Track Motion IRBT 2002S/1402S IRC5, M2004 - ABB Group · PDF fileProduct Manual Track Motion IRBT 2002S/1402S IRC5, M2004 3HEA 800 968-001 Rev. A, November 2005

Product ManualTrack Motion

IRBT 2002S/1402SIRC5, M2004

3HEA 800 968-001 Rev. A, November 2005

The information in this document is subject to alteration without prior notice and should not be regarded as an undertaking from ABB Automation Technologies AB. ABB Automation Technologies AB assumes no responsibility for errors that may occur in this document.

ABB Automation Technologies AB bears no responsibility for damage that is a consequence of using this document or the software or hardware described in this document.

The document, or parts of it, may not be reproduced or copied without prior permission from ABB Automation Technologies AB. It may neither be imparted to a third party, nor otherwise be used without authorization. Infringement hereof will be subject to action in accordance with the applicable laws.

Further copies of this document can be obtained from ABB Automation Technologies AB at current prices.

© 2005 ABB Automation Technologies AB

ABB Automation Technologies ABRobotics & Manufacturing

SE-69582 LaxåSweden

3HEA 800 968-001 Rev. A, November 2005 i

Contents

Product ManualTrack MotionIRBT 2002S/1402S, IRC5

Specification Tab 1:

Description 1

Safety instructions 5

Technical specification 9

Variants and options 15

Installation and operation Tab 2:

Unpacking and handling 1

Mechanical installation 5

Electrical installation 11

Commissioning 15

Maintenance Tab 3:

Maintenance 1

Spare parts 9

ii 3HEA 800 968-001 Rev. A, November 2005

3HEA 800 968-001 Rev. A, November 2005 Specification i

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Tab 1: Specification1 Description 1

1.1 General 1

1.2 Identification 31.2.1 Parameter diskette 31.2.2 Terms and concepts 4

2 Safety instructions 5

2.1 Description 5

2.2 Safety during Unpacking and handling 6

2.3 Safety during mechanical installation 6

2.4 Safety during assembling the cable tray and manipulator 6

2.5 Safety during electrical installation 6

2.6 Safety during commissioning 7

2.7 Safety during mechanical maintenance 7

3 Technical specification 9

3.1 IRBT 2002S 93.1.1 Positioning accuracy IRBT 2002S 9

3.2 IRBT 1402S 103.2.1 Positioning accuracy IRBT 1402S 10

3.3 Dimensions 113.3.1 Floor mounting 113.3.2 Cross section, floor mounting 113.3.3 Ceiling mounting 123.3.4 Cross section, ceiling mounting 123.3.5 Cable chain 13

3.4 Foundation drawing, floor mounting and ceiling mounting 14

4 Variants and options 15

4.1 General 15

4.2 Ordering list 15

Specification ii 3HEA 800 968-001 Rev. A, November 2005

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DescriptionGeneral

3HEA 800 968-001 Rev. A, November 2005 1-1

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1 Description

1.1 General

The Track Motion is primarily intended for IRB 2400 and IRB 1400. The Track Motion is fully adapted to the robots and therefore requires a very short installation time before the system is ready to use.

The systems for Track Motion IRBT 2002S and IRBT 1402S add an extra degree of programmable freedom to the movement pattern of robot IRB 2400 and IRB 1400.

Design

The Track Motion consists of a drive unit, a carriage and rail modules. The drive unit consists of an AC motor with a mounted gear drive. The drive is transferred via a gear rack attached at the rail modules. The rail modules are manufactured of continuously cast aluminum sections.

The carriage is supported on both sides by a four-point linear guide with high precision.

All the information on the robot can be found in the robot documentation.

The robot must be equipped with hardware and software for a built-in 7th axis.

Figure 1 Track Motion 2002S/1402S

Description

General

1-2 3HEA 800 968-001 Rev. A, November 2005

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The Track Motion performs movements that are programmed and controlled from the robot’s programming unit. This means that the programming/control of the Track Motion does not differ from the robot’s other axes.

The Track Motion is equipped with a circuit card for measuring, which converts the resolver signals from the Track Motion’s drive system to digital signals. The card has a battery backup, which permits the robot to be restarted after a power failure without needing any synchronization etc. The digital signal transfer is also less sensitive to radio interference than the traditional analog transfer. This guarantees reliable operation, even for very long travel lengths.

Connection

The Track Motion is connected to the robot’s control equipment via a cable as an integrated 7th axis. This means that the robot must be equipped to support this type of function.

Travel length

The length of the Track Motion can be specified in steps of 1 m from 1 m to 13 m. Up to 44 m can be quoted on request.

Installation

The Track Motion is available either for floor mounting or ceiling mounting.

During the installation the base of the robot can be placed in one of the three positions, 90° in relation to each other. The neutral position of the first axis can lie at position 1 (i.e. towards the robot ), 2 or 3. The full working area of all the axes can be utilized.The Track Motion’s calibration position lies in the standard design at one of the end positions, but can be changed to any position on request.

Cables

The control and power cables for the Track Motion and robot are routed through a cable chain. This also contains an air hose with a diameter of 10 mm, which supplies compressed air to the robot. As an option a broader cable chain can be delivered.

DescriptionIdentification


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1.2 Identification

Identification plates specify the type and year of delivery etc. of the Track Motion.

1.2.1 Parameter diskette

Example of label on parameter diskette:

Figure 2 Identification plates on Track Motion 2002S/1402S

ABB Automation Made inSweden

Type IRBT 2002Art. no.: 3HXDXXXX-XSerial no.: 2002-XXXDeliv. year: 2001Weight kg: 425Order: XXXXXXXX

Technologies AB

Figure 3 Label on parameter diskette

Track Motion

ABB Automation Technologies AB

System parametersPart No: 3HEA xxxConfiguration files:IRBTProperty of ABB Västerås/Sweden. All Rights reserved. Reproduction, modification, use or disclosure to third parties without express authority is strictly forbidden. Copyright 2005

Description

Terms and concepts


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1.2.2 Terms and concepts

Definitions

The table below lists terms and concepts used in the documentation.

Name Definition

Robot system Robot and Track Motion together.

Robot Manipulator and control equipment together (IRB 1400 IRB 2400).

Manipulator The mechanical, moving part of the robot.

Control equipment The control equipment is of the IRC5 type

Track Motion Carriage, stand and cable chain, including attendant parts, assembled (IRBT 2002S/1402S).

Carriage The moving part, on which the manipulator is mounted.

Stand The assembled framework for the Track Motion.

Stand module Track Motions with a travel length longer than 5 meters are supplied with the stand in modules that are interconnected according to the instructions in “Mechanical installation” on page 2 - 3.

Travel length The carriage’s maximum range.

SMB Serial measurement box.

Safety instructionsDescription


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2 Safety instructions

2.1 Description

There are safety instructions in this chapter for all steps that involve a risk of personal injury or material damage. In addition, they are written out by the instructions for each step.General warnings where the intention is to avoid difficulties are only set out by the instruction in question.

Key to symbols The different types of warnings are marked with symbols in accordance with the table below:

Symbol Name Meaning

!Danger Warning for severe or fatal personal injury, and/or serious

damage to the product if the instructions are not followed.

Warning Warning for the risk of personal injury, or serious damage to the product. Always follow the instructions given in association with this symbol.

Electric shock Warning for electric shock that can cause severe or fatal personal injury. Always follow the instructions given in association with this symbol.

Caution Draws your attention to the fact that damage to the product can occur if an action is not performed, or is performed incorrectly.

Static electricity, ESD

The ESD symbol indicates the risk of static electricity that can result in serious damage to the product.

Note Information on important details.

Tip The Tip symbol refers to an instruction that provides further information on a special procedure.

Safety instructions

Safety during Unpacking and handling


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2.2 Safety during Unpacking and handling

Read carefully through the safety instructions, before the Track Motion is unpacked and installed.

Lifting instructions

Only units that are 6 meters or shorter may be lifted. If the units are joined, the joints must be prefitted on delivery.

2.3 Safety during mechanical installation

Adjusting the level

The distance between the leveling bolts and the top edge of the ground plates must be at least 10 mm.

2.4 Safety during assembling the cable tray and manipulator

Assembling the manipulator

Always refer to the documentation for the manipulator when the manipulator is to be lifted.

2.5 Safety during electrical installation

The robot’s cable harness

Make sure that the cable harness cannot come into contact with any moving parts.

Safety instructionsSafety during commissioning


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2.6 Safety during commissioning

Calibration

Make sure no persons are on the Track Motion when the carriage is in motion. Also make sure that the Track Motion’s cover plates are free from loose objects, otherwise they can get trapped between the carriage and the plates.

Checking the working area

The Track Motion’s working area must be inspected before the system is taken into operation.

2.7 Safety during mechanical maintenance

Refilling the lubricant

Only use grease injectors with 3 months supply or less.

Safety instructions

Safety during mechanical maintenance


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Technical specificationIRBT 2002S


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3 Technical specification

3.1 IRBT 2002S

3.1.1 Positioning accuracy IRBT 2002S

The diagram applies to finely divided points from stationary to stationary:

Function Performance

Travel length 1.0 - 44 meters in increments of 1 meter.

Rail length travel +1.0 m

Travel speed 1.8 m/s

Acceleration with IRB 2400 + 100 kg 2.0 m/s2

Braking with IRB 2400 + 100 kg 2.5 m/s2

Repeatability during repeated stops in direction to same point

± 0.15 mm

Max. load, regardless of floor or ceiling mounting robot weight + 100 kg

Weight approx. 200 kg (carriage) + 40 kg/m

Figure 4 Positioning accuracy IRBT 2002S

Time (s)

0.0

0.40.2

0.60.81.01.21.41.61.82.0

2.42.2

3.63.4

2.6

3.8

3.23.0

2.8

4.04.24.44.64.8

5.0

5.25.45.6

0.0

3.2

4.0

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.6 Time (s)

len

gth

(m

)

Technical specification

IRBT 1402S


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3.2 IRBT 1402S

3.2.1 Positioning accuracy IRBT 1402S

The diagram applies to finely divided points from stationary to stationary:

Function Performance

Travel length 1.0 - 44 meters in increments of 1 meter.

Rail length travel +1.0 m

Travel speed 1.8 m/s

Acceleration with IRB 1400 + 100 kg 2.5 m/s2

Braking with IRB 1400 + 100 kg 2.5 m/s2

Repeatability during repeated stops in direction to same point

± 0.15 mm

Max. load, regardless of floor or ceiling mounting robot weight + 100 kg

Weight approx. 200 kg (carriage) + 40 kg/m

Figure 5 Positioning accuracy IRBT 1402S

len

gth

(m

)

Time (s)

0.0

0.4

0.2

0.6

0.81.0

1.2

1.4

1.6

1.8

2.0

2.4

2.2

3.63.4

2.6

3.8

3.2

3.0

2.8

4.0

4.2

4.4

4.6

4.8

5.0

5.25.4

5.6

0.0

3.2

4.0

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.6 Time (s)

Technical specificationDimensions


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3.3 Dimensions

3.3.1 Floor mounting

3.3.2 Cross section, floor mounting

Figure 6 IRBT 2002S/1402S, floor mounting

Figure 7 Cross section, floor mounting

3HX

D 7

8000

275

870

1060

Connection tocontrol system


Ceiling mounting


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3.3.3 Ceiling mounting

3.3.4 Cross section, ceiling mounting

Figure 8 IRBT 2002S/1402S, ceiling mounting

Figure 9 Cross section, ceiling mounting

Connection to

500

1215

275

1250

control system

Technical specificationCable chain


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3.3.5 Cable chain

Inne

rdim

ensi

ons_

of_t

he_I

RB

T20

02_C

hain

.wm

f

Figure 10 Dimensions for cable chain


Foundation drawing, floor mounting and ceiling mounting


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3.4 Foundation drawing, floor mounting and ceiling mounting

Figure 11 Foundation drawing, IRBT 2002S/1402S, floor mounted and ceiling mounted

Travel length 2002/1402 1 2 3 4 5 6 7 8 9 10

N 0 1 2 3 4 5 6 7 8 9

16 28 32 28 16

Mounting bolts, M12

Only ceiling mounted unitsBolts for

Cable tray

IRBT 2002/1402 Travel length – 1,000

900 N x 1,000 900 , M12

840

870

level adjusting

Variants and optionsGeneral


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4 Variants and options

4.1 General

Track Motion IRBT 2002S/1402S functions as a built-in seventh axis and requires supplement 39x, 'Drive unit T', on the robot’s specification form. The robots standard cables are used from the control unit to the Track Motion.The motor cable to the seventh axis has a length of 15 m, measured from the middle of the coupler on the Track Motion.

4.2 Ordering list

The tables describe the variants and options that can be ordered for IRBT 2002S/ 1402S. Please contact ABB for further specializations.

Key to symbols

“x” Where the last number of the article number is replaced by “x” this specifies the Track Motion’s travel length in meters. A Track Motion with a travel length of 2 meters therefore has the article number 3HXD 1546-2. With a travel length of 3 meters the article number will be 3HXD 1546-3 etc.

“yy” Where the last numbers of the article number are replaced by “yy” the cable length should be specified in decimeters (-70 for 7 meters, -150 for 15 meters and -220 for 22 meters).

Variants

The article numbers refer to IRB 2400 and IRB 1400 of year model M97. Other robots and year models have different article numbers.

Art. no. Description

3HXD 1239-x IRBT 1402S floor mounted version M2000

3HXD 1240-x IRBT 1402S ceiling mounted version M2000

3HXD 1468-x IRBT 2002S floor mounted version M2000

3HXD 1467-x IRBT 2002S ceiling mounted version M2000

Variants and options

Ordering list


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Options

Art. no. Description

3HXD 1204-x Protective plates for guide rail (only for floor mounted version and when the robot is mounted so that the zero position on axis 1 is parallel to the movement on the track).

3HXD 1141-yy Custom-designed signal cable for IRB 1400.

3HXD 1187-yy Custom-designed signal cable and supply cable for IRB 2400.

3HXD 1193-yy End position breaker cable, axis 1.

3HEA 800 968-001 Rev. A, November 2005 Installation and operation i

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Tab 2: Installation and operation1 Unpacking and handling 1

1.1 General 1

1.2 Acceptance inspection 1

1.3 Lifting instructions 21.3.1 Rail module < 5 m 2

1.4 Emergency stop 3

1.5 Manual release of the brake 3

2 Mechanical installation 5

2.1 Floor mounted Track Motions 52.1.1 Installation 52.1.2 Alignment, all lengths 6

2.2 Track Motions mounted in the ceiling 72.2.1 Portal mounting 7

2.3 Foundation, all Track Motions 8

2.4 Installing the manipulator 92.4.1 Installation 92.4.2 Dynamic loads 9

3 Electrical installation 11

3.1 General 11

3.2 The robot’s cable harness 11

3.3 External axis cabling 12

3.4 Wiring diagram 13

4 Commissioning 15

4.1 General 15

4.2 Before starting 164.2.1 Loading the operating parameters 164.2.2 Activating the automatic lubrication system (option) 17

4.3 Calibration 184.3.1 Calibrating the Track Motion 184.3.2 Calibration during restart 184.3.3 Checking the working area 184.3.4 Checking for abnormal wear and noise 18

Installation and operation ii 3HEA 800 968-001 Rev. A, November 2005

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Unpacking and handlingGeneral


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1 Unpacking and handling

1.1 General

Unpack the equipment and check for any visible transport damage.

Before transport the equipment has been protected against rust by a thin film of oil that has been applied before packing. Wipe off any surplus oil before installation with a lint-free cloth

1.2 Acceptance inspection

A standard Track Motion includes the following:

• One carriage with drive unit.

• Rail module(s) and cable chain. Track Motions with a travel length of > 5 m are designed with more than one rail module, which are interconnected during installation.

• Three mounting bolts with washers, and two guide bushings for the robot.

Read very carefully through the safety instructions and other instructions, before the Track Motion is unpacked and installed.

Unpacking and handling

Lifting instructions


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1.3 Lifting instructions

1.3.1 Rail module < 5 m

• If the rail modules are to be lifted with a crane the lifting straps should be wrapped round the rails. See Figure 1.

• The carriage weighs approx. 160 kg and the rail modules approx. 38 kg/meter (IRBT 2002S).

• The rail modules can also be lifted with a fork lift truck, in which case the forks must be placed on the long side of the rail modules.

Lyft

IRB

T14

02.w

mf

Figure 1 Rail module < 5 m

Unpacking and handlingEmergency stop


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1.4 Emergency stop

The emergency stop button must only be used in an emergency to stop the travel movement.

1.5 Manual release of the brake

The carriage is normally locked with the motor brake. If the carriage needs to be moved by hand the brake must be released.

The emergency stop must never be used as a stop function to stop the travel movement.

Action

1. Press in the brake release button (on the SMB) and keep it pressed. This releases the brake, so that the carriage can be moved by hand.

Unpacking and handling

Manual release of the brake


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Mechanical installationFloor mounted Track Motions


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2 Mechanical installation

2.1 Floor mounted Track Motions

A standard Track Motion includes the following units ready for installation:

• A carriage with one rail module and cable chain holder. Track Motions with travel lengths over 6 m consist of more than one rail module.

• Two guide pins for the robot, and three mounting bolts.

2.1.1 Installation

One rail module

Several rail modules

Anchor bolts are not included in the delivery since they must be selected on the basis of the material the foundation is made of.

Action

1. Insert flat bars (not included in the delivery, 4 × 50 × 50) for the leveling bolts. Each ground plate requires four flat bars.

2. Use the aligned rail modules as a template and drill 14 mm holes for the chemical anchor bolts (recommended anchoring method). The holes in the rail modules are 15 mm.

3. Adjust the rails alternately with the leveling bolts until they are correctly aligned.

Action

1. Insert flat bars (not included in the delivery, 4 × 50 × 50) for the leveling bolts. Each ground plate requires four flat bars.

2. Place the T-nuts that follow along with the guide rail in the rail’s groove.

3. Align the rail modules in the correct sequence, but do not tighten the bolts.

4. Use the aligned rail modules as a template and drill 14 mm holes for the chemical anchor bolts (recommended anchoring method). The rail modules have Ø 15 mm holes.

5. Check that the ends of the guide rails fit together.

6. Adjust the rails alternately with the anchor bolts and leveling bolts until they are correctly aligned.

7. Tighten the guide rail bolts, the side bolts on the rails, and the lower bolts.

8. Check the pitch of the joints in the driving gear rack by comparing them with the loose bar part in the last rail module. The free part of the gear rack is 200 mm long. If the loose part is held to the joint in the driving, any differences in the pitch will be detected. Adjust if necessary by releasing the joint and pulling the gear rack so that the correct pitch is obtained.

Mechanical installation

Alignment, all lengths


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2.1.2 Alignment, all lengths

• The final alignment is done alternately with the anchor bolts and adjusting bolts until the rails are aligned to within 0.5 mm/m.

• The carriage can be moved by hand if 24 V DC is connected to the SMB and the brake release button is pressed in. If the control equipment has not yet been connected, information on this procedure can be found in the enclosed electrical wiring diagram.

• The carriage must be checked with a spirit level both in the direction of travel and across this, along the entire travel length. Every deviation must be corrected.

The guide rails are parallel on delivery. Do not release the adjusting bolts!

Note that a force of 50 - 100 N is required to overcome the preset resistance of the ball element when the carriage is moved without a mounted robot. When the robot is mounted the carriage moves more freely.

Mechanical installationTrack Motions mounted in the ceiling


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2.2 Track Motions mounted in the ceiling

Track Motions mounted in the ceiling are installed in principle in the same way, except that they have twice as many anchor bolts.

2.2.1 Portal mounting

If the rails are to be mounted in some form of portal the best way of doing this is mount them and adjust the level while they are turned upside down on the floor, and then to turn them round and lift them into the correct position. This simplifies the installation, especially for long travel lengths with more than one rail module. Contact ABB Automation Technologies AB for further information.


Foundation, all Track Motions


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2.3 Foundation, all Track Motions

Figure 2 Foundation, IRBT 2002S/1402S, floor mounted and ceiling mounted

28 32 16

840

870

60

IRBT travel length + 1,000

900 N x 1,000 900

16 28

Mechanical installationInstalling the manipulator


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2.4 Installing the manipulator

The lifting instructions for the manipulator (IRB 1400 and IRB 2400) can be found in the Manipulator Manual, Installation and commissioning.

The best way of lifting the manipulator is to use lifting straps and an overhead crane. The lifting straps must be dimensioned in accordance with the applicable lifting standards.

2.4.1 Installation

• Secure the manipulator’s guide bushing to the wall.

• Install the manipulator by securing it with the 3 screws (socket head cap screws M16 × 30).

• Lubricate the screws and tighten them to 190 Nm.

2.4.2 Dynamic loads

See robot documentation for dynamic loads.

The lifting instructions are applicable for an "empty" manipulator. As soon as the manipulator is fitted with additional equipment the center of gravity will be moved, whereby lifting operations become dangerous.

Never walk under a suspended load.


Dynamic loads


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Electrical installationGeneral


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3 Electrical installation

3.1 General

Drive package The Track Motion’s drive package includes an AC motor with return feed unit.

Measurement system

The measurement system uses a resolver and a serial measurement card to convert the resolver signals to digital form, and includes a battery pack for memory backup. These components are placed in the SMB on the carriage.

Cable chain The cable chain contains, in addition to the cables needed to control the Track Motion, all the control cables to the robot. An air hose (D = 12/10) is also included in the cable chain.

3.2 The robot’s cable harness

The robot’s cable harness is sufficiently long for installation in any of the three possible positions on the carriage. Any surplus length should be placed in a cable chain on the floor, or in the case of reversed mounting be wound up, depending on the local conditions.

Connection point J1

The cable harness that normally connects the robot and the control equipment is connected to the Track Motion’s connection point (J1), which is on the outside of the track approximately in the middle of the travel length.From connection point J1 the cable harness is routed through the cable chain, via the SMB to the robot’s connectors.

Make sure that the cable chain cannot come into contact with any moving parts.

Electrical installation

External axis cabling


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3.3 External axis cabling

Power cable The travel motor cable runs from the control equipment connector XS7 through the cable chain and up to the drive unit’s serial measurement unit. One cable runs to the Track Motion’s drive motor M7.

Signal cable The signal cable runs from the control equipment through connection point J1, through the cable chain to the SMB, and then to the connector on the base of the robot.

Electrical installationWiring diagram


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3.4 Wiring diagram

The wiring diagram below describes the connections between the control equipment, manipulator and Track Motion.The position numbers in the table refer to the positions in the illustration above. Cables marked with (R) in the illustration are supplied with the robot.

For numbers replaced with characters in the article numbers, see “Key to symbols” on page 1 - 15.

Ans

lutn

inga

r 20

02_1

402.

wm

f

Figure 3 Connections on IRBT 2002S/1402S

Description Standard no. Item Option

Signal cable 3HXD 1432-x 1

End position breaker cable 3HXD 1193-x 2 X

Motor cable, external axis 3HXD 1249-yy 3

Resolver cable, external axis 3HXD 1250-yy 4

Customer power and signal cable 3HXD 1187-yy 5

Motor cable 3HXD 1232-yy 6

Position cable 3HXD 1433-yy 7 X

Signal cable 3HXD 1443-yy 8

7th axis power cable (chain) 3HXD 1252-yy 9

7th axis power cable (floor), 7 m 3HEA 800 896-001 10




IRC5

ÅKVAGN KABELKEDJA GOLV

5

6

7

8

9

1

2

3 4

R

R

R

R

10

Electrical installation

Wiring diagram


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CommissioningGeneral


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4 Commissioning

4.1 General

The system will stop on the emergency stop if the carriage runs at a speed 25% higher than the programmable speed.

The values of the commutation and synchronization offset are defined on a diskette supplied with the equipment.

Track Motion 2002S

The Track Motion is set for robot IRB 2400 with maximum load + 300 kg extra load.

Track Motion 1402S

The Track Motion is set for robot IRB 1400 with maximum load +100 kg extra load.

Commissioning

Before starting


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4.2 Before starting

The following measures must be taken before starting:

4.2.1 Loading the operating parameters

Loading from a diskette is described in the robot documentation.The IRBT commutation offset is a fixed value that is read in at the factory. All IRBT 2002S/1402S Track Motions have the same offset value, and there is no need to change this value.The different travel length working areas are defined on the basis of the calibration mark. The Track Motion must be defined in the system before starting with the operating parameters, which can be found on the supplied diskette.

IRBT 2002S/IRBT 1402S

New drive unit: Select DC2T when booting

Action

1. Load the operating parameters.

2. Activate the automatic lubrication system (option).

3. Calibrate.

Default parameters “-do_not_allow_deactivation” is set to “yes”

When “act_unit” and “deact_unit” are used, change to “no”

On delivery the travel length has been set to maximum.

x in the file name varies, depending on which drive module the conveyor is connected to.

Action

1. Select File: Add New Parameters

2. Load the file MOC_T2002_DMx_M7.cfg

CommissioningActivating the automatic lubrication system (option)


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4.2.2 Activating the automatic lubrication system (option)

The grease injectors are activated as follows:

The grease injectors are not activated on delivery.

Action

1. Set the lubrication time on the drive unit with a 3 mm Allan key.

2. Set the gas generator to the required dosing time, 1 - 3 months, marked on the drive unit.

3. Note the start date on the grease injector label.

Figure 4 Activating the grease injectors

Commissioning

Calibration


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4.3 Calibration

4.3.1 Calibrating the Track Motion

Before the Track Motion can be used, the resolvers need to be calibrated. Perform the calibration in accordance with the instructions below.

4.3.2 Calibration during restart

A robot system that uses a serial measurement system does not need to be calibrated before a restart, since the measurement system automatically monitors the position of the robot in the working area.

4.3.3 Checking the working area

Check the working area

Run the system manually using the joystick and check that:

• It can be run in both directions

• Both end positions are reached

4.3.4 Checking for abnormal wear and noise

If the event of abnormal noise when the Track Motion is taken into operation this may be due to incorrect assembly of the linear guides or gear racks, or because the gear play’s meshing pressure needs to be adjusted.

Make sure no persons are on the Track Motion when the carriage is in motion. Also make sure that the Track Motion’s cover plates are free from loose objects, otherwise they can get trapped between the carriage and the plates.

Action

1. Calibrate in accordance with the instructions in the robot documentation.

2. Check that the carriage stops exactly on the calibration mark.

3. Save the system parameters according to the instructions in the robot documentation.

The Track Motion does not need to be calibrated during restart. The resolvers only need to be calibrated when commissioning the system.

The Track Motion’s working area must be inspected before the system is taken into operation.

3HEA 800 968-001 Rev. A, November 2005 Maintenance i

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Tab 3: Maintenance1 Maintenance 1

1.1 Routine checks and preventive maintenance 1

1.2 Maintenance chart 1

1.3 Mechanical maintenance 21.3.1 Gearbox 21.3.2 Ball element 21.3.3 Gear racks 21.3.4 Cleaning the linear guides 2

1.4 Electrical maintenance 31.4.1 Inspection of electrical functions 31.4.2 Check the emergency stop 31.4.3 Inspection of the cable chain 31.4.4 Checking the cabling 31.4.5 Inspection of connectors 31.4.6 Replacement of batteries for memory backup 4

1.5 Automatic lubrication system (option) 51.5.1 System Simalube 5

1.6 Adjustments 61.6.1 Gear play 6

1.7 Electrical adjustments 71.7.1 Direction of resolver signal 71.7.2 Resolver offset in commutation mode 7

2 Spare parts 9

2.1 IRBT 2002S/1402S 92.1.1 Drive unit 10

2.2 Accessories for automatic lubrication system 11

Maintenance ii 3HEA 800 968-001 Rev. A, November 2005

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MaintenanceRoutine checks and preventive maintenance


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1 Maintenance

1.1 Routine checks and preventive maintenance

1.2 Maintenance chart

The Track Motion is designed to work with a minimum of maintenance. However, routine checks and preventive maintenance must be carried out at regular intervals.The maintenance chart describes the routine maintenance and routine checks in chronological order.

Interval Part Maintenance More info.

Each month Ball element Lubricate page 3 - 2

Lubrication system1 (option, Simalube)

1. Only if option for automatic lubrication with Simalube system is ordered.

Check, fill up page 3 - 5

Cables Visual inspection page 3 - 3

Drive motor Visual inspection page 3 - 3

Junction boxes Visual inspection page 3 - 3

Function Visual inspection page 3 - 3

Emergency stop Check function page 3 - 3

Every third month Linear guides Inspect and clean page 3 - 2

Every seventh month Gear racks Clean and lubricate page 3 - 2

Every 5,000 hours of operation

Gearboxes Change the oil page 3 - 2

Every 5 years Backup battery Replace page 3 - 4

Maintenance

Mechanical maintenance


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1.3 Mechanical maintenance

1.3.1 Gearbox

On delivery the gearbox is filled with the correct amount of oil. The oil must be changed every 5 years. Shorter intervals will only reduce the gearbox’s service-life.

Every other time the oil is changed the gearbox must be completely dismantled and all the old oil thoroughly flushed out.

Oil The oil must comply with the standards for high-pressure oil under CLP 198–242 mm2/s /-40°C ISO VG 220, which includes for example:

1.3.2 Ball element

Lubricate until grease begins to be forced out.Lubricant: Ball element grease as per NLGI2

1.3.3 Gear racks

Clean and lubricate with OPTIMOL VISCOGEN 4, or one of the following brands:

1.3.4 Cleaning the linear guides

Inspect and clean the linear guides if necessary.

Action

1. All parts must be completely cleaned and their function checked, especially the shaft seals. When they are replaced they must be lubricated with gearbox grease.

2. Test run the gearbox, check the oil level, and top up with oil to the specified level if necessary.

• The oil volume is 600 cm3.

Manufacture Type

Statoil Loadway EP 680

SHELL Omala Oil 680

MOBIL Mobilgear 633

Manufacture Type

BP MOG

Statoil ESL10

Mobiloil Mobiltec 81

Texaco Texclade

MaintenanceElectrical maintenance


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1.4 Electrical maintenance

1.4.1 Inspection of electrical functions

The Track Motion must be checked monthly with regard to:

• All electrical functions

• End position functions

• Run the Track Motion and check that both end positions are reached.

1.4.2 Check the emergency stop

Check the function of the emergency stop once a month:

1.4.3 Inspection of the cable chain

Check every 3 months:

• Lift up the side guard for the gear racks and inspect the full length of the chain (link system, attachment points, dirt deposits, and wear).

1.4.4 Checking the cabling

Check monthly:

1.4.5 Inspection of connectors

Check monthly:

• that all connectors are correctly fitted and that there is no risk of loose contact.

Action

1. Allow the Track Motion to stop.

2. Press in the emergency stop.

3. Try to start the Track Motion.

If any cables... then...

have been damaged through wear or pinching

replace the cable.

rub against sharp edges route the cable so that it runs freely.

Maintenance

Replacement of batteries for memory backup


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1.4.6 Replacement of batteries for memory backup

The Track Motion’s measurement card uses a battery for the memory backup in order to maintain position data. This battery must be replaced every 5 years, or if the battery shows signs of going flat. This is generally indicated by the RUN lamp flashing on start up and an error code on the FlexPendant character display.

The battery unit is located together with the serial measurement card inside the SMB.

In a new system the batteries may be poorly charged, but are charged to full capacity by the system after a few hours in STANDBY mode.

The codes are described in Trouble Shooting Manual 3HAC 020738-001.

Action

1. Open the SMB and localize the battery.

2. Cut off the cable tie holding the battery and disconnect the two-wire cable.

3. Replace the battery.

MaintenanceAutomatic lubrication system (option)


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1.5 Automatic lubrication system (option)

1.5.1 System Simalube

The grease nipple can be filled. A new drive unit and grease nipple can be ordered from ABB Automation Technologies AB, Arc Welding Products.

Filling

A grease gun or grease pump, filler nipple and charge are need to fill the distributor.

The grease injector is not activated on delivery.It is activated by setting the lubrication time on the drive unit with an Allan key. The lubrication time 1 - 12 months is marked on the drive unit. Note the start date on the grease injector label.

Action

1. Remove the cover plate. Unscrew the gas generator with a 21 mm socket. Deposit the complete generator at a recycling system for button cells zinc/air, if such exists.

2. Screw the filler nipple onto the pipe.

Maintenance

Adjustments


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1.6 Adjustments

1.6.1 Gear play

The play between gear rack and gear can be adjusted on this unit, it has been set prior to delivery and should not need further adjustment during installation. However, after several years, or if the repeater precision has exceeded ± 0,15 mm, the play will need to be adjusted. Adjust as follows:

Note that a negative gear play leads to overloading of the gearbox and support roller bearings, including the surface on the gear rack support.

Action

1. Identify parts 1, 2 and 3 as shown in figure page 3 - 9.

2. Unscrew the nuts, part 1 and 2.

3. Unscrew the nut, part 2.

4. Turn the nut, part 3, clockwise so that the play between the gear rack and support roller is reduced.

5. Use a feeler gauge to check that the play is not less than 0.1 mm.

6. After the adjustment the nuts, part A and B, must be retightened.

7. Check the play after retightening.

MaintenanceElectrical adjustments


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1.7 Electrical adjustments

1.7.1 Direction of resolver signal

Check if necessary in accordance with the product manual for the control equipment IRC5.

1.7.2 Resolver offset in commutation mode

When necessary the resolver offset in commutation mode must be adjusted with the following special tool: Commutator arm 6808 0011-LT.

• Remove the protective cover over the return feed unit.

• Remove the return feed unit from the motor axis.

• Place commutator arm 6808 0011-LT on the axis.

Maintenance

Resolver offset in commutation mode


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Spare partsIRBT 2002S/1402S


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2 Spare parts

2.1 IRBT 2002S/1402S

Figure 1 IRBT 2002S/1402S

Item Qty Art. no. Description Remark

1 1 3HXD 0100-102 Drive unit See page 3 - 10

2 1 2321 0848-8 Gear rack L=1,000

3 2 6399 0003-376 Rubber scraper

4 1 2185 0441-1 Ball element

5 1 2213 1923-4 Cam roller

6 1 5373 193-1 Limit switch Option

7 1 3HXD 0100-89 Serial measurement box

8 1 3HAC 16831-1 Battery unit

9 1 3HAC 022286-001 Serial measurement card

6

17, 8, 9

3, 5

2

4

Spare parts

Drive unit


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2.1.1 Drive unit

Figure 2 Drive unit IRBT 2002S/1402S


1 1 3HXD 1000-112 Motor Medium

2 1 2334 0001-14 Gear drive

3 1 2154 381-6 Bushing ETP-25/34-27

4 1 2321 0849-7 Gear

5 4 9ADA 183-39 Socket head cap screw M8×35

6 4 9ADA 267-7 Hexagonal nut M8

Spare partsAccessories for automatic lubrication system


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2.2 Accessories for automatic lubrication system

Figure 3 Options


1 1 6399 0003-596 Filler nipple

2 1 6399 0003-597 Clamp

3 1 6399 0003-594 Grease injector

4 1 6399 0003-595 Gas drive unit

1

2

3 4

Spare parts

Accessories for automatic lubrication system


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3HEA 800 968-001 Rev. A, November 2005

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Documents

Track Motion IRBT 2002S/1402S IRC5, M2004 - ABB Group · PDF fileProduct Manual Track Motion IRBT 2002S/1402S IRC5, M2004 3HEA 800 968-001 Rev. A, November 2005