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Training
Course Overview
Day 1
Equipment Overview
Safety Review
Fault Overview
Power Flow
On/Off Control
Class 1 Fault Troubleshooting
Day 2
CPU Overview
Class 2 Fault Troubleshooting
File Manipulation
Servo Loop Discussion
Robot mastering
Day 3
Servo Amplifier
E-stop Circuitry
Class 3 Troubleshooting
I/O
Day 4
120iB/R2000 Hands On
Mastering
Post Test
SYSTEM OVERVIEW
Robot Overview
R-J3i B Controller
R-J3i A Controller
R-J3i A Controller
SOP Board
Panel Board
Controller Disconnect
SOP Board
Panel Board
Fan
220 VAC
Single Phase
R-J3i B Controller Internal
Components
6 Axis Servo Amp
Disconnect
Main CPU
Estop PCB
Power Supply
Backplane
R-J3i B Controller Internal
Components
Advise all personnel who must teach the robot or otherwise manually operate the robot to
observe the following rules:
Before teaching, visually inspect the robot and work envelope to make sure that no
potentially hazardous conditions exist. The work envelope is the area defined by the
maximum motion range of the robot. These include tooling attached to the wrist
flange that extends this range.
The area near the robot must be clean and free of oil, water, or debris.
Only the person with the teach pendant should be in the work envelope.
Know the path that can be used to escape from a moving robot; make sure the
escape path is never blocked.
Test any program being run for the first time in the following manner:
Using a low motion speed, single step the program for at least one full cycle.
Using a low motion speed, test run the program continuously for at least one full cycle.
Using the programmed speed, test run the program continuously for at least one full cycle.
Make sure all personnel are outside the work envelope before running production.
Staying Safe During Inspection
Class 1 Fault
Class 2 Fault
Class 3 Fault
Class 4 Fault
Class 1 Fault Overview
Symptoms
● Dead controller/teach pendant screen is blank
Potential Causes
● Problem with AC power to controller
● Circuit Breaker
● Transformer
● Problem with controller DC power circuit
● Teach pendant/cable problem
● Problem with power supply unit
● Problem with the On/Off circuit
● Cables
Class 2 Fault Overview
Symptoms
● Teach pendant locked up, no response
Potential Causes
● Corrupt software
● CPU/DRAM module
● FROM/SRAM module
● Teach pendant/cable problem
● Problem with power supply unit or backplane
Class 3 Fault Overview
Symptoms
● Fault light is on
● KM1 and KM2 are off, no power to servos
● Diagnostic message displayed on screen
Potential Causes
● Servo amp
● Motors/SPC’s
● Emergency stop circuit
● Emergency stop circuit board
● Emergency stop unit including KM1 and KM2
● Panel board
● Cables
Class 4 Fault Overview
Symptoms
● Robot will run only when cell interface is not required
● Can run programs from the teach pendant
Potential Causes
● No comm with PLC, weld controller, etc.
● Faulty limit switch, prox., etc.
Fuse Based Troubleshooting
Power Supply Fuse Locations
Fuse F3 24E
Fuse F4 24V
PIL LED
CP5 24V
CP6 24E
ALM LED
On/Off Circuit Diagram
Troubleshooting by LEDs on
Power Supply Unit
Panel Board
TBOP3 CRM64
External On/Off 24V & Estop
TBOP4 JRS11
Estops and other HSSB
External circuits TP&On/Off
CRT9 TBOP6
Mode Select Estop relay
Switch outputs
CRM65 CRP5
Non teach Hour meter
Enable device
CRS16
CRT8 TP
Push-buttons
And LEDs CRM62
Robot Disconnect
Panel Board
D1 & D2
SVON 1&2
Fuse F1
External 24V
Fuse 2
TP 24V
RDY LED
PON LED Com with
5V power Main board
CRM63
Optional Digital
Input
Troubleshooting by LEDs on Panel Board
24V Power Flow
Backplane
Power Supply
Main Board
Lab Assignment 2
Use a fault code to determine which
fuse has blown
Lab Assignment 2b
Remove and Replace the Panel Board.
Lab Assignment 3
JD17
RS232C & RS485
JD1A
Fanuc I/O
JRS11
HSSB to Panel PCB
TBDL Model B
COP10B FSSB
CD38 Ethernet
Main Board
Battery
3V Lithium
7 Segment Display
Status LEDs
Setting the default device specifies which device to use when manipulating
programs and files. You must set the default device before you can perform
any program or file manipulations, including formatting a memory card. The
following devices are allowed, if available:
Flash File Storage disk (FR:) - Built-in storage for controller system files.
F-ROM Device (FRD:) (for use only with the Controller Version
Upgrade option)
BACKING UP FILES
When you back up a file you save it from controller memory to a storage device so that you have a
second copy of the file.
Program Files
When you back up program files, all teach pendant program files currently loaded onto controller
memory (listed on the SELECT menu) and default motion instruction files (DF_xxxx.DF)will be
saved to the default device
System Files
System files are binary files that store values for system variables, servo parameter data, and
mastering data. They contain information specific to the controller, robot, and software.
When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robot’s positional
information.
When the controller is shut down under normal conditions, each serial pulse
coder’s present reading is maintained in the pulse coder by backup
batteries on the robot.
When the controller is turned on, the controller requests the stored reading
from the serial pulse coder. When the controller receives the pulse coder
reading, the servo system can operate normally. This process is called
calibration . Calibration occurs automatically each time the controller is
turned on.
When pulse coder backup battery power is interrupted while the controller is
powered down, calibration fails at power up and the only robot motion
possible is joint mode jogging. To restore proper operation, the robot must
be mastered and calibrated.
SINGLE AXIS MASTERING
You can master a single axis of any robot
provided that there is a reference mark at
a known position on that axis.
SYSTEM Master/Cal
1 FIXTURE POSITIONMASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
1 FIXTURE POSITIONMASTER
quick master 2 ZERO POSITION MASTER
3 QUICK MASTER
Select Calibrate
Lab Assignment 6
FS3
Regenative discharge
Thermal power protection
FS2
24E Power Protection
Servo Amplifier
DC Link Circuit
Power Amplifier
Servo Amplifier LEDs
Lab Assignment 7
Fault light is on
KM1 and KM2 are off, no power to servos
Diagnostic message displayed on screen
Potential Causes
Servo amp
Motors/SPC’s
Emergency stop circuit
Emergency stop circuit board
Emergency stop unit including KM1 and KM2
Panel board
Cables
Dual E-Stop Chain
E-Stop Unit
220V input QF2
From transformer Circuit breaker
CRM67 CP6
Interlock signals 24E from PSU
To servo amp (24V)
CRM73 CRM64
Transformer overheat Signals from
panel board
CRM72 CNMC2
Aux E-stop Pre-charge
Output
CNMC3 CRR66
KM1 & KM2 Aux. Axis amp
Contacts 220 VAC power
CRM71 CP5A
Robot off Optional 24V
From PSU
CRM70 CNMC1
Door Interlock 220 VAC from
transformer
for precharge
XT4 CP2
KM1 and KM2 Signals from
Aux contacts panel board
LED 3
Status Of
Relay KA3
E-Stop Unit LEDs
E-Stop Unit LEDs
E-Stop Unit LEDs
Panel Board E-Stop Connections
KA21&KA22
Estop condition contact
output relays
TBOP4
Estops and other TBOP6
External circuits Estop relay outputs
Panel Board E-Stop Connections
Lab Assignment 8
32 16 8 4 2 1
1 0 0 1 1 0
38
User Operator Panel (UOP) I/O
Allen-Bradley
Remote I/O Rack 16
Interface
The slot is the space Modular (Model A) The space on the rack where the I/O
I/O module is connected.
on the rack where the
Distributed (Model B) Determined by the DIP switch
modular I/O module is I/O settings on the unit.
connected. The Process I/O Begin at Slot 1 for the first unit
meaning of slot
Allen-Bradley Remote
depends on the kind I/O Interface
Slot 1
16 8 4 2 1
7 OFF OFF ON ON ON
Basic Digital I/O Module DIP
Switches
Set the termination resistor, represented by
switch R. Examine the terminals for S+ and S-
and set switch R as follows:
If one twisted-pair cable is attached to these
terminals, set switch R to ON.
If more than one twisted-pair cable is attached to
these terminals, set switch R to OFF.
Setting Up Model B Basic Digital
I/O Units
Steps
Press MENUS.
Select I/O.
Press F1, [TYPE].
Select I/O Link. You will see a screen similar to
the following.
RV Reducer
Ballscrew
Harmonic Reducer
Gearboxes
RV Reducer
The rotating vector (RV) reducer is used to
reduce the speed of the servo motor. The RV
reducer allows components to roll and move
smoothly under extreme heat expansion or load
conditions.
RV Reducer
All parts of the RV speed reducer have a common centre with the
shafts and two cycloidal discs transmit power through the unit.
The discs are mounted at 180 degree opposition to balance the
motion. The result is smooth, quiet operation.
RV Reducer
The input gear mounted to the servomotor shaft and the
servo motor supply power to rotate the RV Reducer.
The input gear meshes with the three RV drive gears.
As the shaft rotates, the discs oscillate in 180 degree
opposition.
RV Reducer
Depending on the reduction ratio of the reducer there are one there
are one or two fewer teeth on the cycloidal disc than are pins.
A progressive mis-meshing of rollers and teeth cause the cycloidal
discs to rotate in the direction oppositie of the input shaft.
Ballscrew
The ballscrew is a speed reducer that converts rotary
motion into linear motion.
The high precision device uses steel balls to carry the
load resulting in quiet, backlash free operation.
Ballscrew
The input rotation of the motor is applied directly to the lead screw.
As the screw is turned, it forces the ball bearings in the nut to roll,
causing the nut to move along the screw shaft.
The robot axis is typically mounted to the nut, and is driven by it.
Harmonic Drive
The Harmonic Drive is a compact, high speed reducer. It consists of
three main components:
360 Degrees
Gearboxes
Gearboxes are used with the 100i, 120i
and 120iB models for reduction.
The reduction is accomplished with spur
and/or pinion gears alone, or in
conjunction with Rotary Vector drives or
Harmonic reducers.
100i J4 Gearbox
100i, 120i, 120iB J5 Gearbox
Mechanical Units Overview
100i
120i
R2000iA
AM100i/M6i CONFIGURATION
J1 AXIS DRIVE MECHANISM
The rotation of the AC servo motor is reduced by the two
step gear reduction and rotates the J2-axis base.
J2 Axis Drive Mechanism
The rotation of the AC servo motor is reduced by
the reducer and rotates the J2-axis arm.
The J2-axis arm is supported by the J2-axis
base via the reducer
J3 Axis Drive Mechanism
The rotation of the AC servomotor is reduced by
the reducer and rotates the J4-axis drive
mechanism.
The J3-axis unit is supported by the J4-axis gear
box and the J2-axis arm via the reducer.
J4 Axis Drive Mechanism
The rotation of the AC servo motor is reduced by
the two step gear reduction and rotates J3-axis
arm.
J5 & J6 Axis Drive Mechanism
The rotation of the AC servomotor is reduced by the
three step gear reduction of J5-axis and rotates the J6-
axis unit.
The rotation of AC servomotor is decelerated by the J6-
axis reducer and rotates the output flange.
Greasing
Never exceed 1 cc per second
17 PSI will exceed motor seals
AM120iB/M16iB CONFIGURATION
J1 Axis Drive Mechanism
J2 Axis Drive Mechanism
J3 Drive Mechanism
J4 Drive Mechanism
J5 & J6 Drive Mechanism
Greasing
R2000iA Configuration
J1 Axis Drive Mechanism
J2 Axis Drive Mechanism
J3 Axis Drive Mechanism
J4 Drive Mechanism
J5/J6 Axis Drive Mechanism
Greasing