Hyundai HX200L User manual

Hyundai Robot

Manipulator Maintenance Manual

- HX200L , HX200L-2000,

- HX300 , HX300L,

- HX400

HX300060301MME2

The information presented in the manual is the property of HHI

Any copy or even partial is not allowed without prior written authorization from

HHI

It may not be provided to the third party, nor used for any other purposes

HHI reserves the right to modify without prior notification

Printed in Korea - Oct 2005 1st Edition

Contents

1 Safety 1-1

1.1. Introduction............................................................................................1-2

1.2. Relevant Safety Regulations .................................................................1-4

1.3. Safety Training.......................................................................................1-4

1.4. Safety Related Nameplate.....................................................................1-5

1.4.1. Safety arking....................................................................................1-5

1.4.2. Safety Nameplate ...............................................................................1-6

1.5. Definition of Safety Functions ................................................................1-7

1.6. Installation .............................................................................................1-8

1.6.1. Safety Fence.......................................................................................1-8

1.6.2. Placement of Robot & Peripheral Equipment....................................1-10

1.6.3. Installing the Robot ...........................................................................1-12

1.6.4. Space for Robot Installation ..............................................................1-14

1.7. Safety Operation for Robot Handling...................................................1-15

1.7.1. Safety Precautions for Robot Handling.............................................1-15

1.7.2. Safety Precautions for Operating Test..............................................1-18

1.7.3. Safety Precautions for Automatic Operation.....................................1-19

1.8. Safety Precautions for Access to Safety Fence...................................1-20

1.9. Safety Precautions for aintenance and Repair..................................1-21

1.9.1. Safety Precautions for Hi4a Controller aintenance and Repair...... 1-21

1.9.2. Safety Precautions for Robot System & anipulator aintenanace.1-22

1.9.3. Necessary Actions after aintenance and Repair ............................1-23

1.10. Safety Functions................................................................................1-24

1.10.1. Operating a Safety Circuit...............................................................1-24

1.10.2. Emergency stop..............................................................................1-26

1.10.3. Operating Speed.............................................................................1-29

1.10.4. Connecting the Safety Devices.......................................................1-29

1.10.5. Restricting the working Envelope....................................................1-30

1.10.6. onitoring Function ........................................................................1-30

1.11. Safety Related to End Effectors.........................................................1-31

1.11.1. Gripper............................................................................................1-31

1.11.2. Tool / Workpiece..............................................................................1-32

1.11.3. Pneumatic and Hydraulic Systems .................................................1-32

1.12. Liabilities............................................................................................1-33

2 Specifications 2-1

2.1. Robot achinery Part ............................................................................2-2

2.2. Location of Robot Identification Plate ....................................................2-3

2.3. Basic Specifications...............................................................................2-4

2.4. Robot Dimension and Working Envelope ..............................................2-6

1. Safety

2. Specifications

Contents

2.5. Axis Identification.................................................................................2-11

2.6. Details of Wrist Axis Attachment Surface ............................................2-12

2.7. Details of Upper 1st AR Attachment Surface.....................................2-13

2.8. Application Wiring and Inspection Wiring Diagram ..............................2-14

2.8.1. Details of Customer Application Connectors.....................................2-15

2.9. Restricting the Working Envelope........................................................2-16

2.9.1. Axis 1(Axis S)....................................................................................2-16

3 Instructions 3-1

3.1. Robot Component Name .......................................................................3-2

3.2. Location of Safety Nameplate................................................................3-3

3.3. How to operate ......................................................................................3-4

3.3.1. Using Crane........................................................................................3-4

3.3.2. Using Forklift Truck .............................................................................3-6

3.4. How to Install .........................................................................................3-7

3.4.1. Operating Conditions ..........................................................................3-7

3.4.2. Installating the Robot anipulator ......................................................3-8

3.4.3. Dimension of Installation Surface .......................................................3-9

3.4.4. Accuracy of Installation Surface........................................................3-10

3.5. Allowable Load of Wrist Axis................................................................3-11

3.6. Recommended Standy Posture...........................................................3-16

4 Inspection 4-1

4.1. Inspection Item and Period ....................................................................4-2

4.2. Inspection Item and Period ....................................................................4-3

4.3. Inspection of ain External Bolts...........................................................4-5

4.4. Inspection of Wrist Backlash..................................................................4-7

4.5. Inspection Internal Wiring ......................................................................4-8

4.5.1. The Conditions of Safety Inspection ...................................................4-8

4.5.2. Inspection Part....................................................................................4-9

5 Maintenance 5-1

5.1. Grease Replenishment/Replacement....................................................5-2

5.1.1. S-Axis Reduction Gear .......................................................................5-3

5.1.2. H-Axis Reduction Gear .......................................................................5-4

5.1.3. V-Axis Reduction Gear .......................................................................5-6

5.1.4. R2-Axis Reduction Gear .....................................................................5-8

5.1.5. B-Axis Reduction Gear .......................................................................5-9

5.1.6. R1-Axis Reduction Gear ................................................................... 5-11

5.1.7. Bearing Joint Parts ...........................................................................5-13

3. Instructions

4. Inspection

5. Maintenance

iii

5.1.8. A1 Frame - Gear Box........................................................................5-14

5.1.9. Wrist - Gear Box ...............................................................................5-15

5.2. Battery Replacement ...........................................................................5-16

5.2.1. Instructions for Battery Storage.........................................................5-18

5.3. Internal Wiring......................................................................................5-19

5.3.1. Wiring Connection Diagram..............................................................5-20

6 Trobleshooting 6-1

6.1. Troubleshooting Procedure ...................................................................6-2

6.2. Trouble Symptoms and Possible Causes ..............................................6-3

6.3. Diagnostics and Resolutions for ajor Parts Failure .............................6-4

6.3.1. Fulcrum Bearings................................................................................6-4

6.3.2. Reduction Gear...................................................................................6-5

6.3.3. Brakes ................................................................................................6-7

6.3.4. otor ..................................................................................................6-8

6.3.5. Encoder ..............................................................................................6-9

6.4. otor Replacement .............................................................................6-10

6.4.1. Necessary Tools and Parts ...............................................................6-12

6.4.2. How to Replace otor ......................................................................6-13

6.5. Encoder Zero Setting...........................................................................6-15

6.5.1. Zero Setting ......................................................................................6-16

6.5.2. Encoder Reset..................................................................................6-17

6.5.3. Confirming the Reset ........................................................................6-19

6.5.4. Encoder Calibration(Data input) and Selection.................................6-20

7 Recommended Spare Parts 7-1

8 Internal Wiring Diagram 8-1

8.1. anipulator Configuration......................................................................8-2

8.2. Wiring Diagram......................................................................................8-3

9 Decommissioning 9-1

6. Troubleshooting

7. Recommended Spare Parts

8. Internal Wiring Diagram

9. Decommissioning

Contents

List of Figures

Fig 1.1 Recommended Size for Fence and Gate Hole (Square Gate)......... 1-8

Fig 1.2 Recommended Size for Fence and Gate Hole (Slot Gate) .............. 1-8

Fig 1.3 Placement of Peripheral Equipment and Operator ........................ 1-10

Fig 1.4 Space for robot installation............................................................. 1-14

Fig 1.5 Robot’s Safety Circuit .................................................................... 1-24

Fig 1.6 Emergency Stop ............................................................................ 1-27

Fig 1.7 Emergency Stop Connection of External System .......................... 1-28

FIg 2.1 Robot achinery Part...................................................................... 2-2

Fig 2.2 The location of identification plate.................................................... 2-3

Fig 2.3 Robot Dimension and Working Envelope : [HX300] ........................ 2-6

Fig 2.4 Robot Dimension and Working Envelope : [HX400] ........................ 2-7

Fig 2.5 Robot Dimension and Working Envelope : [HX200L]....................... 2-8

Fig 2.6 Robot Dimension and Working Envelope : [HX200L-2000] ............. 2-9

Fig 2.7 Robot Dimension and Working Envelope : [HX300L]..................... 2-10

Fig 2.8 Robot Dimension and Axis [HX300/400/200L/200L-2000/300L].....2-11

Fig 2.9 Details of Wrist Axis Attachment Surface : [HX300/400/300L] ....... 2-12

Fig 2.10 Details of Wrist Axis Attachment Surface : [HX200L] ................... 2-12

FIg 2.11 Details of Upper 1st AR Attachment Surface............................. 2-13

Fig 2.12 Application Wiring and Inspection Wiring Diagram ...................... 2-14

Fig 2.13 Details of Application Connector (Encoder) ................................. 2-15

Fig 2.14 Details of Application Connector (Power)..................................... 2-15

Fig 3.1 Identification of Robot Components................................................. 3-2

Fig 3.2 Location of Safety Nameplate.......................................................... 3-3

Fig 3.3 How to Transport: Using crane [HX300/400].................................... 3-4

Fig 3.4 How to Transport: Using crane [HX200L/300L]................................ 3-5

Fig 3.5 How to Transport : Using Forklift Truck

[HX300/400/200L/200L-2000/300L] .............................................. 3-6

Fig 3.6 Dimension of Robot Installation..................................................... 3-9

Fig 3.7 Accuracy of Installation surface ..................................................... 3-10

Fig 3.8 Wrist Axis Torque apping:[HX300/300L]...................................... 3-14

Fig 3.9 Wrist Axis Torque apping : [HX400]............................................. 3-14

Fig 3.10 Wrist Axis Torque apping : [HX200L]......................................... 3-15

Fig 3.11 Recommended Standby Posture ................................................. 3-16

Fig 4.1 Inspection Part for ain Bolts [HX300/400/300L] ............................ 4-6

Fig 4.2 Abnormal Backlash Inspecting Directions........................................ 4-7

Fig 4.3 Cable Inspection Parts : [HX300/400/200L/200L-2000/300L].......... 4-9

Fig 5.1 Explains of internal wiring .............................................................. 5-20

Fig 5.2 Wiring connection diagram : [HX300/400/200L/200L-2000/300L].. 5-21

Fig 6.1 How to prevent dropping of AR Axis H & V ..................................6-11

List of Figures

Fig 6.2 Encoder Reset Connector.............................................................. 6-18

Fig 8.1 anipulator Configuration................................................................ 8-2

Fig 8.2 otor and Brake wiring connection No.1 ......................................... 8-3

Fig 8.3 otor and Brake wiring connection No.2 ......................................... 8-4

Fig 8.4 Encoder wiring Connection No.1 ..................................................... 8-5

Fig 8.5 Encoder Wiring Connection No.2..................................................... 8-6

Fig 8.6 Encoder Wiring Connection No.3..................................................... 8-7

Fig 8.7 Application Wiring Connection No.1................................................. 8-8

Fig 8.8 Application Wiring Connection No.2................................................. 8-9

List of Tables

Table 1-1 Safety marking ............................................................................. 1-5

Table 1-2 State of robot stop...................................................................... 1-17

Table 2-1 Basic Specifications for odels.................................................... 2-4

Table 2-2 Axis otion..................................................................................2-11

Table 3-1 Components name....................................................................... 3-2

Table 3-2 Allowable load weight..................................................................3-11

Table 3-3 Allowable Load Torque................................................................3-11

Table 3-4 Allowable oment of Inertia....................................................... 3-12

Table 4-1 Inspection Schedule..................................................................... 4-2

Table 4-2 Inspection Items and Periods....................................................... 4-3

Table 4-3 Inspection part for main bolts ....................................................... 4-5

Table 6-1 Trouble phenomenon and cause.................................................. 6-3

Table 6-2 otor Weight.............................................................................. 6-10

Table 6-3 Necessary Tools......................................................................... 6-12

Table 6-4 Necessary parts ......................................................................... 6-12

Table 6-5 Reset connectors corresponding to axes................................... 6-17

Table 6-6 Data range after resetting .......................................................... 6-20

Table 7-1 Spare Parts ListⅠ........................................................................ 7-2

Table 7-2 Spare Parts ListⅡ........................................................................ 7-4

Table 7-3 Spare Parts List Ⅲ...................................................................... 7-5

Table 7-4 Spare Parts List Ⅳ...................................................................... 7-6

Table 7-5 Spare Parts List Ⅴ...................................................................... 7-7

Table 9-1 aterials of each part................................................................... 9-2

List of Tables

1. Safety

1-1

1 Safety

Safety

HX200/HX200L-2000/HX300/HX300L/HX400

1-2

Safety

1 1 Introduction

The main purpose of this chapter is to describe the safety precautions for users and

operators who repair and manipulate the industrial robot.

This manual describes safety precautions for robot manipulator and controller, in

comply with the requirement of ANSI/RIA R15.06-1999, Standard for Safety,

Industrial Robots, and qualified with safety regulations. The technical description and

installation method of robot system is presented in detail at the specifications

regarding installation of robot manipulator and controller.

Every operator, who installs, replaces, adjusts, manipulates, maintains, and repairs,

must read thoroughly and fully understand the manipulation and maintenance

manual, in particular, the special attention must be paid to the WARNING symbol, the

most important marking related to the safety.

Installation, replacement, adjustment, manipulation, maintenance, and repair of robot

system must be performed by the personnel who was duly trained for these purposes,

following the indicated operating procedure.

This company is planning and carrying out the relevant training such as maintenance,

repair, and manipulation for the above operations, so robot users make sure that

robot operators should get the relevant training. And make sure that the robot

handling work should be carried out only by the operators who completed this

training course.

The Users of HR and HX industrial robots have a responsibility under the safety

relavant regulations valid in the country where the robot is installed, and a

responsibility to properly design, install, and operate the safety devices to protect

workers.

The dangerous zone of robot system, that is the working range in which the robot,

tool, and peripheral equipment are operated, must be safeguarded to prevent

workers or objects from entering the zone. If a person or object should nevertheless

enters the dangerous zone, make sure that the robot system is immediately shut

down by emergency stop system. The operators of robot system have a

responsibility to take all necessary steps to make correct installation, examination

and operation of the relevant safety devices.

This manual is provided for the utilization of HR and HX Series anipulator models

and Hi4a controller.

Valid application and invalid environment of HR and HX Series robots are as follows.

Application

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