Toshiba THP700-IP User manual

STE85336-0
THP700-IP/TS3100
INSTRUCTION MANUAL
DUST- & DRIP-PROOF TYPE
INDUSTRIAL ROBOT SPECIFICATIONS
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.
April 2011
TOSHIBA MACHINE CO., LTD.

DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
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Copyright 2011 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.

DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
Preface
This manual describes the specifications of the THP700 dust- and drip-proof type industrial
robot.
This manual is 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.
Precautions on Safety
Important information on the robot and controller is noted in the instruction manual to
prevent injury to the user and persons nearby, prevent damage to assets and to ensure
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 major 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 treatment.
*2) Physical damage refers to major fires due to destruction of assets or resources.
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DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
[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 and caution.
The details of the actual caution are indicated with pictures or
words in or near the symbol.
[Maintenance and inspection]
Be sure to observe the following items to use this product 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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DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
This manual is comprised of the following seven (7) sections:
Section 1 Specifications
This section describes the basic specifications and names of respective parts
for the dust- and drip-proof type industrial robot.
Section 2 Transportation
This section describes how to remove the dust- and drip-proof type robot from
its box and how to transport it to the installation site. This section also deals
with the precautions to be taken when the robot is to be stored temporarily
after unpacked.
Section 3 Installation
This section discusses the dust- and drip-proof type robot installation
environment, space requirements, and how to install the robot.
Section 4 Tool Interface
This section discusses how to connect the cables and pipelines for the tool of
the dust- and drip-proof type robot.
Section 5 Maintenance
This section describes the structure of the dust- and drip-proof type robot and
all items required for the maintenance and inspection of the same robot.
Section 6 Cleaning of Robot Body
This section describes the precautions to be taken when the robot body is to
be cleaned and washed.
Section 7 Replacement Parts for Maintenance
This section explains the replacement parts for the maintenance.
Section 8 Optional Parts
This section explains the optional parts.
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DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
Table of Contents
Page
1. Specifications........................................................................................................7
1.1 Name of Each Part.......................................................................................7
1.2 Outer Dimensions .......................................................................................8
1.3 Specifications Table..................................................................................10
2. Transportation.....................................................................................................11
2.1 Unpacking..................................................................................................11
2.2 Transportation...........................................................................................12
2.2.1 Mass and Outer Dimensions ................................................................12
2.2.2 Transporting the Robot.........................................................................13
3. Installation ...........................................................................................................15
3.1 Installation Environment...........................................................................15
3.2 Ingress Protection (IP) Class of Dust- and Drip-Proof Specification....16
3.3 Air Purge....................................................................................................17
3.4 Coordinate System....................................................................................18
3.5 Installing the Robot...................................................................................19
4. Tool Interface.......................................................................................................20
4.1 Tool Wiring.................................................................................................20
4.1.1 How to Connect Connectors.................................................................21
4.2 Tool Air Piping...........................................................................................27
5. Maintenance.........................................................................................................28
5.1 Maintenance and Inspection Items..........................................................28
5.1.1 Inspection in Power-Off State (Non-operating State)............................28
5.2 Layout of Robot Components..................................................................29
5.3 Tools and Supplies for Maintenance .......................................................30
5.4 Replacing Bellows.....................................................................................30
5.4.1 Replacing Lower Bellows .....................................................................31
5.4.2 Replacing Upper Bellows .....................................................................32
5.5 Mounting and Dismounting Covers.........................................................34
5.5.1 Base Cover...........................................................................................34
5.5.2 Arm 1 Covers .......................................................................................36
5.5.3 Arm 2 Cover .........................................................................................37
6. Cleaning Robot Body..........................................................................................39
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7. Replacement Parts for Maintenance..................................................................40
7.1 Replacement Parts List for Maintenance ................................................40
8. Optional Parts......................................................................................................41
8.1 List of Optional Parts................................................................................41
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1. Specifications
1.1 Name of Each Part
The names of respective parts of the dust- and drip-proof type robot are shown in Fig.
1.1 below.
Fig. 1.1 Name of each part
A
xis 4
(rotation)
Battery box
A
xis 3
(vertical)
Tool flange
Wiring panel
A
rm 1
A
xis 2
(rotation)
A
xis 1
(rotation)
Cover
Base
Bellows
Ball screw spline
(tool shaft)
Bellows
A
rm 2
Z
Cannon
connector CN0
Motor drive cable
Spare (clamp)
A
ir purge joint
With speed controller
Quick-operated joint (φ8)
Spare (clamp)
Quick-operated
j
oint for air tube
(φ6) 4 places
Hand air joint
(4×M5)
Details of wiring panel
When viewed from arrow-mark Z
Brake OFF
switch
Motor brake cable
Hand I/O cable Encoder
cable

DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
1.2 Outer Dimensions
Fig. 1.2 shows the outer dimensions and Fig. 1.3 shows operating range of the robot.
Hand air joint: For 4×φ 6 tube
Hand I/O connecto
r
Brake OFF switch
Z-axis stroke 300 mm
Z-axis stroke 150 mm
Z150: Upper limit
Z300: Upper limit
Z-axis stroke
Option: Z-axis stroke
Space required for cable connection
Z150: Origin Z300: Origin
Fig. 1.2 Outer dimensions of the robot
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(
Axis
1
operating range
)
(A
x
i
s
2
operat
i
ng range
)
(A
x
i
s
2
operat
i
ng range
)
(A
x
i
s
1
operat
i
ng range
)
Fig. 1.3 Operating range of the robot
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1.3 Specifications Table
Item Specifications
Structure Horizontal multi-joint type SCARArobot
Model THP700-IP
Ingress protection (IP) class of dust- and
drip-proof structure IP65 (*1)
Applicable controller TS3100 (*2)
Mass of robot body 58 kg
No. of controlled axes 4
Arm length 700 mm (350+250)
Axis 1 1500 (W)
Axis 2 1000 (W)
Axis 3 400 (W)
Motor capacity
Axis 4 400 (W)
Axis 1 ±120 (deg)
Axis 2 ±145 (deg)
Axis 3 150 (mm) [Option: 300 (mm)]
Operating range
Axis 4 ±340 (deg)
Axis 1 340 (deg/s)
Axis 2 600 (deg/s)
Axis 3 2050 (mm/s)
Axis 4 1800 (deg/s)
Maximum speed (*3)
Composite speed
of axes 1 and 2 7.8 (m/s)
Rated payload mass 2 (kg)
Maximum payload mass 10 (kg)
Permissible load inertia (*3) 0.1 (kg·m2)
X, Y ±0.015 (mm)
Z ±0.01 (mm)
Repeatability (*4) C ±0.01 (deg)
Cycle time (*5)
(When payload mass is 2 kg) 0.345 (sec) 120 cycles/min
Drive system By means of AC servo motors
Position detection method Absolute
*1: For details of the IP class, see Para. 3.2.
*2: The structure of the robot controller is not dust- and drip-proof.
*3: When the mass of load exceeds 2 kg, or when the gravity center position of load is away from the axis
4 center position, both the speed and acceleration should be reduced, using the PAYLOAD command.
*4: The ambient temperature is predetermined at 20°C.
*5: Shuttle time for rough positioning in horizontal direction of 300 mm and vertical direction of 25 mm.
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!CAUTION
If possible, movement of Axes 1, 2, and 4 should be performed while the Z-axis
(Axis 3) is in the raised position.
Moving Axis 1, 2, or 4 while the Z-axis is lowered can result in premature
damage to the ball screw spline (Z-axis shaft).
If Axis 1, 2, or 4 must be moved while the Z-axis is lowered due to unavoidable
circumstances, use the SPEED and ACCEL/DECEL/PAYLOAD commands to
adjust the operating speed and acceleration so that the ball screw spline does
not vibrate.
When moving Axis 1, 2, or 4 while the Z-axis is lowered, pay careful attention to
ensure that no collision occurs with obstacles or other objects.
Even if Axis 1, 2, or 4 is moved at low speed, a collision with an obstacle or
other mishap can cause damage to the ball screw spline (Z-axis shaft) before
an alarm occurs.
2. Transportation
2.1 Unpacking
The robot and controller are shipped separately in wooden crates or corrugated
cardboards.
Open the packages in a location easily accessible, where the equipment is to be
installed. Take careful precautions not to damage the robot and controller.
After opening the packages, make sure that all the accessories are present and that no
part has been damaged during transport.
The package posture and contents are the same as in the standard robot. See the
THP700 Installation and Transportation Manual provided separately.
For the dust- and drip-proof type robot, strictly observe the following cautions.
!CAUTION
• The main robot is factory-packed in a vinyl bag for shipment. Carefully
remove the bag after the shipment has reached your office. If the vinyl bag
is pulled by force, the bellows or cover may be damaged.
• Note that if the controller power is turned on while the robot is still in the
shipping position, an interference zone error (4-033 Interfere Error) will
occur. However, this is not a malfunction.
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DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
2.2 Transportation
Move the robot and controller very carefully. Make sure that no excessive impact or
vibration is exerted on the equipment. If the equipment is to be subject to vibration
over a long period, be sure to tighten all of the clamp and base set bolts completely
and put the equipment back into the wooden crates or corrugated cardboards.
2.2.1 Mass and Outer Dimensions
The mass and outer dimensions of the robot are shown in Fig. 2.1.
Mass of main robot = 58 kg
When Z-axis stroke is 300 mm When Z-axis stroke is 150 mm
Fixture
Fig. 2.1 Outer dimensions at transport
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2.2.2 Transporting the Robot
The dust- and drip-proof type robot equals the standard robot added with a cap and
bellows. The precautions to be taken at transport are stated below. The precautions
other than the below are the same as in the standard robot. See the THP700
Installation and Transportation Manual provided separately.
Fig. 2.2 Robot handling prohibited areas
After the installation, remove the clamp and eyebolt used for transport.
DO NOT hold
the bellows.
DO NOT hold
the bellows.
DO NOT hold the tool flange
and ball screw spline shaft.
DO NOT
connecto
DO NOT hold
the arm 2 cover.
DO NOT hold the
cable duct.
Handling area
(shaded area
hold the
rs.
s
s)

DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
!CAUTION
• When lifting up the robot by workers, hold the shaded locations by hands, as
shown in Fig. 2.2. If the ball screw spline shaft is held by hands, an
unusually large force is exerted, resulting in a malfunction.
• If the bellows is held or gripped by hands, it may be broken due to friction
with the parts inside.
• When carrying the robot by workers, take careful precautions to prevent
their hand or leg from being caught in the robot.
• The work should always be performed by two (2) or more workers.
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DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
3. Installation
3.1 Installation Environment
Table 3.1 shows the environmental conditions for the location in which the robot and
controller are to be installed.
Table 3.1 Environmental conditions for robot and controller
Item Specifications
In operation : 0 to 40°CTemperature In storage : –10 to 50°C
Humidity 20 to 90 % (Non-condensing)
Altitude 1000 m or less
Vibration In operation : 0.98 m/s2or less
Dust No inductive dust should exist.
Gas No corrosive or combustible gas should exist.
Sunlight The robot and controller should not be exposed to direct sunlight.
Power noise A heavy noise source should not exist nearby.
Magnetic field A heavy magnetic field source should not exist nearby.
Dust-proof and
drip-proof Any place where the equipment sinks in liquid shall not exist. Small chips involved in turning or cutting operation shall not be
contained.
Mist of cutting fluid or coolant oil shall not be contained.
!DANGER
• Do not place the robot or controller near combustible. Doing so could lead
to fires if it ignites due to a fault, etc.
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DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
3.2 Ingress Protection (IP) Class of Dust- and Drip-Proof Specification
For the dust- and drip-proof specification of THP700, the ingress protection (IP) class
against dust and water is IP65 or equivalent.
Be sure to perform air purge. Under some operating environment, water or dust may
enter.
I P 6 5
Ingress protection class against water infiltration: 5
Water jetting from a desired angle shall not cause harmful adverse
effects.
Jetting water pressure: 30 kPa (30 kN/m2=: 0.3 kgf/cm2)
Flowrate: 12.5 L/min
Distance from nozzle: 2.5 ~ 3 m
Duration: Three (3) minutes
IP class against solid contaminant: 6
No dust shall enter the inside.
Protection characteristic symbol: IP
!WARNING
• DO NOT use the entire robot or part of the robot sinking in water. Otherwise, the
water will enter the robot interior.
• DO NOT use the robot in an environment exceeding the specified IP class against
water and dust. Otherwise, the water or dust may enter the robot interior,
resulting in shortening of the robot life, deterioration of operating accuracy or
mis-operation of the robot.
• The robot controller does not have dust- and drip-proof specification.
• For the drip-proof ability against other than water, consult us.
• The bellows may discolor under some operating environment, which poses no
problem, however, to the dust- and drip-proof performance.
• Be sure to perform air purge. Otherwise, the dust- and drip-proof performance will
drop.
• The dust- and drip-proof specification does not mean the explosion-proof structure.
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DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
3.3 Air Purge
The dust- and drip-proof type robot is provided with an air supply port for air purge in its
base connector unit. See Para. 1.1. (Quick-operated joint with speed controller)
By feeding air into the air supply port, entry of dust into the robot can be prevented.
The air supply unit (reducer or pressure reducing valve, air filter, etc.) and air tube (8
mm-dia.) should be provided by the customer.
• Air specifications
Maximum operating pressure: 0.58 MPa (6 kgf/cm2)
Tube size: Outer dia. 8 mm ×Inner dia. 5 mm
Fluid used: Fresh dry air not containing compressor oil, etc.
Filtration accuracy of air filter 10 µm or less
• How to regulate flowrate
Fully close the speed controller attached to the robot base connector unit.
Set the pressure to 0.3 MPa ~ 0.58 MPa (maximum pressure), using a regulator (or
pressure reducing valve: to be provided by the customer), then connect the air tube.
Turn the needle of the speed controller counterclockwise from the fully closed state
to increase the flowrate. Regulate the flowrate while observing the bellows
condition and tighten the lock nut of the speed controller.
If the air volume fed is too much, the bellows will swell out. Regulate the air to just
before the bellows starts expanding.
Speed controller
Lock nut
Tube insertion hole
(φ8 mm) Needle
Close (Flowrate decreases.)
Open (Flowrate increases.)
!CAUTION
• Be sure to use fresh dry air. Otherwise, the robot interior will condense and water
stays there, resulting in an electric leak or malfunction.
• DO NOT increase the pressure exceeding the specified maximum pressure.
Otherwise, the seal, etc. of each joint will be broken to damage the dust- and
drip-proof performance.
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3.4 Coordinate System
The robot's joint angle origin (0° or 0 mm position) is factory-calibrated according to the
base reference planes. Fig. 3.1 shows the base coordinate system (XB, YB, ZB) and
origin of each axis joint angle.
Fig. 3.1 Base coordinate system and joint angle origin
Z-axis stroke
Option: Z-axis stroke
Z-axis stroke 300 mm
Z-axis stroke 150 mm
Origin of base coordinate
system
When Z-axis stroke is 150 mm
Origin of base
coordinate system
When Z-axis stroke is
300 mm
（-）
（+）
Reference surface Reference surface
A
xis 2
A
xis 1
A
xis 4
（+）
（-）
XB
（+）
（-） （-）
（+）
YB
Z300: Origin
Z150: Origin
Z150: Upper limi
t
Z300: Upper limi
t

DUST- & DRIP-PROOF TYPE SPECIFICATIONS MANUAL
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3.5 Installing the Robot
The robot is secured, using the set holes on the base (four (4) places).
Use M12 hexagon socket head cap screws.
The robot installation method is shown in Fig. 3.3. The reference surfaces are
provided on the base.
When you wish to adjust the robot position in the base coordinate system, or replace
the robot with another one, provide appropriate reference surfaces and secure the
robot by applying them to the reference surfaces of the base.
!CAUTION
• The robot will suddenly accelerate and decelerate during operation. When
installing it on a frame, make sure that the frame has sufficient strength and
rigidity.
If the robot is installed on a frame that does not have sufficient rigidity,
vibration will occur while the robot is operating, and could lead to faults.
When the robot is installed on the floor, secure it completely with anchor
bolts, etc.
• Install the robot on a level place. Failure to do so could lead to a drop in
performance or faults.
Fig. 3.2 Installation method
Detail of robot set hole
(4 locations)
Reference surface
Hexagon socket
head cap screw
M16
Robot bottom view