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OPERATION MANUAL Sony Desktop Robot GA CAST-AU4/B2521E.
CAST-AU4/B2521E This Operation Manual is intended as a guide for users of the Sony Desktop Robot ROBOKIDS. Before operating this system, you should first throughly read this manual. You may not understand all of the explanations the first time through, but be on the lookout for any special directions.
CAST-AU4/B2521E First Time Users Read this manual form chapter 1 through chapter 4 before starting any operation. The manual describes the procedures required in setting up ROBOKIDS for users who have little experience with FA (Factory Automation) equipment.
CAST-AU4/B2521E Manual Configuration This operation manual describes the procedures required to operate the desktop robot ROBOKIDS Various types of applications such as dispensing and soldering may be accomplished by exchanging the memory cards (RK card) which stores the programs required to run an application.
CAST-AU4/B2521E Contents Safety Instruction ............................................................................................................. .. S-1 Unpacking ................................................................................
S-1 Safety Instruction CAST-AU4/B2521E Safety Instruction Sony Corporation designs and manufactures all its equipment with strict attention to safety. However, if the machine is operated or maintained without regard to the safety guidelines, damage or injury to the machine or operator may occur.
S-2 CAST-AU4/B2521E Definition of warning symbols Pay particular attention to the following symbols and conventions shown on the machine and on the Operation Manual. Fully understand the contents of symbols and conventions before reading the Operation Manual.
S-3 Safety Instruction CAST-AU4/B2521E Caution ■ Important Safeguards ◆ The tool driving mechanism are subject to unexpected movement. Pay attention to safety measures.
S-4 CAST-AU4/B2521E Precautions on Usage Operate on the specified voltage Operate the ROBOKIDS only on AC power voltage as specified on the label of the machine. The power cord must be directly connected to the electrical output, and grounded. The ROBOKIDS conforms with the safety requirements of the target country to which it is shipped.
S-5 Safety Instruction CAST-AU4/B2521E Precaution on memory cards Before inserting or removing a memory card, always turn the power off. The data stored in the memory card may be damaged if a memory card is inserted or removed while the power is on. Precaution on the teaching pendant ROBOKIDS uses a teaching pendant for the CAST-PRO or SRX.
S-6 CAST-AU4/B2521E On handling batteries The following battery is used in the base machine controller. Lithium battery (primary battery) of type : CR17335SE-CN21 Manufactured by Sanyo Electric Co. Incorrect handling of the battery may result in dangerous situation.
U-1 Unpacking CAST-AU4/B2521E Unpacking Transport it to the installation position while taking care not to drop or fall. Pay extra attention not to give any vibration or shock because the controller contains precision electronic parts. Be sure to use the packaging material specified by Sony Corporation when transporting the machine.
U-2 CAST-AU4/B2521E When the machine is unpacked, make sure the following items are in the package. Base machine Power cable Operation box USER I/O connector (For AC 200V to 240 V) PCR-E68FS (connector) PCS-E68LA (connector cover) (Honda Communications Company) Operation Manual External supply power connector for USER I/O MC 1.
1-1 1. Outline CAST-AU4/B2521E 1. Outline ROBOKIDS is a desktop assembly tool designed to automate cell production systems saving a significant amount of power consumed by assembly lines. It may be used in a variety of applications by simply exchanging the work unit and memory card.
1-2 CAST-AU4/B2521E 1-1 Nomenclature Front View * Debug station • • • Option Either the “ SRX teaching pendant ” or the program transfer cable can be directly connected to the debug station connector.
1-3 1. Outline CAST-AU4/B2521E Rear View CAST-PRO Teaching Pendant SRX Teaching pendant CAST-P06 (option) SRX-P005/S (option) 8 8 8 POWER switch Internal/external selecting switch for I/O (Upper : OUT.
1-4 CAST-AU4/B2521E 1-2 Outline Drawings ■ ROBOKIDS Standard Type (CAST-AU4/B2521E) 320 (35) (69) 250 (Stroke) 105 40 105 (250) 203 (300) 18 A 2 48 (60) (6) 26 (40) 4 φ 4 4-M4 + 0.
1-5 1. Outline CAST-AU4/B2521E Height Adjustable Type (CAST-AU4/BT2521E) 320 (35) (69) 250 (Stroke) 105 40 105 (250) 203 (300) 18 A A (52) 210 (Stroke) (4.
1-6 CAST-AU4/B2521E ■ 3-Axes Model Z-unit ■ 4-Axes Model ZR-unit φ 12h7 5 280 50 T ool attachment position 63 162 97 45 144.5 5 30 57 45 58 11 5 76 26 97 162 68 10 (13) 179 (202) 70 48 14 26 .
1-7 1. Outline CAST-AU4/B2521E Service Tapped-Hole Position 50 50 128 10 50 50 128 10 (120) 6-M3 10 10 (250) Side A 10 20 6-M3 (Side A only) (1.6) 4-φ 22.
1-8 CAST-AU4/B2521E 4-φ 22 Service Tapped-Hole Position (Tall Model).
1-9 1. Outline CAST-AU4/B2521E 1-3 Specifications 1-3-1 Machine Specifications Item X-axis Work envelope Y-axis Z-axis R-axis X-axis Maximum speeds Y-axis (*4) Z-axis R-axis X-axis Pose-repeatability .
1-10 CAST-AU4/B2521E 1-3-2 Control Specifications Drive method Movement method Control axis count Interpolation function CP control speed Teaching method Program capacity Point data storage capacity P.
2-1 2. Preparation CAST-AU4/B2521E 2. Preparation 2-1 Attaching the Units 2-1-1 Attaching the Z-unit 1. Fix the supplied mounting plate to the work table. (Two positions) Hexagon socket head cap screws M4 × 10, 2 pieces Tightening torque 15 kgfcm 2. Remove the Z-unit front cover.
2-2 CAST-AU4/B2521E 4. Attach the removed front cover. (Four positions) Tightening torque 8 kgfcm 5 . Connect the connectors to the Z-/ZR- unit connectors. Be sure to fix the connector by tightening the screws. 6. Attach the cable holder supplied, to the post.
2-3 2. Preparation CAST-AU4/B2521E 7. Fix the cable clamp of the cable to the cable holder..
2-4 CAST-AU4/B2521E 2-1-2 Attaching the ZR-unit 1. Remove the front cover. (The cover to which Sony logo mark is attached.) (Six positions) 2. Fix the ZR-unit to the mounting plate. (Four positions) Determine the fixing position using the positioning pin that is supplied with the equipment.
2-5 2. Preparation CAST-AU4/B2521E 4 . Connect the connectors to the Z-/ZR- unit connectors. Be sure to fix the connector by tightening the screws. 5. Attach the cable holder supplied, to the post.
2-6 CAST-AU4/B2521E 5. Fix the clamp of the cable on the cable holder..
2-7 2. Preparation CAST-AU4/B2521E 2-2 Connecting the External Signal The base machine is equipped with the following connectors for external signal communication.
2-8 CAST-AU4/B2521E Wiring diagram of connector for external switch (SAFETY) Applicable plug Type : DA-15PF-N (pin connector) Applicable shell Type : DA-C4-J10 ◆ An external stop button can be inserted between pins-14 and –15, or between pins-14 and –7.
2-9 2. Preparation CAST-AU4/B2521E 2. Connect the external signals to the USERl I/O connector by soldering. Connect the wires to the corresponding pins of the USER I/O connector.
2-10 CAST-AU4/B2521E ■ Input Circuit 24V 0V 0V IN 24V IN 680pF 470 Ω Maximum 7mA SI1 operates when SW1 is ON. Pin No. 1 35 2 36 3 37 4 51 18 52 19 53 SW1 SW30 Direction of current S1 I 1 I 2 I 3 I 4 I 5 I 21 I 22 COM1 0V SI1 (SYSRUN) SI3 SI2 SI8 ( Reservation ) input ( Reservation ) input ( Reservation ) input 3.
2-11 2. Preparation CAST-AU4/B2521E ■ Output Circuit ◆ Add the diodes as shown when relay coils are connected as the load. ◆ Be careful that the thermistor operates to shut down the +24 V power supply when 24 V output is used and the current of 1 A or more flows.
2-12 CAST-AU4/B2521E 2-3 Connecting to an Electrical Outlet Prepare the power cable for AC 200 V to 240 V referring to the following connection diagram.
2-13 2. Preparation CAST-AU4/B2521E 2-4 Starting Up the Base Machine Make sure that the main power is turned off. Connect the operation box. 2-4-1 Full-open Programmable Specification Turn on the power switch on the rear panel. Subsequent operating procedure changes depending on the application created by user.
2-14 CAST-AU4/B2521E 3. Turn the base machine on. About five seconds later, the white indicator of START button starts flashing in green. 4. Press the START button. The machine starts returning home. The green indicator of the START button turns on and changes to slow flashing after completing home return.
3-1 3. Maintenance CAST-AU4/B2521E 3. Maintenance 3-1 Maintaining the Machine Clean the surfaces of the machine with a soft dry cloth. If the stain is difficult to remove, use cloth moistened with a mild detergent solution, followed by using a dry cloth.
3-2 CAST-AU4/B2521E 3. Move the work table and the work unit to the ends by hand, remove the X-axis and Y-axis covers by pulling them, then remove the fallen materials such as screws.
3-3 3. Maintenance CAST-AU4/B2521E 6. Apply grease to the Z unit and the ZR unit as shown in the same manner. 7. Attach the covers of the X-axis, Y-axis, Z unit and ZR unit to their original positions. ◆ Be careful not to damage the covers when they are reinstalled.
3-4 CAST-AU4/B2521E 3-3 Cleaning and Replacing the Air Filter Air is circulated in the controller of the base machine to cool the controller. The cooling air is introduced through the air filter on the rear of the machine.
3-5 3. Maintenance CAST-AU4/B2521E 3. Replace the media (filter). 4. Reinstall the front cover as before. Replacement media Sony Order No. ......... 4-761-607-01.
3-6 CAST-AU4/B2521E NOTE 3-4 Replacing the Battery 1. Turn off the POWER switch and unplug the AC power cord from the AC outlet. The battery is located in the recess at the bottom on the rear of the Z-axis. 2 . Exchange the battery with the new lithium battery.
4-1 4. Troubleshooting CAST-AU4/B2521E 4. Troubleshooting 4-1 Common Items 4-1-1 Stepping Out (Note 1) The machine performs open loop servo control using a pulse motor (stepping motor) without positional feedback.
4-2 CAST-AU4/B2521E (4) Synthesis of movements in the same direction In some programs, the machine is operated by synthesizing two movements (the FOS and PFOS with the AWAKE instruction of LUNA). When the teaching points to be synthesized are aligned on the same line, the machine can step out.
4-3 4. Troubleshooting CAST-AU4/B2521E 4-1-2 External Noise External electrical noise is a difficult problem because it is invisible. Take the following remedial measures. If the symptom disappears, electrical noise was probably the cause of the trouble.
4-4 CAST-AU4/B2521E 4-2 Full-open Programmable Specifications Connect the SRX teaching pendant via a debug station and check the error codes and error history using the following procedure. 1 Connect a debug station. 2 Connect the SRX teaching pendant.
4-5 4. Troubleshooting CAST-AU4/B2521E 5 Check the error code number E*** on display and find out causes and countermeasures referring to the following table. When the machine does not operate normally, check the error contents referring to the following table.
4-6 CAST-AU4/B2521E Error No. E301 E302 E303 E304 E314 E315 E316 E317 Causes X-axis limit sensor error Y-axis limit sensor error Z-axis limit sensor error R-axis limit sensor error X-axis command posi.
4-7 4. Troubleshooting CAST-AU4/B2521E 4-3 When Memory Card (RK Card) is Used The operational flow starting from turning on the main power of the machine until the programmed operation or teaching is started, is shown as follows. Causes and countermeasures when trouble occurs in the respective state from 1) to 9) are shown on the next page.
4-8 CAST-AU4/B2521E Solutions Start operation from the very beginning Confirm the sensor cable connection Correct the controller data from TP of the SRX Symptoms “ E07 ” appears on display Machine movement does not stop (It moves in the reverse direction.
4-9 4. Troubleshooting CAST-AU4/B2521E Fault-Finding Chart of 5) Fault-Finding Chart of 6) or 7) or 8) Solutions Turn on the main power of the machine system and start operation from the very beginnin.
4-10 CAST-AU4/B2521E If a trouble occurs, check the following items before contacting your Sony dealer or the nearest Sony FA offices. 1) Name of dealer from which you purchased the ROBOKIDS Company name : Person in charge : Tel: 2) What is the serial number of your ROBOKIDS? (It is marked on the sticker of the rear cover.
5-1 5. Repair Parts Lists CAST-AU4/B2521E 5. Repair Parts Lists 5-1 ROBOKIDS Body 5-2 Z-axis Unit Descriptions TASK board BASE board Battery DC switching power supply ZWS30-5/J DC switching power supp.
5-2 CAST-AU4/B2521E 5-3 Z/R-axis Unit Descriptions Z-axis motor R-axis motor Z-axis home position sensor harness R-axis home position sensor harness Spline ball screw Z-axis timing belt R-axis timing belt Z/R-axis relay cable harness Bearing Mechanism block assembly Part No.
6-1 6. Appendix CAST-AU4/B2521E 6. Appendix ■ User Input/Output Specifications of USER I/O Connector Input Connector pin No. 3 37 4 38 5 39 6 40 7 41 8 42 9 43 10 44 11 45 12 46 13 47 14 48 15 49 16.
6-2 CAST-AU4/B2521E Output Connector pin No. 20 54 21 55 22 56 23 57 24 58 25 59 26 60 27 61 28 62 29 63 30 64 31 65 32 66 33 67 34 68 I/O names in terms of software SO1 SO2 SO3 SO4 SO5 SO6 SO7 SO8 L1.
6-3 6. Appendix CAST-AU4/B2521E ■ Specifications of the Connected I/O (Used only in the semi-programmable specifications and the full open programmable specifications) Input Output ■ User external.
6-4 CAST-AU4/B2521E ■ Connector for Debug Station Type : DBLC-J25SAF-10L9 Manufacturer : JAE Applicable plug : DBSP-JB25PF Manufacturer : JAE Applicable shell : DB-C8-J10-F4-1 Manufacturer : JAE Sig.
6-5 6. Appendix CAST-AU4/B2521E ■ Connector for Operation Box Type : 17HE-13150-73 Manufacturer : DDK Applicable plug : 17HE-23150-CD8A Manufacturer : DDK Applicable shell : 17H-7PCR-102 Manufacturer : DDK Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Contents Work program No.
6-6 CAST-AU4/B2521E ■ SAFETY Connector Type : DA-J15PF1L9 Manufacturer : JAE Applicable plug : DA-15PF-N Manufacturer : JAE Applicable shell : DA-C4-J10 Manufacturer : JAE Signal 24V SA START OUT SA.
6-7 6. Appendix CAST-AU4/B2521E ■ Connector for ZR-axis Cable Model : DBLC-J25SAF-10L9 Manufacturer : JAE Applicable plug : DB-25PF-IN Manufacturer : JAE Applicable shell : DB-C4-J11 Manufacturer : .
Supply Period of Repair Parts The functional repair parts (parts needed to maintain product performance) of this machine will be supplied for up to seven years in principle after production is discontinued.
1st Edition November, 1998 3rd Edition October, 2001.
Printed in Japan © 2001.10 3-864-81 1-13 Sony Manufacturing Systems Corporation.
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