ROBO Cylinder RCP3 Actuator Rod Type Operating Manual Fourth Edition Motor coupling types [Slim Small ROBO Cylinders] RA2AC/RA2BC Motor reversing types [Slim Small ROBO Cylinders] RA2AR/RA2BR IAI America, Inc.
Please Read Before Use Thank you for purchasing our product. This Operation 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 operation manuals for IAI products.
CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Table of Contents Safety Guide.................................................................................................................................. 1 Handling Precautions .................................................................................................................... 8 1. Part Names .......................................................................................................................... 12 2. External Drawings .............................................
12. Life........................................................................................................................................ 38 12.1 Life of Actuator Using Ball Screws .............................................................................. 38 12.2 Life of Actuator Using Slide-screws ............................................................................ 38 12.2.1 Relationship of Cycle Time and Product Life ..............................................................
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 before 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 Operation 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.
Handling Precautions 1. Do Not Set Speed and Acceleration/Deceleration Higher Than the Rated Values. Do not set speed and acceleration/deceleration higher than the rated values. It causes vibration, failure, or shortening of life. If acceleration/deceleration higher than the rated value is set, creeping phenomenon or coupling slide may occur. 2. Do Not Apply External Force on the Rod from Directions Other Than the Rod Traveling Direction.
5. Transportation 5.1 Handling a Single Actuator Please adhere to the following when handling a single actuator. 5.1.1 Handling the Packed Unit Unless otherwise specified, the actuator is shipped with each axis packaged separately. 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. Transport a heavy package with at least more than two operators. Consider an appropriate method for transportation.
5.2 Handling the Actuator Assembly When carrying the actuator, exercise caution not to bump it against nearby objects or structures. Secure the sliders to prevent sudden movement during transport. If any end of the actuator is overhanging, secure it properly to avoid significant movement due to external vibration. When transporting the assembly without the ends of the actuators fastened, do not subject the assembly to an impact of 0.3 G or more.
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1. Part Names 1. Part Names The names of the actuator parts are indicated below. In this manual, the right and left are determined by viewing the actuator from the top and from the motor side. z “Motor coupling type” RA2AC/RA2BC (Lead screw, ball screw) Motor unit with brake Rod cover Right Left Motor unit Other side Rod end bracket Motor side Rod * Refer to 2, “External Dimensions” for details.
3H7 depth 3 (from base bottom surface) Detail view of Z Scale: 2:1 : Stroke end : Mechanical end : Home For those with a brake, the weight increases by 0.1kg. 25 50 75 100 ST L (20 square)) L (20P L (20SP (20 square)) A B C D Weight [kg] without with Without brake With brake Without brake With brake brake brake 168 212 94.5 25 0 4 0.31 193 237 119.5 50 0 4 0.33 218 262 144.5 75 0 4 0.36 243 287 169.5 100 50 6 0.37 2-3H7 depth 3 (from base bottom surface) D-M3 depth 5 (73.
4-M3 depth 4 3h7 depth 3 (from base bottom surface) 14 Detail view of Z Scale: 2:1 20SP (20 square) with motor brake : Stroke end : Mechanical end : Home For those with a brake, the weight increases by 0.1kg. 25 50 75 100 125 150 ST Without brake (73.5) 20P (20 square) motor (without brake) 20P (20 square) with motor brake 25 50 75 100 125 150 B 0 0 0 50 62.5 75 C Without brake 4 4 4 6 6 6 0.36 0.39 0.42 0.45 0.48 0.
2-M3 depth 4 Detail view of Z Scale: 2:1 3H7 depth 3 (from base bottom surface) 15 : Stroke end : Mechanical end : Home For those with a brake, the weight increases by 0.1kg. L 111.5 136.5 161.5 186.5 ST 25 50 75 100 B 94.5 25 119.5 50 144.5 75 169.5 100 A 0 0 0 50 C 4 4 4 6 D 0.34 0.36 0.39 0.4 Weight [kg] 20P (20 square) with motor brake D-M3 depth 5 2-3H7 depth 3 (from base bottom surface) (88.5) 20P (20 square) motor (without brake) 20SP (20 square) without motor brake 2.
4-M3 depth 4 20SP (20 square) with motor brake 16 3H7 depth 3 (from base bottom surface) Detail view of Z Scale: 2:1 : Stroke end : Mechanical end : Home For those with a brake, the weight increases by 0.1kg. 25 50 75 100 125 150 ST 111.5 136.5 161.5 186.5 211.5 236.5 L 94.5 25 119.5 50 144.5 75 169.5 100 194.5 125 219.5 150 A B 0 0 0 50 62.5 75 C 4 4 4 6 6 6 D 0.38 0.41 0.44 0.47 0.5 0.
3. 3.1 Cable Drawings PMEC, PSEP Controller Cables Integrated motor/encoder cable (CB-APSEP-MPA***) [1][2] Model Nameplate [5] No. [6] Item 1 Housing 2 3 4 Contact Housing Contact 5 Coupler cover 6 ZUL2854-OHFRPCVVSW Lot number [3][4] Model number Manufacturer D-1100D 1-1827863-1 (black, 2.0-mm pitch, 22 poles) AMP D-1 1827570-2 (AWG 22 to 18, 1.08 to 1.6 ) PADP-24V-1-S (white, 2.0-mm pitch, 24 poles) JST SPND-001T-C0.5 (AWG 26 to 22, 1.0 to 1.
3.2 PCON Controller Cable RCA3 Integrated motor/encoder cable (CB-PCS-MPA***) 3. Cable Drawings *** indicates the cable length (L). Up to 10 m can be specified. Example) 080 = 8 m [1][2] [3][4] [7] Model Nameplate [7] No. [1] [2] [3] [4] [5] [6] Item Receptacle housing Receptacle contact Socket Socket contact Housing Contact Model number D-1100D 1-1827863-1 D-1 1827570-2 D2100D 1-1318119-3 D-2 1318105-1 PHDR-16VS SPHD-001T-P0.
4. 4.1 Options Brake Type The brake is a mechanism designed to prevent the slider from dropping on a vertically installed actuator when the power or servo is turned off. Use the brake to prevent the installed work part, etc., from being damaged due to the falling rod. 4. Options (Notes on installation) With the RA2AC and RA2BC, the brake project from the bearing surface by 1 mm. When using a base surface for installation, a measure to raise the unit using a foot bracket, etc. is required.
5. Checking after Unpacking After unpacking, check the product condition and the included items. 5.1 Included Items No. 5. Checking after Unpacking 1 Item Actuator Model number Refer to “How to Read Model Nameplate” and “How to Read Model Number.” Remarks Accessories 2 RCP3 integrated motor/ encoder cable 3 4 5 First Step Guide Operating Manual Safety Guide 5.2 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 5.
5.4 How to Read Model Number I: Incremental 20P (20, square), 20SP (20, square) RA2AC, RA2BC, RA2AR, RA2BR RA2AC, RA2AR, 1/2/4 1S/2S/4S RA2BC, RA2BR 1/2/4/6 2S/4S/6S 5.
6. Specifications RA2AC (Lead screw) RA2AR (Lead screw) Item 6. Specifications Lead Maximum speed (*1) Stroke Maximum thrust Horizontal Maximum loading capacity (*2) Vertical Positioning repeatability (*3) (*3) Lost motion Number of encoder pulses (*4) *1 *2 *3 *4 mm mm/sec mm N kg kg 1 50 2 100 25 to 100 (in 25 steps) 18 0.5 0.25 36 1 0.5 mm 4 200 9 0.25 0.125 0.05 0.3 800 mm Pulse The maximum speed may not be reached depending on the stroke. The acceleration/deceleration is assumed to be 0.
RA2BC (Lead screw) RA2BR (Lead screw) Item Lead Maximum speed (*1) Stroke Maximum thrust Horizontal Maximum loading capacity (*2) Vertical Positioning repeatability (*3) (*3) Lost motion Number of encoder pulses (*4) 2 100 4 200 25 to 150 (in 25 steps) 9 0.5 0.25 18 1 0.5 mm 6 300 6 0.25 0.125 0.05 0.3 800 mm Pulse 6. Specifications *1 *2 *3 *4 mm mm/sec mm N kg kg The maximum speed may not be reached depending on the stroke. The acceleration/deceleration is assumed to be 0.
7. 7.1 Operation Operational Conditions for Positioning Operation By following the procedures below, check whether the operation is available. 7. Operation [1] Operation Check the operational conditions [1] to [5].
[2] Stroke, maximum speed, acceleration Check whether the operation is available by [2] stroke, [3] maximum speed and [4] acceleration. Table 1 Installation Orientation Horizontal Upright Vertical Model RA2AC RA2AR (Lead screw) RA2BC RA2BR (Lead screw) Horizontal Upright RA2BC RA2BR (Ball screw) RA2AC RA2AR (Ball screw) Vertical RA2BC RA2BR (Ball screw) Acceleration (G) Max Speed (mm/s) 1 2 4 2 4 6 1 2 4 1 2 4 6 1 2 4 1 2 4 6 0.2 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.2 0.2 0.2 0.2 0.
Horizontal Vertical Correlation diagram of speed vs. loading capacity (horizontal) Correlation diagram of speed vs. loading capacity (vertical) Lead 1 Lead 2 Lead 4 Loading capacity (kg) (Lead screw) Pulse motor (RCP3) Loading capacity (kg) Graphs 1 7. Operation Lead 2 Lead 4 Lead 6 Correlation diagram of speed vs.
Correlation diagram of speed vs. loading capacity (horizontal) Correlation diagram of speed vs. loading capacity (vertical) Lead 1 Lead 2 Lead 4 Lead 6 Loading capacity (kg) Vertical Loading capacity (kg) (Ball screw) motor : 20P Horizontal Lead 1 Lead 2 Lead 4 Speed (mm/sec) Speed (mm/sec) Lead 2 Lead 4 Lead 6 Speed (mm/sec) Loading capacity (kg) Lead 1 Correlation diagram of speed vs. loading capacity (vertical) 7. Operation Loading capacity (kg) Correlation diagram of speed vs.
7.2 Operational Conditions for Pressing Operation 7.2.1 RA2AC, RA2AR, RA2BC, RA2BR (Lead Screw) [1] Operation Check the operational condition of pressing force F (N). * For push & hold operations, movement speed is set at 5 mm/s. [2] Push force Check whether the operation is available by pressing force. (The graphs provide some margin by considering a drop in lead screw efficiency over time.) How to decide: The operation is available as long as the pressing force is in the ranges shown in the graphs.
7.2.2 RA2AC, RA2AR, RA2BC, RA2BR (Ball Screw) [1] Operation Check the operational condition of pressing force F (N). * For push & hold operations, movement speed is set at 5 mm/s. [2] Push force Check whether the operation is available by pressing force. How to decide: The operation is available as long as the pressing force is in the ranges shown in the graphs.
8. 8.1 Installation Environment and Storage Environment Installation Environment 8. Installation Environment and Storage Environment Install the actuator in an environment meeting the following conditions: Is a normal environment for assembly work where there is not much dust. (If the actuator is used in an environment where dust is floating in air, the life of the actuator will become significantly shortened.
9. Installation The actuator mounting surface should be machined or otherwise processed to a smooth surface of equivalent precision. 9.1 Installation of Actuator This actuator contains installation tap holes which allow it to be secured from the rear. (Note that tap hole size depends on model. Please see 2, "External Dimensions." The actuator also contains reamed holes for use with positioning pins.
9.2 Installation Surface 9. Installation Mount on a strong, rigid structure to prevent vibration. The actuator mounting surface should be machined or otherwise processed to a smooth surface of equivalent precision, within ±0.05 mm/m. Provide adequate space around the device to allow for future maintenance.
10. Connection with Controller Use IAI’s dedicated controller. For the connection cable between this actuator and the controller, use IAI’s connection cable. This chapter explains the wiring method based on single-axis use. If you wish to change the cable, consult IAI. IAI’s dedicated connection cable (Connects the RCP3XX and dedicated controller) r = 68 mm or more (movable) r = 34 mm or more (mounted) Dedicated controller 10.
IAI’s dedicated connection cable (Connects the RCP3-RAXX and dedicated controller) r = 84 mm or more (movable) r = 42 mm or more (mounted) Dedicated controller 10. Connection with Controller Dedicated connection cable Pulse motor cable: CB-PCS-MPA*** *) *** indicates the cable length. Up to 20 m can be specified.
The prohibited items relating to cable wiring are explained below. Do not cut and reconnect the cable for extension or shorten the cable. If the cable cannot be secured, reduce the load on the cable by allowing it to deflect only by the weight of the cable or wire it in a self-standing cable hose, etc., having a large radius. Prevent the cable from bending at the same point. Steel band (piano wire) Bundle loosly. Do not let the cable bend, kink or twist. 10.
When fixing the cable, provide a moderate slack and do not tension it too tight. Do not use a spiral tube where the cable flexes frequently. Separate the I/O and communication lines from the power and drive lines. Do not wire them together in the same duct. Power line Duct 10. Connection with Controller I/O lines (flat cable) Pay attention to the following points when using a cable track. Do not let the cable get tangled or kinked in a cable track or flexible tube.
11. Notes on Operation 11.1 Loads Received by the Actuator 11.1.1 Loads applied to RA2AC, RA2AR, RA2BC and RA2BR actuators Align the shaft center of the rod with the moving direction of the load. Application of a lateral load may cause actuator damage or malfunction. If the rod receives a lateral load, provide a guide, etc., in the moving direction of the load. Do not apply a rotational torque to the rod. If the rod receives a rotational torque, actuator damage or malfunction may occur.
12. Life 12.1 Life of Actuator Using Ball Screws The life of actuator using ball screws is set to 5,000 km (guideline), assuming it is operated with the maximum loading capacity and maximum acceleration/deceleration. 12.2 Life of Actuator Using Slide-screws The lead-screw type actuator uses a lead screw and its nut wears over time. A reference for product life is presented based on the wear amount of the nut.
(2) Vertical application The graph below shows the relationship between the cycle time for one back-and-forth operation and the life of the product in a vertical application (product life: 50 million back-and-forth operations). The lines based on 8 hours of operation and 24 hours operations a day, for 240 days a year, are shown. Use this graph as a reference when determining the product life. 8 hours of operation 24 hours of operation Life (years) Cycle time (sec) 12.
13. Maintenance and Inspection 13.1 Inspection Items and Schedule Perform maintenance and inspection at the schedule specified below. This schedule assumes 8 hours of operation a day. If the actuator is operated continuously day and night or at a higher utilization rate, shorten the inspection intervals according to the situation.
13.4 Inspection of Interior Inspect the interior with the power turned off. Remove the rod cover. When inspecting the interior, check the items specified below. Main unit Guide section Loose actuator mounting bolts, other loose items Lubrication, buildup Visually inspect the interior of the equipment. Check whether dust or other foreign matter has gotten inside and check the lubrication state. The lubrication may have turned brown.
13.6 Greasing 13.6.1 Applicable Grease [Lead screw type] The lead screw product has been shipped with synthetic poly- olefin grease applied to both the lead screw and lead guide. IAI uses the following grease in our plant. Location Lead screw/lead guide Manufacturer Sumico Lubricant Co., Ltd. Model number Sumitec 308 Equivalent greases are also available from other manufacturers, but exercise caution when selecting the grease because the life of the product may be affected.
13.6.2 How to Apply Grease For the guide, use a grease syringe to apply grease between the rod and base (guide-piece retention groove) and then move the rod back and forth to spread the grease evenly. For the lead screw, pull out the rod and clean the lead screw, and apply grease manually and then move the rod back and forth to spread the grease evenly. (Caution) When moving the rod back and forth, do not move the rod directly by hand, but operate it using the jog function, etc.
13.7 Belt 13.7.1 Inspection of Belt When inspecting the belt, remove the pulley cover and check the condition visually. Although the durability of the belt is affected significantly by the operating conditions, generally the belt has a flex life of several million times. As a reference on when to replace the belt, replace the belt if any of the following conditions is observed: Significant wear of the teeth or end face of the belt Swelling of the belt due to attached oil, etc.
13.8 Motor Replacement (Pulse Motor: RCP3) * Refer to 13.9 for the reversing types. [Items required for replacing the stainless sheet] Replacement motor unit Model number Without Brake With Brake RCP3-MU00A RCP3-MU00A-B Hex wrench set [Procedure] [1] Remove the cable connecting the actuator and controller and the motor unit cable. Remove the cross-recessed socket screws on the cover to expose the screws affixing the motor. Remove the affixing screws using a hex wrench of 2 mm across flats.
[3] Align the actuator side and replacement motor unit side projection section and the slit orientation. Align protrusion with recess. Apply grease to coupling. (TL101Y grease made by NOK) 13. Maintenance and Inspection [4] Install the replacement motor by fitting the protrusion of one unit in the recess of the other. [5] Secure the affixing screws using a hex wrench of 2 mm across flats. Install the cover and tighten the cross-recessed socket screws.
13.9 Replacement of Belt and Motor for Reversing Type (Pulse Motor: RCP3) [Items required for replacement] Replacement motor unit of reversing type Model number Without brake With brake RCP3-MU00B RCP3-MU00B-B Belt Manufacturer: Mitsuboshi Belting Ltd. Belt model number (type) 40S2M104G (clean rubber type) Tension gauge Hex wrench set [Procedure] [1] Remove the pulley cover. Remove the mounting screws (2 pcs). Mounting screw Nominal thread size Applicable Allen wrench M3 2.5 mm across flats 13.
[3] Remove the belt from the pulleys. When replacing the belt, proceed to step [6]. 13. Maintenance and Inspection [4] Remove the tension adjustment bolts and pull out the motor unit. [5] Install the replacement motor unit. As shown below, install the motor unit so that its specified surface faces the actuator base. Use the tension adjustment bolts to loosely secure the motor unit.
[6] Move the motor unit in the direction of the arrow shown below, and then install the belt. When replacing the belt, install the replacement belt. [7] Pass around the base of the unit a strong string (or long tie band) that has been looped into a ring shape, and pull the ring with a tension gauge. After confirming that the tension gauge is indicating the specified tension, tighten the tension adjustment bolts uniformly. Tension gauge Tension 0.51 kgf 13.
14 Warranty 14.1 Warranty Period One of the following periods, whichever is shorter: y 18 months after shipment from our company y 12 months after delivery to the specified location 14.2 Scope of Warranty Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: (1) The breakdown or problem in question pertains to our product as delivered by us or our authorized dealer.
14.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications (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 May 2009 First edition April 2010 Second edition A page for CE Marking added July 2011 Third edition Added “Handing Precautions” on page 8. Contents changed in 4.
Manual No.: ME3674-4A (March 2012) 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.
