Mitsubishi Electric CR800-D Series User manual

CR800-D/R/Qseriescontroller
Predictive Maintenance Function
User’s Manual
Mitsubishi Electric Industrial Robot
BFP-A3663

CAUTION All teaching work must be carried out by an operator who has received special
training. (This also applies to maintenance work with the power source turned ON.)
Enforcement of safety training
CAUTION For teaching work, prepare a work plan related to the methods and procedures of
operating the robot, and to the measures to be taken when an error occurs or when
restarting. Carry out work following this plan. (This also applies to maintenance
work with the power source turned ON.)
Preparation of work plan
WARNING Prepare a device that allows operation to be stopped immediately during teaching
work. (This also applies to maintenance work with the power source turned ON.)
Setting of emergency stop switch
CAUTION During teaching work, place a sign indicating that teaching work is in progress on
the start switch, etc. (This also applies to maintenance work with the power source
turned ON.)
Indication of teaching work in progress
DANGER Provide a fence or enclosure during operation to prevent contact of the operator
and robot.
Installation of safety fence
CAUTION Establish a set signaling method to the related operators for starting work, and
follow this method.
Signaling of operation start
CAUTION As a principle turn the power OFF during maintenance work. Place a sign indicating
that maintenance work is in progress on the start switch, etc.
Indication of maintenance work in progress.
CAUTION Before starting work, inspect the robot, emergency stop switch and other related
devices, etc., and confirm that there are no errors.
Inspection before starting work
Safety Precautions
Always read the following precautions and the separate "Safety
Manual" before starting use of the robot to learn the required
measures to be taken.

The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.
DANGER When automatic operation of the robot is performed using multiple control devices
(GOT, programmable controller, push-button switch), the interlocking of operation
rights of the devices, etc. must be designed by the customer.
CAUTION Use the robot within the environment given in the specifications. Failure to do so
could lead to a drop or reliability or faults. (Temperature, humidity, atmosphere,
noise environment, etc.)
CAUTION Transport the robot with the designated transportation posture. Transporting the
robot in a non-designated posture could lead to personal injuries or faults from
dropping.
CAUTION Always use the robot installed on a secure table. Use in an instable posture could
lead to positional deviation and vibration.
CAUTION Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.
CAUTION Do not apply excessive force on the connector or excessively bend the cable.
Failure to observe this could lead to contact defects or wire breakage.
CAUTION Set work masses, including hands, so as not to exceed the rated load or permitted
torque.
Exceeding either of these can cause an alarm or breakdown.
WARNING Securely install the hand and tool, and securely grasp the workpiece.
Failure to observe this could lead to personal injuries or damage if the object
comes off or flies off during operation.
WARNING Securely ground the robot and controller. Failure to observe this could lead to
malfunctioning by noise or to electric shock accidents.
CAUTION Indicate the operation state during robot operation. Failure to indicate the state
could lead to operators approaching the robot or to incorrect operation.
WARNING When carrying out teaching work in the robot's movement range, always secure
the priority right for the robot control. Failure to observe this could lead to personal
injuries or damage if the robot is started with external commands.
CAUTION Keep the jog speed as low as possible, and always watch the robot. Failure to do
so could lead to interference with the workpiece or peripheral devices.
CAUTION After editing the program, always confirm the operation with step operation before
starting automatic operation. Failure to do so could lead to interference with
peripheral devices because of programming mistakes, etc.
CAUTION Make sure that if the safety fence entrance door is opened during automatic
operation, the door is locked or that the robot will automatically stop. Failure to do
so could lead to personal injuries.

CAUTION Never carry out modifications based on personal judgments, or use non-
designated maintenance parts.
Failure to observe this could lead to faults or failures.
WARNING When the robot arm has to be moved by hand from an external area, do not place
hands or fingers in the openings. Failure to observe this could lead to hands or
fingers catching depending on the posture.
CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's
main power OFF. If the robot controller main power is turned OFF during automatic
operation, the robot accuracy could be adversely affected. Moreover, it may
interfere with the peripheral device by drop or move by inertia of the arm.
CAUTION Do not turn off the main power to the robot controller while rewriting the internal
information of the robot controller such as the program or parameters. If the main
power to the robot controller is turned off while in automatic operation or rewriting
the program or parameters, the internal information of the robot controller may be
damaged.
DANGER Do not connect the Handy GOT when using the GOT direct connection function of
this product. Failure to observe this may result in property damage or bodily injury
because the Handy GOT can automatically operate the robot regardless of
whether
the operation rights are enabled or not.
DANGER Do not connect the Handy GOT to a programmable controller when using an iQ
Platform compatible product with the CR800-R/CR800-Q controller. Failure to
observe this may result in property damage or bodily injury because the Handy
GOT can automatically operate the robot regardless of whether the operation
rights are enabled or not.
DANGER Do not remove the SSCNET III cable while power is supplied to the multiple CPU
system or the servo amplifier. Do not look directly at light emitted from the tip of
SSCNET III connectors or SSCNET III cables of the Motion CPU or the servo
amplifier. Eye discomfort may be felt if exposed to the light.
(Reference: SSCNET III employs a Class 1 or equivalent light source as specified
in JIS C 6802 and IEC60825-1 (domestic standards in Japan).)
DANGER Do not remove the SSCNET III cable while power is supplied to the controller.
Do not look directly at light emitted from the tip of SSCNET III connectors or
SSCNET III cables. Eye discomfort may be felt if exposed to the light.
(Reference: SSCNET III employs a Class 1 or equivalent light source as specified
in JIS C 6802 and IEC60825-1 (domestic standards in Japan).)
DANGER Attach the cap to the SSCNET III connector after disconnecting the SSCNET III
cable. If the cap is not attached, dirt or dust may adhere to the connector pins,
resulting in deterioration connector properties, and leading to malfunction.

CAUTION Make sure there are no mistakes in the wiring. Connecting differently to the way
specified in the manual can result in errors, such as the emergency stop not being
released. In order to prevent errors occurring, please be sure to check that all
functions (such as the teaching box emergency stop, customer emergency stop,
and door switch) are working properly after the wiring setup is completed.
CAUTION Use the network equipments (personal computer, USB hub, LAN hub, etc)
confirmed by manufacturer. The thing unsuitable for the FA environment (related
with conformity, temperature or noise) exists in the equipments connected to USB.
When using network equipment, measures against the noise, such as measures
against EMI and the addition of the ferrite core, may be necessary. Please fully
confirm the operation by customer. Guarantee and maintenance of the equipment
on the market (usual office automation equipment) cannot be performed.
CAUTION To maintain the safety of the robot system against unauthorized access from
external devices via the network, take appropriate measures. To maintain the
safety against unauthorized access via the Internet, take measures such as
installing a firewall.

■Revisions
Revision Date
Instruction Manual No.
Revision Details
2019-04-25
BFP-A3663
• First print

Introduction
Thank you for purchasing the Mitsubishi industrial robot "MELFASmart Plus Card/Card Pack Option".
This instruction manual explains the " Predictive Maintenance Function" that can be used with the MELFA
Smart Plus Card/Card Pack Option.
This product provides features that support maintenance and inspection so that the robot can be used for a
long time without trouble.
Efficient maintenance is supported though early detection of abnormalities or deterioration of robot
components and notification of the time of maintenance parts replacement or overhaul based on theactual
operating status of the robot.
Furthermore, due to the feature of estimating the parts replacement time or the recommended maintenance
time, this function can be used for decision making on the maintenance cycle.
To ensure correct usage of the product, always read through this manual before starting to use
"Predictive maintenance function".
For details of basic robot operation, refer to the separate "Instruction Manual / Detailed Explanations of
Functions and Operations".
■ Notation used in this manual
Caution
Warning
Danger
This indicates an item for which incorrect handling could present
imminent danger of death or serious injury.
This indicates an item for which incorrect handling could present a
danger of death or serious injury.
This indicates an item for which incorrect handling could present a
danger of injury. It could also present a danger of just physical damage.
•No part of this manual may be reproduced by any means or in any form, without prior consent from
Mitsubishi.
•The details of this manual are subject to change without notice.
•The specification value is based on our standard test method.
•An effort has been made to make full descriptions in this manual. However, if any discrepancies or
unclear points are found, please contact your dealer.
•This specifications is original.
•Company names and product names described in this document are trademarks or registered
trademarks of each company.
•
R
and TM are omitted in the text of this guide.
Copyright(C) 2019 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVED

Contents
1. Before starting use................................................................................................................................. 9
1.1. Contents of the instruction manual..................................................................................................... 9
1.2. Compatible products......................................................................................................................... 10
1.3. Related manuals................................................................................................................................11
1.4. Maintaining the robot........................................................................................................................ 12
1.4.1. Type of maintenance and inspection........................................................................................ 12
1.4.2. Inspecting/replacing timing belt ................................................................................................ 13
1.4.3. Lubrication ................................................................................................................................ 14
1.4.4. Replacing the battery................................................................................................................ 15
1.4.5. About Overhaul......................................................................................................................... 16
2. Basic specifications.............................................................................................................................. 17
2.1. Overview of basic specification of the predictive maintenance function.......................................... 17
2.1.1. Maintenance simulation............................................................................................................ 18
2.1.2. Consumption degree calculation function................................................................................. 20
2.1.3. Abnormality detection function.................................................................................................. 24
2.1.4. Target models/target axes......................................................................................................... 26
2.2. How to utilize the predictive maintenance function.......................................................................... 28
3. Startup and initial settings .................................................................................................................... 30
3.1. Enabling the predictive maintenance function.................................................................................. 31
3.2. Initial setting of the predictive maintenance function........................................................................ 34
3.2.1. Setting how to notify.................................................................................................................. 34
3.2.2. Setting detection level............................................................................................................... 35
3.2.3. Setting signals........................................................................................................................... 43
3.3. Setting of maintenance simulation ................................................................................................... 44
4. Basic screen structure.......................................................................................................................... 48
5. Total score............................................................................................................................................ 50
6. Consumption degree calculation function............................................................................................ 52
7. Abnormality detection function............................................................................................................. 56
8. Operating information........................................................................................................................... 60
9. Maintenance simulation ....................................................................................................................... 62
9.1. "1 Cycle" operation........................................................................................................................... 64
9.2. Program operation............................................................................................................................ 70
10. When consumption occurred/abnormality detected............................................................................. 74
10.1. Consumption Degree........................................................................................................................ 74
10.1.1. Maintenance parts .................................................................................................................... 74
10.1.2. Overhaul parts .......................................................................................................................... 75
10.1.3. Servo ON time .......................................................................................................................... 77
10.2. Abnormality detection....................................................................................................................... 78
10.2.1. Reduction gear.......................................................................................................................... 78
10.2.2. Encoder..................................................................................................................................... 78
10.2.3. Battery....................................................................................................................................... 79
11. Maintenance......................................................................................................................................... 80
11.1. Warning Pause................................................................................................................................. 81
11.2. Maintenance Reset........................................................................................................................... 82
11.3. Backup and restore.......................................................................................................................... 83
11.3.1. Backup (robot personal computer)....................................................................................... 85
11.3.2. Restore (personal computer robot)...................................................................................... 86
11.4. Maintenance Log.............................................................................................................................. 87
11.4.1. Maintenance Log screen .......................................................................................................... 87
11.4.2. Data to be recorded in the maintenance log............................................................................. 88
12. Batch management of maintenance information ................................................................................. 90
12.1. Functional overview.......................................................................................................................... 90
12.2. Output data....................................................................................................................................... 91
12.3. Request ID (MelfaRXM.ocx) specified by RequestService.............................................................. 93
13. Robot (system) status variables........................................................................................................... 94
13.1. Robot (system) status variable list ................................................................................................... 94
13.1.1. Consumption degree calculation function................................................................................. 94

13.1.2. Abnormality detection function.................................................................................................. 97
13.1.3. MELFA Smart Plus.................................................................................................................... 99
13.2. Consumption degree calculation function ...................................................................................... 100
13.2.1. Serial number.......................................................................................................................... 100
13.2.2. Operating information ............................................................................................................. 102
13.2.3. Maintenance Log .................................................................................................................... 108
13.2.4. Consumption degree............................................................................................................... 120
13.2.5. Consumption status................................................................................................................ 129
13.2.6. Notification.............................................................................................................................. 137
13.3. Abnormality detection function....................................................................................................... 143
13.3.1. Abnormality detection log ....................................................................................................... 143
13.3.2. Score....................................................................................................................................... 147
13.3.3. Abnormality detection status................................................................................................... 150
13.3.4. Notification.............................................................................................................................. 154
13.3.5. Detection level ........................................................................................................................ 157
14. Parameter........................................................................................................................................... 160
14.1. Common to predictive maintenance functions............................................................................... 160
14.2. Consumption degree calculation function ...................................................................................... 161
14.2.1. Setting parameters.................................................................................................................. 161
14.2.2. Data acquisition parameters................................................................................................... 163
14.2.3. Operation parameters............................................................................................................. 167
14.3. Abnormality detection function....................................................................................................... 172
14.3.1. Setting parameters.................................................................................................................. 172
14.3.2. Data acquisition parameters................................................................................................... 173
14.3.3. Operation parameters............................................................................................................. 175
15. Dedicated input/output signals........................................................................................................... 178
15.1. Consumption degree calculation function ...................................................................................... 178
15.2. Abnormality detection function....................................................................................................... 182
16. Troubleshooting.................................................................................................................................. 184
16.1. Error number list............................................................................................................................. 184
16.1.1. Common to predictive maintenance functions........................................................................ 184
16.1.2. Consumption degree calculation function............................................................................... 185
16.1.3. Abnormality detection function................................................................................................ 188
16.1.4. MELFA Smart Plus card.......................................................................................................... 190

Before starting use 9
1. Before starting use
1.1. Contents of the instruction manual
This function can be used with the RT ToolBox3 Predictive maintenance screen, parameters, status
variables, and dedicated input/output signals.
In this manual, the following structure is used to explain how the predictive maintenance function using
examples of the RT ToolBox3 Predictive maintenance screens.
For functions and operation methods provided in the standard robot controller, refer to the "Instruction
Manual" supplied for the robot controller.
Chapter
Title
Description
1
Before starting use
Explains the structure of this manual, products compatible
with this function, related manuals, and
maintenance/inspection.
2
Basic specifications
Explains the specification of the predictive maintenance
function.
3
Startup and initial settings
Explains how to start the predictive maintenance function
and the initial setting method.
4
Basic screen structure
Each predictive maintenance function is explained using
examples of the RT ToolBox3 Predictive maintenance
screens.
5
Total score
6
Consumption degree
calculation function
7
Abnormality detection function
8
Operating information
9
Maintenance simulation
10
When consumption
occurred/abnormality detected
Explains pause of warning occurrence related to this
function and operation at the time of maintenance using
examples of the RT ToolBox3 Predictive maintenance
screens.
11
Maintenance
Explains actions to take when consumption or abnormality
is detected.
12
Batch management of
maintenance information
Explains how to collectively manage maintenance
information of the entire production line with the host
system.
13
Robot (system) status
variables
Explains robot (system) status variables, parameters, and
dedicated input/output signals related to the predictive
maintenance function.
14
Parameter
15
Dedicated input/output signals
16
Troubleshooting
Explains error details related to the predictive maintenance
function and actions to take.

Before starting use 10
1.2. Compatible products
The following products are compatible with this function.
Item
Description
Remarks
1)
Robot arm
Vertical multi-joint
type RV-FR series
RV-2FR series,
RV-4FR series,
RV-7FR series,
RV-13FR series,
RV-20FR series
Standard model
6-axis robot only
Horizontal multi-joint
type RH-FR series
RH-3FRH series,
RH-6FRH series,
RH-12FRH series,
RH-20FRH series,
RH-3FRHR series
Standard model only
2)
Robot controller
CR800-D
Ver.A4 or later
CR800-R
Ver.A4 or later
CR800-Q
Ver.A4 or later
3)
Robot total engineering
support software (Note 1)
RT ToolBox3
Ver.1.50C or later
Robot program
language:
MELFA-BASIC VI
RT ToolBox3 mini
(Note 2)
Ver.1.50C or later
RT ToolBox3 Pro
Ver.1.50C or later
4)
Function expansion card
MELFA Smart Plus
Card Pack(Note 3)
AB type (2F-DQ520)
Either one
MELFA Smart Plus
Card (Note 3)
B type (2F-DQ521)
Note 1) Must be purchased separately.
Note 2) When RT ToolBox3 mini is used, simulation on RT ToolBox3 cannot be used.
Note 3) In this instruction manual, "MELFA Smart Plus card" may be used as the general term for MELFA
Smart Plus card pack and MELFA Smart Plus card.
Vertical multi-joint type
Horizontal multi-joint type
2) Robot controller
CR800 series
3) Robot total engineering support software
4) Function expansion card
1) Robot arm
RT ToolBox3

Before starting use 11
1.3. Related manuals
The following manuals are related to the predictive maintenance function.
Manual name
Description
Robot Arm Setup & Maintenance
Explains the procedures required to operate the robot arm
(unpacking, transportation, installation, confirmation of operation),
and the maintenance and inspection procedures.
Detailed explanations of functions
and operations
Explains details on the functions and operations such as each
function and operation, commands used in the program,
connection with the external input/output device, and parameters,
etc.
CR800 Series Controller Instruction
Manual
Troubleshooting
Explains the causes and remedies to be taken when an error
occurs. Explanations are given for each error No.
RT ToolBox3 / RT ToolBox3 mini
User's Manual
The operation manuals for the robot total engineering support
software "RT ToolBox3", "RT ToolBox3 mini", "RT ToolBox3 Pro"
(Option).
MELFA Smart Plus User’s Manual
Describes the installation method and setting method of MELFA
Smart Plus card (Option).
Communication Middleware Manual
(MelfaRXM.ocx)
The operation manual for ActiveX controller "MelfaRXM.ocx" that
communicates with the robot controller.
Ethernet Function Instruction
Manual
The operation manual for the Ethernet function that enables
Ethernet communication with PCs using the TCP/IP protocol. Also,
explains the SLMP connection.

Before starting use 12
1.4. Maintaining the robot
This function supports maintenance and inspection so that the robot can be used for a long time without
trouble.
Efficient maintenance is supported though early detection of abnormalities or deterioration of robot
components and notification of the time of maintenance parts replacement or overhaul based on the actual
operating status of the robot. However, in order to prevent failure beforehand and ensure prolonged
service life and safety of the robot, we strongly recommend periodic maintenance and inspection be
carried out.
This chapter explains maintenance and inspection of parts that are subject to this function.
For details on robot inspection items, implementation time of periodic inspection, calculation of operating
time, and maintenance and inspection procedures, refer to "5. Maintenance and Inspection" in the
separate volume "Instruction Manual/RobotArm Setup & Maintenance"
1.4.1. Type of maintenance and inspection
There are two types of maintenance and inspection, daily inspection and periodic inspection.
The following table shows the type of maintenance and inspection.
Type of maintenance and inspection
No.
Type of inspection and
maintenance works
Description
Operating
time
(Note1)
1
Daily inspection
Inspection works to be performed every day
before starting operation for the safe use of the
robot.
2
Periodic
inspection
Monthly
inspection
Inspection and maintenance works to be
performed every month.
Every 300 hr
3
6-month
inspection
Inspection and maintenance works to be
performed every 6 months.
Every 1,800 hr
4
2-year
inspection
Inspection and maintenance works to be
performed every 2 years.
Every 7,200 hr
5
Battery
replacement
Replacement of the backup battery of the robot.
Replace the battery every year regardless of the
operating hours.
6
Lubrication
Lubrication of each axis of the robot.
Refer to "1.4.3 Lubrication" for the lubrication
schedule.
Note 1) Robot operating hours are based on 15 hours/day, 20 days/month. If the robot operates 8
hours/day, the operation hours per month are about half the above condition. Therefore,
monthly inspection shall be performed once every two months.

Before starting use 13
1.4.2. Inspecting/replacing timing belt
This robot uses a timing belt for the drive conveyance system.
Compared to gears and chains, the timing belt does not require lubrication and has a low noise. However,
if the belt usage method and tension adjustment are inadequate, the life could drop and noise could be
generated. depending on the robot working conditions, elongation will occur gradually over a long time.
The tension must be confirmed during the periodic inspection.
The inspection/replacement method of the timing belt differs depending on the model. Perform
inspection/replacement by referring to "5. Maintenance and Inspection" in the separate volume "Instruction
Manual/RobotArm Setup & Maintenance".
Timing belt replacement period
The timing belt life is greatly affected by the robot working conditions, so a set time cannot be given.
However, if the following symptoms occur, replace the belt.
1) The belt tension value becomes less than the guideline value.
2) Position mismatch or gear teeth skipping occurs.
3) Cracks or wear occurs on the belt.
4) The tooth bottom of the belt is worn out and the core is exposed.
The timing belt can be replaced by customers; however, if adjustment is not
appropriate, it could lead to failure of related parts. When the timing belt needs to be
replaced, we recommend that you contact our Mitsubishi Service Department to
request replacement.
Caution
If you need to remove the timing belt for repair and others, measure the tension before
removing the belt.
When installing the belt, make sure to install with the same degree of tension as
before removal.
Failure to do so could shorten the service life of the belt and related parts.
Caution

Before starting use 14
1.4.3. Lubrication
Grease is used for the reduction gears of the robot. Grease has various roles, such as suppressing of wear
of reduction gears, removal of frictional heat, and prevention of burn-in.
If you use a robot for a long period of time, the grease will deteriorate due to loads during operation
(operating speed, operation frequency, heat generation condition, and others.). Degraded grease loses
initial performance and adversely affects machine service life.
Therefore, periodic replacement of grease is essential.
Lubrication intervals, lubrication locations, lubrication specifications and lubrication methods for grease are
different for each model.
Lubricate the robot before the lubrication interval shown in the following table elapses.
In addition, before the servo ON time reaches the specified hours (24,000 hours), overhaul work to replace
the grease inside the robot is necessary.
If it is unavoidable that overhaul cannot be performed at the specified interval, lubricate at the lubrication
intervals shown in the following table.
For details on overhaul, refer to "1.4.5About Overhaul".
Refer to "5. Maintenance and Inspection" in the separate volume "Instruction manual/RobotArm Setup &
Maintenance" for lubrication locations, lubrication specifications, and lubrication methods.
Lubrication interval
Robot type
Lubrication interval
RV-2FR / RV-2FRL
All axes: 6,000 hr
RV-4FR / RV-4FRL
RV-7FR / RV-7FRL
All axes: 24,000 hr
RV-7FRLL
RV-13FR / RV-13FRL
RV-20FR
J1 axis to J3 axis: 20,000 hr
J4 axis to J6 axis: 24,000 hr
RH-3FRH series
RH-6FRH series
RH-12FRH series
RH-20FRH series
J1 axis to J2 axis: 24,000 hr
Shaft part (ball screw / spline): 2,000 km/travel
RH-3FRHR series
J1 axis to J2 axis: 6,000 hr
Shaft part: 2,000 km/travel
• The lubrication intervals are the cumulative value of operation at maximum speed. In
case of intermittent operation or slow specified speed, the lubrication interval can be
extended accordingly.
•Since the lubrication interval changes depending on the operation status of the robot,
make decisions as necessary so that grease will not run out.
•Avoid excessive lubrication as it could cause grease leakage. Also, lubrication shall
be performed a maximum of three times. For maintenance after that, overhaul work is
required to replace the grease inside.
Caution

Before starting use 15
1.4.4. Replacing the battery
An absolute encoder is used for the position detector, so while power of controller is turned off the position
must be saved by the backup battery. These batteries are installed when the robot is shipped from the
factory, but as these are consumable parts, they must be replaced periodically by the customer. The
guideline for replacing the battery is one year, but this will differ according to the robot's usage state. When
a battery-related error occurred, replace the battery of the robot arm.
For details of battery related errors, refer to "16.1 Error number list" and "16.1.3Abnormality detection
function”.
The robot arm battery replacement method differs depending on the model. Refer to "5. Maintenance and
Inspection" in the separate volume "Instruction Manual/Robot Arm Setup & Maintenance".

Before starting use 16
1.4.5. About Overhaul
Robots which have been in operation for an extended period of time can suffer from wear and other
forms of deterioration. In regard to such robots, we define overhaul as an operation to replace parts
running out of specified service life or other parts which have been damaged, so that the robots may be
put back in shape for continued use.
As a rule of thumb, it is recommended that overhaul be carried out before the total amount of servo-on
time reaches the specified time (24,000 hours for the robot arm and 36,000 hours for the controller).
(Refer to the figure below.)
However, the degree of the equipment's wear and deterioration presumably varies depending on their
operating conditions. Especially for operation with high load and frequency, the maintenance cycle may
be shorter.
Predetermined time
period
If overhaul is not performed
If overhaul is performed
Servo-on time
Failure rate λ
Periodic inspection
Over-
haul
Shipment

Basic specifications 17
2. Basic specifications
2.1. Overview of basic specification of the predictive maintenance
function
The predictive maintenance function roughly consists of the following three functions.
Information on predictive maintenance by each function can be checked on the Predictive maintenance
screen, status variables, and parameters of RT ToolBox3. The following features are also available.
•Allows predictive maintenance information to be output to the host system of your production line and
collectively managed.
(Compatible with MelfaRXM.ocx and SLMP)
•If you are using a CR800 series Ver.A4 or later robot controller, by enabling this function using the MELFA
Smart Plus card, this function can be used by taking over the previous consumption degree and check
the score log data of abormality detection even during operation of the robot.
(For compatible cards, refer to "1.2 Compatible products , 4) Function extension card".)
Function
Overview
1
Maintenance
simulation
Using the real machine or simulations on RT ToolBox3, this function
estimates the parts replacement time or the recommended maintenance
time when specific motion patterns are repeated.
This can be used for pre-study of maintenance cycles or parts-friendly
operation verification of robots.
(Refer to "9 Maintenance simulation".)
2
Consumption
degree calculation
function
This function calculates the consumption degree [%] of robot components
based on the actual operating status (motor speed, load status, and others),
and displays/notifies the period up to maintenance/inspection or overhaul.
This supports efficient maintenance through notification of maintenance
timing and deciding the maintenance priority order.
<Target parts>
Maintenance parts : Grease, timing belt
Overhaul parts : Reduction gear, bearing, ball screw, ball spline
(Refer to "6 Consumption degree calculation function".)
3
Abnormality
detection function
This function detects abnormalities or deterioration of robot components
early.
Without adding sensors or analysis personal computer, the robot controller
alone can detect abnormalities in reduction gear or the encoder.
Early detection of abnormalities is possible thus downtime can be reduced.
<Target parts>
Encoder, battery, reduction gear including reduction gear
(Refer to "7 Abnormality detection function".)
The consumption degree of the robot arm is saved in the robot controller, thus it is
necessary to use the correct combination of the robot arm and robot controller.
To replace the robot arm or robot controller only, perform backup/restore of
predictive maintenance information to migrate the predictive maintenance
information. (For backup/restore, refer to "11.3 Backup and restore".)
Caution
When using this function by upgrading from a non-compatible controller software
version to a compatible controller software version, the consumption degree during
the period of the non-compatible software version is not added up, thus the result of
consumption degree calculation function cannot be the correct value.

Basic specifications 18
2.1.1. Maintenance simulation
Using the real machine (online) or simulations on RT ToolBox3, this function estimates the parts
replacement time or the recommended maintenance time when specific motion patterns (robot
programs) are repeated.
Maintenance simulation estimates the following items.
1) Number of years up to the time of replenishing grease
2) Number of years up to the time of timing belt replacement
3) Recommended number of years up to the maintenance time for overhauling parts
(Of reduction gear, bearing, ball screw, and ball spline, the part for which there is the shortest
number of years of maintenance)
There are two types of estimation methods, "Program operation" and "1 Cycle operation".
For the real machine (online), estimation is possible using "Program operation", and for simulation, in
addition to "Program operation", "1 Cycle operation" can also be used.
•1 Cycle operation: Specify the start line and end line of the robot program to estimate the parts
replacement/ the recommended maintenance time based on its 1 cycle operation
pattern.
Because 1 cycle can be accurately specified on a robot program, it is possible to
more accurately estimate the number of years when 1 cycle operation is repeated
than when using Program operation.
The estimation result of the number of years is from the brand new robot state.
• Program operation: While running a robot program automatically, the parts replacement/ the parts
replacement/ the recommended maintenance time is estimated based on the
operation pattern from when the start button is pressed to when the end button is
pressed.
Accurate 1 cycle (start line and end line) cannot be specified but Program
operation is used when it is difficult to specify 1 cycle on the program, such as
when the program uses external signals.
The estimation result for a real machine (online) is the number of years from the
current consumption degree of the robot.
The estimation result for simulation is the number of years from the brand new
robot state.
Output data
Number of years up to the time of replenishing grease (for each joint axis)
Number of years up to the time of timing belt replacement (for each joint axis)
Number of years up to the recommended maintenance time for overhaul parts (for each joint axis)
(Of reduction gear, bearing, ball screw, and ball spline, the part for which there is the shortest number of years of
maintenance)
Estimation method
Real machine (online)
· Program operation
· Estimates the number of years from the current consumption degree of the robot.
Simulation
· 1 Cycle operation, Program operation
· Estimates the number of years from the brand new robot state.
Usage
Usage
RT ToolBox3 Predictive maintenance screen (Refer to 9 Maintenance simulation)
Setting item
· Operation hours per day, operation days per month
* For models and joint axes subject to this function, refer to "2.1.4 Target models/target axes".