ZX-T Series

Cat. No. I201E-EN-01D

CR_UGD4_XXL1300H Series

USER´S MANUAL

Delta 3+1 RobotIP65 protection class

CONTENTS CR_UGD4_XXL1300HUser's Manual

T-1

Safety Instructions

1. Attention S-1

2. Explanation of warnings and notes S-1

3. Safety information S-2

3.1 General S-23.2 Qualifiedpersonnel S-23.3 Liability S-23.4 Installationandoperatingconditions S-23.5 Residualrisks S-23.5.1 Releasedevice S-3

3.5.2 Transport S-3

3.5.3 Assemblyandstart-up S-3

3.5.4 Maintenanceandrepair S-3

3.5.5 Systemintegrator S-4

Chapter 1 Introduction

1. Introduction 1-1

1.1 Descriptionoftherobot 1-11.2 Typecodeexplanation 1-1

2. Identification 1-1

3. Part names 1-2

Chapter 2 Model overview

1. Overview 2-1

Chapter 3 Installation

1. Unpacking 3-1

1.1 Unpackingtheshippingbox 3-11.2 Checkthedamage 3-11.3 Liftingandtransportation 3-1

2. Mounting the robot 3-3

3. Mounting the motors and cabling 3-4

3.1 Mountingthemotors 3-43.2 Connectingthecables 3-4

CONTENTS CR_UGD4_XXL1300HUser's Manual

T-2

3.3 Mountingthemotorcovers 3-53.4 Mountingtherotationmotororgearboxwithhisadaptorring 3-6

4. Assembling the secondary arms 3-7

4.1 Makeanassembly 3-74.2 Mountthearmassemblyontherobot 3-8

5. Mounting the rotational axis on the gearbox shaft 3-9

6. Calibration 3-10

7. Gripper interface 3-11

7.1 Withrotationalaxis 3-117.2 Withoutrotationalaxis 3-12

Chapter 4 Maintenance

1. Periodic maintenance 4-1

1.1 Springs 4-11.2 Ballbearingcups 4-21.3 Rotationalaxis 4-2

2. Cleaning the robot 4-4

3. Spare parts 4-4

Chapter 5 Robot settings

1. Kinematics 5-1

2. Workspace 5-2

3. Software limits 5-3

Chapter 6 Specifications

1. Basicspecifications 6-1

1.1 Cycletime 6-1

2. External view and dimensions 6-2

3. Designspecifications 6-3

3.1 Occupationareaofrobot 6-33.2 Softwaredesign 6-43.2.1 Dimensionsandlimits 6-5

Contents

1. Attention S-1

2. Explanation of warnings and notes S-1

3. Safety information S-23.1 General S-2

3.2 Qualified personnel S-2

3.3 Liability S-2

3.4 Installation and operating conditions S-2

3.5 Residual risks S-2

3.5.1 Releasedevice S-33.5.2 Transport S-33.5.3 Assemblyandstart-up S-33.5.4 Maintenanceandrepair S-33.5.5 Systemintegrator S-4

Safety Instructions

Sa

fety Instruc

tions

S-1

1. AttentionInformationinthisdocumentcanchangewithoutpriornotice.

OMRONEUROPEB.V.cannotbeholdresponsibleforanydamagetotheenvironment,tothemachineortothefunctioningofthemachineoccurredbyerrorsormissingdataintheillustrations,drawingorspecifications.

Nopartofthismanualandaddeddocumentationmaybecopied,reproducedortranslatedintoanotherlanguagewithoutpriorwrittenapproval.

Readandunderstandthematerialcontainedinthisuser'smanualbeforeyouworkontheCR_UGD4_XXL1300Hrobotforthefirsttime.Thisuser'smanualissupposedtohelpyouusethecapabilitiesoftheCR_UGD4_XXL1300Hrobotsafelyandproperly.

2. Explanation of warnings and notesThismanualusesthefollowingsafetyalertsymbolsandsignalwordstoprovidesafetyinstructionsthatmustbeobservedandtodescribehandlingprecautions,prohibitedactions,andcompulsoryactions.Makesureyouunderstandthemeaningofeachsymbolandsignalwordandthenreadthismanual.

DANGER THISINDICATESANIMMEDIATELYHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,WILLRESULTINDEATHORSERIOUSINJURY.

WARNING THISINDICATESAPOTENTIALLYHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,COULDRESULTINDEATHORSERIOUSINJURY.

NOTE Explainsthekeypointintheoperationinasimpleandclearmanner.

Sa

fety Instruc

tions

S-2

3. Safety information3.1 General

This´3. Safety information´subchaptercontainsinformationregardingworkingwiththeCR_UGD4_XXL1300Hrobot.QualifiedpersonnelworkingwiththeCR_UGD4_XXL1300HrobotmusthavereadandunderstoodtheCR_UGD4_XXL1300Hrobotdocumentation,includingthesafetyinformationchapter.

3.2 Qualified personnel

Thesearepeoplewho,duetherespecialisttraining,knowledgeandexperience,andtheirfamiliarizationwiththerelevantstandards,areabletoassesstheworktobecarriedoutanddetectanypotentialhazards.

3.3 Liability

TheCR_UGD4_XXL1300Hrobotisbuildusingstate-of-the-arttechnologyandinaccordancewiththerecognizedsafetyrules.Nevertheless,misuseoftheCR_UGD4_XXL1300HrobotmayconstitutearisktolifeandlimborcausedamagetotheCR_UGD4_XXL1300Hrobotandtoothermaterialproperty.

3.4 Installation and operating conditions

Youmayonlyusethecomponentsinaccordancewiththeinstallationandoperatingconditionsdescribedinthedocumentation.Theoperatingconditionsattheinstallationlocationmustbecheckedandmaintainedinaccordancewiththerequiredtechnicaldata.WithinthemeaningoftheMachineryDirectivetheCR_UGD4_XXL1300Hrobotisanincompletemachine.CommissioningisprohibiteduntiltheusablemachineorsysteminwhichtheCR_UGD4_XXL1300HrobotisinstalledmeetsallrequirementsoftheMachinedirective2006/42/EC.

FortheCR_UGD4_XXL1300Hrobotyouhavetoobservethefollowingstandards,directivesandregulations:

• ENISO10218-1:2011Robotsandroboticdevices-Safetyrequirementsforindustrialrobots-Part1:Robots.• ENISO10218-1:2011Robotsandroboticdevices-Safetyrequirementsforindustrialrobots-Part2:Robotsystems andintegration.

3.5 Residual risks

Safetyandhealthrisksarisingfromtherobotmechanicshavebeenreducedbymeansofsafetytechnologyanddesignengineering.Howeveraresidualriskremains,sincetherobotmechanicswillbemovebyanautomatedcontrolsystem.

Thefollowingaretypicalwarningsconcerningresidualriskswhichcannotbeassignedtoaspecificaction.Theexpressionofsafetylabelsisidenticaltothesafetyinformation.

Sa

fety Instruc

tions

S-3

3.5.1 Release device

Therobotmechanicsarenotsuppliedwithanreleaseswitchtocontrolthebrakesofthemotors.

WARNING • MOUNTARELEASESWITCHONTHEMACHINESOTHEARMS(MOTOR)OFTHEROBOTCOULDBEMANUALLY MOVED. • MOVINGANAXISWITHANIMPROPERLYWORKINGRELEASESWITCHCANDAMAGETHEMOTORBRAKE.THIS CANRESULTINPERSONALINJURYANDMATERIALDAMAGE. • BEFORERELEASINGTHEBRAKE,YOUHAVETOBESURETHATNOONEISINTHEHAZARDAREAOFTHEROBOT.

3.5.2 Transport

Theprescribedtransportpositionoftherobotmustbeobserved.Transportationmustbecarriedoutinaccordancewiththetransportationinstructionsorassemblyinstructionsoftherobot.

WARNING • ONLYUSEAUTHORIZEDHANDLINGEQUIPMENTWITHASUFFICIENTLOAD-BEARINGCAPACITYTOTRANSPORT THEROBOT. • WEARSUITABLEPROTECTIVECLOTHINGIFNECESSARY.

3.5.3 Assembly and start-up

Beforestartingupsystemsanddevicesforthefirsttime,acheckmustbecarriedouttoensurethatthesystemanddevicesarecompletedandoperational,thattheycanbeoperatedsafelyandthatanydamageisdetected.

Thevalidnationalorregionalworksafetyregulationsmustbeobservedforthischeck.Thecorrectfunctioningofallsafetycircuitsmustalsobetested.

Thefollowingtestsmustbecarriedoutbeforestart-upandrecommissioning.Itmustbeensuredthat:

• Therobotiscorrectlyinstalledandfastenedinaccordancewiththespecificationsintheassemblyinstructions.• Therearenoforeignbodiesorloosepartsontherobot.• Allrequiredsafetyequipmentiscorrectlyinstalledandoperational.

WARNING • AWRONGINSTALLEDROBOTMAYTHROWOFFHISARMS. • WEARSUITABLEPROTECTIVECLOTHINGIFNECESSARY.

3.5.4 Maintenance and repair

Aftermaintenanceandrepairwork,checksmustbecarriedouttoensuretherequiredsafetylevel.Thevalidnationalorregionalworksafetyregulationsmustbeobservedforthischeck.Thecorrectfunctioningofallsafetycircuitsmustalsobetested.

Thepurposeofmaintenanceandrepairworkistoensurethatthesystemiskeptoriginalor,intheeventofafault,toreturnthesystemtoanoperationalstate.Repairworkincludestroubleshootinginadditiontotheactualrepairitself.

Thefollowingsafetymeasuresmustbecarriedoutwhenworkingontherobot:

• Switchofthemachine(system)wheretherobotisbuilt-in(e.g.withapadlock)topreventitfrombeingswitchedon again• Labelthemachine(system)withasignindicationthatworkisinprogress.Thissignmustremaininplace,even duringtemporaryinterruptionstothework.• Theemergencystopfromthemachine(system)mustremainactive.Ifsafetyfunctionsorsafeguardsaredeactivated duringmaintenanceorrepairwork,theymustbereactivatedimmediatelyaftertheworkiscompleted.

Sa

fety Instruc

tions

S-4

3.5.5 System integrator

Therobotissafelyintegratedintoacompletesystembythesystemintegrator.Thesystemintegratorisresponsibleforthefollowingtasks:

• Installingtherobot• Performingriskassessment• Implementingtherequiredsafetyfunctionsandsafequards• Issuingthedeclarationofconformity• AttachingtheCEmark• Creatingtheoperatinginstructionsforthecompletesystem

Chapter 1 Introduction

Contents

1. Introduction 1-11.1 Description of the robot 1-1

1.2 Type code explanation 1-1

2. Identification 1-1

3. Part names 1-2

1-1

1

Introd

uctio

n

1. IntroductionCongratulationswiththepurchaseofyourhighspeedDeltarobotXXL.Thisisahighspeedpickandplacerobotwhichusesstate-of-the-artcarboncompositematerialsandthelatestservodrivetechnologytobeputinuseinthemostdemandingpickandplaceapplications.

Thismanualshouldbereadbeforethecommissioningoftherobot.Bymechanicalengineersinthedesignphaseduringtheintegrationoftherobotinthemachineandbysoftwareengineerstochecktheperformanceenvelopeoftherobot.

ThismanualdescribesthemainversionsoftheCR_UGD4_XXL1300Hrobot,andalloptions.Whereapplicablechecktheappropriatedataforyourrobottype,thetypecanbefoundontheidentificationtagoftherobot.

1.1 Description of the robotTheCR_UGD4_XXL1300HDeltarobotisahighspeedpickandplacerobotwhichusesstate-of-the-artcarboncompositematerialsandthelatestservodrivetechnologytobeputinuseinthemostdemandingpickandplaceapplications.Therobotisdesignedasa3-axis(optional4throtationalaxis)Deltakinematicsystem.

Characteristicsoftherobot:• Requiresverylowmaintenance• 3+1(rotationalaxisoptional)degreesoffreedom• Compactdesignformountinginamachine• Lownoiselevel<68dB(A)

1.2 Type code explanationCR_UGD4_XXL1300H_R:3+1axes(withrotationalaxis),1300mmworkingrange,max.payload:8kgCR_UGD4_XXL1300H_NR:3axes(withoutrotationalaxis),1300mmworkingrange,max.payload:8kg

2. IdentificationOntherobotbaseplateanidentificationtagismounted,importantdataonthisplate:• Robottype• Totalweightoftherobot• Yearofproduction• Serialnumber,importantfororderingspareparts

1-2

Introd

uctio

n

1 3. Part names

CR_UGD4_XXL1300H

Primary arm

TCP (Tool Center Point)

Cable entry plate Rotary servo motor

Motor cover

Secondary arm

Rotational axis

TheCR_UGD4_XXL1300HrobotconsistsofthreeradiallyplacedaxiswhichgivetheTCPfreedomtomoveinthreedirections,X,YandZ.Anoptionalfourthaxiscantakecareoftherotation,Rz,oftheTCP.

Theprimaryandsecondaryarmsoftherobotareconstructedfromanodizedaluminumendsandcarboncompositematerial;theyaredirectlymountedonadouble-stagegearboxtoguaranteehighstiffness.ThesecondaryarmsaremountedwithhardenedstainlesssteelballjointbearingstotheprimaryarmsandtheTCP,thisguaranteeslowwearandfrictionandisveryeasytoservice.

Optionallytherobotisequippedwithanextraservomotorfortherotationalaxis,theslidingshaftisconstructedoftitaniumtomaintainthehighlydynamiccharacteroftherobot.

Chapter 2 Model overview

Contents

1. Overview 2-1

2

Mo

de

l overview

2-1

1. OverviewTheCR_UGD4_XXL1300Hhasaworkingrangeof1300mm.Thespecificationsaregiveninthebelowfigure,ifspecificationsdifferformodels,forinstancewith-orwithoutrotationaxis,itisindicatedinthespecificationlist.TheDeltarobotisdeliveredstandardwithsanitarysecondaryarms,thismeanstheyarefullyclosedtopreventanycontaminationontheinsideofthesecondaryarms.

CR_UGD4_XXL1300H (1300 mm)

300

150

900

with

rota

tiona

l axi

s85

1 w

ithou

t rot

atio

nal a

xis

780

1300

NOTE Notethattherotationservomotor,onthetopoftherobot,isoptional.

Chapter 3 Installation

Contents

1. Unpacking 3-11.1 Unpacking the shipping box 3-1

1.2 Check the damage 3-1

1.3 Lifting and transportation 3-1

2. Mounting the robot 3-3

3. Mounting the motors and cabling 3-43.1 Mounting the motors 3-4

3.2 Connecting the cables 3-4

3.3 Mounting the motor covers 3-5

3.4 Mounting the rotation motor or gearbox with his adaptor ring 3-6

4. Assembling the secondary arms 3-74.1 Make an assembly 3-7

4.2 Mount the arm assembly on the robot 3-8

5. Mounting the rotational axis on the gearbox shaft 3-9

6. Calibration 3-10

7. Gripper interface 3-117.1 With rotational axis 3-11

7.2 Without rotational axis 3-12

3

Installa

tion

3-1

1. Unpacking1.1 Unpacking the shipping boxTherobotcomesinaspecialshippingbox.

Thefollowingstepmustbecarriedouttoremovetheshippingbox:• Unscrewthescrewsfromthecoverofthewoodenbox• Nowremovethecover

1.2 Check the damageFirsttakeouttheindividualcomponentsfromthepackageandcheckthateverythingiscompleteaccordingtothefollowinglist:• 1xrotationalaxis(incaseofCR_UGD4_XXL1300H_Rmodel)• 1xadaptorringfortherotationalaxisgearormotor(incaseofCR_UGD4_XXL1300H_Rmodel)• 1xTCP-ToolCenterPoint(incaseofCR_UGD4_XXL1300H_NRmodel)• 6xsecondaryarms• 6xspringpackage(12xspringbracketsand6xspring)

Checkallthecomponentsandtherobotfortransportationdamage.

1.3 Lifting and transportationBeforetherobotislifted,itmustbeensuredthatitisfreefromobstructions.Removeallthescrewswheretherobotismountedwithinthebox.

1

No. Description

1 3xscrewswithprotectionmaterial

Therobotmustbeliftedandtransportedbyusingliftingtackleorforklifttruck.Twoliftingstrapshastobeattachedintotwoeyeboltsthatarescrewedintothebaseplate.Theliftingstrapshastobelongenoughandmustberoutedinsuchawaythattherobotisnotdamaged.

3

Installa

tion

3-2

WARNING • THEROBOTMAYTILTDURINGTRANSPORTATION. • ADDITIONALSAFEGUARDINGMEASUREMUSTBETAKEN. • WEARSUITABLEPROTECTIVECLOTHINGIFNECESSARY. • WHENUSINGAFORKLIFTTRUCK,DRIVEEXTREMELYSLOWLYANDCAREFULLY.

1

2

3

No. Description

1 Liftingtackle

2 2xliftingstraps

3 2xeyebolts

3

Installa

tion

3-3

2. Mounting the robotThemountingsurfacefortherobotmustbemachinedandofanappropriatequality.It'salsopossibletousealevellingelementtoaligntherobot.ThreeM20boltsareneededtomountingtherobottotheframe,exactboltlengthdependsonframelayout.ThetighteningtorqueofaM206.8boltis300Nm.

Thebelowfigureshowsthemountingpatternfromtherobot.

NOTE Itisadvisabletoputonemotoroftherobotinlinewiththedirectionofthetransportbelttomakeprogrammingeasier.

3

Installa

tion

3-4

3. Mounting the motors and cabling3.1 Mounting the motorsWhenyourrobotisdeliveredwithoutmotors,youhavetomountthembyyourself.Firstofall,youhavetoremovethethreemotorcoversfromtherobot.

Thefollowingstepsmustbecarriedouttoremovethemotorcoversfromtherobot.Pleaseseealsothefollowingpicture:• RemovetheM6Allenbolt

1

2

No. Description

1 1xM6Allenbolt

2 Motorcover

• Removethemotorcover• Repeattheprocessfortheothertwomotorcovers

3.2 Connecting the cablesTherobotisdeliveredwith3cableentryplates.Theyaremountedaboveeveryprimaryarmmotortofeedhiscablesthrough.

Thefollowingstepsmustbecarriedouttofeedthecablesthroughtheentryplates.Pleaseseealsothebelowpictures:• Removethe4boltsofthecableentryplates• Removethecableentryglands

1

2

3

3

Installa

tion

3-5

No. Description

1 4xM5Allenbolt

2 Cableentryglands

3 Blindthule

• Insertthecablesintotheopeningofthemotorcover• Connectthecables

• Clampthecableentryglandsaroundthecableandslideitbackintothecableentryplate.Afterwardsalsoslidethe blindthulebackintothecableentryplate• Mountthecableentryplateonthebaseplate,usingthe4M5Allenbolts

3.3 Mounting the motor covers• Mountthecoverinthemachinedgroove• InstalltheAllenM6boltinthecoverbracketandtighten• Repeattheprocessfortheothertwomotorcovers• Themotorcoversarenowmounted

2

1

No. Description

1 Coverbracket

2 Machinedgroove

3

Installa

tion

3-6

3.4 Mounting the rotation motor or gearbox with his adaptor ringThissectionisapplicableonlytotheCR_UGD4_XXL1300H_Rmodel(withrotationalaxis).Dependentonthetypeofrotationmotororgearboxwithrotationmotor,aspecialadaptorringformountingisincluded.

1

2

No. Description

1 Gearboxormotor

2 Adaptorring

Nowmounttheadaptorring(withthemotororgearbox)onthelowersideofthebaseplatefromtherobotwiththeincludedboltsandrings.

1

2

No. Description

1 Lowersideofthebaseplate

2 Rotationadaptorringwithmotororgearbox

3

Installa

tion

3-7

4. Assembling the secondary arms4.1 Make an assemblyBeforemountingthesecondaryarmsontherobot,wehavetopre-assemblethemasshownonthebelowfigure,sothatwegetanarmassembly.

1

2

3

No. Description

1 Sanitarycupholderincl.ballbearingcup

2 Springpackage

3 Secondaryarm

Repeatthisactionfortheother2armsets.

WARNING • INCORRECTMOUNTEDSPRINGSCANJUMPAWAY. • WEARSUITABLEPROTECTIVECLOTHINGANDSAFETYGLASSES. • NEVERPULLTHESPRINGSFURTHERAPARTTHANNECESSARYWHENMOUNTINGTHEARMASSEMBLYONTHE PRIMARYARMORTCPBALLJOINTS. • REPLACESPRINGSAFTEROVERSTRETCHING.

3

Installa

tion

3-8

4.2 Mount the arm assembly on the robotFormounting,pullasecondaryarmwithhiscupholderovertheballjointoftheprimaryarm.Nowpullthearmsapartwiththeincluded"secondaryarmexpander"againsttheforceofthespringinordertoputthesecondarmoverthesecondballjointoftheprimaryarm.

No. Description

1 Secondaryarmexpander

ThenrepeatthisactionfortheTCP(seebelowpicture).

1

No. Description

1 TCP-ToolCenterPoint(withorwithoutrotationalaxis)

Repeatthisactionfortheother2secondaryarmassembly's.Nowyourrobotmechaniciscompletelyinstalled.

3

Installa

tion

3-9

5. Mounting the rotational axis on the gearbox shaftThissectionisapplicableonlytotheCR_UGD4_XXL1300H_Rmodel(withrotationalaxis).

Pleaseperformthefollowingstepsfirst.• Extendtherotationalaxistoitsentirelength,thenretractthesameandcheckwhetheritiseasytooperateorwhether someresistanceoccurs

NOTE Alightirregularresistanceisnormalandcausedbythemanufacturingtolerancesofthetubes.Theaxisisruninduringthefirst150hoursofoperation.Incaseofproblems,pleasechecktheaxisfordamageorcontactyourOMRONrepresentative.

1

2

No. Description

1 Clampingbushwithbolts

2 Rotationalaxis

ReleasethetwoM5Allenboltswhicharemountedintotheclampingbush(seeabovepicture).

Indeliverycondition,anextrafillbushislocatedintheclampingbush.Measureyourmotor/gearboxaxisanddetermineifyouneedtheextrafillbush.

1

2

3

Installa

tion

3-10

No. Description

1 Motororgearshaft

2 Topconnectorrotationalaxis

Nowpushthetopconnectorintotheshaftuntilthetopconnectorcomesintoitsstoppositionontheshaft.TightenthetwoM5Allenboltswith7Nm.

Therotationalaxisisnowmounted.

6. CalibrationNoteveryrobotthatisdeliverediscalibrated.Ifyouwanttocalibratetherobotbyyourself,acalibrationkitwithaspecialtoolisavailable(showninthebelowpicture).ThecalibrationsetcanbeorderedasCR_ART.1098

No. Description

1 Calibrationset

Thefollowingstepsmustbecarriedouttoputthethreeupperarmsfromtherobotinthezeroposition.Please,seethebelowpictures:

• Makesureallthesecondaryarmsaredisassembled• Releasethemotorbrakeandmakesurealltheprimaryarmsarerotateddownfarenough,sothecalibrationtool couldbemounted• Slidethecalibrationtoolonthebaseplateasshowninthenextpicture• Nowtightenthestarnutuntilthetoolisfixed

3

Installa

tion

3-11

• Releasethemotorbrakefromtheselectedmotorandpushtheupperarmwithhisballjointagainstthecalibrationas shownintheabovepicture• Nowfixthemotorbrakefromtheselectedmotor• Repeatthecalibrationstepsfortheothertwoprimaryarms• Removethetool

WARNING • CALIBRATINGTHEROBOTMUSTBECARRIEDOUTBYQUALIFIEDPROGRAMMINGPERSONNELONLY,ASTHIS REQUIRESANEXCELLENTLEVELOFKNOWLEDGEOFTHECONTROLSYSTEM. • WHENCARRYINGOUTTHEHOMINGYOURSELF,THISMUSTBECARRIEDOUTEXACTLYINTHEWAYANDTHE ORDERTHATTHEYAREDESCRIBED.

• Nowalltheprimaryarmsareinzeropositionfromthekinematicmodel• Nowputtheencodervaluesfromtheservomotorsin0º• Checkthattheangleindicatedforthethreemotorsis0º(±0.1°)• Yourrobotisnowcalibrated

7. Gripper interface7.1 With rotational axisThebelowfigureshowsthegripperconnectionsizesfortheCR_UGD4_XXL1300H_Rrobot(withrotationalaxis)accordingtoISO9409-1-A31,5.

3

Installa

tion

3-12

7.2 Without rotational axisThebelowfigureshowsthegripperconnectionsizesfortheCR_UGD4_XXL1300H_NRrobot(withoutrotationalaxis).

Thedesignofthegripperthatismountedundertherobothavegreatinfluenceontheperformanceoftherobot.BoththeweightofthegripperandthedistanceofthecenterofgravityofthegrippertotheTCPbasepointhavenegativeinfluenceonthefinalperformanceoftherobot.

Ifyouneedtoinstallcablingforthegripper,pleasefollowthefollowingsteps:• Mountthecablesonthebaseplateorframe,neartheturningpointfromtheprimaryarmonthegearbox• Mountthecablesontheprimaryarm,withty-rapsorclampingparts• Keepabigloopatthehingepointfromtheprimaryandsecondaryarm• Mountthecablesonthesecondaryarm,withty-rapsorclampingparts• Keepabigloopfromthelowestmountingpointatthesecondaryarmtilltheconnectiononthegripper

Chapter 4 Maintenance

Contents

1. Periodic maintenance 4-11.1 Springs 4-1

1.2 Ball bearing cups 4-2

1.3 Rotational axis 4-2

2. Cleaning the robot 4-4

3. Spare parts 4-4

4

Ma

intena

nce

4-1

1. Periodic maintenanceBeforeworkingontherobot,pleasebeensuredthatthemachinewheretherobotisbuiltin,istotallyswitchedoff.

DANGER • SWITCHOFFTHEMACHINE(SYSTEM)WHERETHEROBOTISBUILTIN(E.G.WITHAPADLOCK)TOPREVENTIT FROMBEINGSWITCHEDONAGAIN. • LABELTHEMACHINE(SYSTEM)WITHASIGNINDICATIONTHATWORKISINPROGRESS.THISSIGNMUST REMAININPLACE,EVENDURINGTEMPORARYINTERRUPTIONSTOTHEWORK. • THEEMERGENCYSTOPFROMTHEMACHINE(SYSTEM)MUSTREMAINACTIVE.IFSAFETYFUNCTIONSOR SAFEGUARDSAREDEACTIVATEDDURINGMAINTENANCEORREPAIRWORK,THEYMUSTBEREACTIVATED IMMEDIATELYAFTERTHEWORKISCOMPLETED.

1.1 SpringsHowtomaintainthesprings:• Thespringshastobereplacedevery3800workinghoursoronceayear• Whentherobotisfallapart,checkthespringsondamages• OnlyusespringsdeliveredbyOMRON,otherwisetheguaranteewillexpire• Replacespringsafteroverstretching• Forspareparts,seeSection 3 Spare partsinthischapter

WARNING • INCORRECTMOUNTEDSPRINGSCANJUMPAWAY. • WEARSUITABLEPROTECTIVECLOTHINGANDSAFETYGLASSES. • NEVERPULLTHESPRINGSFURTHERAPARTTHANNECESSARYWHENMOUNTINGTHEARMASSEMBLYONTHE PRIMARYARMORTCPBALLJOINTS.

Howtodisassemblethesprings:• Disassemblethesecondaryarmsfromtherobotwiththe"secondaryarmexpander"• Replacethesprings• Forre-assemblingthesecondaryarms,seeSection 4 Assembling the secondary armsinChapter3

4

Ma

intena

nce

4-2

1.2 Ball bearing cupsTheballbearingcupshasthesamelifetimeasthesprings.Werecommendtoexchangetheseatthesametimeasthesprings.

Howtomaintaintheballbearingcups:• Theballbearingcupshastobereplacedevery3800workinghoursoronceayear• Whentheballbearingcupsmakesqueakingnoises,takeofthesecondaryarmassembly’sandcleanthecupswith pressedair• Do not lubricate the ball bearing cups!

Forinstructionstoreplacetheballbearingcups,seebelowpicture:

1

No. Description

1 M6bolt

• ScrewanM6boltinthebacksidefromthecupholder• Nowtheballbearingcupwillcomeout

1.3 Rotational axisTheplainbearingsontherotationalaxiswearwithtimesothatbacklashstartstooccurontherotationalaxis.Howfasttheplainbearingsbecomeworndependsstronglyonthefollowingfactors:• Theworkingpath• Thepayload• Thespeedoftherobot• Therotationactions

WhendoIhavetoexchangetheplainbearings?• Ifthereisalotofplayontherotationalaxis• Every3000workinghoursoronceayear

Forinstructionstoreplacetheplainbearings,seethebelowpicture:

1

2

4

Ma

intena

nce

4-3

No. Description

1 Sliderblock

2 M6boltwithwasher

• UnscrewthetwoM6boltswithwasherandtakeofthebolts

• Removethetwotubes(sometimesthetubeswillclampinsidethesliderblock,useasmallplastichammertorelease them)

1

No. Description

1 Plainbearing

• Exchangetheoldplainbearingswiththenewones• Putbackthetwotubesontherotationalaxis• MountthetubeswiththetwoM6boltsincludingwashers

WARNING • PLAINBEARINGSHASTOBEMOUNTEDVERYCAREFULLY. • WRONGMOUNTEDPLAINBEARINGSMAYDAMAGE. • EXTENDTHEROTATIONALAXISTOITSENTIRELENGTH,THENRETRACTTHESAMEANDCHECKWHETHERITIS EASYTOOPERATEORWHETHERSOMERESISTANCEOCCURS.

4

Ma

intena

nce

4-4

2. Cleaning the robotCleantherobotbywashingwithsoftclothorsponge.Usesoapormilddetergentandwarmwaterfollowedbyclearwaterrinse.Foroilandgreasestainsusealcoholwithsoftcloth.Donotuseahighpressurewatercleaner,oranyotherhighpressurecleaningdevice.

3. Spare parts

DescriptionOMRON Part No.

CR_UGD4_XXL1300H

Primaryarmset •2xballbearing•1xdowelpin•1xprimaryarm

CR_ART.1239

Secondaryarmset •2xsecondaryarm•2xspringpackage

CR_ART.1240

Ballbearingcups •12xballbearingcup CR_ART.1124

Springpackage •6xspring•12xspringholder

CR_ART.1123

Splinepartrotationalaxis •1xsplinepartrotationalaxis CR_ART.1241

Plainbearingrotationalaxis •1xplainbearing CR_ART.1128

Cardancoupling •1xcardancoupling(insideballbearingmadeofstainlesssteel)

CR_ART.1382

Clampingbushwithbolts •1xtopclamp22mmwithbolts CR_ART.1495

TCP-ToolCenterPoint •1xTCP•6xsanitaryballjoint

CR_ART.1269

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DescriptionOMRON Part No.

CR_UGD4_XXL1300H

Gripperinterface (robotswithserialnumber1470orhigher)

•1xgripperinterface CR_ART.1350

Gripperinterface (robotswithserialnumber1469orlower)

•1xgripperinterface CR_ART.1363

Motorcover •1xmotorcover CR_ART.1498

Gearboxfortheprimaryarm •1xgearbox CR_ART.1143

Gearboxfortherotationalaxis •1xgearbox CR_ART.1154

Calibrationset •1xcalibrationtool•1xsuitcase

CR_ART.1098

Secondaryarmexpander •1xsecondaryarmexpander CR_ART.1186

Hingerollers •24xhingeroller CR_ART.1127

Chapter 5 Robot settings

Contents

1. Kinematics 5-1

2. Workspace 5-2

3. Software limits 5-3

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1. KinematicsThekinematicsparametersfortheCR_UGD4_XXL1300Hrobotareshownbelow.Settheseparameterscorrespondingtothecontrollersettings.

WARNING IFTHEKINEMATICSPARAMETERSARENOTSETPROPERLY,THISMAYCAUSETHEROBOTTOMALFUNCTION.SO,BESURETOSETTHESEPARAMETERSCORRECTLY.

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2. WorkspaceTheworkspaceparametersfortheCR_UGD4_XXL1300Hrobotareshownbelow.Settheseparameterscorrespondingtothecontrollersettings.

WARNING IFTHEWORKSPACEPARAMETERSARENOTSETPROPERLY,THISMAYCAUSETHEROBOTTOMALFUNCTION.SO,BESURETOSETTHESEPARAMETERSCORRECTLY.

Zu + offset: -790 mm with rotational axis / -741 mm without rotational axis Distance from the Z-axis origin position to the tool flangeRcy: 650 mm Radius of the cylinder Hcy: 300 mm Height of the cylinder Rco: 390 mm Radius of the frustum cone of underside Hco: 150 mm Height of the frustum cone

Zu + offset

Rcy

Hcy

Hco

Rcy

Rco

Workspace parameters

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3. Software limitsThesoftwarelimitsfortheCR_UGD4_XXL1300Hrobotareshownbelow.

WARNING IFTHEα-,β- OR γ-AXISSOFTLIMITISSETINCORRECTLY,THEARMMAYCOLLIDEWITHTHEROBOTBASEORBASEPREPAREDBYTHEUSER,CAUSINGBREAKAGE.SO,BESURETOSETTHESOFTLIMITSCORRECTLY.

Minus directionsoft limit [-30°]

Plus directionsoft limit [88°]

Chapter 6 Specifications

Contents

1. Basic specifications 6-11.1 Cycle time 6-1

2. External view and dimensions 6-2

3. Design specifications 6-33.1 Occupation area of robot 6-3

3.2 Software design 6-4

3.2.1 Dimensionsandlimits 6-5

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1. Basic specifications

Robot model CR_UDG4_XXL1300H_R CR_UDG4_XXL1300H_NR

Working volume

X, Y axis Stroke Ø1300mm

Z axis Stroke 300mm (max. Ø1300mm)/450mm (center Ø780mm)

θ axis Rotation range±180° (default setting, it can be

changed)

Servo motorArm 1, 2, 3 3000W

Rotational axis 4 1000W

Repeatability*1X, Y, Z axis ±1mm

θ axis ±0.3°

Maximum through-put*2 90 CPM*3

Maximum payload 8kg

Gearbox ratioX, Y, Z axis 1:38,5

θ axis 1:20

θ axis torque limitation 26 Nm

User tubing (outer diameter) Ø8*4

Travel limit Soft limit

Noise level < 68 dB (A)

Ambient temperature 5ºC to 45ºC

Relative humidity Max. 90%

Protection class IP65

Weight 90kg

*1: This is the value at a constant ambient temperature. *2: With 0.1kg payload. When reciprocating 305mm in horizontal and 25mm in vertical directions. *3: CPM: Cycle per minutes. Check the note 2 for the cycle definition. *4: Only for the air suctioning. The air injection is not allowed.

1.1 Cycle time

Z1

Y

Z2

P&P path Payload Cycle time

25 x 305 x 25 mm (Z1 x Y x Z2) 1 kg 0.47 s

25 x 305 x 25 mm (Z1 x Y x Z2)8 kg

0.90 s

200 x 1000 x 200 mm (Z1 x Y x Z2) 1.5 s

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2. External view and dimensions

NOTE Robotswithserialnumber1469orlowerhavedifferentgripperdimensions.Refertosection“3.2Gripperinterface”inthischapterformoredetailedinformationaboutdimensions.

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3. Design specifications3.1 Occupation area of robotIftherobotisintegratedintothemachineitmustbeconsideredwhatthereachisofallrobotpartstopreventcollisionwithotherpartsinthemachine.

WhentheTCPmovestoitsouterpositions,theprimaryandsecondaryarmscanriseabovethebaseplate,takecarethatnomechanicalobstructionsareintheareasindicatedinthebelowpicture.

400

100

200

420

600

WARNING IFMECHANICALOBSTRUCTIONSAREINTHEINDICATEDAREA,THEROBOTORTHEOTHERMACHINEPARTSCOULD BE DAMAGED.

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3.2 Software designThearmlengthsandpitchcirclesoftherotationpointsareshowninthebelowpicture.

Upper arm length440 mm

Lower arm length950 mm

Lower arm rotation pointscircle diameter 140 mm

Upper arm rotation pointscircle diameter 295 mm

Flange offset59 mm with rotational axis

10 mm without rotational axis

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3.2.1 Dimensions and limits

Description Value

With rotational axis Without rotational axis

Negativesoftwarelimit -30º

Positivesoftwarelimit 88º

Tb-z(topbaseplatetozeroposition) 110mm

Z-tw(zeropositiontoballbearings) 731mm

Flangeoffset 59mm 10mm

Revision history

A manual revision code appears as a suffix to the catalog number on the front cover manual.

The following table outlines the changes made to the manual during each revision.

Revision code Date Description

01 July 2015 Original production

01A July 2016 Secondary arm expander was included

01B October 2016 New gripper interface was included

01C May 2017 Spare parts section was updated. Robot dimensions were updated

01D September 2017 Basic specifications section was updated

Cat. No. I201E-EN-01D Note: Specifications subject to change without notice.

Authorized Distributor:

Printed in Europe