Okura Yusoki A Series Guide
Okura Yusoki Co., Ltd.
Robot Manual
Maintenance
UL-MAI-11
UL(11)
Updating history
Version
(Date)
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10 (2005.1.31) Newly released
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inspection
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Figure sharpening 2-2, 2-4
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the battery -> the brand new battery 2-10
10 (2006.7.31)
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10(2006.11.01)
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Encoder battery type change(A700III)
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Correction Key Controller Parts
NFB1 --- From “50AT” To “30AT”
Change Model of Key Controller Parts “NFB3”
Change Model of Key Controller Parts “C1,C5”
Change Model of Key Controller Parts “SVC”
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UL(11)
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(Date)
Content Page
11(2009.01.28)
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and Inspection“
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and Inspection“
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2-6 2-7,2-10,
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Last page
UL(11)
Introduction
Thank you for purchasing a model from the Okura Robot Palletizer A series.
This manual is a guidebook to help you safely and correctly use your A Series Robot
Palletizer. It should be useful not only to beginners who are using an Okura Palletizer
for the first time, but also to experienced users, who can use this Manual to reconfirm
their knowledge. Please read this Manual carefully and use the Palletizer with a clear
understanding of its content.
Definition of Operator
Important!
Definition of operator:
Only AUTHORIZED PERSONNEL can operate the robot.
The definition of “AUTHORIZED PERSON” is described below:
The only personnel that can operate the robot and/or robot
system, are those who have enough knowledge or experience of
robot operation and have also been trained to operate the robot.
They must also have been authorized by the employer.
UL(11)
Table of Contents
1. ROBOT .......................................................................................1-1
1.1. Robot Main Unit .................................................................................. 1-2
1.2. Periodic Maintenance and Inspection ................................................. 1-5
1.3. Inspection Contents ........................................................................... 1-6
1.4. Reference Materials Concerning Maintenance................................... 1-11
2. CONTROLLER .............................................................................2-1
2.1. Controller Internal Component Arrangement Diagram ....................... 2-2
2.2. Periodic Maintenance and Inspection ................................................. 2-6
2.3. Inspection Contents ........................................................................... 2-8
3. TROUBLESHOOTING ..................................................................3-1
3.1. Cases Where There is an Error Message ............................................. 3-2
3.2. Cases Where There is No Error Message............................................. 3-2
4. MAINTENANCE MENU.................................................................4-1
4.1. Menu structure ................................................................................... 4-2
4.2. Ordinary maintenance menu .............................................................. 4-3
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1-1
1.Robot
UL(11)
1-2
1.1.Robot Main Unit
A1800
Parts list of robot main unit
No. Name Model
1 Servo motor (T-axis) SGMPH04
2 Servo motor (D-axis) SGMGH55
3 Servo motor (O-axis) SGMGH55
4 Servo motor (R-axis) SGMGH55
5 Grease nipple A type,M6×1.0
6 Harness
7 Limit Switch D4D-1A32R
2
3
6
4
5
1
7
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1-3
A1600 III
Parts list of robot main unit
No. Name Model
1 Servo motor (T-axis) SGMPH04
2 Servo motor (D-axis) SGMGH55
3 Servo motor (O-axis) SGMGH55
4 Servo motor (R-axis) SGMGH55
5 Grease nipple B type,M6×1.0
6 Harness
7 Limit Switch D4D-1A32R
2
3
1
4
5
6
7
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1-4
A700II
Parts list of robot main unit
No. Name Model
1 Servo motor (T-axis) TS4609
2 Servo motor (D-axis) TS4836
3 Servo motor (O-axis) TS4836
4 Servo motor (R-axis) TS4836
5 Grease nipple B type,M6×1.0
6 Harness
7 Limit Switch D4D-1A32R
3
2
1
4
5
6
7
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1-5
1.2.Periodic Maintenance and Inspection
This section gives the periodic maintenance and inspection schedule, and explains
inspection contents.
1.2.1.Inspection Types and Items
For an Okura A series Robot Palletizer, there are the following four types of inspection:
3 basic types and overhaul.
No. Inspection type Explanation
1 Routine
inspection
Routine inspection items
2 A inspection Perform every 1000 hours of operation
3 B inspection Perform every 10000 hours of operation
4 C inspection Perform every 20000 hours of operation
1. Inspection Schedule
Generally, the inspection schedule follows the cycles given below.
Operation time per day, and
number of years
Hours of
operation
Routine
inspection
A
inspection
B
inspection
C
inspection 8hours 16hours 24hours
1000 О
2000 О1year
3000 О
4000 О2years 1year
5000 О
6000 О3years 1year
7000 О
8000 О4years 2years
9000 О
10000 ОО5years
11000 О
12000 О6years 3years 2years
13000 О
14000 О7years
15000 О
16000 О8years 4years
17000 О
18000 О9years 3years
19000 О
20000
Routine Inspection
ООО10years 5years
3.3years
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1-6
1.2.2.Inspection Items
Periodic maintenance and inspection is divided into 4 levels, including overhaul,
and the inspection contents at each level is as given in the following Table.
Inspection item Inspection contents
Routine
A
B
C
1 Routine inspection
Inspection for harness damage and
interference etc.
Check for abnormal noise and vibration
during operation.
O
2 Hand
Inspection for hand rattling.
Check whether hand orientation is
horizontal.
Lubrication of hand bearing section.
O
3 Electrical equipment Inspection for harness damage and kinking. O
4 Bearing lubrication Lubrication of R-axis bearing. O
5 Reduction gear
grease
replacement
Grease replacement. O
6 Parts replacement Replacement of standard replacement parts. O
1.3.Inspection Contents
1.3.1.Routine inspection
Follow the instructions described in the Daily Service manual.
1.3.2.Hand
The explanation here concerns standard hands for bags and cases.
Hand rattle
1. Check the fingers so that they are oriented
correctly and securely fastened.
2. Check the actuator (air cylinder etc.) so that
they are securely fastened and have no
abnormal wear.
3. Check the harnesses so that they have no
damages.
4. Check the air cylinder so that there are no
loose nuts on the flow controls.
5. Check bolts so that they are securely
fastened.
6. Check the frame for signs of cracking.
1
2 3
4, 5
4
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1-7
Hand level
The robot hand may deviate from horizontal if it
touches or collides with stacked articles due to a
programming mistake etc.
This is because the hand incorporates a design
feature to absorb the impact of the collision and
minimize damage.
A700III/ A1600III features as follows,
The following explains how to recover when the hand
deviates from horizontal.
1. Remove the plate of the wrist link
lever.(See diagram at right)
2. Loosen the internal power lock screws,
M8-30L 6 (in case A700III)
M8-22L 11
(in case A1600III)
in alternating diagonal fashion a little at a
time. (Screws need only to be loosened to
the point where the hand inclination can be
corrected.)
3. Place a level on the top surface of the hand,
and level the hand while checking the level
reading. (Check that the hand mounted to
the T-axis output shaft is horizontal.)
4. Using a torque wrench and proceeding in
alternating diagonal fashion at a torque,
14.8 N-m (150kgf-cm) (in case A700 III)
23.5 N-m (240kgf-cm) (in case A1600III)
5. Raise the torque to
37.0 N-m (380kgf-cm) (in case A700III)
34.5 N-m (352kgf-cm) (in case A1600III)
40.2 N-m (410kgf-cm) (in case A1600III-W)
Tighten in alternating diagonal fashion.
Repeat this a few times. (at least 3 times)
If there is reason for concern about
corrosion, prevent bolt rusting by filling
between the power lock and cover with
grease.
Hand lubrication ( only for hands with LM guide)
Open the hand palm, and use a grease gun to supply grease (Albania No.2, Showa Shell
Petroleum) to the grease nipple on LM guide bearing case.).
After lubricating, open and close the hand a few times, and lubricate again.
Moreover, please wipe off the grease adhering to the rail etc.
11(2009.01.28)
Caution
Thehandmightinclinefurtherin
procedure2.Pleaseworkinthe
situationthehandissupported,.
Plate
A
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1-8
Caution
Thehandmightinclinefurtherin
procedure1.Pleaseworkinthe
situationthehandissupported.
(A)
A1800 features as follows,
1. Loosen 10-bolts (M8 x 45L) in part (A)
until just enough to get T axis back to
level.,
2. Place a level on the top surface of the hand,
and level the hand while checking the level
reading. (Check that the hand mounted to
the T-axis output shaft is horizontal.)
3. Using a torque wrench and proceeding in
alternating diagonal fashion at a torque,
14.8 N-m (151kgf-cm)
4. Raise the torque to
29.0 N-m (296kgf-cm)
Tighten in alternating diagonal fashion. Repeat
this a few times.
Hand lubrication ( only for hands with LM guide)
Open the hand palm, and use a grease gun to supply grease (Albania No.2, Showa Shell
Petroleum) to the grease nipple on LM guide bearing case.).
After lubricating, open and close the hand a few times, and lubricate again.
Moreover, please wipe off the grease adhering to the rail etc.
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1.3.3. Electrical equipment
Harnesses (Cables and air hoses)
1. Check that there is no looseness of harness
connectors, no cable damage or kinking,
no interference with the robot and
peripheral equipment, no disconnection of
connectors and no looseness of terminal
block screws. Tighten if necessary.
2. Remove the cover on robot base and check
the harness inside. Check that there is no
damage, kinking. If there were any trouble,
contact our service section.
3. Purchase of spare Harness between T Axis
with hand is recommended. The Harness is
included in the articles of consumption
because it is influenced by environment
such as the dust existence, the rotation
frequency and the operation angle of the
hand.
1.3.4.Bearing lubrication
R-axis bearing
1. Move to the stroke end by operating in
teach mode. Lock out and tag out the
robot.
2. Using a grease gun, supply grease (Alvania
No.2, Shell Petroleum) from the grease
nipple. (about 10 pumps)
3. After lubrication, operate through the full
stroke a few times. Then move to the
opposite stroke end, lock out and tag out
the robot.
4. Lubricate again at this point.
5. After lubrication, operate through the full
stroke a few times.
* See Lock out and Tag out procedure in safety manual.
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1-10
1.3.5.Reduction gear grease replacement
Reduction gears are parts which might be replaced at B and C level inspection
depending on wear.
Note
B and C
inspection are conducted in accordance with an agreement by Okura
Service Co., Ltd.
1.3.6.Limit Switch
R axis limit switch
In the layout for which the revolution angle of R axis exceeds 260 degrees, please
operate a limit switch manually and check the thing of an "emergency stop" out of
which an error message comes.
In addition, after the above-mentioned check should cancel operation of a limit switch
with the reset button (blue) in a limit switch main part.
1.3.7.Parts replacement
Standard Replacement Parts
The following are standard replacement parts, which are replaced at C inspection
(20000 hours inspection)
No. Parts name Parts code location When to replace
1
Robot
internal
wiring
From robot
base to robot
hand
Recommend replacing wiring
inside robot base if R Axis
rotation angle is 180 degree
or more.
Recommend replacing wiring
between robot and hand if T
Axis rotation angle is 180
degree or more.
2
Servo motor See robot main
part list
Recommend to replace servo
motor if ambient
temperature is close to 40
degree because electrical
parts in encoder could be
damaged.
３Bearing All Axis Recommend to replace
Bearing if it could be
damaged.
４R axis
Cooling Fan
(Only
A1800)
109R1224M
102
Rotor Recommend to replace fan.
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1-11
1.4.Reference Materials Concerning Maintenance
1.4.1.Maintenance Parts
The lubricants recommended here are designed to meet the demands of robot
operation, compliment scheduled maintenance, and maximize the useful service life of
the equipment.
No. Name/Model Qty. Area used
1 Lithium-based soap type grease #2 1kg Hand ,R-Axis bearing
1.4.2.Lubricant List
No. Lubrication point Lubricant grease
type
Recommended
grease brand
Appropriate
amount /time
1 End Effector
(Linear Bearings/Varies)
2 R-Axis Turntable Bearing
Double Cross Roller
Bearing
Lithium-based soap
type grease #2
Albania No. 2
(Showa Shell)
40g
100gx2times
3
*)
Gear Reducers For Each Axis Only recommended
type
Moly-white
(Kyodo Yushi)
See the table
below
*)Replace grease for No.3 at overhaul.
Amount of grease needed for reduction gear
Axis
Model R D O T
A1600III
A1800
1920 1850 1850 120
A700III 1200 1000 1000 105
Units: cc
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1-12
Material
Size
Type
1.4.3.Bolt Fastening Torque
Units:N·m (kgf-cm)
Allen bolt
S C M 4 3 5
M 5 7.0 (71.4)
M 6 14.8 (151)
M8 37.0 (378)
M10 74.0 (755)
M12 128 (1306)
[106 (1082)]
M14 206 (2100)
[172 (1750)]
M16 314 (3200)
M18 [363 (3700)]
M20 617 (6300)
Power lock A1600III:34.5 (352)
A1600III-W:40.2 (410)
A1800:29.0(296)
Figures inside the parenthesis [ ] indicate the bolt for reduction gear.
1.4.4.Parts supply assurance
After shifting to robot new model, present model robot parts are continuing to supply
for 10 years. And Okura repairs robot for 10 years.
After those 10 years, Okura repair robot and supply robot parts as far as Okura can deal
with.
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2-1
2.Controller
UL(11)
2-2
FRONT VIEW BACK VIEW
LEFT VIEW RIGHT VIEW
2.1.Controller Internal Component Arrangement Diagram
2.1.1.A1600III A1800
The diagram here shows the arrangement of parts inside the robot controller. Please
correlate these with the table on the following page.
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Other manuals for A Series
4
This manual suits for next models
5
Table of contents
Other Okura Yusoki Robotics manuals
