Toshiba SR Series User manual

STE 73872–0
SR series/TS2000
INSTRUCTION MANUAL
CASSETTE TRANSFER ROBOT
MAINTENANCE
Notice
1. Make sure that this instruction manual is delivered to the
final user of Toshiba Machine's industrial robot.
2. Before installing and operating the industrial robot, read
through and completely understand this manual.
3. After reading through this manual, keep it nearby for future
reference.
May, 2004
TOSHIBA MACHINE CO., LTD.
TOKYO, JAPAN

MAINTENANCE MANUAL
Copyright 2004 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 prior notice to
effect improvements.
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MAINTENANCE MANUAL
PREFACE
This manual describes how to maintain the robot and controller.
Maintenance and inspection are essential to keep the robot performance for a long time,
to prevent failures and to assure safety. Be sure to look through this manual and set
up a maintenance program before actually starting the robot.
This manual is composed of the following sections.
Section 1: Maintenance Items
This section describes the maintenance schedule of the robot and
controller and items required for inspection and maintenance.
Section 2: Maintenance of the Robot
This section refers to the robot structure and items required for inspection
and maintenance of the robot.
Section 3: Maintenance of Controller
This section refers to the robot controller structure and items required for
inspection and maintenance of the controller.
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MAINTENANCE MANUAL
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 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.
Details of the actual danger are indicated with pictures or words in
or near the symbol.
!
This means caution.
The details of the actual caution are indicated with pictures or
words in or near the symbol.
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MAINTENANCE MANUAL
!CAUTION
• Be sure to read through the safety instruction manual provided separately before
starting actual work to assure the safe work covering from the robot installation to
operation.
[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......................................................................... 1–1
1.1 Maintenance Schedule ........................................................................ 1–1
1.2 Items for Maintenance and Inspection................................................. 1–2
1.3 Maintenance Tools............................................................................... 1–4
1.4 Maintenance Contract and Repair ....................................................... 1–5
Section 2 Maintenance of the Robot .............................................................. 2–1
2.1 Cautions on Maintenance and Inspection............................................ 2–1
2.2 Layout of Robot Components and Drive Mechanism........................... 2–1
2.3 Robot Maintenance Procedures .......................................................... 2–3
2.3.1 Check for Vibration and Abnormal Noise................................ 2–3
2.3.2 Check for Lubrication.............................................................. 2–4
2.3.3 Replacement of Position Detector (or Encoder) Batteries...... 2–6
2.3.4 Check for Stainless Belt ......................................................... 2–7
Section 3 Maintenance of Controller .............................................................. 3–1
3.1 Cautions on Maintenance and Inspection............................................ 3–1
3.2 Layout of Controller Parts.................................................................... 3–2
3.3 Maintenance Procedures..................................................................... 3–3
3.3.1 Check for Controller Air Vent Holes........................................ 3–3
3.3.2 Check of Safety Devices for Function..................................... 3–4
3.3.3 Battery Replacement.............................................................. 3–7
3.3.4 Replacement of Switching Power Supply Unit........................ 3–9
3.3.5 Replacement of Fuse (X8HN, X8HI Printed Boards).............. 3–12
3.3.6 Replacement of Output ICs (X8HN, X8HI Printed Boards)..... 3–14
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MAINTENANCE MANUAL
Page
Appendix Table 1 List of Mechanical Replacement Parts for Maintenance. 4–1
Appendix Table 2 List of Controller Replacement Parts for Maintenance ... 4–3
Appendix Drawing 1 Component Connection Diagram ................................... 4–4
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MAITENANCE MANUAL
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.
0
3-month check
3-month check 6-month check
3-month check
3-month check 6-month check
3-month check
3-month check 6-month check
3-month check
3-month check 6-month check
1-year check
1-year check
Overhaul (every 5 years)
1200
2400
3600
4800
6400
7200
8400
9600
24000
(h)
Daily inspection
Running hours
(h)
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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MAITENANCE MANUAL
1.2 Items for Maintenance and Inspection
This section describes the items for maintenance and inspection. For the execution
procedures, see the relevant paragraph listed in the table below.
a) Daily inspection
No. Item Inspection procedures Relevant
Para.
1 Robot harness
and cable duct Make sure that no local torsion or curve is caused in the robot harness and cable
duct during robot operation.
Also, make sure that the robot harness is
tightened completely.
2.3.1
2 Robot installation
bolts Make sure that the robot base installation bolts are tightened completely. 2.3.1
3 Vibration and
noise Make sure that each axis can move smoothly. 2.3.1
4 Change in
positioning
accuracy
Make sure that the robot can stop at a
predetermined position accurately.
5 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
6 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
b) Quarterly (every three (3)-month) inspection
No. Item Inspection procedures Relevant
Para.
1 Lubricated state of
ball screw and
linear guide
Make sure that the ball screw and linear
guide of each axis is greased completely
and that no rust is developed on them.
2.3.2
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c) Semi-annual (every six (6)-month) inspection
No. Item Inspection procedures Relevant
Para.
1 Orthogonal axis
stainless belt Make sure that the orthogonal axis stainless belt is tightened completely and
that it is not damaged and in a good
shape.
2.3.4
2 Each axis drive
system Move each axis by hand and make sure that it moves smoothly. 2.3.1
3 Timing belts (1) Make sure that each timing belt is not
worn off or cracked.
(2) Check each timing belt for tension.
d) Annual (every year) inspection
No. Item Inspection procedures Relevant
Para.
1 Greasing Apply the grease to each axis ball screw
and linear guide. 2.3.2
2 Wiring Check for the state of the cables and
connectors. 2.3.1
e) Battery replacement
No. Item Inspection procedures Relevant
Para.
1 Replacement of
position detector
battery
(Replace the
battery every
three (3) years.)
Replace the position detector backup
batteries (housed in the pool box under
the orthogonal axis).
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 lamp flickers. Replace the battery
immediately.
2.3.3
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MAITENANCE MANUAL
f) Overhaul (every five (5) years)
No. Item Inspection procedures Relevant
Para.
1 Inspection of
consumable parts Inspect the ball screws, linear guides, flexible cables, reduction gears, bearings
and motors and 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 lamp illuminates. Replace the
battery immediately.
Alarm message: "MAIN Battery alarm"
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. If the ambient
temperature is high, the life becomes
short.
3.3.4
1.3 Maintenance Tools
We recommend to use the following tools for maintaining the robot and controller.
• Phillips screwdrivers
• Hexagonal wrench set: M3 ~ M10
• Assembly wrench set
• Water pump pliers
• Nippers
• Grease guns
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MAITENANCE MANUAL
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
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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MAINTENANCE MANUAL
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.
a) Axis 1
The output of axis 1 AC servo motor is input to the reduction gear via the spur
gear. The output of the reduction gear directly controls the arm 1 motion.
b) Axis 2
The output of axis 2 AC servo motor is input to rotate the ball screw to move
the slider.
c) Axis 3
The output of axis 3 AC servo motor is input to the reduction gear to move the
vertical axis up and down.
d) Axis 4
The output of axis 4 AC servo motor is input to the reduction gear via the timing
belt. The output of the reduction gear controls the axis 4 hand rotation.
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Hand Solenoid valve
Chuck
Axis 4 reduction gear
Axis 4 motor
Axis 1 reduction gear
Axis 1 motor
Axis 3 reduction gear
Axis 3 motor
Axis 2 motor
Manifold
For scavenging
Air pressure supply
Air return
Pool box
Fig. 2.1 Layout of robot mechanical components
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MAINTENANCE MANUAL
2.3 Robot Maintenance Procedures
2.3.1 Check for Vibration and Abnormal Noise
1) Approach the robot and its peripheral equipment outside the predetermined
operating range and make sure that no abnormal noise of operation is heard.
Otherwise, locate the source of the abnormal noise.
When necessary, turn off the power of the robot and its peripheral equipment
and manually move the part suspected to be the trouble source to confirm
that the abnormal noise is heard from it.
If the abnormal noise is heard from the ball screw and linear guide,
contaminant has possibly entered them, or they have run out of grease. For
the former cause, remove the contaminant and make sure that other parts are
not damaged. For the latter cause, apply grease.
2) If chattering is caused in the cover, etc., make sure that all screws are
tightened completely and that relevant parts are not deformed. Otherwise,
completely tighten the screws or repair the parts as necessary.
3) Make sure that the screws of each arm joint are tightened completely.
Otherwise, tighten the screws completely.
4) Possible causes other than the above-mentioned are the wrong method of
use, controller-related cause, etc. In either case, adjustment is not easy.
Consult us at the after-sale service agent in your territory.
!DANGER
• When nearing the robot in the servo-free status, be sure to carry out the work by
two (2) persons. One person should carry out the work while the other is
monitoring the work outside the hazardous zone. The latter person should
watch the work and be ready to press the emergency stop switch if any
abnormality occurs.
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2.3.2 Check for Lubrication
1) Check of ball screw and linear guide for lubrication state
Make sure that the ball screw and linear guide of each axis are greased
sufficiently and that no rust has developed on them. If they have run out of
grease, fill it.
!CAUTION
• NEVER mistake the kind of grease. Otherwise, the robot performance will
deteriorate or the robot will malfunction.
• After you touched the ball screw, ball screw spline or linear guide by hand, be
sure to fill the grease. Otherwise, rust will develop on it.
2) Greasing
Use the following grease for the orthogonal axes.
LG2 (NSK)
To grease the orthogonal axes, observe the following procedures.
i) Dismantle the stainless belt.
Grease each linear guide from the grease nipple attached to the slider.
ii) Greasing of linear guide:
Fill the grease from the clearance between the frame and frame cover,
taking careful precautions on the bent-up of the stainless belt.
iii) Greasing of ball screw
Fill the grease to the roller surface of the ball screw shaft from the clearance
between the frame and frame cover.
iv) Restretching of stainless belt:
Restretch the stainless belt according to the predetermined procedures.
The greasing volume is as follows:
• Ball screw ··· Approx. 5 g
• Linear guide ··· Approx. 15 g (per slider)
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For the greasing procedures of the orthogonal axes, see Section 6 of the
COMPO Arm Axis Instruction Manual provided separately.
The axis 2 reduction gear is of an oilless type and need not be greased.
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MAINTENANCE MANUAL
2.3.3 Replacement of Position Detector (or Encoder) Batteries
To back up the data of the position detector attached to each motor, batteries
(lithium dry batteries) are used. Replace the batteries every three (3) years.
If the controller has detected the battery voltage drop alarm, replace the batteries
at an early stage.
For the battery replacement, observe the following procedures according to the
battery power ON time.
If the batteries are replaced after they are turned on for more than one (1) hour,
start with Step 2). If the battery power ON time is one (1) hour or less, start with
Step 1).
1) Turn on the main power of the controller for more than one (1) minute.
2) Turn the power off.
3) Remove the pool box cover.
4) A battery box is housed in the pool box or cover.
5) Remove the battery box cover inside, then the batteries.
6) Set three (3) new batteries within five (5) minutes, taking care of the "+" and
"–" polarities.
When the lithium battery is used, disconnect it from the connector (BATT) and
set a new battery.
7) Set the battery box cover, then the pool box cover.
!CAUTION
• Batteries should be disposed of according to the user's in-house regulations.
• NEVER drop the batteries into fire. NEVER short-circuit, charge,
disassemble or heat them. Otherwise, liquid leakage or rupture may be
caused.
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MAINTENANCE MANUAL
2.3.4 Check for Stainless Belt
Make sure that the X-axis stainless belt is not loosened and not damaged at all.
To restretch the belt, observe the following procedures.
1) Use the following stainless belt.
Material : SUS301–H
Belt width : 40 mm ±0.1 mm (Alignment is necessary.)
Maker : Dymco Ltd.
Full length : Belts which are 100 mm longer than the full length of the
orthogonal axis are used at a rate of two (2) pcs. per
axis.
2) Move the slider of an axis requiring change of the stainless belt to the stroke
center.
Remove the belt keepers on the motor side (lower side, pool box side) and
joint the end of this belt with that of a new belt.
Caution: The surface of the stainless belt having burr of surface machining
should be the front side.
3) Remove the belt cover and belt keepers on the anti-motor side, then carefully
roll the stainless belt. When the new stainless belt has reached the end of
the anti-motor side, passing through the slider, peel off the jointed tape to
separate the belts.
4) Align the end of the stainless belt on the motor side with the frame end, and
temporarily clamp them with the belt keepers. Align both ends of the
stainless belt with the frame according to the scribed lines, then secure the
belt on the motor side.
5) Secure the stainless belt while pulling the belt on the anti-motor side by the
force of 14.7 (1.5 kg) and aligning it with the scribed line on the frame.
6) Bend the stainless belt projecting from the shaft and hold it with the belt
cover.
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MAINTENANCE MANUAL
Section 3 Maintenance of Controller
3.1 Cautions on Maintenance and Inspection
When performing maintenance and inspection of the controller, follow the items
given below so that the work can be carried out safely.
!CAUTION
• Before removing the controller cover for maintenance or inspection, be sure to
turn off the main power switch of the controller.
Also, turn off the power breaker when connecting or disconnecting the power
cable.
• DO NOT touch the servo driver for at least two (2) minutes after the main power
switch is turned off. The large-capacity capacitor in the servo driver may be
charged with voltage, and touching the servo driver could lead to electric
shocks.
• DO NOT disconnect the battery connector at other than battery replacement.
Otherwise, files saved in the memory may be lost.
!DANGER
Be sure to turn off the main power switch. If the main power switch remains ON,
the servo power printed board, servo printed board and switching power supply are
charged, and touching them could lead to electric shocks.
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