CMA Dishmachines GR Series User manual

GR 6160
Industrial Robot
工业机器人
6 axis GR series
6轴GR 系列
Mechanical useand maintenance manual
机械使用维护手册
The first edition
第一版
CMA (WuHu) Robotics CO.,LTD
希美埃（芜湖）机器人技术有限公司

CMA（WuHu）Robotics co., Ltd
希美埃（芜湖）机器人技术有限公司
CMA(WuHu) Robotics co., ltd is a Joint-Venture company specialized for painting
robots. In 2015, it is established byAnhui Efort Intelligent Equipment co., Ltd and Italy
CMA Robotics spa. The company is located in National Robots Industry Park-Wuhu
City.
希美埃（芜湖）机器人技术有限公司是一家专业从事喷涂机器人研发、制造和
应用的的中外合资企业。2015 年由安徽埃夫特智能装备有限公司与意大利 CMA
机器人技术有限公司共同创立。公司位于国家级机器人产业聚集区——国家(芜
湖)机器人产业园。
CMA Robotics spa is established in 1994, and the headquarter is located in North
Italy Udine City. As the first supplier that has proposed painting robots self-learning
function, CMA has a great influence in Italy and European market for automobile and
the components, metals, mechanical, furniture, wood, ceramics, sanitary ware and
plastic products
意大利 CMA 机器人技术有限公司成立于 1994 年，总部位于意大利北部的乌
迪内市, 是全球第一家提出机器人自学习功能的喷涂机器人供应商。 CMA 在意
大利乃至欧洲的汽车及零部件、五金、机械、家具、木材、陶瓷、卫浴、塑料制
品等喷涂机器人市场有着重要的影响力。

Anhui Efort Intelligent Equipment co., Ltdis one of the first enterprises engaged in
the development and application of industry robots in China.It is established in 2007,
Efort has experienced an eight-year continued development, currently has been an
advanced manufacturer of national Robots.The company has leaded some important
scientific and technological projects of national class, and has accumulated fruitful
achievements in robot industry field.
安徽埃夫特智能装备有限公司是国内较早从事工业机器人的研发和应用企
业之一。公司于 2007 年成立，经过 8年多的发展，目前已跻身于国产机器人的
第一梯队。公司先后牵头承担国家重大科技项目, 在中国机器人产业领域硕果累
累。
The company is based on the goal of recover equipment production industry, with
a long-term prospect,sustainable innovation and development.
公司以振兴装备制造业为目标，立足长远，不断创新，永续发展。

CMA (WuHu) Robotics CO., LTD
希美埃（芜湖）机器人技术有限公司
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目录
CHAPTER 1-SAFETY...................................................................................................................1
第一章安全 ......................................................................................................................................1
1.1 FOR SAFE USE OF THE ROBOT...........................................................................................................1
1.1 机器人安全使用须知 ....................................................................................................................1
1.1.1 Precautions when performing adjustment, operation or maintenance....................................1
1.1.1 进行调整、操作、保全等作业时的安全注意事项 .............................................................1
1.1.2 Safety measures for robot........................................................................................................5
1.1.2 机器人本体的安全对策 .........................................................................................................5
1.2 MOVEMENT,ALIENATION AND SELLING OF THE ROBOT..................................................................12
1.2 机器人的转移、转让、变卖 ......................................................................................................12
1.3ABANDON THE ROBOT ...................................................................................................................13
1.3 机器人的废弃 .............................................................................................................................13
CHAPTER 2-BASIC SPECIFICATIONS..................................................................................15
第二章基本说明 ............................................................................................................................15
2.1 ROBOT MODELAND NAMEPLATE DETAILS......................................................................................15
2.1 型号规格说明 .............................................................................................................................15
2.2 MECHANICAL SYSTEM...................................................................................................................16
2.2 机械系统组成 .............................................................................................................................16
2.3 THE MECHANICAL PERFORMANCE PARAMETERS............................................................................17
2.3 机械性能参数 .............................................................................................................................17
2.3.1 The definition of performance parameters............................................................................17
2.3.1 性能参数定义 .......................................................................................................................17
2.3.2 The performance parameters of the robot.............................................................................19
2.3.2 机器人性能参数 ...................................................................................................................19
2.4 HOME POSITION ADJUSTMENT .......................................................................................................22
2.4 零点校对......................................................................................................................................22
2.4.1Home position adjustment method .........................................................................................22
2.4.1 零点校对方法 .......................................................................................................................22
2.4.2 Mechanicalhome position adjustmentof all axes...................................................................24
2.4.2 各轴机械零点校对 ...............................................................................................................24
2.5 ALLOWABLE WRIST LOAD .............................................................................................................25
2.5 手腕部分负荷允许值 ..................................................................................................................25
2.5.1 Allowable pay load mass.......................................................................................................25
2.5.1 可允许搬运重量 ...................................................................................................................25
2.5.2 Allowable maximum static load torque .................................................................................25
2.5.2 容许最大静态负荷扭矩 .......................................................................................................25
2.5.3 Allowable maximum inertia moment.....................................................................................26
2.5.3 容许最大惯性矩 ...................................................................................................................26
CHAPTER3-INSPECTIONAND MAINTENANCE................................................................27

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第三章检修及维护 ........................................................................................................................27
3.1 PREVENTIVE INSPECTION...............................................................................................................27
3.1 预防性维护..................................................................................................................................27
3.1.1 Daily inspection ....................................................................................................................28
3.1.1 日常检查 ...............................................................................................................................28
3.1.2 Quarterly inspection..............................................................................................................28
3.1.2 每季度检查 ..........................................................................................................................28
3.1.3 Annual inspection..................................................................................................................29
3.1.3 每年检查 ...............................................................................................................................29
3.1.4 Inspection every two years ....................................................................................................29
3.1.4 每 2 年检查 ..........................................................................................................................29
3.2 INSPECTION ON MAJOR BOLTS........................................................................................................30
3.2 主要螺栓的检修 ..........................................................................................................................30
3.3 INSPECTION OF GREASE .................................................................................................................31
3.3 润滑油的检查..............................................................................................................................31
3.4 GREASE REPLACEMENT.................................................................................................................33
3.4 更换润滑油..................................................................................................................................33
3.4.1 Lubricationamount................................................................................................................33
3.4.1 润滑油供油量 .......................................................................................................................33
3.4.2 Robot orientation of lubricate grease....................................................................................34
3.4.2 润滑的空间方位 ...................................................................................................................34
3.4.3Procedure of grease replacement in reducer of J1,J2,J3,J4 and gear box of motor base ......35
3.4.3 J1/J2/J3/J4 轴减速机、马达座齿轮箱的润滑油更换步骤 ................................................35
3.4.4 Procedure of grease replacement in wrist .............................................................................35
3.4.4 手腕部件的润滑油更换步骤 ...............................................................................................35
3.4.5Residual pressure release lubricant chamber.........................................................................39
3.4.5 释放润滑油腔内残压 ...........................................................................................................39
CHAPTER 4-MAINTENANCE..................................................................................................41
第四章 故障处理 ..........................................................................................................................41
4.1 INVESTIGATE THE CAUSE OF THE FAILURE METHOD.......................................................................41
4.1 调查故障原因的方法 ..................................................................................................................41
4.2 THE FAULT AND THE REASON.........................................................................................................43
4.2 故障现象和原因 ..........................................................................................................................43
4.3 CHECKINGAND PROCESSING METHOD OF EVERY PARTS AND COMPONENTS....................................44
4.3 各个零部件的检查方法及处理方法 ..........................................................................................44
4.3.1Reducer ..................................................................................................................................44
4.3.1 减速机 ...................................................................................................................................44
4.3.2Motor......................................................................................................................................45
4.3.2 马达 .......................................................................................................................................45
4.4REPLACEPARTS ...............................................................................................................................46
4.4 更换零部件..................................................................................................................................46
4.4.1 Replace the wrist parts ......................................................................................................47
4.4.1 更换手腕部件 ......................................................................................................................47

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4.4.2 Replace the motor..................................................................................................................49
4.4.2 更换马达 ...............................................................................................................................49
4.4.3Sealant Application ................................................................................................................64
4.4.3 密封胶应用 ...........................................................................................................................64
4.5 PIPELINE MAINTENANCE PACKAGE ................................................................................................65
4.5 本体管线包的维护 ......................................................................................................................65
4.6 MAINTENANCE AREA.....................................................................................................................66
4.6 机器人维护和使用区域 ..............................................................................................................66
CHAPTER 5-HANDLING AND INSTALLATION..................................................................69
第五章搬运及安装 ........................................................................................................................69
5.1 HANDLING ROBOT.........................................................................................................................69
5.1 机器人搬运..................................................................................................................................69
5.1.1Handling Precautions.............................................................................................................69
5.1.1 搬运注意事项 .......................................................................................................................69
5.1.2 TransportMethod...................................................................................................................70
5.1.2 搬运方法 ...............................................................................................................................70
5.2 INSTALLATION ...............................................................................................................................71
5.2 安装..............................................................................................................................................71
5.2.1External Interface Dimensions...............................................................................................71
5.2.1 外部接口尺寸图 ...................................................................................................................71
5.3 INSTALLATION SPECIFICATIONS AND ENVIRONMENTAL CONDITIONS..............................................76
5.3 安装规范及环境条件 ..................................................................................................................76
5.3.1Environment and climate adaptation should meet the requirements of Table 2. ....................76
5.3.1 环境气候适应性应符合表 2 的规定 ..................................................................................76
APPENDIX....................................................................................................................................77
附录 ................................................................................................................................................77
ASCREW TIGHTENING TORQUE TABLE.................................................................................................77
A螺钉上紧力矩表 ............................................................................................................................77
BSPARE PARTS LIST.............................................................................................................................78
B备件清单 ........................................................................................................................................78

CMA (WuHu) Robotics CO., LTD
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Chapter 1-Safety
第一章安全
1.1 For safe use of the robot
1.1机器人安全使用须知
Read this section carefully prior to installation, operation, maintenance, or inspection and
use equipment correctly. Use the robot only after fully understanding the equipment, all safety
points, and comments/suggestions. Thefollowing table shows the importance of the following
tags/marks in this Operation manual.
实施安装、运转、维修保养、检修作业前，请务必熟读本书及其它附属文件，正
确使用本产品。请在充分掌握设备知识、安全信息以及全部注意事项后，再行使用本产
品。本说明书采用下列记号表示各自的重要性。
Case where a mistake made in handling is likely to cause the user to be
exposed to the dangerof death or serious injury and where the degree of
the urgency (imminence) of the warning.
表示处理有误时，会导致使用者死亡或者负重伤，且危险性非常高的情形。
Given for the danger to occur is at the high end of the scales (including
high-level danger).
表示处理有误时，会导致使用者死亡或者负重伤的情形。
Cases where a mistake made in handling is likely to cause the user to be
exposed to thedanger of death or serious injury.
表示处理有误时，会导致使用者轻伤或发生财产损失的情形。
1.1.1 Precautions when performing adjustment, operation or maintenance
1.1.1 进行调整、操作、保全等作业时的安全注意事项
1). Operators must be involved in industrial robot operating professional training, andmust

CMA (WuHu) Robotics CO., LTD
希美埃（芜湖）机器人技术有限公司
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wear overalls, helmets, safety glasses and safety shoes.
1）作业人员须经过工业机器人操作专业培训，须穿戴工作服、安全帽、安全鞋等。
2). Make sure there is no one in the robot work area when the power is turned ON. Take off
gloves when operating,save the data on a regular basis; Please confirm that the axial limited
block be intactand effective.
2）投入电源时，请确认机器人的动作范围内没有作业人员，操作时摘下手套，定期保
存数据；请确认各轴限位块完好有效。
3). Only perform work within the robot work area after making sure the motor power is OFF.
3）必须切断电源后，方可进入机器人的动作范围内进行作业。
4). In cases where inspection or maintenance work has to be done with motor power
ON,perform the work in pairs. One person must stand guard and ready to press an
emergencystop button. The other person must work quickly and carefully within the robot
operatingarea. Always allocate, confirm and know an escape route prior to beginning work.
4）有时，检修、维修保养等作业必须在通电状态下进行。此时，应2人1组进行作业。1
人保持可立即按下紧急停止按钮的姿势，另1人则在机器人的动作范围内，保持警惕
并迅速进行作业。此外，应确认好撤退路径后再行作业。
5). Ensure payload on the wrist and forearm is within specifications. Excessive loads
maycause poor robot operation and eventually damage the robot.
5）手腕部位及机械臂上的负荷必须控制在允许搬运重量以内。如果不遵守允许搬运重
量的规定，会导致异常动作发生或机械构件提前损坏。
6).Please read carefully the instructions of robot electrical maintenance manual "safety notes"
section.
6) 请仔细阅读使用说明书《机器人电气维护手册》的“安全注意事项”章节的说明。
7). Do not disassemble or operate any part that is not explained in the Maintenance manuals.
7) 禁止进行维修手册未涉及部位的拆卸和作业。
It is possible the robot will make an emergency/safe stop if an abnormal situation occurs,
this is due to various self diagnostic functions and abnormality detecting functions provided.
However, the robot is not 100% safe.
机器人配有各种自我诊断功能及异常检测功能，即使发生异常也能安全停止。即便

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如此，因机器人造成的事故仍然时有发生。
Robot accidents that occurred in the past were mostly due to the following
situations:
机器人事故以下列情况居多：
1、Auto operation started without confirming there were no workers
within the robot operating area.
2、People being within the robot operating area when the robot was in auto
operationmode and the robot unexpectedly started.
3、People carefully watching one robot but forgetting another one was
operating withinreach of them.
1、未确认机器人的动作范围内是否有人，就执行了自动运转。
2、自动运转状态下进入机器人的动作范围内，作业期间机器人突然起动。
3、只注意到眼前的机器人，未注意别的机器人。
We can summarize the above as unsafe activities caused by human error such as“careless
mistakes” and “not following the established procedures.” Workers not be ableto take
appropriate actions, such as “emergency stop” or “escape from the danger”, whenunexpected
robot motion occurs which may result in disastrous accidents.Unexpected robot motion
includes:
上述事故都是由于“疏忽了安全操作步骤”、“没有想到机器人会突然动作”的相同
原因而造成的。换句话说，都是由于“一时疏忽”、“没有遵守规定的步骤”等人为的不
安全行为而造成的事故。“突发情况”使作业人员来不及实施“紧急停止”、“逃离”等
行为避开事故，极有可能导致重大事故发生。“突发情况”一般有以下几种。
1) Sudden change of movement from low speed to high speed.
2) Manipulation by other workers.
3) Robot operated by a different program due to program mistakes or faulty peripheral
equipment.
4) Abnormal behavior due to noise, faults or errors.
5) Mishandling.
6) Operation at a high speed in spite of intended low speed playback.