Mitsubishi MELFA RH-3SDHR3512C, Instruction Manual

Page 1: ...Mitsubishi Industrial Robot RH 3SDHR3515 3512C 3512W INSTRUCTION MANUAL ROBOT ARM SETUP MAINTENANCE BFP A8839 D...

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Page 3: ...on the start switch etc This also applies to maintenance work with the power source turned ON Indication of teaching work in progress Provide a fence or enclosure during operation to prevent contact...

Page 4: ...this could lead to malfunctioning by noise or to electric shock accidents Indicate the operation state during robot operation Failure to indicate the state could lead to operators approaching the rob...

Page 5: ...is turned off while in automatic operation or rewriting the program or parameters the internal information of the robot controller may be damaged Use the network equipments personal computer USB hub...

Page 6: ...e with specified speed Especially as for the corner section short cut distance may change Therefore when beginning automatic operation moves at low speed at first and you should gather speed slowly wi...

Page 7: ...id valve set 2011 02 02 BFP A8839 B The note of installing the hand input cable was added The precautions about interference of the ball screw shaft and the movement locus were added 2011 05 09 BFP A8...

Page 8: ...vironment which can access the robot with the stepladder etc in RH 3SDHR The contents of this manual correspond to the following robot types Type RH 3SDHR3515 General environment RH 3SDHR3512C Clean s...

Page 9: ...data 2 19 2 Turning ON the control power 2 19 3 Preparing the T B 2 20 4 Selecting the origin setting method 2 21 5 Inputting the origin data 2 22 6 Installing the base cover B L 2 23 2 5 Confirming t...

Page 10: ...the robot arm battery 5 78 5 4 About Overhaul 5 79 5 5 Maintenance parts 5 80 5 6 Resetting the origin 5 81 5 6 1 Mechanical stopper method 5 82 1 J1 axis origin setting mechanical stopper 5 82 2 J2...

Page 11: ...ed Explains the procedures required to operate the robot arm unpacking transportation installation confirmation of operation and the maintenance and inspection procedures Explains the procedures requi...

Page 12: ...y if handling is mistaken Always observe these precautions to safely use the robot Precaution indicating cases where the operator could be subject to fatalities or serious injuries if handling is mist...

Page 13: ...g work This also applies to maintenance work with the power source turned ON Setting of emergency stop switch During teaching work place a sign indicating that teaching work is in progress on the star...

Page 14: ...juries or damage if the object comes off or flies off during operation Securely ground the robot and controller Failure to observe this could lead to malfunctioning by noise or to electric shock accid...

Page 15: ...ic operation or rewriting the program or parameters the internal information of the robot controller may be damaged When the SSCNETIII cable is removed install the cap in the connector If the cap is n...

Page 16: ...stic bag of attachment in the robot arm Note2 The numbers 8 and 9 are installed in the robot arm No Part name Type Qty Remarks 1 Robot arm R 1 unit 2 Guarantee card 1 copy 3 Installation bolts M8 90 4...

Page 17: ...material 5 and remove packing material 4 Unpacking is complete above Unpacking the robot with hoisting Utilize the hanging tools two places 4 of the robot arm Please unpack near the installation place...

Page 18: ...ched certainly to installation stage 8 3 Remove hanging tools two places 4 after installation Loosen the screw M5 x 4 M4x1 fixing the fixing plate 7 and remove the fixing plate 7 Also remove the nut f...

Page 19: ...t moves 4 When installing use a common table to prevent the position of the devices and jigs subject to robot work from deviating 5 The installation surface must have sufficient strength to withstand...

Page 20: ...imum reaction force design values that may be applied to an installation stand Please use these values as reference when designing the installation stand Table 2 3 Magnitude of each reaction force Sec...

Page 21: ...grounding point should be as close to the robot arm and controller as possi ble and the length of the grounding wire should be short Fig 2 4 Grounding methods 2 Grounding procedures 1 Prepare the gro...

Page 22: ...ttached to the connector on the machine cable side to the rear of the projection of the robot arm connector to fix securely in place 4 To remove the cable insert a minus screwdriver into the hook whil...

Page 23: ...ion Take special care to the leading of the connection cable If the cable is pulled with force or bent excessively wires could break or the connector could be damaged Connect the machine cable at the...

Page 24: ...socket bolt four M4 8 fixing the No 2 arm cover and remove the No 2 arm cover 3 Confirm spare wiring ADD 4 Remove either one grommet on the No 2 arm cover 5 Install the connector after letting the cab...

Page 25: ...too much load is added the breaking of a wire and the air hose break and the robot cannot operate normally When No 2 arm cover is installed catch neither the cable nor the air hose If the bolt is tigh...

Page 26: ...g ADD Since spare wiring is bundled in the cable tie if length is necessary cut the cable tie 5 Remove the grommet on the base 6 Install the connector after letting the cable for spare wiring connecti...

Page 27: ...too much load is added the breaking of a wire and the air hose break and the robot cannot operate normally When base cover B R is installed catch neither the cable nor the air hose If the bolt is tigh...

Page 28: ...the dummy connector or draw it out Please do not pull the cable of T B strongly or do not bend it too much It becomes the breaking of a wire of the cable and the cause of breakage of the connector Ple...

Page 29: ...origin data to input is found on also the robot examination report sheet Always install remove the cover with the controller control power turned OFF Failure to do so could lead to physical damage or...

Page 30: ...appear The following operations are carried out with the T B MODE MANUAL AUTOMATIC ENABLE DISABLE Up Disable Down Enable Lighting Operating from the T B Always set the MODE switch mode selection key...

Page 31: ...BRK 5 SET INIT 6 ENHANCED CLOSE 123 ORIGIN BRAKE 1 ORIGIN 2 BRAKE CLOSE 123 ORIGIN 1 DATA 2 MECH 3 TOOL 4 ABS 5 USER CLOSE 123 ORIGIN DATA D J1 J2 J3 J4 J5 J6 J7 J8 CLOSE 123 Selecting a menu The menu...

Page 32: ...the key five times will be set Press the key once and advance the cursor Press the key twice input and press the PQRS key four times input S Press the CHARACTER key and set to the numeral input mode C...

Page 33: ...rect operations or to physical damage or personal injury ORIGIN DATA D V S29 J1 06DTYY J2 2 HL9X J3 1CP55V J4 T6 MSY J5 Z21J Z J6 A12 Z0 J7 J8 CLOSE ABC ORIGIN DATA CHANGE TO ORIGIN OK No 123 Yes Movi...

Page 34: ...re no operators near the robot and that there are no obstacles such as tools in the robot operation range To immediately stop the robot release the deadman switch on the back of the T B The servo powe...

Page 35: ...s straight along the base coordinate system Also while maintaining the end axis position the end axis posture changes Base coordinate system reference orgin End axis Z Z X Y Y C X While maintaining th...

Page 36: ...posture is not maintained Also the end axis posture changes Base coordinate system reference orgin End axis X X Y Y Z Z C The current position is set as the arc centering on the Z axis and the axis m...

Page 37: ...K jog operation X X Y Y Z Z Z Z Zw Zw Xw Xw Yw Yw WORK coordinate system Controll point Tool length While maintaining the end axis posture the axis moves straight along the work coordinate system Also...

Page 38: ...never it presses the key of OVRD the override goes up Conversely if the OVRD key is pressed it will go down The current setting speed is displayed on screen upper right and STATUS NUMBER of the contro...

Page 39: ...keys are pressed the J4 axis will rotate in the plus direction When the A J4 keys are pressed Rotate in the minus direction When the robot is in the transportation posture The axes may be outside the...

Page 40: ...the X axis plus direction When the X J1 keys are pressed Move along the minus direction When the Y J2 keys are pressed the robot will move along the Y axis plus direction When the Y J2 keys are press...

Page 41: ...d the robot does not move In this case please move to the counter direction X X Z Y Z Y X Y X Z Z Y C Changing the end axis posture When alarm No 5150 occurs If alarm No 5150 ORIGIN NOT SET occurs the...

Page 42: ...of the controller Set the override to 10 here for confirmation work When the X J1 keys are pressed the robot will move along the X axis plus direction of the tool coordinate system When the X J1 keys...

Page 43: ...carry out XYZ jog If the buzzer of T B sounds and the robot does not move If it is going to move the robot across the operation range the buzzer of T B sounds and the robot does not move In this case...

Page 44: ...ight and STATUS NUMBER of the controller Set the override to 10 here for confirmation work When the X J1 keys are pressed the robot will move along the X axis plus direction When the X J1 keys are pre...

Page 45: ...n the minus direction The flange surface end axis posture cannot be maintained with 3 axis XYZ jog With 3 axis XYZ jog the flange surface end axis posture orientation is not maintained when moving lin...

Page 46: ...0 here for confirmation work Assuming that the current position is on an arc centering on the Z axis the robot moves along that arc When the X J1 keys are pressed the robot will expand in the radial d...

Page 47: ...g the operation 2 37 When the C J6 keys are pressed The Z axis will rotate in the plus direction When the C J6 keys are pressed Rotates in the minus direction X X Z Y Z Y C The position of the end axi...

Page 48: ...versions T B Ver 1 3 or later SQ series N8 or later SD series P8 or later The work coordinates system teaches and sets up the three points WO WX WY Fig 2 18 Setting of the work coordinates system teac...

Page 49: ...screen is displayed MENU 1 FILE EDIT 2 RUN 3 PARAM 4 ORIGIN BRK 5 SET INIT 6 ENHANCED CLOSE 123 EMHANCED 1 SQ DIRECT 2 WORK COORD CLOSE 123 The screen shows the coordinate value of the origin WO of t...

Page 50: ...re teach the three points This work coordinate data is registered into parameter WKnCORD n means the work coordinates numbers 1 8 If the function key corresponding to CLOSE is pressed it will return...

Page 51: ...s confirm that the number of the target work coordinates system is displayed correctly Display of W1 W8 at the upper right of the screen If mistaken the robot will move in the direction which is not m...

Page 52: ...coordinates system When the Y J2 keys are pressed Move along the minus direction When the Z J3 keys are pressed the robot will move along the Z axis plus direction on the work coordinates system When...

Page 53: ...t is not possible from the transportation posture In this case the robot will not move Refer to section 1 JOINT jog operation on page 28 and move the robot to a position where linear movement is possi...

Page 54: ...t Elbow type 4 Hand output cable GR2 5 Hand output cable Robot arm side A port B port 4 Hand output cable GR1 Primary piping air hose 6 x 2 Secondary piping air coupling 4 x 4 Secondary piping air hos...

Page 55: ...er preparation Customer preparation hose 4 x 4 Hand output signal connector Secondary piping air coupling 4 x 4 Connect the hand tube optional Secondary piping air hose Customer preparation hose 4 x 4...

Page 56: ...If the cable enters within the bracket it will rub to the timing belt and will become the cause of breaking down Fig 3 3 Storing of the hand output cable 6 Install the No 2 arm cover 3 and the arm co...

Page 57: ...onnection correspondence after installation is as shown in Table 3 1 1 Nylon clamp Screw 2 M5 and nut for T slots Air hose for secondary piping customer preparation Air hose for secondary piping custo...

Page 58: ...ces Table 3 1 Solenoid valve ports and hoses Correspondence of couplings and hand ports Hand Hand port Solenoid valve port Solenoid valve used Hand 1 OPEN 1 1 st row CLOSE 2 Hand 2 OPEN 3 2 nd row CLO...

Page 59: ...is shown below 1 Motor cover J3 Hand tube 3 Piping fixing bracket The grease is applied 2 Secondary piping air coupling 4 x 4 places Insert the union installation side 4 Shaft The grease is applied 5...

Page 60: ...ree This position is adjustment basis for fixing hand tube The hand tube and the hand input cable having the mark at the position which rolls the rubber sheet The hand tube is the four places a b c an...

Page 61: ...e rubber sheet attachments in the same way and fix it by cable tie etc attachments with maintaining this adjustment position The example of the fixing method is shown in Fig 3 8 9 Remove the tape and...

Page 62: ...n devices Fig 3 8 Tool side fixing image of hand tube example Metal plate for tool side fixing Tool Hand flange Union 4 to 3 Nylon clamp Rubber sheet Enlargement On the Clean Waterproof specifica tion...

Page 63: ...ing the connector at flat surface on the J4 motor to make the connector parallel to the motor cover J3 1 6 Pass through the hand input cable into the shaft 4 along the piping fixing bracket 3 7 Fixing...

Page 64: ...etc attachments with maintaining this adjustment position Fixing like the fixing method shown in Fig 3 8 10 Install motor cover J3 1 securely as before The grease is applied to hand input cable contac...

Page 65: ...m cover 3 is completely inseparable 2 Remove one of the three grommets on No 2 arm cover Install the cable clamp here 3 Remove the lock nut of attachment on the hand output cable and let the connector...

Page 66: ...will become the cause of breaking down Fig 3 11 Storing of the hand output cable 5 Install the No 2 arm cover 3 and arm cover A 2 4 as before Be careful not to catch any the cables 6 Connect to the so...

Page 67: ...r B L and R with referring to the Page 66 5 3 2 Installing removing the cover 3 There is the pin cover at back in the base A of Fig 3 12 Two places Loosen the fixing screw and remove the two pin cover...

Page 68: ...alue Press the JOG key of T B and display the current coordinate value Choose joint jog mode If the coordinate value of the J1 axis is nearly 90 degrees the mechanism stopper is installed correctly 10...

Page 69: ...oint jog operation confirming the coordinate value of T B as follows Note This operation is necessary for position adjustment of the mechanism stopper Although it is not alteration visible especially...

Page 70: ...inate value Choose joint jog mode If the coordinate value of the J2 axis is nearly 60 degrees the mechanism stopper is installed correctly 10 Confirm the minus side in the same way If not installed co...

Page 71: ...61 4 Basic operations The basic operations from creating the program to automatic operation are explained in section 4 Basic operations in the From Controller Setup to Maintenance manual Refer that m...

Page 72: ...0 Hr operation hours Fig 5 1 Inspection schedule 0 Hr Daily inspection Monthly inspection Monthly inspection 500 Hr Monthly inspection 3 month inspection Monthly inspection Monthly inspection 1 000 Hr...

Page 73: ...connect 6 Are there any cracks foreign contamination or obstacles on the robot and controller cover Replace with a new part or take remedial measures 7 Is any grease leaking from the robot arm Visual...

Page 74: ...act the Mitsubishi Service Department 3 month inspection items 1 Is the timing belt tension abnormal If the timing belt is loose or too tense adjust it 2 Is there any grease of the shaft section still...

Page 75: ...n of the J1 axis motor 1 arranged in the base is conveyed to the reduction gears 3 via the timing belt 2 to rotate the J1 axis Brakes are not mounted in the J1 axis motor 2 The rotation of the J2 axis...

Page 76: ...ight bolts Note2 5 No 1 Arm cover B Low head hexagon socket bolt M4 x 8 four bolts SUS hexagon socket bolt M4 10 eight bolts Note2 6 Motor cover J2 Low head hexagon socket bolt M4 x 8 four bolts SUS h...

Page 77: ...he covers 2 The names of the covers are given in Table 5 3 and a list of the cover installation screws is given in Table 5 3 3 When installing the cover after maintenance and inspection use the proced...

Page 78: ...gauge in inspection and adjustment of the timing belt The recommendation gauge is shown below Please prepare by customer Refer to the Page 74 6 Timing belt tension for the tension adjustment value of...

Page 79: ...The nut which is fixing tension adjustment screw 3 is loosened turn tension adjustment screw 3 and adjust the tension of timing belt 2 When the screw is turned to the right the belt will be stretched...

Page 80: ...much 3 The nut which is fixing tension adjustment screw 3 is loosened turn tension adjustment screw 3 and adjust the tension of timing belt 2 When the screw is turned to the right the belt will be str...

Page 81: ...and adjust the tension of timing belt 2 When the screw is turned to the right the belt will be stretched and when turned to the left will loosen Lightly press the center of the belt A and confirm tha...

Page 82: ...the No 2 arm cover and the belt pulley cover J4 The belt can be pushed and adjusted by removing the No 2 arm cover Idler 2 Timing belt 4 Timing pulley No 2 arm No 2 arm cover section Idler 2 Timing be...

Page 83: ...2 Lightly loosen the two idler installation bolts 1 Do not loosen too much 3 The nut which is fixing tension adjustment screw 3 is loosened turn tension adjustment screw 3 and adjust the tension of ti...

Page 84: ...he belt tension side will vibrate The detailed adjustment tension is shown in Fig 5 8 Check and adjust with the belt pressing force f and the slack amount d between span s F Pressing force The preset...

Page 85: ...unction of the personal computer support software option the guidance of lubrication time is calculated according to the operating environment of the customer The numbers in the Table 5 4 correspond t...

Page 86: ...n Table 5 4 using a grease gun from the lubrication grease nipple Add only the specified amount of grease Adding excess grease may cause grease to leak 3 The J1 axis has the grease nipple and the timi...

Page 87: ...time is over Error No 133n Encoder battery voltage low n indicates the axis number The encoder battery voltage of the robot arm is low Error No 7510 Battery voltage low R C The battery voltage of the...

Page 88: ...ttery should be performed one by one Extract the old battery from holder and remove the lead connector 3 Insert the new battery into the holder and connect the lead connector Replace all batteries wit...

Page 89: ...r operating conditions and thus with the degree of the equipment s wear and loss of performance As a rule of thumb however it is recommended that overhaul be carried out before the total amount of ser...

Page 90: ...Table 5 5 Consumable part list Table 5 6 Spare parts list No Part name Type Note1 Note1 Confirm the robot arm serial No and contact the dealer or service branch of Mitsubishi Electric Co for the type...

Page 91: ...Origin data input method The origin data set as the default is input from the T B The setting method is explained in Page 18 2 4 Setting the origin 2 Mechanical stopper method This origin posture is...

Page 92: ...safety purposes the brakes must be released by two workers 1 J1 axis origin setting mechanical stopper 1 Press the 4 key on the menu screen and dis play the Origin Break selection screen 2 With both...

Page 93: ...23 ORIGIN MECH CHANGE TO ORIGIN OK No 123 Yes Release the brake Do cursor movement into the parenthesis of each axis by the arrow key The brakes can be released only for the axis for which a 1 is disp...

Page 94: ...mechanical stopper 3 Press the 1 key and display the Origin setting selection screen 4 Press the 2 key and display the Mechanical stopper selection screen 5 Input 1 into the J2 axis Set 0 to other axe...

Page 95: ...ement into the parenthesis of each axis by the arrow key The brakes can be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and...

Page 96: ...s direction and contact the axis against the mechanical stopper Match the alignment mark of J4 axis in this con dition next Go to the following procedure continuously For safety purposes the step for...

Page 97: ...ke of the J3 axis and the J3 axis contact to the mechanical stopper Note If the J3 axis has slid move the J3 axis against the mechanical stopper and con tact again 8 Detach the F1 key and work the bra...

Page 98: ...USER CLOSE 123 ORIGIN MECH J1 J2 J3 1 J4 1 J5 J6 J7 J8 CLOSE 123 ORIGIN MECH CHANGE TO ORIGIN OK No 123 Yes ORIGIN MECH COMPLETED J1 J2 J3 1 J4 1 J5 J6 J7 J8 CLOSE 123 Release the brake Do cursor move...

Page 99: ...display the Origin set ting selection screen 3 Press the 2 key and display the Mechanical stopper selection screen 4 Input 1 into the J1 to J4 axis Set 0 to other axes 5 Press the EXE key and display...

Page 100: ...position There are the method of releasing the brake and adjusting with the origin position manually and the method of adjusting with the origin position by jog feed Here explain operation by brake re...

Page 101: ...creen 5 Input 1 into the J1 axis Set 0 to other axes 6 Press the EXE key and display Confirmation screen 7 Press the F1 key and the origin position is set up 8 Setting of the origin is completed 9 Ref...

Page 102: ...es are not to be released press the 0 key and display a 0 If the F1 key on the teaching pendant or the enabling switch is detached while the brakes are released the brakes will be work immediately Sel...

Page 103: ...splay the Tool selection screen 5 Input 1 into the J2 axis Set 0 to other axes 6 Press the EXE key and display Confirmation screen 7 Press the F1 key and the origin position is set up 8 Setting of the...

Page 104: ...nto the parenthesis of each axis by the arrow key The brakes can be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display...

Page 105: ...display the Mechanical stopper selection screen 4 Input 1 into the J1 to J4 axis Set 0 to other axes 5 Press the EXE key and display Confirmation screen 6 Press the F1 key and the origin position is...

Page 106: ...s for which the origin is to be set with jog operation This can be set for all axes simultaneously or each axis independently When setting the ABS mark always view the operations from the mark and set...

Page 107: ...tion screen 4 Input 1 into the axis to origin setting Press the EXE key and display Confirmation screen 5 Press the F1 key and the origin position is set up This completes the setting of the origin wi...

Page 108: ...Page 24 2 5 Confirming the operation for details on the jog operation Choose the user origin position as the position where it doesn t move by the gravity This position is left as a guideline to posi...

Page 109: ...gin setting Press the EXE key and display Confirmation screen 9 Press the F1 key and the origin position is set up This completes the setting of the origin with the user origin method USER J1 1 J2 0 J...

Page 110: ...onto the origin label 1 Confirming the origin data label Remove the Refer to Page 66 5 3 2 Installing removing the cover and remove the 2 Confirming the origin data Confirm the value displayed on the...

Page 111: ...change to The posture is expressed by this configuration flag and the posture is saved with FL1 in the position constant X Y Z A B C FL1 FL2 The types of configuration flags are shown below 1 RIGHT LE...

Page 112: ...Appendix 102 Configuration flag 6Appendix...

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Page 114: ...without notice HEAD OFFICE TOKYO BUILDING 2 7 3 MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN NAGOYA WORKS 5 1 14 YADA MINAMI HIGASHI KU NAGOYA 461 8670 JAPAN Authorised representative MITSUBISHI ELECTRI...