Tài liệu hướng dẫn sử dụng robot Kawasaki, cách kiểm tra hoạt động robot, bảo trì robot. Mô tả đầy đủ trạng thái và các lỗi của robot trong quá trình làm việc và cách xử lý các lỗi. User guide of Kawasaki robots, how to check robot operation, and maintenance of robots. Fully describe the status and errors of the robot in the process of working and how to handle the error.
B Series Inspection & Maintenance Manual Kawasaki Heavy Industries, Ltd 90205 1140DEF B Series Kawasaki Robot Inspection and Maintenance Manual PREFACE This manual describes inspection and maintenance procedures for Kawasaki Robot B Series Read and understand the contents of this manual and the safety manuals thoroughly, and strictly observe all rules for safety before proceeding with any operation Never proceed with any operation until you understand the contents of this manual completely Kawasaki is not responsible for any accidents and/or damages resulting from operations/ maintenance based on only a limited reading or limited understanding of some parts of this manual This manual is applicable to the following robot arms BX100S, BX100N, BX100L, BX130X, BX165N, BX165L BX200L, BX250L, BX300L, BT165L, BT200L This manual does not constitute a guarantee of the systems in which the robot is utilized Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems relating to industrial property rights as a result of using the system It is recommended that all personnel assigned for activation of operation, teaching, maintenance or inspection of the robot attend the necessary education/training course(s) prepared by Kawasaki, before assuming their responsibilities Kawasaki reserves the right to change, revise, or update this manual without prior notice This manual may not, in whole or in part, be reprinted or copied without the prior written consent of Kawasaki Store this manual with care and keep it available for use at any time If the robot is reinstalled or moved to a different site or sold off to a different user, attach this manual to the robot without fail In the event the manual is lost or damaged severely, contact Kawasaki Copyright © 2016 Kawasaki Heavy Industries Ltd All rights reserved B Series Kawasaki Robot Inspection and Maintenance Manual SYMBOLS The items that require special attention in this manual are designated with the following symbols Ensure proper and safe operation of the robot and prevent physical injury or property damages by complying with the safety matters given in the boxes with these symbols DANGER Failure to comply with indicated matters can result in imminent injury or death WARNING Failure to comply with indicated matters may possibly lead to injury or death CAUTION Failure to comply with indicated matters may lead to physical injury and/or mechanical damage [ NOTE ] Denotes precautions regarding robot specification, handling, teaching, operation, and maintenance WARNING The accuracy and effectiveness of the diagrams, procedures, and detail explanations given in this manual cannot be confirmed with absolute certainty Accordingly, it is necessary to give one’s fullest attention when using this manual to perform any work Should any unexplained questions or problems arise, please contact Kawasaki Safety related contents described in this manual apply to each individual work and not to all robot work In order to perform every work in safety, read and fully understand the safety manual, all pertinent laws, regulations and related materials as well as all the safety explanations described in each chapter, and prepare safety measures suitable for actual work B Series Kawasaki Robot Inspection and Maintenance Manual CONTENTS Preface Symbols 1.0 Precautions 2.0 Items of Maintenance & Inspection 14 3.0 Details of Daily Check 18 4.0 4.1 4.2 4.3 4.4 4.5 4.6 Grease Replacement for Reduction Units 19 JT1 Reduction Unit 20 JT2 Reduction Unit 23 JT3 Reduction Unit 26 JT4 Reduction Unit 29 JT5 Reduction Unit 32 JT6 Reduction Unit 35 5.0 5.1 5.2 5.3 Check of Timing Belt 38 Check Procedure 40 Readjustment Procedure 40 Replacement Procedure (Unused Items) 41 6.0 Check of Motor Brake Torque 42 7.0 Check of Internal Machine Cables and Tubes 43 8.0 8.1 8.2 8.3 8.4 Check of Gas Spring 44 Check of Gas Pressure 45 Gas Replenishment 49 Gas Discharging 51 Check of Rod Section 53 9.0 Grease Replenishment for Balancer Bearing 55 10.0 Battery Replacement on 1HG Board 56 B Series Kawasaki Robot 11.0 Inspection and Maintenance Manual Retightening 57 B Series Kawasaki Robot Precautions Inspection and Maintenance Manual 1.0 PRECAUTIONS Prior to starting maintenance on a Kawasaki robot, pay attention to the following matters to ensure safety WARNING Prior to starting maintenance, turn OFF the controller power switch and the external power switch for shutting off power supply to the robot controller Display signs indicating clearly “Inspection and maintenance in progress”, and lockout/tagout the external power switch to prevent accidents of electric shock, etc caused when personnel accidentally turns ON the power If changing the joint angle is required for grease replenishment, etc., first, turn ON the motor power Then, set the arm to the specified pose Be careful not to be caught by or between any moving parts of the arm due to careless approach to the arm at this time After moving the arm to the desired pose, turn OFF the controller and external power Display signs indicating clearly “Inspection and maintenance in progress”, and lockout/tagout the external power switch before starting maintenance Some arm parts may be very hot after continuous operations, depending on ambient temperature when conducting maintenance immediately after the continuous operations Be sure the arm has cooled before starting any work Handling hot machine parts is extremely dangerous and may result in injury, burns, etc Warning labels are affixed to the arm to identify areas with possibility of electric shock, high temperature or pinching, so check these areas beforehand See the next pages for the warning labels and their positions CAUTION Do not apply excessive force to the robot arm while robot is not operating Applying excessive force may result in a shortened service life and/or damage to parts or the brake mechanisms in the joints Use only Kawasaki designated greases and other lubricants For replenishing and replacing grease, use manual type grease gun When using air pump type grease gun, reduce air pressure on the supply side to 0.26 Mpa (2.5 kgf/cm2) or lower by a regulator, etc and apply grease using grease pump P3L (manu by Macnaught, pump ratio 50:1, part No.:50154-0349) (When using all other grease pump models/brands, contact Kawasaki before using.) Never remove any bolts unless specifically instructed by the maintenance or inspection procedure B Series Kawasaki Robot Precautions Inspection and Maintenance Manual Hazardous places for high temperature and electric shock (BX100S, BX100N) Hazardous place for high temperature Hazardous place for electric shock B Series Kawasaki Robot Precautions Inspection and Maintenance Manual Hazardous places for high temperature and electric shock (BX100L, BX130X, BX165N, BX165L, BX200L) Hazardous place for high temperature Hazardous place for electric shock B Series Kawasaki Robot Precautions Inspection and Maintenance Manual Hazardous places for high temperature and electric shock (BX250L, BX300L) Hazardous place for high temperature Hazardous place for electric shock B Series Kawasaki Robot Precautions Inspection and Maintenance Manual Hazardous places for high temperature and electric shock (BT165L, BT200L) Hazardous place for high temperature Hazardous place for electric shock B Series Kawasaki Robot Check of Gas Spring Inspection and Maintenance Manual BT165L, BT200L Procedure Move the robot so that the posture of JT2 becomes minus 115º(±4º)*, then turn OFF the power Remove the cap from the gas inlet of gas spring Attach the gas pressure checking jig on the gas inlet and check the pressure For the specified pressures of the gas, see the next page Remove the jig after checking the pressure Gas inlet cap Gas inlet Gas pressure checking jig Surface temperature check [ NOTE ] Two gas springs are mounted for BT200L/BT165L Internal pressure decreases by approx 0.05 MPa each time the gas pressure is checked Replenish gas at approximately sixth check 47 B Series Kawasaki Robot Check of Gas Spring Inspection and Maintenance Manual NOTE* If it is not possible to confirm the JT2 posture is minus 115º by Teach Pendant, make the match mark of the moving side face vertical direction shown below Rated pressure of gas spring See the figure below for the rated pressure of the gas spring Measure the surface temperature of the gas spring using a radiation thermometer (HORIBA, model: IT540-W or equivalent) Rated reference pressure of gas spring Rated pressure [MPa] Rated lower limit pressure of gas spring Rated upper limit pressure of gas spring Surface temperature of gas spring [C ] [ NOTE ] If the gas pressure exceeds upper/lower limit of rated pressure, discharge/ replenish gas and adjust the gas pressure so that the gas pressure is within the upper/lower limit range 48 B Series Kawasaki Robot Check of Gas Spring Inspection and Maintenance Manual 8.2 GAS REPLENISHMENT Replenish the nitrogen (N2) gas whose content of nitrogen is 99.99 V/V % or more if the gas pressure is below the specified lower limit [ NOTE ] Check the gas pressure 24 hours after the replenishment of nitrogen gas Replace the gas spring if the gas pressure is below the specified lower limit BX100L, BX130X, BX165N, BX165L, BX200L, BX250L, BX300L Procedure Move the robot so that the posture of JT2 becomes minus 5º, then turn OFF the power Remove the cap from the gas inlet of gas spring and attach a gas replenishment coupler Attach the gas replenishment jig on a nitrogen gas cylinder NOTE Confirm that pressure adjustment handles on the body side of the gas replenishment jig and that on the inlet side are closed Adjust the pressure to the pressure in 8.1 by turning the pressure adjustment handle on the body side of the gas replenishment jig Connect the gas replenishment jig and the gas spring Open the handle on the inlet side of the gas replenishment jig slowly, and replenish nitrogen gas Remove the jig and close the cap after checking the pressure Gas replenishment coupler Gas replenishment jig Pressure adjustment handle Gas cylinder Handle on the inlet side Surface temperature check 49 B Series Kawasaki Robot Check of Gas Spring Inspection and Maintenance Manual BT165L, BT200L Replenish gas when gas pressure becomes 0.5 MPa or more lower than the specified value Procedure Move the robot so that the JT2 posture becomes minus 115º, then turn OFF the power Remove the cap from the gas inlet of gas spring and attach a gas replenishment coupler Attach the gas replenishment jig on a nitrogen gas cylinder NOTE Confirm that pressure adjustment handles on the body side of the gas replenishment jig and that on the inlet side are closed Adjust the pressure to the pressure in 8.1 by turning the pressure adjustment handle on the body side of the gas replenishment jig Connect the gas replenishment jig and the gas spring Open the handle on the inlet side of the gas replenishment jig slowly, and replenish gas Remove the jig and close the cap after checking the pressure Gas replenishment coupler Gas replenishment jig Pressure adjustment handle Gas cylinder Surface temperature check Handle on the inlet side 50 B Series Kawasaki Robot Check of Gas Spring Inspection and Maintenance Manual 8.3 GAS DISCHARGING BX100L, BX130X, BX165N, BX165L, BX200L, BX250L, BX300L Discharge gas in the following cases: When removing gas spring at the JT2 posture of other than minus 5° (If removing it at the JT2 posture of other than minus 5°, gas spring jumps and an accident may happen.) When transporting robot arm by air (Transportation without discharging high pressure gas is prohibited by law.) Procedure Remove the cap from the gas inlet of the gas spring Attach a gas discharging jig The gas discharging speed changes depending on how much the discharging jig is screwed CAUTION If gas is discharged rapidly, the gas spring is cooled and fingers may stick to it or grease may blow out Discharge the gas slowly Remove the jig after discharging the gas Gas discharging jig 51 B Series Kawasaki Robot Check of Gas Spring Inspection and Maintenance Manual BT165L, BT200L Discharge gas in the following cases: When removing gas spring at the JT2 posture of other than minus 115° (If removing it at the JT2 posture of other than minus 115°, gas spring jumps and an accident may happen.) When transporting robot arm by air (Transportation without discharging high pressure gas is prohibited by law.) Procedure Remove the cap from the gas inlet of the gas spring Attach a gas discharging jig The gas discharging speed changes depending on how much the discharging jig is screwed CAUTION If gas is discharged rapidly, the gas spring is cooled and fingers may stick to it or grease may blow out Discharge the gas slowly Remove the jig after discharging the gas Gas discharging jig 52 B Series Kawasaki Robot Check of Gas Spring Inspection and Maintenance Manual 8.4 CHECK OF ROD SECTION BX100L, BX130X, BX165N, BX165L, BX200L, BX250L, BX300L Procedure Remove the cover of gas spring rod section and check no foreign materials and no dirt is attached on the rod If attached, wipe them off Apply grease (Daphne Eponex #3 or equivalent) lightly on the rod Remount the cover Rod section cover Protective cover* Rod NOTE For the environment where foreign objects and dusts easily attach to the rod, optional protective cover (Part No.: 60375-6603) is available Contact Kawasaki Robot Service, if necessary 53 B Series Kawasaki Robot Check of Gas Spring Inspection and Maintenance Manual BT165L, BT200L Procedure Remove the cover of gas spring rod section at the JT2 posture of minus 90 , make the posture of minus 115 and check no foreign materials and no dirt is attached on the rod If attached, wipe them off Apply grease (Daphne Eponex #3 or equivalent) lightly on the rod Return the JT2 posture to be minus 90 and remount the cover Rod section cover Rod 54 B Series Kawasaki Robot Grease Replenishment for Balancer Bearing Inspection and Maintenance Manual 9.0 GREASE REPLENISHMENT FOR BALANCER BEARING WARNING Read WARNING and CAUTION in 4.0 before starting operation Model Volume Grease Working location BX100L, BX130X, BX165N, BX165L, BX200L, BX250L, BX300L, BT165L, BT200L 10 cc (Approx.) Pilonock Universal N6C (See 2.0-2 and 2.0-3.) Procedure Remove the plug (R1/8) from the filler port and attach a grease nipple (R1/8) Put a container for drained grease and remove the plug (R1/8) from the drain port [ NOTE ] The pressure in the grease bath may be increased due to the influence of temperature change, etc and grease may be disgorged Cover each port with a rag, etc so that grease may not spatter when removing the plug Supply specified amount of grease from the filler port Remove the grease nipple from the filler port and return the plugs* to the filler and drain ports Wipe away any grease around the filler and drain ports with the rag NOTE* Grease port plugs are coated with sealant To prevent grease leakage, it is recommended to use sealant tape when returning the plug or to replace the plugs with new ones at every grease replenishment Filler port Drain port Filler port Drain port (Opposite side of filler port) 55 B Series Kawasaki Robot 10 Battery Replacement on 1HG Board Inspection and Maintenance Manual 10.0 BATTERY REPLACEMENT ON 1HG BOARD WARNING Prior to replacing 1HG board, turn OFF the controller and external power switches Display signs indicating clearly “Inspection and maintenance in progress”, and lockout/tagout the external power switch to prevent personnel from accidentally turning ON the power Model Working location BX100S, BX100N, BX100L, BX130X, BX165N, BX165L, BX200L, BX250L, BX300L, BT165L, BT200L (See 2.0-1, 2.0-2 and 2.0-3.) Battery Battery holder Tying band Battery relay connector Procedure Prior to replacing the battery, record the encoder values (Refer to “Monitor screen” in “Operation Manual” of controller for encoder value check.) Turn OFF the controller power, then remove the battery holder from the robot base section paying attention not to damage the harness Remove the tying band fixing the battery and disconnect the battery relay connectors, then remove the battery Set a new battery on the holder and reconnect the battery relay connectors after fixing the battery with a new tying band Return the battery holder to its original position Turn ON the controller power and check if the encoder values remain the same Perform zeroing if encoder values have been changed 56 B Series Kawasaki Robot 11 Retightening Inspection and Maintenance Manual 11.0 RETIGHTENING Check if any fixing bolts or nuts are loosened If necessary, retighten the bolts, nuts, etc firmly The following are the most important items that require retightening Servo motor/Encoder mounting bolts Motor bracket mounting bolts Reduction unit mounting bolts Tool mounting bolts Base mounting bolts Cover mounting bolts Harness clamp mounting bolts [ NOTE ] The tightening torque for the hexagon socket head cap bolts is shown below: Hexagon socket head cap bolts M3 Hexagon socket button head cap bolts M4 M5 3.43 N·m M5 M6 6.86 N·m M6 M8 General section Specific section (See next fig for - ) 1.47 N·m M8 11.76 N·m 1.5 N·m (Plastic cover) 2.5 N·m (Plastic harness clamp, plastic cover, rubber stopper) 29.40 N·m M10 56.84 N·m M12 98.00 N·m M14 M16 M20 156.80 N·m 235.20 N·m 431.20 N·m 57 73.5 N·m (JT5 reduction unit mounting section) 78.4 N·m (5 kW motor mounting section) B Series Kawasaki Robot 11 Retightening Inspection and Maintenance Manual BX100S, BX100N -2 -8 -2 -2 x -2 -2 x -4 -2 x -4 -21 -2 -16 -2 x -2 -2 x -2 BX100L, BX130X, BX165N, BX165L, BX200L -2 -8 -2 x -2 -2 x -2 -4 -2 x -21 -4 -16 -4 -2 x -2 -2 x 58 -2 -2 B Series Kawasaki Robot 11 Retightening Inspection and Maintenance Manual BX250L, BX300L -2 x -2 -2 -2 -2 -2 -4 -2 -21 -4 -2 -2 x -4 -2 -2 BT165L, BT200L -2 -2 x -8 -2 x -4 -2 x -4 -2 x -4 -21 -16 -2 -2 -2 -2 x -2 x 59 B Series Kawasaki Robot Inspection and Maintenance Manual 60 B Series Inspection & Maintenance Manual January 2012 : 1st Edition January 2016 : 6th Edition Publication : KAWASAKI HEAVY INDUSTRIES, LTD ROBOT DIVISION 90205-1140DEF Copyright 2016 KAWASAKI HEAVY INDUSTRIES, LTD All rights reserved ... some parts of this manual This manual is applicable to the following robot arms BX100S, BX100N, BX100L, BX130X, BX165N, BX165L BX200L, BX250L, BX300L, BT165L, BT200L This manual does not constitute... BX250L, BX300L BX165L, BX200L, BT165L, BT200L 3750 cc (Approx.) 6400 cc (Approx.) Moly White A -1 (See 2.0-1, 2.0-2 and 2.0-3.) BX100S, BX100N, BX100L, BX130X BX165N, BX165L, BX200L, BT165L BT200L BX250L,... location BX100S, BX100N, BX100L, BX130X, BX165N, BX250L,BX300L BX165L, BX200L, BT165L, BT200L 1920 cc (Approx.) 2050 cc (Approx.) Moly White A -2 (See 2.0-1, 2.0-2 and 2.0-3.) BX100S, BX100N, BX100L,