ABB機器人維修手冊簿

1、實用標(biāo)準(zhǔn)文檔ABB機器人維修手冊0.0.1前言本手冊包含了一些維修的詳細(xì)說明指導(dǎo)，包括電氣及機械 閱讀者需要有：*熟練的技能*有電氣上的知識或*機械上的知識本手冊由以下幾部分組成1 安全2 相關(guān)信息3 機械手4 控制柜6附錄Circuit Diagrams, Manipulator 3HAC 13347-1 Included in Repair Manual, part 2電路圖，機械手3HAC 13347-1在“維修手冊2”里面Circuit Diagrams, Controller 3HAC 6582-2 Included in Repair Manual, part 2電路圖，控制柜3H

2、AC 5582-2在“維修手冊2 ”里面0.0.2產(chǎn)品文件這個文件包包含控制柜，機械手及硬件信息，有以下內(nèi)容Tlie Installation and Connnisioiiiii Manual contin th? following niforniatioir安裝及試車手冊包含以下信息安全，維護 相關(guān)信息 拆箱現(xiàn)場安裝 電氣連接開始安裝控制柜軟件系統(tǒng)結(jié)構(gòu)目錄 校正模型定義信息The Repair Manual contains (he following nifonnation:維修手冊包含以下信息：安全，維護相關(guān)信息機械手的所有的維修工作詳細(xì)指導(dǎo)控制柜的所有的維修工作詳細(xì)指導(dǎo)TIk Ma

3、mtenaace Mamwl comaiu rlw following infbniiacioiL維護手冊包含以下信息：安全，維護相關(guān)信息維護計劃表維護計劃表中的各部分的詳細(xì)說明，如清潔,潤滑及檢查等通常分為機械手及控制柜兩部分第一章：安全，維護1.0.1說明Tins chapter details safety- mfbmiatioii for service personnel i.e. perscmuel perfoniiins uistal- laTiaii. repair find maintenance work本章講述對于安裝及維護維修人員需要了解的安全信息由于前面專門有安全手冊

4、，這里只作一些補充A danger of high voltage is associated with the fallowing parts:注意以下元件的高壓危險* Be aware of stored electrical energy (DC link) in the controller.注意控制柜里面DC link儲存的能量* Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.控制柜里面，如,1/0模塊，有可能由外部供電* The ma

5、ins supply/mains switch主開關(guān)* The power unit電源* The pov/er supply unit for the computer system (230 VAC)計算機系統(tǒng)的供電單元(230VAC)* The rectifier unit (4004&0 VAC and 700 VDC Note: Capacitors!)整流部分(400-480 VAC 及700VDC.注意:電容) The drive unit 700 VDC)驅(qū)動單元(700VDC) The servi ce outlets (115/230 WC)輸出部分(115/230VAC)

6、 The power supply unit for tools, ar special powe( supply units tor the machining pro* cess工裝的電源或一些其它特殊的電源 The external voltage connected to the control cabinet remains live even when the robot is di芳匚onnected from the mains.當(dāng)機器人關(guān)電后注意外部到控制柜的供電線路仍然有電 Additional connections其它連接A danger of high voltage

7、 is associaW with thf Liiatupuhtcr in:機械手里面的高壓危險* The power supply f-or the motors (up to 800 VDC)電機的供電進線(800 VDC 左右) The user connections for tools ar other parts of ihe installation (nax 230 VAC, seeInstallation and Commissioning Manual)連接到工裝或其它部分(最大230VAC)1.3.4測試剎車During opeiatiou the holding bra

8、kes of each fixis maror wear normally A tet may be per- foTtned co deTeniutie whether the brake can sttll perforin its fimchon.運行的時候，軸電機的剎車都會正常磨損所以要定期對剎車進行檢查The function of each aximotor holding biake may be checked detailed below:具體檢查如下：1. Run each mani pulator axis to a position where the combined

9、 weight of the ma nip- ulator arm and any load is maximized (max static load)運行機械手的軸到最大的靜態(tài)負(fù)載位置2. Switch the motor to the MOTORS OFF position with the Operating made selector on the controller用控制柜上的工作模式選擇開關(guān)將電機關(guān)掉3. Check that the axis maintains its position檢查軸是否維持原位置If the manipulator does not change

10、position as the motors are switched off. then the brake (unction is adequate.如果電機關(guān)了后，機械手保持不動，說明剎車正常第三章機械手3.0.1說明This chapter details all repair acnvines lecoinLiiended for rlie nianipiilatcr. mclucLiiig for any eKtenial uuit of the ni-ampulator本章詳細(xì)敘述了機械手的維修，包括機械手的一些外部設(shè)備3.11.1 Removal of cable harnes

11、s移除電纜保護殼The cable harness i弓 located throughoiu the manipulator 眄 shown in the figure below,電纜保護殼在機械手里面的位置如下圖A Connector at manipulator base. R1 MP and R1.SMB 機械手底座的插頭，R1.MP和R1.SMBB Connectors at motor 1; R2.FB1 and R2 MP1 電機1的插頭；R2.FB1及R2.MP1C Connectors at motor 2, R2.FB2 and R2.MP2電機2的插頭;R2.FB2及R

12、2.MP2D Connectors at serial measurement board; R 1.SMB1-3, R1.SMB4-6. R1.SMB1.7, R2.FB7 and R2 SMB. Battery connector X3 R1 .G and R2 G. Connectors at brake release unit X8, X9 and X10.測量板上的插頭；R1.SMB1-3,R1.SMB4-6,R1.SMB1.7, R2.FB7 及R2.SMB電池插頭X3 R1.G及R2.G剎車釋放單元的插頭 X8,X9及X10E Connectors at motor 3, R2

13、.FB3 and R2 MP3 and tor signal lamp R2.H1 and R2.H2 電機3的插頭;R2.FB3及R2.MP3及信號燈插頭R2.H1及R2.H2F Connectors at motor 4, R2.FB4 and R2.MP4電機4的插頭;R2.FB4及R2.MP4G Connectors at cable harness separation; R2 M5/6電纜保護殼分離處的插頭；R2.M5/6H Connectors at cable harness division, inside of upper arm tube; R3 FB5 and R3.r

14、JP5. Connectors at motor 5; R4 FB5 and R4 MP5,電纜保護殼分離處的插頭在上臂的管道里；R3.FB5和R3.MP5電機5的插頭;R4.FB5及R4.MP5J Connectors at motor 0; R3 FB6 and R3MP6電機6的插頭;R3.FB6及R3.MP6KRear cover plate后蓋板LConnector R1.MP插頭R1.MPMConnector R1.SMB插頭R1.SMBNConnection of earth cable地線接頭0 Velcro strap that secures the cable harne

15、ss tc the arm house保護尼龍帶所需設(shè)備設(shè)備丿予列號、亠注意電路圖3HAC13347-1在維修手冊2里面標(biāo)準(zhǔn)工具3HAC15571-1其它工具或步驟見下面的詳細(xì)說明Removal, cableharness, axes 14移除，電纜保護殼，軸1-4I在開始維修機械手之前需仔細(xì)閱讀下面幾條：-在機器人運行后，電機和齒輪溫度都很高，注意燙傷-關(guān)掉所有的電源、液壓源及氣壓源-當(dāng)移動一個部位時，做一些必要的措施確保機械手不會倒 下來，如：當(dāng)拆除軸2的電機時，要固定低處的手臂* 電纜保護殼容易損壞，所以要小心，特別是接頭處1In order to facilitate refittin

16、g of cable harness Axes 2 and 3 may be tilted slightly torun the manipulator to the specified position: improve access.為了更容易移除，請將機械手運行到如下位置軸2和3可以稍為斜起點 Axis 1:0 Axis 2.0 Axis 3:0 Axis 4;C Axis 5:+90e Axis 6:no significance軸6:不重要2. Remove the rear cover plate on the manipulator by unscrewing its attac

17、hment screws.擰開機械手的后蓋的螺栓，將后蓋拆除3.Disconnect the earth cable.Shown in the figure Location completeharness on page 24!斷開地線連接位置見上圖去Disconnect connectors RI MP and R1 SMB斷開插頭R1.MP及R1.SMB5.Pull the cable and connectors up through the centeof the frame.拉出電纜及插頭6.Dis匚onnect all connectors at motor 1 and moto

18、r 2.Specified in the figure Locaf/on complete cable harness on page 24I斷開電機1和2的所有的插頭位置見上圖7 仔細(xì)地打開SMB蓋,電池及SMB單元見的電纜可以不斷開，這樣就不需再校正注意不要讓蓋子的重量把電纜拉得太緊如果要徹底取下蓋子，必須斷開插頭R1.G這樣以后就必須要校正機器人8.Disconnect connectors R2.SMB, RI .SMB I3, R1 SMB4-G DisconntiU X8, X9 c.md X10.斷開插頭 R2.SMB,R1.SMB1-3,R1.SMB4-6.斷開 X8,X9 和

19、 X10This releases the cable harness from the frame.松開4顆保護螺栓這將從結(jié)構(gòu)上松開電纜保護殼g Jnscrev/ the four screws securing the cable gland.文案大全10 通過拆除尼龍帶及保護殼上的兩顆螺栓不同的機械手有不同的調(diào)節(jié)盤來拆除調(diào)節(jié)盤請選擇合適的11. Remove the bracket securing the cables inside the lover arm by unscrewing the nuts from the stud bolts securing the clamp t

20、o the lower arm擰開下臂中保護螺栓的螺帽來拆除電纜保護架12. Remove the upper bracket securing the cables to the arm house by unscrewing its two attachnient screws.通過擰開上臂的兩顆螺栓拆除到手臂房的電纜保護架13. Disconnect connector R2.M5/6 at the rear cable division pointShown in the figure Location com- p/ete cable harness on page 241斷開后蓋電

21、纜分離點的插頭R2.M5/6位置見上圖14 Disconnect all connectors at motor 3 and motor 4.Specified in the figure Location complete cable harness on page 24!斷開電機3和4的插頭位置見上圖15 Gently pull the cable harness out.輕輕地將電纜保護殼拉出軸5-6電纜保護殼的位置見下圖軸5-6電纜保護殼的位置Location of cable The location of the cable harness, axes 5-6, is shown

22、m the figure belowr harness ax 5-6實用標(biāo)準(zhǔn)文檔A Cable bracket, wrist unit_. :. J.電纜支架，腕節(jié)單兀. i 和F電纜支架，上臂管里面D Connectors in upper arm tube; R3 FB5 and R3 5 電機插頭；R4.FB5 及 R4.MP5 上臂管插頭 R4.FB5及R4.MP5GConnectors at cable harness division point; R2.M5/6- : : I - :-電纜夾 _* 電纜保護殼分離點插頭；R2.M5/6軸6電機插頭;R3.FB6及R3.MP6移開軸

23、5,6的電纜保護殼這里是講移除上臂電纜的保護殼，而單獨的電纜從上臂管里面的連接點到軸5電機的移除方法這里沒有敘述，但緊節(jié)著在后面會講到.A在開始維修機械手之前需仔細(xì)閱讀下面幾條：-在機器人運行后，電機和齒輪溫度都很高，注意燙傷-關(guān)掉所有的電源、液壓源及氣壓源-當(dāng)移動一個部位時，做一些必要的措施確保機械手不會倒 下來，如：當(dāng)拆除軸2的電機時，要固定低處的手臂 電纜保護殼容易損壞，所以要小心，特別是接頭處必須將軸5導(dǎo)向正確的方向來打開軸6電機的蓋子移開蓋子，腕節(jié)單元及上臂管里面A:蓋子，腕節(jié)單元B:蓋子，上臂管里面Specified in the figure Location of cable

24、harness ax 5-6 on page 27!位置見上圖Shown in the figure Location ofcabfe harness ax on page 27!2. Remove the cover of motor axis 6 and disconnect all connectors beneath.2 移開軸6電機的蓋子并斷開所有的插頭3. Loosen the cable bracket on top of the wrist unit by unscrewing the three attachment screws.Two of the attachment

25、screws are located visible at the rear attachment and the third is located at the bottom of the cable bracket in the c已nter,cation of cable harnGss on page 30!455667接上地線位置見上圖Refit the rear cover plate on the manipulator with its attachment screws.上好后蓋的螺栓Reconnect all connectors at motor 1 白nd motor

26、2Specified in the figure Location of cable harness on page 30!接好電機1和電機2的插頭位置見上圖Secure the gland plate with four attachment s匚rews from i nside the SlvIB巳cese.從SMB里面上好密封盤nO10ODOC110. Reconnect connectors R2.SMB, R1.SMB1- & R1 SMB4-6. Reconnect X8k X9 and X10.ReconrtEct R1 G if it has been disconnecte

27、d接好插頭 R2.SMB, R1.SMB1-3,R1.SMB4-6.接好 X8,X9 和 X10.如果R1.G被斷開了也請接好t3：CCCGC1-ck3iD0C0C129.Secure the SMB cover with its attachment 生匚mws用螺栓上好SMB蓋子10.Secure the correct adapter plate io the harness with its two attachment screws.Note! Different maniipulator versions are fitted with different plate versio

28、ns. Make sure the correct one is used to avoid cable failure.10|上好保護殼的調(diào)節(jié)盤的兩顆螺栓 注意:不同的機械手有不同的調(diào)節(jié)盤，請選擇合適的1L Pull the cable harness through the lower arm.11將電纜保護殼穿過下臂12. Refit the bracket secunng the cables inside the lower arm.裝回下臂上保護電纜的支架13. Refit the bracket securing the cables to the arm house.Make

29、sure not to twist the harness!裝回保護到手臂房的支架確定保護殼沒有打攪14.Reconrtmct all connectors at motor 3 and motor 4Specified in the figure Location of cable harness on page 30!14接上電機3和電機4的所有插頭位置見上圖15.Reconnect connector R2.M5/5 gently at theShown in the figure Location of cablerear cable division point.harness an

30、 page 30!Be careful not to bend the attachment plateM6r 2 pcs.when fastening the screwsl15接上后面的電纜分離點的插頭 R2.M5/6位置見上圖注意上螺栓時，不要將附盤弄彎了M6,兩顆16.Secure the cable harness to the arm house wrtti 日 velcro strapShown in the figure Location of cable harness on page 30!16上好到手臂房的電纜保護殼的尼龍帶位置見上圖軸5-6的電纜保護殼的位置如下圖所示m

31、ciiE-zra:i45A Cable bracket, wrist unit電纜支架，腕節(jié)單元B Cable bracket, upper arm tube電纜支架,上臂管C Connectors at motor axis 5; R4.F85 and R4.MP5軸5電機插頭;R4.FB5和R4MP5D Connectors in 叩per arm tube; R3 FB5 and R3 MP5 上臂管里的插頭；R3.FB5和R3.MP5F Cable atlactiment, rear電纜夾，后面的G Connectors at cable harness division point;

32、 R2.M5/6電纜保護殼分離點的插頭；R2.M5/6H Connectors at motor, axis 6; R3.FB6 and R3.MP6軸6電機插頭;R3.FB6和R3.MP6下面詳細(xì)敘述如何裝回上臂電纜保護殼，而軸5那段單獨的到電機的電纜將緊接 著在后面講述I在開始維修機械手之前需仔細(xì)閱讀下面幾條：-在機器人運行后，電機和齒輪溫度都很高，注意燙傷-關(guān)掉所有的電源、液壓源及氣壓源-當(dāng)移動一個部位時，做一些必要的措施確保機械手不會倒 .，冷 下來，如：當(dāng)拆除軸2的電機時，要固定低處的手臂 電纜保護殼容易損壞，所以要小心，特別是接頭處必須將軸5導(dǎo)向正確的方向來打開軸6電機的蓋子1.

33、The manipulator is required to be positioned in the following position:機械手需調(diào)整到如下位置： Axis 4: 0 degrees* Axis 5: +90 degrees- Axis 6: no significance軸6位置不重要2.Gently insert the cable harness froni the rear into the upper arm2輕輕地將電纜保護殼從后面插入到上臂3.Connect the two connectors inside the upper arm tube. R3.FB

34、5R3.MP5 and securethe cabfe bucket with thE two attachment screws to the tube.Shown in the figure Location of cable harness axes 5-6 on page 33!3將上臂管里面的兩個插頭R3.FB5和R3.MP5連上，并用兩顆螺栓將電纜支位置見上圖架裝到管上Place the cabling to motor, axis 6P correctly on the upper arm and gently pull the connectors through the ho

35、le on top ofFasten the cable bracked unit with three attachment sitews. two of them visible at the rear attachment point 日nd the third legated on the bottom of the cable bracket, in the center. wrist unit to motor, axis 6C23C0C0ie5 In case of excess cable length: put a loop of cable in this area wit

36、h cable straps (A). The cables are Ionger in order to fit different upper arm lengths.裝好軸6的電纜，在上臂的正確位置 輕輕地將插頭通過腕節(jié)單元頂端的 孔穿過至軸6的電機如果電纜長了，可以在這個區(qū)域?qū)㈦娎|打個環(huán)，并用扎帶捆住Also shown in the figure Location of cable ham-ess axes 5-6 on page 33!用三顆螺栓上緊電纜支架，腕節(jié)單元, 其中后面兩顆容易看見，第三顆位于 電纜支架底部的中心 B: Attachment screws, rear of

37、 cable bracket.* C: Attachment screw, bottom of cable bracket.B：電纜支架后面的兩顆螺栓C:電纜支架底部的螺栓6 Reconnect the connectors to riotor. axis 6 and refit the motor 匚over.重新連接到軸6電機的插頭并裝好電機蓋子7.Refit the cover, upper arm and the cover, wrist unit裝好上臂及腕節(jié)單元的蓋子確定電纜裝正確的，另外，裝蓋子時，不Make sure the cabling is placed correctl

38、y when refitting the covers, and does not get jammed.* A: cover, wrist unit* B: cover, upper arm tuX要有擠壓A:腕節(jié)單元的蓋子B：上臂管的蓋子9Refit eventually removed cable straps to theharness.裝好保護殼的扎帶9, Refit the cable attachment, rear.Shown in the figure Location Qf cable harness axes 鼻歧 on page 331裝好后面的電纜夾位置見上圖10 R

39、econnect connector R2.M5/6 gently at the rear cable division point with two screws, M6.Be carelul not to bend the attachment plate when fastening the screws 1Shown in the figure Location ofcable harness axes 5-6 on page 331用兩顆M6螺栓將后面的電纜分離點位置見上圖的插頭連上注意緊螺栓時，不要把附盤弄彎了F面敘述如何裝回軸5的電纜1.Reconned all connecto

40、rs at motorr axis 6.1接好軸5電機的所有插頭2. Refit the cable gland 匚日tthe cable exit with its two attachment screws.2用兩顆螺栓將電纜出口處的電纜密封蓋裝好3.Refit the cover of motor, axi 5.3裝好軸5電機的蓋子4.Refit the complete wrist unit.Detailed in section Refitting of complete- wnst unit on page 504裝好腕節(jié)單兀如何裝腕節(jié)單兀后面有敘述A當(dāng)進行一次維護（維修，安裝或保

41、養(yǎng)）過后，下面幾點很重要：-所有的工具及其它不相關(guān)的物品都應(yīng)拿走，不要留在機械手上了-所有的正常的安全設(shè)備都正確地安裝了,如:TPU使能設(shè)備-所有的人都應(yīng)站在安全范圍外-特別關(guān)注前次維修產(chǎn)生的效果JJ.S Removal of complete arm system移除整個手臂系統(tǒng)1變速箱也就是上下整個手臂系統(tǒng)的定義就是整個機械手除了基座及軸臂，平衡設(shè)備及構(gòu)架，見下圖AB.CGEA Upper armIKI2030C02：-上臂需要的設(shè)備Lifting device, manipulator3HAC 15607-1 Instruction 3HAC 15971-2enclosed!吊裝設(shè)備，機

42、械手3HAC 15607-1 說明書3HAC15971-2Standard toolkit3HAC 15571-1 The con tents are definedin section Standard toolkit on page 18!標(biāo)準(zhǔn)工具包3HAC 15571-1內(nèi)容見維護手冊其它一些特殊的工具會在以后的詳細(xì)步驟里面指出F面詳細(xì)敘述如何升起及移除整個機械手系統(tǒng)I在開始維修機械手之前需仔細(xì)閱讀下面幾條：-在機器人運行后，電機和齒輪溫度都很高，注意燙傷 -關(guān)掉所有的電源、液壓源及氣壓源-當(dāng)移動一個部位時，做一些必要的措施確保機械手不會倒 ；下來，如：當(dāng)拆除軸2的電機時，要固定低處的手

43、臂 整個機械手重1300kg!提升工具一定要選足夠大的.操作步驟見下頁1M自k巳 sure the manipulator is positioned as shown in figure to the right If it is not. posit io n it that way.確定機械手的位置如右圖所示， 如果不是這個位置，必須運行到 如右圖所示Manually releasing the brakes is detailed in Manually neleasirig the brakes1 in the Installation ManuaL手動松開剎車見安裝手冊里的“手動松開剎車章節(jié)”KxDKnODOKBDrain the oil from gearbox axis 1.Detailed in Oil change, gearbox axis 1 in the M