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Yaskawa's fully electric industrial robot .

system consists of an industrial robot (Motoman-K6S/KlOS) , a numerical control unit (Y ASNAC ERC) , an operating station, a wo~kpiece mounting fixture and another equipment. I This manual is intended to give operating instructions and maintenance procedures primarily for the Motoman-K6S/KlOS robot. For the numerical control urit, refer to the maintenance manual for y ASNAC ERC. Instructions for i the operating fixture and the another equipment are not described in th~s manual, since they a're not furnished by Yaskawa Refer to each supplier of those devices for instructions. Read thoroughly this manual prior to maintenance and retain this for further reference.

CONTENTS

1.

BASIC

SPECIFICATIONs

1.1 1.2 1.3 1.4 1.5

BASIC SPECIFICATIONS .3 PARTS NAM~ ANp WORKING AXES Motoman-K6S/KlO,~ DIMENSIONS AND "'IORKING RANGE OF B-AXIS 7 ALTERABLE WORkING RANGE 7

4 WORKING

RANGE

.s

2.

ALLOWABLE 2.1 2.2

LOAD

Folk

V/RIST

PRECAUTIONS

ALLO"IABLE ATTACHMENT

LOA~ FOR '!'11RIST 8 MdUNTING PRECAUTIONS

3.

ALLOWABLE

LOAD

oNlu-Axls

10

4.

HANDLING

12

s.

SHIPPING

BOLTS

ANOIJIC-'S

13

6.

INSTALLATION

14

7.

".'iotoman

CO"!STRUCTld)N

16
FOR AXES

7.1 7.2

POSITIO1"IS OF LI~1IT SWITCHES Il'~TERNAL CONNBcTIONS 17

16

8.

MAI

~~TENANCE

AND

Ad>JUST~~EI\jT

20

8.1 INSPECTION SCHtDULE 20 8.2 INSPECTION ITEMs 21 8.2.1 Replacement Progedures for Battery Unit 8.2.2 Grease Replacem,nt Procedures for S-, LReduction f\lotor 24 8.2.3 Note for Wrist U~it Maintenance 25

23 and U-axis

9.

RECO~.1~.~ENDED

SPARE

I PARTS

26

2 -

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BASIC

SPECIFICATIONS

1.1

BASIC SPECIFICATIONS
Table 1.1 Basic Specifications
Mode!
Item

of K6S and

K1OS
l\1otoman-K
Verticallv articulated

Motoman-K6S
VerticalIy articuIated

1 OS

Operating
Degree Payload of

Mode
Free.dom

6 6 kg

. -

Repeatitive

Positioning
s

Accuracy
axis (turning)

tO.l

mm

3400 2400
arm)

3400

axis

2400

(lower

axis arm)

2700 3600
roll)

275
3600 2700 4000 12015

(upper

Motion

Range
R (wrist axis

13 axis (wrist pitch/yaw)

2700 4000
110/5 .90/s 110/5

Maximum

Speed

240/5 240/s 400/s 1.2 kg.m kg.mkg.~ kg.~ kg.m2 kg.m2 kg 7.5R3/12 to 45C 80%RH densin
O.5G

Allowable

Moment

1.0 0:6 0.91

Allowable GD2.. Weight

Inertia

0.67 0.24 180 MunselI

Temperature

Humidity Vibration Ambient Conditions

20 to ( non-con
Less than

g)

Free from corrosive or explosive gascs Others .Clean Free all1d dry from excessive

gases

or liquids,

electrical

noise

(plasma)

Power Capaci ty

5 kVJI.

8 kVA

-3

1.2

PARTS

NAME

AND

WORKING

AXES

UPPER (U)

ARM

WRIST

~!

03

1!;!::=1 I:rr;"fij
ROTARY (S) HEAD

03

~
FLANGE

~
~ I' =l ,

LOWER ARM

CONNECTOR BASE

/*-=
Fig.

BASE

1.1

Parts

Name and \AJorking Axes

1.3

Motoman-K6S/KlOS

DIMENSIONS

AND

WORKING

RANGE

Motoman-K6S Dimensions in mm

VIEW

"'rist

Flange

16 ~ f-+-

J ~

< ~

< ~

< ~

3 ~

<:;'009 :'1 :;(

VIE\-l

Baseplate

Fig.

1.2 and

l\1otoman-K6S Oimensions Working Range

1.4

WORKING

RANGE

OF B-AXIS

B-axis moves in the range maintainirig U-axis, as shown in Fig. 1.4.

, constant I

angle to the center of

~.

."'

Fig.

, .4

\"Jorking
RANGE

R~nge of B-axis

1.5

ALTERABLE

WORKING

The working
conditions Yaskawa as

range of S-axis can be al l ered


shown in Table in 1.2. advance. If al eration

according to is necessary,

the

operating contact

your

representative

Table
Item

1 J2

Specifications
:t 17 o (Standard) :t150o

S-axis Working Range

:t120o :t90o :t60o :t30o

2.

ALLOWABLE

LOAD

FOR

WRIST

AND

PRECAUTIOf'IS

2.1

ALLOWABLE

LOAD FOR WRIST

(1) The allowable load for wrist of Motoman-K6S and -KIOS is 6 kg and 10 kg, respectively, including the weight of the grip. The following conditions should be observed.

(2) If force is applied to the wrist instead of the load, force on R-, Band T-axis should be within the values shown in Table 2.1. Contact your Yaskawa representative for further information or assistance.
(3) Where the Fig. 2.1. volume of load is small, refer to limit load gravity shown in

Lb(mm)

Lb(mm)

(a)

Motoman-K6S

(b)

Motoman-K1OS

Fig.

2.1

Limit
-8

Load Gravity
-

.Inside

fitting : depth must be 5 mm or less .

The fitting .Gutside

fitting : is used, the fitting depth must be 5 mm or less.

If th'e outside fitting

=:>

Wrist

Flange

3. ALLOWABLE

LOAD ON U-AXIS

When peripheral equipment is attached conditians should be observed.


(1) Motoman-K6S .A1lowable .Unbalance 3 kg:m load on U-axis the :

to thi~ U-axis,

the following

lS kg max
center of U-axis; rotation :

(at

moment at Wl=3 kg)

.Never perform additional modifications on the robot to make provisions for other conditions. For attaching the equipment on U-axis use clamps shown in Fig. 3. 1. 4-}16 x PI, 28 j5 12

t5

t
(kg), 15 ""' N

~ Rr

WI

LOAD

CAPACITY

(kg)

'-'
E-o :I: C H t.J ~

10

'When load capacity WI equals 10 kg, un1;~lanced nment is not permitted.


-200100

100200 300 400 \mn)


I
I DISTANCE POINT U BETWEEN AND LOAD GRAVITY

w,'

"' ~

...w,

U-AXIS ROTATION CENTER (POINT U)


(

1 J
Fig. 3.1 Allov.Jable Load on U-axis -10 for

Dimensions in mm
~.1otoman-K6S

3.

ALLOWABLE

LOAD

0"'1 U-AXIS

(Cont'd)

(2)

~1otoman-KlOS

.A11owable load on U-axis:

25 kg max.

.Unbalance moment at the center of U-axis rotation: 6 kg:m (at WI=5 kg) .Never perform addition al modifications on the robot to make provisions for other conditions. For attaching the equipment on U-axis, use clamps shown in Fig. 3.2. 4-M6 x -.&.-- 45 12PI, .
-.,

-. I
~ ~

L
(kg)
" :1= -

81

W1

LOAD

GRAVITY

('kg)

25 20 15 10

~
WI

I 5

~ "

E-:I: c H t.J :1=

-Wll~

*When load capacity W1 equals 10 kg, UnbalancErl m:xrent is not pennitteCI.

200 100

100200 300 400 (mm) DI S TANCE BETWEEN POINT U AND LOAD

GRAVITY

w.

$:1

-fV!
U-AXIS CENTER ROTATION (POINT

+w,

U)

..o:

-ILL..L

Dimensions in mm
3.2

Fig.

Allowable

Load on U-axis 11

for

Motoman-K10S

5.

SHIPPING

BOL TS

AND

JIGS

Motoman is provided with shipping bolts and ji!~s at @ to @ in Fig. 5.1 to protect the robot from the movement and forces during shipment. The jigs are painted yellow. Be sure to remove thE~mbefore .insta11ation. NOTE
Before turning ori the power, check to be shipping bolts and jigs have been removed. so may cause ciamage to the driving parts. sure that the Failure to do

These shipping bolts and jigs must be stored for future event of moving or carrying the robot.

use in the

-~ ~~ ~

Fig.

5.1

Positions

of Shipping

E3olts and Jigs

-13

6.

INSTALLATION

The Motoman should be firmly mounted on a baseplate, or foundation rigid enough to support the Motoman and withstand repulsion forces during acceleration and deceleration. Mount the baseplate in either of the following ways. For mounting dimensions of Motoman baseplate, see par. 1.3. (1) Where the Motoman and the mounting fixture flat steel plate (common base) : are installed on a comm9n

The common base should be rugged and durable to prevent shifting of the Motoman or the mounting fixture. When the Motoman is used for welding, connect the ground lead to the Motoman baseplate.
For Motoman baseplate mounting, see Fig. 6.1

SPRING

WASHER

~ BOLT WASHER Motoman COMMON BASEPLATE BASE

Fig. (2) ~ere

6.1

Motoman Baseplate directly

t,1ounting

the Motoman is mounted

on the floor: the Motoman.

The floor should be rigid enough to support construction procedure are as follows . ."IThere the concrete thickness (f1oor)

Foundation

is 150 mm or more

(i} The surface of floor should be level and even. grind the swell and flatten the surface.

If it is uneven,

(n) Check for cracks on the floor. If any c:rack is found, remove the material around the crack and rebuild the floor with concrete. Place the robot by fastening the plate with M20 anchor bolts. The plate is tapped for M20 bolts . Where the cancrete thickness faundatian . (flaar) is less 1:han 150 mm ar an earth

(i) Dig a footing in the floor area. (n) Spread stones in the excavated area and tamp them sufficiently make a solid stone bed . to

(~ Fi11 the empty space of the stone bed with grout, and 1ay the concrete foundation. It should be more than 150 mm thick, and the surface must be leve1 and even.
(v) The concrete the robot. should be ,cured for more than a week before installing

14 -

6.

INSTALLATION

(Cont'd)

(3)

Mounted

types (Standard),

Foot-mounted available .

wall-mounted
type, !3ao !45 S-axis

and c:eiling-mounted
range

types

are

l.

For wall-mounted Motoman-K6S: .Motoman-KlaS:

working

is as follow.

2. The brakes in S-axis and in ""rist (R-, B- and T-axis) are optional. When using wall-mounted type, S-axis should be provided with a brake.
( 4) Incorporated cables and air duct duct for application in tl1otoman for user

1. Six cables and an air application . .Allowable .Max pressure


(:1:>

are incorporated 6.6 A or below 9.9 kgf/cm2

curren t of cables: of air duct:


CD

or below

(i)

Incorpora1:ed cable connector Type M53102A 18-15 (with cap): Connect the plug type M53106B to this .

18-1P

(J)

..

@ O)

Air

intet:

PT3/8

tap,

with

bull

plug

~~
VIEW

Incorpora1:ed cable connector Type M53102A 18-1? (with cap) : Connect the plug type M53106B 18-15 to this .
Air inlet: PT3/8 tap, with bull plug

A:

@)
Locations Connectors

Fig.6.2

of Incorporated and Air Inlet

Cable

2. The same pin Nos. (A to F) between O. 75 mm2 lead wires .


.Incorporated

connectors
cables: 0.75

are connected
mm2, 6 cables

with

.Using
Fig. 6.3 Detailed

pins:

A to F

Drawing

of Connector

Pin No.

-15

7.
7.1

Motoman
POSITIONS

CONSTRUCTION
OF LIMIT SWITCHES FOR AXES

Fig. 7.1 Locations of S- and L-axis Limit Switches

16

7.2

INTERNAL

CONNECTIONS
are used with each pin connector which of connectors, see

Highly reliable connectors which can be easily removed connector part. In Figs. 7.3 and 7.4, "-<I;:-" shows can also be removed. For the numbers and locations Fig. 7.2.

Fig.

7.2
Table

Locations and t~umbers of Connectors


7.2

List of Connector

Type
Plug Type
I-CA3106B. 32P:lOS

Name Base Connector


lFor Incorporated

!'-!o.

Receptacle. Ty~)e

ZBC 3BC
MS3102A.18-1P
172170-1

MS3106B.36AIOS l-.f53106B .18-15 i2p~n~-I)


172162-1 1-171196-0 172160-1 172160-1

ICable

Intermediate Connector

1-480276-0

s~
Feedback Unit Connector Connector for . Incorporated Cable

172168-1

lfiJ:tf

172168-1 MS3106B.18-P

MS3102A.18-1S (Optional)

17 -

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8.

t..1Alt-JTENANCE

AND

ADJUSTt..1ENT

8.1 INSPECTION

SCHEDULE

To insure optimum life of operation, a suggested schedule of periodicalinspections and adjustments is offered. Adjust the schedule according to your operating conditions. Especially, axes frequently used for handling should be checked at half-periods of the follo~'ing schedule .

Fig.

8.1

Inspection

Schedule

-20

8.2

INSPECTION

ITEMS

(Contid)

-E~-AXIS
/,.--~-~

~ -AXIS

R-AXIS

Fig.

8.2

Inspection

Parts

and Inspection

Number

-22

8.2.1 If the to the (1) (2) (3)

Replacement
battery following the the the

Procedures

for Battery
too low or is

Unit
depleted, replace it according

charge becomes procedures . side battery pins cover unit CD. @

Remove Remove Remove

(U-axis

motor

side)

of rotary (M5) .

head.

mounting

screw

(PC-2005-M,

W) on both

sides

of battery.

-<

~BATTERY -E{=:J-< oE-c:)--< (D (g; f DIODO

-E--{>

( 4) Remove the old battery

and mount

the new battery.

NOTE
l. When the battery unit is replaced. Keep the power ON between y ASNAC
Be sure to insert the pins in correct

and Motoman .
direction.

2.

Fig.

8.3

Battery

Loca1~ion

-23

8.2.2 Grease Replacement Reduction Motor (l) (2) Remove Inject using plugs grease grease @ , @

Procedures

for

S-,

L-

and

U-axis

and APO)

(f) . into grease inlet on

(EPINOC gun. Table

@,

@ and @

8.2

Amount
S-axis

of Greasing L- and U-axis


300 cc

MotomanK6S MotomanK1OS

700 cc 600 cc

400 cc

(3) The grease replacement is completed when new grease appears from @ @ and @ .The new grease is distinguished. ofrom old grease by color.
(4) "Iipe parts @ ,
@ and @ with ~
@ GREASE

a cloth

and

reinstall

the

plug

(f)
INLET U-AXIS REDUCTION MOTOR ~

@ ~ L-AXIS REDUCTION MOTOR


~

~-

.1 .~
--.

'.

--,--~ r-:~

7SIS GREASE INLET @

REDUCTION

MOTOR

I Oetailed LReduction

S-axis t-.~otor S-AXIS

l Par~ MOTOR

Ioetailed L- and u-axisl L Reduction f\"otor PartJ


;,
.1..'

n ,..,.,.-r--

I "
@-:
~ CQVER

I ~.:J ":-7" ~/

MOTOR BASE S-AXIS REDUCTION MOTOR

I" /Uf~ L-AXIS~\ MOTOR

~ -~

FLANGE \LOWER L-AXIS REDUCTlON Parts (L) ARM

t""" ~ U-AXIS

MOTOR MOTOR

REDUCTION

MOTOR

Fig.

8.4

Grease

Lubricated

24 -

8.2.3

Note for Wrist

Unit

tJaintenance

The motor and feedback unit are provided ,:X'ith the wrist unit. To counteract fumes from welding operation, etc. , the hatched parts are sea]ed with sealing compound so that fumes from welding operation, etc. do not penetrate into the wrist unit. Therefore" if the wrist shaft is disassembled, reseal with seaUng compound (KE4~;RTV) .

Fig.

8.5

Sealing

Part of V~'rist Unit

-25

9. RECOMMENDED SPARE PARTS

It is recommended that the following parts and components be kept in stock as spare parts for the Motoman-K6S/K10S. List of spare parts for Motoman-K6S and KIOS is shown in Table 9.1 and 9.2, respectively. They are ranked A, B and C, as follows .
Rank A: Expendable be expected. parts and those"1or which frequent replacement can

Rank

B: Pal-ts for which replacement frequent operation .

may be necessary

as a result

of

Rank C: Drive units


Table
Rank Spare Part No.

9.1

Spare Parts for Motoman-K6S


Type Manufacturer
Qty I Oty per Unit

Parts Name

Rema..ks
S-axis, Lead terminal treatment completion L-2xis, Lead terminal treatment completion

1
z 3
A

H\\'8471013-A

Limit switch set

4 S 6
7 Sillcon rubber compound (tube) Grease 2.5 kg

1
1 1
Yaska~.a EJectric I.Ug. Go., Ltd.

Gear
9 10 II 12 13

l
2 1

T-axis (Tip)

1 ~

1 1 1 1

Speed reducer
~ 1 I

14 15

1
2

16
17

AG Servomotor

Without brake With brake Without brake

1
Yaska~.a Elcctric "Ifg. Go. .Ltd. Interna! wiring

With key. Lead terminal treatmcnt completion

18 19 ZO ZI ZZ

1 1
1 I

1 1 1

In L ann

Wrist unlt

26 -

9.

RECOM""\ENDED

SPARE Table 9.2

PARTS Spare
Type

(Contid) Parts for Motoman-KlOS


j Qty ()Cr Unit

Rank

Sp;)re P;)rt No.

Parts Nanle

I.\anu(acturcr

Qty\

Rcm;)rks I k"d tcrminal l treatment , completion S-ax Is

1 2 3 4
A

Limit swltch set

5 6
7

Grease

2.5 kg

Silicon rubber compound (tube)

Shln-Etsu Chemical

KE4SRTV
Co.. Ltd.

1 1
1

8 Gear
9

11\\.8~2S13S-1 H\\'8~2S133-1

2 2 l l 1 2
, 1
~ brake Ilith

10

II

1Z 13 14 15

l With I L.ead treatment

key. terminal

16

3 1 1 1 1

Without

brake

completion

17 18 ]9 20 21 1

in L arm

-27

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TOE..c945-111
MOTOMAN Box 504 8-38525 ROBOTICS Torss 8weden AB

MAY 1994

Tel. int. 46486-10575 Fax. int 46486-11410

MOTOMAN

ROBOTICS
OXON

U.K

LTD

1 Swan Industrial Estate Banbury Tel. int. 44295-272755 Fax. int. 44295-267127

OX16 8DJ England

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