Precautions for Robot Handling and Installation
1.1、Unpacking the robot
• Six-axis industrial robots are shipped in a uniform wooden box. The bottom plate is fixed between the load- bearing portion of the package and the inner package; the inner package does not sway on the bottom plate is a force portion of the crane or forklift handling. The outer casing and the upper cover only play a protective role, the bearing capacity is limited, the heavy weight cannot be placed on the packaging box, and it cannot be dumped or rained.
• Please check if there is any damage before unpacking. If there is any damage, please contact the transportation or supplier. After confirming that there is no damage, use a crowbar, a wrench and other tools to remove the cover first, then remove the surrounding casing, taking care not to damage the inner product. Finally move the robot to a position that is ready to be fixed. Check that the robot system components are complete according to the checklist provided below.
note: The above is only a list of machine configurations. It may be packaged. If there are two or more internal devices, the configuration list will be multiplied by the standard. For details, please check the shipping list, which is subject to the shipping order.
1.2、Requirements for installing the robot
• The ambient temperature should be between 0 and 45 ° C (32 to 113 ° F) during operation and -10 to 60 ° C (14 to 140 ° F) during handling and maintenance.
• Must be used in an environment with an average altitude of 0-1000M.
• The humidity must be below the dew point (less than 10% relative humidity).
• Locations with less dust, oil, fumes, and water.
• Flammable materials and corrosive liquids and gases are not allowed in the work area.
• Locations where the vibration or impact energy of the robot is small (vibration below 0.5G).
• There should be no large electrical noise sources (such as gas shielded welding (TIG) equipment), electromagnetic interference sources, and electrostatic discharge. • There is no potential hazard of collision with moving devices such as forklifts.
1.3、Robot installation
• First ensure the robot installation environment and space, and the robot installation location. The plant layout, ground leveling, power supply, etc. of the robot installation should be evaluated first, and then the robot position should be arranged according to the range of motion described. To ensure that the robot has enough space for movement, if there is a corresponding application space, refer to the instruction manual or contact the supplier to determine whether it can be used safely. Refer to the operating range and parameters of the equipment in the following chapter for details of the robot's motion range.
• After confirming the installation position, use a tool such as a forklift to transport the robot to the installation position. The robot must be firmly fixed in the installation position because the robot itself has a large inertia when moving. If the installation position is not heavy enough or the installation is unstable, it is easy causes the robot to dump excessively due to excessive force, causing unnecessary damage. It may even damage personal safety.
• The safety fence is designed to prevent people from entering the robot's range of motion or colliding with the robot to prevent personal injury.
• After placing the robot and control box, insert the power box control cabinet cable and body. Control cabinet cable plugging Note: First of all, for the power and code socket, gently close the socket and lock it tightly. If the force is too strong, the socket will be damaged. According to the six-axis robot electric box nameplate identification, connect the corresponding power supply. Note that the equipment must be grounded to the ground and ensure good grounding. Finally, insert the teaching box into the control box.
• Other installations and port wiring, please check the relevant information or consult the agent.
1.4、Robot inspection test before leaving the factory
The components used in the equipment are purchased strictly according to the requirements. The hardware and so on must be tested strictly according to the drawings. After passing the assembly, the finished products are assembled. The assembled semi-finished products also need to be inspected according to the requirements before they can flow into the next process. Please check the inspection items attached to the machine for details. Each robot will do several important tests and checks before leaving the factory.
1. Whether the parts of the robot body are installed stably, whether they meet the installation requirements, and whether the appearance has scratches. Whether the connection line between the robot and the control box is normal, whether the buttons of the teaching box are valid, and whether the commands of the touch screen can be normally received.
2.Whether the robot control box emergency stop button, teaching box emergency stop button, and brake release button can work normally.
3.Speed test. First, the speed test of the manual movement is performed in the teaching mode. When the joint mode, right angle mode, and tool coordinate coordinate mode are tested, whether the motion speed is within the standard range, and then modify the speed to see if the speed control is valid.
4.Stability test. A general test program has been written in the company. Each axis of the robot performs the maximum range of motion, and the speed is incremented step by step and then decremented step by step. After running for a certain period of time, the test machine is stable.
5.Qualified after the above tests and inspections (within the specified range). The robot is a high-precision installation equipment, and it is inevitable that errors will occur during installation. In order to prevent the accuracy of the robot movement, each machine must be subjected to precision instrument calibration detection and compensation correction before leaving the factory. In the reasonable accuracy range, the shaft length, the speed reducer, the eccentricity and other parameters are compensated to ensure the equipment movement and the track accuracy. After the calibration compensation is within the qualified range (see the calibration table for details), if the compensation commissioning is not within the qualified range, it will be returned to the production line for re-analysis, debugging and assembly, and then calibrated until qualified.
1.5、First use of robot production attention
When the robot is used for the first time and the program has been programmed to be ready for production, a safety test is required:
The test should be run in a single step to confirm whether each point is reasonable and whether there is a risk of impact.
Reduce the speed to a standard that can be reserved for sufficient time, then run, and test whether the external emergency stop and protective stop are normal use, whether the program logic meets the requirements, whether there is a risk of collision, and need to be checked step by step.
Note: The test procedure must be followed by a single step in the order of the program action.
1.6、Precautions of changing robot parts
When changing the robot components, including updating the system software, it is necessary to be operated by a professional, and the test is performed by a professional to meet the usage requirements before being used again. Non-professionals are prohibited from performing such operations.
Confirm the operation under power off.
Turn off the input power first, then disconnect the output and ground cable.
Do not use too much force when disassembling. After replacing the new device, connect the output and ground wire before connecting the input cable.
Finally check the line and confirm before power on to testing.
Note: Some key components may affect the running track after replacement. In this case, you need to find the reason, whether the parameters are not restored, whether the hardware installation meets the requirements, etc. If necessary, you may need to return to the factory for calibration to correction for hardware installation errors.
1.7、Safeguard
Robots are often different from other mechanical equipment, such as its large range of motion, fast operation, and rapid movement of the arms, all of which pose a safety hazard.
Read and understand the instruction manual and related documents, and follow the various procedures to avoid personal injury or equipment accidents. It is the responsibility of the user to ensure that their safe operating environment complies with and complies with local and national safety laws and regulations.
• The teaching and maintenance of robots must comply with the following regulations:
- Law on industrial safety and health.
- Mandatory order regarding industrial safety and health laws.
- Corresponding regulations on industrial safety and health laws.
Other relevant laws are:
- American occupational safety and health law.
- German factory law.
- UK work safety and health law.
- EU's 89/392 Machinery Industry Directive and the European Community's 91/368.
• Prepare
- Safety technical rules
Conduct safety management in accordance with specific policies that comply with relevant regulations.
• Observe
- Safe operation of industrial robots (ISO 10218).
• Supplement
- Safety management system
Designate authorized operators and safety managers and provide further safety education.
• The work of teaching and repairing robots is included in the “dangerous operation” of industrial safety and health laws.
• Never lean on a robot or other control cabinet;Don't push the action button at random
Otherwise, it may cause unexpected movements of the robot, resulting in personal injury and equipment damage.
• During operation, no non-staff member is allowed to touch the robot.
Otherwise, it may cause unexpected movements of the robot, resulting in personal injury and equipment damage.
1.8、guidelines for rescuing trapped personnel
When the robot starts to run, it is necessary to make sure that no one is in the range of motion of the robot. If there are still workers trapped by the robot, please carefully perform the following steps:
1. When a worker is found trapped, he/she should immediately take a quick stop to stop the operation of the equipment.
2. Rescue personnel will hold the robot beside, but the robot should not move to avoid greater harm to trapped personnel.
3. Open the protection device and press the button of manually unlocking the brake, then the rescue personnel will move the trapped robot manually and rescue the trapped personnel.