߿ߓࠆ㧿 High-Speed Orthogonal Robot CT4 Instruction Manual Third Edition IAI America, Inc.
Please Read Before Use Thank you for purchasing our product. This Instruction Manual explains the handling methods, structure and maintenance of this product, among others, providing the information you need to know to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product. The DVD that comes with the product contains instruction manuals for IAI products.
Table of Contents Safety Guide............................................................................................................... 1 Caution in Handling .................................................................................................... 8 Names of the Parts ..................................................................................................... 9 1. Specifications Check .......................................................................................... 10 1.
. Life...................................................................................................................... 61 7. Warranty ............................................................................................................. 62 7.1 7.2 7.3 7.4 7.5 7.6 Warranty Period .............................................................................................................62 Scope of the Warranty...................................................................................
Safety Guide “Safety Guide” has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it 1before the operation of this product. Safety Precautions for Our Products The common safety precautions for the use of any of our robots in each operation. No.
No. 2 2 Operation Description Transportation 3 Storage and Preservation 4 Installation and Start Description Ɣ When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. Ɣ When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.
No. 4 Operation Description Installation and Start Description (2) Cable Wiring Ɣ Use our company’s genuine cables for connecting between the actuator and controller, and for the teaching tool. Ɣ Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around. Do not insert it. Do not put any heavy thing on it. Failure to do so may cause a fire, electric shock or malfunction due to leakage or continuity error.
No. 4 5 4 Operation Description Installation and Start Teaching Description (4) Safety Measures Ɣ When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Ɣ When the product is under operation or in the ready mode, take the safety measures (such as the installation of safety and protection fence) so that nobody can enter the area within the robot’s movable range.
No. 6 7 Operation Description Trial Operation Automatic Operation Description Ɣ When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Ɣ After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation.
No. 8 9 6 Operation Description Maintenance and Inspection 10 Modification and Dismantle Disposal 11 Other Description Ɣ When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Ɣ Perform the work out of the safety protection fence, if possible.
Alert Indication The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, and described in the Instruction Manual for each model. Level Degree of Danger and Damage Symbol Danger This indicates an imminently hazardous situation which, if the product is not handled correctly, will result in death or serious injury.
Caution in Handling 1. Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings. If the robot is operated at a speed or acceleration/deceleration exceeding the allowable value, abnormal noise or vibration, failure, or shorter life may result. 2. Keep the load moment within the allowable value. If the robot is operated under a load equal to or greater than the allowable load moment, abnormal noise or vibration, failure, or shorter life may result.
Names of the Parts Z-axis cover Screw Cover X1-axis (master axis) Y-axis Table Screw Cover Z-axis Screw Cover X2-axis (slave axis) Frame Y direction datum surface X-Y cable X-Y cable M cable PG cable Connector BOX Connector Joint Details Connector Joint X direction datum surface 9
1. Specifications Check 1. Specifications Check 1.1 Checking the Product If based on a standard configuration, this product consists of the items listed below. Check the packed items against the packing specification. Should you find a wrong model or any missing item, please contact your IAI dealer or IAI. 1.1.1 Components No. 1 Name Actuator Main Body Accessories Model number Refer to “How to Read the Model Nameplate” and “How to Read the Model Number.
1.1.4 How to Read the Model Number C T 4 - G 1 - A - 4 0 - 4 0 - 3 0 - 1 0 B - T 2 - 3 L - 㧖㧖 Identification for IAI use only (Note 1) 3L : 3m A 5L : 5m : Absolute 40 T2 : XSEL-PCT/QCT : 400mm 40 : 400mm 30 : 300mm 10B : 100mm with brake Note 1 Identification for IAI use only : It may be displayed for IAI use. It is not a code to show the model type.
1.2 1. Specifications Check 1.2.1 Specification Speed Axis Max. Speed (Unit: mm/s) Motor Type [W] Stroke [mm] Max. Speed [mm/s] X1-axis 400 400 2500 X2-axis 400 400 2500 Y-axis 400 300 2500 Z-axis 50 100 833 1.2.2 Maximum acceleration and transportable weight Acceleration and Deceleration [G] 3.2 Transportable Weight [kg] 1.0 Caution: Do not have the settings of acceleration/deceleration exceeding the rated values. It may cause vibration, malfunction or shortened life.
1.2.3 Driving System and Position Detector Motor Type [W] No. of Encoder Pluses Lead [mm] X1-axis X2-axis Y-axis Z-axis 400 400 400 50 16384 16384 16384 16384 30 30 30 10 1.2.4 Ball Screw type Type Rolled Rolled Rolled Rolled 1. Specifications Check Axis Diameter [mm] I16 I16 I16 I8 Positioning Accuracy Item Specifications X direction ±0.02 mm Positioning Repeatability Y direction ±0.02 mm Z direction ±0.02 mm X direction 0.05 mm or less Lost Motion Y direction 0.
1. Specifications Check 1.3 1.3.1 Motor • Encoder Cables Motor Cables CB-CT4-MAƑƑƑ ƑƑƑ shows the cable length. (Max 30m) Example) 080 • 8m [Minimum Bending Radius] When used under moving condition: 51mm When used in fixed condition: 34mm 4 3 2 1 CN3 4 3 2 1 CN4 4 3 2 1 CN5 B1 A1 B10 A10 M2 CN2 M1 4 3 2 1 CN1 M3 M4 L CN1 Electric wire color CN2 Width AWG18 Electric wire color Signal Name Pin No. Pin No.
1.3.2 Encoder Cables CB-CT4-PAƑƑƑ 1. Specifications Check ƑƑƑ shows the cable length.
2. Installation 2. Installation 2.1 Transportation 2.1.1 Handling of the Robot [1] Handling of the Robot Pay attention to the following when carrying the High-Speed Orthogonal Robot CT4. (described as CT4 from now on) (1) When delivered with the axes attached at the IAI factory It will be delivered in a package with an outer case fixed to a wooden base. The sliders are fixed so they will not accidently move while in transportation. x Do not damage or drop.
(2) Handling after Unpackaged Hanging hook with locking feature String’ rope, etc. Eyebolt Eyebolt Eyebolt Danger: Use the enclosed eye bolts to tighten the unit firmly. It is extremely dangerous to use unspecified eye bolts or to have bolts not tightened firmly enough since it may cause a drop of the product. Also, for those tools such as a crane and hook, choose standardized ones with enough stiffness. x Be sure not to apply a load on any of the actuator brackets or covers or on the connector box.
2.2 Installation and Storage/Preservation Environment 2. Installation [1] Installation Environment The robot should be installed in a location other than those specified below. In general, the installation environment should be one in which an operator can work without protective gear. Also provide sufficient work space required for maintenance inspection.
2.3 How to Install Shown below is how to install High-Speed Orthogonal Robot CT4. 2.3.1 Installation of the Main Body A 30 A 280 3-M10 (for eyebolt attachment at transportation) Through holes for installation 12-φ11 through φ23 Counterbore, Depth 22 35 (100) (35) (100) 100 35 100 φ 11 φ 23 200 B Datum Surface B Datum Surface 20 200 350 200 Apply the socket head cap screw indicated in the table below suitable for the platform material.
2.3.2 Datum Surface 2. Installation Ɣ The side faces on the base is referred as the datum surface for the slider’s run. Use these surfaces as the datum surfaces for mounting.
2.3.3 Platform for installation Axis X-axis Y-axis Z-axis Reaction Force 660N 235N 85N Ɣ Prepare a platform with its specific frequency at 75Hz or more. [Example for Installation Platform] Shown in the figure below is an example for an installation platform. Build an installation platform by referring to it. 0.05/1000 25 or more □100 x 100 x t6.0 (Steel Squares) 800 or less 900 500 or less 21 2.
Attachment of Transported Objects x There are tapped holes on the table and the end of the Z-axis. Affix the transported object here. x The way to affix follows the installation of the main unit. x There are reamed holes and slotted holes on the top surface of the table. Use these reamed holes and slotted holes if repeatability of attaching and detaching is required. Also, if small readjustment such as the perpendicularity is required, use one of the reamed holes on the table for the readjustment.
There are restrictions in the moment and load overhang length when attaching a load on the table. Dynamic Allowable Moment [N㨯m] Ma Mb Mb 6.4 9.2 14.2 Allowable Overhang Length Load length L (mm) X, Y, Z directions 50 2.
3. Connecting to the Controller 3. Connecting to the Controller For the controller, those other than the controller dedicated for CT4 cannot be used. Using other controllers may cause a problem such as burning the product, ignition or generating heat. Use the dedicated cables enclosed in the package when connecting of the CT4 and the controller.
Warning: For wiring, please follow the warnings stated below. When constructing a system as the machinery equipment, pay attention to the wiring and connection of each cable so they are conducted properly. Not following them may cause not only a malfunction such as cable breakage or connection failure, or an operation error, but also electric shock or electric leakage, or may even cause a fire. 3. Connecting to the Controller • Use dedicated cables of IAI indicated in this instruction manual.
3. Connecting to the Controller • Do not pull the cable with a strong force. • Pay attention not to concentrate the twisting force to one point on a cable. • Do not pinch, drop a heavy object onto or cut the cable. • When a cable is fastened to affix, make sure to have an appropriate force and do not tighten too much. Do not use spiral tube in any position where cables are bent frequently.
• If using a cable track, arrange the wiring so that there is no entanglement or kink of the cables in the cable carrier or flexible tube, and do not bind the cables so that the cables are relatively free. (Arrange the wiring so the cables are not to be pulled when bent.) 3. Connecting to the Controller • The occupied volume rate for the cables, etc., inside the cable track should be 60% or less.
4. Maintenance Inspection 4.1 Inspection Items and Inspection Schedule Have maintenance inspections following the intervals below. 8 hours per day is assumed as the operation condition Have inspections more frequently if the operation frequency is high for night and day continuous operation, etc. 4.
4.4 Internal Inspection Turn OFF the power, remove the screw cover and have a visual inspection. Include the items below in the internal check. Main Body Ball screw guide Looseness of attachment screws Condition and dirt of lubricant [X1-axis, X2-axis, Y-axis] 1) Detach the four screws holding the screw cover (at the points where circled) and remove the screw cover. Screw Cover Y-axis X1-axis X2-axis Tool to use: Hex Wrench 2.5mm-sized 2) Check inside.
4. Maintenance Inspection [Z-axis] 1) Remove the four screws holding the Z-axis cover. Detach the Z-axis cover. Z-axis Tool to use: Hex Wrench 2.5mm-sized 2) Turn ON the controller, put the brake switch up (to RLS side) to release the brake and move the table down. Turn OFF the controller.
3) Detach the four screws holding the screw cover (at the points where circled) and remove the screw cover. Screw Cover 4. Maintenance Inspection Tool to use: Hex Wrench 2.5mm-sized 4) Check inside. 5) After the work is finished, attach the screw cover and tighten the screws. Tightening Torque : 83N㨯cm 6) Attach the Z-axis cover Caution: Be careful in case a hand or a work piece is attached and the Z-axis brake is released. It may cause an injury or may damage the hand or work piece by dropping it. 4.
4.6 Grease Supply 4.6.1 Grease Applied The following grease is applied when the product is shipped out from IAI factory. 4. Maintenance Inspection Ball screw guide Bearing Kyodo Yushi Maltemp ET-R No.2 (Urea-based) Warning: Do not attempt to apply any other type of grease than described above. It may not only impact the performance of the grease, but also may damage the CT4. 4.6.
3) Move the X1, X2-axis several times with hand. 33 4. Maintenance Inspection Caution: Ɣ Applying too much grease will increase the stirring resistance and may make the ball screw easy to generate heat or make the excess grease on the ball screw splash around with the rotation and dirt the surrounding. Do not supply grease more than three or four times with a grease gun. Ɣ In case the grease got into your eye, immediately go to see the doctor to get an appropriate care.
4. Maintenance Inspection [2] Y-axis 1) For the Y-axis, there is a grease nipple on the back side. Y-axis Grease nipple Nipple Inlet Diameter [mm] I 4.0 2) Supply grease 3 to 4 times with a grease gun. 3) Turn OFF the controller and move the Y-axis with hand for several rounds.
[3] Z-axis 1) Remove the four screws holding the Z-axis cover. Detach the Z-axis cover. 4. Maintenance Inspection Z-axis Tool to use: Hex Wrench 2.5mm-sized 2) Turn ON the controller, put the brake switch up (to RLS side) to release the brake and move down the table. Turn OFF the controller.
3) Detach the four screws holding the screw cover (at the points where circled) and remove the screw cover. 4. Maintenance Inspection Screw Cover Tool to use: Hex Wrench 2.5mm-sized 4) Apply grease to the ball screw with finger. Wipe off the excess grease. Ball Screw 5) Move the table several times with hand. 6) After the work is finished, attach the screw cover and tighten the screws.
4.7 Motor Replacement Process Shown in the description below is how to replace the motor in such a case that it gets a wire broken. The screws and other components detached for the replacement will be necessary when rebuild the product. Prepare a storage box beforehand to keep the components in it. Caution: It is necessary to have the controller turned ON and operate the servo to turn it ON and OFF for the operation of the brake (Z-axis) when replacing the motor.
4.7.1 Motor Replacement for X1 and X2 [Items Required for Replacement Work] x Motor Unit for Replacement Model No. : M-CGXY-TMA400-TA-CQ Model No. : HDS-1 x Heat Radiation Sheet (Note 1): Two pieces x Hex Wrench: 2.5mm, 3mm and 4mm-sized Note 1 Prepare it because it is likely to be torn in motor replacement work. 4. Maintenance Inspection [Procedure] (1) Detaching the Motor Cover Turn OFF the power to the controller and disconnect the motor cable and encoder cable.
(3) Detaching the Motor 1) Detach the four screws holding the plate at the back and remove the plate. Tool to use: Hex Wrench 4mm-sized 2) There are connectors of the motor cable and encoder cable stored inside. Pull the connectors out and unplug them. 39 4.
4. Maintenance Inspection 3) Detach the two screws (at the points where circled) holding the plate of the heat radiation sheet at the bottom of the motor. Tool to use: Hex Wrench 3mm-sized 4) Turn OFF the controller and move the Y-axis to the direction shown with an arrow below so you can see the coupling tightening screws (at the points where circled). Loosen the coupling screw with the hex wrench. Y-axis Coupling Tool to use: Hex Wrench 2.
5) Detach the four screws holding the motor (at the points where circled and two places at the bottom) and remove the motor together with the plate on the bottom of the motor. 4. Maintenance Inspection Tool to use: Hex Wrench 4mm-sized 6) It is likely that the heat radiation sheet attached on the plate at the bottom of the motor is torn when removing the motor. In such a case, attach a new heat radiation sheet.
4. Maintenance Inspection (4) Attaching the New Motor 1) Adjust the coupling on the new motor so the screw on it faces up. Screw 2) Move the Y-axis and adjust it to the position where the clearance gets to 7mm as shown in the figure.
3) Insert the motor together with the plate at the bottom of the motor, and temporarily tighten the screws to hold the motor (at the circled places and 2 places on the bottom) with a hex wrench. Tighten the coupling tightening screw (at the circled places). Coupling Tool to use: Hex Wrench 4mm-sized Tool to use: Hex Wrench 2.5mm-sized Tightening Torque : 83N•cm 4) Tighten the four screws holding the motor (at the circled places and 2 places on the bottom).
4. Maintenance Inspection 5) Attach the two screws (at the points where circled) to hold the plate on the bottom of the motor. Tool to use: Hex Wrench 3mm-sized Tightening Torque : 176N•cm 6) Joint the connectors and store the cables inside. 7) Tighten the four screws to hold the plate at the back to affix the plate.
(5) Screw Cover 4. Maintenance Inspection Attaching the Screw Cover Tighten the four screws holding the screw cover (at the points where circled) and remove the screw cover. Tool to use: Hex Wrench 2.5mm-sized Tightening Torque : 88.
4. Maintenance Inspection (6) (7) 46 Attaching the Motor Cover Attach the four screws to hold the motor cover to affix it. Tool to use: Hex Wrench 2.5mm-sized Tightening Torque : 88.7N•cm Connection to the controller Connect the connectors on the motor cable and encoder cable to match the connector numbers on the connectors to those indicated on the controller.
4.7.2 Process to Replace the Motor for the Y-Axis [Items Required for Replacement Work] x Motor Unit for Replacement Model No. : M-CGXY-TMA400-TA-CQ x Hex Wrench: 2.5mm, 3mm and 4mm-sized [Procedure] 4. Maintenance Inspection (1) Detaching the Motor Covers 1 and 2 Turn OFF the power to the controller and disconnect the motor cable and encoder cable. X1-axis, Y2-axis and Z-axis can be at any position.
4. Maintenance Inspection (2) Detaching the Motor 1) Detach the connectors of the motor cable and encoder cable. 2) Detach the four screws holding the screw cover (at the points where circled) and remove the screw cover. Screw Cover Tool to use: Hex Wrench 2.5mm-sized 3) Move the Z-axis to a position where the coupling tightening screw can be seen. Loosen the coupling tightening screw (at the circled places). Z-axis Coupling Tool to use: Hex Wrench 2.
4) Detach the four screws holding the motor (at the points where circled and two places at the bottom) and pull out the motor unit and the coupling to the direction indicated below with an arrow. Tool to use: Hex Wrench 4mm-sized 49 4.
4. Maintenance Inspection (3) 1) 2) Attaching the New Motor Adjust the coupling on the new motor so the screw on it faces up. Screw Move the Z-axis and adjust it to the position where the clearance gets to 7mm as shown in the figure.
3) Slide in the motor to the main body and temporarily tighten the four screws to hold the motor (at the circled places and 2 places on the bottom). Tighten the coupling screw (at the circled places). Tool to use: Hex Wrench 4mm-sized Coupling Tool to use: Hex Wrench 2.5mm-sized Tightening Torque : 83N•cm 4) Tighten the four screws affixing the motor (at the circled places and 2 places on the bottom). Tool to use: Hex Wrench 4mm-sized Tightening Torque : 342N•cm 51 4.
4. Maintenance Inspection 5) Join the connectors. 6) Tighten the four screws holding the screw cover (at the points where circled) and attach the screw cover. 52 Screw Cover Tool to use: Hex Wrench 2.5mm-sized Tightening Torque : 88.
(4) Attaching the Motor Covers 1 and 2 Attach the four screws to hold Motor Cover 1, then another four to hold Motor Cover 2 next, to affix Motor Cover 1 and 2. Motor Cover 1 Tool to use: Hex Wrench 3mm-sized Tightening Torque : 207N•cm Tool to use: Hex Wrench 2.5mm-sized Tightening Torque : 88.7N•cm Attach the cable clamps and tighten the four screws affixing the cable clamps on the top of Motor Cover 1. Motor Cover 1 Tool to use: Hex Wrench 2.
4.7.3 Process to Replace the Motor for the Z-Axis [Items Required for Replacement Work] x Motor Unit for Replacement Model No. : M-CGZ-TMA050-TA-B-CQ x Cable Band x Hex Wrench: 2mm, 2.5mm and 3mm-sized [Procedure] 4. Maintenance Inspection (1) Detaching the Z-axis Cover Turn OFF the controller. X1-axis, X2-axis and Y-axis can be at any position. Remove the four screws holding the Z-axis cover. Z-axis 54 Tool to use: Hex Wrench 2.
(2) Detaching the Motor 1) Cut and remove the cable band clamping the cables. Disconnect the motor cable connector from the ribbon cable. Cable Band Brake Switch Detach the screws holding the screw cover and remove the screw cover. Screw Cover Table Tool to use: Hex Wrench 2.5mm-sized 55 4. Maintenance Inspection 2) Turn ON the controller, put the brake switch up (to RLS side) to release the brake and move down the table.
3) Move the table to a position where the coupling tightening screw can be seen(at the circled places). Loosen the coupling screw. 4. Maintenance Inspection Coupling Tool to use: Hex Wrench 2mm-sized Caution: Be careful of the table dropping down. Hold the table (and/or work piece) so it would not drop down before loosening the coupling screw. 4) Remove the motor fixing screws and pull out the motor unit and the coupling from the body.
Attaching the New Motor Adjust the coupling on the new motor so the screw on it faces below. Screw 4. Maintenance Inspection (3) 1) 2) Locate the table at a point of 2mm from the mechanical end. Hold the slider so it would not drop down. 3) Slide in the motor to the main body and temporarily tighten the screws to affixing the motor. Tighten the coupling tightening screw (at the circled places).
4. Maintenance Inspection 4) Tighten the screws affixing the motor (at the circled places). Tool to use: Hex Wrench 3mm-sized Tightening Torque : 176N•cm 5) Plug in the motor cable and ribbon cable, and clamp them with cable bands. Cable Band 6) 58 Tighten the screws holding the screw cover and remove the screw cover. Screw Cover Tool to use: Hex Wrench 2.5mm-sized Tightening Torque : 88.
(4) (5) 4. Maintenance Inspection Attaching the Motor Cover Tighten the four screws holding the screw cover and remove the screw cover. Tool to use: Hex Wrench 2.5mm-sized Tightening Torque : 88.7N•cm Connection to the controller Connect the connectors on the motor cable and encoder cable to match the connector numbers on the connectors to those indicated on the controller.
680.5 Attachment Datum Surface 245 130 60 C Y : STROKE 300 B 60 130 E E 164 X : XTROKE 400 Detail B Scale 1 : 2 Attachment Datum Surface Sectional view E-E Scale 1 : 2 100 100 φ 23 φ 11 Attachment hole size 30 s +0.
6. Life The mechanical life of the High-Speed Orthogonal Robot CT4 is represented by the guide that receives the moment load mostly. One of the elements determining the operation life is “rated load”. There are two types of “rated load”, one is the “static rated load” and the other is the “dynamic rated load”.
7. Warranty 7.1 Warranty Period One of the following periods, whichever is shorter: y 18 months after shipment from IAI y 12 months after delivery to the specified location y 2,500 hours of operation 7. Warranty 7.2 Scope of the Warranty Our products are covered by warranty when all of the following conditions are met.
7.5 (1) (2) 7.6 If our product is combined with another product or any system, device, etc., used by the customer, the customer must first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such combination with our product conforms to the applicable standards, etc. In such a case we will not be liable for the conformance of our product with the applicable standards, etc. Our product is for general industrial use.
Change History 8. Change History Revision Date 64 Description of Revision 2012.08 First edition 2012.11 Second edition Caution in Handling (2) 1) The No.158 of control parameter was corrected to 153. 2013.01 Third edition 1.2.4 Positioning Accuracy Lost Motion X direction 0.1mm or less ψ Corrected to 0.05mm or less. Lost Motion X direction 0.1mm or less ψ Corrected to 0.05mm or less.
Manual No.: ME3724-3A (January 2013) Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan TEL +81-54-364-5105 FAX +81-54-364-2589 website: www.iai-robot.co.jp/ Technical Support available in USA, Europe and China Head Office: 2690 W.
