""

Yaskawa's fully electric industrial robot .system consists of an industrialrobot (Motoman-K6S/KlOS) , a numerical control unit (Y ASNAC ERC) , anoperating station, a wo~kpiece mounting fixture and another equipment.I

This manual is intended to give operating instructions andmaintenance procedures primarily for the Motoman-K6S/KlOS robot. Forthe numerical control urit, refer to the maintenance manual for y ASNACERC. Instructions for i the operating fixture and the another equipmentare not described in th~s manual, since they a're not furnished by YaskawaRefer to each supplier of those devices for instructions. Read thoroughlythis manual prior to maintenance and retain this for further reference.

CONTENTS

31. BASIC SPECIFICATIONs

1.11.21.31.41.5

BASIC SPECIFICATIONS .3PARTS NAM~ ANp WORKING AXES 4Motoman-K6S/KlO,~ DIMENSIONS AND WORKING RANGE"'IORKING RANGE OF B-AXIS 7ALTERABLE WORkING RANGE 7

.s

2. ALLOWABLE LOAD Folk V/RIST PRECAUTIONS 8

2.12.2 9

ALLO"IABLE LOA~ FOR '!'11RIST 8

ATTACHMENT MdUNTING PRECAUTIONS8

3. ALLOWABLE LOAD oNlu-Axls 10

4. HANDLING 12

s. SHIPPING BOLTS ANOIJIC-'S 13

6. INSTALLATION 14

7. ".'iotoman CO"!STRUCTld)N 16

7.17.2

POSITIO1"IS OF LI~1IT SWITCHES FOR AXESIl'~TERNAL CONNBcTIONS 17

16

8. MAI ~~TENANCE AND Ad>JUST~~EI\jT 20

8.1 INSPECTION SCHtDULE 208.2 INSPECTION ITEMs 218.2.1 Replacement Progedures for Battery Unit 238.2.2 Grease Replacem,nt Procedures for S-, L- and U-axisReduction f\lotor 248.2.3 Note for Wrist U~it Maintenance 25

8

9. RECO~.1~.~ENDED SPARE I PARTS 26

2 -

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1 BASIC SPECIFICATIONS

1.1 BASIC SPECIFICATIONS

Table 1.1 Basic Specifications of K6S and K1OS

Mode!Motoman-K6S l\1otoman-K 1 OSItem

Operating Mode.

Degree of Free.dom

VerticalIy articuIated Verticallv articulated

Payload

6.

6 kg-

tO.l mm

6

Repeatitive Positioning Accuracy

3400 3400s axis

(turning)

2400 2400L axis

(lower arm)

2700 275°u axis

(upper arm)

Motion Range3600 3600R axis

(wrist roll)

2700 270013 axis

(wrist pitch/yaw)

4000 4000

Maximum Speed

Allowable Moment

Allowable InertiaGD2..

Weight

110°/5

.90°/s

110°/5

240°/5

240°/s

400°/s

1.2 kg.m

1.0 kg.m-

0:6 kg.~

0.91 kg.~

0.67 kg.m2

0.24 kg.m2

180 kg

MunselI 7.5R3/12

° to 45°C

20 to 80%RH( non-con densin g )

120°15

Temperature

Humidity

Less than O.5GVibrationAmbient Conditions

Others

Free from corrosive gases or liquids,or explosive gascs

.Clean all1d dry

Free from excessive electrical noise

(plasma)

5 kVJI. 8 kVAPower Capaci ty

-3 -

1.2 PARTS NAME AND WORKING AXES

UPPER (U) ARM

~

WRIST

~! 03

031!;!::=1

I: rr;"fij ~

~ LOWER ARMFLANGE

ROTARY (S)HEAD

~

I' =l ,

/*-=CONNECTOR BASE

~ BASE

Fig. 1.1 Parts Name and \AJorking Axes

4

1.3 Motoman-K6S/KlOS DIMENSIONS AND WORKING RANGE

Motoman-K6SDimensions in mm

VIEW @ : "'rist Flange

J

~

16

~f-+-

~< < <~ ~ ~

§ 3 ~

<:;'009:'1 :;(

VIE\-l @ : Baseplate

Fig. 1.2 l\1otoman-K6S Oimensionsand Working Range

5

1.4 WORKING RANGE OF B-AXIS

B-axis moves in the range maintainirig , constant angle to the center ofU-axis, as shown in Fig. 1.4. I

~.."'

Fig. , .4 \"Jorking R~nge of B-axis

1.5 ALTERABLE WORKING RANGE

The working range of S-axis can be al l ered according to the operatingconditions as shown in Table 1.2. If al eration is necessary, contact your

Yaskawa representative in advance.

Table 1 J2

Item Specifications:t 17 o (Standard)

:t150o

:t120o

:t90o

:t60o

:t30o

S-axis

Working Range

7

2. ALLOWABLE LOAD FOR WRIST AND PRECAUTIOf'IS

2.1 ALLOWABLE LOAD FOR WRIST

(1) The allowable load for wrist of Motoman-K6S and -KIOS is 6 kg and10 kg, respectively, including the weight of the grip. The followingconditions should be observed.

(2) If force is applied to the wrist instead of the load, force on R-, B-and T-axis should be within the values shown in Table 2.1. Contactyour Yaskawa representative for further information or assistance.

(3) Where the volume of load is small, refer to limit load gravity shown in

Fig. 2.1.

Lb(mm) Lb(mm)

(b) Motoman-K1OS(a) Motoman-K6S

Fig. 2.1 Limit Load Gravity

-8 -

.Inside fitting :

The fitting depth must be 5 mm or less .

.Gutside fitting :

If th'e outside fitting is used, the fitting depth must be 5 mm or less.

=:>

Wrist Flange

Q

3. ALLOWABLE LOAD ON U-AXIS

When peripheral equipment is attached to thi~ U-axis,conditians should be observed.

the following

(1) Motoman-K6S

.A1lowable load on U-axis : lS kg max

.Unbalance moment at the center of U-axis; rotation :3 kg:m (at Wl=3 kg)

.Never perform additional modifications on the robot to make pro-visions for other conditions. For attaching the equipment on U-axisuse clamps shown in Fig. 3. 1.

4-}16 x PI,j5 1228

t

~ t5

t

(kg),15 - ~

Rr

WI = LOAD CAPACITY (kg),""'N

~'-' 10

E-o:I:CHt.J~

--200100

'When load capacity W Iequals 10 kg, un1;~lancednment is not permitted.

100200 300 400 \mn)I DISTANCE BETWEEN

POINT U AND LOAD GRAVITYI

"'~w,'

...w,

(

~

Fig. 3.1

Dimensions in mm1J

Allov.Jable Load on U-axis for ~.1otoman-K6S-10 -

U-AXIS ROTATIONCENTER (POINT U)

3. ALLOWABLE LOAD 0"'1 U-AXIS (Cont'd)

(2) ~1otoman-KlOS

.A11owable load on U-axis: 25 kg max.

.Unbalance moment at the center of U-axis rotation:6 kg:m (at WI=5 kg)

.Never perform addition al modifications on the robot to make pro-visions for other conditions. For attaching the equipment on U-axis,use clamps shown in Fig. 3.2.

4-M6 x PI,-.§&.-- 45 12 .-.,

I-.

~~

~ 81

L

~ I

WI 5

-Wll~

(kg)

25

20

15

10

W1 = LOAD GRAVITY ('kg)

":1=-

E--:I:cHt.J:1=

~ *When load capacity W1equals 10 kg, UnbalancErl

" m:xrent is not pennitteCI.

200 100 100 200 300 400 (mm)

DI S TANCE BETWEENPOINT U AND LOAD GRAVITY

w.$:1

-fV!+w,

U-AXIS ROTATION

CENTER (POINT U)

..o:

-ILL..L

Q Dimensions in mm~

Fig. 3.2 Allowable Load on U-axis for Motoman-K10S

11

5. SHIPPING BOL TS AND JIGS

Motoman is provided with shipping bolts and ji!~s at @ to @ in Fig. 5.1to protect the robot from the movement and forces during shipment. Thejigs are painted yellow. Be sure to remove thE~m before .insta11ation.

NOTE

Before turning ori the power, check to be sure that theshipping bolts and jigs have been removed. Failure to doso may cause ciamage to the driving parts.

These shipping bolts and jigs must be stored for future use in theevent of moving or carrying the robot.

~

--

~~

~

Fig. 5.1 Positions of Shipping E3olts and Jigs

-13

6. INSTALLATION

The Motoman should be firmly mounted on a baseplate, or foundation rigidenough to support the Motoman and withstand repulsion forces duringacceleration and deceleration. Mount the baseplate in either of thefollowing ways. For mounting dimensions of Motoman baseplate, see par.1.3.

(1) Where the Motoman and the mounting fixture are installed on a comm9nflat steel plate (common base) :

The common base should be rugged and durable to prevent shifting of theMotoman or the mounting fixture. When the Motoman is used for welding,connect the ground lead to the Motoman baseplate.

For Motoman baseplate mounting, see Fig. 6.1

SPRING WASHER ~ BOLT

WASHER

Motoman BASEPLATE

COMMON BASE

Fig. 6.1 Motoman Baseplate t,1ounting

(2) ~ere the Motoman is mounted directly on the floor:

The floor should be rigid enough to support the Motoman.construction procedure are as follows .

Foundation

."IThere the concrete thickness (f1oor) is 150 mm or more

(i} The surface of floor should be level and even.grind the swell and flatten the surface.

If it is uneven,

(n) Check for cracks on the floor. If any c:rack is found, remove thematerial around the crack and rebuild the floor with concrete. Place therobot by fastening the plate with M20 anchor bolts. The plate is tappedfor M20 bolts .

Where the cancrete thickness (flaar) is less 1:han 150 mm ar an earthfaundatian .

8 (i) Dig a footing in the floor area.

(n) Spread stones in the excavated area and tamp them sufficiently tomake a solid stone bed .

(~ Fi11 the empty space of the stone bed with grout, and 1ay theconcrete foundation. It should be more than 150 mm thick, and thesurface must be leve1 and even.

(v) The concrete should be ,cured for more than a week before installingthe robot.

14 -

6. INSTALLATION (Cont'd)

(3) Mounted types

Foot-mounted (Standard),available .

wall-mounted and c:eiling-mounted types are

l. For wall-mounted type, S-axis working range is as follow.

Motoman-K6S: !3ao

.Motoman-KlaS: !45°

2. The brakes in S-axis and in ""rist (R-, B- and T-axis) are op-tional. When using wall-mounted type, S-axis should be providedwith a brake.

8

(:1:> CD

(i)Incorpora1:ed cable connectorType M53102A 18-15 (with cap):Connect the plug type M53106B 18-1Pto this .

@

O)

Air intet: PT3/8 tap, with bull plug(J) ..

~~

Incorpora1:ed cable connectorType M53102A 18-1? (with cap) :Connect the plug type M53106B 18-15to this .

@

VIEW A: ~

~

@) PT3/8 tap, with bull plugAir inlet:

Fig.6.2 Locations of Incorporated Cable

Connectors and Air Inlet

2. The same pin Nos. (A to F) between connectors are connected withO. 75 mm2 lead wires .

.Incorporated cables: 0.75 mm2, 6 cables

A to F.Using pins:

Detailed Drawing of Connector Pin No.Fig. 6.3

-15 -

( 4) Incorporated cables and air duct for application

1. Six cables and an air duct are incorporated in tl1otoman for userapplication .

.Allowable curren t of cables: 6.6 A or below

.Max pressure of air duct: 9.9 kgf/cm2 or below

7. Motoman CONSTRUCTION

7.1 POSITIONS OF LIMIT SWITCHES FOR AXES

Fig. 7.1 Locations ofS- and L-axis Limit Switches

16

7.2 INTERNAL CONNECTIONS

Highly reliable connectors which can be easily removed are used with eachconnector part. In Figs. 7.3 and 7.4, "-<I;:-" shows pin connector whichcan also be removed. For the numbers and locations of connectors, seeFig. 7.2.

Fig. 7.2 Locations and t~umbers of Connectors

Table 7.2 List of Connector Type

Receptacle. Ty~)e Plug TypeName !'-!o.

I-CA3106B. 32P:lOS

Base Connector ZBC MS3106B.36AIOS

l-.f53106B .18-15

i2p~n~-I)

lFor Incorporated

ICable

3BC MS3102A.18-1P

172162-1172170-1

IntermediateConnector

1-480276-0 1-171196-0

s~

lfiJ:tf

172160-1172168-1

Feedback UnitConnector

172160-1172168-1

MS3102A.18-1S

(Optional)

Connector for .Incorporated Cable MS3106B.18-P

17 -

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8. t..1Alt-JTENANCE AND ADJUSTt..1ENT

8.1 INSPECTION SCHEDULE

To insure optimum life of operation, a suggested schedule of periodical-inspections and adjustments is offered. Adjust the schedule according toyour operating conditions. Especially, axes frequently used for handlingshould be checked at half-periods of the follo~'ing schedule .

Fig. 8.1 Inspection Schedule

-20 -

8.2 INSPECTION ITEMS (Contid)

-E~-AXIS~

-AXIS/,.--~-~

~ R-AXIS

Fig. 8.2 Inspection Parts and Inspection Number

-22

8.2.1 Replacement Procedures for Battery Unit

If the battery charge becomes too low or is depleted, replace it accordingto the following procedures .

(1) Remove the side cover (U-axis motor side) of rotary head.

(2) Remove the battery unit mounting screw (M5) .

(3) Remove the pins CD. @ (PC-2005-M, W) on both sides of battery.

~BATTERY-< -E{=:J-< oE-c:)--< -E--{>

(D (g; f

DIODO

( 4) Remove the old battery and mount the new battery.

NOTE

l. When the battery unit is replaced.Keep the power ON between y ASNAC and Motoman .

2. Be sure to insert the pins in correct direction.

Fig. 8.3 Battery Loca1~ion

-23 -

8.2.2 Grease Replacement Procedures for S-, L- and U-axisReduction Motor

(l) Remove plugs @ , @ and (f) .

@, @ and @(2) Inject grease (EPINOC APO) into grease inlet on

using grease gun.

Table 8.2 Amount of Greasing

Motoman-K6S

Motoman-K1OS

S-axis L- and U-axis

300 cc700 cc

400 cc600 cc

(3) The grease replacement is completed when new grease appears from @@ and @ .The new grease is distinguished. ofrom old grease bycolor.

(4) "Iipe parts @ , @ and @ with a cloth and reinstall the plug .

~

(f)@

GREASEINLET ~

U-AXIS

REDUCTION MOTOR

@

L-AXISREDUCTION MOTOR

~ .1.~~- '.

--.

--,--~~ r-:~

7SIS REDUCTION MOTOR

GREASE INLET @

Ioetailed L- and u-axislL Reduction f\"otor PartJ

I Oetailed S-axis l

L Reduction t-.~otor Par~

S-AXIS MOTOR

MOTOR BASES-AXISREDUCTIONMOTOR

;, n,..,.,.-r--.1..'

~t""" .~ U-AXIS

REDUCTION MOTOR

MOTOR@-:

I" I ~.:J

I" ":-7"

/Uf~ -~ ~/

L-AXIS~\ FLANGE

MOTOR \LOWER (L) ARML-AXISREDUCTlON MOTOR

Grease Lubricated Parts

~

CQVER

Fig. 8.4

24 -

8.2.3 Note for Wrist Unit tJaintenance

The motor and feedback unit are provided ,:X'ith the wrist unit. Tocounteract fumes from welding operation, etc. , the hatched parts aresea]ed with sealing compound so that fumes from welding operation, etc. donot penetrate into the wrist unit. Therefore" if the wrist shaft is dis-assembled, reseal with seaUng compound (KE4~;RTV) .

Fig. 8.5 Sealing Part of V~'rist Unit

-25 -

9. RECOMMENDED SPARE PARTS

It is recommended that the following parts and components be kept instock as spare parts for the Motoman-K6S/K10S. List of spare parts forMotoman-K6S and KIOS is shown in Table 9.1 and 9.2, respectively. Theyare ranked A, B and C, as follows .

Rank A: Expendable parts and those"1or which frequent replacement canbe expected.

Rank B: Pal-ts for which replacement may be necessary as a result offrequent operation .

Rank C: Drive units

Table 9.1 Spare Parts for Motoman-K6SSparePartNo.

Rank I Oty perQty Unit

Parts Name Type Manufacturer Rema..ks

S-axis,Lead terminaltreatment completion

1 H\\'8471013-A

Limit switchset 1 1z

L-2xis,Lead terminaltreatment completion

3

4

S

6

A

2.5

kgGrease

Sillcon rubber

compound (tube)7 1

8 1 l T-axis (Tip)Gear

9

10

II

12

13

14

15

2

1

1

1

~n Yaska~.a

EJectric

I.Ug. Go., Ltd. 1

111

Speedreducer

~

1 I

~

-Without

brake

With

brake

Without

brake

1With key.Leadterminaltreatmcntcompletion

AGServo-motor

16 1 2

17

18

19

ZO

ZI

ZZ

1

1

1

3

1

1

c Yaska~.aElcctric"Ifg. Go. .Ltd.

Interna!

wiring

In L ann

1 I 1Wrist unlt 1 1

26 -

9. RECOM""\ENDED SPARE PARTS (Contid)

Table 9.2 Spare Parts for Motoman-KlOS

Sp;)reP;)rtNo.

j Qty ()CrQty\ UnitTypeRank Parts Nanle I.\anu(acturcr Rcm;)rks

I k"dtcrminal

l treatment

, completion

S-ax IsLimit swltchset

1 1

A 2.5kg

1

2

3

4

5

6

Grease

1I Shln-Etsu Chemical

Co.. Ltd.

Silicon rubber

compound (tube)KE4SRTV7

11\\.8~2S13S-1H\\'8~2S133-1

18 1Gear

9

10

II

~

2

2

ll1

2

B

1Z

13

14

15~ Ilith brake

Without

brake

l With key.

I L.ead terminal

treatment

completion16

17

18

]9

20

21

, 1

1

cin L arm

3

1

1

11

.8

8

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TOE..c945-111

MAY 1994MOTOMAN ROBOTICS AB

Box 504 8-38525 Torsås 8weden

Tel. int. 46486-10575

Fax. int 46486-11410

MOTOMAN ROBOTICS U.K LTD1 Swan Industrial Estate Banbury OXON OX16 8DJ England

Tel. int. 44295-272755Fax. int. 44295-267127