Toshiba THP700 User manual

STE 85320–2
INSTRUCTION MANUAL
INDUSTRIAL ROBOT
TRANSPORTATION AND INSTALLATION MANUAL
Notice
•Make sure that this instruction manual is delivered to the final
user of Toshiba Machine’s industrial robot.
•Before operating the industrial robot, read through and
completely understand this manual.
•After reading through this manual, keep it nearby for future
reference.
January, 2011
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN
TH
P700/TS3100

TRANSPORTATION AND INSTALLATION MANUAL
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.
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TRANSPORTATION AND INSTALLATION MANUAL
Preface
This manual describes the basic specifications of the industrial robot and controller, and
how to unpack and install them. Specifically, it describes how to unpack the shipment
containing the equipment, how to install the equipment, how to connect wiring and air
piping, and how to attach tools. Be sure to look through this manual before unpacking
the shipment.
Before beginning the work according to this manual, read through the Safety Manual so
that you can understand the safety measures.
This manual is divided into the following five (5) sections:
Section 1 Specifications
This section describes the basic specifications and names of respective units
of the robot and controller.
Section 2 Transportation
This section describes how to remove the robot and controller from their
boxes and how to transport them to the installation site. This section also
discusses how to temporarily store the equipment after unpacking the
shipment.
Section 3 Installation
This section discusses the equipment installation environment, space
requirements, and how to install the equipment.
Section 4 System Connections
This section describes how to connect the robot, controller and peripheral
equipment.
Section 5 Tool Interface
This section describes how to connect the tool to the robot arm and how to
connect pipes and wires to the tool. This section also discusses maximum
permissible loads of the tool.
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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 lead to
fatalities or major injuries".
! WARNING
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 treatment.
*2) Physical damage refers to major fires 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).
The 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).
The 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 are indicated with pictures or words in or near the
symbol.
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!
CAUTION
• Always read through the Safety Manual provided separately before starting
actual work to ensure safety work covering from the robot installation to
operation.
[Installation and transportation]
Always observe the following items to safely use the robot.
!
DANGER
Prohibited
• DO NOT install or operate if any parts are damaged or
missing.
Doing so could lead to electric shocks, fires or faults.
• DO NOT install the robot where it may be subject to fluids
such as water. Doing so could lead to electric shocks, fires
or faults.
• Do not place the robot near combustible matters. Doing so
could lead to fires if the matter ignites due to a fault, etc.
Mandatory
• Always secure the robot with the attached clamps before
transporting it. Failure to do so could lead to injuries if the
arm moves when the robot is suspended.
• Wire the robot after installation.
Wiring the robot before installation could lead to electric
shocks or injuries.
• Always use the power voltage and power capacity designated
by Toshiba Machine. Failure to do so could lead to device
faults or fires.
• Always use the designated power cable. Using a cable other
than that designated could lead to fires or faults.
Always
ground
• Completely connect the grounding cable. Failure to do so
could lead to electric shocks or fires if a fault or fault current
occurs. Noise could lead to malfunction.
Also, it could cause mis-operation by noise.
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!CAUTION
Prohibited
• NEVER lift the robot by the arm 2 cover or arm 2. Doing so
will apply an excessive force on the robot's mechanism
section and could lead to faults.
• For the controller, secure the ample space for air vent.
Heating of controller could lead to malfunction.
Mandatory
• When lifting the robot, lift it up slowly. The robot will tilt
slightly, so lifting it up suddenly could be hazardous.
• When storing the robot, secure it to the base. The robot will
be unstable if just set down, and it could tilt over.
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Table of Contents
Page
1. Specifications ...........................................................................................................9
1.1 Robot Configuration Diagram..........................................................................9
1.2 Name of Each Part........................................................................................10
1.3 External Dimensions......................................................................................11
1.4 Specifications Table ......................................................................................12
2. Transportation ........................................................................................................14
2.1 Unpacking......................................................................................................14
2.2 Transportation ...............................................................................................15
2.2.1 Mass and Dimensions.......................................................................15
2.2.2 Transporting the Robot .....................................................................16
2.2.3 Transporting the Controller................................................................18
2.3 Storage..........................................................................................................19
2.3.1 Storage Precautions for the Robot....................................................19
2.3.2 Storage Precautions for the Controller..............................................19
3. Installation ..............................................................................................................20
3.1Installation Environment................................................................................20
3.2 Robot Installation...........................................................................................21
3.2.1 External Dimensions and Working Envelope....................................21
3.2.2 Coordinate System............................................................................23
3.2.3 Installing the Robot ...........................................................................24
3.3 Installing the Controller..................................................................................25
3.3.1 External Dimensions .........................................................................25
3.3.2 Precautions for Direct Installation......................................................26
3.3.3 Rack Mounting Dimensions...............................................................27
3.3.4 Precautions for Rack Mounting.........................................................27
3.4 Precautions for Handling the Teach Pendant................................................29
3.5 Safety Measures............................................................................................30
4. System Connections...............................................................................................31
4.1 Cable Wiring..................................................................................................31
4.1.1 Connector Arrangement on the Controller ........................................31
4.1.2 Connecting the Power Cable “ACIN”
(of Fig. 4.1) (Plug connector attached)..........................................32
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4.1.3 Connecting the Motor Cable “MOTOR” (of Fig. 4.1) (Cable attached)
..........................................................................................................33
4.1.4 Connecting the Encoder Cable “ENC” (of Fig. 4.1) (Cable attached)34
4.1.5 Connecting the Robot Control Signal Cable “HAND” (of Fig. 4.1)
(Cable: option)...................................................................................34
4.1.6 Connecting and Disconnecting Cables .............................................34
4.1.7 Examples of Connector Terminal Arrangement................................36
4.2 Controller Connector Signals.........................................................................39
4.2.1 Connector Signal Connection Diagrams...........................................39
4.2.2 Jumpers for Safety Related Signals..................................................39
4.3 Separating Control Panel from Controller......................................................41
4.3.1 Removing Control Panel ...................................................................41
4.3.2 Cable between Controller and Control Panel....................................41
4.3.3 Control Panel Mounting Dimensions.................................................42
4.3.4 Mounting Dummy Panel on Controller ..............................................43
5. Tool Interface .........................................................................................................45
5.1 Mounting Tool................................................................................................45
5.2 Tool Wiring and Piping ..................................................................................46
5.2.1 Tool Signals (Controller Side) ...........................................................46
5.2.2 Tool Wiring........................................................................................50
5.2.3 Tool Air Piping...................................................................................60
5.3 Permissible Load Conditions and Program Setting.......................................62
5.3.1 Permissible Load Conditions.............................................................62
5.3.2 Load Conditions and Program Setting ..............................................63
5.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration
for Load Conditions...........................................................................67
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Tables and Drawings
Page
Fig. 1.1 Robot Configuration Diagram...............................................................................9
Fig. 1.2 Name of each part..............................................................................................10
Fig. 1.3 External dimensions of the robot........................................................................11
Fig. 2.1 Packaging state..................................................................................................14
Fig. 2.2 Outer dimensions at transport............................................................................15
Fig. 2.3 Lifting up the robot .............................................................................................16
Fig. 2.4 Lifting up the robot .............................................................................................17
Table 3.1 Environmental conditions for robot and controller...........................................20
Fig. 3.1 External view and working envelope..................................................................22
Fig. 3.2 Base coordinate system and joint angle origin...................................................23
Fig. 3.3 Installation method.............................................................................................24
Fig. 3.4 External view of controller..................................................................................25
Fig. 3.5 Controller ventilation space................................................................................26
Fig. 3.6 Screw hole dimensions for securing controller...................................................27
Fig. 3.7 Removing upper cover.......................................................................................28
Fig. 3.8 Clearance of controller front side.......................................................................29
Fig. 4.1 Robot controller connector arrangement............................................................31
Table 4.1 Power supply specifications............................................................................32
Fig. 4.2 Robot side connector arrangement....................................................................33
Fig. 4.3 Connecting and disconnecting a circular connector...........................................35
Fig. 4.4 Connecting and disconnecting a square connector ...........................................35
Fig. 4.5 Removing control panel......................................................................................41
Fig. 4.6 Control panel mounting dimensions...................................................................42
Fig. 4.7 Mounting dummy panel......................................................................................43
Fig. 4.8 Cable connections of dummy panel and control panel.......................................44
Fig. 5.1 Tool mounting dimensions.................................................................................45
Fig. 5.2 Wiring to PLC, etc..............................................................................................51
Fig. 5.3 Tool wiring..........................................................................................................54
Fig. 5.4 Tool wiring（Type-N）.......................................................................................55
Fig. 5.5 Tool wiring（Type-P）.......................................................................................56
Fig. 5.6 Example of hand cable wiring ........................................................................57
Fig. 5.7 Example of hand cable wiring ........................................................................58
Fig. 5.8 Example of hand cable wiring ........................................................................59
Fig. 5.9 Tool air piping.....................................................................................................61
Table 5.1 Permissible load conditions.............................................................................62
Fig. 5.10 Robot tool.........................................................................................................62
Fig. 5.11 Setting of maximum speed and acceleration/deceleration in relation
to load mass ....................................................................................................67
Fig. 5.12 Setting of maximum speed and acceleration/deceleration in relation to
gravity center offset (Axes 1 and 2).................................................................68
Fig. 5.13 Setting of maximum speed and acceleration/deceleration in relation to
gravity center offset (Axes 3 and 4).................................................................69
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1. Specifications
1.1 Robot Configuration Diagram
Fig. 1.1 Robot Configuration Diagram
Operation panel
Split type (option)
PC (obtained by customer)
Program support software
TSPC (option)
TCPRGOS (option)
Teach pendant
(option)
TP cable
THP700
Robot unit
Robot controller
TSPC
communication
cable (obtained
by customer)）
THP700
robot unit
Cable between
robot and controller
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1.2 Name of Each Part
Fig. 1.2 shows the name of each part of the robot.
Fig. 1.2 Name of each part
Ball screw spline
(tool shaft)
Arm 2
Arm 1
Cover
Axis 2 (rotation)
Axis 1
(rotation)
Axis 3
(vertical
movement
)
Eyebolt
Battery box
Wiring panel
(base side)
Axis 4
(rotation)
Base
D-SUB connector
Spare (grommet)
Brake OFF switch
4xM5
Air joint for hand
Wiring panel (base side)
Hand I/O cable
Motor brake cable
Encoder cable
Air joint for φ6 mm
tube
Spare (grommet)
Motor power cable
Spare (clamp)
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1.3 External Dimensions
Fig. 1.3 refers to the external dimensions of the robot.
Fig. 1.3 External dimensions of the robot
Air joint for hand 4 x M5
Hand I/O connector
765 (Z-axis stroke at 300 mm)
Standard
stroke
Space for cable connection
Brake OFF switch
Option stroke
Z-stroke at 300 mm
615 Z-axis stroke 150 mm
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1.4 Specifications Table
Item Specifications
Structure Horizontal multi-joint type SCARA robot
Model THP700
Applicable controller
TS3100
Mass of robot body 57 kg
No. of controlled axes 4
Arm length 700 mm (350 mm + 350 mm)
Motor capacity
Axis 1 1500 (W)
Axis 2 1000 (W)
Axis 3 400 (W)
Axis 4
400 (W)
Operating range
Axis 1 ±
120 (deg)
Axis 2 ±
145 (deg)
Axis 3 150 (mm) [Option: 300 (mm)]
Axis 4 ±360 (deg)
Maximum speed
(*1)
Axis 1 340 (deg/s)
Axis 2 600 (deg/s)
Axis 3 2050 (mm/s)
Axis 4 1800 (deg/s)
Composite speed
of axes 1 and 2 7.8 (m/s)
Rated payload mass 2 (kg)
Maximum payload mass
10 (kg)
Permissible load inertia (*1) 0.1 (kg･m2)
Repeatability X, Y ±0.015 (mm) Z ±0.01 (mm)
C ±0.01(deg)
Cycle time (*2)
(When payload mass is 2 kg) 0.34 (sec) 120 cycles/min
Drive system By means of AC servo motors
Position detection method Absolute
*1: 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.
*2: Shuttle time for rough positioning in horizontal direction of 300 mm and vertical direction
of 25 mm.
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!CAUTION
Put the Z-axis (axis 3) in the raised position as much as possible, when moving Axes 1, 2, and 4.
Moving Axis 1, 2, or 4 when the Z-axis is in low positions can lead to premature damage to the
ball screw spline (Z-axis shaft).
If Axis 1, 2, or 4 must be moved while the Z-axis is in low positions due to unavoidable
circumstances, prevent the ball screw spline vibrations by using the SPEED, ACCEL/DECEL,
and PAYLOAD commands to adjust the operation speed and acceleration.
If Axis 1, 2, or 4 is moved while the Z-axis is in low positions, be extremely careful not to collide
with any objects. Even if Axis 1, 2, or 4 is moved at low speed, a collision or other impact with an
object can damage the ball screw spline (Z-axis shaft) before alarm occurs.
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2. Transportation
2.1 Unpacking
The robot and controller are shipped separately in corrugated cardboards. Fig. 2.1
shows each packaging state.
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
nothing has been damaged during transport.
Fig. 2.1 Packaging state
Teach pendant
Accessories included in the controller package
System and instruction manual CD-ROM: 1 pc.
CD-ROM for TCPRGOS (option): 1 pc.
CD-ROM for TSPC (option): 1 pc.
Wooden pallet
Robot body (actuator)
packed in a polyethylene
shipping bag.
Corrugated
cardboard
Cables
Instruction manuals
Controller
Corrugated cardboard
(external box)
Corrugated cardboard
(Cushion f
or the top plate)
Controller
C
orrugated
cardboard
(Cushion for the
bottom plate)
Accessories included in the controller package
EMS dummy connector: 1 pc.
SYSTEM dummy connector: 1 pc.
TP dummy connector: 1 pc.
[Controller details]
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! DANGER
• If any parts of the equipment are found damaged or any accessories are missing
after the shipment containing the robot and controller have reached your office, DO
NOT install and operate them. Otherwise, the equipment will malfunction.
Contact Toshiba Machine immediately.
• Dispose of the wooden pallet, corrugated cardboards, polyethylene shipping bags
and cushion material according to the customer’s in-house regulations.
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 the clamp and base set bolts completely.
If the equipment is to be moved to a location some distance from where it was
unpacked, reposition the cushions as they were and put the equipment back into the
corrugated cardboards.
2.2.1 Mass and Dimensions
The mass and outer dimensions of the robot are shown in Fig. 2.2.
For the mass and outer dimensions of the controller, see Fig. 3.5 of Para. 3.3.1.
Fig. 2.2 Outer dimensions at transport
Mass of robot body
57 kg
Clamp
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2.2.2 Transporting the Robot
In principle, the robot should be transported in the state shown in Fig. 2.2 above.
Fold back and secure the arm with the attached clamp. (The robot is shipped in this
posture. After you have unpacked the shipment, you should move it as it is.) At this
time, take careful precautions not to impose a large force on the tool shaft.
! DANGER
• Be sure to secure the arm with the attached clamp before transporting the
robot. Failure to do so could cause a hazardous situation as the arm will
move when the robot is lifted.
It is possible to lift up and transport the robot. Pass the wire through the attached
eyebolt, then lift up the robot carefully, as shown in Fig. 2.3.
Fig. 2.3 Lifting up the robot
Wire
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!
CAUTION
• The wire to be used should be such that can well withstand the mass of the
robot.
• When lifting up the robot, it may tilt a little. Lift it up slowly.
• Lifting up and down should be performed carefully so that any impact
cannot be exerted on the robot.
• When carrying the robot by workers, take careful precautions to prevent
their hand or leg from being caught in the robot.
Fig. 2.4 Lifting up the robot
Handling areas (shaded areas)
DO NOT hold the ball screw
spline shaft.
DO NOT hold the cover
DO NOT hold the cable.
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After the installation, remove the clamp and eyebolt used for transport.
! CAUTION
• When lifting up the robot by workers, hold the locations (shaded areas) by
hands as shown in Fig. 2.4. If the arm 2, cover or ball screw spline shaft is
held by hands, an unusually large force is exerted, resulting in a
malfunction.
• When carrying the robot by workers, take careful precautions to prevent
their hand or leg from being caught in the robot.
• The work should be performed by two (2) or more workers.
2.2.3 Transporting the Controller
Disconnect all cables and teach pendant before transporting the controller.
! DANGER
• When placing the controller on the floor, etc., make sure not to have your
hands or feet caught.
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2.3 Storage
Avoid storing the robot and controller for long periods of time after unpacking them. If
this is unavoidable, however, strictly observe the following precautions for storage.
2.3.1 Storage Precautions for the Robot
!
CAUTION
• Secure the base completely to prevent the robot from falling over. When
placed directly on the floor, the robot is unstable and will fall over.
• Keep the robot out of direct sunlight. The timing belts and resin covers
may deteriorate.
• Seal the robot in a vinyl bag to prevent rust development and contaminant.
Put a desiccant in the bag to absorb moisture. As the tool shaft is
susceptible to rust development, coat it with rust-preventive agent or grease
the entire tool shaft beforehand.
• Before the use, apply the grease to the tool shaft.
• Before starting an operation, perform running completely.
• During storage, the life of the backup batteries will shorten. It is
recommended to replace the batteries at the time of operation.
2.3.2 Storage Precautions for the Controller
!
CAUTION
• Keep the controller out of direct sunlight. Otherwise, the controller interior
will be excessively heated up, causing a trouble.
• Seal the controller in a vinyl bag to prevent rust development and
contaminant. Put a desiccant in the bag to absorb moisture.
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