BC6 Assembly Guide
November, 2018
Draft 1
Contents
Contents
1
Overview...............................................................................................................3
1.1
1.2
2
3
Safety .....................................................................................................................5
Before You Begin.................................................................................................6
3.1
3.2
3.3
3.4
4
Fitting the Robot Controller onto the Frame ................................................... 15
Interface Panel Assembly ................................................................................18
7.1
7.2
8
Unpacking the Robot Arm ................................................................................. 10
Preparations ......................................................................................................... 10
Attaching the Robot ............................................................................................ 12
Installing the Robot Controller ......................................................................15
6.1
7
The Return Conveyor............................................................................................8
Preparation .............................................................................................................8
4.2.1
Mounting the Return Conveyor .........................................................8
Attaching the Robot ..........................................................................................10
5.1
5.2
5.3
6
Required Materials and Equipment ....................................................................6
Workflow ................................................................................................................6
Pre-Assembly Procedures ....................................................................................6
3.3.1
Work Area .............................................................................................6
3.3.2
Components ..........................................................................................7
3.3.3
Inspecting the Frame ............................................................................7
3.3.4
Inspecting All Parts of the Assembly .................................................7
Directional Definitions for the assembly of the BC6.........................................7
Assembly Guide ..................................................................................................8
4.1
4.2
5
About This Document...........................................................................................3
Terms and Acronyms............................................................................................3
Preparation ........................................................................................................... 18
Mounting the Interface Panel Assembly .......................................................... 18
Front Door Emergency Off (EMO) Assembly .............................................20
8.1
8.2
Preparation ........................................................................................................... 20
Attaching the Front Door EMO ......................................................................... 20
9 White Columns ..................................................................................................21
10 Assembling the Sub-Assemblies ...................................................................22
10.1
10.2
10.3
10.4
Return Conveyor / Separator Wall .................................................................... 22
Robot Controller .................................................................................................. 25
10.2.1
Robot Controller Mounting brackets ............................................... 25
Interface Panel Assembly ................................................................................... 27
10.3.1
Main Emergency Switch .................................................................... 28
10.3.2
Pneumatic Unit Assembly ................................................................. 31
10.3.3
The Air Connection ............................................................................ 31
EMO Panel Assembly ......................................................................................... 32
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1
Overview
1.1
About This Document
This document describes the procedure for assembling the Bright Machines BC6.
It is divided into two parts:

BC6 assembly instructions for assembling the BC6

BC6 sub-assembly instructions for assembling components that are used in
the main BC6 assembly instructions
It is recommended to assemble and prepare the sub-assembly components before
beginning the BC6 assembly.
This document is meant to be used by those involved in assembling the BC6 and
its components.
Note
Some assembly procedures, such as connecting electrical components, must
only be performed by qualified personnel.
IMPORTANT!
Review and follow the safety requirements before beginning the assembly. For
more information, see section 2 “Safety”.
1.2
Terms and Acronyms
The following terms and acronyms are used throughout this document:
Term
Description
BOM
Bill of materials
RHS
Right Hand Side
LHS
Left Hand Side
LH
Left Hand
RH
Right Hand
ASSY
Assembly
REV
Revision
IPA
Interface Panel Assembly
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Term
Description
EMO
Emergency Off
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2
Safety
IMPORTANT!
Review and follow the safety requirements before beginning the assembly.
It is important to take note of the following safety requirements:

Wear proper work boots (such as steel-toe boots), or boot-saver toe guards at
all times during the assembly.

Wear gloves when lifting heavy parts of the unit.

Take note of the number of people required to lift and position certain
components. Attempting to lift heavy items without the correct number of
people can cause personal injury and/or damage to the component.
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3
Before You Begin
3.1
Required Materials and Equipment
To assemble the BC6 you will need the following materials and equipment:
3.2

Isopropyl alcohol (IPA)

Soft cloth

BOM

Set of drawings

Set of hex (Allen™) keys

Step-ladder

Forklift

Ratcheting socket wrench set

Utility knife with a sharp blade

Torque wrench

Philips screwdrivers

Adhesive protective plastic dispenser on bench

Sheets of cardboard (or a blanket) for protecting surfaces of the BC6
Workflow
1.
Pre-Assembly Procedures
2.
…
3.3
Pre-Assembly Procedures
3.3.1
Work Area

Set up the frame on its wheels in a room or area that is at least 4m x 4m in
size.

Prepare a working table of at least 1.5m x 1m for assembly of smaller
components.
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3.3.2
3.3.3
3.3.4
3.4
Components

Ensure that a complete range of screws, flat washers (normal and wide), and
spring washers is available.

Ensure that all items listed on the BOM are available. This ensures that there
are no delays in the assembly process.
Inspecting the Frame
1.
Visually inspect the whole frame for scratches, blemishes or other defects.
2.
Using IPA and a soft cloth, clean and dry the entire frame.
Inspecting All Parts of the Assembly
1.
Visually inspect all other parts for scratches, blemishes or other defects.
2.
Compare the number and position of screw holes, bolt holes, and studs to the
drawings. If any are missing or are out of place, do not proceed with the
assembly.
3.
Visually inspect all threaded holes and re-tap any holes that are damaged or
blocked with paint build-up.
Directional Definitions for the assembly of the BC6.
The definitions for left and right, and front and back for the main BC6 assembly
are as shown below.
[Double-click to insert figure here]
Figure 1
[Figure Caption]
The definitions for left and right, and front and back for all sub-assemblies are as
shown below.
[Double-click to insert figure here]
Figure 2
[Figure Caption]
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4
Assembly Guide
It is recommended to assemble all sub-assemblies before beginning the main
assembly procedure. For instructions on assembling sub-assemblies, see section 10
“Assembling the Sub-Assemblies”.
4.1
The Return Conveyor
This part is also known as the “Separator Wall” and is used as a channel for the
removal of unwanted or defective parts.
Refer to drawing no. XXXXXX
4.2
Preparation
Assemble the return conveyor. For instructions, see section 10.1 “Return
Conveyor / Separator Wall”.
4.2.1
Mounting the Return Conveyor
1.
Carry the return conveyor to the frame and insert in position as shown.
CAUTION!
Heavy part! Four (4) people are required to put the return conveyor in place.
Note
When viewed from the front of the BC6, the conveyor’s open sides run from left
to right.
Figure 3
Installing the Return Conveyor
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2.
Secure the return conveyor using eight (8) M5x12 screws with flat washers
and spring washers.
Once secured, the return conveyor appears as shown.
Figure 4
Return Conveyor installed
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5
Attaching the Robot
This is the robot that performs automated commands. It is mounted to the underside of the top of the frame.
Refer to drawing no. XXXXXX
5.1
Unpacking the Robot Arm
The Robot arrives assembled and includes the following components:

Robot - balloon 37

Controller

Cables (attached to the controller)

Remote-control unit
When opening the cardboard boxes, take care that the contents are not damaged
in any way.
Remove all packaging materials from the area so that the work space is kept clean.
5.2
Preparations
Parts
Make sure that the following items are readily available before beginning this part
of the assembly:

Robot

Forklift

Four (4) M10x65 socket-head cap-screws

Eight (8) M10 nuts

Eight (8) M10 flat washers

Four (4) spring washers
Prepare four sets of these items in preparation for the attachment of the Robot.
Each set contains:

One (1) M10x65 screw

Two (2) M10 nuts

Two (2) flat washers

One (1) spring washer
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Damage Protection
Protect the frame’s base plate from damage by covering it with a blanket or
cardboard.
Figure 5
Frame base plate
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5.3
Attaching the Robot
CAUTION!
Heavy part! Four (4) people are required to put the robot in place.
Procedure:
1.
Insert the four (4) M10 screws with one flat washer each through the top of
the frame from the outside as shown.
Figure 6
2.
Robot bolts from top of frame
Carefully place the Robot onto the “forks” of the forklift as shown.
[Double-click to insert figure here]
Figure 7
3.
[Figure Caption]
Turn the Robot on the forklift so that its connector is facing the RHS of the
frame (as seen from the front).
[Double-click to insert figure here]
Figure 8
4.
[Figure Caption]
Using the forklift, carefully raise the Robot towards the top of frame.
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Note
The forklift does not have enough reach to place the Robot directly below it’s
mounting position. Ensure that four (4) people are available to manually lift it
into its final position.
5.
Manually (by hand) lift the Robot Arm so that each of the four screws
protrude through the corresponding hole in the base of the Robot.
[Double-click to insert figure here]
Figure 9
[Figure Caption]
6.
Attach one flat washer, one spring washer, and one nut to each of the four
screws.
7.
Hand-tighten each of the four nuts as tightly as possible.
At this stage the Robot is secure and only two people are needed to complete the
rest of this procedure.
8.
Tighten the nuts securely, using a torque wrench set to …….Nm.
IMPORTANT!
This must be done with one person securing the fixed head of the screws on top
of the frame with a spanner.
Figure 10
Tightening the nuts
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9.
Add the second nut to each of the four screws.
10. Tighten with the torque wrench set to …….Nm.
The assembly appears as shown.
Figure 11
Robot attached
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6
Installing the Robot Controller
This unit controls the Robot. It is fitted onto the bottom section of the frame in the
left-hand corner.
Refer to drawing no. XXXXXX
6.1
Fitting the Robot Controller onto the Frame
CAUTION!
Heavy part! Two (2) people are required to put the robot in place.
Notes

The controller is located at the rear of the frame, on the bottom LHS,
facing outwards.

Make sure that the base of the frame is protected so that it does not get
scratched while the unit is being positioned.
Procedure:
1.
Lift the unit onto the base of the frame, as shown.
Figure 12
Inserting the Robot controller
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Note
Ensure that the pre-attached cables do not get caught underneath the
controller.
2.
Using M5x10/12 screws with flat and spring washers, attach the LHS bracket
to the corresponding holes in the base of the frame.
IMPORTANT!
The holes on the LHS of the controller are those closest to the outer edge of the
frame.
Figure 13
LHS controller bracket mounting holes
Once the controller is lined up for mounting on the LHS, the RHS bracket will be
in the correct position.
3.
Using M5x10/12 screws with flat and spring washers, attach the LHS bracket
to the corresponding holes in the base of the frame.
4.
On the RHS of the controller, remove the cable cover.
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Figure 14
Removing the cable cover (RHS)
Figure 15
Securing the Robot controller bracket (RHS)
5.
Reattach the cable cover.
Figure 16
RHS bracket and cable cover secured
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7
Interface Panel Assembly
This panel provides the main external electrical interfaces to the BC6. It also
includes the main power switch.
Refer to drawing no. XXXXXX
7.1
Preparation
Assemble the Interface Panel. For instructions, see section 10.3 “Interface Panel
Assembly”.
7.2
Mounting the Interface Panel Assembly
Procedure:
1.
Place the unit at the rear of the frame on the LHS.
The front panel faces outwards to the left, as shown.
Figure 17
Interface Panel Assembly in position
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2.
Line up the three (3) slots in the unit with the three (3) three screw-holes in
the base of the frame, as shown.
Figure 18
3.
Interface Panel Assembly mounting slots
Using three (3) M5x12 screws, with flat and spring washers, attach the unit to
the base.
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8
Front Door Emergency Off (EMO) Assembly
This assembly is a safety mechanism that turns off the robot if the front door is
opened while the robot is operating.
Refer to drawing no. XXXXXX
8.1
Preparation
Assemble the front door EMO. For instructions, see section 10.410.3 “EMO Panel
Assembly”.
8.2
Attaching the Front Door EMO
1.
Locate the correct mounting studs on the front RHS vertical beam of the
frame.
2.
Using M4X….. (2 off) with M4 spring washers and M4 wide flat washers,
attach the EMO assembly to the frame as shown.
Figure 19
EMO attached to frame
Note
Do not tighten the screws completely. This will be done once the door is fitted
so that the interlock and the door can be lined up accurately
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9
White Columns
These are white decorative columns that get fitted to the frame on each of the (4)
four vertical upright beams. They do not serve any functional purpose.
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10
Assembling the Sub-Assemblies
This section describes how to put together each of the smaller assemblies that get
integrated onto the main frame of the BC6.
10.1
Return Conveyor / Separator Wall
The following items are required for this part of the assembly. Refer to drawing
number fRC-60020-00 Rev 11.

The Return Conveyor (item 7)

Cable duct (item 10) -x3 off

Cable duct (item 11) x2 off

Philips pan head screw M5x8 (item 31) x13 off

M5 flat washer (item 23) x13 off
1.
Place the return conveyor on a work table as shown.
Figure 20
2.
Return Conveyor
Fit the (3) three long (750mm) cable ducts (items 10).
The order in which these are fitted is not important. The three cable ducts are
mounted in a ‘U’-shape.
a.
Locate the correct holes for each cable duct as shown
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Figure 21
b.
Cable Duct holes
To secure each cable duct use (3) three M5x8 Philips screws and a flat
washer for each screw.
Note

The mounting holes in the cable ducts are slotted so that fine adjustments
to their position can be made before tightening the screws.

The closed part of the ‘U’ overhangs the side wall of the return conveyor
by ±20mm.

On the open side of the ‘U’ the edges of the cable ducts are flush with the
edge of the return conveyor.
Once the three long cable ducts have been fitted, the return conveyor will appear
as shown.
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Figure 22
3.
Cable ducts on top of return conveyor
Fit the (2) two short cable ducts (items 11). The order in which these are fitted
is not important.
a.
Locate the correct holes for each cable duct as shown
Figure 23
Fitting the smaller vertical cable ducts
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b.
Secure each cable duct using (2) two M5x8 Philips screws and a flat
washer for each screw.
Note

The mounting holes in the cable ducts are slotted so that fine adjustments
to their position can be made before tightening the screws.
Once the two short cable ducts have been fitted, the return conveyor will look as
shown.
Figure 24
Cable ducts fitted to return conveyor
The return conveyor is now ready to be integrated with the BC6.
10.2
Robot Controller
10.2.1
Robot Controller Mounting brackets
There are two mounting brackets, a LH bracket and a RH bracket as shown. These
brackets hold the Robot Controller unit in position on the frame.
Note
The left side of the unit is as seen when looking directly at the door of the
controller.
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Figure 25
Robot Controller Fixing Brackets
To fit the mounting brackets:
1.
Remove 1 screw from the back of the controller in each of the left and righthand corners. The screw to remove is the second one from the bottom on each
side.
Figure 26
Removing the controller screws for bracket attachment
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2.
To attach each bracket to the controller, use the screws that were just
removed.
3.
Attach both brackets securely.
Notes
10.3

It may be necessary to loosen the ground cable mounting screw so the RHS
bracket can be easily fitted.

It may also be necessary to loosen and/or remove completely the cable
entry box on the RHS of the controller to make it easy to attach the RH
bracket.
Interface Panel Assembly
Refer to Drawings:
60092-00 REV 11 Interface Panel Assy
60087-00 REV 10 Pneumatic Unit Assy
To assemble this unit, the following items are required:
Table 1
Interface Panel Assembly Main Components
Item Number
Description
Part Number
1
Pneumatic Panel
60038-00
6
Main Emergency Switch
VCF1
4
Service Outlet
6600.3300.21
10
Pneumatic unit assy
60087-00
2
LAN Ethernet Connection
ECF504-C5
2
WAN Ethernet Connection
ECF504-C5
5&7
Main Power input Connector
53111240/53119140
PREV connector
NEXT connector
3
AIR input connector
PM 10
Input Power Cable
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10.3.1
Main Emergency Switch
This switch is in kit form and all necessary parts are in the kit. The individual
parts supplied are as shown:
Figure 27
The parts of the main emergency switch

The red and white switch (knob)

The main body of the switch

The flexible gasket

The square plastic interface block

x (4) four screws

Yellow on/off decal

Yellow warning label
To assemble the switch:
1.
Insert the square metal shaft of the interface block through the hole in the
center of the flexible gasket.
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2.
Hold the main switch body on the inside of the pneumatic panel with the red
tag facing down as shown.
Figure 28
Orientation of main switch on inside of pneumatic panel
3.
Line up the square hole in the switch with the corresponding hole in the
panel.
4.
Insert the interface block with gasket through the panel and into the switch
body.
IMPORTANT!
The orientation of the interface block and shaft is important. The final
orientation of the switch (knob) must be such that “1” is in the vertical upright
position, and the “0” is at the “9 o’clock” position. Check this before fixing the
interface block in position with the screws.
5.
Screw in the (4) four screws supplied as shown.
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Figure 29
Attaching the main switch interface block with shaft
6.
Press on the yellow on / off (1 / 0) indicator decal. Ensure that the “0” is
vertical.
7.
Press on the red and white switch and tighten the set screw.
8.
Check that the switch operates correctly.
9.
Attach the yellow warning label ………………?????
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10.3.2
Pneumatic Unit Assembly
This unit gets attached to the LHS of the IPA as shown.
Figure 30
Attaching the pneumatic unit to the IPA
To attach the pneumatic unit:
1.
Hold the unit against the LHS of the pneumatic panel as shown.
Ensure that the filter regulator (item 1 on drawing 60087-00) is pointing vertically
downwards.
2.
Line up the four attachment holes of the unit with the corresponding holes in
the side panel.
3.
Use (4) four M5x12 socket head cap screws to attach the unit to the side
panel.
Ensure that each screw has an M5 spring washer and an M5 flat washer. The
spring washer goes over the screw first, followed by the flat washer.
10.3.3
The Air Connection
This is the connector that interfaces to the externally supplied compressed air.
It is item number 3 on Drawing 60092-00.
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To fit the connector:
10.4
1.
Remove the nuts from both ends of the connector.
2.
Insert the body of the connector through the hole in the pneumatic so that the
panel is midway through the body of the connector.
3.
Re-attach the fixing nuts to the connector on both sides of the panel.
EMO Panel Assembly
This unit contains an emergency safety interlock that will stop the operation of the
robot if the front door is opened.
Refer to drawing number 60051-00 REV 11
The following items are required:
Table 2
[Table Caption]
Item
Description
Part Number
1 (1 off)
Push Button Support (bracket)
60052-00
2 (1 off)
EMS 1 Cbl Assy
86416-10
3 (1 off)
Interlock Block
D4NS-9BF
4 (2 off)
Flat washers
DIN433 M4
5 (2 off)
Spring washers
BN760 M4
6 (2 off)
Socket head CAP screws M4X30
DIN 912
7 (1 off)
Cable strap mount M5
116 0009 000 02
8 (1 off)
Socket button head CAP screw M5X6
BN1593
9 (1 off)
Emergency stop label
MLB-0756-01
BC6 Assembly Guide
Confidential
Page 32
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To assemble the unit:
1.
Hold the push button support bracket so that the EMS button hole points left,
and the interlock location is pointing upwards, as shown.
Figure 31
[Figure Caption]
2.
Hold the interlock block in its position with the push button support bracket
in this orientation.
3.
Check the location of the interlock. It must face outwards. If not, proceed as
follows:
4.

Remove the (4) four screws holding the red block in place

Turn the red block till it is facing the correct direction.

Insert and tighten the (4) four screws.
Mount the interlock block to the push button support bracket using the M4
screws and washers.
Note
The red block points upwards and the connector faces downwards as shown.
Ensure that the edge of the block and the edge of the bracket are parallel.
BC6 Assembly Guide
Confidential
Page 33
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Figure 32
5.
Interlock block orientation on push button support bracket
Attach the cable strap mount with the M5 screw in the position as shown.
Figure 33
Attach the cable strap mount
To attach the emergency off button:
1.
Place yellow emergency stop label over the large hole in the push button
support bracket as shown.
BC6 Assembly Guide
Confidential
Page 34
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Figure 34
Emergency Stop label
2.
Remove and discard the yellow clip on the body of the push button switch.
3.
Insert the push button from the front through the hole with the emergency
stop label.
4.
Tighten nut against body of pushbutton support bracket.
5.
Attach the body of the switch to the other side of the push button making
sure to lock the unit in place. (check writing on switch).
The unit is now ready for attachment to the BC6 frame.
BC6 Assembly Guide
Confidential
Page 35