fanuc ltd - gongkongdownload.gongkong.com/file/2006/3/26/r2000pr.pdf · 2006. 3. 26. · r-2000ia...

FA & ROBOT

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FANUC LTD

Multi-purposeIntelligent

RobotR-2000iA

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Intelligent FunctionIntelligent Function• Newly developed robot controller R-J3iB makes robot intelligent by the newest servo

function, network function, sensor control function, etc.

By combining various sensors (force sensor, 2D sensor, 3Dsensor, etc.), robot can be realized better performance.

Simultaneous motion or coordinated motion is realized bymultiple robots which are connected with ethernet. This canhandle heavy /large workpiece which can’t be handled bysingle robot or can reduce system cost by replacing from current special machine to multiple robot handling system.

Floating function is realized by software. This can reducethe system cost by eliminating mechanical floating device.

Robot identifies payload by itself and realizes bestperformance automatically.

Automatic Payload Identification

Soft Float

Robot Link

Sensor Control

This is safety function which detects the symptom of thecollision and stops the robot urgently. This can protects robotand peripherals without traditional mechanical clutch.

High Sensitive Collision Detection

Diagnostic function for appropriate maintenance is enrichedby using various information(voltage, current,temperature,etc.) from amplifier and pulsecoder.

Diagnosis

Force sensor

3D sensor

2D sensor

Intelligent software function Sensor

MIG EYEHigh Sensitive Collision Detection

Automatic Payload Identification

Soft Float

Robot Link

Sensor Control

Diagnosis

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ConfigurationConfiguration

R-2000iA Mechanical Unit

R-2000iA Controller(R-J3iB)

• Newly developed control unit, amplifier, transformer,etc.• Remote type controller only.

• Newly developed motor

• Same operation as R-J3• Same programs of R-J3 can be used • Existing servo spot gun,servo

hand can be used for R-2000iA by adding aux. axis amplifier and aux. axis brake unit.

• Aux. axis amplifier (option)

Aux.axis

• Aux. axis brake unit (option;this unit is required in case of aux axis with existing motor) • Existing aux. axis unit can be used for R-2000iA by adding aux.

axis amplifier and aux. axis brake unit.

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Flip over mechanism as the standardand 360 degree rotation axis enablesoperation to all directions.

As the wrist size becomes compact,interference with car body is reduced.

As the rear side interference area is small, line width can be reduced and floor space is used effectively.

As the height becomes lower, robot canbe mounted in low ceiling places.

As the minimum maintenance period is extended from 6 months to 1 year,maintenance becomes easier.

Features of the Mechanical UnitFeatures of the Mechanical Unit

As the allowable wrist load moment isincreased, it is easily applied spot weldingwith large size gun or handling of heavyworkpiece.

As the distance from J5 axis center to wristflange is reduced, the substantial allowablewrist load moment is increased

As the diagnostic function is enriched, customer can use robot more safely.

As the projection of J2 and J3 axis motor isreduced, high density installation of therobots and peripherals is possible.

As the various models and options are prepared, customer can choose the mostsuitable model and use more wider application.

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1) Box pattern 2) Actual programs used by customers

In order to evaluate motion performance, the following many programs are used.• Box pattern - from short pitch to long pitch• Actual programs used by customers

Improvement of Motion PerformanceImprovement of Motion Performance

Programs with servo weld gun

S-430iW R-2000iA/165FNo.1 29.3 23.1 -21%No.2 18.0 13.4 -26%No.3 25.0 22.0 -12%No.4 25.8 21.7 -16%

-19%

Programs without servo weld gun

S-430iW R-2000iA/165FNo.1 25.8 24.7 -4.2%No.2 21.9 21.7 -1.2%No.3 19.3 17.3 -10.5%No.4 22.9 22.6 -1.5%No.5 18.1 15.8 -13.1%No.6 29.2 28.8 -1.5%No.7 14.5 14.1 -2.5%No.8 17.5 17.6 0.6%

-4.2%

Improve-ment

Cycle Time [sec]

Cycle Time [sec]

Average Improvement

0.0

0.2

0.4

0.6

0.8

1.0

1.2

30 50 100 150 200 300 400 500 600 700Pitch [mm]

Cyc

le T

ime

[sec

]

S-430iW R-2000iA/165F

Improve-ment

Average Improvement

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Outer view and Specification (R-2000iA/165F)Outer view and Specification (R-2000iA/165F)

Payload at wristReach

J1J2J3J4J5J6J4J5J6J4J5

RepeatabilityJ6

Maximum speed

Allowable loadmoment at wrist

Allowable loadinertia at wrist

165 kg2650mm

105 deg/sec105 deg/sec105 deg/sec130 deg/sec130 deg/sec210 deg/sec

921 Nm921 Nm461 Nm

78.4 kgm2

78.4 kgm2

40.2 kgm2

±0.3mm

Note) All specifications are subject to change without notice.

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Compact Mechanical Unit(1)Compact Mechanical Unit(1)• Total height is reduced 98mm still maintaining a motion range equivalent to the S-430i. This reduction enables

mounting in low ceiling places.

• Thanks to the newly developed small size motor, the projection of J2 and J3 axis motor is reduced, and then total width of the robot is reduced 158mm. This enables high density installation of the robots and peripherals.


S-430iW

R-2000iA/165F

2211

2113

868

699

J3 axis motor

J2 axis motor

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Compact Mechanical Unit(2)Compact Mechanical Unit(2)

• The wrist size becomes further more compact. This reduces its interference with car body and the robot can be operated even through smaller opening. And besides, rubbing against cable/hose is reduced.

φ21

0

φ22

6

φ21

4φ

222

215240

R168

R161


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Compact Mechanical Unit(3)Compact Mechanical Unit(3)

• Simple direct drive mechanism reduces rear side projection at robot escape position. Line width can be reduced and floor space is used effectively.


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Excellent Performance and Function(1)Excellent Performance and Function(1)

• As maximum reach is extended 7mm, wider operating area can be covered.

• Flip over mechanism as the standard and 360 degree rotation axis enables operation to all directions.

2650(Reach is increased 7mm)

R-2000iA/165F

360 degree rotation

J3 arm flip over

Wide operation area at flip over side


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215mm(▲25mm)

Excellent Performance and Function(2)Excellent Performance and Function(2)

• Payload at wrist is 165kg as standard, and allowable load moment at wrist is increased. It is easily applied spot welding with large size gun or handling of heavy workpiece.

• The distance from J5 axis center to wrist flange is reduced 25mm.(ISO flange)

This reduction increases the substantial allowable load moment at wrist.

Allowable wrist moment at wrist J4,J5 : 921 NmJ6 : 461 Nm

165kg

Substantial allowable load momentis increased by reduction of the distancefrom J5 axis center to wrist flange.


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Improvement of MaintainabilityImprovement of Maintainability• Every 6 months greasing points are eliminated and minimum maintenance period is extended to 1 year.

• As all motors and pulsecoders are faced to outside, replacement of these elements is easy.

• New pulsecoder mechanism enables automatic uniting with temperature detecting device which is wired so far. This can reduce replacing time of pulsecoder.

• As the mechanical unit cable is routed along with the outside of the J2 arm, it is easy to replace.

All motors and pulsecodersare faced to out side.Replacement of these elementsis easy.

Minimum maintenance period

6 months 1 year

J1 motor

J2 motor

J3 motor

Wrist motors

Mechanical unit cableis easy to replace

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Information is displayed on the teach pendant.

Margin of alarmsHistory of collision detection

Reducer overhaul time calculated from torque and current

reducerJ1 98356.2 hours J2 28940.6 hoursJ3 93746.5 hoursJ4 164856.2 hoursJ5 26374.5 hoursJ6 18273.9 hours

overheatpresent max

J 1 32.5 % 46.4 %J 2 35.8 % 32.7 %J 3 10.0 % 123.4 %J 4 10.0 % 123.4 %J 5 10.0 % 123.4 %J 6 10.0 % 123.4 %

currentJ 1 11.4 %J 2 43.6 %J 3 10.0 %J 4 10.0 %J 5 10.0 %J 6 10.0 %

disturbancecurrent max(%)/min(%)

J 1 5.2 % 123.4/ -20.1%J 2 13.5 % 123.4/ -20.3%J 3 10.0 % 123.4/ -20.7%J 4 10.0 % 123.4/ -20.3%J 5 10.0 % 123.4/ -20.2%J 6 10.0 % 123.4/ -20.3%

OVCJ 1 23.8 %J 2 27.5 % J 3 25.4 %J 4 19.3 %J 5 75.4 %J 6 28.3 %

Collision detectionJ1 1 timesJ2 ***** timesJ3 ***** timesJ4 ***** timesJ5 5 timesJ6 ***** timeslast detection2001 / 1 / 10, 12: 15: 57

• SERVO DIAGNOSIS displays the information useful to maintain robots.

- It calculates the recommended reducer overhaul time- It displays the percentage of margin of alarms(overheat, OVC etc.) withpresent duty useful to evaluate the propriety of the duty- It keeps the history of collision detection useful to maintain the robot

SERVO DIAGNOSISSERVO DIAGNOSIS

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Various Models and OptionsVarious Models and Options• Various models are prepared. Customers can choose the most suitable model according to their use.

- Floor mount 165kg payload type

- Floor mount 200kg payload type

- Long arm 125kg payload type

- Rack mount 165kg payload type

- Rack mount 200kg payload type

- Compact 165kg payload type

• By using various options, robot will become more convenient and can be used for wider application. - Spot welding dressout package

- Severe dust / liquid protection option

- Mechanical unit option cable（signal,power,DeviceNet,etc.)

- Servo weld gun cable（inside of the mechanical unit - J3 casing - servo weld gun）

- Over travel switch（J1-J3 axis）

- Stopper for motion range restriction

- Insulated wrist flange(ISO）

- Brake release unit

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Replacement from S-430i Replacement from S-430i

Operation space(1)

In case of same positionOperation space(2)

In case of 70mm rise

J1 axis rotation center(S-430iW, R-2000iA/165F) S-430iW

R-2000iA/165F

70m

m

70m

m

• In case of replacement from S-430iW to R-2000iA/165F , almost operation space can be covered even installed at the same position.

• Further more, if R-2000iA/165F is installed 70mm rise, almost entire operation space can be covered.

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Wrist Flange Interface(R-2000iA/165F)Wrist Flange Interface(R-2000iA/165F) Wrist Load Diagram(R-2000iA/165F)Wrist Load Diagram(R-2000iA/165F)

注1）

注1）

注2）

注2）

注2）

注2）

注2）

注2）

Note 1) The length of fitting(outside) is 1-4 mm shorter than S-430i.Note 2) The depth of tap/pin holes is 4mm/8mm shallower than S-430i.

ISO Flange

Standard/Special Flange

Note 1)

Note 1)

tap depth EEQSP

depth HEQSP

tap depth EEQSP

depth HEQSP

ISO Flange Standard Flange Special Flange

Note 2)

Note 2)

Note 2)

Note 2)

Note 2)

Note 2)(Based on ISO 9409-1-A125)

R-2000iA/165FWrist load diagram(ISO Flange)Note) In case of Standard/Special flange,

the allowable position of X directionbecomes 25mm shorter


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Dimensions of the Robot BaseDimensions of the Robot Base Equipment Mounting Surface(R-2000iA/165F)Equipment Mounting Surface(R-2000iA/165F)

• Dimensions of the robot base is the same as S-430i


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Maximum load capacity at wrist

J1 axis

J2 axis

J3 axis

J4 axis

J5 axis

J6 axis

J4 axisJ5 axisJ6 axis

200 kg

360 deg(90 deg/s)135 deg

(85 deg/s)367.4 deg(90 deg/s)720 deg

(110 deg/s)250 deg

(110 deg/s)720 deg

(155 deg/s)1274 Nm1274 Nm686 Nm

117.6 kgm2

Motion range(Maximum speed)

Allowable load moment at wrist

Allowable load inertia at wrist 117.6 kgm

2

58.8 kgm2

Maximum load capacity at J3 arm 25kgMaximum load capacity at J2 base 550kg


+/-0.3 mm1,240 kg

RepeatabilityMass

R-2000iA/200F specificationR-2000iA/200F specification


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R-2000iA/200F wrist load conditionsR-2000iA/200F wrist load conditions R-2000iA/200F equipment mounting surfacesR-2000iA/200F equipment mounting surfaces


R-2000iA/200FWrist load diagram(ISO Flange)

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J1 axis

J2 axis

J3 axis

J4 axis

J5 axis

J6 axis


125 kg

360 deg(105 deg/s)

135 deg(105 deg/s)352.4 deg

(105 deg/s)720 deg

(170 deg/s)250 deg

(170 deg/s)720 deg

(260 deg/s)588 Nm588 Nm343 Nm

58.8 kgm2




2

22.5 kgm2

Maximum load capacity at J3 arm 20 kgMaximum load capacity at J2 base 550 kg


+/-0.3 mm1,230 kg

RepeatabilityMass

R-2000iA/125L specificationR-2000iA/125L specification


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R-2000iA/125L wrist load conditionsR-2000iA/125L wrist load conditions R-2000iA/125L equipment mounting surfacesR-2000iA/125L equipment mounting surfaces


R-2000iA/125LWrist load diagram(ISO Flange)Note) In case of Standard/Special flange,


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J1 axis

J2 axis

J3 axis

J4 axis

J5 axis

J6 axis


165 kg

360 deg(105 deg/s)


(105 deg/s)720 deg

(130 deg/s)250 deg

(130 deg/s)720 deg

(210 deg/s)921 Nm921 Nm461 Nm

78.4 kgm2




2

40.2 kgm2



+/-0.3 mm1,540 kg

RepeatabilityMass

R-2000iA/165R specificationR-2000iA/165R specification


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R-2000iA/165R wrist load conditionsR-2000iA/165R wrist load conditions R-2000iA/165R equipment mounting surfacesR-2000iA/165R equipment mounting surfaces


R-2000iA/165RWrist load diagram(ISO Flange)Note) In case of Standard/Special flange,


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J1 axis

J2 axis

J3 axis

J4 axis

J5 axis

J6 axis


200 kg


(85 deg/s)365 deg

(90 deg/s)720 deg

(110 deg/s)250 deg

(110 deg/s)720 deg

(155 deg/s)1274 Nm1274 Nm686 Nm

117.6 kgm2




2

58.8 kgm2



+/-0.3 mm1,570 kg

RepeatabilityMass

R-2000iA/200R specificationR-2000iA/200R specification


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R-2000iA/200R wrist load conditionsR-2000iA/200R wrist load conditions R-2000iA/200R equipment mounting surfacesR-2000iA/200R equipment mounting surfaces


R-2000iA/200RWrist load diagram(ISO Flange)

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R-2000iA/165CF specificationR-2000iA/165CF specification

165 kg

360 deg(110 deg/s)


(100 deg/s)720 deg

(130 deg/s)250 deg

(130 deg/s)720 deg

(210 deg/s)911 Nm911 Nm451 Nm

88.2 kgm2

88.2 kgm2

44.1 kgm2

25kg550kg

+/-0.3 mm1,050 kg


J1 axis

J2 axis

J3 axis

J4 axis

J5 axis

J6 axis




Allowable load inertia at wrist

Maximum load capacity at J3 armMaximum load capacity at J2 base


RepeatabilityMass


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R-2000iA/165CF wrist load conditionsR-2000iA/165CF wrist load conditions R-2000iA/165CF equipment mounting surfacesR-2000iA/165CF equipment mounting surfaces


R-2000iA/165CFWrist load diagram(ISO Flange)

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PC Card Slot

Flash ATA Card

R-2000iA

Host PC

Remote accessby MODEL Card

R-J3iB Controller

• Special controller designed for R-2000iA robot• Based on current R-J3 and increase performance with keeping reliability• Enhance communication function

Integrated PMC

(Option)

Line control PLC

Teach Pendant

Serial I/O (Master)- AB Remote I/O- DeviceNet- InterBus-S- Profibus-DP- ControlNet

Weld timer I/O deviceEthernet

Serial I/O (Slave)

R-2000iA Controller Configuration (R-J3iB)

R-2000iA Controller Configuration (R-J3iB)

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•Providing Main CPU and communication CPU as dual processor system

‐64 bit RISC processor for Main CPU‐Enhancement of communication processor to realize 100 BaseTEthernet

•Expanding Flash memory from 4-16MB to 16,32MB

•Enhancement servo DSP‐Two times faster than R-J3

•Adopting ECC for battery-backed up SRAM for high reliability

Controller（Hardware)Controller（Hardware)

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•For CE mark and RIA standard, to provide category-4 safety level of IEC standard and control reliable of RIA standard.

External E-Stop Fence

….

E-StopDead-man

E-Stop3-Mode switch

Primary power

Redundant E-Stop

Servo Amp

Dual MCC

24V

0V

24V

0V

OP panel

Teach Pendant

Dual chain Circuit

Dual chain

Dual chain of EMG input

•Dual contact•Approved parts

Controller(Hardware)Controller(Hardware)

•Dual contact•Approved parts

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Control unit

OP Panel

FSSB(FANUC Serial Servo Bus)•50 Mbps optical fiber communication•High reliable ECC function•Various data transfer except motor control signal•High speed Communication directly to/from servo DSP

HSSB（High Speed Serial Bus）•Serial bus to OP panel•Providing PCMCIA port at OP panel•Switch/LED control•Status of E-Stop signal

Motor powerPulsecoder signalROT/HBKRDI/RDO

•Two expandable high speed reliable serial buses are provided


6-ch amplifier

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6-ch amplifier

FSSB(FANUC Serial Servo Bus)

•FSSB(aux axis, analog input)Aux amp

Analog input board

•Flow sensor•Welding sensor•Pressure sensor•Force sensor

Analog input

•Providing high speed serial communication between servo DSP and aux axis amplifier/analog input board by FSSB

•Realizing real time control based on the data from sensors

Control unit

Controller(hardware)Controller(hardware)

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6-ch amplifier


•FSSB(Servo amplifier)

•Improvement of servo control by use of voltage information.

•Providing good maintenance information based on various data from servo amplifier

Various data transfer directly to servo DSP

•Voltage information

•Discharge current

•Detail alarm status

Control unit


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6-ch amplifier


•FSSB(Pulse coder)

•High speed serial communication of absolute position data

•Because of absolute data, higher reliability than pulse transfer

•Detecting alarms at pulsecoder and transfer them to control unit for better maintenance

Control unit

Serial communication Pulsecoder


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•Reducing transformer size and Robot connection cable

•Transformer S-430iW : 10.5KVA R-2000iA : 7.5KVA

•Connection cable S-430iW : (4) cables R-2000iA : (2) cablesS-430iF : (3) cables

Robot connection cable: (2) cables


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Control unit

OP panel

HSSB(High Speed Serial Bus)

•Providing PCMCIA port at OP panel

•Expanding PCMCIA bus to OP panel by HSSB

•Easy to access PCMCIA port for Data back-up or modem connection

•Available to use large size ATA flash memory card

•Easy to back-up to/from PC through memory card


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Control unit

•Enhancement of network•Providing 100BaseT Ethernet by enhancement of communication processor

•Field Bus option‐Device Net‐Control Net‐FL Net‐Profi Bus ‐InterBus S

100BaseT

Field Bus


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•Sensor BoardSensor board 2D vision

3D vision/MigEye

Force sensor

•Having all sensor I/F at one board(sensor board)

•Possible to provide various sensors to robot system easily

Full size option


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6ch amplifierAux amp

Control PCB

I/O unit

E-Stop unit

Breaker

•Inside of cabinet

Fan unit

Transformer

Discharge resister

Controller(Configuration)Controller(Configuration)

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(Option)


•OP panelMode switch(key switch)

IEC-947-5-1(force opening) AUTO : RunningT1 : Teach(safety speed)T2 : Teach(100% speed)

ON/OFF (alternate)Alarm LED

Start switch(with cover)

Reset switchUser #1,#2

E-Stop switchIEC-947-5-1(force opening)

PCMCIARS-232-CEthernet(option)

ON/OFF (alternate)Hour meter (option)

Optional panel with Alarm LED,Start switch, Reset switch andUser #1, #2 switch is available.

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•Option PCB

2-mini slot

Mini slot•Profibus•DeviceNet•FL Net•Aux axis

Wide mini slot•Line Tracking•Interbus-S(PC104)•ControlNet(PC104)

Full size slot•DeviceNet(PC104)•Interbus-S(PC104)•ControlNet(PC104)•Process I/O•Sensor Board

Main CPU PSUOption PCB

Wide mini

Full size

4 slot back-plane


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•Servo Gun

•Add servo amplifier and cables to realize servo gun

Brake power is provided from 6 ch amplifier

DC link is also provided from 6 ch amplifier

Amplifier for servo gun

Gun change unit

•Add gun change unit to realize gun change


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6ch amplifier

•Servo amplifier•Connector for all connection

•Reduce 18% weight as R-J3

•Exchanging within 5 minutes

Fan unit

Air Flow

Exchanging fan

•Fan unit•Rear-to-rear air flow

•No maintenance space at side of cabinet

•Exchanging fan unit from front side

Controller(Maintenance)Controller(Maintenance)

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• 100Base-TX Ethernet is supported• Higher data transfer is available than current 10Base-T• Robot can connect 100Base-TX Ethernet directly in factory without any converter

R-J3iB SoftwareR-J3iB Software

Ethernet 100Base-TX

R-J3iB

Ethernet 100Base-TX100Base-TX

100Base-TX

10Base-T

100Base-TX -> 10Base-Tconverter

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• HTTP interface is supported• Access robot data through Internet or Intranet• Access robot data through Internet Explorer on PC. Special software is not needed on PC• Customer can look/modify/save robot data as same manner of Internet Home Page

R-J3iB SoftwareR-J3iB SoftwareWeb Server

R-J3iB

Web server

Ethernet

PC

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• 3 mode switch (AUTO, T1, T2) is provided as standard. Previously, only CE/RIA controller provides 3 mode switch.

• In T1 mode, robot speed is limited under 250mm/sec. Teaching operation becomes safe.• In T1 and T2 mode, robot is energize only when Dead-man switch of TP is held • Mode can be fixed by key-lock. Prevent to change mode unexpectedly

R-J3iB SoftwareR-J3iB Software３ Mode Switch

3 Mode Switch

R-J3iB Controller

AUTOT1

T2

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• User programs and other system setup are saved in system automatically • Reduce effort to data backup when program is changed and prevent to forget to save

modified program• When user programs and/or system setup are lost in unexpected reason, easy to

recover system with minimum effort and time

R-J3iB SoftwareR-J3iB SoftwareAutomatic Backup Function

R-J3iB Backup is automatic done at following timing− Specified time (5 times per day)− Specified digital input signal turning on− Power on

Multiple backups are available. If wrong program and setup is saved, previous another backup can be loaded

Save user programs and system setup in integrated Flash memory

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R-J3iB SoftwareR-J3iB Software

Robot Link Simultaneous Motion• Handling for heavy / large workpiece by multiple robots• By handling with multiple robots, robot hand can be simple and small • Does not need special hardware• When one robot is stopped, other robots are also stopped automatically.

Master robot moves by program or jogging

Slave robot follows a motion of master robot

MasterRobot

SlaveRobot

Ethernet

Master Robot

Slave Robot #1

Ethernet

Move master robot by program or jogging

Slave Robot #2

Slave robots follow a motion of master robot

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R-J3iB SoftwareR-J3iB SoftwareRobot Link Approach Deterrence

• Approach stop functionFeature: This function detects near-miss between a robot and

another one/fixed object. This function decelerates and stops robots before collision.If deceleration is not in time, robots are E-stopped.

Usage : This function prevents interference by operation error.

• Approach wait functionFeature: If distance between a robot and another one/fixed

object is less than approach wait distance, this functiondecelerates former robot to stop. According to situation,motion of stopped robot can be restartedautomatically.

Usage : This function is used when robots move in close range to each other.

Approach stop

Approach wait

(Waiting for I/O condition)

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R-J3iB SoftwareR-J3iB SoftwareROBOGUIDE

• Connect PC to robot controller and execute high accurate simulation is available on PCRobot motionTCP path trajectoryCycle timeI/O Interlock

• Easy to switch simulation to actual robot. After simulating a robot program, execute this program and move actual robot.

• 3D animation on PC is available for create/edit robot program, teach/modify taught robot position

• Multiple robots animation is available

R-J3iB

Ethernet

ROBOGUIDE

fanuc ltd - gongkongdownload.gongkong.com/file/2006/3/26/r2000pr.pdf · 2006. 3. 26. · r-2000ia...

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