ABB机器人维修手册

1、ABB 机器人维修手册前言本手册包含了一些维修的详细说明指导，包括电气及机械. 阅读者需要有：*熟练的技能*有电气上的知识或*机械上的知识 本手册由以下几局部组成1 平安2 相关信息3 机械手4 控制柜6附录Circuit Diagrams: Manipulator 3HAC 13347-1 Included in "Repair Manual, part 2'电路图,机械手3HAC 13347-1在“维修手册2里面Circuit Diagrams, Controller 3HAC 5582*2 Included in "Repair Manual, part T

2、电路图,控制柜3HAC 5582-2在“维修手册2里面产品文件这个文件包包含控制柜，机械手及硬件信息，有以下内容The Iiistallation and ConmiiSiSioniti呂 Manual contains the following information: 安装及试车手册包含以下信息平安,维护相关信息拆箱现场安装电气连接开始安装控制柜软件系统结构目录校正模型定义信息The Repair Manual contains the following infoiiiiauon:维修手册包含以下信息：平安,维护相关信息机械手的所有的维修工作详细指导控制柜的所有的维修工作详细指导Tli

3、e Maintenance Manual eotitains rlie foliowitig infbnnation.维护手册包含以下信息：平安,维护相关信息维护方案表 维护方案表中的各局部的详细说明，如清洁,润滑及检查等通常分为机械手及控制柜两局部第一章：平安,维护说明Tins, chapter details safety- mfbniiation for service personnel i.e. percumel perfoniiing uistal- hTian. repair and niaintenance work本章讲述对于安装及维护维修人员需要了解的平安信息由于前面专门有

4、平安手册，这里只作一些补充A danger of high voltage is associated with the following parts:注意以下元件的高压危险* Be aware of stored electrical energy (DC link) in the controller.注意控制柜里面DC link储存的能量 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模块,有可能由外部供电 The

5、mains supply/mains switch主开关+ The power unit电源 The power supply unit for the computer system (230 VAC) 计算机系统的供电单元(230VAC) The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!) 整流局部(400-480 VAC及700VDC注意：电容) The drive unit (700 VDC)驱动单元(700VDC) The servi ce outlets (115/230 WC)输出局部(115/230VA

6、C) The power supply unit for tools, ar special power supply units for the machimng process工装的电源或一些其它特殊的电源 The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains,当机器人关电后注意外部到控制柜的供电线路仍然有电 Additional connections其它连接A danger of high vokaee i

7、s associated with the maiupulator in:机械手里面的高压危险 The power supply foir the motors (up to 800 VDC)电机的供电进线(800 VDC左右) The user connections for tools or otheparts of the installation (max 230 VAC, see Installation and Commissioning Manual)连接到工装或其它局部(最大230VAC)测试刹车EXiring operation the holding brakes of e

8、ach axis motor wear normally. A test may be performed to determine whether the brake can vill perform ftniction运行的时候，轴电机的刹车都会正常磨损所以要定期对刹车进行检查The function of each aKi<>'motor holding biakes. may be checked detailed below: 具体检查如下：1 Run each manipulator axis tod position wheEthe combined weig

9、ht of the manipulator arm and any load is maximized (max. static load).运行机械手的轴到最大的静态负载位置2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller用控制柜上的工作模式选择开关将电机关掉3. Check that the axis maintains its position.检查轴是否维持原位置If the manipulator does not ch a ngE pos

10、ition as the motors are switched off, then the brake function is adequate如果电机关了后，机械手保持不动，说明刹车正常第三章机械手说明Tins chapter details nil repair activities reconwiended for the manipulator, including for any exrenial mnts cf rhe manipulator.本章详细表达了机械手的维修，包括机械手的一些外部设备3.1.1 Removal of cable harness移除电缆保护壳The ca

11、ble harness is located tlwoi)ahoiit the manipulator as shown m the figure below.电缆保护壳在机械手里面的位置如下列图A Connector at manipulator base, R1 MP and R1.SMB 机械手底座的插头，R1.MP和R1.SMBBGonnectors at motor 1; R2,FB1 and R2.MP1电机1的插头;R2.FB1及R2.MP1C Connectors at motor 2; R2.FB2 and R2,MP2电机2的插头;R2.FB2及R2.MP2D Connec

12、tors at serial measurement board; R1 .SMB 1-3, R1.SMB4-6, R1 .SMB1 7. R2.FB7 and R2 SMB Battery connector X3 RI G and R2.G. Connectors at brake release unit X8, X9 and X10.测量板上的插头;R1.SMB1-3, R1.SMB4-6, R1.SMB1.7, R2.FB7 及 R2.SMB 电池插头X3 R1.G及R2.G刹车释放单元的插头 X8,X9及X10E Connectors at motor 3; R2 F03 and

13、R2 MP3 and for signal lamp R2 H1 and R2.H2 电机3的插头;R2.FB3及R2.MP3及信号灯插头R2.H1及R2.H2F Connectors at motor 4 R2.FB4 日nd R2.MP4电机4的插头;R2.FB4及R2.MP4G Connectors at cable harness separation; R2.M5/6电缆保护壳别离处的插头；R2.M5/6H Connectors at cable harness division, inside of upper arm tube： R3.FB5and R3.MP5. Connect

14、ors at motor 5; R4 FB5 and R4.MP5.电缆保护壳别离处的插头在上臂的管道里;R3.FB5和R3.MP5电机5的插头;R4.FB5及R4.MP5J Connectors at motor 6; R3.FB6 and R3.MP6电机6的插头;R3.FB6及R3.MP6KRear cover plate后盖板LConnector RLMP插头R1.MPMConnector R1.SMB插头R1.SMBNConnection of earth cable地线接头O Velcro strap that secures the cable h也rn巳to the arm h

15、ouse保护尼龙带所需设备设备序列号注意电路图 3HAC13347-1在维修手册2里面标准工具3HAC15571-1其它工具或步骤见下面的详细说明Removal, cable The procedure below details how to liemove the cable harness: axes 1-4. harness, axes 14下面详细表达如何移除电缆保护壳,轴1-4移除,电缆保护壳,轴1-4A 在开始维修机械手之前需仔细阅读下面几条：在机器人运行后，电机和齿轮温度都很高，注意烫伤 -关掉所有的电源、液压源及气压源-当移动一个部位时，做一些必要的措施确保机械手不会倒 下来

16、，如：当撤除轴2的电机时，要固定低处的手臂 :f '电缆保护壳容易损坏，所以要小心，特别是接头处1. In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to run the manipulator to the specified position: improve 日 ex ess.为了更容易移除，请将机械手运行到如下位置轴2和3可以稍为斜起点* Axis1：0 0* Axis2:0 0* Axis3:0 0* Axis4:0 0* Axis 5: +90 &q

17、uot;» Axis 6: no significan匚e ,丁壬亦轴6：不重要2.Remove the rear cover plate on the manipulator by unscrewing its attachment screws.拧开机械手的后盖的螺栓，将后盖撤除3.DisconnEct the earth cable.Shown in the figure Location complete cable harness on page 24!断开地线连接|位置见上图4.Disconnect connectors R1 MP and R1.SMB断开插头R1.MP

18、及R1.SMB5.Pull the cable and connectors up through the center of the frame拉出电缆及插头6.Disconnect all connectors at motor 1 and motor 2Specified in the figure Locatfon complete cable harness on page 24!7断开电机1和2的所有的插头 仔细地翻开SMB盖,电池及SMB单元位置见上图见的电缆可以不断开，这样就不需再校正 注意不要让盖子的重量把电缆拉得太紧 如果要彻底取下盖子，必须断开插头R1.G 这样以后就必须

19、要校正机器人8 Disconnect connectors R2 SMB, Ri .SMB l- 3, R1 SMB4-6. Disconnect X8r X9 and X10断开插头 R2.SMB,R1.SMB1-3,R1.SMB4-6.断开 X8,X9 和 X109 Unscrew the four screws securing the cable This releases the cable harness from glandthe frame.1011松开4颗保护螺栓这将从结构上松开电缆保护壳通过撤除尼龙带及保护壳上的两颗螺栓 来撤除调节盘Remove the bracket s

20、ecuring the cables inside the lower arm by unscrewing the nuts from the stud bolts securing the damp to the lower arm.拧开下臂中保护螺栓的螺帽来撤除 电缆保护架不同的机械手有不同的调节盘 请选择适宜的xxC1C0000142.*TTTfKXC icaoogi42 .wmf12 Remove the upper bracket securing the cables to the arm house by unscrewing its two attachment screws.

21、通过拧开上臂的两颗螺栓撤除到手臂 房的电缆保护架13.Disconnect connector R2 M5/6 at the rear cable division pointShown in the figure Location complete cable harness on page 24!断开后盖电缆别离点的插头R2.M5/6位置见上图14Disconnect all connectors at motor 3 and motor 4Spec帀ed in the figure Location complete cable harness on page 24!断开电机3和4的插头

22、位置见上图15.Gently pull the cable harness out轻轻地将电缆保护壳拉出Locati on of cableThe location of the cable harness, axes 5 -6, is shown in the figure below.轴5-6电缆保护壳的位置见下列图轴5-6电缆保护壳的位置XGii020：-COC2i3ACable bracket, wrist unit电缆支架 腕节单元BCable bracket, upper arm tube 电缆支架 上臂管里面C. - -1 .1 . ：. . .1轴 5 电机插头;R4.FB5

23、及 R4.MP5D匚二.1 I：；-| _ 上 臂管插头R4.FB5 及 R4.MP5FCable attachment, rearG电三缆丿夹Connectors at cable harness division point; R2.M5/6 电缆保护壳别离点插头；R2.m5/6H1厂丁_：十-轴 6 电机插头;R3.FB6 及 R3.MP6移开轴5,6的电缆保护壳这里是讲移除上臂电缆的保护壳，而单独的电缆从上臂管里面的连接点到轴5电机的移除方法这里没有表达，但紧节着在后面会讲到.A在开始维修机械手之前需仔细阅读下面几条：在机器人运行后，电机和齿轮温度都很高，注意烫伤-关掉所有的电源、液压

24、源及气压源-当移动一个部位时，做一些必要的措施确保机械手不会倒下来，如：当撤除轴2的电机时，要固定低处的手臂电缆保护壳容易损坏，所以要小心，特别是接头处必须将轴5导向正确的方向来翻开轴6电机的盖子Remove the cover, wrist unit and the cover upper arm tube.移开盖子，腕节单元及上臂管里面A:盖子,腕节单元B:盖子,上臂管里面XXD2000DQ2H A: cover, wrist unit B: cover, upper arm tube2 Remove the cover of motor, axis 6 日nd dlis- Specifi

25、ed in the figure Location of cable connect all connectors beneathharness ax 5-6 on page 27!2 移开轴6电机的盖子并断开所有的插头位置见上图3. Loosen the cable bracket on top of theShown in the figureof cable«xa20C<iCCC£4wrist unrt by unscrewing the three attach- Hamess ax 5-6 on page 27* ment screws.Two of the

26、 attachment screws are located visible at the rear attachment and the third is located at the bottom of the cable bracket, m the centx B: Atta匚hment screwsr rear of cable bracket, 2 pcs C: Attachment screw, bottom of cable bracket, 1 pc通过松开腕节单元顶端的3颗螺栓B:电缆支架后的螺栓,2颗来松开电缆支架C:电缆支架底部的螺栓,1颗有两颗螺栓是很容易看见的，还有

27、一 颗在电缆支架的底端中心处4.Pick out the cabling from motor, axis 6.4将电缆从轴6电机里面拉出来5.Loosen the cab旭 bracket in the upper arm tube by unscrew ng the two screws on top of the tube.Shown in the figure Location of cable harness ax 5-6 on page 27!5松开上臂管顶部的两颗螺栓来松开位置见上图电缆支架6.Disconnect ttie two connectors (R3.FB5 and

28、R3.MP5) im the tube.Shown in the figure Location of cable harness ax 5*时 on page 2716断开管子里面的两个插头R3.FB5和I位置见上图|R3.MP5)7.Remove eventual cable straps from the harness-移开最后的电缆扎带8.Remove the cable attachment, rearShown 泊 the figure Location of cable 血e&ss ax 5-£ on page 2718移开电缆夹，后面的位置见上图9.Disc

29、onnect connectors R2.M5/6 at the cable harness division pantShown in the figure Location of cable harness ax 5-6 on page 27!9断开电缆保护壳别离点的插头R2.M5/6 位置见上图10,Gently pull the cable harness out.10 轻轻地拉出保护壳F面讲如何撤除轴5的电缆1.Remove the complete wrist unit.Detailed in Removal of coinpfete wnst unit on page 47.1移

30、除腕节单元如何移除在后面有表达2.Remove the cover of motor, axis 5.2移除轴5电机的盖子3.Disconnect all connectors at motor, axis 5.1 3|断开轴5电机上所有的插头|4Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.4|通过松开电缆密封盖电缆出口处的两颗螺栓移除电缆密封管5.Remove the cable, axis 5.5移除轴5的电缆装回电缆保护壳机械手电缆保护壳位置如下列图HKAH3

31、2XO3O2-OM N1cBi7辄A Connector at manipulator base. R1 MP and R1 SMB机械手底座的插头，R1.MP和R1.SMBB Connectors at motor 1; R2.FB1 and R2.MP1 电机1的插头;R2.FB1及R2.MP1C Connectors at motor 2; R2.FB2 and R2 MP2 电机2的插头;R2.FB2及R2.MP2D Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6. R1 SMB1.7.R2.FB7 and R2

32、 SMB Battery connector X3 R1.G and R2.G. Connectors at brake release unit X8, X9 and X10.测量板上的插头;R1.SMB1-3, R1.SMB4-6, R1.SMB1.7, R2.FB7 及 R2.SMB 电池插头X3 R1.G及R2.G刹车释放单元的插头 X8,X9及X10E Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2 H2电机3的插头;R2.FB3及R2.MP3及信号灯插头R2.H1及R2.H2F Co

33、nnectors at motor 4, R2.FB4 and R2 MP4电机4的插头;R2.FB4及R2.MP4G Connectors at cable harness separation; R2.M5/6电缆保护壳别离处的插头；R2.M5/6H Connectors at cable harness division, inside of upper arm tube: R3 FB5 and R3.MP5.Connectors at motor 5; R4 FB5 and R4.MP5.电缆保护壳别离处的插头在上臂的管道里；R3.FB5和R3.MP5电机5的插头;R4.FB5及R4.

34、MP5J Connectors at motor 0, R3 FB6 and R3MP6电机6的插头;R3.FB6及R3.MP6KRear cover plate后盖板LConnector R IMP插头R1.MPMConnector R1 SMB插头R1.SMBN Connection of earth cable地线接头0 Velcro strap that secures the cable harness to the arm house保护尼龙带所需设备Catie harness, axes 1-43HAC1d&d(MIRB 6600电缆保护壳，轴1-4Cable harne

35、ss, axes 1-43HAC 16331*1IRB 6650电缆保护壳，轴1-4Cable harness, axes 5-63HAC 14140-1电缆保护壳,轴5-6Cable harness, ixis 63HAC 14139-1轴5电缆保护壳Circuit Diagram3HAC 13347-1Included in the Repair Manual, part2.电路图在维修手册2里面Standard toolkit3HAC 15571-1The contents are defined in section Standard tooikrt on page 13!标准工具内容

36、见前面详细表达其它工具或步骤见下面的详细说明装回轴1-4的电缆保护壳 下面详细表达如何装回轴1-4的电缆保护壳A在开始维修机械手之前需仔细阅读下面几条：在机器人运行后，电机和齿轮温度都很高，注意烫伤-关掉所有的电源、液压源及气压源-当移动一个部位时，做一些必要的措施确保机械手不会倒下来，如：当撤除轴2的电机时，要固定低处的手臂 : '电缆保护壳容易损坏，所以要小心，特别是接头处1 In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to run the manipu

37、lator to the specified position: improve access.2.为了更容易移除，请将机械手运行到如下位置Pull the cable and connectors down through the center of the frame轴2和3可以稍为斜起点Make sure the cables are not Uvisted with each other or with eventual customer harnesses!Make a note of the corect positions of the con ne ctors i2从结构的中间

38、放下电缆及插头注意电缆不要互相搅在起 注意插头的正确位置3.Reconnect connectors R1 MP and R1.SMB at the rear cover plateMake a note of the corect positians of the connectors!3 接上后盖处的插头R1.MP和R1.SMB4.Reconnect the earth cable.Shown in the figure Location of cab(eharness on page 3014接上地线位置见上图5.Refit the rear cover plate on the man

39、ipulator with its attachment screws.51上好后盖的螺栓6.Reconnect all connectors at motor 1 and motor 2.Specified in the figure Location of cable harness on page 3016接好电机1和电机2的插头位置见上图7Secure the gilandl plate with four attachment 5匚rews from inside the SMB recess.KliCOOOOlil从SMB里面上好密封盘8 Reconnect connectors

40、R2.SMB, R1.SMB1-3, R1.SMB4-6. Reconnect X8f X9and X10.F?econnect R1I,G if it has been disconnected接好插头 R2.SMB, R1.SMB1-3, R1.SMB4-6. 接好 X8,X9 和 X10.XS X9 X1D-R2.SMBR15MB3R1 .SMB4-E-X32QOCOC11S如果R1.G被断开了 ,也请接好9.Secure the SMB cover with its attachment screws用螺栓上好SMB盖子10Secure the correct adapter plat

41、e to the harness with its two attachment screwsNate! Different manipulator versions are fitted with different plate versions. Make sure the correct one is used to avoid cable failure.101上好保护壳的调节盘的两颗螺栓注意：不同的机械手有不同的 调节盘,请选择适宜的iikPull the cable harness through the lower arm.11将电缆保护壳穿过下臂12. Refit the br

42、acket secunng the cables inside the lower arm.>k31COODD142装回下臂上保护电缆的支架13. Refit the bracket securing the cables to the arm houseMake suire not to twist the harness!装回保护到手臂房的支架r1?QCCjC143确定保护壳没有打搅14.Reconnect all connectors at motor 3 and motor 4.Specified in the figure Location of cable harness o

43、n page 30!14接上电机3和电机4的所有插头位置见上图I15.Reconnect connector R2 M5 6 gently at the rear cable division point.Be careful not to bend the attachment plate when fasleming the screws!Shown in the figure LocatJon of cableharness on page 3012 pcs.15接上后面的电缆别离点的插头 R2.M5/6位置见上图 注意上螺栓时,不要将附盘弄弯了M6, 两颗16,Secure the c

44、able harness to the arm house with a velcro strap.Shown in the figureofcbleharness on page 30116上好到手臂房的电缆保护壳的尼龙带位置见上图轴5-6的电缆保护壳的位置如下列图所示A Cable bracket, wrist unit电缆支架,腕节单元B Cable bracketr upper arm tube电缆支架,上臂管C Connectors at motor axis 5; R4.FB5 and R4.MP5轴5电机插头;R4.FB5和R4MP5D Connectors in upper a

45、rm tube; R3.FB5 and R3.MP5 上臂管里的插头；R3.FB5和R3.MP5F Cable attachment, rear电缆夹,后面的G Connectors at cable harness division point； R2.M5/6电缆保护壳别离点的插头；R2.M5/6H Connectors at motor, axis 6： R3.FB6 and R3.MP6轴6电机插头;R3.FB6和R3.MP6下面详细表达如何装回上臂电缆保护壳，而轴5那段单独的到电机的电缆将紧接 着在后面讲述A 在开始维修机械手之前需仔细阅读下面几条：在机器人运行后，电机和齿轮温度都很

46、高，注意烫伤-关掉所有的电源、液压源及气压源当移动一个部位时，做一些必要的措施确保机械手不会倒必须将轴5导向正确的方向来翻开轴6电机的盖子下来，如：当撤除轴2的电机时，要固定低处的手臂电缆保护壳容易损坏，所以要小心，特别是接头处 Axis 5： +90 degrees- 亠一' . J . i . ii. 轴 6位置不重要2.Gently insert the cable harness from the rear into the upper arm.2轻轻地将电缆保护壳从后面插入到上臂3.Connect the two connectors inside the upper arm

47、 tube. R3.FB5 and R3.MP5 and secure the cable bracket wiith the two attachment screws to the tubeShown in the figure Location of cable harness axes 5-6 on page 33!3将上臂管里面的两个插头R3.FB5和位置见上图R3.MP5 连上,并用两颗螺栓将电缆支架装到管上In case of excess cablePlace the cabling to motor, axis 6, correctly on the upper arm an

48、d gently pull the connectors through the hole on top of wrist unit to motor, axis 6.装好轴6的电缆,在上臂的正确位置， 轻轻地将插头通过腕节单元顶端的 孔穿过至轴6的电机length: put a loop of cablle in this area with cable straps (A)P The cables are longer in order to fit different upper arm如果电缆长了，可以在这个区域 将电缆打个环，并用扎带捆住Also shown in the figur

49、e Location of cable harness axes 5-6 on page 33!Fasten the cable bracket, wnst unit with three attachment screws, two of them visible at the rear attachment point and the third Seated on the bottom of the cable bracketr in the center.用三颗螺栓上紧电缆支架，腕节单元, 其中后面两颗容易看见，第三颗位于 电缆支架底部的中心B:C:电缆支架后面的两颗螺栓 电缆支架底部

50、的螺栓Reconnect the connectors to motor axis 6 and refit the motor cover.A: coverh wrist unit重新连接到轴6电机的插头并装好电机盖子Refit the cover upper arm and the cover, wnst uniLMake sure the cabling is placed correctly when refitting the covers. and does not get jammed.装好上臂及腕节单元的盖子确定电缆装正确的，另外,装盖子时，不 要有挤压 B: coverr up

51、pearm tubeA:B:腕节单兀的盖子 上臂管的盖子8.Refit eventually removed cable straps to the harness.装好保护壳的扎带9.Refit the cabfe attachment fearShown in the figure Location of cable harness axes 5-6 on page 33!装好后面的电缆夹位置见上图10.Reconnect connector R2 M5/6 gently at the rear cable division point with two screws, M6. Be ca

52、reful not to bend the attachment plate when fastening the screws!Shown in the figureofcabieharness axes 5-6 on page 33!用两颗M6螺栓将后面的电缆别离点位置见上图的插头连上注意紧螺栓时，不要把附盘弄弯了F面表达如何装回轴5的电缆1.Reconnect all connectors at motorr sxis 5.1接好轴5电机的所有插头ABCGDEA Upper anri2. Refit the cable glmnH cover at the cable exiit wit

53、h3.1.3 Removal of complete arm system移除整个手臂系统整个手臂系统的定义就是整个机械手除了基座及轴1变速箱.也就是上下臂,平衡设备及构架，见下列图2用两颗螺栓将电缆出口处的电缆密封盖装好3.Refit the cover of motor, axis 5.3装好轴5电机的盖子4.Refit the complete wrist unitDetailed in section Refitting of complete wnst unit on page 504装好腕节单兀如何装腕节单兀后面有表达当进行一次维护维修,安装或保养过后,下面几点很重要：所有的工具及

54、其它不相关的物品都应拿走,不要留在机械手上了所有的正常的平安设备都正确地安装了,如:TPU使能设备-所有的人都应站在平安范围外-特别关注前次维修产生的效果its two atta匚hmERt screws上臂D Gearbox, axis 1齿轮箱，轴1EBase attachment screws基座螺栓FBalancing device平衡设备GBlock for calibration校准滑轮HMotor axis 1轴1电机需要的设备Lifting devicer manipulator3HAC 15607-1Instruction 3HAC 15971 -2 enclosed!吊装设

55、备，机械手3HAC 15607-1说明书 3HAC15971-2Standard toolkit3HAC 15571-1The contents are defined in section Standard toolkit on page 18!标准工具包3HAC 15571-1内容见维护手册其它一些特殊的工具会在以后的详细步骤里面指出F面详细表达如何升起及移除整个机械手系统A 在开始维修机械手之前需仔细阅读下面几条：在机器人运行后，电机和齿轮温度都很高，注意烫伤-关掉所有的电源、液压源及气压源-当移动一个部位时，做一些必要的措施确保机械手不会倒下来，如：当撤除轴2的电机时，要固定低处的手臂 、二整个机械