User`s manual
Contents
1. a VAN 4 A Si gt TL ees aD Fixing bracket Fasten with bolt from outside 6 5 Operating area The stroke described on robot s framework indicates the distance from location to location controlled by Limit sensors installed in both ends http www alpharobotics kr A01 15 6 6 Installation of End effecter 6 6 1 affix End effecter interface through counter bored and tapped holes of slide as following drawing a MS bolt tightening torque Standard 5 N m 45kef cm Practical use 110kgf cm 0 M6 bolt tightening torque Standard 7 1 N m 70kgf cm gt Practical use 125kgf cm M8 bolt tightening torque Standard 14 7 N m 140 kgf cm Practical use 230kgf cm 6 6 2 Refer detail drawing for location of counter bored and tapped holes of each model Standard Normal Type End Effector an Ui 7 f Yj E A we WARNING nes A Model i AR230 S1 1000 75N H Serial No 0000000 http Awww ALPHARobotics kr 123456789ABCDEFG e UNL MADE IN KOREA 2008 01 22 E AAN OE oe T Standard Plane Type End Effector p2. ae Il D WARN Please do not operate durin instruction guide before installation certainly Model Serial No AR230 S2 1000 75N H 0000000 http www ALPHARobotics kr TEL 82 55 320 0800 MADE IN KOREA 123456789ABCDEFG MT 2008 01 22 AE http www alpharobotics kr 7 Inspection and repair Refer the following schedule charts OH 250 H month month month 3 months 750 H Daily month inspection R 0 a month 3 months 6 months 1 500 Fn month month ssa month 3 months 3 000 H month month 1 month 3 months 6months year 7 1 Items of inspection and repair E E hree E ix E Method of inspection Daily WEED ONS Every asce very Six EVET One Check bolt tightened condition and tighten again any loosened bolt Foreign substance inside framework Loosening of coupling O sounds during Rack of grease operating from Damage of ball screw framework mechanical sounds over 1 500hr operating Damage of bearing over 35 000hr operating Vibration in Check excessive Vibration framework vibration during operating operation shape Condition of Connected conditions of Cable system i
3. and structure of BR Robots Before use of this robot please read this manual for correct use of robot 2 Safety precautions Please read this manual and related documents for all equipment and peripheral devices connected to this robot before installation operation inspection for safe use of this robot Precautions mentioned below is for assisting you to use our robot correctly and safely in order to prevent bodily injury or property damage Marks for safety In this manual marks for safety are as follows Please read contents carefully and follow directions Failure of handling will result in serious damage like death or serious injury I n Danger Failure of handling may result in serious damage like death or serious injury Warning Failure of handling may result in injury or property damage Caution N Information for handling robot properly guide to check possibility of any loss VAIN ote Indication of compulsion For example mark of grounding Compulsion According to condition or situation even in case of Caution or Note failure of handling will and or may result in serious damage All contents contain important information so please be all aware of this manual The mark of Danger between ISO and KS or JIS are different as follows ISO standard KS standard JIS standard In this manual ISO standard was applied The mark of Warning consists of ISO standard and KS or JIS standard Please treat them as the s
4. connection junctions and connectors Ball screw Check condition of Lubricated LM guide grease In case of lack of O condition of block grease insert grease each axis TSK AFE Screw application Stans 400 OA LM inserting in Nipple oporalipn Belt is subject to be inspected 1 3months after first operation and from then on once every six months Daily inspection is visual checking and supposed to be done before starting operating Checking chart for inspection and repair is recommendable http www alpharobotics kr A01 17 7 2 Checking points of Belt s damage After uncover the Robot s main cover and then move Slide and check condition of belt as shown in the chart Chart 7 2 Checking points of Belt s damage Cases and or states of parts Breakdown or damage of Belt Scratches vertically Abrasion of tooth Crack of tooth Abrasion of the lateral face of Belt Soft and gluey surface of Belt Split on the reverse side of Belt Abrasion of Pulley http www alpharobotics kr Belt has been torn partly by external factors In case of Belt s running on Pulley flange In case of abrasion or damage of tooth and or separation or scar or discoloration of surface rubber In case of crack of tooth In case of abrasion of the lateral face of Belt In case of attachment of soft rubber on the reverse side of Belt In state of split on the reverse side of Belt horizontally with tooth In case
5. Installation Inappropriate installation may cause mechanical damage or injury a Assemble an interface between robot and equipment securely b when assembling axes firmly assemble main amp base axis and other axes with genuine brackets and bolts c Be cautious of mechanical interference which may cause damage of robots or injury Be careful for hands not to be caught in slides of assembled robots equipped with End Effectors by unexpected movement of slide When transporting fix slides and do not make movement of them When transporting do not hold End cover and or Cable http www alpharobotics kr A01 12 6 2 Installation flow Checking environment regarding dangerous factors and safety regulation Checking area regarding installation and operation of robots Occupying space for robot installation Checking the condition of robots Checking foreign substance chopping holes taps pins etc Checking direction of robot s installation and location of cables Checking condition of fixed and assembled robots Checking swing transformation etc of robots Checking if slide table Checking if each axis robot move smoothly move smoothly Checking working area Checking if anything interfere with movement inside working area Operating each axis robot Operating assembled robots Installation of End effecter http www alpharobotics kr A01 13 6 3 Operating space for maintenance and repair S
6. assembles and inspects and tests robots and then make a shipment with outer frame with skids Slides are tied up during transportation The front of robot is fixed in order not to be swung from outer vibration a This package is not able to guarantee no damage from shock by dropping and or collision Take good care of handling products Do not place heavy stuff on the surface package b When tying tie supporter located under skids and product When using a forklift lift the plane under skids c When taking it down be careful of collision and or bounce After unpacking follow instructions described below 4 2 2 Handling of assembly combined with peripheral units After opening package in the condition of assembly by Alpha or assembled by user be cautious to transport products as mentioned below a Fix slides carefully so as not to move unnecessarily during transportation b If the front of robot protrudes be careful not to swing from outer vibration c In transportation without fixation of front part impact over 0 3G is not allowable d When tying all units including robots and peripheral equipment do not place ropes on the surface of units directly Design the base of each axis to receive load of lopes through sufficient shock absorbers http www alpharobotics kr A01 11 e Design Y axis to be maintained horizontally with special rope Make a hook through using bolts and hang the rope on the hook so as for main c
7. result in malfunction of controller b When mounting and using the product vertically be sure to use brake built in type c Put protecting cover on operating parts of mechanical devices etc in order not to be contacted by operators or others d Any object must not drop in case of stoppage of power supply or emergency stop Configurate control system of prevention of dropping e The conditions for optimum movement of ball screw or LM guide through high straightness of robot table are as follows a Flatness of mounting surface must be within 0 02mm for high accurate operation Flatness of mounting surface must be within 0 01mm for super accurate operation 6 For rigidity of the product occupy large space of mounting http www alpharobotics kr A01 04 2 4 2 Installation operation repair When handling the products wear protective gloves glasses shoes etc for safety 2 4 3 Repair inspection maintenance Use designated grease for Linear robots Low lint grease made from Urea thickener must be used in Semi conduct or Liquid crystal manufacturing equipments requiring high resolution Do not use Fluoro grease applying to general robots 2 4 4 Disposal In case of being useless or unusable treat 1t properly as industrial waste 2 5 Others 2 5 1 In cases of injury or unusable product by mistake of observation of the mentioned safety precautions Alpha Robotics is not liable of them 2 5 2 Please contact our sales representative i
8. system of Linear robot and Controller if the lineup or connection of cable is inappropriate some troubles like disconnection or malfunction of electric contact or sudden unexpected operating may be caused Alpha Robotics explains hereunder the prohibition or note for cable installation and or treatment Please read the following conditions before installing and or using the products 2 6 1 Do not bend in one concentrated spot bending of cable must be decentralized 2 6 2 Do not twist cable 2 6 3 Do not pull cable excessively http www alpharobotics kr A01 06 2 6 4 Do not use Spiral Tube where cables are bended repeatedly 2 6 5 Do not fix cable too much strongly Be sure not to transform cable by strong fixation 2 6 6 Do not being scratched or chopped on the surface of cable http www alpharobotics kr A01 07 2 7 Caution in handling cableveyor Do use genuine robot cable as a junction cable Use over r 50mm of bend radius of cableveyor 2 7 1 The space of contained cables inside cableveyor must be below 60 of allowable space inside cableveyor 2 7 2 Do not tie cables together with cable tie etc for free movement of cables inside cableveyor Do not twist cables http www alpharobotics kr A01 08 3 Outline of Robot External amp internal figures and name of Linear Robot is mentioned as follows On below drawing the direction of right and left are indicated by the location of cable unit pla
9. the cables Scratches bending pulling twisting laying amp inserting heavy things of or on cables by force cause fire electric shock or disorder by short circuit or interruption of current d Turn off the power to products in case of power outages Sudden movement of products after resupply of power cause damage of products and injury of people e Turn off the power to products in case of heat smoke smell generated from products to avoid damage of products or fire f Stop operating immediately in case of strange noise or unusual vibration from products in order to prevent damage disorder of products g Turn off the power to products if the protective devices alarms do not work Failure of protective devices may result in damage of products or injury Inspect and solve the problems after shutting off the power and then resupply the power h Turn off the power in case of no LED light on when power is supplied 1 Do not step on products or place things on products Doing so may cause overturn injury damage amp malfunction of products 2 2 4 Repair inspection maintenance Very important to shut off the power before such operations as repair inspection replacement etc Be sure to confirm following subjects a Place indicator On operation Do not turn on the power in well visible place avoiding turning on the power accidentally by people while operation is on b When more than 2 operators work together be sure to cal
10. the end surface of the Rear block after regulation of the Tension a If the Belt and Pulley stick out from the Rear block Cut the Belt and regulate tension again Rear block http www alpharobotics kr A01 20 7 4 Grease injection 7 4 1 It s necessary to inject grease cyclically Cycle of 6 months of is appropriate 7 4 2 Use excellent characteristic of low lint grease fit for Linear robot 7 4 3 Do not clean LM guide unless foreign substance is stuck 7 4 4 Make 4 5times round trip movement by hands after grease injection 7 4 5 Do not stain other frames or Encoder units with foreign substances when injecting grease 7 4 6 Inject grease as much as not overflowing into LM guide 7 5 Inner inspection of Linear robot 7 5 1 Be careful of foreign substances not to come inside Linear robot when inspecting inside of Linear robot 7 5 2 Cleaning by vacuum cleaner is recommended and do not put excessive power on all units Use adhesive tape to remove scraps of iron and otherwise 7 5 3 Checking parts of sensor and other inner parts is the final process of inspection and cleaning 7 5 4 Be always sure to turn off power supply of Servo driver before inspecting and cleaning 8 Warranty of product Products of Alpha Robotics is always under strict Quality Control System If defect of product is detected Alpha Robotics provide service described below 8 1 Warranty period a 12months after delivery to assigned destination b 3000 hours o
11. Fito wwy clorneroootics te User s manual BR Series Rev 1 0 A A r ES ALPHA 202784 Reference No ARO9RDOO01D Table of Contents Operating manual Items 1 Foreword 1 1 Foreword 2 Safety Management A01 01 2 0 Safety precautions 2 1 Danger 2 2 Warning 2 3 Caution 2 4 Note 2 5 Others 2 6 Caution in handling cable 2 7 Caution in handling cableveyor A01 01 A01 02 03 A01 03 04 A01 05 A01 06 07 A01 08 3 Outline of Robot 3 1 External figure 3 2 Internal figure and name of part 4 Transportation and handling A01 09 A01 10 4 1 Handling packed and unpacked robot body 4 2 Handling the assembly of robots AOI 11 A01 11 12 5 Operating and storage environment 5 1 Operating environment 5 2 Storage environment of storage A01 12 A01 12 6 Installation conditions 6 1 Installation 6 2 Installation flow 6 3 Operating space for maintenance and repair 6 4 Fixation of robot s framework 6 5 Operating area 6 6 Installing of End effecter 7 Inspection and repair A01 12 A01 13 A01 14 A01 14 15 A01 15 A01 16 7 1 Items for inspection and repair 7 2 Checking points of Belt s damage 7 3 Replacement of Belt 9 Warranty of product A01 17 A01 18 A01 19 20 9 1 Warranty period 9 2 Range of warranty http www alpharobotics kr A01 21 A01 21 A00 01 1 Foreword Thanks for purchasing Alpha Robotics robot This manual is for explaining correct use installation repair
12. ame http www alpharobotics kr A01 01 2 1 A Danger 2 1 1 General information No allowable applications are as follows a Medical instruments related with maintaining managing human life and health b Equipments for transporting people c Important safety parts of machinery This robot isn t designed for application of high levels of safety No warranty of human life The range of warranty is only products as it 1s delivered 2 1 2 Installation a Do not use this robot in a place with dangerous substance such as ignitable inflammable or explosive materials There are possibilities of ignition inflammation or explosion in the above places b When installing robots make sure to support and fix them otherwise there may be injury by tumble over drop or malfunction etc of products c Do not use or install robots in a place with being humid or greasy d Never cut or reconnect cables in order to extend or shorten the length of cable Cutting or reconnecting cables may cause fire 2 1 3 Operation a Do not move in the scope of robot s operation during the operating or operable status of robots A sudden movement of robots may cause injury b People who use a pace maker must stay 1m away from robots Pace maker may be disordered by magnetic field of products c Do not spray water on products Spraying washing or using in water may cause electric shock fire or injury by malfunction 2 1 4 Repair inspection mainten
13. ance a Do not remodel products Remodeling may cause electric shock fire injury b Do not disassemble or reassemble parts of products related with basic structure function Doing so may cause electric shock fire injury 22 Warning 2 2 1 General a Do not use robots beyond specifications of them Using beyond specifications may cause disorder malfunction or breakage of robots Be sure to conform maximum payload and speed 2 2 2 Installation a In case of stoppage of machinery by system disorder such as Emergency stop stoppage of power supply design safety circuit or device for avoiding damage of products or injury b Class D grounding 1s essential for robots and controllers A short circuit may cause electric shock or disorder c Be sure to confirm safety of operating range of products before power supply or operating products Careless supplying power may result in an electric shock or injury caused by contacts of moving parts of products d Wire products correctly by direction of operation manual Connection of cable and connector should not be disconnected Disconnection may result in malfunction or fire http www alpharobotics kr A01 02 2 2 3 Operation a Do not touch a terminal block or switches during power supply on Doing so may result in malfunction or electric shock b When operating moving parts of products by hands be sure to confirm servo is turned off in order to prevent injury c Do not scratch
14. ced left side of robot when operator watch robot horizontally The closer end from operator is Front and the opposite end is Rear 3 1 External figure 3 1 1 BR series BR090 SL SR BR120 SR SL BR160 SL SR BR200 SR SL BR230 SL SR BR300 SR SL http www alpharobotics kr A01 09 3 2 Internal figure and name of part Motor cover AN Cushion AC Servo Motor Motor Pulley Front Block LM Rail Main cover h Slide Table Rear cover otor Plate Belt Cover haft Pulley imming Belt Rear Cover LM Block http www alpharobotics kr A01 10 4 Transportation and handling 4 1 Handling the body of robot 4 1 1 Handling packed robot body Unless user requests otherwise each axis robot body is packed individually Please pay attention not to be dropped or collided in transportation and handling a Do not carry heavy unit by operator alone b Lay robot bodies horizontally in custody c Do not step on the package d Do not place heavy thing which may cause transform of package on the package 4 1 2 Handling unpacked robot body When handling unpacked robot transport robot with holding the base part a Be cautious not to collide in transporting b Do not press or hold excessively any part of robot Be careful of holding the part of cable 4 2 Handling the assembly of robots Please be cautious to handle assembled system of each axis robot as follows 4 2 1 Assembled in Alpha Alpha
15. f operation time 8 2 Range of warranty Within warranty period if defect is detected due to error of Alpha Robotics we will repair it free of charge However the following are exception to range of warranty a Inappropriate handling inspection storage and or maintenance by user b Generated noise or similar sensing phenomena regardless of performance of product c Alterations by third party other than Alpha Robotics or representative of Alpha Robotics d Defect caused by no genuine or designated parts or grease etc of Alpha Robotics e Defect caused by natural disasters like fire earthquake storm amp flood etc f Defect caused by using up consumption goods g Defect caused by failure to observe Alpha s manuals h Natural discoloration of coating amp painting The warranty gives assurance for provided product itself Please comprehend that the warranty does not cover damages caused by failure and or defect of the product Repairs will be done at Alpha Robotics factory We are going to ask for separate cost of dispatch of our engineer even under warranty period http www alpharobotics kr A01 21
16. f you have any question We provide detailed information sales department or agents on website www alpharobotics kr 2 5 3 Prohibition and note for handling of cable In the application or system of Linear robot and Controller if the lineup or connection of cable is inappropriate some troubles like disconnection or malfunction of electric contact or sudden unexpected operating may be caused Alpha Robotics explains hereunder the prohibition or note for cable installation and or treatment Please read the following conditions before installing and or using the products a Do not bend cable in one concentrated spot b Do not connect cables where there is a bend twist or curve of c Do not pull cables excessively d Do not twist cable in one concentrated spot f Do not fix cable too much strongly g Do not insert or scratch cables 2 5 4 Caution in handling cableveyor a Attached cable is not robot cable so please do not contain attached cable and robot cable together b Do use genuine robot cable as a junction cable c Use over r 50mm of bend radius of cableveyor d Do not make twist between cableveyor and flexible tube and do not set up cable with resistance of bend e The space of contained cables inside cableveyor must be below 60 of allowable space inside cableveyor f Do not twist signal cable with strong electric current circuit http www alpharobotics kr A01 05 2 6 Caution in handling Cable In the application or
17. l out the power on and or off or movement of moving parts for safety 2 2 5 Disposal Do not throw into fire Doing so may result in blowout of products and or generation of toxic gases 2 3 Caution 2 3 1 Installation a Do not use this product in such place as under direct sunlight amp ultraviolet ray salty amp moist atmosphere place of organic solvent and phosphate ester machine oil etc Using in those places may result in degradation of function in short time or shortened product life or abnormal operations b Do not use in atmosphere of corrosive gases like sulphuric acid hydrochloric acid etc that may result in rust of product causing degradation of product s accuracy c Proper shielding is necessary in the following places in order to prevent malfunction a In a place of existing large current or high magnetic field 0 In a place of arc electric discharge generated by welding or other working C In a place of noise generated by static electricity d In a place of efflux of radioactivity generated http www alpharobotics kr A01 03 d Do not install in a place of big vibration or impact generated Big vibration or impact cause malfunction of products e Install Emergency stop device in a place where operators handle the Emergency stop device immediately after noticing emergency in order to protect injury f Sufficient space 1s necessary for repairs Failure of sufficient space cause malfunction of
18. over not to receive the load of rope f Design brackets covers connectors not to receive loads Do not make cable be transformed 5 Operating and storage environment 5 1 Operating environment Regarding installation please follow conditions mentioned below 5 1 1 Direct sunlight is not allowable 5 1 2 Do not allow radiant heat generated by strong heat source like heat treatment furnace etc to be applied to the body of robot 5 1 3 0 4 C of surrounding temperature 5 1 4 Below 85 of humidity and no condensation 5 1 5 No corrosive and or flammable gases 5 1 6 Space of little dust and suitable for general assemble environment 5 1 7 No oil mist and cutting solution 5 1 8 Vibration over 0 3G is not allowable 5 1 9 No excessive electric magnetic waves and or ultraviolet rays and or radiation Generally in the environment operators work without protective equipments 5 2 Storage environment Storage environment is in accordance with operating environment but in long term storage there should be no condensation Unless requested otherwise moisture absorbents are not included in package In an environment where condensation may be expected do take a protective treatment of condensation of package s entire or unit itself Up to 60 C of storage temperature may be applicable to short term storage but in case of over 1 month storage do not store products above 50 C of storage temperature 6 Installation conditions 6 1
19. products or injury due to lack of proper inspection or repair g When transporting or mounting products support strongly with lifter or supporter or working together with at least more than 2 persons for safety h Do not touch moving parts or cable during installation 1 Do use our company s genuine cables which connect body of robot and controller Do use robot body controller teaching pendant etc of Alpha s genuine products for configuration j Brake unit is for prevention of slide s dropping in case of power off on vertical axis device Do not use it as a safety brake etc k In case of installing adjusting etc install indicator On operation Do not turn on the power on well visible spot A sudden supply of power results in electric shock or injury by movement of moving parts VA 2 3 2 Operation a When supplying power Supply power from highest level device one after another b Do not insert fingers or objects into the parts of opening in the products It may cause fire electric shock or injury c Do not make floppy disk or magnetic objects approach the products within 1m Magnetic fields may destroy data of floppy disk etc 2 3 3 Repair inspection maintenance Do wear protective glasses when applying grease on products If the grease enters into eyes there is an inflammation on eyes 2 4 Note 2 4 1 Installation a Do not place objects protecting ventilation around controller Problem of ventilation may
20. that surrounding temperature is higher and or lower than normal temperature In case of inappropriate material of Pulley and or in case that fine dust occurs A01 18 7 3 Replacement of Belt When replacing Belt of BR200 230 types due to damage or periodical replacement follow procedures mentioned below Machine tools sizes are changeable in accordance with the sizes of robots 7 3 1 Prepare machine tools for replacement T wrench 5 4 3mm L wrench 1Set Torque wrench box head19 mm etc 7 3 2 Unfasten Screw bolt and Wrench bolt in the Rear block In case of BR200 type the width of Belt is narrower than the distance of tapped holes on the Belt block so assemble without cutting Belt 7 3 4 Assemble Belt block and Belt into Slide 2 l a al When assembling leave equal space on end of both sides http www alpharobotics kr A01 19 7 3 5 Stick the Belt to the Front cushion and then pull opposite end and then cut the position where the end of the Belt pass by bolt holes to 1 2 pitches Caution do not cut the Belt so shortly 7 3 6 After assembling as 7 3 2 and 7 3 3 mentioned above regulate Tension through Screw bolt of Rear block a In case that the Tension is weak jumping phenomenon may occur so regulate Tension a little stronger b Regulate balance of the Pulley in order not to make the Belt contact both edges of the Pulley when operating 7 3 7 Check if the Pulley and Belt protrude out from
21. ufficient Operating or working area for maintenance and repair is necessary The drawing shown below indicates the minimum space for maintenance and repair 500 500 6 4 Fixation of robot s framework Consult Alpha Robotics on the dimensions of tapped holes for fixing robot s framework When fixing robot s framework the flatness of installation surface must be 0 05mm and below Thickness of fixing bracket must be 12mm and above 6 4 1 Detail drawing for fixation of robot s framework and base Ex Counter bored and tapped holes of AR230 S2 on the base are shown below 200 gt 2356 50140 140 140 B_ NPTCH200NxPTCH200 B 140 140 140 BO http www alpharobotics kr A01 14 6 4 2 Ex Framework of ALR160 1S1 A008 has counter bored and tapped holes for M8 bolt so as to fix framework from both upside and downside ut 2 si H i i ese A DG FERRE 162303000600 Ni vo A O SE A M8 TAP DP10 B Di Dimension of A and B
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