IAI Intelligent Actuator IX Series, Operation Manual

Page 1: ...Horizontal Articulated Robot IX Series Tabletop Type Dust proof Splash proof Specification Arm Length 250 350 IX NNW 2515 IX NNW 3515 Operation Manual Fourth Edition ...

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Page 3: ...ting them out or displaying them on a PC After reading the operation manual keep it in a convenient place so that whoever is handling this product can reference it quickly when necessary Important The product cannot be operated in any way unless expressly specified in this operation manual IAI shall assume no responsibility for the outcome of any operation not specified herein Information containe...

Page 4: ...CE Marking If a compliance with the CE Marking is required please follow Overseas Standards Compliance Manual ME0287 that is provided separately ...

Page 5: ...3 3 Storage Environment 16 4 How to Install 17 4 1 Installation Posture 17 4 2 Installing the Robot 18 4 3 Connecting the Controller 19 4 4 Checking after Installation 20 5 Precautions for Use 21 5 1 Reference Acceleration Deceleration Settings 21 5 2 Tools 23 5 3 Carrying Load 24 5 4 User Wiring and Piping 25 5 5 Air Purge 28 6 Inspection Maintenance 29 6 1 Inspection Maintenance 29 6 2 How to Ch...

Page 6: ... 66 8 2 Scope of Warranty 66 8 3 Honoring the Warranty 66 8 4 Limited Liability 66 8 5 Conditions of Conformance with Applicable Standards Regulations Etc and Applications 67 8 6 Other Items Excluded from Warranty 67 Change History 68 ...

Page 7: ...ant safety parts of machinery Safety device etc Do not use the product outside the specifications Failure to do so may considerably shorten the life of the product Do not use it in any of the following environments 1 Location where there is any inflammable gas inflammable object or explosive 2 Place with potential exposure to radiation 3 Location with the ambient temperature or relative humidity e...

Page 8: ...the safety factor of the hook in such factors as shear strength Do not get on the load that is hung on a crane Do not leave a load hung up with a crane Do not stand under the load that is hung up with a crane 3 Storage and Preservation The storage and preservation environment conforms to the installation environment However especially give consideration to the prevention of condensation Store the ...

Page 9: ...oseness Failure to do so may cause a fire electric shock or malfunction of the product Never cut and or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length Failure to do so may cause the product to malfunction or cause fire 4 Installation and Start 3 Grounding The grounding operation should be performed to prevent an electric shock or electros...

Page 10: ... to secure safety Do not insert a finger or object in the openings in the product Failure to do so may cause an injury electric shock damage to the product or fire When releasing the brake on a vertically oriented actuator exercise precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity 5 Teaching When the work is carried out with 2 or more persons make it c...

Page 11: ...minal block or any of the various setting switches in the power ON mode Failure to do so may result in an electric shock or malfunction 7 Automatic Operation Check before starting the automatic operation or rebooting after operation stop that there is nobody in the safety protection fence Before starting automatic operation make sure that all peripheral equipment is in an automatic operation ready...

Page 12: ...sult in a damage to the product When releasing the brake on a vertically oriented actuator exercise precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity The slider or rod may get misaligned OFF the stop position if the servo is turned OFF Be careful not to get injured or damaged due to an unnecessary operation Pay attention not to lose the cover or untigh...

Page 13: ...he product is not handled correctly will result in death or serious injury Danger Warning This indicates a potentially hazardous situation which if the product is not handled correctly could result in death or serious injury Warning Caution This indicates a potentially hazardous situation which if the product is not handled correctly may result in minor injury or property damage Caution Notice Thi...

Page 14: ... the vertical articulated robot properly by following this operation manual Using the product with the vertical articulated robot not being certainly retained or affixed may cause abnormal noise vibration malfunction or shorten the product life ...

Page 15: ...axis Ball screw spline shaft Inside dust cover Cover arm 2 Axis 3 vertical axis Mechanical stopper for axis 3 vertical axis Arm 2 Arm 1 Front panel base Reference surface Axis 4 R axis Wiring duct End cover arm 1 Base Rear panel base Axis 2 Axis 1 T slot for peripheral installation M3 M4 ALM indicator I4 user piping black red white 3 locations Purge air inlet Outer diameter I6 inner diameter I4 In...

Page 16: ...cautionary information provided on the labels may result in serious injury or damage to the robot Prohibition of entry into the operation area Warning on handling of the vertical axis Warning against electric shock Robot serial number CE certified robot Provided only for CE certified models Caution warning on handling of the controller Designation of the connected robot Controller serial number Ot...

Page 17: ... Designation of the connected robot Controller serial number CE certified models Other than CE certified models Caution warning on handling of the controller View A A Warning on handling of the vertical axis Warning against electric shock Robot serial number CE certified robot Provided only for CE certified models ...

Page 18: ...ticle whose shape allows a load to be concentrated at one point 2 2 Packing Condition of the Robot z The robot and controller are very heavy When transporting the carton containing the robot and controller handle it with extra care so as not to drop the carton or apply impact due to forcible contact as it may cause injury or damage to the robot or controller z Serious injury may result if the cart...

Page 19: ...obot 1 Operation manual for controller 1 Eyebolt 1 D sub connector 1 Hood set for D sub connector 1 Caution label 2 Positioning label 1 PIO flat cable 1 PC software type IA 101 X MW Floppy disk 2 PC connection cable 1 Hand held emergency stop switch 1 Operation manual for PC software 1 Absolute reset adjustment jig type JG 2 Positioning jig for axes 1 and 2 pin 1 Positioning jig for axis 4 plate 1...

Page 20: ...cables remain free the arms may turn unexpectedly and pinch a hand or a person may be tripped by the trailing cables z Do not attempt to carry the robot by hand as it may injure the back Additionally an injury may result if the robot is dropped onto the feet z Serious injury may result if a person is caught under a fallen robot during transportation z Never stand below the robot as it is hoisted z...

Page 21: ...he structure According to the IP standard the water jet pressure is 30 kPa 30 KN m 2 0 3 kgf cm2 injection speed is 12 5 liters min and duration of spray is 3 minutes Please note that the dust proof splash proof specification does not provide an explosion proof structure The robot must be installed in an environment satisfying the following conditions y Will not become immersed in liquid y Free fr...

Page 22: ...ovement due to operation of the robot x The installation platform must allow the robot to be mounted on a level surface 3 3 Storage Environment The storage environment conforms to the installation environment If the robot is to be stored for a prolonged period of time be sure the robot will not be exposed to dew condensation Unless otherwise specified desiccant is not placed in the carton when shi...

Page 23: ...17 4 How to Install 4 4 1 How to Install Shown below is how to install SCARA Robot Installation Posture Ceiling Mount Wall Mount Horizontally Oriented Mount ż s ż Available s Not available s ...

Page 24: ...r the hex bolts use high tension bolts with an ISO rating of 10 9 or higher z Always insert a washer below each bolt Without a washer the bolt bearing surface may sink z Tighten the hex bolts securely to the correct torque Improperly tightened bolts may reduce the accuracy of robot operation and in the worst case cause the robot to overturn Warning Caution 4 2 ...

Page 25: ...isk of danger Be sure to affix each connector with the supplied screws Connect the cables securely after confirming that they are free from damage or bent connector pins Connect each cable by aligning the indication on the marking tube on the cable with the indication on the controller panel When installing the PG connector D sub connector ensure correct orientation of the connector The brake powe...

Page 26: ...x each connector with the supplied screws 4 3 Checking after Installation Once the robot has been installed check the following items x Visually check the robot controller and cables for dents and other abnormalities x Confirm that the cables are connected properly and that the connectors are inserted securely z Failure to perform these checks may result in a malfunctioning robot or a damaged cont...

Page 27: ...z If an overload error occurs lower the acceleration deceleration setting as appropriate or provide an appropriate stopping time following each acceleration deceleration z Depending on the position of the vertical axis the robot may generate vibration when axis 1 axis 2 or the rotational axis turns If vibration occurs lower the acceleration deceleration as appropriate z To move the robot horizonta...

Page 28: ...rtical axis as close as possible to the top position If the vertical axis is operated at the bottom position the spline shaft for the ball screw will bend and the vertical axis will be disabled z Keep the permissible moment of inertia of axis 4 to 0 015 kg m or less z The carrying load indicates a load above the rotational center of axis 4 z Operate the robot by using an appropriate acceleration d...

Page 29: ...set the rotating direction using the D cut surface and setscrews be sure to use setscrews with resin or brass pad or set pieces made of soft material Avoid attachment of the tool at the D cut surface via thread fastening Doing so may damage the D cut positioning surface z Turn off the power to the controller and robot before installing a tool z If the tool mounting part does not have sufficient st...

Page 30: ...turely or may result in damage or vibration z If vibration occurs lower the acceleration deceleration as appropriate z If the load gets offset the robot becomes more likely to cause vibration Design the tools so that the load s center of gravity aligns with the center of axis 4 z Do not move the robot horizontally with axis 3 vertical axis extended It may cause the vertical axis to bend and disabl...

Page 31: ...x I2 5 mm 3 pieces Working medium Air ALM indicator specifications Rated voltage 24 VDC Rated current 12 mA Illumination color Red LED Shape of Y terminal Spacer for user part installation M4 depth 5 30 N or less External force applied to the spacers must not exceed 30 N in the axial direction or 2 N m in the rotating direction for each spacer 2 N m or less I 7 10 2 6 5 9 5 2 3 2 BK SW Brake relea...

Page 32: ...nd left until it moves smoothly and then tighten setscrew B to the specified torque Tightening torque of each part y End bell 10 kgf cm to 15 kgf cm y Clamp nut 15 kgf cm to 20 kgf cm y Setscrew A B 2 kgf cm to 3 kgf cm If the waterproof user connector and user piping joint are not used attach the supplied cap and blank plug on the connector and joint respectively Failure to do so will cause water...

Page 33: ...d cable to pin 16 Failure to do so may cause the robot to malfunction due to noise To base Inside unit Cable Arm 2 side Connection D sub 15 pin Indicator LED Controller side Y terminal designation Wire color Orange 1 red Light gray 1 red Connection Y terminal Orange 1 black Light gray 1 black White 1 red White 1 black Yellow 1 red Yellow 1 black Pink 1 red Pink 1 black Orange 2 red Orange 2 black ...

Page 34: ...ce the air pressure to a range of 0 3 to 0 6 MPa and adjust the flow rate using the speed controller supplied with the robot Supplying too much air will inflate the bellows Adjust the speed controller by following the procedure below Increasing the flow rate To increase the flow rate turn the needle on the speed controller counterclockwise from the fully closed state Supplying too much air will in...

Page 35: ...ble the following components or cut cables at the user site Disassembly of servo motor Disassembly of reduction gear unit Disassembly of ball screw spline Disassembly of bearing Disassembly of harmonic speed reducer Disassembly of brake Cutting of cable IAI will not be responsible for any malfunction or damage resulting from the conduct of any operation cited above z Performing inspection or maint...

Page 36: ...nctions properly 6 1 2 Six Month Inspection Check the following items on the robot every six months Observe the precautions for work near the robot and for inspection maintenance adjustment operations when carrying out each check Check location Description Robot Check the arm mounting sections for looseness If any of the arm mounting sections is loose tighten the fastening parts securely Ball scre...

Page 37: ...f an abnormality is found Harmonic speed reducer Change the grease Contact IAI Based on 24 hour operation Change the grease every three years or so if the robot is operated eight hours a day Performing inspection or maintenance without fully understanding the details of work may result in a serious accident If inspections are neglected the drive part may wear prematurely or the robot may malfuncti...

Page 38: ...s to be pulled with excessive force when lifting the panel 3 Lift the cover and remove upward z If the cover is removed absolute reset must be performed again for the rotational axis and vertical axis See 6 4 Absolute Reset Procedure z Do not cause the wires to be pulled with excessive force when lifting the panel Rotary joint 1 CAP 4 M3 x 18 with sealing washer Panel Remove the motor connectors L...

Page 39: ...the amount of deflection If the deflection is 2 4 mm the belt tension is normal If the deflection is not 2 4 mm adjust the tension by referring to 6 2 6 Adjusting the Belt Tension for the Vertical Axis z When measuring deflection do not use a gauge with a sharp tip that may damage the belt Timing belt for vertical axis Timing belt for rotational axis Push pull gauge Deflection 2 4 mm Pulley Pulley...

Page 40: ... 400 gf and measure the amount of deflection If the deflection is 0 7 mm the belt tension is normal If the deflection is not 0 7 mm adjust the tension by referring to 6 2 7 Adjusting the Belt Tension for the Rotational Axis z When measuring deflection do not use a gauge with a sharp tip that may damage the belt Push pull gauge Deflection 0 7 mm Pulley Pulley Belt Caution ...

Page 41: ...n by referring to 6 2 4 Checking the Belt Tension for the Vertical Axis 4 Tighten the M5 bolts 1 loosened in step 1 tightening torque 7 6 N m and tighten the lock nut 2 5 Check the belt tension again by referring to 6 2 4 Checking the Belt Tension for the Vertical Axis If the deflection has changed perform the adjustment again z After fixing the axis center be sure to confirm once again that the d...

Page 42: ...ing to 6 2 5 Checking the Belt Tension for the Rotational Axis 4 Tighten the bolts 1 loosened in step 1 tightening torque 1 3 7 N m 5 Check the belt tension again by referring to 6 2 5 Checking the Belt Tension for the Rotational Axis If the deflection has changed perform the adjustment again z After fixing the axis center be sure to confirm once again that the deflection meets the specified value...

Page 43: ... cap screws M3 x 18 2 to a tightening torque of 0 08 kgf m to affix the dust cover Don t forget to insert a sealing washer z Check the marking tubes to prevent improper connections z Be careful not to bend the air tubes z Be careful not to pinch the cables z Place the wires neatly in the upper space without letting them rest on top of one another Do not forcibly tighten the screws with the panel s...

Page 44: ...cing the batteries turn off the power to the controller control panel and other relevant units z Performing inspection or maintenance without fully understanding the details of work may result in a serious accident z Display a Work in Progress sign so that other operators will not operate the controller operation panel etc z Use dedicated batteries for IX Batteries for the old model IH cannot be u...

Page 45: ...ost and an absolute reset will become necessary x Replace batteries one axis at a time If the batteries for all axes are replaced at once the work may not be completed within the specified time 4 Install the batteries into the battery holder 5 Affix the rear panel base using the six low head cap screws 1 z When installing the rear panel base be careful not to pinch the cables inside z Don t forget...

Page 46: ...adjustment jig is always required when performing an absolute reset of the rotational axis or vertical axis However the jig is not always necessary when performing an absolute reset of arm 1 or arm 2 Rotation data can be reset as long as a positioning accuracy of center of positioning mark label r1 graduation is ensured z Performing inspection or maintenance without fully understanding the details...

Page 47: ...t window from the PC software 2 The absolute reset window opens x One of three absolute reset screens for arm 1 arm 2 and rotational axis vertical axis is displayed when a corresponding tab is clicked Absolute reset screen for arm 1 or 2 Absolute reset screen for rotational axis vertical axis ...

Page 48: ...42 6 Inspection Maintenance 6 4 3 Absolute Reset Procedure for Arm 1 or 2 1 Click the Encoder Rotation Data Reset1 button 2 Click the Reset Controller Error button ...

Page 49: ...43 6 Inspection Maintenance 3 Click the Servo ON button 4 Jog the arm to near the reference position see reference position drawing in step 7 and click the Jog end button 5 Click the Servo OFF button ...

Page 50: ...ove the setscrews and detach the cover before setting the jig x It is recommended that an adjustment jig be used to perform an absolute reset With arm 1 or 2 however rotation data can be reset as long as a positioning accuracy of center of positioning mark label r1 graduation is ensured z Always press the emergency stop switch before setting an adjustment jig Failure to do so may cause the robot t...

Page 51: ...45 6 Inspection Maintenance 8 Click the OK button 9 Click the Encoder Rotation Data Reset2 button ...

Page 52: ...out using an adjustment jig the home position will become offset x If the home position has been updated by mistake perform an absolute reset again using an adjustment jig This time end the procedure before home position automatic update x Always click the OK button after removing the jig and releasing the emergency stop switch 13 Click X in the top right hand corner to exit the absolute reset win...

Page 53: ...47 6 Inspection Maintenance 6 4 4 Absolute Reset Procedure for the Rotational Axis Vertical Axis 1 Click Encoder Rotation Data Reset1 button 2 Click the Reset Controller Error button ...

Page 54: ...p Standard posture standby button x The vertical axis returns to its home position Exercise caution so as not to be injured by the axis during movement 5 Jog the rotational axis to the reference position see reference position drawing in step 8 and click the Jog end button ...

Page 55: ...49 6 Inspection Maintenance 6 Click the Servo OFF button 7 Press the emergency stop switch ...

Page 56: ... jig on the rotational axis by causing its side labeled UPPER ARM SIDE to face up 3 Insert a pin jig from the bottom to set the rotating direction of arm 2 4 Turn the rotational axis until the plate jig contacts the pin lightly z Always press the emergency stop switch before setting an adjustment jig Failure to do so may cause the robot to malfunction and result in a serious accident Reference pos...

Page 57: ...51 6 Inspection Maintenance 9 Click the OK button 10 Click the Encoder Rotation Data Reset2 button ...

Page 58: ...52 6 Inspection Maintenance 11 Click the Home pos automatic update button 12 Remove the adjustment jig 13 Release the emergency stop switch 14 Click the OK button ...

Page 59: ...nce 15 Click the Servo ON button 16 Click the Standard posture standby button x The vertical axis returns to its home position Exercise caution so as not to be injured by the axis during movement 17 Click the Servo OFF button ...

Page 60: ...r Rotation Data Reset3 button 19 Click the Home pos automatic update button and then click X in the top right hand corner to exit the absolute reset window x Once the absolute reset is complete be sure to write the flash ROM and reset the controller ...

Page 61: ...solute reset window is closed Click the Yes button x Clicking Yes writes the information in the flash ROM x The flash ROM must also be written when home position automatic update has been performed for arm 1 or 2 2 When the writing of flash ROM is complete the following screen is displayed Click the Yes button x The controller is restarted and the software is reset ...

Page 62: ...56 6 Inspection Maintenance 6 4 6 Resetting the Controller 1 Select Software Reset from the Controller menu on the tool bar 2 Click the Yes button The controller is reset and restarted ...

Page 63: ...al axis 1 mm 150 Movement range Axis 4 rotational axis degree r360 Axis 1 Axis 2 maximum composite speed 3142 Axis 3 vertical axis mm sec 1106 Maximum operating speed 2 Axis 4 rotational axis degree sec 1600 Axis 1 Axis 2 r0 010 Axis 3 vertical axis mm r0 010 Positioning repeatability 3 Axis 4 rotational axis degree r0 005 Cycle time 4 sec 0 51 2 kg Rated 1 Load capacity Maximum kg 3 Dynamic 5 90 ...

Page 64: ...erted to a value at the rotational center of axis 4 The offset from the rotational center of axis 4 to the tool s center of gravity is assumed to be 40 mm or less Fig 3 If the tool s center of gravity is further away from the rota tional center of axis 4 the speed and acceleration must be reduced as appropriate 8 If the tool exceeds the permissible diameter it will contact the robot inside the rob...

Page 65: ...s 1 Axis 2 maximum composite speed 3979 Axis 3 vertical axis mm sec 1106 Maximum operating speed 2 Axis 4 rotational axis degree sec 1600 Axis 1 Axis 2 r0 010 Axis 3 vertical axis mm r0 010 Positioning repeatability 3 Axis 4 rotational axis degree r0 005 Cycle time 4 sec 0 59 2 kg Rated 1 Load capacity Maximum kg 3 Dynamic 5 90 9 9 3 Push in thrust of axis 3 vertical axis Static 6 N kgf 65 3 6 7 P...

Page 66: ...is 4 The offset from the rotational center of axis 4 to the tool s center of gravity is assumed to be 40 mm or less Fig 3 If the tool s center of gravity is further away from the rota tional center of axis 4 the speed and acceleration must be reduced as appropriate 8 If the tool exceeds the permissible diameter it will contact the robot inside the robot s range of movement Fig 4 9 Pins 1 to 15 of ...

Page 67: ...ves controller I O output signal and supplies 24 VDC to the LED terminal in the user connector Reference surface Reference surface ALM indicator Arm 2 stopper I4 quick air tube joint black red white 3 locations BK SW Brake release switch Tapped hole for peripheral installation 4 locations M4 depth 12 T slot for peripheral installation M3 M4 I4 red quick joint I4 black quick joint I4 white quick jo...

Page 68: ...nal in the user connector Reference surface Reference surface ALM indicator Arm 2 stopper I4 quick air tube joint black red white 3 locations BK SW Brake release switch T slot for peripheral installation M3 M4 I4 red quick joint I4 black quick joint I4 white quick joint Detailed view of panel inner diameter User connector Same on opposite surface Detailed view of arm tip BK SW Brake release switch...

Page 69: ...oof Splash proof Specification IX NNW 3515 Arm Length 350 Dust proof Splash proof Specification Area of prohibited entry Mechanical stopper position Movement range Area of prohibited entry Area of prohibited entry Mechanical stopper position Movement range Area of prohibited entry ...

Page 70: ... 4 Wiring Diagram Wiring Piping Diagram Arm Length 250 350 Controller Cable fix cap Capcon M cable outside robot PG cable outside robot BK power cable outside robot U cable outside robot Brake power terminals User wiring terminals Inside base Servo motor for axis 1 arm 1 Board FG To base Air joint red I4 Air joint black I4 Air joint white I4 Flexible cable Inside arm 2 PG cable inside robot M cabl...

Page 71: ...ified 3 Axis 3 servo motor w brake TS4606 N7032 E200 AC servo motor 60 100 W w brake round shaft CE certified 4 Axis 4 servo motor TS4602 N2032 E200 Tamagawa Seiki AC servo motor 40 50 W key groove CE certified 5 M cable inside robot IAI Wire 300 V 105qC rated AWG18 0 84 mm 2 flexible cable UL VW 1 c UL FT 1 6 M cable outside robot IAI Wire 300 V 80qC rated AWG18 0 89 mm 2 oil resistant cable UL V...

Page 72: ...rranty 1 Anything other than our product 2 Modification or repair performed by a party other than us unless we have approved such modification or repair 3 Anything that could not be easily predicted with the level of science and technology available at the time of shipment from our company 4 A natural disaster man made disaster incident or accident for which we are not liable 5 Natural fading of p...

Page 73: ...aining to maintenance or management of human life or health 2 A mechanism or mechanical equipment intended to move or transport people such as a vehicle railway facility or aviation facility 3 Important safety parts of mechanical equipment such as safety devices 4 Equipment used to handle cultural assets art or other irreplaceable items 3 Contact us at the earliest opportunity if our product is to...

Page 74: ...eted 4 1 Installation Posture added Safety Guide added Caution in Handling added Brake voltage source capacity from 20W to 30W ĺ changed to 20W Caution notes added telling to go to see the doctor to have an appropriate treatment when the grease got into an eye Brake voltage source capacity 20W added to specifications Contents changed in 8 Warranty April 2011 March 2012 August 2012 Second edition T...

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Page 76: ... D 65824 Schwalbach am Taunus Germany TEL 06196 88950 FAX 06196 889524 SHANGHAI JIAHUA BUSINESS CENTER A8 303 808 Hongqiao Rd Shanghai 200030 China TEL 021 6448 4753 FAX 021 6448 3992 website www iai robot com Technical Support available in USA Europe and China Head Office 2690 W 237th Street Torrance CA 90505 TEL 310 891 6015 FAX 310 891 0815 Chicago Office 1261 Hamilton Parkway Itasca IL 60143 T...