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TRANSPORTATION AND INSTALLATION MANUAL Notice Make sure that this instruction manual is delivered to the final user of Toshiba Machine’s industrial robot. Before operating the industrial robot, read through and completely understand this manual. After reading through this manual, keep it nearby for future reference.
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TRANSPORTATION AND INSTALLATION MANUAL Copyright 2007 by Toshiba Machine Co., Ltd. All rights reserved. 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.
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TRANSPORTATION AND INSTALLATION MANUAL Preface This manual describes the basic specifications of the industrial robot and controller, and how to unpack and install them. Specifically, it describes how to unpack the shipment containing the equipment, how to install the equipment, how to connect wiring and air piping, and how to attach tools.
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TRANSPORTATION AND INSTALLATION MANUAL Precautions on Safety Important information on the robot and controller is noted in the instruction manual to prevent injury to the user and persons nearby, prevent damage to assets and to ensure correct use. Make sure that the following details (indications and symbols) are well understood before reading this manual.
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Wiring the robot before installation could lead to electric shocks or injuries. • Always use the power voltage and power capacity designated by Toshiba Machine. Failure to do so could lead to device faults or fires. • Always use the designated power cable. Using a cable other than that designated could lead to fires or faults.
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION • NEVER lift the robot by the arm 2 cover or arm 2. Doing so will apply an excessive force on the robot's mechanism section and could lead to faults. • For the controller, secure the ample space for air vent. Heating of controller could lead to malfunction.
TRANSPORTATION AND INSTALLATION MANUAL Table of Contents Page Specifications ......................10 Name of Each Part ..................10 External Dimensions ..................11 Specifications Table ..................12 Transportation ......................14 Unpacking ...................... 14 Transportation ....................16 2.2.1 Mass and Dimensions ............... 16 2.2.2 Transporting the Robot ..............
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TRANSPORTATION AND INSTALLATION MANUAL 4.1.3 Connecting the Motor Cable “MOTOR” ( of Fig. 4.1) (Cable attached) ......................36 4.1.5 Connecting the Robot Control Signal Cable “HAND” ( of Fig. 4.1) (Cable: option) ................... 37 4.1.6 Connecting and Disconnecting Cables ..........37 4.1.7 Examples of Connector Terminal Arrangement ........
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TRANSPORTATION AND INSTALLATION MANUAL Tables and Drawings Page Fig. 1.1 Name of each part ....................10 Fig. 1.2 External dimensions of the robot ................ 11 Fig. 2.1 Packaging state ....................15 Fig. 2.2 Outer dimensions at transport ................16 Fig. 2.3 Lifting up the robot ..................... 17 Fig.
TRANSPORTATION AND INSTALLATION MANUAL Specifications Name of Each Part Fig. 1.1 shows the name of each part of the robot. Axis 2 (rotation) Cover Ball screw spline Axis 1 (tool shaft) (rotation) Eyebolt Arm 2 Tool flange Arm 1 Axis 3 (vertical Battery box movement) Base...
TRANSPORTATION AND INSTALLATION MANUAL External Dimensions Fig. 1.2 refers to the external dimensions of the robot. Fig. 1.2 External dimensions of the robot STE 85305 – 11 –...
TRANSPORTATION AND INSTALLATION MANUAL Specifications Table Item Specifications Structure Horizontal multi-joint type SCARA robot Model TH650A Applicable controller TS2100 Mass of actuator 52 kg No. of controlled axes Four (4) Arm length 650 mm (300 mm + 350 mm) Axis 1...
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TRANSPORTATION AND INSTALLATION MANUAL When the mass of load exceeds 2 kg, or when the gravity center position of load is away from the axis 4 center position, both the speed and acceleration should be reduced, using the PAYLOAD command. Shuttle time for rough positioning in horizontal direction of 300 mm and vertical direction of 25 mm.
TRANSPORTATION AND INSTALLATION MANUAL Transportation Unpacking The robot and controller are shipped separately in corrugated cardboards. Fig. 2.1 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed. Take careful precautions not to damage the robot and controller. After opening the packages, make sure that all the accessories are present and that nothing has been damaged during transport.
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If any parts of the equipment are found damaged or any accessories are missing after the shipment containing the robot and controller have reached your office, DO NOT install and operate them. Otherwise, the equipment will malfunction. Contact Toshiba Machine immediately. • Dispose of the wooden pallet, corrugated cardboards, polyethylene shipping bags and cushion material according to the customer’s in-house regulations.
TRANSPORTATION AND INSTALLATION MANUAL Transportation Move the robot and controller very carefully. Make sure that no excessive impact or vibration is exerted on the equipment. If the equipment is to be subject to vibration over a long period, be sure to tighten all the clamp and base set bolts completely. If the equipment is to be moved to a location some distance from where it was unpacked, reposition the cushions as they were and put the equipment back into the corrugated cardboards.
TRANSPORTATION AND INSTALLATION MANUAL 2.2.2 Transporting the Robot In principle, the robot should be transported in the state shown in Fig. 2.2 above. Fold back and secure the arm with the attached clamp. (The robot is shipped in this posture. After you have unpacked the shipment, you should move it as it is.) At this time, take careful precautions not to impose a large force on the tool shaft.
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION • The wire to be used should be such that can well withstand the mass of the robot. • When lifting up the robot, it may tilt a little. Lift it up slowly. • Lifting up and down should be performed carefully so that any impact cannot be exerted on the robot.
TRANSPORTATION AND INSTALLATION MANUAL CAUTION • When lifting up the robot by workers, hold the locations (shaded areas) by hands as shown in Fig. 2.4. If the arm 2, cover or ball screw spline shaft is held by hands, an unusually large force is exerted, resulting in a malfunction.
TRANSPORTATION AND INSTALLATION MANUAL Storage Avoid storing the robot and controller for long periods of time after unpacking them. If this is unavoidable, however, strictly observe the following precautions for storage. 2.3.1 Storage Precautions for the Robot CAUTION • Secure the base completely to prevent the robot from falling over. When placed directly on the floor, the robot is unstable and will fall over.
0.98m/s or less Dust No inductive dust should exist. Consult with Toshiba Machine first if you wish to use the robot and controller in a dusty environment. No corrosive or combustible gas should exist. Sunlight The robot and controller should not be exposed to direct sunlight.
Also, high temperatures can reduce the performance and lifespan of the battery. If using the robot under high temperatures, please consult with the Toshiba Machine sales office. When starting fast-movement operation in low-temperature environment, errors may occur because of the increased torque. In operating the robot in...
TRANSPORTATION AND INSTALLATION MANUAL 3.2.2 Working Envelope Fig. 3.2 shows the working envelope of the robot. Each axis can operate within the working envelope. To prevent the robot from moving out of the working envelope by mis-operation, the robot is equipped with mechanical stoppers outside the working envelope.
TRANSPORTATION AND INSTALLATION MANUAL 3.2.3 Coordinate System The robot's joint angle origin (0° or 0 mm position) is factory-calibrated according to the base reference planes. Fig. 3.3 shows the base coordinate system and origin of each axis joint angle. Reference Reference plane plane...
TRANSPORTATION AND INSTALLATION MANUAL 3.2.4 Installing the Robot The robot is secured, using the set holes on the base (four (4) places). Use M16 hexagon socket head cap screws. The robot installation method is shown in Fig. 3.4. Reference planes are provided on the base unit.
TRANSPORTATION AND INSTALLATION MANUAL Installing the Controller 3.3.1 External Dimensions External view of the controller is shown in Fig. 3.5. Mass of controller: 17 kg Fig. 3.5 External view of controller STE 85305 – 27 –...
TRANSPORTATION AND INSTALLATION MANUAL 3.3.2 Precautions for Direct Installation It is necessary to provide a clearance of 50 mm or more in the horizontal direction and a clearance of 100 mm or more in the upward direction near the controller. When installing the controller lengthwise, be sure to locate the right lateral side for sideways installation at the bottom side.
TRANSPORTATION AND INSTALLATION MANUAL 3.3.3 Rack Mounting Dimensions When mounting the robot controller in a rack, set the side brackets using the screw holes provided on both ends of the front panel, and secure the controller to the rack. The side brackets [1] in Fig. 3.7 are optional. Fig.
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TRANSPORTATION AND INSTALLATION MANUAL As the cable connectors are connected to the rear side of the controller, provide a space of 110 mm on the rear side. For maintenance, the upper cover should be removed. (See Fig. 3.8.) Keep this in mind when installing the controller. At maintenance, the controller should be removed from the rack.
TRANSPORTATION AND INSTALLATION MANUAL When the controller is mounted on the rack, the weight of the controller should be supported with the legs of the controller. Screw holes for rack-mounting the controller are used for securing the controller panel, and the weight of the controller cannot be supported only with these screws.
TRANSPORTATION AND INSTALLATION MANUAL Safety Measures When installing the robot, provide sufficient space to carry out the work safely. Clarify the hazard zone, and provide a safety fence so that other persons cannot enter the zone easily. The hazard zone is the zone near the robot's working space where a hazardous state could occur if a person enters.
TRANSPORTATION AND INSTALLATION MANUAL System Connections Cable Wiring This section describes the various types of cables and connectors and explains how these are to be connected. 4.1.1 Connector Arrangement on the Controller The cables connected to the robot controller are shown in Fig. 4.1. Fig.
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TRANSPORTATION AND INSTALLATION MANUAL In the subsequent paragraphs, we explain how to connect cables to inclusive. For information on how to connect cables , and , refer to the Interface Manual. 4.1.2 Connecting the Power Cable “CN1” ([1] of Fig.
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TRANSPORTATION AND INSTALLATION MANUAL DANGER • Be sure to use the designated wire. Failure to do so could lead to fires or faults. • When connecting the connector and wires, make sure not to mistake the terminal arrangement. • After making the connection, use a tester, etc., to confirm the connection. For the terminal arrangement, see Para.
TRANSPORTATION AND INSTALLATION MANUAL 4.1.3 Connecting the Motor Cable “MOTOR” ( of Fig. 4.1) (Cable attached) The motor cable connects the controller and robot, and supplies the power required to rotate the motor from the controller servo driver to each axis feed motor of the robot. The connector for connecting the motor cable is MOTOR (...
TRANSPORTATION AND INSTALLATION MANUAL 4.1.5 Connecting the Robot Control Signal Cable “HAND” ( of Fig. 4.1) (Cable: option) The robot control signal cable is used for motor brake ON and OFF, and input and output of robot control signals such as hand operation signal. The connector for connecting the robot control signal cable is HAND (...
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TRANSPORTATION AND INSTALLATION MANUAL Square connectors: ENC, HAND, SYSTEM, INPUT, OUTPUT, TRIG, CONV Firstly, completely insert the cable side connector into the controller connector. Then tighten the lock screws on both ends of the cable side connector with a screwdriver. A loose screw can cause a contact failure or other accident. To avoid this, make sure that the screws are clamped completely.
TRANSPORTATION AND INSTALLATION MANUAL 4.1.7 Examples of Connector Terminal Arrangement Power cable connector ACIN Connects to controller. Type: DANGER JL04HV-2E22-2 • Completely connect the 2PE-B grounding cable. Manufacturer: Otherwise, an electric Japan Aviation shock or fire may be Electronics Industry caused if a fault or electric leak occurred.
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TRANSPORTATION AND INSTALLATION MANUAL Universal input signal cable connector INPUT Connects to controller. Type: DHA-RC36-R132N-FA Manufacturer: DDK, Ltd. Universal output signal cable connector OUTPUT Connects to controller. Type: DHA-RC40-R132N-FA Manufacturer: DDK, Ltd. System input/output signal cable connector SYSTEM Connects to controller. Type: 52986-5079 Manufacturer: Molex Trigger input connector TRIG...
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TRANSPORTATION AND INSTALLATION MANUAL Emergency stop, safety input, and external P24V supply connector EMS Connects to controller. Type: ML-4000CWJH-10PGY Manufacturer: SATO PARTS Brake connector BRK Connects to controller. Type: 1-1827876-6 Manufacturer: TYCO ELECTRONICS AMP STE 85305 – 41 –...
TRANSPORTATION AND INSTALLATION MANUAL Controller Connector Signals 4.2.1 Connector Signal Connection Diagrams Diagrams showing which signals correspond to which terminals are shown in Section 2 of the Interface Manual. 4.2.2 Jumpers for Safety Related Signals The following system input signals are provided to serve for the safety purpose. System input signals SYSTEM-12 ( STOP )
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Unless the signals of SVOFF and emergency stop contacts 1, 2 are jumpered, the controller servo power cannot be turned on. • Unless the CYCLE signal is jumpered, the controller enters the cycle operation mode.
TRANSPORTATION AND INSTALLATION MANUAL Separating Control Panel from Controller 4.3.1 Removing Control Panel Remove the control panel in the following manner. Loosen the four (4) screws at the four (4) corners, which secure the control panel. Remove these screws, then carefully draw out the control panel toward your side. Caution: Be careful of the cable connected on the rear side.
TRANSPORTATION AND INSTALLATION MANUAL 4.3.3 Control Panel Mounting Dimensions The dimensions of mounting the control panel are shown in Fig. 4.6. Cross truss head screws (ø3×6, ZN3–B) are used. Fig. 4.6 Control panel mounting dimensions STE 85305 – 45 –...
TRANSPORTATION AND INSTALLATION MANUAL 4.3.4 Mounting Dummy Panel on Controller When the control panel has been disengaged from the controller, mount a dummy panel on the place where the control panel was set before, as shown in Fig. 4.7. The dummy panel, set parts, etc.
TRANSPORTATION AND INSTALLATION MANUAL 4.3.5 Dimensions when Separating Control Panel Fig. 4.8 shows the connections of the control panel and dummy panel. Provide a clearance of 50 mm or more (with cover, 60 mm or more) on the rear side of the separated control panel.
TRANSPORTATION AND INSTALLATION MANUAL Tool Interface Mounting Tool The tool is mounted on the end of the tool shaft. Dimensions of the tool shaft section are shown in Fig. 5.1. As shown in Fig. 5.1, the tool is centered with the ø20H7 mating section. The tool direction is adjusted by means of the 5 ×...
TRANSPORTATION AND INSTALLATION MANUAL Tool Wiring and Piping The robot is provided with wiring and air piping for the tool. These wiring and piping extend to the arm 2 and are used as follows: 5.2.1 Tool Signals (Controller Side) The controller is provided with the tool signals of eight input signals for sensors, eight control signals for solenoid valves, DC24 V (P24V) signal, and DC24 V GND (P24G) signal.
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TRANSPORTATION AND INSTALLATION MANUAL a-2) Input signal connector HAND (Type-P) Signal Input circuit and example of Signal name connections Input D-IN0 signal 0 Input D-IN1 Customer’s side signal 1 Input D-IN2 signal 2 Input D-IN3 signal 3 Input D-IN4 signal 4 Contact or transistor Input...
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TRANSPORTATION AND INSTALLATION MANUAL b-1) Output signal connector HAND (Type-N) Input circuit and example of Signal name Signal No. connections Output D-OUT0 signal 0 Customer’s side Output D-OUT1 signal 1 DC relay Output D-OUT2 signal 2 Output DOUT3 signal 3 Output D-OUT4 Diode for preventing...
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TRANSPORTATION AND INSTALLATION MANUAL b-2) Output signal connector HAND (Type-P) Input circuit and example of Signal name Signal No. connections Output D-OUT0 signal 0 Customer’s side Output D-OUT1 signal 1 Output D-OUT2 signal 2 DC relay Output D-OUT3 signal 3 Output D-OUT4 signal 4...
TRANSPORTATION AND INSTALLATION MANUAL 5.2.2 Tool Wiring Five (5) input signals are provided for sensors, etc. and four (4) control signals for solenoid valves, etc. A supply power signal of P24V is also provided. They are connected to the controller. The wiring arrangement for these cables is shown in Fig. 5.2.
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TRANSPORTATION AND INSTALLATION MANUAL JOFP JOEP JOES JOFS From PLC, etc. Grommet inner dia. 7 mm JOES JOFS Disconnect. Cable inlet (2 places) (HAND side) Fig. 5.2 Wiring to PLC, etc. Input/output signal connector CN0 (Type-N) Signal Input/output circuit Signal name (D-SUB) and example of connections (Cannon)
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TRANSPORTATION AND INSTALLATION MANUAL Input/output signal connector CN0 (Type-P) Signal Input/output circuit Signal name (D-SUB) and example of connections (Cannon) Not used User side TS3100 Not used P24V Not used D-IN0 Input signal 0 D-IN1 Input signal 1 Contact or transistor D-IN2 Input signal 2...
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TRANSPORTATION AND INSTALLATION MANUAL As input signals, no-voltage contacts or transistor open collector inputs are used. No-voltage contact specifications: Contact rating: DC24 V, 10 mA or over (circuit current: approx. 7 mA) Minimum contact current: DC24 V, 1 mA Contact impedance: 100 Ω or less Transistor specifications: Withhold voltage between collector and emitter: 30 V or over Current between collector and emitter: 10 mA or over (circuit current: approx.
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TRANSPORTATION AND INSTALLATION MANUAL Wiring panel Details of wiring panel 4xM5 air joint for hand CN0 hand connector D-SUB connector 4xM5 air joint for hand CN0 hand connector JOFP JOEP Cannon connector JOFS JOES (option) JOEP JOES JOFS JOFP hand connector Connect to TS3100.
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TRANSPORTATION AND INSTALLATION MANUAL To brake OFF switch Robot base section To motor brake Arm 2 top surface of robot To TS3100 Customer’s side: Plastic connector JOES: SMP-07V-BC*JST JOFS: SMP-06V BC*JST To PLC (To be Contact: BHF-D01T-0.8SS*JST connected by customer.) Fig.
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TRANSPORTATION AND INSTALLATION MANUAL The cables are connector-connected at the upper side of the arm 2 cover. The wiring panel on the upper side of the same cover can also be mounted on the lower side of the arm 2. The following three (3) manners are available for the tool wiring and piping.
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TRANSPORTATION AND INSTALLATION MANUAL Cover Remove the cover at the lower side 4. Mount the wiring panel which was of the arm 2. dismounted in Step 2. Guide Bracket The cables connecting the panel with the actuator are fabricated long so that the panel can be mounted on the lower side, and are secured to the bracket with TY-RAP.
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Be sure to connect all connectors properly. Otherwise, the robot may malfunction. • Take careful precautions not to interfere the cables with the belts. Otherwise, the cables may break. • When relocating the panel, take utmost care not to damage the belts. STE 85305 –...
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TRANSPORTATION AND INSTALLATION MANUAL Tool connection by using the hollow hole (18 mm-dia.) on Z-axis ball screw shaft. Fixed stay (To be provided by customer.) Tool connection by attaching the fixed stays to the lower side of the arm. Tool connection by mounting the wiring panel on the lower side of the arm.
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Be sure to use a highly flexible robot cable, which should be secured below the arm with a cable clamp, etc. Unless a robot cable is used, the wire may be broken. • When performing tool wiring and piping, take all necessary measures against breakage due to rub, etc.
TRANSPORTATION AND INSTALLATION MANUAL The air tube is identified by the number and color. At piping, make sure that each tube is connected properly, referring to the below-mentioned. 1 : Red 2 : White 3 : Blue 4 : Yellow D-SUB connector Cannon connector (option) Fig.
TRANSPORTATION AND INSTALLATION MANUAL Permissible Load Conditions and Program Setting This paragraph describes the permissible load conditions of the robot and how to set up the program according to the load. 5.3.1 Permissible Load Conditions The robot load conditions are defined by the tool mass, moment of inertia and offset value of tool gravity center from the center of the tool shaft, as shown in Fig.
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TRANSPORTATION AND INSTALLATION MANUAL Tool gravity center Robot arm Moment of inertia Tool Offset value of gravity center Fig. 5.8 Robot tool 5.3.2 Load Conditions and Program Setting This robot can automatically change the maximum speed, acceleration/deceleration and servo gain by using the PAYLOAD command in the program according to the load conditions.
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TRANSPORTATION AND INSTALLATION MANUAL • The servo gain of each robot axis is automatically changed according to the set load conditions. Program examples Basic program examples using the PAYLOAD command are shown below. For further information, see the Robot Language Manual. (Program example 1) The robot is moved under the load conditions of 5 kg mass and 100 mm gravity center offset.
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TRANSPORTATION AND INSTALLATION MANUAL DELAY 1 PAYLOAD={3,30} MOVE P2+POINT(0,0,100) GOTO LOOP FIN: MOVE P0 DOUT(1) STOP Setting of PAYLOAD command In the default state, or when the PAYLOAD command is not used, the maximum speed and acceleration/deceleration are set to 100 % and the servo gain is set to the value under the minimum load.
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION • When guiding manually, the robot may vibrate if the load mass or gravity center offset is large. This is because the servo gain is not appropriate. When this happens, perform the following operation while setting the load conditions in the test run mode.
TRANSPORTATION AND INSTALLATION MANUAL 5.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration for Load Conditions When the PAYLOAD command is used, the maximum speed and acceleration/deceleration of the robot are automatically changed according to the load conditions. The maximum speed and acceleration/deceleration change with the load mass, as shown in Fig.
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TRANSPORTATION AND INSTALLATION MANUAL Additionally, if there is an offset of load gravity center, the maximum speed and acceleration/deceleration change as shown in Fig. 5.10 and Fig. 5.11. For the axis 3, however, no restriction is imposed on the offset. Load mass =<...
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TRANSPORTATION AND INSTALLATION MANUAL Load mass =< 2 (kg) Load mass =< 2 (kg) 2 (kg) < Load mass =< 5 (kg) 2 (kg) < Load mass =< 5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in...