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INSTAL (AlmegaBASIC (EX-C) TEACH (EX-C) UTILIZIFUNCT (EX-C) INTERF (EX-C) OPTION (EX-C) EXTER (Externa

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Be Sure to Read Instruction Manuals Before Use

nk you for selecting DAIHEN arc welding robot Almega series. ega series are the robots with high performance and various functions developed by making full use of the

technology. Since the knowledge of welding peculiar to a welding machine maker is applied to both are and software, we are sure that each user can be fully satisfied rder to use the superior performance and the abundant functions safely and fully, be sure to read the ing instruction manuals including this manual and other attached documents, and understand the edge of the machines, safety information, and notes thoroughly.

truction manuals related to the manipulator “EX-M series”, and the robot control unit “EX-C series” are as lows.

Instruction Manual Type Instruction Manual No. Main Contents

LATION & MAINTENANCE

EX-V6 / V6L / V16)

1L8300A

Specifications of a robot, installing & connecting method, starting up, periodical inspection, solution at the time of failure, maintenance parts list, etc.

OPERATIONS 1L8300C

Explanation of operation switch of robot, basic operation method from teaching to automatic operation, frequently used functions, etc.

ING 1L8300D

Detailed explanation of each command and teaching method, etc.

NG FEATURES and IONS 1L8300G

Setting of the environment in which a robot is being used, useful function, explanation of the function to manage a robot and the operation method, etc.

ACE WITH JIG 1L8300E

Interfacing method with robot jigs, usage of sequence control function, etc.

1L8300F

Optional functions such as multi-task and general operation method, etc.

NAL AXES CONTROLLER

l Axes Controller for EX-C) 1L8600A

Installation and connection method of external axes controller which are required when using 3 external axes or more in EX-C, maintenance parts list, etc.

otes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.

2. Optional hardware or software is necessary in order to use the function described as “Optional” in the manual.

3. The screen display of a teach pendant shown in the manual are described as examples, which may be different from the actual ones.

4. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we do not take any responsibility for damages resulting from neither direct nor indirect errors.

5. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the manual.

6. No part of this manual may be reproduced without permission.

- 1 -

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(2) Instruction manuals related to the manipulator “AX-M series”, and the robot control unit “AX-C series” are as follows.

■Standard Manuals


INSTALLATION

1L8800A Safety precautions, installing & connecting method, starting up, periodical inspection, solution at the time of failure

CONTROLLER MAINTENANCE/ STANDARD CONFIGURATIONS

1L8800B Specifications of controller, explanation of each parts and maintenance, parts list, etc.

MANIPULATOR 1L7700A Specifications or maintenance of manipulator, parts list, etc.

BASIC OPERATIONS

1L8800C Explanation of manual operation, teaching, automatic operation, file utilities, backing-up data, basic operations of Arc/Spot welding application, etc.

REFERENCE (Built-in Tutorial) 1L8800D

Basic operations, terms, explanations of Constants/Service menus, Details of function command, list of short-cut code, parts replacing procedure, trouble shooting, etc. ※ This manual is not provided as the paper manual,

but is built in the robot as Help tutorial function. EXTERNAL INPUT/OUTPUT 1L8800H

Interfacing method with external control device, list of I/O signals, start/halt the automatic operation, and usage of software PLC, etc.

■Application Manuals


APPLICATION MANUAL (ARC WELDING) 1L8800F Basic settings, functions for arc welding, teaching

technic, etc. APPLICATION MANUAL (HANDLING) 1L8800G Basic settings, functions for handling, teaching

technic, etc. APPLICATION MANUAL (SPOT WELDING) 1L8800E Basic settings, functions for spot welding, teaching

technic, etc. Instruction manuals are available other than the above for each optional function that you have purchased.

[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice. 2. Optional hardware or software is necessary in order to use the function described as “Optional” in the

manual. 3. The screen display of a teach pendant shown in the manual are described as examples, which may be

different from the actual ones. 4. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we do

not take any responsibility for damages resulting from neither direct nor indirect errors. 5. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the

manual. 6. No part of this manual may be reproduced without permission.

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(3) Instruction manuals related to the manipulator “V/B series”, and the robot control unit “AX21” are as follows.

■Standard Manuals


INSTALLATION

1L20400A Safety precautions, installing & connecting method, starting up, periodical inspection, solution at the time of failure

CONTROLLER MAINTENANCE/ STANDARD CONFIGURATIONS

1L20400B Specifications of controller, explanation of each parts and maintenance, parts list, etc.

MANIPULATOR （NB4 / NB4L / NV6 / NV6L / NV20） 1L10460A Specifications or maintenance of manipulator, parts

list, etc. BASIC OPERATIONS

1L20400C Explanation of manual operation, teaching, automatic operation, file utilities, backing-up data, basic operations of Arc/Spot welding application, etc.

REFERENCE (Built-in Tutorial) 1L20400D

Basic operations, terms, explanations of Constants/Service menus, Details of function command, list of short-cut code, parts replacing procedure, trouble shooting, etc. ※ This manual is not provided as the paper manual,

but is built in the robot as Help tutorial function. EXTERNAL INPUT/OUTPUT 1L20400H

Interfacing method with external control device, list of I/O signals, start/halt the automatic operation, and usage of software PLC, etc.

■Application Manuals


APPLICATION MANUAL (ARC WELDING) 1L20400F Basic settings, functions for arc welding, teaching

technic, etc.

Instruction manuals are available other than the above for each optional function that you have purchased. [Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.

2. Optional hardware or software is necessary in order to use the function described as “Optional” in the manual.

3. The screen display of a teach pendant shown in the manual are described as examples, which may be different from the actual ones.

4. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we do not take any responsibility for damages resulting from neither direct nor indirect errors.

5. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the manual.

6. No part of this manual may be reproduced without permission.

Notice

About this manual

This instruction manual describes the installation and maintenance of Positioner headstock. Read and understand the entire contents of this manual, with special emphasis on the safety devices, before installing, operating or maintaining Manipulator, Robot Control Unit, and their positioner. Manipulator, Robot Control Unit, their positioner and the relevant instructions are to be used only by trained and experienced personnel for safety reasons. Do not allow untrained personnel to install,operate, or maintain those products. Notes on Safety

Before installation, operation, maintenance and inspection, be sure to read this manual and other attached

documents thoroughly and acquire all the knowledge of machines, safety information, and precautions. If operating machines in a wrong way, the accident resulting in various ranks of injury or death, or damage may occur. In order to call attention to wrong handling, the following four ranks of safety notes (“DANGER”, “WARNING”, “CAUTION”, and “IMPORTANT”) are provided.

DANGER

Cases where a mistake made in handling is likely to cause the user to be exposed to the danger of death or serious injury and where the degree of the urgency (imminence) of the warning given for the danger to occur is at the high end of the scale (including high-level danger).

WARNING

Cases where a mistake made in handling is likely to cause the user to be exposed to the danger of death or serious injury.

CAUTION

Cases where a mistake made in handling is likely to cause the user to be exposed to the danger of minor injuries or of property damage only.

The following symbol is also used for particularly important checkpoints:

IMPORTANT This is a particularly important checkpoint.

Note that even the matters which are described as CAUTION can result in serious accident depending on the conditions. Be sure to keep the safety notes since they describe very important matters.

The meanings of “Serious injury”, “Minor injury”, and “Damage” described above are as follows.

Serious injury ： Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low temperature), an electric shock, fracture, poisoning, etc. and that which requires hospitalization and long-term treatment as an outpatient.

Minor injury ： Injury which does not require either hospitalization or long-term treatment as an outpatient,

a burn (high temperature, low temperature), and an electric shock.

Damage ： Direct and indirect damage in connection with damage of property and equipment.efore

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Labels on Positioner

DAIHEN robot positioner is labeled with alarm signs for safe use. Do not tear them off, damage them or cover. If it is the case, contact our engineers for making an order. For how to order, inquire of our sales engineers in your local area. The following shows the alarm signs attached to positioner.

ＮＫ３７１７Ａ

ＮＫ３６４５Ａ

ＮＫ３６８１Ａ

ＥＸ－１ＰＢ５００，１０００

ＡＸ－１ＰＢ５００，１０００

ＡⅡ－１ＰＢ５００，１０００

ＥＸ－１ＰＢ２５０ＡＸ－１ＰＢ２５０ＡⅡ－１ＰＢ２５０

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C o n t e n t s 1 Basic Specifications............................................................................................................................................................1

1.1 Basic Specifications ......................................................................................................................................................1 1.2 Outside Dimensions......................................................................................................................................................3 1.3 Name of Each Parts......................................................................................................................................................5 1.4 Dimensions for Mounting on Table Face.......................................................................................................................5

1.4.1 Mounting a Load on Table (EX-1PB250/AX-1PB250/AⅡ-1PB250) .....................................................................5

1.4.2 Mounting a Load on the Table (EX-1PB500/AX-1PB500/AⅡ-1PB500) ...............................................................6

1.4.3 Mounting a Load on the Table (EX-1PB1000/AX-1PB1000/AⅡ-1PB1000)..........................................................6

2 Allowable Load ...................................................................................................................................................................7

2.1 Maximum Allowable Load .............................................................................................................................................7 2.2 Payload Moment Diagram ............................................................................................................................................7 2.3 Allowable Rotation Moment ..........................................................................................................................................9 2.4 Allowable Moment Of Inertia .........................................................................................................................................8

3 Installation Guidelines....................................................................................................................................................... 11

3.1 Foundation.................................................................................................................................................................. 11 3.2 Environmental Requirements...................................................................................................................................... 11 3.3 Installing a Safety Fence............................................................................................................................................. 11 3.4 Installation method...................................................................................................................................................... 12

4 Transport Method ............................................................................................................................................................. 14

4.1 Positioner Transport Method....................................................................................................................................... 14

5 Options ............................................................................................................................................................................. 15

5.1 Air Rotary Joint (Option).............................................................................................................................................. 15 5.2 Equipped Cable (Option) ............................................................................................................................................ 16

5.2.1 Curl Code (Option) ............................................................................................................................................ 16

5.2.2 Slip Ring (Option) .............................................................................................................................................. 19 5.3 Tail stock (Option) ....................................................................................................................................................... 25

5.3.1 Tail stock(L7090B)............................................................................................................................................. 20

5.3.2 1-axis double support positioner........................................................................................................................ 21

6 Grounding Method ............................................................................................................................................................ 28

7 Maintenance ..................................................................................................................................................................... 29

7.1 Welding Current allowance........................................................................................................................................ 29 7.2 Maintenance of Collector (Collector Print Element)................................................................................................... 29 7.3 Tension Adjustments of Timing Belts ......................................................................................................................... 30

8 Parts List for Maintenance ................................................................................................................................................ 31

8.1 Parts List ................................................................................................................................................................... 31 8.2 Replacement Parts.................................................................................................................................................... 31 8.3 Lubricant ................................................................................................................................................................... 31 8.4 Replacing Battery ...................................................................................................................................................... 27

9 Internal Wiring of the Main Unit......................................................................................................................................... 33

9.1 Electric Circuit Diagram............................................................................................................................................. 33

10 Inspection Items................................................................................................................................................................ 35

11 Warranty ........................................................................................................................................................................... 35

11.1 Warranty Period..................................................................................................................................................... 35 11.2 Deadline for Supplying/ Repairing the Robot Maintenance Parts.......................................................................... 36

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1 Basic Specifications 1.1 Basic Specifications

Name Positioner Headstock

Type EX-1PB250 AX-1PB250 AⅡ-1PB250

EX-1PB500 AX-1PB500 AⅡ-1PB500

EX-1PB1000 AX-1PB1000 AⅡ-1PB1000

Max.allowable load 250kg 500kg 1000kg Max. Eccentricity of

Center of gravity 85mm

(loading capacity =250kg) 100mm


(loading capacity 1000kg)Max. Height of

Center of gravity 520mm



(loading capacity =1000kg)Rotation speed 25min-1 2.6rad/sec 20min-1 2.1rad/sec 12min-1 1.3rad/sec

Allowable Rotation moment 206N･m 490N･m 1078N･m Allowable Moment of inertia *2 4.6kg･m2 12.7kg･m2 37.4kg･m2

Rotation range

±92 rotation (EX-1PB250 standard spec.) *1±23 rotation (AX/AⅡ-1PB250 standard spec.) *1

±129 rotation (EX-1PB500 standard spec.) *1 ±32 rotation (AX/AⅡ-1PB500 standard spec.) *1

±69 rotation (EX-1PB1000standard spec.) *1±17 rotation (AX/AⅡ-1PB1000standard spec.) *1

Rotation axis repeatability ±0.1mm (position at R300) Rotation stopping position Any position

Detection of Rotation stopping position Absolute encoder Rotation control Controlled by Robot control Unit Mass (weight) 110kg 170kg 220kg

Allowable welding current 500A : Rated duty cycle 60% Configurable control unit EX-C / AX-C / AX21 External Axes Controller

Applicable welding CO2, MAG, MIG Installation method Installable on the 5 sides of a cabinet Grounding Method It shall be independent from peripheral equipment and the resistance shall be less than 100 ohms.

Color Sky gray(EX-1PB250,500,1000) White(AX/AⅡ-1PB250,500,1000) Ambient temperature / humidity 0~45℃, 20~80% (no condensation)

*1 ･The rotation range is limited to±1 rotation if using Curl code Assy equipped type. ･Endless rotation could be chosen as an option. *2 The allowable moment of inertia is the allowable value where the load equivalent to the allowable load

moment has been added.

Table 1.1 Optional Structure and Type Type Optional Structure

EXPB251-E AXPB251-E A2PB251-E



None (standard specification) *3

EXPB251-EA AXPB251-EA A2PB251-EA



With Air-rotary joint Assy *4

EXPB251-EC AXPB251-EC A2PB251-EC



With Air-rotary joint Assy + Curl code Assy

EXPB251-ES AXPB251-ES A2PB251-ES



With Air-rotary joint Assy + Slip ring Assy

*3 Could change to a specification of EA, EC, or ES type with an option. *4 Could change to EC or ES type by mounting Curl code Assy or Slip ring Assy afterward.

IMPORTANT

1. The positional repeatability is a measured value obtained when the manipulator operating conditions

are stabilized with the automatic operation of the manipulator repeated sufficiently. 2. The positional data are backed up by the battery in this positioner. The period of battery backup with the primary

power off is approximately 3 years.After this period, it is necessary to replace the battery and adjust the ABSO position.

3. The battery backup period may be shorter depending on the environmental conditions, the operating conditions and so on.

4. A holding brake is provided in this machine’s motor. 5. The above specifications are subject to change without notice.

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1.2 Outside Dimensions

Fig. 1.1 Outer Dimensions of EX-1PB250/AX-1PB250/AⅡ-1PB250 (mm)


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Fig. 1.4 Outside Shape

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1.3 Name of Each Parts

Origin marker Service hole

Welding earth termiMotor / Encoder connection

Fig. 1.5 Outside View 1.4 Dimensions for Mounting on Table Face

1.4.1 Mounting a Load on Table (EX-1PB250/AX-1PB250/AⅡ-1PB

Fig. 1.6 Mounting Dimensions on Table Side (mm)

・ φ100H7(depth:10)fitting can be used if the point mark on the table side is remove・ Holes, 8-M12 depth: 20 (P.C.D.250), are used as jig clamp screw holes. ・ Mounting bolts are to be prepared by the customer. ・ φ71 Penetrating hole on the center of a table can be used. However, the hole m if options are mounted. (See Chap5. Option)

Mounting a Load on the Table Side

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Inspection cover

nal

250)

d.

ight be unusable

1.4.2 Mounting a Load on the Table (EX-1PB500/AX-1PB500/AⅡ-1PB500)

Fig. 1.7 Mounting Dimensions on the Table Side (mm)

・ φ100H7(depth:10)fitting can be used if the point mark on the table side is removed. ・ Holes, 8-M16 depth: 25 (P.C.D.220), are used as jig clamp screw holes. ・ Mounting bolts are to be prepared by the customer. ・ φ71 Penetrating hole on the center of a table can be used. However, the hole might be unusable if options are mounted. (See Chap5. Option)


1.4.3 Mounting a Load on the Table (EX-1PB1000/AX-1PB1000/AⅡ-1PB1000)

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Fig. 1.8 Mounting Dimensions on the Table Side (mm)

・ φ150H7(depth:15)fitting can be used if the point mark on the table side is removed. ・ Holes, 8-M16 depth: 30 (P.C.D.310), are used as jig clamp screw holes. ・ Mounting bolts are to be prepared by the customer. ・ φ116 Penetrating hole on the center of a table can be used. However, the hole might be unusable if options are mounted. (See Chap5. Option)


2 Allowable Load The mass of the load must be acceptable within both limits of the eccentricity of the center of gravity from the

rotation axis and the height of the center of gravity from the table. 2.1 Maximum Allowable Load

Type Max. allowable load

Allowable rotation moment

Max. Eccentricity of center of gravity

Max. height of center of gravity


250kg 206N・m 85mm 520mm


500kg 490N・m 100mm 540mm

EX-1PB1000 AX-1PB1000 AⅡ-1PB1000

1000kg 1078N・m 110mm 600mm

2.2 Payload Moment Diagram

Fig. 2.1 Allowable Payload Moment (EX-1PB250/AX-1PB250/AⅡ-1PB250)


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2.3 Allowable Rotation Moment

For the use of this Positioner, the rotational moment of each axis must be within the limit for the mass of the maximum load. The rotational moment caused by the mass of the load is given by the following:

[Rotational moment (1)] = [Mass of Load] × [Gravitational acceleration ] ×

Also, if any external force is applied to the load, the load moment acting on each axis is given from the following.

[Rotational Moment (2)] = [Mass of Load]×[Eccentricity to the external force acting point]

A total of the above rotational moment (1) and (2) is the maximum rotational moment. [Example calculation] analyzing type

Eccentricity of the center of gravity

EX-1PB500/AX-1PB500/AⅡ-1PB500

Mass of the load = 400kg, The height of the center of Gravity = 150mm, Eccentricity of the center of gravity = 100mm, no external force (1) Calculating the allowable rotation moment M 400 9.8 0.100 Mass (kg) Gravitational Acceleration (m/s2) Eccentricity of Center of gravity (m)

M = ××

= 392N・m < 490N・m ← Allowable Rotation Moment (2) In addition to the above calculation of allowable rotational moment (1), it is necessary to examine the height of the height of the center of load gravity from the table center.

Height of the center of gravity of the load 150mm <675mm ←Allowable Height of Center of Gravity (when 400kg is boarded)

The determination value of (1) and (2) is under the allowable load. Therefore, the operation of the work in the example is allowable.

Note) In case that the external forces are added as shown in Fig. 2.4 The determination of the added value of the center of gravity height and the moment by the external forces is necessary. [Example] [Mass of Load] × [Height of Center of Gravity (B) ] + [External Force] × [Height to the External Forces acting point(C)] ＜ 500kg × 0.1m Mass of Max. Load Max. Height of Center of Gravity

A: Eccentricity of the center of gravity B: Height of the center of gravity C: Height to the external force acting point D: Eccentricity of the external force acting point

Fig. 2.4

Externalforce

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Example of Positioner + Grinding Robot

2.4 Allowable Moment Of Inertia

If the diameter of the workpiece is large for the rotation axis which is centered on, considering the effect of the moment of inertia is needed. To decide the acceptable value of the moment of inertia for the moment, refer to the figures below. If the value of the moment of inertia exceeds the value shown in the figures, contact us in advance.

100 200 300 400 500

10

20

30

40

0

50

6059.5

12.7

490負荷モーメント (N･m) Moment

慣性モーメントMoment of inertia(kg･m^2)


負荷モーメント (N･m) Moment

50 100 150 200 250

5

10

15

20

4.6

20.3

2060


Fig. 2.5 **-1PB250 Fig. 2.6 **-1PB500

100 200 300 400 500

20

40

60

80

0

100

600 700 800 900 1000

209

11001078

37.4

120

140

160

180

200

220

負荷モーメント (N･m)] Moment


E.g.1) In the case of the moment of 600N･m for 1PB1000, the allowable moment of inertia should be up to 110kg･m2.

E.g.2) In the case of the moment of 0N･m for 1PB1000, the allowable moment of inertia should be up to 209kg･m2. (The turntable rotating in the horizontal plane is equivalent to this condition.)

Fig. 2.7 **-1PB1000

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3 Installation Guidelines 3.1 Foundation

Installation of the Positioner is the most important factor to maintain the proper Positioner functions. Particularly, as well as the installation of the Positioner base, the foundation on which the base Is mounted Is Important to secure the Positioner positioning accuracy and interpolation accuracy. In addition, for fixing the base, the foundation must have a substantial strength to withstand the reaction force at acceleration / deceleration and the static load. The ambient atmosphere is another consideration when installing the Positioner as It affects not only the life of Positioner but also safety.

3.2 Environmental Requirements Install the Positioner in the place that satisfies these conditions listed below.

(1) Environment which is not exposed to the sun and where the ambient temperature is 0 to 45℃ throughout the year.

(2) Environment where the humidity is not larger than RH80%. (3) Environment which is free from dust, dirt, oily smoke, water,etc. (4) Environment which is free from flammable or corrosive fluid or gas. (5) Environment where shock or vibration caused by the operation of peripheral equipment Is not

larger than 0.5G at the positioner. (G: gravitational acceleration, 1G = 9.8 m/s2)

(6) Environment which has no large electrical noise sources( plasma, high frequency,etc) 3.3 Installing a Safety Fence

Be sure to install a safety fence around the manipulator and the peripheral devices (such as positioner) as shown in Fig. 3.1 so that no careless or accidental access to the robot is allowed. Furthermore, install the control unit, the operation box, the teach pendant, the starting box, and other devices outside the safety fence.

ManipulatorBase

Robot Control unit

Welding power Supply

Safety Fence

Fig. 3.1 Installation Example

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3.4 Installation method

The installation dimensions for the positioner headstock is shown below. The mounting parts of the headstock have been worked on. Use them as a datum side and close unused

mounting tap hole with attached hole plug as is shown in Fig. 3.2.

Fig. 3.2 Mounting Hole Plug

Fig. 3.3 Installation Dimensions of EX-1PB250/AX-1PB250/AⅡ-1PB250 Bolt: Hex. Socket Head Cap Screw M16 (Strength Grade 12.9) Clamping torque in mounting: 255 N・m

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Fig. 3.4 Installation Dimensions of EX-1PB500/AX-1PB500/AⅡ-1PB500

Bolt: Hex. Socket Head Cap Screw M20 (Strength Grade 12.9) Clamping torque in mounting: 500 N・m

Fig. 3.5 Installation Dimensions of EX-1PB1000/AX-1PB1000/AⅡ-1PB1000 Bolt: Hex. Socket Head Cap Screw M20 (Strength Grade 12.9) Clamping torque in mounting: 500 N・m

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4 Transport Method 4.1 Positioner Transport Method

Use a crane to transport this machine. In lifting up, use eyebolts and hook a rope using shackles. The machine must be lifted up in the posture shown in Fig. 4.1.

Fig. 4.1 Transport Method and Posture

Hook a rope on the eyebolt on the top of positioner headstock (EX-1PB250/AX-1PB250/AⅡ-1PB250 = M16, EX-1PB500/AX-1PB500/AⅡ-1PB500,EX-1PB1000/AX-1PB1000/AⅡ-1PB1000 = M20) with shackles and transport them using cranes.

The weight of the main unit of the positioner alone is listed below. EX-1PB250/AX-1PB250/AⅡ-1PB250 : 110kg EX-1PB500/AX-1PB500/AⅡ-1PB500 : 170kg EX-1PB1000/AX-1PB1000/AⅡ-1PB1000 : 220kg

Note) In lifting up, use a rope and shackles with the specifications described below. R o p e : Durable load → more than 500kg, Length→ more than 1.0m Shackle : Type SC-12, Durable load → 900kg

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5 Options

The 2 kinds of options, Air rotary joint and equipped cable, are provided for EX/AX/AⅡ-1PB series. Also, when using a work by both durability support, Tailstock and a stand are prepared with the option. Use

them according to the use. 5.1 Air Rotary Joint (Option)

The placement of the air rotary joint enables the air drive machine on the table to be always provided with air even when the table is rotating.

The usable air is: > maximum air pressure usage 1MPa.

Table 5.1 Air Rotary Joint Assy Specification

Type EXPB251-EA AXPB251-EA A2PB251-EA



Parts No. L6968H L7420E L7220E Number of Port 4

Piping Connect Diameter External Diameter : 8mm (for polyurethane tube) Adaptable Fluid Air

Max. Air Pressure Usage 1Mpa Hollow hole Diameter φ40mm

Fig. 5.1 Outside Dimensions of Air Rotary Joint (mm)

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5.2 Equipped Cable (Option)

The equipped cables can be stored in the center of the table for EX-1PB/AX-1PB/AⅡ-PB series. One of the following 2 kinds of the equipment is usable with the air rotary joint as a signal (or as a drive) for the

peripheral devices on board of the table. Choose one according to the use.

5.2.1 Curl Code (Option)

Fig. 5.2 shows how the code is placed. Refer Table 5.3 for the use of equipped cable. Be careful that the rotation is limited to ±1 while placing the curl code.

Air rotary joint must be placed if the curl code is to be placed. Furthermore, make sure that the slip ring (in 5.2.2 5.2.3) cannot be placed if the curl code is placed.

Table 5.2 Curl Code Assy Specification

Type EXPB251-EC AXPB251-EC A2PB251-EC



Parts No. L6968J Number of Conductor 12 (0.5mm2×12)

Connecting Part Fasten side: Receptacle MS3102A28-20P Rotation side: 0.5mm2×12 (crimp contact A1. 25-YS4A)

Accessories Fasten side for connection Plug MS3106B28-20S Cable clamp MS3057-16A

Hollow hole Diameter None

Fig. 5.2 Outside Dimensions of Positioner / Curl Code (mm)

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RedＡＡ

WhiteＢＢ

BlackＣＣ

GrayＤＤ

OrangeＥＥ

BlueＦＦ

BrownＧＧ

YellowＨＨ

GreenＪＪ

Brown/White markＫＫ

Red/White markＬＬ

PurpleＭＭ

Ｎ

ＭＳ３１０２Ａ－２８－２０Ｐ

Ｐ

Table 5.3 Equipped Cable Specifications Number of Conductor 12 Cross section 0.5mm2

Power capacity 1A

Fig. 5.3 Wiring for Curl Code Specification

Fig. 5.4 Outside Dimensions of EXPB251-EC/AXPB251-EC/A2PB251-EC (mm)

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5.2.2 Slip Ring (Option 32-cores type)

Fig. 5.7 shows how the ring is placed. See Table 5.5 for the specification of the equipped cable. Note that the rotation is changed to the endless rotation while placing the slip ring.

Air rotary joint must be placed if the slip ring is to be placed. Furthermore, make sure that the curl code (in 5.2.1) cannot be placed if the slip ring is placed.

Table 5.4 Slip Ring Assy Specification

Type EXPB251-ES AXPB251-ES

EXPB501-ES AXPB501-ES

EXPB1001-ES AXPB1001-ES

Parts No. L6968K Number of Conductor 32 (0.3mm2×16P)

Connecting Part Fasten side: Receptacle MS3102A28-21P Rotation side: 0.3mm2×16 (no terminal processing)



Fig. 5.7 Outside Dimensions of Slip Ring (mm)

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Table 5.5 Equipped Cable Specifications Number of wire core 32 cores Cross section 0.3mm2

Power Capacity 0.5A (within 1 minute)0.3A (Continuously)

Fig. 5.8 Wiring for Positioner and Slip Ring

Fig. 5.9 Outside Dimensions of EXPB251-ES/AXPB251-ES (mm)-20-

Fig. 5.10 Outside Dimensions of EXPB501-ES/AXPB501-ES (mm)

Fig. 5.11 Outside Dimensions of EXPB1001-ES/AXPB1001-ES (mm)

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5.2.3 Slip Ring (Option 36-cores type)

Fig. 5.12 shows how the ring is placed. See Table 5.7 for the specification of the equipped cable. Note that the rotation is changed to the endless rotation while placing the slip ring.

Air rotary joint must be placed if the slip ring is to be placed. Furthermore, make sure that the curl code (in 5.2.1) cannot be placed if the slip ring is placed.

Table 5.6 Slip Ring Assy Specification Type A2PB251-ES A2PB501-ES A2PB1001-ES

Parts No. L10545E Number of Conductor 36 (0.3mm2×18P)

Connecting Part Fasten side: Receptacle MS3102A28-21P Rotation side: 0.3mm2×18P (no terminal processing)



Fig. 5.12 Outside Dimensions of Slip Ring (mm)

-22-

Table 5.7 Equipped Cable Specifications Number of wire core 36 cores Cross section 0.3mm2

Power Capacity 0.5A

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Fig. 5.13 Wiring for Positioner and Slip Ring

Fig. 5.14 Outside Dimensions of A2PB251-ES (mm)



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5.3 Tail Stock (Option) 5.3.1 Tail stock (L7090B) The tailstock to support the end of a long workpiece is available as an option.

The collector (L7090C) can be mounted as an option to the tailstock before shipment from the factory. The collector capacity is 500A and the usage rate is 60 %.

Fig. 5.17 Outside Dimensions of Tailstock(L7090B) (mm)

Fig. 5.18 Outside Dimensions of collector(L7090C) (mm) -25-

5.3.2 1-axis double support positioner

Tailstock provides support of stock when using the one axis head stock positioner. See Table5.8 for the composition of 1-axis double support positioner.

Table 5.8 The composition of 1-Axis Double Support Positioner Stand Positioner Headstock Tailstock Headstock side Tailstock side


L7090D (Stand A) L7090D (Stand A)


L7090E (Stand B) L7090D (Stand A)

EX-1PB1000 AX-1PB1000 AⅡ-1PB1000

L7090B

L7090E (Stand B) L7090F (Stand C)

（Option）

StandA

Baseplate

StandA

TailstockHeadstock

EX-1PB250AX-1PB250AⅡ-1PB250

Fig. 5.19 Outside Dimensions of EX-1PB250/AX-1PB250/AⅡ-1PB250 and Tailstock (mm)

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StandA（Option）

BaseplateStandB

TailstockHeadstockEX-1PB500AX-1PB500AⅡ-1PB500


HeadstockTailstock

StandB StandC（Option）Baseplate

AX-1PB1000AⅡ-1PB1000

EX-1PB1000


-27-

6 Grounding Method

For safety, install such an earth system as shown in Fig. 6.1.

(1) Be sure to connect the welding cable to the Work-side earth terminal provided beneath the connection box of positioner.

(2) For the manipulator and the robot control unit, install each individual earth cable of 3.5mm2 or larger. For details, refer to the Instruction Manual, “Control Unit”.

(3) Ensure that the earth resistance Is not larger than 100 ohms. (4) As shown in Fig.6.1, be sure to separate each of ①,②,③, and ④, and never share It as an earth

cable or electrode for other power lines. (5) For wiring of earth cables using metallic conduits, ducts and cable racks, follow the Electrical

Technical Standards in your country.

Fig. 6.1 Grounding Method

-28-

7 Maintenance 7.1 Welding Current allowance

For welding a load on the positioner, the availability is determined by the collector capacitance of the collector print element mounted at the positioner collector end and of the earth cable.

In this section, EX-1PB500/AX-1PB500/AⅡ-1PB500 is analyzed. The conditions for welding a load on the positioner Include; collector capacitance of 500A and the rates

availability of 60%: [Actual welding time (min.)]

<

0.6 ( 60% )

[Reference welding time: 10min.] If the operation current is below the rating (500A), the allowable availability is given by the following:

[Allowable availability] = (Rated current)2

× [Rated availability]

(Operation current) 2

[Example calculation] (1) For using welding current 350A

[Allowable availability] =

(500)2 × 0.6 ≒ 1.2 = 120%

(350) 2

As the availability is over 100%, continuous welding is possible.

(2) For using welding current of (300A + 300A)

[Allowable availability] =

(500)2 × 0.6 ≒ 0.41 = 41%

(300 + 300) 2

Reference welding time: 10min. × 0.41 = 4.1min., Pause: 10min.－ 4.1min. = 5.9min. According to the availability of 41%, a 5.1min. pause is necessary following 4.1min. welding. Welding exceeding the allowable availability may cause burnout of the collector print element, abnormal

heating of the table face, unstable arc, etc.

7.2 Maintenance of Collector (current-collecting brush)

Check periodically the amount of abrasion of a carbon chip mounted at the tip of the current collecting parts in the collector. Make sure if V-channel at the rear end of current collecting shaft is above the datum level, and if V-channel is hidden, replace with the new carbon chip.

Current Collecting DeviceDatum Level

Guide bars

V-channel

Carbon Chip

-29- Fig. 7.1 Replacing Current Collecting Brush

7.3 Tension Adjustments of Timing Belts

Timing belts are used between the motor unit and the reduction gear in this positioner. Attaining smooth transmission by the timing belts requires appropriate belt tension. For the adjusting method of the timing belts, see the following instructions.

(1) Removing reverse side covers and belt covers will reveal the timing belts as shown in Fig. 7.2. (2) To make their tension adjustments, loosen the four motor fixing bolts and the lock nut and adjust

the belt tension using the tension adjusting bolt. (3) When the specified deflection value is obtained, lock the adjusting bolts with the lock nut, retighten

the motor fixing bolts with a clamping torque of 28.4N・m, and apply LOCKTITE to these bolts in order to prevent them from loosening.

Table 7.1 Belt Deflection Values for Timing Belt tension Adjustments

Pressing Force Deflection EX-1PB250 AX-1PB250 AⅡ-1PB250

6.9N 2mm

EX-1PB500 AX-1PB500 AⅡ-1PB500 EX-1PB1000 AX-1PB1000 AⅡ-1PB1000

15N 2.5mm

Fig. 7.2 Tension Adjustments of Timing Belts

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8 Parts List for Maintenance 8.1 Parts List

Major parts and components are shown in the table below. Type Item Name DWG. No. & Model Parts No. Q’ty Remarks

W-L01503 5096-496 1 EX-1PB250 AX-1PB250 AC servo motor

W-L02150 -- 1 AⅡ-1PB250 Cyclo reduction gear W-L01409 5096-462 1

Timing belt W-L01414 5096-463 1 Grease Multemp FZ No.00 2670-051 - Grease Shell, Albania EP-2 ――― -


Battery W-L01399 5096-434 1


W-L02150 -- 1 AⅡ-1PB500 Cyclo reduction gear W-L01410 5096-465 1



Battery W-L01399 5096-434 1


W-L02150 -- 1 AⅡ-1PB1000 Cyclo reduction gear W-L01191B 5096-467 1


EX-1PB1000 AX-1PB1000 AⅡ-1PB1000

Battery W-L01399 5096-434 1 8.2 Replacement Parts

Location Parts Name DWG. No. & Model Parts No. Q’ty

Current collecting Unit

Carbon chip (Current collecting brush)

L6968D07 (EX/AX /AⅡ-1PB250) (EX/AX /AⅡ-1PB500) L6970D02 (EX/AX /AⅡ-1PB1000)

L6968D07 L6970D02

2

See Chap. 6.3 Current Collecting Device (Current Collecting Brush) Maintenance

Cyclo reduction gear Grease Multemp FZ No.00 2670-051 500 g

Actual uptime of 6000 hours or 3

years

②

①

8.3 Lubricant Ref. No. Lubrication location Lubricant

1 Pinion gear section Shell, Albania EP-2 2 Cyclo reduction gear Multemp FZ No.00

-31- Fig. 8.1 Lubrication of Gear

8.4 Replacing Battery This section describes the replacement procedures for battery as follows. (See Fig. 8.2) (1) Perform “check go/back” operation in accordance with the basic posture check program <such as P9999>

and make sure that the reference position is in alignment with the matchmark <▲> . If that is not the case, mark that position.

(2) Then, take out the connector plate of positioner. (3) Remove the battery connector with the control power ON. (4) Replace the battery with a new one. Replace with only DAIHEN Part No.5096-434. (5) Joint a battery connector. (6) Mount a connector plate. (7) Perform “check go/back” operation in accordance with the basic posture check program <P9999>, and

make sure that the reference position will not change from that obtained in (1)above. (8) Perform “encoder reset” operation at the basic posture check program <P9999>. Refer to the instruction

manual “INSTALLATION-4.2 Configuration” in the instruction manual “MANIPULATOR” (Rev 8 and after). Also, see the aforementioned section to reset the encoder if the encoder data have been lost.

Fig. 8.2 Replacing Battery

-32-

9 Internal Wiring of the Main Unit 9.1 Electric Circuit Diagram

Motor(750W) W-L01503

Fig. 9.1 Electrical Connection Diagram of EX-1PB250/AX-1PB250

Motor(1500W) W-L01504

Fig. 9.2 Electrical Connection Diagram of EX-1PB500/AX-1PB500 , EX-1PB1000/AX-1PB1000

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Fig. 9.3 Electrical Connection Diagram of AⅡ-1PB250/ AⅡ-1PB500/ AⅡ-1PB1000

-34-

-35-

10 Inspection Items

Inspection Maintenace No.

Daily 3 months

1 year

3 years

6 years

Location Description Corrective Action

1 ○ Entire outer appearance Attached spatter, dust of other foreign matter. Visual check and cleaning

2 ○ Matchmark panel Peeling, fracture Visual check

3 ○ External cable Scratches, soiling, loose connectors Visual check

4 ○ Mounting bolt Loose bolts Retightening 5 ○ Cannon plug Loose bolts Retightening

6 ○ Carbon blush ･Scratches, soiling and loose connectors. ･Abrasion Check.

･Check visually and replace if necessary. ･Remove abrasion and clean.

7 ○ Collector ring Abnormality in the Current-collecting ring Visual check

○ ○ Tester check ･Visual check, inspection

and retightening. ･Continuity test 8

●

Internal wiring

Replacement Replacement

○ Tension check

･Check for abnormality ･Tension adjustment ･Replacing timing belt ･Tension adjustment

9

●

Timing belt

Replacement Replacement

10 ○ ● ● Gear ･Grease replenishment. ･Abnormality check.

･Grease replenishment. ･Replacing if the gear is abnormal.

11 ● ● Reduction gear ･Grease replenishment. ･Abnormality check.

･Grease replenishment. ･Replacing if the gear is abnormal.

12 ● ● Battery Replacement Replacement (See Chapter 8.4)

13 ○ ○ ○ Rotary Joint(Option)

･Scratches, soiling and loose connectors ･A lowering of air pressure

･Check visually, inspection. ･Replacing if the rotary joint is abnormal.

14 ○ ○ ○ Slip Ring(Option) ･Scratches, soiling and loose connectors ･Cable check

･Check visually, inspection. ･Replacing if the slip ring is abnormal.

15 ● Overhaul

○Inspection ●Replacement

11 Warranty 11.1 Warranty Period (1) We guarantee the robot system and provide the repair free of charge if the failures occurred within the shorter

-36-

period of the followings under the condition that the robot system has been properly operated and periodically inspected as described in the instruction manual, and that the failures are due to the manufacturing defects.

The warranty period shall be: ･14 months based on B/L date of its shipment of the products. ･12 months in case of delivery to domestic customer that afterwards export our products outside of Japan. ･Practical cumulative operating time of 2000 hours.

(2) However, the warrantee policy shall not apply to the following cases even when in the guarantee period.

Therefore, repairs will be charged.

(a) Failure due to misuse or operational error. (b) Failure due to unauthorized repair or modification made by other than DAIHEN. (c) Damage or failure due to natural disasters such as earthquake, fire and flood. (d) Failure due to improper transfer or storage after delivery. (e) Others similar to those above. (f) Consumable and maintenance parts

11.2 Deadline for Supplying/ Repairing the Robot Maintenance Parts

DAIHEN will supply robot (including a positioner) maintenance parts for seven years and repair parts for ten years from the discontinuation date of the product.

※ Repair of the parts is provided for the above-mentioned period in principle. However, DAIHEN will repair as

long as the stock is available. DAIHEN will make our every effort to secure the parts. However, please note that it may become unavailable due to the external factors such as the market situation even during the period of time. Your understanding and cooperation in this regard is very much appreciated.

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Positioner Headstock Instruction Manual No. 1L7410A-E-1 SEPTEMBER 1, 2001 THE 1st

EDITION

No. 1L7410A-E-2 JULY 3 , 2003 THE 2nd EDITION

No. 1L7410A-E-3 OCTOBER 3 , 2007 THE 3rd EDITION

No. 1L7410A-E-4 MARCH 1 , 2009 THE 4th EDITION

1l7410a-e-4_exaxa2-1pb

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