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Comau RoboticsInstruction handbook

Manuali

SMART5 Arc 4

Technical specification

CR00757638_en-01/2011.07

The information contained within this manual is the property of COMAU S.p.A..

Any reproduction, even partial is forbidden without previous written authorisation from COMAU S.p.A.

COMAU reserves the right to modify without previous warning, the characteristics of the product presented in this manual.

Copyright © 2009 by COMAU - Date of publication 11/2006

Summary

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...17Robot SMART5 Arc 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Robot mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Interchangeability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3. TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...21General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. OPERATING AREAS AND ROBOT OVERALL DIMENSIONS . . . . . . . . . . . . . . . . ...23SMART5 Arc 4 - Operating Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SMART5 Arc 4 - Operating Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SMART5 Arc 4 - Restrictions for the Operating Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5. ROBOT FLANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27Fixture mounting flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6. LOADS AT WRIST AND ADDITIONAL LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Determination of max loads at wrist flange (QF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Additional loads (QS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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7. PREPARATION FOR ROBOT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..38Environment conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Environment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Operating space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Robot installation on horizontal plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Attachment to a steel plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Attachment to a plate with adjustable level (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Stress on the robot structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Installing the robot on a sloping surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Securing to a raised support (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Stress to floor for a robot installed on support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8. OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..48Axis 1 adjustable mechanical stop (code 82282500). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Axis 2 adjustable mechanical stop (code 82282600). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Axis 3 adjustable mechanical stop assembly (code 82282700) . . . . . . . . . . . . . . . . . . . . . . . . 54Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Axis 1 work area sectoring assembly (code CR82284900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Screw and pin unit for the robot-base fastening (code 82281900) . . . . . . . . . . . . . . . . . . . . . . 57

Leveling plate assembly (code 82283200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Manual calibration kit (code CR82222100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Gauged tool assembly(L = 117mm - code 81783801). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Fork liftable assembly (code CR82287500). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Distribution connections protection assembly (treadable - code CR82287700) . . . . . . . . . . . . 65Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Support on horizontal surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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Preface

PREFACE

Symbols used in the manualThe symbols for WARNING, CAUTION and NOTES are indicated below together withtheir significance.

This symbol indicates operating procedures, technical information andprecautions that if ignored and/or are not performed correctly could causeinjuries.

This symbol indicates operating procedures, technical information andprecautions that if ignored and/or are not performed correctly could causedamage to the equipment.

This symbol indicates operating procedures, technical information andprecautions that it are important to highlight.

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Preface

Reference documentsThis document refers to the robot versions listed hereunder in the standard outfitting:

– SMART5 Arc 4;

The complete set of robot system documentation manuals consists of:

These manuals are to be integrated with the following documents:

Comau Robot – Technical Specifications– Transport and installation– Maintenance– Electrical diagram

Comau C5G Control Unit – Technical Specifications– Transport and installation– Guide to integration, safeties, I/O and

communications– Maintenance– Use of Control Unit.– Electrical diagram

Programming – EZ PDL2 Programming environment – PDL2 Programming Language Manual– VP2 - Visual PDL2– Move programming

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General Safety Precautions

1. GENERAL SAFETY PRECAUTIONS

This specification deals with the following topics:

– Responsibilities

– Safety Precautions.

1.1 Responsibilities– The system integrator is responsible for ensuring that the Robot System (Robot

and Control System) are installed and handled in accordance with the SafetyStandards in force in the country where the installation takes place. The applicationand use of the protection and safety devices necessary, the issuing of declarationsof conformity and any CE markings of the system are the responsibility of theIntegrator.

– COMAU Robotics & Service shall in no way be held liable for any accidents causedby incorrect or improper use of the Robot System (Robot and Control System), bytampering with circuits, components or software, or the use of spare parts that arenot included in the spare parts list.

– The application of these Safety Precautions is the responsibility of the personsassigned to direct / supervise the activities indicated in the Applicability sectionallyare to make sure that the Authorised Personnel is aware of and scrupulously followthe precautions contained in this document as well as the Safety Standards inaddition to the Safety Standards in force in the country in which it is installed.

– The non-observance of the Safety Standards could cause injuries to the operatorsand damage the Robot System (Robot and Control System).

It deals with a general specification that apply to the whole Robot System. Due toist significance, this document is referred to unreservedly in any systeminstruction manual.

The installation shall be made by qualified installation Personnel and shouldconform to all national and local codes.

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1.2 Safety Precautions1.2.1 Purpose

These safety precautions are aimed to define the behaviour and rules to be observedwhen performing the activities listed in the Applicability section.

1.2.2 Definitions

Robot System (Robot and Control System)The Robot System is a functional unit consisting of Robot, Control Unit, Programmingterminal and possible options.

Protected AreaThe protected area is the zone confined by the safety barriers and to be used for theinstallation and operation of the robot

Authorised PersonnelAuthorised personnel defines the group of persons who have been trained and assignedto carry out the activities listed in the Applicability section.

Assigned Personnel The persons assigned to direct or supervise the activities of the workers referred to inthe paragraph above.

Installation and Putting into ServiceThe installation is intended as the mechanical, electrical and software integration of theRobot and Control System in any environment that requires controlled movement ofrobot axes, in compliance with the safety requirements of the country where the systemis installed.

Programming ModeOperating mode under the control of the operator, that excludes automatic operationand allows the following activities: manual handling of robot axes and programming ofwork cycles at low speed, programmed cycle testing at low speed and, when allowed,at the working speed.

Auto / Remote Automatic ModeOperating mode in which the robot autonomously executes the programmed cycle at thework speed, with the operators outside the protected area, with the safety barriersclosed and the safety circuit activated, with local (located outside the protected area) orremote start/stop.

Maintenance and RepairsMaintenance and repairs are activities that involve periodical checking and / orreplacement (mechanical, electrical, software) of Robot and Control System parts orcomponents, and trouble shooting, that terminates when the Robot and Control Systemhas been reset to its original project functional condition.

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Putting Out of Service and DismantlingPutting out of service defines the activities involved in the mechanical and electricalremoval of the Robot and Control System from a production unit or from an environmentin which it was under study.Dismantling consists of the demolition and dismantling of the components that make upthe Robot and Control System.

IntegratorThe integrator is the professional expert responsible for the installation and putting intoservice of the Robot and Control System.

Incorrect UseIncorrect use is when the system is used in a manner other than that specified in theTechnical Documentation.

Range of Action The robot range of action is the enveloping volume of the area occupied by the robotand its fixtures during movement in space.

1.2.3 ApplicabilityThese Specifications are to be applied when executing the following activities:

– Installation and Putting into Service;

– Programming Mode;

– Auto / Remote Automatic Mode;

– Robot axes release;

– Maintenance and Repairs;

– Putting Out of Service and Dismantling

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1.2.4 Operating Modes

Installation and Putting into Service

– Putting into service is only possible when the Robot and Control System has beencorrectly and completely installed.

– The system installation and putting into service is exclusively the task of theauthorised personnel.

– The system installation and putting into service is only permitted inside a protectedarea of an adequate size to house the robot and the fixtures it is outfitted with,without passing beyond the safety barriers. It is also necessary to check that undernormal robot movement conditions there is no collision with parts inside theprotected area (structural columns, power supply lines, etc.) or with the barriers. Ifnecessary, limit the robot working areas with mechanical hard stop (see optionalassemblies).

– Any fixed robot control protections are to be located outside the protected area andin a point where there is a full view of the robot movements.

– The robot installation area is to be as free as possible from materials that couldimpede or limit visibility.

– During installation the robot and the Control Unit are to be handled as described inthe product Technical Documentation; if lifting is necessary, check that theeye-bolts are fixed securely and use only adequate slings and equipment.

– Secure the robot to the support, with all the bolts and pins foreseen, tightened tothe torque indicated in the product Technical Documentation.

– If present, remove the fastening brackets from the axes and check that the fixingof the robot fixture is secured correctly.

– Check that the robot guards are correctly secured and that there are no moving orloose parts. Check that the Control Unit components are intact.

– If applicable, connect the robot pneumatic system to the air distribution line payingattention to set the system to the specified pressure value: a wrong setting of thepressure system influences correct robot movement.

– Install filters on the pneumatic system to collect any condensation.

– Install the Control Unit outside the protected area: the Control Unit is not to be usedto form part of the fencing.

– Check that the voltage value of the mains is consistent with that indicated on theplate of the Control Unit.

– Before electrically connecting the Control Unit, check that the circuit breaker on themains is locked in open position.

– Connection between the Control Unit and the three-phase supply mains at theworks, is to be with a four-pole (3 phases + earth) armoured cable dimensionedappropriately for the power installed on the Control Unit. See the productTechnical Documentation.

– The power supply cable is to enter the Control Unit through the specific fairlead andbe properly clamped.

– Connect the earth conductor (PE) then connect the power conductors to the mainswitch.

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– Connect the power supply cable, first connecting the earth conductor to the circuitbreaker on the mains line, after checking with a tester that the circuit breakerterminals are not powered. Connect the cable armouring to the earth.

– Connect the signals and power cables between the Control Unit and the robot.

– Connect the robot to earth or to the Control Unit or to a nearby earth socket.

– Check that the Control Unit door (or doors) is/are locked with the key.

– A wrong connection of the connectors could cause permanent damage to theControl Unit components.

– The C5G Control Unit manages internally the main safety interlocks (gates,enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to theline safety circuits, taking care to connect them as required by the Safetystandards. The safety of the interlock signals coming from the transfer line(emrgency stop, gates safey devices etc) i.e. the realisation of correct and safecircuits, is the responsibility of the Robot and Control System integrator.

– The safety of the system cannot be guaranteed if these interlocks are wronglyexecuted, incomplete or missing.

– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for thesafety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop isonly active in Automatic states; in Programming the power is cut out (powercontactors open) immediately. The procedure for the selection of the controlledstop time (that can be set on SDM board) is contained in the Installation manual .

– When preparing protection barriers, especially light barriers and access doors,bear in mind that the robot stop times and distances are according to the stopcategory (0 or 1) and the weight of the robot.

– Check that the environment and working conditions are within the range specifiedin the specific product Technical Documentation.

– The calibration operations are to be carried out with great care, as indicated in theTechnical Documentation of the specific product, and are to be concludedchecking the correct position of the machine.

– To load or update the system software (for example after replacing boards), useonly the original software handed over by COMAU Robotics & Service.Scrupulously follow the system software uploading procedure described in theTechnical Documentation supplied with the specific product. After uploading,always make some tests moving the robot at slow speed and remaining outside theprotected area.

– Check that the barriers of the protected area are correctly positioned.

In the cell/line emergency stop circuit the contacts must be included of the controlunit emergency stop buttons, which are on X30. The push buttons are notinterlocked in the emergency stop circuit of the Control Unit.

Check that the controlled stop time is consistent with the type of Robot connectedto the Control Unit. The stop time is selected using selector switches SW1 andSW2 on the SDM board.

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Programming Mode

– The robot is only to be programmed by the authorised personnel.

– Before starting to program, the operator must check the Robot System (Robot andControl System) to make sure that there are no potentially hazardous irregularconditions, and that there is nobody inside the protected area.

– When possible the programming should be controlled from outside the protectedarea.

– Before operating inside the Protected Area, the operator must make sure fromoutside that all the necessary protections and safety devices are present and inworking order, and especially that the hand-held programming unit functionscorrectly (slow speed, emergency stop, enabling device, etc.).

– During the programming session, only the operator with the hand-held terminal isallowed inside the Protected Area.

– If the presence of a second operator in the working area is necessary whenchecking the program, this person must have an enabling device interlocked withthe safety devices.

– Activation of the motors (Drive On) is always to be controlled from a positionoutside the range of the robot, after checking that there is nobody in the areainvolved. The Drive On operation is concluded when the relevant machine statusindication is shown.

– When programming, the operator is to keep at a distance from the robot to be ableto avoid any irregular machine movements, and in any case in a position to avoidthe risk of being trapped between the robot and structural parts (columns, barriers,etc.), or between movable parts of the actual robot.

– When programming, the operator is to avoid remaining in a position where parts ofthe robot, pulled by gravity, could execute downward movements, or moveupwards or sideways (when installed on a sloped plane).

– Testing a programmed cycle at working speed with the operator inside theprotected area, in some situations where a close visual check is necessary, is onlyto be carried out after a complete test cycle at slow speed has been executed. Thetest is to be controlled from a safe distance.

– Special attention is to be paid when programming using the hand-held terminal: inthis situation, although all the hardware and software safety devices are active, therobot movement depends on the operator.

– During the first running of a new program, the robot may move along a path that isnot the one expected.

– The modification of program steps (such as moving by a step from one point toanother of the flow, wrong recording of a step, modification of the robot position outof the path that links two steps of the program), could give rise to movements notenvisaged by the operator when testing the program.

– In both cases operate cautiously, always remaining out of the robot’s range ofaction and test the cycle at slow speed.

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Auto / Remote Automatic Mode

– The activation of the automatic operation (AUTO and REMOTE states) is only tobe executed with the Robot System (Robot and Control System) integrated insidean area with safety barriers properly interlocked, as specified by Safety Standardscurrently in force in the Country where the installation takes place.

– Before starting the automatic mode the operator is to check the Robot and ControlSystem and the protected area to make sure there are no potentially hazardousirregular conditions.

– The operator can only activate automatic operation after having checked:• that the Robot and Control System is not in maintenance or being repaired;• the safety barriers are correctly positioned;• that there is nobody inside the protected area;• that the Control Unit doors are closed and locked;• that the safety devices (emergency stop, safety barrier devices) are

functioning;

– Special attention is to be paid when selecting the automatic-remote mode, wherethe line PLC can perform automatic operations to switch on motors and start theprogram.

Robot axes release

– In the absence of motive power, the robot axes movement is possible by means ofoptional release devices and suitable lifting devices. Such devices only enable thebrake deactivation of each axis. In this case, all the system safety devices(including the emergency stop and the enable button) are cut out; also the robotaxes can move upwards or downwards because of the force generated by thebalancing system, or the force of gravity.

– Enabling the brake releasing device may cause the axes falling due to gravity aswell as possible impacts due to an incorrect restoration, after applying the brakereleasing module. The procedure for the correct usage of the brake releasingdevice (both for the integrated one and module one) is to be found in themaintenance manuals.

– When the motion is enabled again following the interruption of an unfinishedMOVE, the track recovery typical function may generate unpredictable paths thatmay imply the risk of impact. This same condition arises at the next automatic cyclerestarting. Avoid moving the Robot to positions that are far away from the onesprovided for the motion restart; alternatively disable the outstanding MOVEprogrammes and/or instructions.

Maintenance and Repairs

– When assembled in COMAU Robotics & Service, the robot is supplied withlubricant that does not contain substances harmful to health, however, in somecases, repeated and prolonged exposure to the product could cause skin irritation,or if swallowed, indisposition.First Aid. Contact with the eyes or the skin: wash the contaminated zones withabundant water; if the irritation persists, consult a doctor.If swallowed, do not provoke vomiting or take anything by mouth, see a doctor assoon as possible.

Before using the manual release devices, it is strongly recommended to sling therobot, or hook to an overhead travelling crane.

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– Maintenance, trouble-shooting and repairs are only to be carried out by authorisedpersonnel.

– When carrying out maintenance and repairs, the specific warning sign is to beplaced on the control panel of the Control Unit, stating that maintenance is inprogress and it is only to be removed after the operation has been completelyfinished - even if it should be temporarily suspended.

– Maintenance operations and replacement of components or the Control Unit are tobe carried out with the main switch in open position and locked with a padlock.

– Even if the Control Unit is not powered (main switch open), there may beinterconnected voltages coming from connections to peripheral units or externalpower sources (e.g. 24 Vdc inputs/outputs). Cut out external sources whenoperating on parts of the system that are involved.

– Removal of panels, protection shields, grids, etc. is only allowed with the mainswitch open and padlocked.

– Faulty components are to be replaced with others having the same code, orequivalent components defined by COMAU Robotics & Service.

– Trouble-shooting and maintenance activities are to be executed, when possible,outside the protected area.

– Trouble-shooting executed on the control is to be carried out, when possiblewithout power supply.

– Should it be necessary, during trouble-shooting, to intervene with the Control Unitpowered, all the precautions specified by Safety Standards are to be observedwhen operating with hazardous voltages present.

– Trouble-shooting on the robot is to be carried out with the power supply cut out(Drive off).

– At the end of the maintenance and trouble-shooting operations, all deactivatedsafety devices are to be reset (panels, protection shields, interlocks, etc.).

– Maintenance, repairs and trouble-shooting operations are to be concludedchecking the correct operation of the Robot System (Robot and Control System)and all the safety devices, executed from outside the protected area.

– When loading the software (for example after replacing electronic boards) theoriginal software handed over by COMAU Robotics & Service is to be used.Scrupulously follow the system software loading procedure described in thespecific product Technical Documentation; after loading always run a test cycle tomake sure, remaining outside the protected area

– Disassembly of robot components (motors, balancing cylinders, etc.) may causeuncontrolled movements of the axes in any direction: before starting a disassemblyprocedure, consult the warning plates applied to the robot and the TechnicalDocumentation supplied.

– It is strictly forbidden to remove the protective covering of the robot springs.

After replacement of the SDM module, check on the new module that the settingof the stop time on selector switches SW1 and SW2 is consistent with the type ofRobot connected to the Control Unit.

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Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to becarried out by Authorised Personnel.

– Bring the robot to transport position and fit the axis clamping brackets (whereapplicable) consulting the plate applied on the robot and the robot TechnicalDocumentation.

– Before stating to put out of service, the mains voltage to the Control Unit must becut out (switch off the circuit breaker on the mains distribution line and lock it inopen position).

– After using the specific instrument to check there is no voltage on the terminals,disconnect the power supply cable from the circuit breaker on the distribution line,first disconnecting the power conductors, then the earth. Disconnect the powersupply cable from the Control Unit and remove it.

– First disconnect the connection cables between the robot and the Control Unit,then the earth cable.

– If present, disconnect the robot pneumatic system from the air distribution line.

– Check that the robot is properly balanced and if necessary sling it correctly, thenremove the robot securing bolts from the support.

– Remove the robot and the Control Unit from the work area, applying the rulesindicated in the products Technical Documentation; if lifting is necessary, check thecorrect fastening of the eye-bolts and use appropriate slings and equipment only.

– Before starting dismantling operations (disassembly, demolition and disposal) ofthe Robot and Control System components, contact COMAU Robotics & Service,or one of its branches, who will indicate, according to the type of robot and ControlUnit, the operating methods in accordance with safety principles and safeguardingthe environment.

– The waste disposal operations are to be carried out complying with the legislationof the country where the Robot and Control System is installed.

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1.2.5 PerformanceThe performances below shall be considered before installing the robot system:

– Stop distances

– Mission time (typ. case).

Stop distances

– With Robot in programming modality (T1), if you press the sttop pushbutton (redmushroom-shaped one on WiTP) in category 0 (secondo norma EN60204-1), youwill obtain:

– Considering the Robot in automatico modality, under full extension, full load andmaximmum speed conditions, if you press the stop pushbutton (redmushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)you will trigger the Robot complete stop with controlled deleration ramp.Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °motion, that correspond to about 3000 mm movement measured on TCP flange.Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5seconds.

Mission time (typ. case)

– We remind you that the safety system efficiency covering is equal to 20 years(mission time of safety-related parts of control systems (SRP/CS), according toEN ISO 13849-1).

Tab. 1.1 - Stop spaces in programming modality (T1)

Mode Expected speed Case Stopping

timeStopping

space

T1 250 mm/sNominal 120 ms 30 mm

Limit 500 ms 125 mm

Tab. 1.2 - Safety electronics reaction time in programming modality (T1)

Mode Expected speed Case Stopping

time

T1 250 mm/s

For the safety inputs of the SDM module (e.g. stop pushbutton of TP in wired version)

150 msFor the stop stop and enabling device inputs from the TP in wireless version, when the safety wire trasmission is active.For the time-out of stop input and enabling device from TP in wireless version, when the safety wire transmission is lost or interrupted.

350 ms

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General Description

2. GENERAL DESCRIPTION

2.1 Robot SMART5 Arc 4SMART5 Arc 4 is the COMAU robot fitted for arc welding applications . The most important features are the following:

– wiring and fitting-out outside the robot frame to facilitate the maintenance activities.

– robot protection category IP65 ;

– all reduction units are oil-lubricated, with the exception of axes 5 and 6 that aregrease-lubricated;

– thanks to the reduced dimensions, the wrist can easily orientate in narrowenvironments;

– large work volume, because axis 2 has been advanced in relation to axis 1 ;

– no specific devices performing the axes balancing.

– the forearm upper part features flat surfaces and threaded holes to mount possibletools and equipment (servo-valves, wire drawing device, etc);

The axes motion is controlled by brushless motors with motion transmission performeddirectly through geared mechanical reduction units in the axis 1-2-3-4, while in axes 5-6a Harmonic Drive type redution unit featuring a belt transmission is used.

For all models and versions, the loads indicated (at wrist and additional) can be movedto maximum performance within the entire working range by means of specific softwarethat, by allowing maximum speeds to be reached in applications where the robot strokesare sufficiently wide, permits maximum accelerations according to the load declared andthe cycle.The design has been optimized by using three-dimensional CAD applications, and thestructures have been dimensioned by means of finite element analysis (FEA); this hasgiven excellent results in terms of performance and reliability.

The attention to detail has resulted in a machine that is user-friendly in daily use,reducing the number of parts and facilitating access for servicing.

The robot requires little maintenance, which is intuitive and does not require the use ofany special equipment.

Interchangeability between robots of the same version is ensured: a robot can besubstituted quickly without any complex corrective operations on the program.

Each robot is equipped with a Control System that conforms to European Union safetystandards and all the other most important standards.

Connection cables between the control and the robot have "plug-in" connectors.

Safety is guaranteed by the availability of a series of optional equipment in compliancewith the most severe European and international standards.

The robots are pre-engineered to incorporate an arc-welding dressing (on request) tobeyond Ax3, thus eliminating the need to incorporate other bulky and unreliable devices.

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General Description

Fig. 2.1 - SMART5 Arc 4-

2.2 Robot mechanicsThe robot structure is anthropomorphous with 6 degrees of freedom.

Anchorage to the ground is by means of a steel plate secured with blocks, to be carriedout by the customer, or else there is an optional assembly available - see consisting ofa plate, secured to the robot base, and four plates underneath welded to this plate andanchored to the ground by blocks. The robot levelling is obtained by acting on the 4screws of the plate.

The robot base is fixed, and the column rotates around the vertical axis (axis 1) thatintegrates the axis 1 geared motor as well as reduction unit and axis 2 motor

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General Description

An arm connects axis 2 to the forearm. On the forearm are mounted the ratiomotors ofaxes 3-4; moreover on its end is fastened the wrist that hosts the reduction units andbelt transmission units controlling axes 5-6.

The robot axes are equipped with software (programmable) and/or damped mechanicallimit switches as standard supply on the main axes (axes 1-2-3), (see Tab. 2.1 - Limitswitches available on page 19). According to the application requirements, the axisstroke can be limited by additional damped mechanical limit switches.

The reduction units are no-clearance type, specific for robotic applications. Thereduction units are oil lubricated on all the axes except axes 5 and 6 which have greaselubrication, lubricant replacement is every 15,000 hours for oil and every 5000 hours forgrease.

The motors are AC brushless and incorporate the brake and encoder inside them.

Tab. 2.1 - Limit switches available

Robot Model

Standard Optional

Software limit switch Mechanical limit switch Area shutter Adjustable mechanical limit

switch

SMART5 Arc4 In all axes axes 1-2-3-5 axis 1 axes 1-2-3

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General Description

2.3 Interchangeability The interchangeability of robots of the same version is a fundamental characteristic toenable rapid substitution, or to transfer the same program onto another robotic station.

This characteristic is guaranteed by:

– adequate construction tolerances of all the parts that make up the structure;

– precise robot location on the mounting plate by means of two pins (supplied withthe robot);

– possibility of bringing the axes to a known position (Calibration) using a specific tool(the same for all axes and all models);

These features make it possible to transfer programs between robots of the sameversion.

– The above-mentioned characteristics are indispensable for effective “off-lineprogramming” executed in a virtual environment.

2.4 CalibrationCalibration is the operation that makes it possible to bring the robot axes to a knownposition to ensure the correct repetition of programmed cycles and interchangeabilitybetween machines of the same version.

There are two calibration methods:

– precise calibration: executed using a special tool that is the same for all axes andall models. This operation must be executed after special maintenance operationsinvolving the separation of the kinematic chain between the motor and the robotaxis, or when cycles that are particularly demanding in terms of precision must beexecuted.

– calibration on location notches: this enables rapid but improper calibration with lessprecision, and it may not reset the robot movements with the precision that isrequired by the specific application. Calibration by notches consists in bringing therobot axes onto the calibration notches, aligning them with precision by sight,without using specific tools, executing the calibration commands axis by axis.

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Technical Characteristics

3. TECHNICAL CHARACTERISTICS

3.1 GeneralThis chapter contains views and characteristics of SMART5 Arc 4 robot models.The operating areas and overall dimensions of all the available robots are contained inChap.4. - Operating Areas and Robot Overall Dimensions on page 23

Fig. 3.1 - SMART5 Arc 4

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Technical Characteristics

(1) See Chap.6. - Loads at Wrist and Additional Loads on page 31 al par. 6.2 Determination of max loads at wrist flange (QF) on page 32

(2) See Chap.6. - Loads at Wrist and Additional Loads on page 31 al par. 6.3 Additional loads (QS) on page 35

(3) See the restrictions for the fastening position on inclined surfaces specified in Chap.7. - Preparation for Robot Installation on page 38 al par. 7.3 Installing the robot on a sloping surface on page 43

Tab. 3.1 - SMART5 Arc 4Characteristics and performance

VERSION SMART5 Arc 4

Structure / n° axes Anthropomorphous 6 axisLoad at wrist 5 kg (11 lb) (1)Additional load on forearm 10 kg (22 lb)(2)Torque axis 4 14 NmTorque axis 5 14 NmTorque axis 6 4,9 Nm

Stroke /(Speed)

Axis 1 +/- 180° (170°/s)Axis 2 +155°/-60°(175°/s)Axis 3 +110°/-170°(185°/s)Axis 4 +/- 185°(360°/s)Axis 5 +/- 123°(375°/s)Axis 6 +/- 270°(550°/s)

Horizontal maximum straddle 1951 mm (76.8 in)Repeteability 0,05 mm (0.2 in)Robot weight 375 kg (826.7 lb)Tool connection flange ISO 9409-1-63-4-M6Motors AC brushlessPosition measurement system with con encoderTotal installed power 8 kVAProtection category IP65Operating temperature 0°C ÷ + 45 °CStorage temperature -40 °C ÷ +60 °CRobot (standard) colour Red RAL 3020

Mounting position (3) Ground / CeilingInclined max 45°

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Operating Areas and Robot Overall Dimensions

4. OPERATING AREAS AND ROBOT OVERALL DIMENSIONSThis chapter describes the operating area and the overall dimensions of the SMART SiXrobot. It also contains the drawings listed below:

– SMART5 Arc 4 - Operating Area

– SMART5 Arc 4 - Restrictions for the Operating Area



SMART5 Arc 4 - Operating Area


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SMART5 Arc 4 - Operating Area



SMART5 Arc 4 - Restrictions for the Operating Area


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Robot Flange

5. ROBOT FLANGE

5.1 Fixture mounting flangeThis chapter contains the drawings of the fixtures mounting flanges with dimensions andcentre distances of the holes for the fixture mounting).The flange is shown with the Gauged Tool option. This option is used to calculate theexact flange center point when installing tools.

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Robot Flange

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Robot Flange

Fig. 5.1 - SMART5 ARC 4Fixture mounting flange and calibrated fixture


Robot Flange


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Loads at Wrist and Additional Loads

6. LOADS AT WRIST AND ADDITIONAL LOADS

6.1 OverviewThis chapter describes the procedures to determine:

– Load capacity on the flange according to the distance from the centre of gravity• Fig. 6.3 - SMART5 Arc4 Maximum load capacity of the flange on page 34

– Areas in which the centre of gravity position related to additional load is allowed • Fig. 6.4 - Additional loads centre of gravity position on page 36

– Centre distances and dimensions of holes to fasten any fixtures applied on therobot forearm• Fig. 6.5 - Holes for connecting tools to the forearm on page 37

AbbreviationsIn this chapter the following abbreviations have been used:• QF =Max. load applied to the flange;• QS = Additional load applied to the forearm;• QT =Max total load applied on the robot;• Lz = distance of load P centre of gravity from the flange axis;• Lxy = distance of load P centre of gravity from axis 6• L2 = distance of axis 5 from fixture mounting flange (see diagram)

Fig. 6.1 - Centre of gravity co-ordinates of the applied load

P



6.2 Determination of max loads at wrist flange (QF)The maximum load that can be applied to the flange is defined using the wrist loadgraphs, where the curves of maximum load QF are plotted according to co-ordinates LZand LXY of the load centre of gravity.

The area below the load curve defines centre of gravity distances allowed for theapplication of the load indicated on it.

Fig. 6.2 - Notes for the load graphics definition


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Kz = (a - 0,25 x J0) / M L1 = 2000 [- b + (c + Kz)0,5] Kxy = (d - 0,25 x J0) / M Lxy = 2000 [ - e +(f + Kxy)0,5]

where: • a, b; c; d; e; f = numeric constants depending on the type of wrist (see Load

Capacity graphs). • J0 (kgm2) = maximum centre of gravity moment of inertia of the total load applied

to the flange• M (kg) = total weight applied to the flange• L2 = L1 curves centre position corresponding to the distance of the flange from

axis 5 (see diagram)

In any case the following conditions must be checked:L1 ≤ H / M; Lxy ≤ N / Mwhere: H and N = numeric constant according to the type of wrist

For load or inertia values that differ from those indicated in the graphs, a specificcurve can be plotted using these formulas:



Fig. 6.3 - SMART5 Arc4Maximum load capacity of the flange

Numeric constants to be applied to the formulas contained in Determination of max loads at wrist flange (QF)a=0,878; b=0,133; c=0,018; d=0,292; e=0,084; f=0,007;H=4000; N=2000; L2 = 120 mm

The inertia specified in the graph curves refers to the centre of gravity of the loadapplied on the flange.

0

50

100

150

200

250

300

350

400

450

0 50 100 150 200 250 300

Lxy [mm]

Lz

[mm]

Massa = 5 kg

Inerzia = 0,2 kg m2

M = 2 kg

= 0,08 kg m2

M = 3 kg

= 0,12 kg m2

M = 4 kgJ0

J0

= 0,16 kg m2

J0


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6.3 Additional loads (QS)It is possible to apply an additional load QS on the forearm, besides the load on theflange QF, for all the robots, except the SH versions. The values of these loads areindicated in Tab. 6.1 - Maximum applicable loads on page 35.

In each application, the centre of gravity of the load applied on flange QF is to be withinthe area subtended by the curves of following graphs in Fig. 6.3 - SMART5 Arc4Maximum load capacity of the flange on page 34. Furthermore the centre of gravity ofadditional load QS has to be within the area of the graph shown in Fig. 6.4 - Additionalloads centre of gravity position on page 36.

For the installation of special fixtures on the robot, the holes can be used in the robotforearm, shown in Fig. 6.5 - Holes for connecting tools to the forearm on page 37

Tab. 6.1 - Maximum applicable loads

Max. total load SMART5 Arc4

Max overall load that can be applied on robot QT 15 kg

Load on the flange QF 5 kg

Additional load on forearm QS 10 kg



Fig. 6.4 - Additional loads centre of gravity position


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Fig. 6.5 - Holes for connecting tools to the forearm


Preparation for Robot Installation

7. PREPARATION FOR ROBOT INSTALLATION

7.1 Environment conditionsThe environment for robot use is the usual workshop environment.

The robot wrist is manufactured to a high protection standard (IP67) so that it is suitablefor applications in aggressive dusty environments.The robot can be installed on a horizontal plane (see par. 7.2 – "Robot installation onhorizontal plane" or on a sloped plane taking into account opportune restrictions (seepar. 7.3 – "Installing the robot on a sloping surface" )

7.1.1 Environment data– Operating environment temperature: 0°C ÷ 45°C

– Relative humidity: 5% ÷ 95% without condensation.

– Storage environment temperature: -40 °C ÷ 60 °C.

– Maximum temperature gradient: 1,5 °C/min.

7.1.2 Operating spaceThe maximum overall dimensions of the operating area from the centre of the wrist areshown in the graphs in Chap.4. - Operating Areas and Robot Overall Dimensions onpage 23.

Before carrying out any type of installation operation carefully read Chap.1. -General Safety Precautions on page 7.The robot has to be coupled to the C5G Control Unit. No other use is permitted.Any exceptions are to be explicitly authorised by COMAU.

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7.2 Robot installation on horizontal plane

7.2.1 Attachment to a steel plateThe robot has to be secured to a steel plate, installed on the floor and provided with theholes for the pins and screws for the robot anchorage. In that case we recommend to use a steel plate featuring flatness tolerance equal to:

. To secure the robot to the plate, an optional Robot-base attachment screws and pins, isavailable, illustrated in Fig. 7.1.

The values of the stress discharged to the ground by the robot, to be taken into accountfor the dimensioning of the plate, are indicated in Fig. 7.3 - Stress on the robotsupporting structure on page 42.

The foundation where the robot is installed is not to be influenced by vibrations comingfrom other machines (for example sledge hammers, presses, etc.).

7.2.2 Attachment to a plate with adjustable level (optional)To secure the robot an optional assembly can be used, consisting of 4 plates securedto the ground and a steel plate secured to the robot that can be levelled by means ofspecial screws (see Fig. 7.2 - Level adjustment plate on page 41).

To secure the plates to the ground the recommended components (not supplied) arelisted in Tab. 7.1 - Components recommended to secure the level adjustment plates tothe floor on page 39

Tab. 7.1 - Components recommended to secure the level adjustment plates to the floor

Due to the considerable stress discharged to the ground by the robot, securingthe robot directly on the floor is not envisaged.

Component Riferimento Reference Code Hole Depth

Chemical capsule HILTI HVU M16x125Ø 16 x 125 mm 8

Pin HILTI HAS M16x125/38

Please read the instructions before using the recommended fasteningcomponents.

To avoid any micro movements of the plate caused by repeated alternatedstresses generated by the robot during normal work cycles, lay the plate on alayer of aligning mortar specifically for metal on concrete applications.

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Fig. 7.1 - Robot-base attachment screws and pins

1. Centring unit Ø = 30 mm L = 80 mm (no. = 1)2. Centring unit Ø = 30 mm L = 60 mm (no. = 1)3. TCEI M 10 x 90 (8.8) screw (no. = 1)4. TCEI M 10 x 70 (8.8) screw (no. = 1)5. TE partially threaded M 16 x 60 (8.8.) screw (no. = 4)6. Split elastic washer Ø = 16mm (no. = 4)7. Flat washer Ø = 16 mm (no. = 4)


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Fig. 7.2 - Level adjustment plate

7.2.3 Stress on the robot structureIn Fig. 7.3 - Stress on the robot supporting structure on page 42 he stresses areindicated that are discharged to the ground by a robot installed on the floor; whendimensioning the robot anchorage plate, the stresses indicated in Fig. 7.3 are to betaken into consideration.



Fig. 7.3 - Stress on the robot supporting structure

Robot on floor installation Robot on ceiling installation

SMART5 Arc4

Robot movement Fv (N) Fo (N) Mr (Nm) Mk (Nm)

Accelerating 5000 2000 1000 4000Emergency braking 6000 3000 2500 6000

Fo

Fv

Mk

Mr

Fo

FvMk

Mr


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7.3 Installing the robot on a sloping surfaceThe robot can be secured on a sloped plane with 45° maximum inclination (seeTab. 7.2).In this case, besides the indications of par. 7.2.1 Attachment to a steel plate on page 39,or par. 7.2.2 Attachment to a plate with adjustable level (optional) on page 39, it isnecessary to consider a limitation of the axis 1 stroke, defined in relation to the slopingangle of the robot securing plane.The stroke limitation is defined in the graph of Fig. 7.4 - Axis 1 stroke limitation with robotmounted on sloped plane on page 44. For example, with the robot secured on a planewith 30° inclination, the rotation of axis 1 will be reduced to ± 35°.

Tab. 7.2 - Installing the robot on a sloping surface

Robot mounting plane inclination permitted

Robot mounting plane inclination not permitted

AX 1



Fig. 7.4 - Axis 1 stroke limitation with robot mounted on sloped plane

– α = Plane inclination angle for robot base attachment

– Ax 1 = allowed stroke of robot axis 1(Travel AX1 value is valid in both positive andnegative)

0

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

105

110

115

120

125

130

135

140

145

150

155

160

165

170

175

180

185

190

0 10 20 30 40 50

á [deg]

Ax

1[d

eg

]


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7.4 Securing to a raised support (optional)If it is required to install the robot on a raised plane, the optional assembly can be usedthat is illustrated in Fig. 7.6 - Raised support with horizontal plane on page 46 availablewith five different heights and identified by the specific codes indicated below:

– cod. CR 82283422 H = 500 mm

– cod. CR 82283423 H = 750 mm

– cod. CR 82283424 H = 1000 mm

– cod. CR 82283425 H = 1300 mm

The support can be levelled by adjusting the M16 screws,(not supplied) in the threadedholes (1) indicated in Fig. 7.6.The support can be secured directly on the floor using the specific components listed inFig. 7.5. otherwise it can be secured to a steel plate. In this case a plate should be usedwith a planarity tolerance : , thickness 25mm and M20 (8.8.) hex head screwsto secure.

Fig. 7.5 - Components recommended to secure the raised support to the floor

Component Reference Code Hole Diameter Depth Qty

Chemical capsule HILTI HVU M20x170Ø 24x170 mm 8

Pin HILTI HAS-E M20x170/48C inst = 160Nm

Before using the recommended securing components, read the specificinstructions for use.



Fig. 7.6 - Raised support with horizontal plane

1. Holes for levelling screws (not supplied - M16; qty 4)2. Holes to secure to the floor or on a plate ( ∅ 24; qty 8)


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7.4.1 Stress to floor for a robot installed on support In Fig. 7.7 - Stress to floor with robot installed on support on page 47 indicates the stressdischarged to the ground by the robot when installed on the floor, and is to be taken intoconsideration when dimensioning the securing plate.

Fig. 7.7 - Stress to floor with robot installed on support

Fv

FoMr

Mk

Movimento

Robot

Altezza Supporto

(mm) Fv (N) Fo (N) Mr (Nm) Mk (Nm)

Accelerazione 6500 2000 1000 6600Emergenza 7500 3000 2500 9900





H=1300 (cod. CR82283425)

H=1000 (cod. CR82283424)

H=750 (cod. CR82283423)

H=600 (cod. CR82283426)

H=500 (cod. CR82283422)


Option

8. OPTION

Tab. 8.1 - Available option

Code Description Applicability

82282500 Axis 1 adjustable mechanical stop (code 82282500) 182282600 Axis 2 adjustable mechanical stop (code 82282600) 182282700 Axis 3 adjustable mechanical stop assembly (code 82282700) 1

CR82284900 Axis 1 work area sectoring assembly (code CR82284900) 1CR82222100 Manual calibration kit (code CR82222100) 1

81783801 Gauged tool assembly (L = 117mm - code 81783801) 182283200 Leveling plate assembly (code 82283200) 182281900 Screw and pin unit for the robot-base fastening (code 82281900) 1

CR82287500 Fork liftable assembly (code CR82287500) 1

CR82287700 Distribution connections protection assembly (treadable - code CR82287700) 1

CR82283422 (H=500)CR82283426 (H=600)CR82283423 (H=750)

CR82283424 (H=1000)CR82283425 (H=1300)

Support on horizontal surface 1


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Option

8.1 Axis 1 adjustable mechanical stop (code 82282500)

8.1.1 DescriptionThe axis 1 adjustable mechanical stop assembly can be used to limit the stroke of axis1 in both directions of work with steps of 22.5°. The assembly consists of two mechanicalstops that are fastened, by means of the screws supplied with the robot, in the seats onthe robot base to limit the stroke of axis 1 in both directions; it is possible to use just oneof the mechanical stops to limit the stroke in one direction only.The axis 1 adjustable mechanical stop assembly satisfies “operator safety”requirements as it can absorb all of the kinetic energy of the axis.

WARNING Once the stop has been used (impact), the following parts must be replaced:

– mechanical stop and fastening screws;

– rubber stop blocks and fastening screws. The parts of the robot concerned must also be checked for any damage, e.g.:

– the part of the base housing the assembly;

– the part of the column housing the stop;

– the equipment being used by the robot. Failure to replace any damaged parts will undermine correct operation (and thusstopping) in future.

After an impact, check the clearance on axis 1 and correct any slackening.


Option

1. Mechanical stop (q.ty 2)2. M16 x 60 socket head cap screw (cl 12.9) (q.ty 4)


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Option

Tab. 8.2 - Axis 1 strokes with the adjustable mechanical stop assembly

1 - - -135 +180

2 -112,5 -180 -112,5 +180

3 -90 -180 -90 +180

4 -67,5 -180 -67,5 +180

5 -45 -180 -45 +180

6 -22,5 -180 -22,5 +180

7 0 -180 0 +180

8 +22,5 -180 +22,5 +180

9 +45 -180 +45 +180

10 +67,5 -180 +67,5 +180

11 +90 -180 +90 +180

12 +112,5 -180 +112,5 +180

a [°]

Pos.

da [°] a [°] da [°]

Corsa asse 1 in senso

negativo

Corsa asse 1 in senso

positivo


Option

8.2 Axis 2 adjustable mechanical stop (code 82282600)

1. Stop block (q.ty 2)2. Stop block (q.ty 2)3. 8 x 20 socket head cap screw (cl 8.8) (q.ty 8)4. Split washer Ø 8 x16 (q.ty 8)


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Option

8.2.1 DescriptionThe axis 2 adjustable mechanical stop assembly can be used to limit the stroke of axis2 in both directions of work with steps of 15°.The assembly consists of two sets of 2 blocks that are fastened to the structure of thecolumn so that they rest against the rebound pads on the robot.

The positive stroke can be limited to +125° or +140° (instead of the standard +155°stroke) and the negative stroke can be limited to -30° or -45° (instead of the standard-60° stroke). The axis 2 adjustable mechanical stop assembly satisfies “operator safety”requirements as it can absorb all of the kinetic energy of the axis.

The limitation of the operating area obtained by installing the stop assembly is shown inthe Operating Area Limitation diagrams in Chap.4. - Operating Areas and Robot OverallDimensions on page 23.

WARNING Once the stop has been used (impact), the following parts must be checked forcorrect operation:

– mechanical stop;

– rubber stop blocks and fastening screws.

– the equipment being moved by the robot.

Failure to replace any damaged parts will undermine correct operation (and thusstopping) in future.


Option

8.3 Axis 3 adjustable mechanical stop assembly (code 82282700)

1. Block (q.ty 1)2. M 8 x 50 socket head cap screw (cl 12.9) (q.ty 3)3. M 10 x 55 socket head cap screw (cl 12.9) (q.ty 2)

8.3.1 DescriptionThe purpose of the axis 3 adjustable mechanical stop assembly is to prevent the forearmfrom overturning by preventing this from entering the work area behind the robot.

The assembly consists of a block that is fastened to the side of the body of the forearmusing the screws and pin supplied with the robot: in case of an impact the stop blockcomes into contact with the fixed block that is always present on board the robot arm.

Axis 3 has a working stroke of between 0° and -170° while the blocked stroke is from 0°to +110°.

The axis 3 adjustable mechanical stop assembly satisfies “operator safety”requirements as it can absorb all of the kinetic energy of the axis.The limitation of the operating area obtained by installing the stop assembly is shown inChap.4. - Operating Areas and Robot Overall Dimensions on page 23.

WARNING


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Option

Once the stop has been used (impact), the following parts must be checked forcorrect operation:

– mechanical stop ;

– rubber stop blocks and fastening screws.

– the equipment being moved by the robot.

Failure to replace any damaged parts will undermine correct operation (and thusstopping) in future.


Option

8.4 Axis 1 work area sectoring assembly (code CR82284900)

8.4.1 DescriptionThe shutting of the axis 1 working stroke depends on the robot operating cycle.The axis 1work area partialization assembly enables electrical partialization of up to 2work areas, each of which is controlled by two safety micro-switches built to the strictestsafety standards.

The assembly consists of:• a 4-pushbutton multiple micro-switch with output to cable gland,• a set of plastic cams to be cut to the length required for the specific application.The cams must be inserted and blocked on the cam holders fastened to the robot bymeans of the specific supportsThe free connector is supplied for the external connection.

For the microswitch assembly internal electrical layout. see the robot CircuitDiagram.


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Option

8.5 Screw and pin unit for the robot-base fastening (code 82281900)

1. Centring device Ø = 30 mm L = 80 mm (no. = 1)2. Centring device Ø = 30 mm L = 60 mm (no. = 1)3. TCEI M 10 x 90 (8.8) screw (no. = 1)4. TCEI M 10 x 70 (8.8) screw (no. = 1)5. TE partially threaded M 16 x 60 (8.8.) screw (no. = 4)6. Split elastic washer Ø = 16mm (no. = 4)7. Flat washer Ø = 16 mm (no. = 4)


Option

8.6 Leveling plate assembly (code 82283200)

8.6.1 DescriptionThe leveling robot mounting plate assembly is used to ensure that the robot is anchoredcorrectly to the floor; this assembly satisfies the following requirements:

– it ensures good mounting plate levelness, to avoid any incorrect stresses on thestructure of the robot base.

– the robot can be assembled using a spirit level to facilitate off-line programmingapplications.

The assembly consists of:

– four steel plates that are anchored to the floor by means of chemical bolts (for atotal of 16 anchor bolts that are not supplied).

– a leveling plate that is welded to the plates described above after using the specificadjustment screws to obtain optimal robot leveling.

Key on page 591. Leveling plate (q.ty =1)2. Plate (q.ty = 4)3. Straight edge (q.ty = 8)4. M20x 100 FULLY THREADED hex head cap screw-CL 8.8 (q.ty = 4)5. M20 -8 FE/ZN 12 hex nut (q.ty = 4)


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Fig. 8.1 - Leveling plate assembly


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8.7 Manual calibration kit (code CR82222100)

1. Gauge holder2. Tapered nut3. Feeler pin4. Gauge

8.7.1 DescriptionThe manual calibration kit cosists of the following items:

– a gauge to manually and accurately detect the axis calibration position.

– a gauge holder. To calibrate axes 1-2-3-4 it has to be screwed in the specialseatings in the robot .

– a calibration block to calibrate axes 5-6, that supports the gauge described above,to be fastened in the special seatings on the wrist.

This kit is used to search the minimum reading position on the gauge with reference tothe indexes prearranged in each robot axis. This position defines the axis calibration.

Gauge holder and gauge Support for gauge holder (used to calibrate axes 5-6)


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Tab. 8.3 - Example of axis 1 calibration

Removal of the guards from the calibration reference surfaces

Visual alignment of calibration reference surfaces

Assembly of the dial indicator holder and finding the axis calibration point


Option

Tab. 8.4 - Example of the kit used to calibrate axes 5-6

Finding the axis 5 calibration point

Finding the axis 6 calibration point


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8.8 Gauged tool assembly(L = 117mm - code 81783801)

8.8.1 DescriptionThe gauged tool assembly is used to calculate the TCP (Tool Center Point) in relationto the robot flange.The assembly consists of a cylindrical test rod of a length that is defined so that the endis at an exact position in relation to the center of the wrist.The prod is screwed directly onto the axis 6 output flange in a radial position in relationto the latter and there is no need to disassemble any tools that are installed on theflange.

SMART Arc


Option

8.9 Fork liftable assembly (code CR82287500)

8.9.1 DescriptionThe fork liftable assembly is an option absolutely necessary to lift the robot using a lifttruck. The truck can be seized both from the robot back and side area. The assemblyconsists of an electrowelded frame made of rectangular steel box-type items, that is tobe fastened to the robot using screws.

The forking option is only appropriate for the insertion of lift truck forks andcannot be used for robot 180° rotation or overturning.


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8.10 Distribution connections protection assembly (treadable - code CR82287700)

8.10.1 DescriptionThe unit consists of a rugged sheet shelf that is fastened to the robot base to protect allcomponents connected to the robot switching unit support on horizontal surface

8.11 Support on horizontal surfaceHeight of available supports:

– cod. CR 82283422 H = 500 mm

– cod. CR82283426 H = 600 mm

– cod. CR 82283423 H = 750 mm

– cod. CR 82283424 H = 1000 mm

– cod. CR 82283425 H = 1300 mm


Option


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Original instructions

COMAU Robotics servicesRepair: [email protected]: [email protected] parts: [email protected] service: [email protected]/robotics

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