Toshiba SR Series Bedienungsanleitung

STE 73872–0

SR series/TS2000

INSTRUCTION MANUAL

CASSETTE TRANSFER ROBOT

MAINTENANCE

Notice

1. Make sure that this instruction manual is delivered to the

final user of Toshiba Machine's industrial robot.

2. Before installing and operating the industrial robot, read

through and completely understand this manual.

3. After reading through this manual, keep it nearby for future

reference.

May, 2004

TOSHIBA MACHINE CO., LTD.

TOKYO, JAPAN

MAINTENANCE MANUAL

No part of this document may be reproduced in any form without obtaining prior written

permission from Toshiba Machine Co., Ltd.

The information contained in this manual is subject to change without prior notice to

effect improvements.

STE 73872

– i –

MAINTENANCE MANUAL

PREFACE

This manual describes how to maintain the robot and controller.

Maintenance and inspection are essential to keep the robot performance for a long time,

to prevent failures and to assure safety. Be sure to look through this manual and set

up a maintenance program before actually starting the robot.

This manual is composed of the following sections.

Section 1: Maintenance Items

This section describes the maintenance schedule of the robot and

controller and items required for inspection and maintenance.

Section 2: Maintenance of the Robot

This section refers to the robot structure and items required for inspection

and maintenance of the robot.

Section 3: Maintenance of Controller

This section refers to the robot controller structure and items required for

inspection and maintenance of the controller.

STE 73872

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MAINTENANCE MANUAL

CAUTIONS ON SAFETY

This manual contains the important information on the robot and controller to prevent

injury to the operators and persons nearby, to prevent damage to assets and to assure

correct use.

Make sure that the following details (indications and symbols) are well understood

before reading this manual. Always observe the information that is noted.

[Explanation of indications]

Indication Meaning of indication

!DANGER

This means that "incorrect handling will lead to fatalities or

serious injuries."

!CAUTION

This means that "incorrect handling may lead to personal

injuries *1) or physical damage *2)."

*1) Injuries refer to injuries, burns and electric shocks, etc., which do not require

hospitalization or long-term medical treatment.

*2) Physical damage refers to damages due to destruction of assets or resources.

[Explanation of symbols]

Symbol Meaning of symbol

This means that the action is prohibited (must not be done).

Details of the actions actually prohibited are indicated with

pictures or words in or near the symbol.

This means that the action is mandatory (must be done).

Details of the actions that must be done are indicated with

pictures or words in or near the symbol.

This means danger.

Details of the actual danger are indicated with pictures or words in

or near the symbol.

This means caution.

The details of the actual caution are indicated with pictures or

words in or near the symbol.

STE 73872

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MAINTENANCE MANUAL

!CAUTION

• Be sure to read through the safety instruction manual provided separately before

starting actual work to assure the safe work covering from the robot installation to

operation.

[Maintenance and inspection]

Be sure to observe the following items to use the robot safely.

!DANGER

Prohibited

• DO NOT incinerate, disassemble or charge the batteries.

Otherwise, they may rupture.

Mandatory

• Be sure to turn off the main power switch of the controller

before starting inspection or maintenance.

• Batteries should be disposed of according to the user's

in-house regulations.

!CAUTION

Disassembly

prohibited

• The user must NEVER replace or modify parts other than

those described in the instruction manual. Otherwise, the

performance may deteriorate or faults or accidents will be

caused.

Mandatory

• Always use the Toshiba Machine's designated spare parts

when replacing the parts.

• Maintenance and inspection should be performed regularly.

Otherwise, the system may malfunction or accidents will be

caused.

STE 73872

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MAINTENANCE MANUAL

Table of Contents

Page

Section 1 Maintenance Items......................................................................... 1–1

1.1 Maintenance Schedule ........................................................................ 1–1

1.2 Items for Maintenance and Inspection................................................. 1–2

1.3 Maintenance Tools............................................................................... 1–4

1.4 Maintenance Contract and Repair ....................................................... 1–5

Section 2 Maintenance of the Robot .............................................................. 2–1

2.1 Cautions on Maintenance and Inspection............................................ 2–1

2.2 Layout of Robot Components and Drive Mechanism........................... 2–1

2.3 Robot Maintenance Procedures .......................................................... 2–3

2.3.1 Check for Vibration and Abnormal Noise................................ 2–3

2.3.2 Check for Lubrication.............................................................. 2–4

2.3.3 Replacement of Position Detector (or Encoder) Batteries...... 2–6

2.3.4 Check for Stainless Belt ......................................................... 2–7

Section 3 Maintenance of Controller .............................................................. 3–1

3.1 Cautions on Maintenance and Inspection............................................ 3–1

3.2 Layout of Controller Parts.................................................................... 3–2

3.3 Maintenance Procedures..................................................................... 3–3

3.3.1 Check for Controller Air Vent Holes........................................ 3–3

3.3.2 Check of Safety Devices for Function..................................... 3–4

3.3.3 Battery Replacement.............................................................. 3–7

3.3.4 Replacement of Switching Power Supply Unit........................ 3–9

3.3.5 Replacement of Fuse (X8HN, X8HI Printed Boards).............. 3–12

3.3.6 Replacement of Output ICs (X8HN, X8HI Printed Boards)..... 3–14

STE 73872

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MAINTENANCE MANUAL

Page

Appendix Table 1 List of Mechanical Replacement Parts for Maintenance. 4–1

Appendix Table 2 List of Controller Replacement Parts for Maintenance ... 4–3

Appendix Drawing 1 Component Connection Diagram ................................... 4–4

STE 73872

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MAITENANCE MANUAL

Section 1 Maintenance Items

1.1 Maintenance Schedule

Maintenance comes in the two (2) types; daily inspection, and regular inspection and

maintenance. For the regular inspection and maintenance, inspection items are

added every 1,200 running hours.

3-month check

3-month check 6-month check

3-month check

3-month check 6-month check

3-month check

3-month check 6-month check

3-month check

3-month check 6-month check

1-year check

Overhaul (every 5 years)

1200

2400

3600

4800

6400

7200

8400

9600

24000

(h)

Daily inspection

Running hours

(h)

Inspection schedule

• When the system is operated for 16 hours per day:

16 hours ×25 days ×3 months = 1,200 hours

• When the system is operated for 24 hours per day:

24 hours ×25 days ×3 months = 1,800 hours

STE 73872

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MAITENANCE MANUAL

1.2 Items for Maintenance and Inspection

This section describes the items for maintenance and inspection. For the execution

procedures, see the relevant paragraph listed in the table below.

a) Daily inspection

No. Item Inspection procedures Relevant

Para.

1 Robot harness

and cable duct Make sure that no local torsion or curve is

caused in the robot harness and cable

duct during robot operation.

Also, make sure that the robot harness is

tightened completely.

2.3.1

2 Robot installation

bolts Make sure that the robot base installation

bolts are tightened completely. 2.3.1

3 Vibration and

noise Make sure that each axis can move

smoothly. 2.3.1

4 Change in

positioning

accuracy

Make sure that the robot can stop at a

predetermined position accurately.

5 Controller vent

holes (1) Make sure that no obstacle stands in

front of the vent holes.

(2) Make sure that no contaminant is left

in the vent hole.

3.3.1

6 Function of safety

devices Make sure that each safety device

connected to the emergency stop

pushbutton switch and external operation

input signal can function properly.

3.3.2

b) Quarterly (every three (3)-month) inspection

No. Item Inspection procedures Relevant

Para.

1 Lubricated state of

ball screw and

linear guide

Make sure that the ball screw and linear

guide of each axis is greased completely

and that no rust is developed on them.

2.3.2

STE 73872

– 1–2 –

MAITENANCE MANUAL

c) Semi-annual (every six (6)-month) inspection

No. Item Inspection procedures Relevant

Para.

1 Orthogonal axis

stainless belt Make sure that the orthogonal axis

stainless belt is tightened completely and

that it is not damaged and in a good

shape.

2.3.4

2 Each axis drive

system Move each axis by hand and make sure

that it moves smoothly. 2.3.1

3 Timing belts (1) Make sure that each timing belt is not

worn off or cracked.

(2) Check each timing belt for tension.

d) Annual (every year) inspection

No. Item Inspection procedures Relevant

Para.

1 Greasing Apply the grease to each axis ball screw

and linear guide. 2.3.2

2 Wiring Check for the state of the cables and

connectors. 2.3.1

e) Battery replacement

No. Item Inspection procedures Relevant

Para.

1 Replacement of

position detector

battery

(Replace the

battery every

three (3) years.)

Replace the position detector backup

batteries (housed in the pool box under

the orthogonal axis).

If the running time is long, battery

consumption is small. If the power OFF

time is long, the consumption is large. If

the battery voltage drops, the battery

alarm lamp flickers. Replace the battery

immediately.

2.3.3

STE 73872

– 1–3 –

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