ZX-T Series

Cat. No. I201E-EN-01B

Delta Robot XXL

USER´S MANUAL

Delta RobotCR_UGD4_XXL1300H Series

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

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 Gripperinterface 6-33.2.1 Withrotationalaxis 6-3

3.2.2 Withoutrotationalaxis 6-4

3.3 Softwaredesign 6-53.3.1 Dimensionsandlimits 6-6

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)

900

300

150

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

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 Calibrationtool

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

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

Description OMRON Part No.

Calibrationtool CR_ART.1098

Springpackage CR_ART.1123

Ballbearingcups CR_ART.1124

Cardancoupling CR_ART.1126

Hingerollers CR_ART.1127

Plainbearing CR_ART.1128

Gearboxfortherotationalaxis CR_ART.1154

Primaryarmset CR_ART.1239

Secondaryarmset CR_ART.1240

Splinepartrotationalaxis CR_ART.1241

Gearboxfortheprimaryarm CR_ART.1268

TCP-ToolCenterPoint CR_ART.1269

Secondaryarmexpander CR_ART.1186

Gripperinterface (robotswithserialnumber1470orhigher)

CR_ART.1350

Gripperinterface (robotswithserialnumber1469orlower)

CR_ART.1363

Chapter 5 Robot settings

Contents

1. Kinematics 5-1

2. Workspace 5-2

3. Software limits 5-3

5

Rob

ot se

ttings

5-1

1. KinematicsThekinematicsparametersfortheCR_UGD4_XXL1300Hrobotareshownbelow.Settheseparameterscorrespondingtothecontrollersettings.

WARNING IFTHEKINEMATICSPARAMETERSARENOTSETPROPERLY,THISMAYCAUSETHEROBOTTOMALFUNCTION.SO,BESURETOSETTHESEPARAMETERSCORRECTLY.

5

Rob

ot se

ttings

5-2

2. WorkspaceTheworkspaceparametersfortheCR_UGD4_XXL1300Hrobotareshownbelow.Settheseparameterscorrespondingtothecontrollersettings.

WARNING IFTHEWORKSPACEPARAMETERSARENOTSETPROPERLY,THISMAYCAUSETHEROBOTTOMALFUNCTION.SO,BESURETOSETTHESEPARAMETERSCORRECTLY.

Zu

Rcy

Hcy

Hco

Rcy

Rco

Workspace parameters

Zu: -731 mm Distance from the Z-axis origin position Rcy: 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

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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 Gripper interface 6-3

3.2.1 Withrotationalaxis 6-33.2.2 Withoutrotationalaxis 6-4

3.3 Software design 6-5

3.3.1 Dimensionsandlimits 6-6

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1. Basic specifications

Robot model CR_UDG4_XXL1300H_R CR_UDG4_XXL1300H_NR

Workingvolume

X,Yaxis Stroke Ø1300mm

Zaxis Stroke 300mm(max.Ø1300mm)/450mm(centerØ780mm)

θaxis Rotationrange±180°(defaultsetting,itcanbe

changed)

ServomotorArm1,2,3 3000W

Rotationalaxis4 1000W

Repeatability*1X,Y,Zaxis ±1mm

θaxis ±0.3°

Maximumthrough-put*2 90CPM*4

Maximumpayload 8kg

θaxistolerablemomentofinertia*3 Accordingtotheservomotor

Usertubing(outerdiameter) Ø8*5

Travellimit Softlimit

Noiselevel <68dB(A)

Ambienttemperature 5ºCto45ºC

Relativehumidity Max.90%

Protectionclass IP65

Weight 90kg

*1: Thisisthevalueataconstantambienttemperature. *2: With0.1kgpayload.Whenreciprocating305mminhorizontaland25mminverticaldirections. *3: Therearelimitstoaccelerationcoefficientsettings. *4: CPM:Cycleperminutes.Checkthenote2forthecycledefinition. *5: Onlyfortheairsuctioning.Theairinjectionisnotallowed.

1.1 Cycle time

Z1

Y

Z2

P&P path Payload Cycle time

25x305x25mm(Z1xYxZ2) 1kg 0.47s

25x305x25mm(Z1xYxZ2)8kg

0.90s

200x1000x200mm(Z1xYxZ2) 1.5s

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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.

3.2 Gripper interface

3.2.1 With rotational axisThebelowfigureshowsthegripperconnectionsizesfortheCR_UGD4_XXL1300H_Rrobot(withrotationalaxis)accordingtoISO9409-1-A31,5.

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3.2.2 Without rotational axisThebelowfigureshowsthegripperconnectionsizesfortheCR_UGD4_XXL1300H_NRrobot(withoutrotationalaxis).

Thedesignofthegripperthatismountedundertherobothavegreatinfluenceontheperformanceoftherobot.BoththeweightofthegripperandthedistanceofthecenterofgravityofthegrippertotheTCPbasepointhavenegativeinfluenceonthefinalperformanceoftherobot.

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

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3.3 Software designThearmlengthsandpitchcirclesoftherotationpointsareshowninthebelowpicture.

Upper arm length440 mm

Lower arm length950 mm

Lower arm rotation pointscircle diameter 140 mm

Upper arm rotation pointscircle diameter 295 mm

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3.3.1 Dimensions and limits

Description Value

Negativesoftwarelimit -30º

Positivesoftwarelimit 88º

Tb-z(topbaseplatetozeroposition) 210mm

Z-tw(zeropositiontotopworkarea) 690mm

Top mounting bracket

Top work area

Tb-z

Z-tw

0°

Pos.°

Neg.°

Primary arm

Revision history

Amanualrevisioncodeappearsasasuffixtothecatalognumberonthefrontcovermanual.

Thefollowingtableoutlinesthechangesmadetothemanualduringeachrevision.

Revision code Date Description

01 July2015 Originalproduction

01A July2016 Secondaryarmexpanderwasincluded

01B October2016 Newgripperinterfacewasincluded

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

Authorized Distributor:

Printed in Europe