of operator's working range so that they would not be directly stepped on by FORK and LIFT. There is a possible danger of accident if the workers are affected by electricity or the wiring is down. (6) Place the controller, interlock panel, and handling stand within the sight of robotic performance.
HX200/HX200L-2000/HX300/HX300L/HX400 1.6.3. Installing the Robot Install the robot as per the planning and layout which has been previously reviewed and studied for its optimized performance and functionality. In case of poor conditions for robot installation, the serious problems can take place, including error of relative position between robot and workpiece during operation, bad performance quality of robot caused by vibration, shortening lifetime, and cause of serious accidents.
1. Safety (3) Install at the ambient temperature ranged 0~45℃. (4) Secure sufficient space for the easier disassembly and maintenance. (5) Install safety fence with a gate, and prohibit any person from entering the robot's working envelope. (6) Remove any obstacles out of the robot’s working envelope. (7) Take a special measure, considering thermodynamics of controller, if the robot is installed near the heating elements or places exposed directly to the sun.
HX200/HX200L-2000/HX300/HX300L/HX400 1.6.4. Space for Robot Installation Install robot after securing sufficient space for maintaining the robot manipulator, Hi4a controller, and other peripheral equipment. Install the robot manipulator and controller, securing space for installation as per the guideline as described in the figure below. Install Hi4a controller outside of the safety fence in order to monitor the robot manipulator and to operate in a safe way.
1. Safety 1.7. Safety Operation for Robot Handling Follow the safety instructions to prevent any accidents. Don't modify nor ignore safety devices or circuits at any time, and be careful of electric shock. All the normal operations in an automatic mode must be performed outside of the safety fence. Check the robot's working envelope if anyone is inside before operating. 1.7.1.
HX200/HX200L-2000/HX300/HX300L/HX400 (9) Operators must pull the safety plug out, and enter the safety fence with the plug. (10) Do not use any devices causing noise in and around the teaching area. (11) Handle the teaching pendant button, while checking the teaching point with your naked eyes, and do not handle it just relying on your sense. (12) Do not work with your back against the robot, and always pay attention to the robot's movement. (13) In teaching, check and examine carefully under your feet.
1. Safety Table 1-2 State of robot stop No. State of Robot Drive Power Access 1 Pause (Minor failure, Pause switch) ON X 2 Emergency stop (Major failure, Emergency stop switch, Safety gate) OFF O 3 Input signal standby of peripheral equipment (START INTERLOCK) ON X 4 Playback Completion ON X 5 Standby ON X Even in the accessible state of robot, be watchful against any possible sudden movement of robot.
HX200/HX200L-2000/HX300/HX300L/HX400 1.7.2. Safety Precautions for Operating Test In case of operating test, errors in design or teaching and inferiority in manufacturing are possibly seen in the entire system such as teaching program, jig, and sequence. Thus, be more careful and safe in case of operating test. Accidents may occur by these combined causes. (1) Before handling, check the stop buttons and signal functions to stop the robot such as emergency stop button or stop button.
1. Safety 1.7.3. Safety Precautions for Automatic Operation (1) While posting a sign [Do Not Enter During Operation] up the safety fence gate, ask the operators not to enter during operation. If the robot stops, you may enter the safety fence under your full understanding of the situation. (2) Be sure to check if any operators are inside of the safety fence when starting the automatic operation. Operating without checking the presence of operators may cause a personal injury.
HX200/HX200L-2000/HX300/HX300L/HX400 1.8. Safety Precautions for Access to Safety Fence Robots are very powerful and heavy even at its low speed. When entering the safety fence, one must observe the relevant safety regulations of its pertinent country. The operators always must be aware of the unexpected movements of robot. Robots are able to move fast shortly after being stopped.
1. Safety 1.9. Safety Precautions for Maintenance and Repair 1.9.1. Safety Precautions for Hi4a Controller Maintenance and Repair (1) Maintenance and repair of the robot must be performed by the personnel who was duly trained in the special maintenance training course and has a good knowledge of maintenance. (2) Perform your work following the maintenance procedures for controller. (3) Perform your maintenance and repair in a safe way by securing emergency exit or safe place.
HX200/HX200L-2000/HX300/HX300L/HX400 1.9.2. Safety Precautions for Robot System & Manipulator Maintenanace (1) Refer to the safety precautions for Hi4a controller maintenance and repair. (2) Perform your maintenance and repair for the robot system and manipulator, following the indicated procedures. (3) Be sure to disconnect the primary power of controller. Post the warning sign [Do not input power] up the primary power to prevent other workers from connecting the power.
1. Safety 1.9.3. Necessary Actions after Maintenance and Repair (1) Check if the cables or parts of controller are properly connected. (2) After maintenance is completed, carefully check that no tools are left around or inside of the controller and manipulator. Make sure that the door is firmly closed. (3) Do not turn on the power if any problems or critical failures are detected.
HX200/HX200L-2000/HX300/HX300L/HX400 1.10. Safety Functions 1.10.1. Operating a Safety Circuit Computer Commands Operating mode selector Man2 LS ASG GSG TP EN EM ASG2 GSG2 EM2 Auto2 LS2 LS1 EM1 GSG1 ASG1 MOTOR POER ON + TP EN1 & Interlocking Auto1 M + & Operating mode selector Man1 Drive Unit MSHP2 Contactor MSHP2 MSHP1 Contactor MSHP1 TP EN2 Limit switch AUTO Mode Safeguard General Safeguard Enabling device in T/P Emergency stop switch Fig 1.
1. Safety MOTORS OFF mode indicates that drive power is removed from the robot's motors and the brakes are applied. The status of the switches is displayed on the teach pendant. (Refer to the I/O monitoring screen of "SERVICE" menu, 『Hi4a controller operation manual』.) Safety circuit The emergency stop buttons on the controller panel and on the teaching pendant and external emergency stop buttons are included in the safety circuit of operation.
HX200/HX200L-2000/HX300/HX300L/HX400 1.10.2. Emergency stop An emergency stop should be activated when people or equipment is located at the dangerous area. The emergency stop buttons are located both on the control panel and on the teaching pendant. All safety control devices such as emergency stop buttons on the control panel must be located outside the working envelope and easily accessible at any time. Status of Emergency stop When the button is pressed, the robot will operate as follows.
1. Safety (1) Emergency stop for control panel and teach pendant (Basic) The emergency stop switch is on the control panel and teach pendant of the controller. Emergency stop switch Fig 1.
HX200/HX200L-2000/HX300/HX300L/HX400 (2) Emergency stop of external system External emergency stop device (button etc.) can be connected to the safety electric circuit in accordance with applied standard for the emergency stop circuit.
1. Safety 1.10.3. Operating Speed To teach the robot, the operating mode switch must be in a MANUAL mode. Then the maximum speed of robot is limited to 250mm/s.. 1.10.4. Connecting the Safety Devices External safety devices such as light beams, light curtains, safety plug, and safety mats which can be adapted by the system builder execute interlocking the controller by way of connecting with safety circuit within the controller.
HX200/HX200L-2000/HX300/HX300L/HX400 1.10.5. Restricting the working Envelope When the robot is not necessary to reach certain area for specific applications, working envelope of the robot can be limited to secure the sufficient safety working area. This will reduce the damage or loss in case of robot's collision with external safety devices such as safety fence, etc.. The movement of axes 1,2, and 3 of HR, HX can be limited by means of mechanical stopper or electrical limit switches.
1. Safety 1.11. Safety Related to End Effectors 1.11.1. Gripper (1) When a gripper is used to grip a workpiece, there should be safety precautions for unexpected dropping of the loaded workpiece. (2) When any end effectors or devices are installed on the robot arm, use the required size and piece of bolt, and securely fasten as per the required torque using torque wrench. Do not use the bolt which has rust or dirt on its surface..
HX200/HX200L-2000/HX300/HX300L/HX400 1.11.2. Tool / Workpiece (1) It must be possible to replace tools such as milling cutters in a safe manner. Make sure that safety devices are working correctly until the cutters stop rotating. (2) Grippers must be designed to keep in gripping workpiece securely even though a power failure or a control failure takes place. It must be possible to release workpiece from the gripper in a manual mode. 1.11.3.
1. Safety 1.12. Liabilities The robot system has been built in accordance with the latest technical standards and approved safety rules. Nevertheless, the serious accidents such as death or personal injury still may take place due to the collision between the robot system and peripheral equipment. The robot system must be used by operator who has a full technical knowledge on its designated use and also pay his close attention to the possible dangers and risks involved in its operation.
HX200/HX200L-2000/HX300/HX300L/HX400 Users must take the full responsibility for any accident caused by their negligence or non-observance of these instructions. The manufacturer will not take any liabilities and responsibilities for any damages or losses caused by the misuse or malfunction of such equipment which is not included in the contract between manufacturer and user and provided by user, or such equipment which is installed around the robot system arbitrarily by the user.
2. Specifications 2.
2. Specifications HX200/HX200L-2000/HX300/HX300L/HX400 2.1. Robot Machinery Part HX300 * - * Specification No. Robot TYPE Rated Payload Series Name FIg 2.
2. Specifications 2.2. Location of Robot Identification Plate The model name, serial number, and manufacturing date of robot are written down in the name plate. The name plate is located in the rear of axis H in the ARM. Product Name Model Name Serial Number Year of Manufacture Weight(Net) : Robot Mnipulator : HX165 : : : Kg Manufactured by Hyundai Heavy Industries Co., Ltd. 1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA Tel : 82-52-230-7901 Home page : www.hhi.co.
HX200/HX200L-2000/HX300/HX300L/HX400 2.3. Basic Specifications Table 2-1 Basic Specifications for Models Item Specification Model HX300 HX400 HX200L HX200L -2000 Construction Articulated Degree of freedom 6 Drive system AC servo system Arm Max. Working envelope S Swivel ±3.142 rad (±180°) H For/ Backward +1.31 ~ -1.31 rad (+75°~ -75°) V Up/ downward +0.52 ~ -2.18 rad (+30°~ -125°) ±6.283 rad (±360°) R2 Rotation 2 Wrist B ±2.094 rad (±120°) Bending ±6.
2. Specifications Item Specification Model Wrist Torque HX300 HX400 HX200L HX200L -2000 HX300L 1668 N·m 1960 N·m R2 Rotation 2 (170 kgf·m) (200 kgf·m) 1290 N·m (131.5 kgf·m) 1668N·m ((170kgf·m) B Bending 1668 N·m 1960 N·m (170 kgf·m) (200 kgf·m) 1290 N·m (131.5 kgf·m) 1668N·m ((170kgf·m) R1 Rotation 1 687 N·m 823 N·m (70 kgf·m) (84 kgf·m) 604.6 N·m (61.6 kgf·m) 687N·m (70 kgf·m) Accuracy of position repeatability ±0.
HX200/HX200L-2000/HX300/HX300L/HX400 2.4. Robot Dimension and Working Envelope Fig 2.
2. Specifications Fig 2.
HX200/HX200L-2000/HX300/HX300L/HX400 Fig 2.
786 720 540 2. Specifications 9 R1185. 67 R7 .9 24 R6 410 2000 236 1000 3073.2 200 300 150 851.2 900 2278 R1112 .3 1490.8 1186 3250.3 Fig 2.
HX200/HX200L-2000/HX300/HX300L/HX400 Fig 2.
2. Specifications 2.5. Axis Identification Table 2-2 Axis Motion Axis Name Operation Teaching Pendant Button S Arm Swivel LFT(S+) RHT(S-) H Arm Forward and Backward BWD(H+) FWD(H-) V Arm Upward and Downward UP(V+) DOWN(V-) R2 Wrist Rotation2 Rx+(R2+) Rx-(R2-) B Wrist Bend Ry+(B+) Ry-(B-) R1 Wrist Rotation1 Rz+(R1+) Rz-(R1-) RyRy+ Rx- Rx+ RHT LFT UP Rz- Rz+ DOWN FWD BWD Fig 2.
HX200/HX200L-2000/HX300/HX300L/HX400 2.6. Details of Wrist Axis Attachment Surface When attaching the operating tool to the mechanical interface of robot's wrist flange, fasten it with a bolt at P.C.D. 125. Fig 2.9 Details of Wrist Axis Attachment Surface : [HX300/400/300L] 2-Ø10H7 D.P.16 12 Ø76H7 Ø180 Ø10H7 D.P.16 6-M10 TAP D.P.13(PCD 125) 6-M10 TAP D.P.14(PCD 160) Fig 2.
2. Specifications 2.7. Details of Upper 1st ARM Attachment Surface There is a Tap in upper 1st ARM to attach peripheral equipment. Attach peripheral equipment within the range marked as ▦. [Attention] Attach peripheral equipment to the upper side of the 1st ARM, or to only one side of upper axis V. When attaching, be sure to the center position of gravity should be located within the range marked as ▦. Max weight on the A1 Frame : 80kg Max weight on the 1st ARM : 80kg FIg 2.
HX200/HX200L-2000/HX300/HX300L/HX400 2.8. Application Wiring and Inspection Wiring Diagram There are air unit and connector to connect the additional equipment to the robot manipulator. Application connectors are indicated as follows. [Note] Max air pressure of air connection : 7bar (7.1 kgf/cm2 , 101 psi) Fig 2.
2. Specifications 2.8.1. Details of Customer Application Connectors [Encoder Connector] CONNECTOR<1> CONNECTOR<2> CONNECTOR<3> Fig 2.13 Details of Application Connector (Encoder) ① CABLE SPECIFICATION : 0.3sq * 40pcs ② CONNECTOR TYPE(Receptacle) <1> CA3102A32A10PX(CNR10) <2> MS3102A24-28S(CNR10A) <3> MS3102A24-28SX(CNR10B) ③ CONNECTOR TYPE(Plug) <1> CA3106B32A10S(CNR10) <2> MS3106B24-28P(CNR10A) <3> MS3106B24-28PX(CNR10B) [Power Connector] CONNECTOR<4> CONNECTOR<5> Fig 2.
HX200/HX200L-2000/HX300/HX300L/HX400 2.9. Restricting the Working Envelope When installing the robot, take into account that the working envelope can be adjusted freely within the entire working envelope. In case of possible collision between the robot and peripheral equipment, the working envelope must be limited mechanically and by means of software. Following instructions explain how to install switches or additional stoppers for setting the working envelope of main axes. This is an optional part. 2.9.
3. Instructions 3.
3. Instructions HX200/HX200L-2000/HX300/HX300L/HX400 3.1. Robot Component Name The following [Fig 3.1] and [Fig 3.2] show and name each component of the robot. Fig 3.1 Identification of Robot Components Table 3-1 Components name No. Component Name No.
3. Instructions 3.2. Location of Safety Nameplate In order to prevent any accidents, safety marking plates such as [Fig 3.2] is attached to the robot. Do not remove or replace it unneccessarily. HYUNDAI WARNING HANDLING WIRES(4 pcs) Length : 3.5m ALVANIA 0769 GREASE 5cc Every 12 months HOSE FOR PROTECTION Length : 50cm 4-M24 EYE BOLT 경고 Moly White RE00 GREASE 30cc Every 12 months 주의 서보모터 분해시 ARM 낙하 주의 Fig 3.
HX200/HX200L-2000/HX300/HX300L/HX400 3.3. How to operate 3.3.1. Using Crane 4 Handling Wires Length : 3.5 M 4 Handling Wires Length : 3.5 M Hose for protection Hose for protection 4-M24 EYE BOLT 4-M24 EYE BOLT Fig 3.
3. Instructions Fig 3.4 How to Transport: Using crane [HX200L/300L] The following lifting instructions are valid for a "naked" robot. If additional equipment is put on the robot, the center of gravity may change and make lifting dangerous. Never walk under the robot. Pose the robot as shown in the Figure. Mount four pieces of EYE BOLTS at the four parts of Base Body. Hook 4 piece of wire hooks up with EYE BOLTS. Use 4 piece of protective hose(four parts/ 50cm) to prevent damage.
HX200/HX200L-2000/HX300/HX300L/HX400 3.3.2. Using Forklift Truck Loading Capacity minimum 3ton Fig 3.5 How to Transport : Using Forklift Truck [HX300/400/200L/200L-2000/300L] Forklift may be used for transporting the robot manipulator. The bracket for the forklift transporting, as an option, is provided. Follow the instruction for safety. Make each model taken a basic posture, referring to the Figure.
3. Instructions 3.4. How to Install NOTE: Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully.. Warning: The installation shall be made by qualified installation personnel and should conform to all national and local codes. When unpacking the robot, check if it has been damaged during transporting or unpacking.
HX200/HX200L-2000/HX300/HX300L/HX400 3.4.2. Installating the Robot Manipulator The manipulator must be firmly fixed with eight M20 bolts. Note that all eight bolts must be used. Bolts Washer Tightening Torque : M20*65 of higher(12.9) SOCKET HEAD BOLT : OD = 44mm, ID = 25mm, T = 4mm : 314Nm The stiffness of the foundation must be designed to minimize the influence of the dynamic behavior of the robot.
3. Instructions 3.4.3. Dimension of Installation Surface Fix the swivel base for robot's installation. Refer to [Fig 3.6] for the dimension. [HX300/400/200L/300L] [HX300/400] [HX130/165,HX130S/165S] Fig 3.
HX200/HX200L-2000/HX300/HX300L/HX400 3.4.4. Accuracy of Installation Surface The degree of flatness for the four attachment plate surfaces should safisty the specification. Use a shim, if necessary. The rest of the surface must be flat within ±2mm. ■ Cautions (1) The flatness of mounting plate must be within 1.0 mm. (2) The flatness of attachment plate surface for the 4 points must be within 1.0 mm (±0.5 mm). Fig 3.
3. Instructions 3.5. Allowable Load of Wrist Axis The load, which will be applied to the mechanical interface of robot's wrist axis, is restricted by allowable weight, allowable load torque and allowable moment of inertia.
HX200/HX200L-2000/HX300/HX300L/HX400 Allowable Moment of Inertia Table 3-4 Allowable Moment of Inertia Allowable Load Torque Robot Model R2 Axis Rotation B Axis Rotation R1 Axis Rotation HX300/300L 150kg·m²(15.3kgf·m·s²) 30 kg·m²(3.1 kgf·m·s²) HX400 120 kg·m²(12.2 kgf·m·s²) 50 kg·m²(5.1 kgf·m·s²) HX200L/200L-2000 117.6 kg·m²(12.0 kgf·m·s²) 58.8 kg·m²(6.0 kgf·m·s²) Loads must be kept below maximum conditions shown in [Fig. 3.8~Fig 3.10]. [Fig 3.8] and [Fig 3.
3. Instructions Allowable position of the center of gravity from the center of Axis B (The center of B axis is on the same axis of this robot, and the value of the allowable load torque and allowable moment of inertia of B and R2 axes are the same. Therefore, if the allowable condition on the B axis is satisfied, it guarantees to satisfy that on the R2 axis..) ① Allowable position of the center of gravity from the allowable torque LB ≤ (Allowable Torque) / (Load Weight) LB = 1668 N·m / (200Kg×9.
HX200/HX200L-2000/HX300/HX300L/HX400 ■ Torque Map Fig 3.8 Wrist Axis Torque Mapping:[HX300/300L] Fig 3.
3. Instructions Fig 3.
HX200/HX200L-2000/HX300/HX300L/HX400 3.6. Recommended Standy Posture Selecting a good standby posture can save energy and reduce motor temperature. If the tool is positioned as the figure below, the load on H and V-axes may be minimized. In case that the posture shown below might not be attained due to the limited space and time caused by peripheral equipment or cycle times, then contact our company. Fig 3.
4. Inspection 4.
4. Inspection HX200/HX200L-2000/HX300/HX300L/HX400 This chapter provides the instructions for regular inspection and overhaul necessary for the prolonged lifetime of robot performance. 4.1. Inspection Item and Period Inspection is positively necessary to continue and maintain the high performance of robot for long-term operation. There are daily inspection and regular inspection.
4. Inspection 4.2. Inspection Item and Period Table 4-2 Inspection Items and Periods Inspection Intervals No.
HX200/HX200L-2000/HX300/HX300L/HX400 Inspection Intervals No.
4. Inspection 4.3. Inspection of Main External Bolts The recommended bolt torque is shown in [Fig 4.1]. Apply the appropriate torque, where required, using the torque wrench and place the paint marking where the check-up is completed Table 4-3 Inspection part for main bolts No. Inspection parts No.
HX200/HX200L-2000/HX300/HX300L/HX400 Fig 4.
4. Inspection 4.4. Inspection of Wrist Backlash Check a diversion by forcing the end-effector (End Effector : spot gun, hand device, etc.), which is attached to the vertical hem of Wrist, in the direction of back and forth, right and left, and up and down. Fig 4.
HX200/HX200L-2000/HX300/HX300L/HX400 4.5. Inspection Internal Wiring Flexible cables are used for internal wiring of robot manipulator. However, when an internal cable is broken or crushed, the robot may malfunction. Therefore, regular inspection is required. When operating in the working envelope according to following inspection conditions, inspection must be completed in advance. 4.5.1.
4. Inspection 4.5.2. Inspection Part Inspection part Fig 4.
5. Maintenance 5.
5. Maintenance HX200/HX200L-2000/HX300/HX300L/HX400 5.1. Grease Replenishment/Replacement Attention If greasing is performed incorrectly, the internal pressure of the grease bath may suddenly increase, possibly causing damage to the seal, which would in turn lead to grease leakage and abnormal operation. When performing greasing, therefore, observe the following cautions. ① Before starting to grease, remove the plug from the grease outlet.
5. Maintenance 5.1.1. S-Axis Reduction Gear Attention If grease is added without removing the outlet plug, the grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug. ■ Grease Replenishment ① Remove the grease outlet plug. ② Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 500cc ③ Attach the outlet plug with seal tape. ■ Grease Replacement ① Remove the grease outlet plug.
HX200/HX200L-2000/HX300/HX300L/HX400 5.1.2. H-Axis Reduction Gear Attention If grease is added without removing the outlet plug, it cause damage to the seal of reduction gear and grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug. ■ Grease Replenishment ① Make the H-Axis Arm vertical for ground.(H:90°-Floor Type, H:0°-Shelf Type ) ② Remove the grease outlet plug. ③ Inject the grease into the grease inlet using a grease gun.
5. Maintenance ■ Grease Replacement ① Make the H-Axis Arm vertical for ground.(H:90°-Floor Type, H:0°-Shelf Type ) ② Remove the grease outlet plug. ③ Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 1,600cc ④ The grease replacement is complete when new grease appears in the outlet port. The new grease can be distinguished from the old one by color.
HX200/HX200L-2000/HX300/HX300L/HX400 5.1.3. V-Axis Reduction Gear Attention If grease is added without removing the outlet plug, it cause damage to the seal of reduction gear and grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug. ■ Grease Replenishment ① Make the V-Axis Arm horizontal for ground.(V:0°-Floor Type, V:-90°-Shelf Type ) ② Remove the grease outlet plug. ③ Inject the grease into the grease inlet using a grease gun.
5. Maintenance ■ Grease Replacement ① Make the V-Axis Arm horizontall for ground. (V:0°-Floor Type, V:-90°-Shelf Type ) ② Remove the grease outlet plug. ③ Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 1,600cc ④ The grease replacement is complete when new grease appears in the outlet port. The new grease can be distinguished from the old one by color.
HX200/HX200L-2000/HX300/HX300L/HX400 5.1.4. R2-Axis Reduction Gear Attention Do not inject excessive grease. The excessive grease would cause an abnormal operation. ■ Grease Replenishment ① ② ③ ④ Prepare a grease nipple A-PT1/4. Remove the grease outlet plug. Remove the grease inlet plug and install grease nipple A-PT1/4. Inject the grease into the grease inlet using a grease gun.
5. Maintenance 5.1.5. B-Axis Reduction Gear Attention Do not inject excessive grease. The excessive grease would cause an abnormal operation. ■ Grease Replenishment ① ② ③ ④ Prepare a grease nipple A-PT1/8 and then Make the R2-Axis 0°degree. Remove the grease inlet plug and install grease nipple A-PT1/8. Make the R2-Axis -90°degree and then Remove the grease outlet plug. Inject the grease into the grease inlet using a grease gun.
HX200/HX200L-2000/HX300/HX300L/HX400 ■ Grease Replacement ① ② ③ ④ Prepare a grease nipple A-PT1/8 and then Make the R2-Axis 0°degree. Remove the grease inlet plug and install grease nipple A-PT1/8. Make the R2-Axis -90°degree and then Remove the grease outlet plug. Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 950cc ⑤ The grease replacement is complete when new grease appears in the outlet port.
5. Maintenance 5.1.6. R1-Axis Reduction Gear Attention Do not inject excessive grease. The excessive grease would cause an abnormal operation. ■ Grease Replenishment ① Remove the grease outlet plug. ② Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 200cc ③ Wipe the outlet port with a cloth and attach the outlet plug with seal tape.
HX200/HX200L-2000/HX300/HX300L/HX400 ■ Grease Replacement ① Remove the grease outlet plug. ② Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 435cc ③ The grease replacement is complete when new grease appears in the outlet port. The new grease can be distinguished from the old one by color. ④ Wipe the outlet port with a cloth and attach the outlet plug with seal tape.
5. Maintenance 5.1.7. Bearing Joint Parts ■ Grease Replenishment ① Prepare a grease nipple A-PT1/8. ② As necessary, remove grease inlet plug and install grease nipple A-PT1/8. ③ Inject the grease into the grease inlet using a grease gun. Grease type : Alvania0769 Amount of grease : 3cc ④ Remove grease nipple A-PT1/8 from grease inlet port. ⑤ Reinstall the grease plugs with seal tape.
HX200/HX200L-2000/HX300/HX300L/HX400 5.1.8. A1 Frame - Gear Box ■ Grease Replenishment ① ② ③ ④ Prepare a grease nipple A-PT1/8. Remove the grease outlet plug. Remove the grease inlet plug and install grease nipple A-PT1/8. Inject the grease into the grease inlet using a grease gun. Grease type : Alvania0769 Amount of grease : 30cc ⑤ Remove grease nipple A-PT1/8 from grease inlet port. ⑥ Reinstall the grease plugs with seal tape.
5. Maintenance 5.1.9. Wrist - Gear Box ■ Grease Replenishment ① Prepare a grease nipple A-PT1/8. ② Remove the grease inlet plug and install grease nipple A-PT1/8. ③ Inject the grease into the grease inlet using a grease gun. Grease type : Alvania0769 Amount of grease : 30cc ④ Remove grease nipple A-PT1/8 from grease inlet port. ⑤ Reinstall the grease plugs with seal tape.
HX200/HX200L-2000/HX300/HX300L/HX400 5.2. Battery Replacement The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every two years. To replace batteries observe the following procedure. ① Keep the power on. Press the Emergency Stop button to prohibit the robot motion. Attention Replacing the batteries with the power supply turned off causes all current position data to be lost. Therefore, zeroing will be required again. ② Dettach the battery bracket.
5. Maintenance Attention Do not dipose the batteries. Dispose of the battery with industrial waste acoording to the laws and other rules in the country where the controller is installed. Do not recharge the batteries, otherwise batteries may result in exploding or everheating. Do not use any batteries other than the recommended one. Change the batteries only with the specified one. Do not short positive and negative terminals of battery.
HX200/HX200L-2000/HX300/HX300L/HX400 5.2.1. Instructions for Battery Storage ① Do not keep the batteries at a high temperature and humidity. Keep it in the well-ventilating place without dew condensation. ② Keep it in a normal temperature, at relatively constant temperature(20±15℃) and at relative humidity of less than 70%. ③ Check the battery storage every six months, and manage them with first-in-first-out.
5. Maintenance 5.3. Internal Wiring Replacement cycle of internal wiring depends on follows. Continuous operation Operating speed Atmosphere/environment Inspect on a regular basis,every three months and check any damage on the cables or cable protect spring. If any damage, replace it. Replace the cable every 16,000 operating hours regardless of working condition. Attention As all the wires are flexible type, do not use any wires other than specified one. Wiring replacement must be done by unit.
HX200/HX200L-2000/HX300/HX300L/HX400 5.3.1. Wiring Connection Diagram Refer to [Fig 5.1] for part symbols of the internal wiring. CONNECTOR BJ2 BJ1 CN JUNCTION BOX CONNECTOR HX300-J2-MB1-A S-Axis MOTOR Brake HX300 - J2 - MB1 - A REVISION CODE(A, B, C... ) Axis No.
5. Maintenance Fig 5.
6. Trobleshooting 6.
6. Trobleshooting HX200/HX200L-2000/HX300/HX300L/HX400 6.1. Troubleshooting Procedure If a failure occurs during robot's operation, but it does not stem from the controller, it must be caused by damage on machine parts. The way to troubleshoot as quick and easy as possible should be to diagnose the problem. In addition, it is necessary to determine which parts cause the problem. (1) Step 1 : Which axis occurs the problem? First of all, check which axis causes the malfunction.
6. Trobleshooting 6.2. Trouble Symptoms and Possible Causes As shown in [table 6-1], there may be many parts as the cause of one phenomenon. Refer to next page to determine which part is malfunction.
HX200/HX200L-2000/HX300/HX300L/HX400 6.3. Diagnostics and Resolutions for Major Parts Failure 6.3.1. Fulcrum Bearings Vibration, abnormal sound and overloads are observed when a fulcrum bearing is damaged. When the Nut holding bearings becomes loose, bearing play occurs. It may damage the bearings. Diagnostics ① Shake the 1st ARM and 2nd ARM back and forth to check if bearing exhibits any play.
6. Trobleshooting 6.3.2. Reduction Gear Vibration and abnormal sound will be occurred when a reduction gear is damaged. In this case, it causes overload and abnormal deviation disturbing normal operation. Sometimes overheating may result. The robot may also become completely immovable, or a position offset error may occur.
HX200/HX200L-2000/HX300/HX300L/HX400 Resolution ① Replace the reduction gear. ② Replace the entire wrist section.
6. Trobleshooting 6.3.3. Brakes In case of brakes failure, each axis possibly drops with the motors [OFF]. Or, in reverse, brakes possibly operate even with the motors [ON]. The latter causes overload and noise. When intending to operate the entire robot without the motors [ON], operate it with the brake release switch [ON]. Before turning the switch [ON], take necessary precautions to prevent the ARM from dropping as the robot ARM will drop by gravity. .
HX200/HX200L-2000/HX300/HX300L/HX400 6.3.4. Motor Motor failure causes abnormal operation of robot such as staggering at stop, irregular twitching and noise in operation. Besides, It may cause overheating and abnormal sound. Check the reduction gear and fulcrum bearing as well in order to determine which part causes the abnormality. It is because that similar phenomenon is observed when the reduction gear is damaged. Diagnostics ① Check for overheating and abnormal sound. .
6. Trobleshooting 6.3.5. Encoder Position offset, malfunction, and out of control movement as well as staggering at stop, irregular twitching may occur when the Encoder is in bad condition. This case has nothing to do with such phenomena as mechanical abnormal sound, overheating, and vibration Diagnostics ① Check for any encoder data failure. ② Use reference pins and blocks to check the positional data is correct at pin position.
HX200/HX200L-2000/HX300/HX300L/HX400 6.4. Motor Replacement Warning: When motor is separated, the ARM will drop due to its built-in brakes inside the motor for holding robot's posture. Take necessary precautions such as fixing A2 FRAME with 2nd ARM by using M20×250 bolts or lifting and hanging the ARM by using crane as shown in the Figure in order to prevent such dropping. Do not hold the ARM in your hand. In case of contacting the motor right after it stops, ensure the motor temperature.
6. Trobleshooting Fig 6.1 How to prevent dropping of ARM Axis H & V Warning: In this work, there is a part performed with the motor [ON]. Therefore, perform the work in pairs. An observer must always be ready to activate an emergency stop. The other perform the work quickly and carefully. An escape route should be determined before starting work. After replacing axis H or V, ensure that M20 bolt for supporting ARM has been removed before operating the robot.
HX200/HX200L-2000/HX300/HX300L/HX400 6.4.1. Necessary Tools and Parts Table 6-3 Necessary Tools Tool Name Axis Name Part No.(Model) S, H, V M12 Torque wrench (Lock type) R2, B, R1 M8 Torque wrench (Lock type) M5 Torque wrench (Lock type) Torque wrench ( prepared by user) Remark Use torque wrench and extension on the market Table 6-4 Necessary parts Part Name Dropping preventive bolt (optional) Axis Name Use or not Part No.
6. Trobleshooting 6.4.2. How to Replace Motor (1) Put the controller into TEACH mode and select motors [ON]. When the motors [On] state cannot be obtained, check the respective ARM is firmly fixed while supporting it to prevent dropping. And then begin at step No.4. (2) The axis requiring motor replacement takes basic posture. (3) In case of main axes(S, H, V) : Refer to [Fig 6.1]. Insert a supporting bolt to prevent ARM dropping. In case of wrist axes (R2, B, R1) : Set the origin by using SACLES.
HX200/HX200L-2000/HX300/HX300L/HX400 Warning Before encoder correction, check motor connections, with motors [ON], while pressing the Enable switch for 2~3 seconds. (13) Perform the encoder calibration about the axis whose motor is replaced. Refer to the chapter [Encoder Calibration] in the controller operating manual.. (14) Remove M20 bolt, a supporting bolt for preventing possible dropping of axis H or V. (15) Confirm that there is no error in robot's motion.
6. Trobleshooting 6.5. Encoder Zero Setting It is necessary to reset the origin when encoder data has been corrupted due to some problems and when the motor is replaced. Level and Block is adopted as the position setting method for each axis. The origin must be set in order of axis 4, 5, and 6 considering axis interference of the wrist due to its structural characteristic. Warning In this work, there is a part performing in the state of motor [ON]. Therefore, this work must be performed in pairs.
HX200/HX200L-2000/HX300/HX300L/HX400 6.5.1. Zero Setting ① Put the controller into TEACH mode and select [MOTORS ON]. If you cannot select MOTOR On due to abnormality, set the origin position of the robot by using the brake release switch. ② Move respective axes to the basic posture, then set them by the scale mark. ③ Reset the Encoder. Refer to 『6.5.2 Encoder Reset』for the method of encoder reset. ④ Correct the encoder. Refer to 『Hi4a Controller Operation Manual』.
6. Trobleshooting 6.5.2. Encoder Reset ① Turn the controller power [ON] for 3 minutes, and then turn it [OFF]. ② Take off the rear cover of the robot. (Check the batteries/encoder backup batteries are well conneceted.) ③ Turn the controller power [ON]. ④ After connecting the reset connector(CNRST1∼6) of the axis to reset with the plug located in the cover of the rear robot for 5 seconds, pull the reset plug out. (Reset connectors of the respective axis should be connected for the reset work only.
HX200/HX200L-2000/HX300/HX300L/HX400 Fig 6.
6. Trobleshooting 6.5.3. Confirming the Reset Warning This operation is used to verify an encoder reset was performed correctly. Note this procedure is different from『Encoder Calibration』which determines encoder data from basic posture of the robot. The number of pulses per revolution of the currently used encoder data is 8192bit irrespective of the robot model. The current value of encoder displays what is added by compensation value to the actual encoder value.
HX200/HX200L-2000/HX300/HX300L/HX400 6.5.4. Encoder Calibration(Data input) and Selection IT is necessary to compensate encoder data for the basic position of each axis. Refer to 『Encoder calibration』in the Controller Manual for details. Select 『Encoder calibration (Position Rec)』in the mode of Constant. [Encoder Calibration Screen] 08:09:05 *** Encoder offset *** S =［00400000］ S =［00400000］ H =［00400000］ H =［00400000］ V =［00400000］ V =［00400000］ R2=［00400000］ R2=［00400000］ A:0 S:3 ［ 0.0］ ［ 90.
7. Recommended Spare Parts 7.
7. Recommended Spare Parts HX200/HX200L-2000/HX300/HX300L/HX400 The recommended spare parts for robot are as follows. Please check robot serial number and manufacturing date when purchasing, and contact our serive office.
7. Recommended Spare Parts Manufacturer Category Part Name Per Unit Applicable Model Specification C C C C C C C C RV Reduction gear RV Reduction gear RV Reduction gear RV Reduction gear RV Reduction gear RV Reduction gear RV Reduction gear RV Reduction gear Application Use Rec.
HX200/HX200L-2000/HX300/HX300L/HX400 Table 7-2 Spare Parts ListⅡ Caterogy Part Name Manufacturer Applicable Model Specification Per Unit Use Application Rec.
7. Recommended Spare Parts Table 7-3 Spare Parts List Ⅲ CategoryPart Name D D D D D Taper Roller Bearing Taper Bearing Taper Bearing Double Row Roller Bearing shperical Roller bearing Manufacturer Specification Applicable Model Per Unit Use Rec.
HX200/HX200L-2000/HX300/HX300L/HX400 Table 7-4 Spare Parts List Ⅳ Part Name Manufacturer Category Specificatio Dwg. No. n Applicable Model Per Unit Application Use Rec.
7. Recommended Spare Parts Table 7-5 Spare Parts List Ⅴ Part Name Manufacturer Specification Dwg. No. Category Per Unit Applicable Model Application Use Rec.
8. Internal Wiring Diagram 8.
8. Internal Wiring Diagram HX200/HX200L-2000/HX300/HX300L/HX400 Internal wiring is shown in a connection diagram per unit, and thus utilize it to inspect and replace the wiring. 8.1. Manipulator Configuration Fig 8.
8-3 Fig 8.2 Motor and Brake wiring connection No.1 [1] [2] [3] [4] (m) (E) (V) (v) (J) (e) (y) (R) (k) (u) (H) (P) ( j) (D) (U) (d) (G) (O) (h) (C) (T) (s) (F) (c) (w) (N) (g) (t) [4] G (TERMINAL 1.25-4R) ETFE 2.0sq0.7m (BK) ETFE 2.0sq/2.33m (BK) ETFE 2.0sq/2.91m (BK) K1V 1.25sq/0.
8-4 Fig 8.3 Motor and Brake wiring connection No.2 G (x) AF () [5] G (TERMINAL 1.25-6) G G G TS BA1 BA2 BA3 BA4 BA5 BA6 (TERMINAL 2-6) MB MB [5] G (TERMINAL 1.
8-5 Fig 8.4 Encoder wiring Connection No.1 (r) (W) (f) (m) M5E P5E ECE [8] (Terminal 2x1.25-4s) M5E [9] (3) [10] (YE) (WH) (GY) (BK) M5E RST1 P3E1 [11] (GN) (YE) (WH) (GY) (BK) P5E M5E RST2 P3E2 (2) OVT1 (WH) (BK) (WH) (1) M1 CNLS1 (WH) (BK) (2) (1) LB2 (OG) /PC2 Bundle 6ECE wires & pressure in contact. After soldering KV0.
8-6 Fig 8.5 Encoder Wiring Connection No.2 (S) (b) (AF) (AD) M5E P5E ECE (2) (2) (1) CNLB4 [9] (3) [10] M5E [10] P3E4 (2) [10] (1) [10] [11] M5E [9] (3) [10] (BK) [11] LB4 (WH) (BK) (WH) LB3 [11] (YE) (WH) (GY) (BK) (7) (8) (9) (10) P5E M5E RST3 P3E3 (YE) (WH) (GY) (BK) Bundle 6ECE wires & pressure in contact. After soldering KV0.
8-7 Fig 8.6 Encoder Wiring Connection No.
8-8 (W) (f) (s) (AB) (n) (w) (h) ( t) (p) (x) (O) (Y) (U) (d) (P) (Z) (V) (e) (a) (k) (E) (M) (J) (R) (S) (b) (X) (g) (T) (c) (F) (N) (C) (K) (A) (G) (D) (L) (B) (H) CNR010 G G (GN) (WH) (BK) (WH) (3) (4) (5) (6) (7) (8) (9) (10) (12) A03 A04 A05 A06 A07 A08 A09 A10 ECE (GN) (WH) (BK) (WH) (RD) (WH) (BN) (WH) (2) (3) (4) (5) (6) (7) (8) (9) (10) A12 A13 A14 A15 A16 A17 A18 A19 A20 ECE (PK) (BU) (PK) (PP) (PK) (OG) (PK) (LBU) (PK) SHIELD (GN) (WH) (BK) (WH) (RD) (WH) (BN) (WH) (3) (4) (5) (6
CNR020 EB 8-9 G [13] SP1 H G (TERMINAL 2-6) TS7A I G [14] TS7 C Bundle two wires & solder in contact. (TERMINAL 2-6) BA7 B [13] K1V 1.25sq (GN) [14] K1V 1.25sq /0.4m(GN) (12) (11) (10) (9) (8) (6) W72 (7) (5) W71 MB (BK) (4) V72 G (BK) (3) V71 (BK) (2) (BK) (BK) (BK) (BK) (BK) (GN) (BK) (BK) (BK) (1) U72 CN65 U71 E F E D MS3102A24-11P SP1 TS7A TS7 BA7 MB G W72 W71 V72 V71 U72 U71 H I C B A G F E D 8. Internal Wiring Diagram Fig 8.
9. Decommissioning 9.
9. Decommissioning HX200/HX200L-2000/HX300/HX300L/HX400 The robot is made up of several materials as shown in [Table 9-1]. Some of them should be properly arranged and sealed up to eliminate any bad influence on the human body or environment. Table 9-1 Materials of each part Parts Materials Battery NiCad or Lithium Wiring, Motor Copper Base body, A2 frame, Upper arm, Link, Hinge etc.
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