IDEA AUTOMATION CO.,LTD
BRTIRUS1820A
Six axis industrial robot
Maintenance Manual
GUANGDONG BO LANGTE INTELLIGENT EQUIPMENT CO., LTD
IDEA AUTOMATION CO.,LTD
Catalog
1. Safety ......................................................................................................................... 1
1.1 Robot safety instructions................................................................................... 1
1.2 Safety precautions for adjustment, operation, maintenance, etc. ...................... 1
1.3 Safety measures for robot body ........................................................................ 2
2. Basic description ........................................................................................................ 4
2.1 Model specification .................................................................................................. 4
2.2 Mechanical system composition ....................................................................... 5
2.3 Mechanical specification .................................................................................. 6
① Robot performance parameter table ........................................................... 6
② Robot workspace ........................................................................................ 7
2.4Robot zero point verify ...................................................................................... 8
① Motor replacement ..................................................................................... 8
② Encoder replacement or battery failure ...................................................... 8
③ Reducer replacement .................................................................................. 8
④ Cable replacement ...................................................................................... 8
⑤ Software zero point calibration .................................................................. 8
⑥ Mechanical zero point calibration .............................................................. 8
3. Robot inspection and maintenance .......................................................................... 10
3.1 Preventive maintenance .................................................................................. 10
3.1.1 Daily inspection .................................................................................... 10
3.1.2 Quarterly inspection .............................................................................. 11
3.1.3 Annual inspection ................................................................................. 11
3.2 Inspection of main bolts .................................................................................. 12
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3.3 Lubricating oil inspection ............................................................................... 12
3.4 Replacement of lubricant ................................................................................ 13
3.4.1 Lubricating oil supply ........................................................................... 13
3.4.2 J1/J2/J3/J4 axis gearbox lubricating oil replacement steps................. 14
3.4.3 Release the residual air pressure in the cavity of each axis gearbox .... 15
3.5 Harmonic reducer installation and maintenance precautions ......................... 16
3.6 How to install the harmonic reducer ............................................................... 17
3.6.1. LCD/LCS series (rigid wheel, soft wheel output. Reduction ratio is the
indicated reduction ratio) ............................................................................... 17
3.6.2. Wave generator connection fixing method .......................................... 19
Appendix ...................................................................................................................... 21
A. Screw tightening torque table ................................................................................. 21
B. Consumable parts list .............................................................................................. 21
IDEA AUTOMATION CO.,LTD
1Safety
1.1 Robot safety instructions
Before installing, operating, maintaining, and repairing, be sure to read
this book and other attached documents to use this product
correctly.Please use this product after fully understanding the equipment
knowledge, safety information and all precautions.
1.2 Safety precautions for adjustment, operation, maintenance, etc.
① Workers must wear overalls, safety helmets, safety shoes, etc.
② When turning on the power, check that there are no workers in the
robot's operating range.
③ The power must be turned off before entering the robot's range of
motion.
④ Maintenance, inspection, etc. must be performed while the power is
on.At this time, work should be performed in groups of two.One person
can maintain the posture of pressing the emergency stop button
immediately, and the other one is alert and quickly performs work within
the range of the robot's motion.In addition, you should confirm the
evacuation path before proceeding.
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⑤ The load on weight must be controlled within the allowable handling
weight.Failure to comply with the allowable handling weight may result
in abnormal movement or premature failure of mechanical components.
⑥ Please read the instructions in the "Safety " section of this manual
carefully.
⑦ Disassembly and operation of parts not covered by the maintenance
manual are prohibited. The robot is equipped with various self-diagnostic
functions and anomaly detection functions to safely stop even if an
abnormality occurs.Even so, accidents caused by robots still occur from
time to time.
1.3 Safety measures for robot body
① The design of the robot should remove unnecessary protrusions
or sharp parts, use materials that are suitable for the working
environment, and adopt a fail-safe structure that is less prone to damage
or accident during operation.In addition, it should be equipped with a
malfunction detection stop function and an emergency stop function
when the robot is in use, and an interlock function to prevent the danger
of the robot when an abnormality occurs in the peripheral device, thereby
ensuring safe operation.
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② The motor is removed without a fixed arm, and the arm may fall or
move back and forth. After inserting the zero bolt, fix the arm with a
wooden block or crane to prevent it falling, and then remove the
motor.(Zero bolts and block are used to align the original position and
cannot be used to fix the arm.)Also, do not remove the motor while the
robot supports by manually.
③ When installing the auxiliary equipment on the robot, should be
strictly follow the size and number of bolts specified in this book.Use a
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torque wrench to tighten according to the specified torque. Do not use
rusty or dirty bolts.
④ When designing and manufacturing the end of arm tooling, it is
controlled within the load tolerance range of the robot.
⑤ The fail-safe structure should be adopted to ensure the separation of
the man and the machine. Even if the supply of the power source or
compressed air is cut off, the accident that the handle is released or flew
out will not occur.The corners or protrusions are treated to prevent
damage to people and objects.
2. Basic description
2.1 Model specification
The robot specifications and models are as follows:
B R T I R 口口 口口 口 口 A
Version number
Loading ability
Arm length
Robot Type
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Industrial robot
Company name
2.2 Mechanical system composition
The robot mechanical system refers to the composition of the
mechanical body. The mechanical body consists of a JO base portion, a
second shaft body portion, a second and a third shaft link portion, a third
and a fourth shaft body portion, and a fourth and a fifth shaft connecting
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barrel portion, the fifth shaft body portion and the sixth shaft body
portion. A total of 6 motors can drive 6 joint movements and achieve
different modes of motion. Figure 2.1 shows the various components of
the robot and the rules for each joint.
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Figure 2.1 Mechanical Structure of Robot
2.3 Mechanical specification
①、 Mechanical specification as the following table 2.1
2.1 Mechanical specification table
Model
BRTIRUS1820A
Axis
6
Loading ability
20KG
（KG）
IP Grade
IP54 Dustproof and waterproof
 0.05
Repeat ability
（MM）
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Arm length（MM）
1850MM
Driver model
AC Servo
Net weight（KG）
Around 210KG
Max. speed（°/S）
Action Range（0°）
8
J1
102°/S
J2
124°/S
J3
125°/S
J4
390°/S
J5
300°/S
J6
375°/S
J1
-165°~+165°
J2
-130°~+60°
J3
-75°~+135°
J4
-180°~+180°
J5
-115°~+115°
J6
-360°~+360°
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Temperature
0℃-40℃
Optimum
15℃-25℃
Temperature
Relative Humidity
20-80%RH
Air pressure
0.5-0.7Mpa
Source Power
380V  10%
50HZ  1%
②The robot workspace diagram is shown in Figure 2.2 and 2.3
2.2 robot work-space diagram
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2.3 robot work-space diagram
2.4 Zero proofing
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Zero proofing refers to an performed operation that associates the
angle of each robot axis with the encoder count value. The purpose is to
obtain an encoder count value corresponding to the zero position.
“Zero proofreading” is done before leaving the factory. In daily
operations, it is generally not necessary to perform a zero proofreading
operation. However, in the following cases, it is necessary to perform a
zero proofreading operation.
① Motor replacement.
② Encoder replacement or battery failure.
③ Gear box replacement
④ Cable replacement
Zero proofing is a more complicated process. According to the actual
situation and objective conditions, there are some tools and methods for
zero calibration and some common problems and methods to solve them.
① Software zero calibration：
This requires the use of a laser tracker to establish the coordinate system
of each joint of the robot, and the system encoder reading is zeroed. The
software calibration is
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complicated and needs to be operated by the company's
professionals.
② Mechanical zero calibration：
Rotate any two axes of the robot to the preset home position of the
machine body, and then insert the origin pin to ensure that the origin
pin can be easily inserted.
The zero calibration of each axis is shown in Figures 2.3 and 2.4.
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J6 Original Point
J5 Original Point
J2 Original Point
J4 Original Point
Figure 2.3
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J3 Original Point
J1 Original Point
Figure 2.4
3.Inspection and maintenance
In order for the robot to maintain high performance for a long time, a
maintenance check must be performed.
The maintenance is divided into daily maintenance and regular
maintenance. The basic cycle is as shown in the following figure. The
inspectors must prepare the maintenance plan and carry out the
inspection. Please refer to the table below for maintenance items.
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In addition, it is necessary to carry out overhaul at a cycle of 40,000
hours per work or a short period of time every 8 years. It is recommended
to perform maintenance and overhaul in a cycle of about 1/2, such as
loading and unloading operations.
Also,if the inspection and adjustment methods are unknown, please
contact our service department.
3.1Preventative maintenance
Follow the instructions in this chapter to perform regular
maintenance steps to maintain optimal robot performance.
3.1.1 Daily inspection
No.
Items
Inspection point
1
Abnormal sound
Check if each transmission presents abnormal
inspection
noise
Interference
Check if the transmission mechanism is running
inspection
smoothly and there is no abnormal jitters.
Air cooling
Check if the fan ventilation in control cabinet
2
3
inspection
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4
5
Pipeline attachment
Whether it is complete, whether it is worn or not,
inspection
whether it is rusted
Peripheral electrical
Check whether the external line of the robot and
accessory inspection button is normal
6
Leak inspection
Check each axis for leaking oil condition
7
Motor brake
Check that each axial brake is in good condition
inspection
3.1.2 Quarterly inspection
No.
Items
Inspection point
1
Control cable
Check the controller cable whether warp
2
Ventilation unit of the If the ventilation unit is dirty, turn off the power
control unit
and clean the ventilation unit
Check whether the mechanical unit socket is
Cable in mechanical
3
damage, abnormal bending, the motor connector
unit
and the aerial plug are connected reliably.
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4
Cleaning and
Check whether the parts have problems and
overhaul of various
handle it.
components
5
Screw fastening
Condition of reducer screw, motor screw
6
Timing belt
Condition of belt wear and tightness
3.1.3 Annual inspection
No.
1
Items
Inspection point
Cleaning and inspect Check whether the parts have problems
each components
and handle it.
2
Robot cable
Robot cable
3
External main screw Tighten the end effector screw and
fastening
outer main screw
①、Regarding the cleaning area, mainly around each axis, cleaning
cutting and splashing.
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②、For the fastening parts, tighten the end effector mounting screws,
robot setting screws, and screws that have been removed for
inspection.All screws exposed to the outside of the robot should be
tightened. For the mounting torque, refer to the screw tightening torque
table in the appendix.
3.2 Inspection of main bolts
No.
Items
1
Robot mounting base
2
Motor for each axis
3
Connection of each axis
4
End of arm tooling installation
Note: To replace the parts for screw tightening and replacement, it
must be tightened with the torque wrench and then fixed by painting.
3.3 Lubricating oil inspection
When the robot is operated for 5,000 hours or one year apart (<2,500
hours per operation or every half year for loading and unloading),
measure the lubricant powder concentration of the reducer.If it is
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necessary to replace the lubricating oil or reducer when the standard
value is exceeded, please contact our service center.
During maintenance, if more than the necessary amount of
lubricating oil flows out of the machine, use a lubricant gun to replenish
the outflow.The nozzle diameter of the lubricating oil gun to be used
should be ≦φ8 mm.If the amount of lubricating oil added is more than the
outflow amount, it may cause leakage of lubricating oil or poor trajectory
during robot operation. Pay attention to it.
After the repair or refueling is completed, in order to prevent oil
leakage, be sure to wrap the sealing tape between the lube fitting and the
perforated plug before installing.It is necessary to use a lubricant gun that
can clearly indicate the amount of fuel added.When it is not possible to
prepare a grease gun that can clearly indicate the amount of oil to be
refueled, the amount of oil to be lubricated can be confirmed by
measuring the change in the weight of the lubricating oil before and after
refueling.
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When the internal pressure rises during a short period of time when the
robot has just stopped, the lubricant may be ejected at the moment when
the plug of the inspection port is removed.
Item
Oil quantity
J1
1400CC
J2
800CC
Oil name
Remark
Rapid oiling will cause the
VONVO
RE No.00
pressure in the oil tank to
rise, causing the seal to crack
J3
700CC
J4
270CC
oil supply speed should be
3.4 Replacement of lubricant
controlled below 40cc/10
and causing oil leakage. The
seconds.
The robot maintenance should be regularly lubricated and overhauled as
required to ensure efficiency.
3.4.1 Lubricating oil supply
For J1/J2/J3/J4 axis reducers, the lubricant must be replaced every
20,000 hours or every 4 years (for 10,000 hours or every 2 years for
loading and unloading).The following table shows the specified lubricant
and oil supply.
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3.4.2 J1/J2/J3/J4 axis reducer lubricating oil replacement steps
1）Return the robot to the zero position.
2）Power off
3）Use 5mm hex wrench remove the lubricant plug. See Figure
3.1-3.2.
4）From the oil drain hole, the oil is blown out by the air gun, and
the oil hole at the other end is connected to the oil.
Until the old lubricating oil flows out from the oil drain, the new grease is
injected into the oil chamber and the new grease is discharged.
5）Install the plug on the lubricant supply port.
6）After the oil is supplied, the residual pressure in the lubricating
oil tank is released.
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J2 exhaust
J1 filler
J1 exhaust
J2 filler
Figure 3.1
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J4 exhaust
J3 exhaust
J3 filler
J4 filler
Figure 3.2
3.4.3 Release the residual air pressure in each reducer
After the oil is supplied, the robot should be properly operated in
order to release the residual pressure in the lubrication groove. At this
time, a recovery bag is installed under the inlet and outlet of the
lubricating oil to prevent the lubricating oil flowing out from scattering.
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In order to release the residual pressure, the J1 axis is within ±30°
and the J2/J3 axis is within ±5°. The range is repeated for more than 20
minutes and the speed is controlled at low speed.
If the above operation cannot be performed due to the surrounding
situation, the robot should be operated the same number of times (when
the axis angle can only be half, the robot should be operated twice as
long). After the above operation is completed, the vent plug is released.
The venting is re-installed (threaded sealant).
3.5 Harmonic reducer installation and maintenance precautions
① According to the service life of the reducer provided by the
reducer manufacturer, the design life of each axis harmonic
reducer is: 15000h.
② The harmonic reducer belongs to high-precision parts and has its
own ultimate force. Excessive push-pull and unreasonable
collisions will damage the internal structure of the reducer,
resulting in reduced accuracy or abnormal noise of the reducer.
Break, the reducer is scrapped.
③ The harmonic reducer must be installed in a sufficiently clean
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environment. During the installation process, no foreign matter
is allowed to enter the reducer to avoid damage to the reducer
during use.
④ Make sure that the gear face and flexible bearing parts of the
gear unit are always fully lubricated. It is not recommended that
the tooth surface be always facing up, which will affect the
lubrication effect.
⑤ After installing the cam, make sure that the flex wheel and the
rigid wheel are 180 degrees symmetrical (Fig. 1). If it is biased
to one side (Fig. 2), it will cause vibration and the soft wheel
will be damaged quickly.
⑥ Please run at low speed (1000 rpm) after installation. If abnormal
vibration or abnormal noise, please stop and contact us to avoid
damage to the reducer caused by incorrect installation.
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3.6 How to install the harmonic reducer
3.6.1、LCD/LCS series (rigid wheel, soft wheel output. Reduction
ratio is the indicated reduction ratio)
① Evenly apply grease on the flexible bearing, and inject 80%
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grease into the cavity at A (please use the specified grease,
do not change the grease at will to avoid damage to the
reducer.), install the wave generator on the input motor
shaft Or connect the shaft and fix it with a screw and a flat
pad.
② Firstly apply a layer of grease on the inner wall of the
flexible wheel. Inject the grease into the space B of the rear
wheel. The injection volume is about 80% of the cavity of
the flexible wheel. Load the direction of the reducer and
load it into the wave generator. Align the long axis with the
long axis of the reducer. When it is in place, fix the reducer
with the corresponding screw and tighten the pin slightly.
③ Set the motor speed to about 100 rpm, start the motor, and
tighten the screws in a crisscross pattern. Increase the
locking force corresponding to the screw four to five times.
All screws with fixed connections must be grade 12.9 and
need to be coated with thread glue to avoid screw failure or
loose work.
④ Mounting plane machining requirements fixed with the
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reducer: flatness 0.01MM and axis perpendicularity
0.001MM, threaded hole or bore and axis concentricity
0.1MM.
⑤ Note: When the reducer is used, if the output end (the output
of the above figure) is always horizontally downward (this
kind of use is not recommended), the grease injected into
the space inside the flexible wheel needs to exceed the
meshing tooth surface (ie, the A and B space must be Live
full of grease) or contact us. Please use the specified grease,
do not change the grease at will to avoid damage to the
reducer.
A static seal is required between the rigid wheel of the
reducer and the mounting plane of the input end to ensure
that the grease will not leak during use of the reducer, and
the reducer is not damaged when it is less oily or oil-free.
3.6.2. Wave generator connection method.
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① The input shaft is directly connected to the wave generator.
The input shaft has a shoulder and can be directly connected
to the waver. Figure:
② After input shaft and spacer, the input to the wave generator
has a shoulder, but the length is too long. You can add a
spacer on the shaft (the parallelism of the spacer should be
within 0.01MM) and then connect with the wave generator.
As shown
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③ After connecting to the wave generator with the connection
pad, connect the input shaft to the input shaft. There is no
shoulder. It needs to be fixed on the wave generator with a
connection pad before connecting with the input shaft, as
shown in the figure:
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Appendix
A. Screw tightening torque table
Screw
Tightening torque（N-m）
M3
2  0.18
M4
4.5  0.33
M5
9.01  0.49
M6
15.6  0.78
M8
37.2  1.68
M10
73.5  3.42
M12
128.4  6.37
M14
204.8±10.2
B. Consumable parts list
NO.
Item
Specification
1
J5 timing belt
MBT233080505
timing belt-5M-8 belt width-85
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tooth
2
Bellows joint
MCN540250001 ￠42.5
3
Bellows
MCN44203601A outer diameter￠
42.5
4
Rotating frame oil seal
PRG01100070B
Specification 70-100-13
5
Four-axis skeleton oil
PRG01047028B
seal
Specification 28-47-7
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Tel :034-130-386 ,( 083-2841047 ) Tax ID : 0745562007511
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