Toshiba TH180 User manual

STE85390-0
MAINTENANCE MANUAL
Notice
1. Make sure that this instruction manual is delivered to the final
user of Toshiba Machine's industrial robot.
2. Before operating the industrial robot, read through and
completely understand this manual.
3. After reading through this manual, keep it nearby for future
reference.
September 2012
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN
TH180
TH250A
TH350A／TS3000

MAINTENANCE MANUAL
Copyright 2012 by Toshiba Machine Co., Ltd.
All rights reserved.
No part of this document may be reproduced in any form without obtaining prior written
permission from Toshiba Machine Co., Ltd.
The information contained in this manual is subject to change without notice to effect
improvements.
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MAINTENANCE MANUAL
WARRANTY
This machine is delivered to each customer only after it is inspected very carefully to
make sure that it satisfies the Toshiba Machine’s standard. Should it cause an
inconvenience, we will guarantee as described below.
1. Warranty period
Toshiba Machine agrees to repair or replace as necessary all defective material or
workmanship up to the period shown below, whichever comes first.
1) Eighteen (18) months from the date of dispatch from our plant.
2) Twelve (12) months from the date of machine installation at customer’s job site.
3) 2,400 running hours from the date of initial machine operation.
2. Contents of warranty
1) Only the product delivered to the customer is subject to Toshiba Machine’s
Guarantee. Such Guarantee covers the specifications and functions as defined
in the product specifications manual, catalog, instruction manual, etc. In no
event does the Guarantee cover any secondary or associated damage caused
by malfunction of the delivered product.
2) Toshiba Machine repairs the product free of charge only when it malfunctioned
after handling or use according to the instruction manual attached to the product
within the specified warranty period.
3. Exemption from responsibility
Toshiba Machine’s Guarantee shall not cover the following cases.
1) Incorrect use not described in the instruction manual, and trouble or damage
caused by negligent use.
2) Inconvenience caused by aged deterioration or long-term usage (natural fading
of coating or painting, deterioration of consumable parts (*1), etc.).
3) Inconvenience caused by sensuous phenomena (noise generation, etc. which
will not affect the function).
4) Remodeling or disassembly which Toshiba Machine will not permit.
5) Trouble and damage caused by insufficient maintenance/inspection or improper
repair.
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MAINTENANCE MANUAL
6) Trouble and damage caused by disaster, fire or other external factor.
7) Internal data such as program and point which were created by the customer.
8) When the robot purchased in Japan was shipped overseas.
4. Precautions
1) Unless the robot was used pursuant to its specifications, Toshiba Machine will
not guarantee the basic performance of the robot.
2) If the customer did not observe the warnings and cautions described in this
manual, Toshiba Machine will not assume the responsibility for any
consequential accident resulting in injury or death, damage or trouble.
3) Please note that the warnings, cautions and other descriptions stipulated in this
manual are only those which can be assumed by Toshiba Machine as of now.
(*1) The consumable parts signify the replacement parts for maintenance as
listed in Section 4 of this manual.
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MAINTENANCE MANUAL
INTRODUCTION
This manual describes the maintenance of the TH series industrial robots and controller.
The maintenance and inspection are essential to maintain the robot performance for long
years to prevent a trouble and improve the safe work.
Before starting an actual operation, it is strongly recommended to read through this
manual and draw up a maintenance schedule.
This maintenance manual consists of the following four (4) sections.
Section 1 Maintenance Items
This section describes a maintenace schedule of the robot and controller
and necessary maintenance and inspection items.
Section 2 Maintenance of the Robot
This section describes the robot mechanism and items required for
inspection.
Section 3 Maintenance of Controller
This section describes the robot mechanism and maintenance and
inspection methods.
Section 4 Maintenance Replacement Parts
This section describes the maintenance replacement parts of the robot
and the robot controller.
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CAUTIONS ON SAFETY
This manual contains the important information on the robot and controller to prevent
injury to the operators and persons nearby, to prevent damage to assets and to assure
correct use.
Make sure that the following details (indications and symbols) are well understood before
reading this manual. Always observe the information that is noted.
[Explanation of indications]
Indication Meaning of indication
!
DANGER
This means that "incorrect handling will imminently lead to
fatalities or serious injuries."
! WARNING
This means that "incorrect handling may
lead to fatalities or
serious injuries."
! CAUTION
This means that "incorrect handling may lead to personal
injuries *1) or physical damage *2)."
*1) Injuries refer to injuries, burns and electric shocks, etc., which do not require
hospitalization or long-term medical treatment.
*2) Physical damage refers to damages due to destruction of assets or resources.
[Explanation of symbols]
Symbol Meaning of symbol
This means that the action is prohibited (must not be done).
Details of the actions actually prohibited are indicated with
pictures or words in or near the symbol.
This means that the action is mandatory (must be done).
Details of the actions that must be done are indicated with
pictures or words in or near the symbol.
This means danger or caution.
Details of the actual danger or caution are indicated with pictures
or words in or near the symbol.
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MAINTENANCE MANUAL
!CAUTION
• Before carrying out the actual operation, read through "Safety Measures" of
the separate Instruction Manual in order to safely run the workflow from
installation to transportation of the robot.
[Maintenance and inspection]
Be sure to observe the following items to use the robot safely.
!
DANGER
Prohibited
• DO NOT incinerate, disassemble or charge the batteries.
Otherwise, they may rupture.
Mandatory
• Be sure to turn off the main power switch of the controller
before starting inspection or maintenance.
• Batteries should be disposed of according to the user's
in-house regulations.
! CAUTION
Disassembly
prohibited
• The user must NEVER replace or modify parts other than
those described in the instruction manual. Otherwise, the
performance may deteriorate or faults or accidents will be
caused.
Mandatory
• Always use the Toshiba Machine's designated spare parts
when replacing the parts.
• Maintenance and inspection should be performed regularly.
Otherwise, the system may malfunction or accidents will be
caused.
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MAINTENANCE MANUAL
Table of Contents
Page
Section 1 Maintenance Items........................................................................................... 9
1.1 Maintenance Schedule........................................................................................... 9
1.2 Items for Maintenance and Inspection................................................................. 10
1.3 Maintenance Tools............................................................................................... 13
1.4 Maintenance Contract and Repair........................................................................ 13
1.4.1 Maintenance Contract.................................................................................... 13
1.4.2 Repair ............................................................................................................ 13
1.4.3 Modification.................................................................................................... 14
Section 2 Maintenance of the Robot.............................................................................. 15
2.1 Cautions on Maintenance and Inspection............................................................ 15
2.2 Layout of Robot Components and Drive Mechanism........................................... 15
2.3 Robot Maintenance Procedures........................................................................... 18
2.3.1 Check of Cable Duct for Abnormality............................................................. 18
2.3.2 Check of Hand and Base for Mounting.......................................................... 20
2.3.3 Check of Air Leakage..................................................................................... 21
2.3.4 Lubrication of Ball Screw Spline Shaft........................................................... 23
2.3.5 Check of Each Axis Drive Status ................................................................... 24
2.3.6 Check of Timing Belt Status........................................................................... 24
2.3.7 Greasing of Reduction Gears (TH250A, TH350A, TH350A-T)...................... 25
2.3.8 Replacement of Position Detector (or Encoder) Batteries ............................. 27
2.3.9 Disconnection of Arm 2 Cover....................................................................... 31
2.4 Cautions on Robot Transport and Storage........................................................... 33
2.5. Robot Home Point and Position Detector Error ................................................ 33
2.5.1 Setting Robot Home Point ............................................................................. 33
2.5.2 Position Detector Error................................................................................... 34
2.5.3 Restoration from position detector error ........................................................ 35
2.6 Restoring Operation from Position Detector Error................................................ 38
2.6.1 Encoder Status Display.................................................................................. 38
2.6.2 Encoder Error Reset Operation ..................................................................... 39
2.6.3 Multi-Turn Data Reset Operation................................................................... 40
2.6.4 REORG Operation......................................................................................... 42
2.6.5 ZEROP Operation.......................................................................................... 48
Section 3 Maintenance of Controller.............................................................................. 54
3.1 Cautions on Maintenance and Inspection............................................................ 54
3.2 Layout of Controller Parts .................................................................................... 55
3.3 Maintenance Procedures..................................................................................... 56
3.3.1 Check of Controller Air Vent Holes ................................................................ 56
3.3.2 Check of Safety Devices for Function............................................................ 57
3.3.3 Battery Replacement ..................................................................................... 59
3.3.4 Replacement of Switching Power Supply Unit............................................... 61
3.3.5 Replacement of Fuse (X8GN, X8GI Printed Board)....................................... 63
3.3.6 Replacement of Output ICs (X8GN, X8GI Printed Board) ............................. 64
Section 4 Maintenance Replacement Parts................................................................... 66
4.1 Robot Main Body Maintenance Replacement Parts List...................................... 66
4.2 List of Mechanical Replacement Parts for Maintenance...................................... 68
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Section 1 Maintenance Items
1.1 Maintenance Schedule
Maintenance comes in the two (2) types; daily inspection, and regular inspection and
maintenance. For the regular inspection and maintenance, inspection items are
added every 1,200 running hours.
3-month
check
3-month
check
3-month
check
3-month
check
1-year
check
3-month
check
3-month
check
3-month
check
6-month
check
6-month
check
6-month
check
6-month
check
1-year
check
Overhaul
(every 5 years)
Daily inspection
Running hours
(h)
0
1200
2400
4800
3600
6400
7200
8400
9600
24000
(h)
3-month
check
Inspection schedule
• When the system is operated for 16 hours per day:
16 hours ×25 days ×3 months = 1,200 hours
• When the system is operated for 24 hours per day:
24 hours ×25 days ×3 months = 1,800 hours
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1.2 Items for Maintenance and Inspection
This section describes the items for maintenance and inspection.
For the executing procedures, see the relevant paragraph listed in the table below.
a) Daily inspection
No. Item Inspection procedures Relevant
Para.
1 Cable ducts (1) Make sure that any cable duct will
not twist, bend or crack locally at the
time of robot motion.
(2) Make sure that all connectors of the
cable ducts are tightened completely.
2.3.1
2 Hand set flange Make sure that the hand set flange bolts
are tightened completely. 2.3.2
Robot installation
bolts Make sure that the robot base installation bolts are tightened completely.
3 Vibration and
noise Make sure that each axis can move smoothly.
4 Change in
positioning
accuracy
Make sure that the robot can stop at a
predetermined position accurately.
5 Air leakage
(When air piping
is used)
Make sure that the air will not leak from
the robot interior or air joints. 2.3.3
6 Controller vent
holes (1) Make sure that no obstacle stands in front of the vent holes.
(2) Make sure that no contaminant is left
in the vent hole.
3.3.1
7 Function of safety
devices Make sure that each safety device connected to the emergency stop
pushbutton switch and external operation
input signal can function properly.
3.3.2
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b) Quarterly (every three (3)-month) inspection
No. Item Inspection procedures Relevant
Para.
1 Lubricated state of
ball screw spline Make sure that the ball screw spline (or tool shaft) is greased completely and that
no rust is developed on it.
2.3.4
c) Semi-annual (every six (6)-month) inspection
No. Item Inspection procedures Relevant
Para.
1 Greasing of ball
screw spline Apply the grease to the ball screw spline. 2.3.4
2 Each axis drive
system Move each axis by hand and make sure that it moves smoothly. 2.3.5
3 Timing belts (1) Make sure that each timing belt is
not worn off or cracked.
(2) Check each timing belt for tension.
2.3.6
d) Annual (every year) inspection
No. Item Inspection procedures Relevant
Para.
1 Lubrication of ball
screw Fill grease to the ball screw spline. 2.3.4
2 Lubrication of
reduction gears Fill grease to the reduction gears from the grease nipples. 2.3.7
3 Wiring and piping Make sure that all cables and air tubes
are in the good state.
4 Replacement of
position detector
batteries
(Be sure to
replace the
batteries every
year.)
Replace the position detector backup
batteries (housed in the robot base unit).
If the running time is long, battery
consumption is small. If the power OFF
time is long, the consumption is large. If
the battery voltage drops, a battery alarm
occurs. Then replace the batteries
immediately.
2.3.8
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e) Overhaul (every five (5) years)
No. Item Inspection procedures Relevant
Para.
1 Inspection of
consumable parts Inspect the flexible cables, reduction gears, ball screw splines, timing belts and
motors, then replace them when
necessary.
2 Battery
replacement
(Replace the
battery every five
(5) years.)
Replace the RAM (controller) backup
battery.
If the running time is long, battery
consumption is small. If the power OFF
time is long, the consumption is large. If
the battery voltage drops, the battery
alarm message saying “1–145 MAIN
Battery alarm” is displayed. Then
replace the battery immediately.
3.3.3
3 Replacement of
switching power
supply unit
(Replace the
battery every five
(5) years.)
As the switching power supply unit uses
an aluminum electrolytic condenser, its
life is limited. Replace the switching
power supply unit (DC5 V, DC24 V) for
preventive maintenance. The life of the
switching power supply unit differs with
load current, running hours and ambient
temperature. If the load current is large,
the running time is long or the ambient
temperature is high, the life becomes
short.
3.3.4
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1.3 Maintenance Tools
We recommend to use the following tools for maintaining the robot and controller.
• Phillips screwdrivers
• Hexagonal wrench set: M3 ~ M8
• Assembly wrench set
• Water pump pliers
• Nippers
• Grease guns
1.4 Maintenance Contract and Repair
1.4.1 Maintenance Contract
With the exception of greasing and lubrication, we recommend that the user
conclude with us an after-sale service contract on the inspection items for
maintenance and inspection to be done semi-annually and after.
1.4.2 Repair
If a fault has occurred or if repair is necessary, turn off the controller power and
contact the Toshiba Machine Service Department. At this time, advise us of the
details of the fault and the following information stated on the robot and controller.
• Robot model
• Manufacture number
• Date of manufacture
• Operating time
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1.4.3 Modification
This robot and controller MUST NOT be modified without the consent from Toshiba
Machine.
!CAUTION
• The user must NEVER replace or modify parts other than those described in
the instruction manual. Otherwise, the performance may deteriorate or faults
or accidents will be caused.
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Section 2 Maintenance of the Robot
2.1 Cautions on Maintenance and Inspection
When performing inspection or maintenance of the robot, strictly observe the following
precautions to protect yourself and coworkers.
! DANGER
• Be sure to turn off the main power switch of the controller before approaching
the robot for maintenance and inspection.
2.2 Layout of Robot Components and Drive Mechanism
The layout of the robot mechanical components is shown in Fig. 2.1 and Fig. 2.2.
The drive mechanism of each axis is described below.
a) Axis 1
The output of axis 1 AC servo motor is input to the reduction gear. The output of
the same gears directly controls the arm 1 motion.
b) Axis 2
The output of axis 2 AC servo motor is input to the reduction gear. The output of
the same gear directly controls the arm 2 motion.
c) Axis 3
The output of axis 3 AC servo motor is input to the ball screw nut through the
timing belt to move the ball screw spline up and down.
d) Axis 4
The rotation of axis 4 AC servo motor is input to the reduction gear and the output
of axis 4 AC servo motor is input to the ball spline nut through the timing belt to
revolve the ball screw spline shaft.
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Air piping 2
Air piping 1 HAND: Hand I/O connector
Air piping 3
Air piping 4
Axis 2 motor
Axis 3 motor
Ball screw spline shaft
Axis 3 belt
Ball screw nut
Arm 2
Ball spline nut
Axis 4 belt
Axis 4
Axis 3
Axis 2
Axis 1
Axis 1 motor
Axis 4 motor
Axis 1 reduction gear
Axis 4
reduction
gear
Arm 1
Axis 2 reduction gear
Robot harness (cable duct)
Clean vacuum air joint
HAND: Hand I/O connector
Axis 3 brake OFF switch
MOTOR: Motor power connector
ENC: Encoder connector
M4 screw hole for grounding
Air piping 4
Air piping 3
Air piping 1
Air piping 2
Fig. 2.1 Layout of robot mechanical components (TH250A, TH350A)
Axis 4 belt Axis 4 motor
Axis 2 motor
Axis 3 motor
Axis 3 belt
Axis 3 motor
Axis 4 reduction gear
Axis 3 belt
Ball screw nut
Arm 2
Ball spline nut
Axis 4 belt
Ball screw spline shaft
Axis 4
Axis 3
Axis 2
Axis 1
Axis 1 motor
Axis 1 reduction gear
Arm 1
Axis 2 reduction gear
Axis 2 motor
Robot harness (cable duct)
HAND: Hand I/O connector
Air piping 1
Air piping 3
Air piping 2
Air piping 4
Clean vacuum air joint
Air piping 2
Air piping 4
ENC: Encoder connector
HAND: Hand I/O connector
MOTOR: Motor power connector
Air piping 3
Air piping 1
Axis 3 brake OFF switch
Fig. 2.2Layout of robot mechanical components (TH180)
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Fig. 2.3Layout of robot mechanical components (TH350A-T)
Air piping 2
Air piping 1
HAND: Hand I/O connector
Air piping 3
Air piping 4
Axis 3 motor
Axis 2 motor
Robot harness
(cable duct)
Axis 4 motor
Ball screw spline shaft
Axis 3 belt
Ball screw nut
Arm 2
Ball spline nut
Axis 1 reduction gear
Axis 1 motor
Arm 1
Axis 2 reduction gear
M4 screw
hole for GND
Air piping 1
Air piping 2
Clean vacuum air joint
HAND: Hand I/O connector
Axis 3 brake OFF switch
MOTOR: Motor power connector
ENC: Encoder connector
Air piping 4
Air piping 3
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2.3 Robot Maintenance Procedures
2.3.1 Check of Cable Duct for Abnormality
a) Visually check to see that the cable duct is not locally twisted, bent or cracked
when the robot moves. If there is any abnormality, replace the cable to
prevent breakage of the cable wire, etc.
b) The connectors securing the cable duct are secured by tightening it to the plate
with a hexagon nut. If the hexagon nut is loosened, tighten it with a pair of
water pump pliers, etc.
Hexagon nut
Robot harness (cable duct)
Hexagon nut
Fig. 2.4Cable duct layout (TH250A, TH350A)
Robot harness (cable duct)
Hexagon nut
Hexagon nut
Fig. 2.5Cable duct layout (TH180)
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Fig. 2.6Cable duct layout (TH350A-T)
Hexagon nut
Robot harness (cable duct)
Hexagon nut
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2.3.2 Check of Hand and Base for Mounting
!DANGER
• Completely tighten the hand clamp bolt. Otherwise, the hand may drop or
shift from a predetermined position.
a) Check of hand set flange (option) for looseness
Make sure, using a hexagonal wrench key, that the hexagon socket head cap
screw of the hand set flange that is tightened to the ball screw spline is not
loosened. Otherwise, tighten it.
Also make sure by means of a hexagonal wrench key that the hexagon socket
head cap screw securing the hand set flange and hand is not loosened.
Otherwise, tighten it.
Fig. 2.7Hand set area
b) Check of basic robot installation bolts
Make sure, using a hexagonal wrench key, that the installation bolts of the robot
base are not loosened. Otherwise, tighten them.
Installation bolt position Installation bolt position
Installation bolt position
Installation bolt position
Fig. 2.8Installation bolt positions
Hexagon socket head cap screw
Hand
20