YASKAWA MH SIGMA-5 Series, Manual

Page 1: ...ceipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN INSTRUCTIONS DX100 INSTRUCTIONS DX100OPERATOR S MANU...

Page 2: ...ct YASKAWA may modify this model without notice when necessary due to product improvements modifications or changes in specifications If such a modification is made the manual number will also be revi...

Page 3: ...mportant items WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to personnel CAUTION Indicates a potentially hazardous situation which i...

Page 4: ...or unexpected positioner motion Figure 2 Release of EMERGENCY STOP Button TURN Observe the following precautions when performing teaching operations within the working envelope of the positioner View...

Page 5: ...ing has been performed Check for problems in positioner movement Check for damage to insulation and sheathing of external wires Always return the Programming Pendant to the hook on the cabinet of the...

Page 6: ...vi 162068 1CD 162068 1CD MH SERIES POSITIONER 6 101...

Page 7: ...on 3 1 3 2 MH Series SIGMA 5 Positioner Assembly Type I 3 1 3 2 1 MH Series SIGMA 5 Positioner Type I Specifications 3 2 3 3 MH Series SIGMA 5 Positioner Assembly Type II 3 3 3 3 1 MH3105 Series SIGMA...

Page 8: ...18 4 4 7 Tooling Fixture Removal 4 21 4 5 MotoMount Installation 4 22 4 5 1 Preparation 4 22 4 5 2 Unpack and Assemble 4 22 4 5 3 Securing MotoMount Drive Components onto Faceplate 4 24 4 5 4 Retrofi...

Page 9: ...Position 6 7 6 5 1 Homing 6 7 6 6 Maintenance Schedule 6 11 6 6 1 MH Series SIGMA 5 Positioner 6 11 6 6 2 MotoMount 6 11 6 7 Troubleshooting 6 12 6 7 1 MH Series SIGMA 5 Positioner 6 12 6 7 2 MotoMoun...

Page 10: ...R 3 DESCRIPTION OF EQUIPMENT Provides a description of the major components CHAPTER 4 INSTALLATION This chapter provides installation procedures CHAPTER 5 TOOLING RECOMMENDATIONS This chapter provides...

Page 11: ...ate single or multiple external axis control packages to provide a complete positioner kit 1 3 System Layout The two major components of a typical headstock and tailstock positioner assembly MHT are M...

Page 12: ...ut Type I Fig 1 2 MHT System Layout Type II DRIVE ASSEMBLY MotoMount ASSEMBLY HS AC SERVO MOTOR MotoMount ASSEMBLY TS TAILSTOCK COLUMN STANDARD TOOL RADIUS LEVELING SCREW TYP HEADSTOCK COLUMN MotoMoun...

Page 13: ...l output bearing faceplate and a cast iron housing It also includes dual integral position switches and weld ground brushes 1 3 1 1 Drive Assembly with MotoMount The Drive Assembly combined with the M...

Page 14: ...sembly with a column that is designed to be floor mounted or mounted to a machine base as required for use in cantilevered stand alone applications The standard configuration provides connectors in th...

Page 15: ...tem This system is designed to be floor mounted or mounted to a machine base Span between the headstock and tailstock is determined by the application The standard configuration provides a 815 mm tool...

Page 16: ...our issue along with complete contact information Please allow approximately 24 to 36 hours for a response to your inquiry Please have the following information ready before calling techsupport motoma...

Page 17: ...e recommend approved Motoman training courses for all personnel involved with the operation programming or repair of the robot system This training is designed to familiarize personnel with the safe a...

Page 18: ...ks Emergency stop palm buttons located on operator station robot controller and programming pendant Check all safety equipment frequently for proper operation Repair or replace any non functioning saf...

Page 19: ...before program changes are made To avoid loss of information programs or jobs a backup must always be made before any service procedures are done and before any changes are made to options accessorie...

Page 20: ...ot perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual Use proper replacement parts Improper connections can damage the robot All connec...

Page 21: ...ion Holes in the faceplate provide for mounting MotoMount drive components or parts fixtures in stand alone cantilevered applications 3 2 MH Series SIGMA 5 Positioner Assembly Type I The design of the...

Page 22: ...95 Headstock Speed rpm 23 8 12 4 9 8 10 8 180 Degree Sweep Time sec 1 56 2 72 3 36 3 28 Rated CG Off Center mm 152 152 152 152 Rated CG Overhang mm 500 250 331 0 Load 500 mm CG Overhang kgf 75 75 168...

Page 23: ...sitioner Assembly Type II 3 3 MH Series SIGMA 5 Positioner Assembly Type II The MH3105 head stock utilizes a Type II drive assembly similar to that used in the MSR505 MSR1005 and MotoSweep O 20 50 pro...

Page 24: ...s Type Rotation Rated Load kgf 3105 Max MHT Load CG Off Center kgf mm 6300 90 Headstock Speed rpm 6 7 180 Degree Sweep Time sec 4 95 Rated CG Off Center mm 152 Rated CG Overhang mm 58 Load 500 mm CG O...

Page 25: ...uired for use with all Motoman MHT series headstock tailstock positioners The MotoMount drive components are mounted onto the headstock faceplate while the tailstock components replace earlier tailsto...

Page 26: ...9 MotoMount HD Layout FACEPLATE WELD GROUND CABLE TAILSTOCK TOOLING ADAPTER DRIVE BUSHING TAILSTOCK COLUMN FACEPLATE WELD GROUND CABLE AUXILARY MOUNTING HOLES AUXILARY MOUNTING HOLES PRIMARY MOUNTING...

Page 27: ...ed This section identifies customer supplied items and tools required to complete installation 4 1 1 Customer Supplied Items Servo motion control unit Incoming power supply Two earth ground cables wit...

Page 28: ...otective plastic wrapping from equipment 2 Inspect equipment for shipping damage 3 Unbolt the equipment from the shipping skid see Fig 4 10 Fig 4 10 Unbolting the Drive Assembly 4 Attach a lifting dev...

Page 29: ...s for positioners The following figures show the mounting hole patterns Fig 4 11 shows the mounting hole pattern for the MH95 185 Fig 4 12 shows the mounting hole pattern for the MH505 Fig 4 13 shows...

Page 30: ...0 1 20 350 0 70 0 210 0 400 0 76 2 SWITCHES BRACKETS NOT SHOWN FOR CLARITY 2X M10 x 1 5 THRU HOLES FOR ADDITIONAL MOUNTING SUPPORT AS REQUIRED FOR SPECIFIC APPLICATIONS 0 5 0 0 4X 11 0 THRU 0 018 0 0...

Page 31: ...eed as follows 1 Set the column assembly in desired position 2 Use the leveling bolt holes as a guide and transfer the hole locations to the concrete 3 Remove column assembly 4 Install the anchors per...

Page 32: ...lace a level on top of the housing perpendicular to the faceplate 2 Use the two leveling bolts beneath the faceplate A and B and a third beneath the motor C to level axially If the faceplate side need...

Page 33: ...g connections can be found in the system manual See separate documentation specific to your system 4 2 5 2 Ground Cables Type I Two locations are provided for attaching weld ground cables see Figure 4...

Page 34: ...ipment proceed as follows 1 Carefully remove protective plastic wrapping from equipment 2 Inspect the equipment for shipping damage 3 Unbolt headstock from the shipping skid using a 3 4 inch socket 4...

Page 35: ...itioner Type II 4 3 3 Unbolting the Drive Assembly Floor Mounting Type II Figure 4 17 provides dimensions for accurately floor mounting the MH3105 headstocks Fig 4 17 MH3105 Floor Mounting SHIPPING BO...

Page 36: ...adstock The headstock must be leveled in two directions Parallel to the faceplate Perpendicular to the faceplate Since it only takes three points to define a plane use only three of the six leveling b...

Page 37: ...ng the Cables Do not connect the encoder power and ground cables until after the drive assembly is securely in place 4 3 4 1 Connection to Motoman Controller When the MH Series SIGMA 5 Positioner asse...

Page 38: ...on the floor from the edge of the headstock base toward the location of the tailstock Fig 4 20 Strike a Chalk Line 3 Set the tailstock in its approximate position on the floor using the chalk line Th...

Page 39: ...n the tailstock on the floor across from the headstock 4 Use the chalk line and the center line of each component as guides for placement of the tailstock column on the floor 5 To position the tailsto...

Page 40: ...ck assembly axially proceed as follows 1 Place a level on top of the tailstock column in the axial direction 2 Use the leveling bolts A B and C to adjust the axial level Adjust bolts A and B equally T...

Page 41: ...sembly axially proceed as follows 1 Place a level on top of the tailstock column in the axial direction 2 Use the leveling bolts A B and C to adjust the axial level Adjust bolts A and B equally To lev...

Page 42: ...Mount HD allows for a misalignment between the tailstock and the tooling fixture without affecting performance A misalignment of 0 5 degrees is allowed If the tailstock is out of alignment more than 0...

Page 43: ...tock assemblies 3 Slowly lower tooling fixture while aligning with the headstock and tailstock locating pins Fig 4 27 Tooling Fixture Installation Headstock Tailstock 4 Continue lowering the tooling u...

Page 44: ...the MotoMount drive components A tooling fixture must be installed to align the system 4 4 6 1 Horizontal Alignment Check the horizontal alignment by measuring the gap see Figure 4 23 between the moun...

Page 45: ...lar to the tailstock adapter within 1 2 degree a visual check with a square is acceptable Repeat this process until the gap at both positions is within 1 mm If moving the bearing housing cannot provid...

Page 46: ...bottom 2 Using calipers measure the alignment gap 3 Rotate the positioner 180 degrees until the drive bushing is at the top 4 Measure the alignment gap at the second position If the gaps are differen...

Page 47: ...rizontal alignment Insure ground cable is installed and properly secured When horizontal and vertical alignment is complete ensure all bolts are tightened to the appropriate torque including tailstock...

Page 48: ...it is part of a larger system MotoMount drive components Dowel pins 2 Mounting hardware Weld ground cable Carefully remove plastic wrapping from components and inspect them for shipping damage 4 5 2...

Page 49: ...wel pins into the appropriate dowel pin hole in the mounting block It is important that the dowel pin is pressed in as far as possible 4 Relocate the spacer behind the other dowel hole and install the...

Page 50: ...er holes in the faceplate and push fixture block in as far as possible 3 Insert both mounting bolts through the fixture block and tighten into the faceplate holes Torque bolts to 76 N m 56 lbf ft 4 In...

Page 51: ...al Center Position Side View 4 6 1 Allowable Misalignment The flexibility of MotoMount allows for misalignment between the tailstock and the tooling fixture without affecting performance A total misal...

Page 52: ...wer tooling fixture onto the tailstock using the locating pin 6 Install the M16 tool mounting bolts and washers onto the tailstock customer supplied grade 8 8 bolts and torque the bolts to 190 N m 140...

Page 53: ...e tailstock adapter until a suitable position is acquired These two processes do not effect MotoMount s performance It is important that a minimum distance is maintained between the tailstock adapter...

Page 54: ...stock with MotoMount To ensure optimal performance from the MH SERIES POSITIONER tooling system Yaskawa Motoman makes the following recommendations for each configuration 5 1 Headstock Only Tooling Re...

Page 55: ...ing fixture please read the following recommendations Use all bolt holes on the faceplate to mount the tooling fixture Use the dowel pins 5 1 1 2 Mounting Holes Faceplate The customer supplied tooling...

Page 56: ...25 MM 2 X SLIP FIT FOR M12 DOWEL 4 X M12 x 1 75 100 MM 100 MM CAUTION To proper secure fixture rated loads required the use of all M16 mounting holes 0 0 30 MM OD X 6 ID THRU PILOT 1 8 28 BSPT M16 X 2...

Page 57: ...mmendations Fig 5 42 Mounting Holes on Faceplate MH3105 0 0 0 0 DIA 120 THRU M16 X 2 THRU 225 0 MM 274 5 MM 30 MM TYP TYP 12 5 MM 4 X M10 1 5 THRU 2 X M12 THRU 225 0 MM 194 9 MM 194 9 MM 112 5 MM 112...

Page 58: ...s Some applications require multiple tooling fixtures that are switched in and out of the positioner as production needs change To prepare these extra fixtures to work with MotoMount the following spa...

Page 59: ...following hole pattern Figure 5 44 Fig 5 44 Tooling Template MotoMount 5 2 3 3 Hole Pattern on MotoMount HD The tooling fixture flange that attaches to MotoMount HD must have the following hole patter...

Page 60: ...Clearance MotoMount Fig 5 47 Drive Component Clearance MotoMount HD 5 2 3 5 Tailstock Flange Specifications Figure 5 48 shows the specifications for the tooling fixture flange that is secured to the...

Page 61: ...mmendations 5 2 Headstock Tailstock with MotoMount MotoMount HD tailstock adapter Fig 5 48 Tailstock Adapter MotoMount Fig 5 49 Tailstock Adapter MotoMount HD 36 5 7 MM MINIMUM TOOLING FIXTURE FLANGE...

Page 62: ...only Do not use the auxiliary mounting holes for the primary tooling support Center shaft clearance required on the tooling fixture when using auxiliary mounting holes on the headstock are shown in Fi...

Page 63: ...ommended spare parts with Yaskawa Motoman part numbers Motoman recommends the following parts be kept on hand 6 2 Servomotor The AC servomotor has no wear parts i e brushes so a simple daily inspectio...

Page 64: ...proceed as follows 1 Shut down cell using main disconnect 2 Use a flathead screwdriver to disconnect the brush cable s from the ground post Figure 6 1 Fig 6 1 Brush Cable Removal 3 Release the spring...

Page 65: ...6 Lower the case below the retaining edge and slowly pull the brush holder out of the housing Figure 6 3 Fig 6 3 Brush removal MH95 185 505 1605 NOTE When pulling the brush holder out identify and sec...

Page 66: ...nto nut plate Thread the screws into nut plate loosely 10 Push the brush holder up in front of the retaining edge and hold steady 11 Squeeze the brush retaining spring and push the brush against the f...

Page 67: ...cell using main disconnect 2 Remove the back panel of the drive assembly 3 Use a flathead screwdriver to disconnect the brush cable s from the ground post Figure 6 4 Fig 6 4 Brush Cable Post 4 Release...

Page 68: ...e case Fig 6 5 Brush Assembly 7 Lower the case below the retaining edge and slowly pull the brush holder out of the housing Figure 6 6 Fig 6 6 Brush Removal 3105 NOTE When pulling the brush holder out...

Page 69: ...Home Position The home position on the drive assembly is set in the controller by the operator Any position of the headstock can be programmed as home The factory setting of home position is found us...

Page 70: ...o the Home position install the homing pin through the hole in the faceplate The pin may need to be tapped in with a hammer 4 Slowly jog the drive assembly until the plastic pin just touches the home...

Page 71: ...To reset each a MH3105 headstock proceed as follows 1 Make sure robot s is in home position 2 Locate the headstock homing hole Using the programming pendant in TEACH MODE jog the faceplate slowly unt...

Page 72: ...amming pendant Cursor to ROBOT and press SELECT Cursor to HOME POSITION and press SELECT Press the PAGE OVER key to the desired station indicated in the top right corner Make sure the headstock is in...

Page 73: ...tment at 937 847 3200 Weld Brushes First Week Check for dirt and ensure full contact with faceplate Weekly Check for dirt and ensure full contact with faceplate Cleaning As required Clean with dry clo...

Page 74: ...stem has been wired correctly Overload Reduce load or reduce unbalanced load Unstable operation Incorrect wiring Inspect and correct wiring across motor terminals L1 L2 L3 and PE Motor overheats Exces...

Page 75: ...215 220 135 202 240 127 191 260 120 181 280 114 171 300 109 163 HTS Applications assume 1 2 load on Note headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum lo...

Page 76: ...350 97 146 375 92 138 400 88 131 425 84 125 450 80 120 475 76 115 500 73 110 HTS Applications assume 1 2 load on Note headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment...

Page 77: ...284 450 182 273 475 174 262 500 168 252 Note HTS Applications assume 1 2 load on headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum load based upon 75 maximum...

Page 78: ...48 260 734 1101 280 705 1058 300 679 1018 Note HTS Applications assume 1 2 load on headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum load based upon 75 maximu...

Page 79: ...750 1018 1527 800 971 1456 850 928 1392 900 889 1333 950 852 1279 Note 1 HTS Applications assume 1 2 load on headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum...

Page 80: ...ttached parts which lose their identity by being welded soldered riveted etc to other parts or assemblies B 1 2 Parts List This form is divided into four columns as follows 1 Figure Item Number Column...

Page 81: ...Symbols and Abbreviations The following is a list of symbols and abbreviations used in the parts list amp ampere AC alternating current cyl cylinder DC direct current fig figure hex hexagon ID inside...

Page 82: ...ction B 3 162068 1CD 162068 1CD Fig B 1 MH95 M185 Head Stock 24 27 19 1 22 23 6 29 20 19 19 3 5 6 4 7 25 26 30 2 11 12 14 15 16 10 9 13 18 17 32 6 31 33 34 26 38 TORQUE TO 40 0 Nm TORQUE TO 6 0 Nm TOR...

Page 83: ...148 5 WASHER_LOCK_M8 1 16 479147 5 WASHER_FLAT_M8 1 17 158342 1 SCREW PPH M4x0 7 X 8 MACHINE 4 18 479154 4 TIE MOUNT 4 19 479281 105 FITTING PLUG 1 8BSPT BLACK 3 20 158941 9 LABEL PRODUCT ID 1 21 1339...

Page 84: ...B 1 Introduction B 5 162068 1CD 162068 1CD Fig B 2 MSR205 MH505 Head Stock 4 37 9 10 1 34 33 28 36 5 4 3 24 15 23 22 25 38 15 35 2 27 28 29 7 6 30 31 32 21 20 19 18 16 17 15 16 17 39 20 19 15 18 16 17...

Page 85: ...1 BRACKET MTG LIMIT SWITCH 2 21 145896 1 PIN HOMING 1 22 144371 1 BRUSH GROUND METAL GRAPHITE 2 23 130235 6 SCREW HHC 1 4 20 X 1 ZP GR5 4 24 130443 15 WASHER FLAT 1 4 SAE 4 25 144372 1 BRUSH HOLDER 1...

Page 86: ...B 3 MH1605 Head Stock TORQUE TO 29 5 Nm TORQUE TO 6 Nm 5 6 3 15 24 16 23 17 18 19 25 26 27 11 29 30 39 31 32 20 6 13 34 35 37 36 22 23 7 38 28 14 4 12 11 10 TORQUE TO 3 6 Nm TORQUE TO 3 6 Nm TORQUE T...

Page 87: ...RV RV 320E 185 1 15 152538 1 ADAPTER FLYWHEEL MRM2 250 750 M3X 1 16 151593 7 GEAR INPUT PINION 185 1 17 145428 2 WASHER FLAT M8 X 16 OD X 3 THK 1 18 470617 1 WASHER CONICAL SPRING M8 1 19 407248 21 S...

Page 88: ...B Illustrated Parts list MH SERIES POSITIONER B 1 Introduction B 9 162068 1CD 162068 1CD Fig B 4 Type II Drive Assembly Components 1 2 3 4 5 6 7 8 21 20 18 13 11 10 10 22 19 15 16 17 9 88 101...

Page 89: ...X 35 6 16 470602 1 WASHER CONICAL SPRING M6 18 17 130060 12 SCREW SHC 1 4 20 X 2 1 2 GR8 6 18 130444 5 WASHER LOCK 1 4 6 19 130443 15 WASHER FLAT 1 4 SAE 6 20 144371 1 BRUSH GROUND METAL GRAPHITE 3 21...

Page 90: ...B Illustrated Parts list MH SERIES POSITIONER B 1 Introduction B 11 162068 1CD 162068 1CD Fig B 5 MotoMountTM Tailstock Components 95 185 505 7 12 13 14 15 3 2 90 101...

Page 91: ...R 1 3 148135 1 SCREW SET CONE PT M8X6 1 4 148124 1 PIN LOCATOR 16MM 1 5 155870 1 ADAPTER BLOCK TAILSTOCK GEN2 1 6 156164 1 RETAINER TAILSTOCK BEARING 2 7 146953 3 RING RETAINING EXTERNAL 55 1 8 407249...

Page 92: ...B Illustrated Parts list B 1 Introduction B 13 162068 1CD 162068 1CD MH SERIES POSITIONER Fig B 6 MotoMountTM Tailstock Components 1605 3105 2 3 4 5 6 7 9 10 11 12 13 14 15 8 92 101...

Page 93: ...120 4 3 146951 1 CLAMP SHAFT 1 4 148124 1 PIN LOCATING DIA16 1 5 146950 4 SHAFT SQUARE 1 6 148136 1 BEARING SPHERICAL ROLLER 1 7 146940 4 RING RETAINING INTERNAL 1 8 146965 3 ADAPTER TAILSTOCK 1 9 14...

Page 94: ...trated Parts list MH SERIES POSITIONER B 1 Introduction B 15 162068 1CD 162068 1CD Fig B 7 MotoMount Components 2 1 19 17 16 3 4 6 28 31 11 7 8 9 10 7 8 18 24 20 23 22 21 12 13 14 15 30 29 26 25 27 5...

Page 95: ...11 146503 1 PLATE SIDE BLOCK 1 12 130887 11 CABLE WELD 4 0 1FT 2 13 131272 1 SCREW HHC M12X25 ZP CLASS 8 8 3 14 479148 7 WASHER LOCK M12 3 15 147462 1 WASHER M12 HIGH STRENGH 5 16 145848 1 SEAL O RING...

Page 96: ...B Illustrated Parts list MH SERIES POSITIONER B 1 Introduction B 17 162068 1CD 162068 1CD Fig B 8 MotoMount HD Drive Components 7 9 10 8 5 3 2 4 6 11 96 101...

Page 97: ...00 2 ADAPTER ASSY MOTOMOUNT HD Ref 2 149227 1 HUB MOUNTING 1 3 146195 3 BLOCK GUIDE 1 4 149768 1 BEARING CAM FOLLOWER 1 5 148124 1 PIN LOCATING DIA 16 MM HEAD 1 6 146196 3 BLOCK MOUNTING FIXTURE 1 7 1...

Page 98: ...B Illustrated Parts list B 1 Introduction B 19 162068 1CD 162068 1CD MH SERIES POSITIONER Fig B 9 Slip Ring Components 2 3 4 5 6 7 8 98 101...

Page 99: ...Title Qty B 9 148634 1 ACCESSORY SLIP RING MOTOMOUNT HD Ref 2 148636 1 SUPPORT GUARD SLIP RING 1 3 148635 1 GUARD SLIP RING 1 4 148848 1 SLIP RING ASSY MOTOMOUNT HD 1 5 146913 2 FITTING NIPPLE PIPE B...

Page 100: ...B Illustrated Parts list B 1 Introduction B 21 162068 1CD 162068 1CD MH SERIES POSITIONER 100 101...

Page 101: ...0 162068 1CD MANUAL NO Specifications are subject to change without notice for ongoing product modifications and improvements MH SERIES SIGMA 5 POSITIONER MANUAL 101 101...