ROBO Cylinder RCP2 Actuator Belt-Drive Type Operating Manual Eighth Edition RCP2-BA6•BA6U•BA7•BA7U IAI America, Inc.
Please Read Before Use Thank you for purchasing our product. This Operating 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 CD or DVD that comes with the product contains Operating Manuals for IAI products.
Table of Contents Safety Guide...................................................................................................................................1 Caution in Handling ........................................................................................................................8 International Standards Compliances ...........................................................................................10 Names of the Parts .........................................................
5. External Dimensions ..............................................................................................................57 5.1 RCP2-BA6/BA6U............................................................................................................57 5.2 RCP2-BA7/BA7U............................................................................................................58 6. How to use the home mark ............................................................................................
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 � When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. � 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 � Use our company’s genuine cables for connecting between the actuator and controller, and for the teaching tool. � 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 � 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. � 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 � 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. � 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 � 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. � 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 Operating Manual for each model. Level Degree of Danger and Damage 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. Ensure use of the product in the specified conditions, environments and ranges. Not keeping this may cause a drop in the performance or even a malfunction of the product. 2. Do not attempt to handle or operate the product in a way that is not described in the operating manual. 3. Use the products of IAI for the wiring between an actuator and a controller. 4. Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings.
International Standards Compliances This actuator complies with the following overseas standards.
Names of the Parts In this Operating Manual, the left and right sides are indicated by looking at the actuator from the motor end, with the actuator placed horizontally, as shown in the figure below.
Specifications Check 1.1 Checking the Product The standard configuration of this product is comprised of the following parts. See the component list for the details of the enclosed components. If you find any fault or missing parts, contact your local IAI distributor. 1.1.1 Parts No. 1 Name Actuator Accessories Motor • encoder cables 2 (Note1) Model number Refer to “How to Read the Model Nameplate” and “How to Read the Model Number.
1. Specifications Check 1.1.3 How to Read the Model Nameplate Model Serial number 1.1.4 MODEL RCP2-BA6-I-42P-54-500-P1-S SERIAL No.
1.2 Specification 1.2.1 Speed BA6/BA6U BA7/BA7U 1. Specifications Check Type Speed limits (Unit: mm/s) � Lead [mm] Maximum Speed [mm/s] 54mm or equivalent 1000 1500 Caution: Use the product with the movement speed of 100mm/s or more, otherwise it may cause vibration or noise in low speed operation. 1.2.2 Maximum Acceleration Speed and Load Capacity Type Lead [mm] Maximum Acceleration [G] BA6/BA6U BA7/BA7U 54mm or equivalent 0.
Relation of Speed and Maximum Load Capacity The load capacity is the value when the actuator is operated at the Max. Acceleration/Deceleration rate of 0.5G. The position gain in the parameters at the delivery is set to 10. If setting the position gain to 20, even though the maximum load capacity is decreased, the cycle time will be shortened by 0.3seconds. Shown below is the graph of the load capacity for each speed.
The way to change the position gain differs depending on the controller. (1) PCON, RPCON, PSEP Controller Change is to be made using the RC PC Software. 1) Select [Parameter] � [Edit] in the main menu 2) Input the password. The default password is set as [5119]. 3) Select the axis number in the axis select window and click [OK]. 4) For PCON and RPCON, change the setting in User Parameter No. 7: Servo gain selection from [1] to [3]. 0 255 3 1000 0. 50 For PSEP, change the setting in User Parameter No.
1. Specifications Check (3) PSEL Controller Change to be made using the X-SEL PC Software. 1) Select [Parameter] � [Edit] in the main menu 2) Change Axis Parameter No. 60: Position Gain [1/s] from 10 to 20. 3) click (Transfer to Controller). The parameters are sent to the controller. 4) Once the parameter transfer is complete, a confirmation message saying [Do you want to write to Flash ROM?] comes up. Click [Yes].
1.2.4 No. of Encoder Pulses 800 Positioning repeatability ±0.1mm * The values shown above are the accuracy at the delivery from the factory. It does not include the consideration of time-dependent change as it is used. 1.2.6 Lost motion 0.1mm or less * The values shown above are the accuracy at the delivery from the factory. It does not include the consideration of time-dependent change as it is used. 17 1. Specifications Check 1.2.
1.2.7 Load Moments of the Actuator and the Allowable Overhang Lengths 1. Specifications Check � Allowable load moments Model Ma BA6/BA6U 8.9N�m(0.91Kgf�m) BA7/BA7U 13.8N�m(1.41Kgf�m) Mb 12.7N�m(1.29Kgf�m) 19.7N�m(2.01Kgf�m) Mc 18.6N�m(1.9Kgf�m) 29.0N�m(2.
1.3 1.3.1 Options Reversed-Home Type (Model: NM) 19 1. Specifications Check The home position is normally set on the motor side, however, the home direction can be set opposite by option if a reversed type is required due to such a reason as the layout of the system.
Motor • Encoder Cables 1. Specifications Check 1.4.1 Motor Cables�(For PCON, RPCON and PSEL) * The motor cable is a robot cable as standard. CB-RCP2-MA��� (20) (15) (14) (28) (20) (φ8) (8) C N 1 CN3 (Front View) (14) 1.4 (Front View) L Controller Side Mechanical Side Min. Bending Radius = 50mm or more (Movable Use) Width I-1318119-3 (AMP) 1.4.2 Electric Wire Color Orange Gray White Yellow Pink Yellow (Green) Signal Name _ A VMN _ B A VMM B Pin No. A1 A2 A3 B1 B2 B3 Pin No.
1.4.3 Motor • Encoder Integrated Cables�(For PMEC, PSEP and MSEP) CB-PSEP-MPA��� L Electric Wire Color Signal Name Pin No. Black �A 1 White VMM 2 Red �B 4 Green VMM 5 � Brown �A 3 � Yellow �B 6 Electric Wire Color Signal Name Pin No. Orange BK+ 16 Gray BK17 5 6 Black LS+ 13 Brown LS14 White A+ 1 Yellow A2 Red B+ 3 Green B4 White VCC 10 Yellow VPS 11 Red GND 9 Green (Reserved) 12 15 7 8 Shield FG 18 1.
2. Installation 2. Installation 2.1 Transportation [1] Handling of the Robot Unless otherwise specified, the actuators are packaged individually. (1) Handling the Packed Unit � Do not damage or drop. The package is not applied with any special treatment that enables it to resist an impact caused by a drop or crash. � An operator should never attempt to carry a heavy package on their own. Also, use an appropriate way for transportation.
[2] Handling in the Assembled Condition This is the case when the product is delivered from our factory under a condition that it is assembled with other actuators. The combined axes are delivered in a package that the frame is nailed on the lumber base. The sliders are fixed so they would not accidently move. The actuators are also fixed so the tip of it would not shake due to the external vibration.
2.2 Installation and Storage • Preservation Environment [1] Installation Environment 2. Installation The actuator 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 This chapter explains how to install the actuator on your mechanical system. General Rules on Installation 2. Installation 2.3.1 Follow the information below when installing the actuator, as a rule. Do pay attention to these items (except with custom-order models).
2.3.2 Installing the Main Body 2. Installation The actuator base has mounting holes. Affix the actuator with M4 hexagon socket-head bolts using these holes. Use of high strength bolts of ISO-10.9 or higher is recommended. The length of mounting bolts varies depending on the material of the machine frame. • Steel frame: M4 × 10 • Aluminum frame: M4 × 15 Tightening torque: 2.3N•m (0.23kgf•m) Reamed positioning pin holes are provided in the back face of the base. Use these holes as necessary.
2.3.3 Mounting Surface Datum surface Datum surface Caution: As shown above, the side faces of the base provide the datum surfaces for slider travel. When precision is required, use these surfaces as the datum surfaces for mounting. When using the base as the datum planes for mounting the actuator to the machine frame, follow the machining dimensions shown below. 2 to 3.5 R0.3 or less 27 2.
2. Installation 2.3.4 Installing the Load to the Slider � There are tapped holes on the top surface of the slider. Affix the work part (transported object) here. � There are two reamed holes on the top surface of the slider. Use these reamed holes if repeatability of attaching and detaching is required. Also, if small tuning such as perpendicularity is required, use one of the reamed holes for the tuning. � Refer to the following table for the screwed depth and reamed depth.
3. Connecting with the Controller For the connection of an actuator to the controller, apply an IAI dedicated controller and dedicated connection cable. Please consult with IAI if you require a different kind of cable than the one supplied.
[Connecting with the PMEC, PSEP and MSEP Controller] 3. Connecting with the Controller Dedicated Connection Cable (Connect RCP2 with the dedicated controller) Dedicated Controller Robot Cable r = 84mm or more (Movable Use) Standard Cable r = 42mm or more (Fixed Use) � � � Dedicated cables � Motor • Encoder Integrated Cables CB-PSEP-MPA��� ��� indicates the cable length. A desired length up to 10m can be specified.
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. • Use dedicated cables of IAI indicated in this operating manual.
3. Connecting with 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.
Follow the instructions below when using a cable track. • If there is an indication to the cable for the space factor in a cable track, refer to the wiring instruction given by the supplier when storing the cable in the cable track. • Avoid getting cables twined or twisted in the cable track, and also having the cables move freely and do not tie them up. (Avoid tension being applied when the cables are bent.) Do not pile up cables. It may cause faster abrasion of the sheaths or cable breakage. 3.
4. Maintenance Inspection 4.1 Inspection Items and Schedule 4. Maintenance Inspection Follow the maintenance inspection schedule below. It is assumed that the equipment is operating 8 hours per day. If the equipment is running continuously night and day or otherwise running at a high operating rate, inspect more often as needed.
4.4 Interior Inspection After turning off the power, remove the side covers and belt cover to conduct visual checks. Check the following items during interior inspection. Main unit Guides Drive belt Backside of belt cover Loose mounting bolts Lubrication appropriate Soiling Scratches Loose Lubrication appropriate The side covers and belt cover can be removed using a hex wrench of 2mm across flats.
4.5 Internal Cleaning • Wipe off dirt with a soft cloth. • Do not use strong compressed air on the actuator as this may force dust into the crevices. • Do not use petroleum-based solvent, neutral detergent or alcohol on the belt. 4. Maintenance Inspection Caution: Do not use flushing oil, molybdenum grease or anti-rust lubricant. When grease is soiled with large amounts of foreign substances, wipe off the dirty grease and then apply new grease.
4.6 Grease Supply to the Guides 4.6.1 Grease to Apply Lithium grease No. 2 is used on the guides. The following grease is applied when we ship the unit. Idemitsu Kosan Daphne Eponex Grease No.2 4.6.2 How to Apply the Grease 1) Remove the side covers on both sides. 2) When greasing the guide, use a spatula or grease applicator to squeeze or inject grease into the space between the slider and base, and then move the slider back and forth several times to let the grease spread evenly.
4.7 4.7.1 Drive Belt Inspecting the Belt 4. Maintenance Inspection Remove the side covers and visually inspect the belt. Durability of the drive belt is affected significantly by the operating condition, and there is no standard guideline as to when the belt should be replaced. Generally, the belt is designed to withstand several million cycles of flexing loads.
4.7.3 Checking and Adjusting the Belt Tension [1] Checking the Tension As a guideline, belt tension is evaluated by the load needed to deflect the belt by 10mm when the belt is pushed near the stroke center. The table below lists the appropriate loads needed to achieve a 10mm deflection on each belt used at different strokes. If the measured load is less than the applicable value by approx. 20% or more, the belt is loose and its tension must be adjusted.
[2] Adjusting the Tension Adjust the tension using the affixing bolts in the pulley bracket on the counter-motor side. 1) Move the slider to the motor-side mechanical end. 2) Loosen the affixing bolts (using a hex wrench of 3mm across flats). 3) Guide a wire around the bracket and pull the wire uniformly from both ends using tension gauges. 4) With the wire pulled to a specified tension from both ends, tighten the affixing bolts carefully by making sure the bracket does not deform.
4.7.4 Replacing the Belt 4. Maintenance Inspection [Items Required for Replacement] • Replacement drive belt • Tension adjustment wire (provide a commercially available wire like the one shown in the photograph at right) • Phillips screwdriver set and hex wrench set • Tension gauge (capable of applying a tensile load of 12kgf or more) • Grease (Kyodo Yushi’s Multemp LRL3 or equivalent) [Procedure] 1) Remove the load from the slider.
4. Maintenance Inspection 5) Loosen the tension adjustment bolts (using a hex wrench of 3mm across flats). If the bolts are not readily accessible, remove the other side cover. 6) Move the slider to expose the belt holder. Belt holder 7) Separate the belt and pull it out of the actuator. • Remove the belt-affixing bolts (using a hex wrench of 2.5mm across flats) .
8) Remove the rear cover (using a hex wrench of 2.5mm across flats). 9) Remove the front-cover affixing bracket (using a hex wrench of 2.5mm across flats). 4. Maintenance Inspection 10) Install a new belt by guiding it around the pulleys. • Insert the belt from the spaces provided on both sides of the motor side pulley. • Guide the belt through the slider. • Guide the belt around the counter motor side pulley (front side).
4. Maintenance Inspection 11) Affix the belt to the belt holder. Align the belt teeth on the belt holder with the drive belt, and tighten the bolts (M3 × 6). Tightening torque: 154N cm (15.7kgf cm) 12) Move the slider to a position where it aligns with the mounting holes in the belt holder, and tighten the bolts (BA6: M3 × 6 / BA7: M3 × 12). Tightening torque: 83N cm (8.5kgf cm) 13) Affix the belt-cover support (resin) using the bolts (M3 × 6).
14) Adjust the belt to the specified tension. Move the slider to the motor-side mechanical end, guide a wire around the counter-motor side pulley bracket, and then pull the wire uniformly from both ends using tension gauges. With the wire pulled to a specified tension from both ends, tighten the adjustment bolts. (Refer to the table below to find the tension appropriate for your actuator and the stroke.
4. Maintenance Inspection 17) Install the belt cover (thin-head screw M4 × 6, 2pcs). Move the slider back and forth over the entire stroke to make sure it does not contact the belt cover. Check if the clearance is sufficient.
4.8 4.8.1 Replacing the Motor BA6/BA7 (Motor on the Top) [Photograph 1)] [Photograph 2)] Pulley assembly [Procedure] 1) First, remove the drive belt. Remove the load from the slider and follow steps 1) to 7) in 4.7.4, “Replacing the Belt,” to remove the belt. 2) Remove the rear cover (using a hex wrench of 2.5mm across flats). 47 4.
4. Maintenance Inspection 3) Loosen the four pan-head screws affixing the motor cap, and pull out the motor cap. 4) Remove the two pan-head screws affixing the cable-mounting plate, and separate the plate from the motor cover. 5) Pull out the encoder connector. Caution: When applying the force, do not touch the encoder directly. 7) Remove the other side cover. 48 6) Pull out the motor connector.
8) Remove the motor bracket. • Remove the affixing bolts (M4 × 45, 4pcs) using a hex wrench of 3mm across flats. [Rear cover side] [Slider side] 4. Maintenance Inspection • Pull out the motor bracket by hand. Caution: A parallel pin is pressed into the base. If the motor bracket does not come off easily, slowly turn the motor bracket by hand and pull it out. Parallel pin 9) Remove the motor from the motor bracket. • Remove the affixing bolts (M3 × 28, 4pcs) using a hex wrench of 2.5mm across flats.
11) Affix the motor bracket on the base. Tighten the affixing bolts (M4 × 45, 4pcs) using a hex wrench of 3mm across flats. 4. Maintenance Inspection Securely tighten the bolts with the slider firmly pressed against the motor bracket. Tightening torque: 176N cm (18kgf cm) 12) Plug in the motor connector. 13) Plug in the encoder connector.. Caution: When applying the force, do not touch the encoder directly.
4.8.2 BA6U/BA7U (Motor at the Bottom) [Items Required for Replacement] • Replacement motor (with the motor shaft preassembled with a joint hub: see photograph 1)) • Tension adjustment wire (provide a commercially available wire like the one shown in photograph 2)) • Setscrew (M4 × 5, flat-tip, precoated) • Setscrew (M4 × 5, recessed-tip, precoated) • 1.
4. Maintenance Inspection 3) Remove the motor bracket. • Remove the affixing bolts (M4 × 45, 4pcs) using a hex wrench of 3mm across flats. • Pull out the motor bracket by hand. 4) Remove the two setscrews (M4 × 5, precoated) affixing the pulley assembly (using a hex wrench of 2mm across flats), and pull out the pulley assembly. If the setscrews do not come off, use a heat gun to heat the adhesive attached at the screw ends. Caution: Remove the set screw carefully so as not to misplace the set pieces.
6) Pull out the motor connector. 7) Pull out the encoder connector. 4. Maintenance Inspection Caution: When applying the force, do not touch the encoder directly. 8) Remove the motor. • Remove the affixing bolts (M3 × 8, 4pcs) using a hex wrench of 2.5mm across flats. • After the motor has been removed • Pull out the motor downward by slightly tilting it to right and left. • Pull out the bearing by hand.
4. Maintenance Inspection 9) Install a new motor on the base and insert the bearing. • Tighten the affixing bolts (M3 × 8, 4pcs) • Insert the bearing by hand. using a hex wrench of 2.5mm across flats. Tightening torque: 90N cm (9.2kgf cm) 10) Plug in the encoder connector. 11) Plug in the motor connector. Caution: When applying the force, do not touch the encoder directly. 12) Store the cables into the motor cover and affix the cable-mounting plate using the pan-head screws (M2.6 × 5, 2pcs).
14) Affix the pulley assembly to the joint hub. • Provide a 1.5mm clearance between the joint hub and pulley assembly. 4. Maintenance Inspection 1.5mm Example: Thickness gauge • Tighten it with new setscrews at two points with using a 2mm hex wrench. D-cut face Opposite side of D-cut face Set piece Setscrew (M4 x 5, flat-tip, precoated) Setscrew (M4 x 5, recessed-tip, precoated) Caution: Always use new setscrews with a new motor.
4. Maintenance Inspection 15) Install the motor bracket. • Align the motor bracket with the pilot section of the bearing and insert the bracket carefully so as not to damage the outer periphery of the bearing. • Tighten the affixing bolts (M4 × 45, 4pcs) using a hex wrench of 3mm across flats. Securely tighten the bolts with the slider firmly pressed against the motor bracket.
5. External Dimensions 5.1 RCP2-BA6/BA6U ME : Mechanical End SE : Stroke End 5 60 50 9 32 ± 0.02 9 5 4-M5 depth 10 (240) 31± 0.02 2-φ 5H7 reamed, depth 10 Cable joint connector 71.5 Stroke 63.5 23 60 SE HOME 4.7 4.7 65 10.5 ME Secure at least 100 55 58 Oblong hole, depth 5.5 from base bottom 2-φ 4H7 reamed, depth 5.5 from base bottom S-4.5 drilled hole, φ8 counterbore depth 4.5 (from opposite side) 75.5 S-4.5 drilled hole, φ8 counterbore depth 4.
5.2 RCP2-BA7/BA7U ME : Mechanical End SE : Stroke End 75 65 47 ± 0.02 5 9 4-M 5×10 (240) 40 ± 0.02 5 2-φ 5H7 reamed, depth 10 9 48 32 10 8 10 (Stroke) 71.5 23 SE HOME 4.7 4.7 65 10.5 ME Secure at least 100 83 60 58 5. External Dimensions 75 Cable joint connector (Motor on bottom type : BA7U) 10 46 128.5 68.5 ME (Motor on top type : BA7) L 58 Datum point for Ma moments 10 8 offset 63 68 Oblong hole, depth 5.5 from base bottom 2-φ 4H7 reamed, depth 5.5 from base bottom S-4.
6. How to use the home mark Please affix these marks to the actuator as home markers as needed. Contents of sticker Home mark sticker × 1 sheet 6. How to use the home mark Home mark scale × 4 Home mark × 4 (Scale: 1 mm graduation mark, 10 mm width) • Peel off the marks from the base sheet. Note 1. Every mark has sticky back. 2. Remove smear and stain from the surface. 3. Avoid label or nameplate as a marking location.
7. Life 7. Life The product life is assumed to be 5,000km (reference) under the condition that it runs with maximum load capacity and maximum acceleration/deceleration.
8. Warranty 8.1 Warranty Period One of the following periods, whichever is shorter: � 18 months after shipment from IAI � 12 months after delivery to the specified location � 2,500 hours of operation 8.
8.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications 8. Warranty (1) 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.
Change History Revision Date Description of Revision First edition Second edition June 2008 April 2011 Change History September 2010 Third edition • Changed the logo at the top of page “IA” to “RC” for all pages. • Danger, Operation Deleted “� If you are using a pace maker ... (snip) ... to malfunction.” • Warning, Installation Deleted “Be sure to provide Class D grounding ... (snip) ... or malfunction.” • Warning, Operation Deleted “� The cable supplied with the product... (snip) ...
Revision Date Change History January 2012 64 Description of Revision Sixth edition • Contents changed in 3.
Manual No.: ME3633-8A (March 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.