ROBO Cylinder. Long Stroke Gripper. Instruction Manual First Edition ME3787-1B

Transcription

1 ROBO Cylinder Long Stroke Gripper RCP6-GRST6C GRST7C RCP6S-GRST6C GRST7C RCP6-GRST6R GRST7R RCP6S-GRST6R GRST7R Instruction Manual First Edition ME3787-1B Specifications Installation Connecting with the Controller Operation Maintenance and Inspection External Dimensions Warranty Appendix ch.1 ch.2 ch.3 ch.4 ch.5 ch.6 ch.7 ch.8

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3 Please Read Before Use Thank you for purchasing our product. This instruction manual explains the handling methods, structure and maintenance of this product, providing the information you need in order to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product. The DVD enclosed with the product contains instruction manuals for IAI products. When using the product, refer to the necessary sections of the applicable instruction manual by printing them out or displaying them on a PC. After reading the instruction manual, keep it in a convenient place so that whoever is handling the product can refer to it quickly when necessary. [Important] This instruction manual is an original document dedicated for this product. This product cannot be used in ways not shown in this instruction manual. IAI shall not be liable for any result whatsoever arising from the use of the product in any other way than what is noted in the manual. The information contained in this instruction manual is subject to change without notice for the purpose of product improvement. If any issues arise regarding the information contained in this instruction manual, contact our customer center or the nearest sales office. Use or reproduction of this instruction manual in full or in part without permission is prohibited. The company names, names of products and trademarks of each company shown in the text are registered trademarks.

4 RCP6 Long Stroke Gripper Type Instruction Manual Configuration Product name RCP6/RC6S Long Stroke Gripper RCP6/RC6S Long Stroke Gripper PCON-CB/CGB Controller PCON-CYB/PLB/POB Controller MCON-C/CG Controller RCON Controller MSEL-PC/PG Controller PC Compatible Software for RC/EC PC Compatible Software for XSEL Touch Panel Teaching Pendant Touch Panel Teaching Pendant Data Setter Touch Panel Teaching Pendant Touch Panel Teaching Pendant Data Setter Instruction manual name First Step Guide Instruction Manual (this document) PCON-CB/CGB Controller Instruction Manual PCON-CYB/PLB/POB Controller Instruction Manual MCON-C/CG Controller Instruction Manual RCON Controller Instruction Manual MSEL-PC/PG Controller Instruction Manual RCM-101-MW/RCM-101-USB Instruction Manual IA-101-X-MW/IA-101-X-USBMW Instruction Manual TB-01/01D/01DR Applicable for Position Controller Instruction Manual TB-02/02D Applicable for Position Controller Instruction Manual TB-03 Applicable for Position Controller TB-01/01D/01DR Applicable for Program Controller Instruction Manual TB-02/02D Applicable for Program Controller Instruction Manual TB-03 Applicable for Program Controller Instruction Manual Control number ME3768 ME3787 ME0342 ME0353 ME0341 ME0384 ME0336 ME0155 ME0154 ME0324 ME0355 ME0376 ME0325 ME0356 ME0377

5 Contents Safety Guide Intro-1 Precautions for Handling Intro-9 International Standard Compliance Intro-12 Names of the Parts Intro-13 Chapter 1 Specifications 1.1 Checking the Product 1-1 Parts 1-1 How to Read the Model Nameplate 1-3 How to Read the Model Number Specifications 1-5 Specifications 1-5 Duty Ratio Operating Conditions 1-12 Procedure 1 Check for the necessary grip force and transportable work piece mass 1-12 Procedure 2 Check for the vertical allowable load of the slider and allowable moment Options 1-19 With Brake (Model Code: B) 1-19 Reversed-home Specification (Model Code: NM) 1-19 Motor Reversed Direction (Model Code: ML, MR) 1-19 Cable Exit Direction Changed (Model Code: CJT, CJR, CJL, CJB, CJO) 1-20 Slider Spacer (Model Code: SS) 1-20 Slider Roller Specification (Model Code: SR) 1-21 Finger Attachment Installation Tool (Model Code: MJF) Accessories 1-22 Motor Encoder Integrated Cables: Except for RCON, RCM-P6PC Controller 1-22 Motor Encoder Integrated Cables Robot Type: Except for RCON, RCM-P6PC Controller 1-23 Motor Encoder Integrated Cables: RCON, RCM-P6PC Controller 1-24 Motor Encoder Integrated Cables Robot Type: RCON, RCM-P6PC Controller 1-25 Chapter 2 Installation 2.1 Precautions for Transportation Installation and Storage/preservation Environment 2-3 Installation Environment 2-3 Storage/preservation Environment How to Install 2-5 Installation Orientation 2-5 Precautions Regarding Stainless Steel Sheet 2-6 Installation Surface 2-7 Installation of the Main Unit 2-8 Finger Attachment, Mounting Transported Objects 2-14 Installation of the finger attachment installation tool (MJF Option) 2-16

6 Chapter 3 Connecting with the Controller 3.1 Connecting with the Controller 3-1 Chapter 4 Operation 4.1 Operation of the Fingers 4-1 Movement Stroke 4-1 Home Return Direction 4-1 Position Indication 4-1 Indication of Speed and Acceleration Release of the Gripped Work Piece 4-3 Chapter 5 Maintenance and Inspection 5.1 Precautions for Maintenance and Inspection Work Inspection Items and Schedule 5-3 Gripper Type Visual Inspection Items 5-4 External Visual Inspection 5-4 Internal Visual Inspection Cleaning 5-7 External Cleaning 5-7 Internal Cleaning Greasing Method How to Replace Components 5-14 Stainless Steel Sheet Replacement/adjustment 5-14 Belt Replacement/adjustment 5-18 Motor Replacement 5-26 Chapter 6 External Dimensions 6.1 External Dimensions 6-1 Standard Specification RCP6-GRST6C 6-1 Built-in Controller Specification RCP6S-GRST6C 6-2 Standard Specification RCP6-GRST7C 6-3 Built-in Controller Specification RCP6S-GRST7C 6-4 Standard Specification RCP6-GRST6R Left Side-Mounted (Model : ML) 6-5 Built-in Controller Specification RCP6S-GRST6R Left Side-Mounted (Model : ML) 6-6 Standard Specification RCP6-GRST7R Left Side-Mounted (Model : ML) 6-7 Built-in Controller Specification RCP6S-GRST7R Left Side-Mounted (Model : ML) 6-8 Chapter 7 Warranty 7.1 Warranty Period Scope of the Warranty Honoring the Warranty Limited Liability Conformance with Applicable Standards/regulations,etc., and Application Conditions Other Items Excluded from Warranty 7-2 Chapter 8 Appendix 8.1 Index Revision History 8-3

7 Safety Guide Safety Guide The Safety Guide is intended to permit safe use of the product and thus to prevent risks and property damage. Be sure to read it before handling the product. Intro-1

8 Safety Guide Safety Precautions for Our Products Common safety precautions for the use of robots in various operations are indicated here. No. Operation Precautions 1 Model Selection This product is not intended or designed for applications where high levels of safety are required, and so cannot guarantee that human lives will be protected. Accordingly, do not use it in any of the following applications. (1) Medical equipment used to maintain, control or otherwise affect human life or physical health (2) Mechanisms or machinery designed for the purpose of moving or transporting people (vehicles, railway facilities, aviation facilities etc.) (3) Machinery components essential for safety (safety devices etc.) Do not use the product outside the range of the specifications. Otherwise, the product life may be drastically shortened, and product damage or facilities stoppage may occur. Do not use it in any of the following environments. (1) Locations with flammable gases, ignitable objects or explosives (2) Locations with potential exposure to radiation (3) Locations with ambient temperature or relative humidity exceeding the specifications range (4) Locations where radiant heat is applied by direct sunlight or other large heat source (5) Locations where condensation occurs due to abrupt temperature changes (6) Locations with corrosive gases (sulfuric acid, hydrochloric acid, etc.) (7) Locations exposed to significant amounts of dust, salt or iron powder (8) Locations subject to direct vibration or impact For an actuator used in vertical orientation, select a model which is equipped with a brake. If a model without brake is selected, the moving parts may fall when the power is turned OFF, causing accidents such as injury or workpiece damage. Intro-2

9 Safety Guide No. Operation Precautions 2 Transportation When transporting heavy objects, do the work with two or more persons or utilize equipment such as a crane. When working with two or more persons, make it clear who is to be in charge and communicate well with each other to ensure safety. During transportation, carefully consider the carrying positions, weight, and weight balance, and be careful to avoid collisions or dropping. Use appropriate transportation measures for transport. 3 Storage and Preservation The actuators available for transportation with a crane have eyebolts attached or tapped holes to attach bolts. Follow the instructions in the instruction manual for each model. Do not climb onto the package. Do not put anything heavy that could deform the package on it. When using a crane with capacity of 1t or more, have an operator qualified for crane operation and sling work. When using a crane or equivalent equipment, make sure not to suspend loads exceeding the equipment's rated load. Use a hook that is suitable for the load. Consider the safety factor of the hook in such factors as shear strength. Also, check to make sure that the hook is free of damage. Do not climb on loads suspended from cranes. Do not leave loads suspended from cranes for long periods. Do not stand under loads suspended from cranes. For the storage and preservation environment, see the installation environment. However, give especial consideration to the prevention of condensation. Store the products so as to prevent them from falling over or down in the case of natural disasters such as earthquakes. Intro-3

10 Safety Guide No. Operation Precautions 4 Installation and Startup (1) Installation of robot body and controller, etc. Be sure to securely hold and fix the product (including the workpiece). If the product falls over, is dropped, or operates abnormally, it may lead to damage and injury. Also, be equipped for falls over or down due to natural disasters such as earthquakes. Do not climb on or put anything on the product. Otherwise, this may lead to accidental falling, injury or damage to the product due to falling objects, product loss of function or performance degradation, or shortening of product life. When using the product in any of the places specified below, provide sufficient shielding. (1) Locations where electrical noise is generated (2) Locations with strong electrical or magnetic fields (3) Locations with mains or power lines passing nearby (4) Locations where the product may come in contact with water, oil or chemical spray (2) Cable wiring Use IAI genuine cables for connecting the actuator and controller, and for the teaching tools. Do not scratch cables, bend them forcibly, pull them, coil them, snag them, or place heavy objects on them. Otherwise, this may lead to fire, electric shock, or abnormal operation due to leakage or conduction malfunction. Perform the wiring for the product after turning OFF the power to the unit, and avoid miswiring. When wiring DC power (+24V), be careful with the positive/negative polarity. Incorrect connections may lead to fire, product breakdown or abnormal operation. Connect the cable connector securely so that there is no disconnection or looseness. Otherwise, this may lead to fire, electric shock, or abnormal operation of the product. Never cut or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length. Otherwise, this may lead to fire or abnormal operation of the product. (3) Grounding Grounding must be performed, in order to prevent electric shocks or electrostatic charge, enhance noise-resistant performance and control unnecessary electromagnetic radiation. For the ground terminal on the AC power cable of the controller and the grounding plate in the control panel, be sure to use a twisted pair cable with wire thickness 0.5mm 2 (AWG20 or equivalent) or more for grounding work. For safeguard grounding, it is necessary to select an appropriate wire diameter for the load. Perform wiring that satisfies the specifications (electrical equipment technical standards). Perform Class D grounding (former Class 3 grounding, with ground resistance 100Ω or below). Intro-4

11 Safety Guide No. Operation Precautions 4 Installation and Startup (4) Safety measures When working with two or more persons, make it clear who is to be in charge and communicate well with each other to ensure safety. When the product is operating or in the ready mode, take safety measures (such as the installation of safety/protection fences) so that nobody can enter the area within the robot's movable range. Contact with an operating robot may lead to death or serious injury. Be sure to install an emergency stop circuit so that the unit can be stopped immediately in an emergency during operation. Take safety measures such that turning the power ON alone will not start up the unit. Otherwise, this may cause the product to start unexpectedly, leading to injury or product damage. Take safety measures such that emergency stop cancel or recovery after power failure alone will not start up the unit. Otherwise, this may lead to injury or equipment damage. When installation or adjustment operation is to be performed, display signs such as "Operating: No Power ON!" etc. Sudden power input may cause electric shock or injury. Take measures to prevent workpieces, etc. from falling during power failures or emergency stop. Wear protection gloves, goggles and safety shoes, as necessary, to secure safety. Do not insert fingers or objects into the openings in the product. Otherwise, this may lead to injury, electric shock, product damage, or fire. When releasing the brake on a vertically oriented actuator, be careful that it does not fall under its own weight, catching the operator's hand or damaging workpieces. 5 Teaching When working with two or more persons, make it clear who is to be in charge and communicate well with each other to ensure safety. Perform teaching operation from outside the safety/protection fence, if possible. If operation must be performed within the safety/protection fence, prepare "Work Regulations" and make sure that all the workers acknowledge and understand them well. When operation is to be performed inside the safety/protection fence, operators should have emergency stop switches available at hand so that the unit can be stopped at any time if abnormalities occur. When operation is to be performed inside the safety/protection fence, have a monitor standing by in addition to the operator(s) so that the unit can be stopped at any time if abnormalities occur. Also, keep watch on the operation so that a third party cannot operate the switches carelessly. Place a sign indicating "Operating" where it can be seen easily. When releasing the brake on a vertically oriented actuator, be careful that it does not fall under its own weight, catching the operator's hand or damaging workpieces. * Safety/protection fence: If there is no safety/protection fence, the movable range should be indicated. Intro-5

12 Safety Guide No. Operation Precautions 6 Trial Operation 7 Automatic Operation 8 Maintenance and Inspection When working with two or more persons, make it clear who is to be in charge and communicate well with each other to ensure safety. After teaching or programming, carry out trial operation step by step before switching to automatic operation. When trial operation is to be performed inside the safety/protection fence, use the same work procedure, determined in advance, as teaching operation. Be sure to confirm program operation at safe speeds. Otherwise, this may lead to accidents due to unexpected motion caused by program error, etc. Do not touch the terminal block or any of the various setting switches while the equipment is live. Otherwise, this may lead to electric shock or abnormal operation. Check before starting automatic operation or restarting after operation stop that there is nobody within the safety/protection fence. Before starting automatic operation, make sure that all peripheral equipment is ready for automatic operation and that there is no alarm indication. Be sure to start automatic operation from outside the safety/protection fence. If the product produces abnormal heat, smoke, odor, or noise, immediately stop it and turn OFF the power switch. Otherwise, this may lead to fire or damage to the product. When a power failure occurs, turn OFF the power switch. Otherwise, this may lead to injury or product damage due to unexpected product motion during recovery from the power failure. When working with two or more persons, make it clear who is to be in charge and communicate well with each other to ensure safety. Perform the work outside the safety/protection fence, if possible. If operation must be performed within the safety/protection fence, prepare "Work Regulations" and make sure that all the workers acknowledge and understand them well. When work is to be performed inside the safety/protection fence, turn OFF the power switch as a rule. When operation is to be performed inside the safety/protection fence, operators should have emergency stop switches available at hand so that the unit can be stopped at any time if abnormalities occur. When operation is to be performed inside the safety/protection fence, have a monitor standing by in addition to the operator(s) so that the unit can be stopped at any time if abnormalities occur. Also, keep watch on the operation so that a third party cannot operate the switches carelessly. Place a sign indicating "Operating" where it can be seen easily. For the grease for the guide or ball screw, use appropriate grease according to the Instruction Manual for each model. Do not perform dielectric strength testing. Otherwise, this may lead to damage to the product. Intro-6

13 Safety Guide No. Operation Precautions 8 Maintenance and Inspection 9 Modification and Disassembly When releasing the brake on a vertically oriented actuator, be careful that it does not fall under its own weight, catching the operator's hand or damaging workpieces. The slider or rod may be misaligned from the stop position if the servo is turned OFF. Avoid injury or damage due to unnecessary operation. Be careful not to lose the cover or any removed screws, and be sure to return the product to the original condition after maintenance and inspection work. Otherwise, this may lead to product damage or injury due to incomplete mounting. * Safety/protection fence: If there is no safety/protection fence, the movable range should be indicated. Do not modify, disassemble/assemble, or use maintenance parts not specified on your own discretion. 10 Disposal When the product exceeds its useful life or is no longer needed, dispose of it properly as industrial waste. When removing the actuator for disposal, avoid dropping components when detaching screws. Do not put the product in a fire when disposing of it. The product may rupture or generate toxic gases. 11 Other If you are equipped with a medical device such as a pacemaker, do not approach the product or its wiring, as the device may be affected. See the Overseas Specifications Compliance Manual to check compliance with overseas standards if necessary. For the handling of actuators and controllers, follow the dedicated instruction manual of each unit to ensure safety. Intro-7

14 Safety Guide Precaution Indications The safety precautions are divided into Danger, Warning, Caution and Notice according to the warning level, as follows, and described in the Instruction Manual for each model. Level Degree of risk to persons and property Symbol Danger This indicates an imminently hazardous situation which, if the product is not handled correctly, will result in death or serious injury. Danger Warning This indicates a potentially hazardous situation which, if the product is not handled correctly, could result in death or serious injury. Warning Caution Notice This indicates a potentially hazardous situation which, if the product is not handled correctly, may result in minor injury or property damage. This indicates a situation in which, while injury is not a likely result, the precautions should be observed in order to use the product appropriately. Caution Notice Intro-8

15 Precautions for Handling Precautions for Handling 1. The Safety Guide attached with the product is intended to permit safe use of the product and thus to prevent risks and property damage. Be sure to read it before handling the product. 2. Do not attempt any handling or operation that is not indicated in this instruction manual. 3. Make sure to secure the actuator properly in accordance with this instruction manual. If the actuator is not securely fixed, this may lead to abnormal noise, vibration, breakdown or shortened product life. 4. Make sure to observe the usage conditions and environment of the product. Operation outside the warranty could cause decreased performance or product breakdown. Use within the allowable range for each item. Item Speed and acceleration/deceleration Cautions for use Use within the allowable range Problems or breakdowns which may occur if the allowable range is exceeded May lead to abnormal noise, vibration, breakdown, or shortened product life. Allowable load moment Overhang length Use within the allowable range May lead to abnormal noise, vibration, breakdown, or shortened product life. In extreme cases, flaking may occur on the guide. 5. Pay attention to the finger moving part to avoid contamination getting in. Contamination may get pinched and cause damage on components. Intro-9

16 Precautions for Handling 6. When it is necessary to remove a workpiece while the power is turned OFF, do not attempt to pull the workpiece forcefully to remove it. Either twist the open/close screw or take off the finger attachment on one side to remove the workpiece. Pulling the workpiece forcefully to remove it may cause damage to the machinery. [Refer to 4.2 Release of the Gripped Work Piece] 7. Remove a workpiece in case of stop for a long period of time. Leaving a workpiece remained for a long time may cause performance drop and bad impact to the guides. 8.Lead 2 possesses the self-lock feature, but Lead 8 does not have the self-lock feature. Lead 2 is constructed to maintain the workpiece grip force with the self-lock feature on the feed screw even if the servo gets turned OFF or the power of the controller gets turned OFF, but Lead 8 does not have the self-lock feature. When using Lead 8, consider an equipment construction that would not require grip force to be remained when the servo gets turned OFF or the controller power gets turned OFF. It a brake feature is required, select an option equipped with a brake. However, it should be considered in the condition that remaining of the workpiece grip force is not to be asked. 9.When equipped with a brake (option), do not attempt to twist the slider open/close screw while the brake is working. It could shorten the brake life. Slider Open/Close Screw Intro-10

17 Precautions for Handling 10.PCON-CB and MCON Controller (Option: T) are capable for switching between high-output setting valid and invalid with the parameter setting, but use it with setting high-output setting invalid. (In the setting at delivery, the high-output setting is set to effective.) For MSEL Controller, the high-output setting is effective and cannot switch it over to ineffective. [Refer to an instruction manual for each controller for details] Controller Parameter Remarks PCON-CB No.152 High-output Setting [0: Ineffective, 1: Effective] MCON No.152 High-output Setting [0: Ineffective, 1: Effective] Intro-11

18 International Standard Compliance International Standard Compliance The ROBO Cylinder complies with the following overseas standards. Refer to the Overseas Standard Compliance Manual (ME0287) for more detailed information. CE Marking RoHS Directive Intro-12

19 Names of the Parts Names of the Parts In this manual, the actuator left/right sides and motor/opposite sides are shown as in the figure below. Standard Specification Motor Straight Type Sheet Retainer Slider Cover Slider Stainless Steel Sheet Right Side Slider Cover Slider Motor Bracket Motor Cover End Cover Opposite Side of the Motor Motor Side Slider Opening / Closing Screw Left Side Side Cover Screw for Motor Unit Attachment Sheet Retainer Connector Front Bracket Base Rear Bracket Tapped Hole for Ground Cable Connection Built-in Controller Specification Motor Straight Type Sheet Retainer Slider Cover Slider Stainless Steel Sheet Right Side Slider Cover Slider Motor Bracket Motor Cover Status LED End Cover Opposite Side of the Motor Motor Side Slider Opening / Closing Screw Left Side Side Cover Screw for Motor Unit Attachment Sheet Retainer Teaching Port Front Bracket Base Rear Bracket Power I/O Cable Connector Tapped Hole for Ground Cable Connection Intro-13

20 Names of the Parts Standard Specification Motor Reversing Type Slider Slider Cover Stainless Steel Sheet Slider Slider Cover Right Side Rear Bracket Sheet Retainer Opposite Side of the Motor Motor Side Sheet Retainer Left Side Slider Opening / Closing Screw End Cover Connector Side Cover Motor Cover Side-Mounted Bracket Pulley Cover Front Bracket Base Tapped Hole for Ground Cable Connection Built-in Controller Specification Motor Reversing Type Slider Slider Cover Stainless Steel Sheet Right Side Slider Slider Cover Rear Bracket Sheet Retainer Opposite Side of the Motor Motor Side Sheet Retainer Slider Opening / Closing Screw Left Side Power I/O Cable Connector End Cover Motor Cover Side-Mounted Bracket Pulley Cover Side Cover Front Bracket Base Teaching Port Tapped Hole for Ground Cable Connection Status LED Intro-14

21 ROBO Cylinder Chapter Specifications 1.1 Checking the product 1-1 Parts 1-1 How to Read the Model Nameplate 1-3 How to Read the Model Number Specifications 1-5 Specifications 1-5 Duty Ratio Operating Conditions 1-12 Procedure 1 Check for the necessary grip force and transportable work piece mass 1-12 Procedure 2 Check for the vertical allowable load of the slider and allowable moment Options 1-19 With Brake (Model Code: B) 1-19 Reversed-home Specification (Model Code: NM) 1-19 Motor Reversed Direction (Model Code: ML, MR) 1-19 Cable Exit Direction Changed (Model Code: CJT, CJR, CJL, CJB and CJO) 1-20

22 Slider Spacer (Model Code: SS) 1-20 Slider Roller Specification (Model Code: SR) 1-21 Finger Attachment Installation Tool (Model Code: MJF) Accessories 1-22 Motor Encoder Integrated Cables: Except for RCON, RCM-P6PC Controller 1-22 Motor Encoder Integrated Cables Robot Type: Except for RCON, RCM-P6PC Controller 1-23 Motor Encoder Integrated Cables: RCON, RCM-P6PC Controller 1-24 Motor Encoder Integrated Cables Robot Type: RCON, RCM-P6PC Controller 1-25

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24 1.1 Checking the Product 1.1 Checking the Product Parts 1. Specifications The following table shows the product configuration for the standard specification. See the component list for the details of the enclosed components. If you find any fault or missing parts, contact your local IAI distributor. Body Appearance Quantity Remarks Actuator 1 Motor Encoder Integrated Cables or Motor Encoder Integrated Robot Cables Type 1 First Step Guide 1 Safety Guide 1 1-1

25 1.1 Checking the Product Body Appearance Quantity Remarks Instruction Manual 1 1. Specifications 1-2

26 1.1 Checking the Product How to Read the Model Nameplate 1. Specifications Model Serial number [Nameplate Position] 1-3

27 1.1 Checking the Product How to Read the Model Number RCP6-GRST6C-WA-42P P3-P-B-** <Series> Identification for IAI use only (Note 1) Standard Specification <Options> RCP6 B : With Brake Built-in Controller Specification NM : Reversed-home Specification RCP6S CJT : Cable Exit Direction Changed (Top) <Type> CJR : Cable Exit Direction Changed Motor Straight Type (Right) GRST6C CJL : Cable Exit Direction Changed GRST7C (Left) Motor Reversing Type CJB : Cable Exit Direction Changed GRST6R (Bottom) GRST7R CJO : Cable Exit Direction Changed (Outward) <Encoder Type> ML : Motor Unit Left-Reversed WA : Battery-less Absolute Direction MR : Motor Unit Right-Reversed <Motor Type> Direction 42P : 42 size SS : Slider Spacer 56P : 56 size SR : Slider Roller Specification MJF : Slider Attachment Installation <Lead> Tool 2/8 <Cable Length> <Stroke> N : None GRST6C, GRST6R P : 1m 180 (One side 90), 230 (One side 115) S : 3m RGST7C, GRST7R M : 5m 210 (One side 105), 260 (One side 130) X : Length specification R : Robot cable Standard Specification <Applicable Controllers> P3 : PCON-CB/CGB PCON-CYB/PLB/POB MCON-C/CG/LC/LCG MSEL-PC/PG P5 : RCON-PC RCM-P6PC Built-in Controller Specification <I/O Type> SE : SIO Type Note 1 Identification for IAI use only:it may be displayed for IAI use. It is not a code to show the model type. 1. Specifications 1-4

28 1.2 Specifications 1.2 Specifications Specifications 1. Specifications [1] RCP6(S)-GRST6C, GRST6R [Maximum Grip Force, Stroke] Model Lead (mm) Maximum Grip force (N) Stroke (mm) RCP6(S)-GRST6C-WA-42P-2-1)-2)-3)-4) RCP6(S)-GRST6R-WA-42P-2-1)-2)-3)-4) (One side 155) 180 (One side 90), 230 (One side 115) RCP6(S)-GRST6C-WA-42P-8-1)-2)-3)-4) RCP6(S)-GRST6R-WA-42P-8-1)-2)-3)-4) (One side 55) 180 (One side 90), 230 (One side 115) Explanation for Symbols 1) Stroke 2) Applicable Controllers 3) Cable Length 4) Option [Stroke and Opening and Closing Maximum Speed Stroke 180, 230 Lead (mm) (mm) 2 45 (One side) (One side) (Note) (Unit: mm/s) It may not reach the maximum velocity in some conditions for the operation stroke and acceleration. [Actuator Specifications] Item Content Drive system Positioning repeatability Trapezoid screw ±0.01mm Backlash Lost motion Lead 2 Lead 8 Lead 2 Lead mm or less 0.3mm or less 0.25mm or less 0.3mm or less Allowable static moment Allowable dynamic moment Ma : 48.5N m Mb : 69.3N m Mc : 103N m Ma : 11.6N m Mb : 16.6N m Mc : 24.6N m 1-5 Brake (option) grip force Lead 2 - Lead Ambient operating 0 to 40 C, 85%RH or less (Non-condensing) temperature/humidity (Note) Lead 2 possesses the self-locking feature, which maintains the grip force on a workpiece even after the power gets turned off.

29 1.2 Specifications [Allowable Moment Reference Position for Offset] Calculate Ma and Mc moment based on the arrow position. [Relation between the Current Limit Value and the Grip Force] The graph shows the grip force on one slider. 1. Specifications GRST6 Lead 2 GRST6 Lead 8 Caution The dispersion of grip force should be +/-25% (F.S.) (reference). 1-6

30 1.2 Specifications 1. Specifications Caution It is a reference when assuming the speed is 5mm/s (lead 2), 10mm/s (lead 8). The maximum grip force shown in the table is a value under the conditions below. Total value of grip force of both slides at the top surface of the slides (grip point = 0mm, overhang = 0mm) F/2 F/2 L The relation between the current limit value and the grip force is a reference and the grip force could vary in the actual use. The variance of the gripping becomes large when the current limit value is low. Use the product within the range in the graph for the current limit value. The gripping will not be stable if used below 30%. There is even a case that it would not operate. An operation cannot be made also when it is beyond 70%. Doing so may cause degradation in the motor coil insulation by heat radiation, which results in shortening the product life. For CON-system controllers such as PCON, when the approach speed to the pressing start position (setting in the position table) is 5mm/s or less, pressing will be performed with the approach speed. In such a case also the pressing force will be unstable. In such cases, check in advance that the actuator can be used with no problem before omit using. For SEL-system controllers, such as MSEL, press at the speed set by PAPR instruction, regardless of the approach speed up to the pressing start position. 1-7

31 1.2 Specifications [2] RCP6(S)-GRST7C, GRST7R [Maximum Grip Force, Stroke] Model RCP6(S)-GRST7C-WA-56P-2-1)-2)-3)-4) RCP6(S)-GRST7R-WA-56P-2-1)-2)-3)-4) RCP6(S)-GRST7C-WA-56P-8-1)-2)-3)-4) RCP6(S)-GRST7R-WA-56P-8-1)-2)-3)-4) Lead (mm) 2 8 Maximum Grip force (N) 880 (One side 440) 340 (One side 170) Stroke (mm) 210 (One side 105), 260 (One side 130) 210 (One side 105), 260 (One side 130) 1. Specifications Explanation for Symbols 1) Stroke 2) Applicable Controllers 3) Cable Length 4) Option [Stroke and Open/Close Maximum Speed] Stroke Lead (mm) 210, 260 (mm) 2 45 (One side) (One side) << 140 (One side) >> (Note) (Note) (Unit: mm/s) It may not reach the maximum velocity in some conditions for the operation stroke and acceleration. In brackets << >> shows the specifications in used ambient operating temperature at 5 C or lower. [Actuator Specifications] Item Content Drive system Positioning repeatability Trapezoid screw ±0.01mm Backlash Lost motion Lead 2 Lead 8 Lead 2 Lead mm or less 0.3mm or less 0.25mm or less 0.3mm or less Allowable static moment Ma : 115N m Mb : 115N m Mc: 229N m Allowable dynamic moment Ma : 44.7N m Mb : 44.7N m Mc : 89.1N m Brake (option) grip force Ambient operating temperature/humidity (Note) Lead 2 - Lead to 40 C, 85%RH or less (Non-condensing) Lead 2 possesses the self-locking feature, which maintains the grip force on a workpiece even after the power gets turned off. 1-8

32 1.2 Specifications [Allowable Moment Reference Position for Offset] Calculate Ma and Mc moment based on the arrow position. 1. Specifications [Relation between the Current Limit Value and the Grip force] The graph shows the grip force on one slider. GRST7 Lead 2 GRST7 Lead 8 Caution The dispersion of grip force should be +/-25% (F.S.) (reference). 1-9

33 1.2 Specifications Caution It is a reference when assuming the speed is 5mm/s (lead 2), 10mm/s (lead 8). The maximum grip force shown in the table is a value under the conditions below. Total value of grip force of both slides at the top surface of the slides (grip point = 0mm, overhang = 0mm) F/2 F/2 L 1. Specifications The relation between the current limit value and the grip force is a reference and the grip force could vary in the actual use. The variance of the gripping becomes large when the current limit value is low. Use the product within the range in the graph for the current limit value. The gripping will not be stable if used below 20% (lead 2), below 30% (lead 8). There is even a case that it would not operate. An operation cannot be made also when it is beyond 70%. Doing so may cause degradation in the motor coil insulation by heat radiation, which results in shortening the product life. For CON-system controllers such as PCON, when the approach speed to the pressing start position (setting in the position table) is 5mm/s or less, pressing will be performed with the approach speed In such a case also the pressing force will be unstable. In such cases, check in advance that the actuator can be used with no problem before omit using. For SEL-system controllers, such as MSEL, press at the speed set by PAPR instruction, regardless of the approach speed up to the pressing start position. 1-10

34 1.2 Specifications Duty Ratio Duty ratio is an operating rate, which indicates the time that the actuator is running in one cycle by percentage. 1. Specifications It can operate continuously when the duty ratio is 100%. 1-11

35 1.3 Operating Conditions 1.3 Operating Conditions It is necessary to satisfy the conditions stated below to use the product. Conduct the following calculation to make sure it is satisfied. Procedure 1 Check for the necessary grip force and transportable work piece mass Procedure 2 Check for the vertical allowable load of the fingers and allowable moment 1. Specifications Procedure 1 Check for the necessary grip force and transportable work piece mass If a work piece is to be gripped on the fingers with the friction force created by the grip force, the formula to calculate the necessary grip force is as follows; (1) In case of ordinary transportation F : Grip force [N] Sum of pressing force on each finger μ : Coefficient of static friction between finger attachment and work piece m : Mass of work piece [kg] g : Gravitational acceleration [= 9.8m/s 2 ] The condition to grip the work piece statically and that the work piece would not drop is; Fμ > W mg F > μ F/2 F/2 Friction coefficient μ W [mg] The necessary grip force assuming the safety factor recommended for ordinary transportation is 2 should be; F > mg μ 2 (safety factor) When coefficient of friction is μ0.1 to 0.2; mg F > 2=(10 to 20) mg 0.1 to

36 1.3 Operating Conditions 1. Specifications * The mass of a transportable work piece will get higher as the coefficient of static friction is higher. However it is necessary to that enables it to obtain a grip force of 10 to 20 times or more to ensure the safety. For ordinary work piece transportation; Necessary grip force 10 to 20 times or more of work piece mass Transportable work piece mass 1/10 to 1/20 or less of grip force (2) In case of high acceleration/deceleration speed or a big impact is applied to the work piece during transportation High inertial force, in addition to the gravity, will be applied to the work piece. In such cases, consider an even higher safety factor if it is necessary. When high acceleration/deceleration speed or a big impact is applied; Necessary grip force 30 to 50 times or more of the work piece mass Transportable work piece mass 1/30 to 1/50 or less of the grip force 1-13

37 1.3 Operating Conditions Procedure 2 Check for the vertical allowable load of the slider and allowable moment Check the vertical load and the moment applicable to the finger. Calculate Fz, Ma, Mb and Mc by referring to (1) to (3) described below, and select a model considering not to exceed the allowable value. Or, consider to make the overhang smaller at the grip point or reduce the grip force so it would not exceed the allowable value. 1. Specifications Load and the moment applicable to the slider Allowable moment reference position for offset *1 MIa, MOa MOc L C L G Slider Reaction force of workpiece gripping FX FZ H C Finger attachment Grip point Center of gravity for finger FY MIb, MOb H G attachment and workpiece *1 Allowable moment reference position for offset, refer to1.2. F X F Y F Z : External force in X direction applied to work piece and finger [N] : External force in Y direction applied to work piece and finger [N] : External force in Z direction applied to work piece and finger [N] (Note 1) L G : Distance from slider attachment surface to grip point [mm] (Note 1) H G : Distance from center of slider to grip point (Overhang) [mm] L C : Distance from slider attachment surface to center of gravity for work piece and slider attachment [mm] H C : Distance from center of slider to center of gravity for work piece and slider attachment [mm] M Ia M Ib : Moment in Ma direction generated on slider due to grip force [N m] : Moment in Mb direction generated on slider due to grip force [N m] M Oa : Moment in Ma direction generated on slider due to external force [N m] M Ob : Moment in Mb direction generated on slider due to external force [N m] M Oc : Moment in Mc direction generated on slider due to external force [N m] Ma : All moments in Ma direction generated on slider [N m] Mb : All moments in Mb direction generated on slider [N m] Mc : All moments in Mc direction generated on slider [N m] Note1 For LG and HG, have the values below as the upper limit. Exceeding the allowable range may generate an excessive moment on the slider sliding mechanism, which may be a cause of a bad impact to the product life. 1-14

38 1.3 Operating Conditions Upper Limit for Grip Point LG and Overhang HG 1. Specifications [GRST6 Lead 2] [GRST6 Lead 8] 1-15

39 1.3 Operating Conditions [GRST7 Lead 2] 1. Specifications [GRST7 Lead 8] 1-16

40 1.3 Operating Conditions Table 1: Allowable Load and Allowable Moment on the Slider (Note 1) 1. Specifications Allowable Load in Max. Allowable Moment [N m] Model Vertical [N] (Note 2) Mamax Mbmax Mcmax FZmax GRST GRST Note 1 The slider show the values for allowable load and allowable moment in static on one finger. Note 2 The values for the allowable moment are those when the load is applied in one direction only. The values become one half when the load is applied from in two directions. (1) Moment generated on slider due to grip force 1) Moment in Ma direction [MIa] 1.5FG MIa = LG FG : Grip force of gripper [N] 2) Moment in Mb direction [MIb] 1.5FG MIb = HG FG : Grip force of gripper [N] Refer to 1.2 Relation between the Current Limit Value and the Grip Force for grip force FG. As the grip force is a reference value, it is multiplied by 1.5 for the safety margin in the moment calculation. 1-17

41 1.3 Operating Conditions (2) Moment generated on the slider due to an external force External force as well as grip force will be applied to the work piece and the finger attachment in the movements such as moving straight or turning in the condition of the gripper being attached on a Cartesian Robot, Articulated Robot or other actuators. Have the following calculation. External force applied on the work piece and finger attachment [FX, FY, FZ] Figure out the following types of external forces in three directions, X, Y and Z, applied on the work piece and finger attachment considering the condition of the gripper use, and sum up all the values to determine FX, FY and FZ. a) Weight of the work piece and finger attachment F = mg m : mass of the work piece and finger attachment [kg], g : gravitational acceleration [= 9.8m/s 2 ] b) Inertial force in the gripper moving straight F = ma a : Acceleration/deceleration during transportation [m/s 2 ] c) Centrifugal force in gripper turning F = mrω 2 r : Radius of turning [m], ω : Angular velocity [deg/s] Confirm that Fz is below the allowable load vertical direction, Fzmax in Table Specifications Moment generated on the slider due to an external force Figure out the moment in each direction due to external forces FX, FY and FZ calculated above. 1) Moment in Ma direction [Moa] Moa = LcFX ) Moment in Mb direction [Mob] Mob = HcFX ) Moment in Mc direction [Moc] Moc = LcFY HcFZ 10-3 (3) All moments in each direction generated to the slider Ma = MIa + Moa, Mb = MIb + Mob, Mc = Moc Confirm that the value figured out in the calculation above is below the allowable moment stated in Table 1. (Note) Attempt to have the finger attachment minimized in size and weight even if it is in the allowable range. If the fingers are long and big in size and heavy in mass, the moment caused by an impact at gripping may cause a performance drop or give a bad impact to the guide area. 1-18

42 1.4 Option 1.4 Options With Brake (Model Code: B) 1. Specifications This is used to prevent the slider from moving during power outages or when the servo is OFF. It prevents from the slider dropped when it is installed in vertical orientation. Reversed-home Specification (Model Code: NM) The standard home position is on the motor side. However, the opposite side specification is selected if the home position direction is reversed in accordance with equipment layout or assembly direction. Motor Reversed Direction (Model Code: ML, MR) The direction to reverse the motor unit can be indicated. ML shows reversed to left and MR to right. ML MR (Left side-mounted) (Right side-mounted) 1-19

43 1.4 Option Cable Exit Direction Changed (Model Code: CJT, CJR, CJL, CJB, CJO) The orientation of the motor / encoder cable to be installed on the actuator unit can be changed to top/bottom/right/left. CJT Top CJL CJR CJO Left Right Outward 1. Specifications Figure viewed motor side from CJB Bottom Figure viewed from opposite outward Motor Reversing Type Motor Straight Type Slider Spacer (Model Code: SS) It is a spacer to set the top of the slider higher than the top of the motor cover. RCP6-GRST7 Model number of single product : RCP6-SS-GRST7 1-20

44 1.4 Option Slider Roller Specification (Model Code: SR) The structure of the slider in the standard type can be changed to the roller structure same as the one in the cleanroom type. 1. Specifications Finger Attachment Installation Tool (Model Code: MJF) It is a tool to attach a finger attachment to the slider. RCP6-GRST6 Model number of single product : RCP6-MJF-GRST6 RCP6-GRST7 Model number of single product : RCP6-MJF-GRST7 1-21

45 1.5 Accessories 1.5 Accessories Motor Encoder Integrated Cables : Except for RCON, RCM-P6PC Controller Model CB-CAN-MPA 1. Specifications (Note) About thickness AWG22/19 The thickness is AWG22 when the cable length is 5m or less, and AWG19 when longer than 5m. The cable length should be 1m at minimum and 20m at maximum. Order can be make in unit of 1m long. An example for model codes is as shown below. Cable length 1m CB-CAN-MPA010-(RB) Cable length 3m CB-CAN-MPA030-(RB) Cable length 10m CB-CAN-MPA100-(RB) 1-22

46 1.5 Accessories Motor Encoder Integrated Cables Robot Type : Except for RCON, RCM-P6PC Controller 1. Specifications Model CB-CAN-MPA -RB (Note) About thickness AWG22/19 The thickness is AWG22 when the cable length is 5m or less, and AWG19 when longer than 5m. The cable length should be 1m at minimum and 20m at maximum. Order can be make in unit of 1m long. An example for model codes is as shown below. Cable length 1m CB-CAN-MPA010-RB Cable length 3miri CB-CAN-MPA030-RB Cable length 10m CB-CAN-MPA100-RB 1-23

47 1.5 Accessories Motor Encoder Integrated Cables : RCON, RCM-P6PC Controller Model CB-ADPC-MPA 1. Specifications (Note) About thickness AWG22/19 The thickness is AWG22 when the cable length is 5m or less, and AWG19 when longer than 5m. The cable length should be 1m at minimum and 20m at maximum. Order can be make in unit of 1m long. An example for model codes is as shown below. Cable length 1m CB-ADPC-MPA010 Cable length 3m CB- ADPC -MPA030 Cable length 10m CB- ADPC -MPA

48 1.5 Accessories Motor Encoder Integrated Cables Robot Type : RCON, RCM-P6PC Controller 1. Specifications Model CB-ADPC-MPA -RB (Note) About thickness AWG22/19 The thickness is AWG22 when the cable length is 5m or less, and AWG19 when longer than 5m. The cable length should be 1m at minimum and 20m at maximum. Order can be make in unit of 1m long. An example for model codes is as shown below. Cable length 1m CB-ADPC-MPA010-RB Cable length 3m CB- ADPC -MPA030-RB Cable length 10m CB- ADPC -MPA100-RB 1-25

49 ROBO Cylinder Chapter Installation 2.1 Precautions for Transportation Installation and Storage/preservation Environment 2-3 Installation Environment 2-3 Storage/preservation Environment How to Install 2-5 Installation Orientation 2-5 Precautions Regarding Stainless Steel Sheet 2-6 Installation Surface 2-7 Installation of the Main Unit 2-8 Finger Attachment, Mounting Transported Objects 2-14 Installation of the finger attachment installation tool (MJF Option) 2-16

50 2.1 Precautions for Transportation 2.1 Precautions for Transportation 2. Installation [Handling the Package] Do not damage or drop the package. The package is not specially designed to withstand dropping or shock due to collision. Keep the unit in horizontal orientation for stationary positioning or transportation. Do not climb onto the package. Do not put anything that could deform the package on it. 2-1

51 2.1 Precautions for Transportation [Handling after unpacking] Hold the base part when you carry the unit. Do not carry the unit by its motor cover or stainless steel sheet. Do not damage or drop the package during transportation. Do not apply excessive force to any part of the actuator. For the names of each part, refer to Names of the Parts on page Intro-13, Installation [Handling when assembled into machinery (system)] Fix the slider so they would not accidently move during transportation. If the actuator or any moving part is overhanging, fix it appropriately to avoid large wobbles due to external vibration. When transporting without fixing the tip, do not apply impact of 0.3G or more. When suspending machinery (system) with ropes, be careful not to catch the rope on the actuator or cable. 2-2

52 2.2 Installation and Storage/preservation Environment 2.2 Installation and Storage/preservation Environment Usage is possible in environments of pollution degree 3 or equivalent. 2. Installation Pollution degree 3: Environment with conductive pollution or dry nonconductive pollution but may get to conductive pollution due to occasional temporary condensation. (IEC ) Installation Environment The actuator should be installed in a location other than those specified below. In general, the installation environment should be one in which an operator can work without protective gear. Where the actuator receives radiant heat from strong heat sources such as heat treatment furnaces Where the ambient temperature exceeds the range of 0 to 40 C Where the temperature changes rapidly and condensation occurs Where the relative humidity exceeds 85% RH Where the actuator receives direct sunlight Where the actuator is exposed to corrosive or combustible gases Where the ambient air contains a large amount of powder dust, salt or iron (at level exceeding what is normally expected in an assembly plant) Where the actuator is subject to splashed water, oil (including oil mist or cutting fluid) or chemical solutions Where the actuator receives impact or vibration Where the altitude is more than 2,000m Also, provide sufficient work space for the following maintenance and inspection: Space to replenish grease Space to replace the motor If the actuator is used in any of the following locations, provide sufficient shielding measures: Where noise generates due to static electricity, etc. Where the actuator is subject to a strong electric or magnetic field Where the actuator is subject to ultraviolet ray or radiation 2-3

53 2.2 Installation and Storage/preservation Environment Storage/preservation Environment For the storage and preservation environment, see the installation environment. However, give especial consideration to the prevention of condensation during long-term storage/preservation. Unless especially specified, desiccant is not included in the package at shipping. If the product is to be stored/preserved in an environment where condensation is anticipated, take condensation preventive measures. For short-term storage, it can be stored at 60 C or below. 2. Installation For storage of one month or more, make sure that the temperature does not exceed 50 C. The product should be placed horizontally for storage and preservation. If storing in the packaged condition, observe the conditions, if any, regarding storage orientation. 2-4

54 2.3 How to Install 2.3 How to Install Installation Orientation : Type: RCP6-GRST6, GRST7 Horizontal installation Vertical installation 2. Installation Gravity Working Direction Gravity Working Direction Sideway installation Ceiling mount installation Gravity Working Direction Gravity Working Direction Caution When installing the unit vertically, keep the motor on top to the greatest extent possible. If the motor is installed on the bottom, the grease may separate due to long-term disuse, causing the base oil to flow into the motor part. The controller and motor/encoder may break down due to the entry of the base oil. 2-5

55 2.3 How to Install Precautions Regarding Stainless Steel Sheet During installation and transport, do not grasp or press on the stainless steel sheet. Otherwise, this may lead to stainless steel sheet damage. Although lateral or ceiling installation is possible, it may cause slackness or misalignment of the stainless steel sheet. Continued usage in this orientation may lead to damage to the stainless steel sheet. (It is the reason posture is judged in the previous page.) Adjust the stainless steel sheet if slackness or misalignment occurs. Install the unit in an environment that would not allow any object that possesses viscosity such as adhesive or paint dropped on the stainless steel sheet, or have a countermeasure so such an object would not be applied on the sheet. It could cause a slider operation error or damage on the stainless steel sheet if any object that possesses viscosity such as adhesive or paint dropped on the stainless steel sheet. 2. Installation 2-6

56 2.3 How to Install Installation Surface The body mounting surface should be a machined surface or a plane with similar accuracy. The mounting stand should have a structure rigid enough to prevent the generation of vibration, etc. 2. Installation Also consider enough space necessary for maintenance work such as actuator replacement and inspection. The bottom surface and both side surfaces of the body base serve as the reference surfaces for slider running accuracy. Use these surfaces as the reference surfaces for mounting when running accuracy is required. Reference surfaces Reference surfaces Reference surfaces effective range When mounting using the side reference surface, machine the installation surface according to the figure below. A dimension R0.3 or less GRST6C GRST6R GRST7C GRST7R 2 to 4mm or less 2-7

57 2.3 How to Install Installation of the Main Unit [When using the tapped holes on the bottom of the base] The unit has a tapped holes at the bottom of the base for mounting. It can be affixed at the back using the tapped holes. For details regarding the position and dimensions, Refer to "Chapter 6 External Dimensions". 2. Installation Dimensions for Tapped Hole Positions Through Hole Tapped Hole Reame Hole Reference Surface Oblong Hole B A Oblong Hole Model Name GRST6C GRST6R GRST7C GRST7R Tapped Hole Size M5 M5 Tapped Holes Depth Reamed Hole [mm] Oblong Hole Through (screwing depth should be 10mm or less) Through (screwing depth should be 10mm or less) 4H7 Depth 5.5 A: B:5 Depth 5.5mm or less H7 Depth 6 A:4 B:5 Depth 6mm or less 0 2-8

58 2.3 How to Install [Tightening Torque] Model Name Tapped Hole Size Tightening Torque In the case that steel is used for the In the case that aluminum is used bolt seating surface: for the bolt seating surface: 2. Installation GRST6C GRST6R GRST7C GRST7R M5 M5 7.27N m (0.74kgf m) 7.27N m (0.74kgf m) 3.42N m (0.35kgf m) 3.42N m (0.35kgf m) Notice The use of high-strength bolts of ISO-10.9 or higher is recommended. Make sure the internal thread and bolt effective engagement length is approximately 1.8 times the nominal diameter or more. 2-9

59 2.3 How to Install [Using the Through Holes on the Top of the Base] As are equipped with through holes on the base for purpose of installation from the top, it is available to screw in from the top side. Detach the side covers on the sides when installing. 2. Installation A For mounting bolts, use hexagonal socket head bolts indicated in the following table depending on the platform material. Model Name Through Hole Mounting Bolt A [mm] Tightening Torque GRST6C GRST6R 4.5 drilled hole, 8 counter boring depth 4.5 M N m (0.18kgf m) GRST7C GRST7R 6 drilled hole, 9.5 counter boring depth 5.5 M N m (0.35kgf m) 2-10

60 2.3 How to Install Detaching Side Cover Remove 4 attachment screws (+) with a Philips screwdriver. The slider cannot be driven only with ROBO Cylinder itself if it is equipped with a brake. Connect a controller and have JOG operation to move the slider to perform installation. 2. Installation Caution Attempt not to drop the bolts, tools, etc. on the stainless steel sheet when tightening the bolts. Please avoid making a dent mark or scratches. Please be sure to follow the following precautions when using the through holes on the top of the base. When the motor cover is removed and the encoder is visible, do not touch the encoder part directly with hands. If touched with hands, the encoder phase may change, resulting in an error. Encoder Notice The use of high-strength bolts of ISO-10.9 or higher is recommended. Make sure the internal thread and bolt effective engagement length is approximately 1.8 times the nominal diameter or more. 2-11

61 2.3 How to Install [When Using Attachment Holes on Bracket in Motor Reversing Type] As there are tapped holes on the reversing bracket, it is available to screw in from the back. (Note) In case of attaching the unit on the back side with using the reversing bracket, it is necessary without failure to have a support block to support the unit body. Avoid installation using the reversing bracket if it is not available to have a support block to support the unit body. Refer to Precautions when using reversing brackets. 2. Installation A B 4-M A Model Name A B Attachment Hole Diameter [M] GRST6R M6 Depth 12 Tightening Torque In the case that In the case that steel is used for the aluminum is used bolt seating for the bolt seating surface: surface: 12.3N m 5.4N m (1.26kgf m) (0.55kgf m) GRST6R 55 8 M8 Depth N m (3.06kgf m) 11.5N m (1.17kgf m) Notice The use of high-strength bolts of ISO-10.9 or higher is recommended. Make sure the internal thread and bolt effective engagement length is approximately 1.8 times the nominal diameter or more. 2-12

62 2.3 How to Install [Precautions when using reversing brackets] Availability of installation for each installation posture is as shown below: 2. Installation Installation Posture Support Horizontal Vertical Ceiling Mount No Yes Caution Do not attempt to affix the unit only with the tapped holes on the side-mounted bracket. Do not apply external force to the actuator body after installation External force may cause malfunctions or damage to parts. [Precautions for horizontal mounting using reversing brackets] Prepare a support block for the body, as shown in the figure below. Support block 2-13

63 2.3 How to Install Finger Attachment, Mounting Transported Objects Use the tapped mounting holes on the top surface of the slider to fix finger attachment and transported objects. There are 4 reamed holes on the top surface of the slider. Use these reamed holes if repeated attaching and detaching is required. If fine-tuning of perpendicularity, etc. is required, use one of the reamed holes for this adjustment. Refer to the figure below for the screw-in depth and reamed hole depth. 2. Installation Pitch tolerance from reamer ± 0.02 Mounting Bolt Model Name A B C Reamed Hole [R] Tapped Hole [M] Bolt Nominal Diameter Tightening Torque In the case that In the case that steel is used for aluminum is the bolt seating used for the bolt surface: seating surface: GRST6C GRST6R H7 Depth 6 M5 Depth 10 M5 7.27N m (0.74kgf m) 3.42N m (0.35kgf m) GRST7C GRST7R H7 Depth 10 M5 Depth 10 M5 7.27N m (0.74kgf m) 3.42N m (0.35kgf m) 2-14

64 2.3 How to Install Caution Be careful with regard to the length of the mounting bolt and positioning pin. The use of screw-in depth greater than that of the tapped or reamed mounting holes may damage the tapped hole or reduce the mounting strength of the transported object, leading to decreased accuracy or unexpected accidents. 2. Installation Notice The mounting bolts are to be prepared by the customer. The use of high-strength bolts of ISO-10.9 or higher is recommended. 2-15

65 2.3 How to Install Mounting on Finger Attachment Installation Tool (MJF Option) (Note) It is not available to attach the finger attachment fixture (Model Code: MJF) on the slider spacer (Model Code: SS). The fixture is equipped with a tapped hole to affix a finger attachment and a reamed hole for positioning. Use these reamed holes if repeated attaching and detaching is required. If fine-tuning of perpendicularity, etc. is required, use one of the reamed holes for this adjustment. 2. Installation * The dimensions of MJF option is in common for GRST6C/GRST6R/GRST7C/GRST7R. In case it is assembled in our factory before shipping, the parallelism between fixtures should be adjusted as shown in the figure below. 0.1 A A 2-16

66 2.3 How to Install The structure of the fixture is as shown in the figure below. When affixing the fixture again, fix it with the tightening torque shown in the table below. 2. Installation Parallel pin 2 6h Base of Affixing Part Hexagonal Socket Head Bolt 2 4-M5 12 Hexagonal Socket Head Bolt 2 2-M Attachment Affixing Part Parallel pin 2 2-5h7 14 Bolts M5 M6 Tightening Torque 4.11N m (0.42kgf m) 6.44N m (0.66kgf m) 2-17

67 ROBO Cylinder Chapter Connecting with the Controller 3.1 Connecting with the Controller 3-1

68 3.1 Connecting with the Controller 3.1 Connecting with the Controller As the connection cable for the controller and the actuator, use the IAI-dedicated connection cable. Please consult with IAI if you require a different kind of cable than the one supplied. 3. Connecting with the Controller RCP6- Dedicated Controller PCON-CB/CGB PCON-CYB/PLB/POB MCON MSEL Dedicated Connection Cable Robot Cable :5m or below r=68mm or more (movable use) :In the case of exceeding 5m r=73mm or more (movable use) Standard Cable :5m or below r=85mm or more (fixed use) :In the case of exceeding 5m r=91mm or more (fixed use) Dedicated Cable Motor Encoder Integrated Cables : CB-CAN-MPA Motor Encoder Integrated Robot Cables : CB-CAN-MPA -RB * represents the cable length. The longest corresponds to 20m. e.g.) 080 = 8m 3-1

69 3.1 Connecting with the Controller RCP6- Dedicated Connection Cable (Connect RCP6 and dedicated controller) Dedicated Controller RCON RCM-P6PC Robot Cable :5m or below (Note 1) r=68mm or more (movable use) :In the case of exceeding 5m (Note 2) r=73mm or more (movable use) Standard Cable :5m or below (Note 1) r=85mm or more (fixed use) :In the case of exceeding 5m (Note 2) r=91mm or more (fixed use) Dedicated Cable Motor Encoder Integrated Cables : CB-ADPC-MPA Motor Encoder Integrated Robot Cables : CB-ADPC-MPA -RB * represents the cable length. The longest corresponds to 20m. e.g.) 080 = 8m 3. Connecting with the Controller 3-2

70 3.1 Connecting with the Controller Caution For wiring, please follow the warnings stated below. When constructing a system as the machinery equipment, pay attention to the wiring and connection of each cable so they are conducted properly. Not following them may cause not only a malfunction such as cable breakage or connection failure, or an operation error, but also electric shock or electric leakage, or may even cause a fire. The actuator cable ejected from the motor unit is a cable to be affixed. Affix the cable so it would not get bent repeatedly. 3. Connecting with the Controller Make sure to turn the power off in the process of power line or cable connection or disconnection. Do not attempt to cut a dedicated cable with connectors on both ends to extend, shorten or re-joint it. Hold the dedicated cable to avoid mechanical force being applied to the terminals and connectors. Use a cable pipe or duct to have an appropriate protection when there is a possibility of mechanical damage on a dedicated cable. In case a dedicated cable is to be used at a moving part, make sure to lay out the cable without applying any force to pull the connector or extreme bend on the cable. Do not attempt to use the cable with a bending radius below the allowable value. Make certain that the connectors are plugged properly. Insufficient connection may cause an operation error, thus it is extremely risky. Do not lay out the cables to where the machine runs over them. Pay attention to the cable layout so it would not hit peripherals during an operation. In case it does, have an appropriate protection such as a cable track. When a cable is used hanging on the ceiling, prevent an environment that the cable swings with acceleration or wind velocity. Make sure there is not too much friction inside the cable storage equipment. Do not apply radiated heat to power line or cables. Do not attempt to bend the cable at any point within 150mm from the end of the connector. Standard Cables CB-CAN-MPA, CB-ADPC-MPA Robot Cables CB-CAN-MPA -RB, CB-ADPC-MPA -RB 150mm 150mm 3-3

71 3.1 Connecting with the Controller Caution Have a sufficient radius for bending, and avoid a bend concentrating on one point. Do not let the cable bend, kink or twist Do not pull the cable with a strong force. 3. Connecting with the Controller Pay attention not to concentrate the twisting force to one point on a cable. 3-4

72 3.1 Connecting with the Controller Caution Do not pinch, drop a heavy object onto or cut the cable. 3. Connecting with the Controller When a cable is fastened to affix, make sure to have an appropriate force and do not tighten too much. PIO line, communication line, power and driving lines are to be put separately from each other and do not tie them together. Arrange so that such lines are independently routed in the duct. 3-5

73 3.1 Connecting with the Controller Caution Follow the instructions below when using a cable track. If there is an indication to the cable for the space factor in a cable track, refer to the wiring instruction given by the supplier when storing the cable in the cable track. Avoid the cables to get twined or twisted in the cable track, and also to have the cables move freely and do not tie them up. (Avoid tension being applied when the cables are bent.) Do not pile up cables. It may cause faster abrasion of the sheaths or cable breakage. 3. Connecting with the Controller 3-6

74

75 ROBO Cylinder Chapter Operation 4.1 Operation of the Fingers 4-1 Movement Stroke 4-1 Home Return Direction 4-1 Position Indication 4-1 Indication of Speed and Acceleration Release of the Gripped Work Piece 4-3

76 4.1 Operation of the Fingers 4.1 Operation of the Fingers Movement Stroke The stroke stated in the specifications is the sum of the movement distance for both slider. The movement distance of one finger is 1/2 of the stroke. Home Return Direction Distance Between Slider 4. Operation Movement Distance of One Side Home Return Direction The open side moving end of the slider is the home position. The home position is on the closing end for the home reversed type (NM). Position Indication The movement distance from the home position of one slider to the closing side is the position value. (Indication of max. position value = 1/2 of stroke) 4-1

77 4.1 Operation of the Fingers Indication of Speed and Acceleration Indication value is the value for one slider. Relative speed and acceleration are double of the indicated values. GRST6C/GRST6R GRST7C/GRST7R Open/Close Stroke [mm] Movement Distance of One Side [mm] Distance Between Slider [mm] MAX MIN Operation 4-2

78 4.2 Release of the Gripped Work Piece 4.2 Release of the Gripped Work Piece This gripper possesses a structure to keep the lead 2 force by the self-locking feature even when the servo is OFF or the power to the controller is OFF. When it is necessary to remove a workpiece off the gripper while the power is OFF, it you need to either twist the slider open/close screw with using a slotted screwdriver or take off the finger attachment on one side of slider. 4. Operation Slider open/close screw [Open side : Counterclockwise Turn] Caution When the work piece removal is required at the power OFF, do not attempt to pull off the work piece forcefully to remove it. Remove the work piece either by twisting the slider open/close screw or detaching one side of the finger attachment. Pulling off the work piece forcefully may cause damage to the product. Remove the gripped work piece when the device would not be used for long time. Leaving the product with a work piece being held for a long term may drop the performance or give a bad impact to the guide. 4-3

79 ROBO Cylinder Chapter Maintenance and Inspection 5.1 Precautions for Maintenance and Inspection Work Inspection Items and Schedule 5-3 Gripper Type Visual Inspection Items 5-4 External Visual Inspection 5-4 Internal Visual Inspection Cleaning 5-7 External Cleaning 5-7 Internal Cleaning Greasing Method How to Replace Components 5-14 Stainless Steel Sheet Replacement/adjustment 5-14 Belt Replacement/adjustment 5-18 Motor Replacement 5-26

80 5.1 Precautions for Maintenance and Inspection Work 5.1 Precautions for Maintenance and Inspection Work Make sure to read the following precautions before conducting any maintenance or inspection. 5. Maintenance and Inspection Caution Do not climb on or put anything on the actuator. Otherwise, this may lead to accidental falling, injury or damage to the product due to falling objects, product loss of function or performance degradation, or shortening of product life. Before releasing the brake, make sure to check there is nothing that will interfere with moving parts within the operation range. The slider may fall, possibly injuring the operator or people nearby and damaging the actuator, workpiece or equipment. Check that the power to the actuator is OFF before conducting any maintenance or inspections. Be careful not to lose the cover or any removed screws. Be sure to return the product to the original condition after maintenance and inspection work. Mounting in an incomplete state may cause injuries or damage to the product. Do not modify, disassemble/assemble, or use maintenance parts not specified on your own discretion under any circumstances. The grease film may run out if the actuator performs return operation continuously over a distance of 30mm or less. As a guideline, every 5,000 to 10,000 cycles, have approximately 5 cycles of return operation over a 50mm distance or more to regenerate the oil film. The trapezoid screw or guide may be damaged if the oil film runs out. 5-1

81 5.1 Precautions for maintenance and inspection work Notice First, be sure to wipe off the old grease, and then supply new grease. The degradation speed of grease may differ depending on the operating environment (temperature, humidity and ambient atmosphere). It is recommended to shorten the grease supply period if the actuator is used under poor environmental conditions such as high temperatures, high humidity or dusty atmospheres. Also, it is recommended to improve the environmental conditions in case the grease changes color notably due to poor operating conditions. Base oil may separate from the grease due to the mounting orientation or operating conditions. Base oil may also leak from the inside of the actuator to the exterior through gaps. Check visually for oil drips when supplying grease. An actuator stored for 6 months or more may suffer from grease degradation. Supply grease before the start of use. For details, refer to 5.5 Greasing Method. 5. Maintenance and Inspection 5-2

82 5.2 Inspection Items and Schedule 5.2 Inspection Items and Schedule Follow the maintenance inspection schedule below. It is assumed that the equipment is operating 8 hours per day. If the equipment is running continuously night and day or otherwise running at a high operating rate, inspect more often as needed. Gripper Type * Stainless steel sheet life guideline: 5,000km 5. Maintenance and Inspection Inspection period External inspection Internal inspection Screw Greasing Start of work inspection month inspection month inspection month inspection Every 6 months thereafter Guide 5-3

83 5.3 Visual Inspection Items 5.3 Visual Inspection Items Refer to 5.5 Greasing Method for how to supply grease in detail. Refer to 5.6 How to Replace Components for detailed information about specific component replacement and adjustment methods. External Visual Inspection Inspection items Maintenance work Is abnormal noise or vibration generated? Are actuator mounting bolts loose? Is the cable scratched? Is the connector loose? Take an action by referring to Troubleshooting in Controller Instruction Manual. Tighten them further. Replace if the damage is severe. Re-insert correctly. 5. Maintenance and Inspection Is grease dripping out? (especially if vertically mounted) Is the stainless steel sheet scratched? Is the stainless steel sheet misaligned or slack? Clean up any drips. Replenish the grease. Replace the stainless steel sheet. Adjust the alignment and hang. 5-4

84 5.3 Visual Inspection Items Refer to 5.5 Greasing Method for how to supply grease in detail. Refer to 5.6 How to Replace Components for detailed information about specific component replacement and adjustment methods. Internal Visual Inspection Inspection items Maintenance work Wear debris found? The trapezoid screw guide may be damaged. Contact IAI. 5. Maintenance and Inspection Has foreign matter penetrated inside? Is the trapezoid screw or guide grease not lubricating well? (Even if the grease is brown, lubrication is adequate if the running surface is shiny) Remove the foreign matter, clean, and inspect the interior for any damage. Wipe away the old grease, then replenish with new grease. Is dust or foreign matter adhered to the trapezoid screw or guide? Replenish with new grease after cleaning. Internal inspection method 1) Loosen the screws on the side cover and detach the side cover. 2) Check inside. 3) After finishing the inspection, assemble back in the reverse order. If you touch the edge of the stainless steel sheet in the attaching the side cover process, the sheet may get damaged or wavy which result in shortening life or earlier wearout. To avoid touching the edge of the sheet, insert a spacer (approximately 0.1 to 0.2mm) between the sheet and cover to push up the sheet, and then push in the cover. When affixing the side cover, tighten the screws with the tightening torque described below. Screw Diameter M3 Tightening Torque 41.4N cm 4) Make sure that the slider and the side cover do not interfere, moving the slider backwards and forwards between the strokes. 5-5

85 5.3 Visual Inspection Items Caution Do not damage the stainless steel sheet by bending it forcefully during internal inspection. Do not tug on the stainless steel sheet or in any way attempt to reposition it. Change in the attached condition may cause the sheet to be mounted unevenly or impact the product life. Keep in mind that the edges of the stainless steel sheet can cause injuries. Always wear gloves when working on it. Please be sure to follow the following precautions when using the through holes on the top of the base. When the motor cover is removed and the encoder is visible, do not touch the encoder part directly with hands. If touched with hands, the encoder phase may change, resulting in an error. Encoder 5. Maintenance and Inspection 5-6

86 5.4 Cleaning 5.4 Cleaning External Cleaning Clean exterior surfaces as necessary. Use a soft cloth to wipe away dirt and buildup. Do not blow too hard with compressed air as it may cause dust to get in through the gaps. Do not use oil-based solvents as they can harm lacquered and painted surfaces. To remove severe buildup, wipe gently with a soft cloth soaked in a neutral detergent or alcohol. 5. Maintenance and Inspection Internal Cleaning Use a soft cloth to wipe away dirt and buildup. Do not blow too hard with compressed air as it may cause dust to get in through the gaps. Do not use oil-based solvents, neutral detergent or alcohol. 5-7

87 5.5 Greasing Method 5.5 Greasing Method [Grease used] Use an equivalent product. Application location During maintenance (recommended product) Default (reference) Guide Kyodo Yushi/Multemp LRL No.3 Kyodo Yushi/Multemp LRL No.3 Trapezoid screw Kyodo Yushi/Multemp AC-D Kyodo Yushi/Multemp AC-D Caution Never use fluorine-based grease and urea-based grease. Mixing with lithium-based grease not only reduces the performance of the grease, it may even cause damage to the actuator. 5. Maintenance and Inspection 5-8

88 5.5 Greasing method [Greasing method] Guide (supply to both through grease fitting), trapezoid screw Greasing method [Guide] Guide (supply to both through grease fitting) 1 Take off the side cover attachment screws. Side Cover Attachment Screws 5. Maintenance and Inspection 2 Take off the side cover. (The grease nipple will appear.) * When the side cover on the other side has been detached, the other grease nipple also appears. Grease Nipple (There is one on the other side) 5-9

89 5.5 Greasing Method 3 Supply grease from the grease nipple, using the grease gun. Wipe off the grease before supplying new in case it is extremely dirty. * Grease can also be applied from the grease nipple on the other side. * Grease gets supplied to the both guides. * Make sure to use a grease gun that is applicable for the grease nipple inlet diameter shown table. Grease Gun Grease Nipple Diameter 3.5 Grease Gun Nozzle Supplier of Nozzle Grease gun of mounting screw R1/8 (Example) GC-57K (Yamada Corporation) NZ3 NSK Model Name Amount of Grease Supply (Reference) GRST6C/GRST6R 0.5cc to 1.0cc GRST7C/GRST7R 1.0cc to 1.5cc 5. Maintenance and Inspection 4 Move the slider back and forth in the stroke range after supplying grease so it spreads out evenly in the area. As Lead 2 possesses the self-lock feature, the slider cannot be moved with hand. Use the slider open/close screw to have the actuators move back and forth. In case it is equipped with a brake, connect a controller and use a teaching tool to have a back and forth move at around 20mm/s. * Confirm that the ball tracks on the guide look glossy with oil of grease. Supply grease again if it is not spread enough. * Wipe off excess grease. 5-10

90 5.5 Greasing method 5 [Trapezoid screw] Wipe off old grease on the trapezoid thread with cloth, and then apply new grease with hand. (Note) Pay attention to the stainless steel sheet not to touch it and make it deformed. Apply to whole area of trapezoid thread 5. Maintenance and Inspection 6 Move the slider back and forth in the stroke range after supplying grease so it spreads out evenly in the area. As Lead 2 possesses the self-lock feature, the slider cannot be moved with hand. Use the slider open/close screw to have the actuators move back and forth. In case it is equipped with a brake, connect a controller and use a teaching tool to have a back and forth move at around 20mm/s. * Confirm that the ball tracks on the guide look glossy with oil of grease. Supply grease again if it is not spread enough. * Wipe off excess grease. Caution Supplying too much guide and trapezoid screw may increase sliding resistance and load to the motor, resulting in a drop of performance. Also, excess grease on the ball screw may be splashed around in the ambience. 5-11

91 5.5 Greasing Method 7 8 Attach the side covers after grease supply is finished. If you touch the edge of the stainless steel sheet in the attaching process, the sheet may get damaged or wavy which result in shortening life or earlier wear-out. To avoid touching the edge of the sheet, insert a spacer (approximately 0.1 to 0.2mm) between the sheet and cover to push up the sheet, and then push in the cover. When affixing the side cover, tighten the screws with the tightening torque described below. Screw Diameter M3 Tightening Torque 41.4N cm Make sure that the slider and the side cover do not interfere, moving the slider backwards and forwards between the strokes. 5. Maintenance and Inspection 5-12

92 5.5 Greasing method Caution Do not damage the stainless steel sheet by bending it forcefully during work. Keep in mind that the edges of the stainless steel sheet can cause injuries. Always wear gloves when working on it. Pay attention not to pinch your hand or finger to the slider when operating the slider with a teaching tool. The front bracket is supporting the ball screw. Do not detach it. If the front bracket loses its tuned condition, it may cause an increase of driving resistance, shortened life of each component or abnormal noise due to the center of the axis being off the right position. In case the grease got into your eye, wash it with clean water for 15 minutes and 5. Maintenance and Inspection immediately go see the doctor to get appropriate care. After finishing the grease supply work, wash your hands carefully with water and soap to rinse the grease OFF. 5-13

93 5.6 How to Replace Components 5.6 How to Replace Components Stainless Steel Sheet Replacement/adjustment Preparation 1) Items required for replacing the stainless steel sheet Replacement stainless steel sheet Phillips screwdriver Scale Adhesive tape Names of the Parts Sheet Retainer Slider Cover Stainless Steel Sheet Sheet Retainer Slider Cover 5. Maintenance and Inspection Caution Degradation and wear-out of the stainless steel sheet relies on its tension of attachment. If the stainless steel sheet is pulled with a huge force and the gap between the sheet and the slider cover is large, there is a risk of metal fatigue. On the other hand, if the tensile strength is too low, the stainless steel sheet would interfere with the back side of the slider cover and make dust to be generated. 5-14

94 5.6 How to Replace Components 1 Remove the screws (4 places) holding the stainless steel sheet and stainless steel sheet retainer plates (2 pieces) with using a Phillips screwdriver. Stainless steel sheet retainer plates 2 Pull the old stainless steel sheet till in front of the slider. 5. Maintenance and Inspection 3 Make sure not to pull it out completely off the both sliders. Join a new stainless steel sheet to the old one with using cellophane tape. In front of slider Pull it till in front of the slider. New stainless steel sheet Join with cellophane tape Old stainless steel sheet 4 Pull the old stainless steel sheet so the new one goes through below the slider. Pull New stainless steel sheet Old stainless steel sheet 5-15

95 5.6 How to Replace Components 5 Pull it till the new stainless steel sheet comes to the edge of the actuator. Remove the old stainless steel sheet. Pull till the edge Edge 6 7 Fix the two stainless steel sheet retainer plates using the screws (four locations). Use a Phillips screwdriver to attach it. Tightening Torque 41.4N cm After the stainless steel sheet retainer plates have been fixed, move the slider from Attachment Guide Groove Put the stainless steel sheet through the attachment guide grooves (2 places) in the center on the main unit and affix it while paying attention not to have the sheet loosened. 5. Maintenance and Inspection one side to the other side (full stroke) with your hand to check that there is no rise or slackness in the stainless steel sheet. If there is any problem, repeat from step 6). 5-16

96 5.6 How to Replace Components Caution Make sure that there is no misalignment or slack in the stainless steel sheet. This may lead to damage to the stainless steel sheet. When installing the sheet clamp, do not apply excessive force to the stainless steel sheet. 5. Maintenance and Inspection Notice As a guideline, the stainless steel sheet should last for about 5,000km of motion. However, depending on the usage or environment, replace the stainless steel sheet appropriately. It is available for customers to replace the stainless steel sheet. However, if you feel anxious about replacing it, it is recommended you ask us to do the replacement work for you. Either you bring in our product to our service office or our service staff visits your site to do the replacement work. 5-17

97 5.6 How to Replace Components Belt Replacement/adjustment [Belt Inspection] 1 Remove two hexagonal socket flat-head bolts Pulley for (where marked with a circle) with a hexagonal wrench. Detach the pulley cover. Cover 2 Belt Check the condition of the belt visually. 5. Maintenance and Inspection In generally speaking, it possesses bending life of several million times. However, the period of replacement for the belt cannot be clearly defined as the durability of it is impacted so much by the operational conditions. The timing belt gets worn away as the time passes, and it is necessary to have replacement at regular intervals with the following conditions as reference. When the gear and belt area show obvious friction. When swelling occurs as a result of oil adhesion. When damages such as a crack occurs on the belt gear and back side. For the toothed belt, it is recommended to set the interval of regular replacement cycle when in use under high wire fatigue condition in high acceleration and deceleration because it is difficult to judge the right timing for replacement by checking appearance or looseness of the wires strengthening the belt. 5-18

98 5.6 How to Replace Components [Belt to Use] IAI uses the following belt in our plant. Model IAI Maintenance Part Code Belt to Use Manufacturer Name GRST6R TB-RCP6-STRA6R 60S2M182 GB Mitsuboshi Belting Ltd. GRST7R TB-RCP6-STRA7R 100S3M225 GB Mitsuboshi Belting Ltd. 5. Maintenance and Inspection 5-19

99 5.6 How to Replace Components [Belt Replacement] Items required for replacing the belt Belt for Replacement Hexagon Wrench 2.5mm, 3mm 2.0mm (For hex socket button head bolts) Phillips screwdriver Tension Gauge (that is available for pulling with 90N) Long Tie-Band (thin string) 1 2 Remove two hex socket button head bolts for (where marked with a red circle) with a hexagonal wrench. Detach the pulley cover. Remove the four cross recessed screws holding the motor cover and the end cover assembly (at points marked in red circles) using a phillips screwdriver. Pulley Cover 5. Maintenance and Inspection GRST6R GRST7R 5-20

100 5.6 How to Replace Components 3 Slide the end cover assembly to a position where the motor connector and the encoder connector can be seen. 4 Unplug the motor connector. 5. Maintenance and Inspection 5 Unplug the encoder connector. * When it is difficult to take it off, use a slotted Motor Connector Encoder Connector precision screwdriver to slide the connector little by little. 6 Slide the end cover assembly and the motor cover to take them off. 5-21

101 5.6 How to Replace Components Caution Pay attention to the encoder so you would not touch it. If you touch the encoder, the phase could move and may cause an error. Encoder 7 Remove the hex socket head cap screw and round washer that are attached for position repeatability of the motor using a hex wrench with 2.5mm parallel face width. The washer is attached in close contact with the motor bracket. Hexagonal Socket Head Bolt Circular Washer 5. Maintenance and Inspection 8 Loosen the screws holding the motor (at points marked in red, two places for GRST6R and four places for GRST7R) using Belt a hex wrench with 3mm parallel face width, take off the belt and replace it with a new one. GRST6R Belt GRST7R 5-22

102 5.6 How to Replace Components 9 Tie-Band Adjust the belt tension. Hand a cable band (thin string) on the edge of the motor unit and (thin string) pull it on a tension gauge with the specified load (specified value of the belt tension). When the load reached the specified, tighten the bolts (where marked with a red circle) with a 3mm-sized hexagonal wrench to hold the unit in the place. Model Tension Force Belt GRST6R GRST7R 25 to 30N 80 to 90N 5. Maintenance and Inspection Model GRST6R GRST7R Tightening Torque 323N cm 323N cm GRST6R Belt GRST7R 10 After adjusting the tensile strength of the belt, hold the hex socket head cap screw and round washer for position repeatability of the motor to the motor bracket and tighten them Hexagonal Socket Head Bolt up using a hex wrench with 2.5mm parallel face width. Tightening Torque The washer is attached in close contact with the motor bracket. Circular Washer 88.7N cm 5-23

103 5.6 How to Replace Components 11 Have the motor cover go through the motor and motor connector and hold it against the motor bracket. 12 Encoder Have the encoder cover assembly close to the motor and plug in the encoder connector. Connector 5. Maintenance and Inspection 13 Plug in the motor connector. Motor Connector 14 Have the end cover assembly slide slowly against the motor cover and hold it on the cover. * Check that there is no cable pinched and there is no gap or looseness. 5-24

104 5.6 How to Replace Components 15 Tighten the four cross recessed screws (at points marked in red circles) using a phillips screwdriver to affix the motor cover and the end cover assembly. Tightening Torque 41.4N cm GRST6R 5. Maintenance and Inspection 16 Hold the pulley cover with the two hex socket button head bolts (at points marked in red circles) and tighten the screws using a hex Pulley Cover GRST7R wrench. Tightening Torque 47.9N cm 5-25

105 5.6 How to Replace Components Motor Replacement [Motor Straight Type] Caution The encoder part of the motor for replacement and the control board of RCP6S may fail due to static electricity. Please be sure to follow the following precautions during work. Pay attention to the encoder so you would not touch it. If you touch the encoder, the phase could move and may cause an error. Encoder Do not touch the control board directly with hands except when replacing the control board of RCP6S. Before replacement work, touch metal objects and the like to release any static electricity from body. Do not perform replacement work at the place where static electricity is likely to occur (carpet, etc). 5. Maintenance and Inspection Items required for replacing the motor Motor Unit for Replacement For RCP6 For RCP6S Hexagonal wrench set 2mm or 2.5mm-sized 5-26

106 5.6 How to Replace Components 1 For Remove the fixing screw affixing the actuator and the motor unit with a 2mm-sized (GRST6C) or 2.5mm-sized (GRST7C) fixed screws actuator and motor unit hexagonal wrench. Detach the motor unit. 5. Maintenance and Inspection 2 Make the profiles on the actuator side and motor unit side aligned so the projection matches to the slit. Make the projection and slit matched with each other. Apply grease to the coupling part. NOXLUB TL1010 grease made by NOK 3 For Attach the motor unit for replacement with the projection being matched with the slit. Tighten the fixing screw to affixing the motor fixed screws actuator and motor unit unit to the actuator with 2.5mm-sized (GRST6C) or 2.5mm-sized (GRST7C) hexagonal wrench. Model GRST6C GRST7C Tightening Torque 167N cm 353N cm 5-27

107 5.6 How to Replace Components 4 Make sure to conduct a home return on a PC or a touch panel teaching after motor replacement. Refer to the instruction manual of the used controller for how to perform the homereturn operation. 5. Maintenance and Inspection 5-28

108 5.6 How to Replace Components [Motor Reversing Type] Items required for replacing the motor Motor Unit for Replacement 5. Maintenance and Inspection 1 Pulley Hexagon Wrench 2.5mm, 3mm 2mm (For hex socket button head bolts) Phillips screwdriver Tension Gauge (that is available for pulling with 90N) Long Tie-Band (thin string) Remove two hex socket button head bolts for (where marked with a red circle) with a Cover hexagonal wrench. Detach the pulley cover. 5-29

109 5.6 How to Replace Components 2 Remove the four cross recessed screws holding the motor cover and the end cover assembly (at points marked in red circles) using a phillips screwdriver. GRST6R 3 Slide the end cover assembly to a position where the motor connector and the encoder connector can be seen. GRST7R 5. Maintenance and Inspection 4 Unplug the motor connector. Motor Connector 5 Unplug the encoder connector. * When it is difficult to take it off, use a slotted Encoder Connector precision screwdriver to slide the connector little by little. 5-30

110 5.6 How to Replace Components 6 Slide the end cover assembly and the motor cover to take them off. * Proceed to [Step 8] if belt is not replaced. 5. Maintenance and Inspection Caution Pay attention to the encoder so you would not touch it. If you touch the encoder, the phase could move and may cause an error. Encoder 7 If the belt is to be replaced at the same time, remove the hexagonal socket head bolt and circular washers that are mounted for position repeatability of the motor by 2.5mm-sized hexagonal wrench, after tension adjustment of the belt. The washer is attached in close contact with the motor bracket. Hexagonal Socket Head Bolt Circular Washer 5-31

111 5.6 How to Replace Components 8 Loosen the bolts (where marked with a red circle; two bolts for GRST6R, four bolts for GRST7R) holding the motor with a 3mmsized hexagonal wrench. GRST6R 9 Detach the belt off the pulleys. Pull out four bolts and remove the motor unit. GRST7R 5. Maintenance and Inspection 5-32

112 5.6 How to Replace Components 10 Attach a new motor, loosely tighten the screws (at points marked in red circles), and then hang the belt on the pulleys. * Proceed to [Step 11] if belt is not replaced. * If it is necessary to replace the belt, hand a new one. Proceed to [Step 12]. Belt 5. Maintenance and Inspection GRST6R Belt GRST7R 5-33

113 5.6 How to Replace Components 11 If the belt is not replaced at the same time and the following hexagonal socket bolts and circular washers are not removed, there is no need to adjust tension of the belt as [prescribed in 12]. Hand a cable band (thin string) on the edge of the motor unit and pull it. When it is The washer is attached in close contact with the motor bracket. Hexagonal Socket Head Bolt Circular Washer abutting against the hexagonal socket bolt, tighten the bolt (where marked with a red Belt circle) with 3mm-sized hexagonal wrench to hold the unit in the place. [To procedure 14] Model GRST6R GRST7R Tightening Torque 323N cm 323N cm GRST6R Belt 5. Maintenance and Inspection GRST7R 5-34

114 5.6 How to Replace Components 12 Tie-Band If the belt has been replaced at the same time, adjust the tension of the belt. Hand a cable band (thin string) on the edge of the motor unit and pull it on a tension gauge with the specified load (specified value of the belt tension). When the load reached the specified, tighten the bolts (where marked with a red circle) with a 3mm-sized hexagonal wrench to hold the unit in the place. (thin string) Belt 5. Maintenance and Inspection Model GRST6R GRST7R Model GRST6R GRST7R Tension Force 25 to 30N 80 to 90N Tightening Torque 323N cm 323N cm GRST6R Belt GRST7R 13 If the belt has been replaced at the same time, tighten the hexagonal socket head bolt and circular washers that are mounted for position repeatability of the motor with 2.5- mm sized hexagonal wrench after tension adjustment of the belt. Tightening Torque The washer is attached in close contact with the motor bracket. Hexagonal Socket Head Bolt Circular Washer 88.7N cm 5-35

115 5.6 How to Replace Components 14 Have the motor cover go through the motor and motor connector and hold it against the motor bracket. 15 Encoder Have the encoder cover assembly close to the motor and plug in the encoder connector. Connector 5. Maintenance and Inspection 16 Plug in the motor connector. Motor Connector 17 Have the end cover assembly slide slowly against the motor cover and hold it on the cover. * Check that there is no cable pinched and there is no gap or looseness. 5-36

116 5.6 How to Replace Components 18 Tighten the four cross recessed screws (at points marked in red circles) using a Phillips screwdriver to affix the motor cover and the end cover assembly. Tightening Torque 41.4N cm GRST6R 5. Maintenance and Inspection 19 Hold the pulley cover with the two hex socket button head bolts (at points marked in red circles) and tighten the screws using a hex Pulley Cover GRST7R wrench. Tightening Torque 47.9N cm 20 Make sure to conduct a home return on a PC or a touch panel teaching after motor replacement. Refer to the instruction manual of the used controller for how to perform the homereturn operation. 5-37