Mitsubishi Electric CR800-D Series User Manual
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Mitsubishi Electric CR800-D Series User Manual

Industrial robot controller
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Mitsubishi Electric Industrial Robot
CR800-D/R/Q series controller
Preventive Maintenance Function
User's Manual
BFP-A3625
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Summary of Contents for Mitsubishi Electric CR800-D Series

  • Page 1 Mitsubishi Electric Industrial Robot CR800-D/R/Q series controller Preventive Maintenance Function User’s Manual BFP-A3625...
  • Page 3 Safety Precautions Always read the following precautions and the separate "Safety Manual" before starting use of the robot to learn the required measures to be taken. CAUTION All teaching work must be carried out by an operator who has received special training.
  • Page 4 The points of the precautions given in the separate "Safety Manual" are given below. Refer to the actual "Safety Manual" for details. DANGER When automatic operation of the robot is performed using multiple control devices (GOT, programmable controller, push-button switch), the interlocking of operation rights of the devices, etc.
  • Page 5 CAUTION Never carry out modifications based on personal judgments, or use non- designated maintenance parts. Failure to observe this could lead to faults or failures. WARNING When the robot arm has to be moved by hand from an external area, do not place hands or fingers in the openings.
  • Page 6 CAUTION Make sure there are no mistakes in the wiring. Connecting differently to the way specified in the manual can result in errors, such as the emergency stop not being released. In order to prevent errors occurring, please be sure to check that all functions (such as the teaching box emergency stop, customer emergency stop, and door switch) are working properly after the wiring setup is completed.
  • Page 7 ■ Revisions Revision Date Instruction Manual No. Revision Details • First print 2018-09-20 BFP-A3625...
  • Page 8 This specifications is original. • Company names and product names described in this document are trademarks or registered trademarks of each company. • and TM are omitted in the text of this guide. Copyright(C) 2018 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVED...

  • Page 9: Table Of Contents

    Contents Before starting use ........................................1 1.1 Contents of the instruction manual ................................1 1.2 Compatible products ......................................2 1.3 Related manuals ........................................3 1.4 Maintaining the robot ......................................4 1.4.1 Type of maintenance and inspection ............................... 4 1.4.2 Inspecting/replacing timing belt ................................5 1.4.3 Lubrication ........................................
  • Page 10 MELFA Smart Plus ..................................... 112 12.3 MELFA Smart Plus card ................................112 12.3.1 13. Parameter ............................................114 Common to preventive maintenance functions .......................... 114 13.1 Consumption degree calculation function ............................. 115 13.2 Setting parameters ..................................115 13.2.1 Data acquisition parameter ................................ 116 13.2.2 Operation parameters ...................................

  • Page 11: Before Starting Use

    1. Before starting use 1.1 Contents of the instruction manual This function can be used with the RT ToolBox3 Preventive Maintenance screen, parameters, status variables, and dedicated input/output signals. In this manual, the following structure is used to explain how the preventive maintenance function using examples of the RT ToolBox3 Preventive Maintenance screens.

  • Page 12: Compatible Products

    Compatible products The following products are compatible with this function. Item Description Remarks RV-2FR series, RV-4FR series, Vertical multi-joint Standard model RV-7FR series, type RV-FR series 6-axis robot only RV-13FR series, RV-20FR series Robot arm RH-3FRH series, RH-6FRH series, Horizontal multi-joint RH-12FRH series, Standard model only type RH-FR series...

  • Page 13: Related Manuals

    Related manuals The following manuals are related to the preventive maintenance function. Manual name Description Explains the procedures required to operate the robot arm Robot Arm Setup & Maintenance (unpacking, transportation, installation, confirmation of operation), and the maintenance and inspection procedures. Explains details on the functions and operations such as each Detailed explanations of functions function and operation, commands used in the program,...

  • Page 14: Maintaining The Robot

    Maintaining the robot This function supports maintenance and inspection so that the robot can be used for a long time without trouble. Efficient maintenance is supported though notification of the time of maintenance parts replacement or overhaul based on the actual operating status of the robot. However, in order to prevent failure beforehand and ensure prolonged service life and safety of the robot, we strongly recommend periodic maintenance and inspection be carried out.

  • Page 15: Inspecting/Replacing Timing Belt

    1.4.2 Inspecting/replacing timing belt This robot uses a timing belt for the drive conveyance system. Compared to gears and chains, the timing belt does not require lubrication and has a low noise. However, if the belt usage method and tension adjustment are inadequate, the life could drop and noise could be generated.

  • Page 16: Lubrication

    1.4.3 Lubrication Grease is used for the reduction gears of the robot. Grease has various roles, such as suppressing of wear of reduction gears, removal of frictional heat, and prevention of burn-in. If you use a robot for a long period of time, the grease will deteriorate due to loads during operation (operating speed, operation frequency, heat generation condition, and others.).

  • Page 17: Replacing The Battery

    1.4.4 Replacing the battery An absolute encoder is used for the position detector, so while power of controller is turned off the position must be saved by the backup battery. These batteries are installed when the robot is shipped from the factory, but as these are consumable parts, they must be replaced periodically by the customer. The guideline for replacing the battery is one year, but this will differ according to the robot's usage state.

  • Page 18: About Overhaul

    1.4.5 About Overhaul Robots which have been in operation for an extended period of time can suffer from wear and other forms of deterioration. In regard to such robots, we define overhaul as an operation to replace parts running out of specified service life or other parts which have been damaged, so that the robots may be put back in shape for continued use.

  • Page 19: Basic Specifications

    2. Basic specifications 2.1 Overview of basic specification of the preventive maintenance function The preventive maintenance function roughly consists of the following two functions. The maintenance simulation can be checked on the preventive maintenance function screen of RT ToolBox3. Information on preventive maintenance by the consumption degree calculation function can be checked on the Preventive Maintenance screen, status variables, and parameters of RT ToolBox3.

  • Page 20: Maintenance Simulation

    2.1.1 Maintenance simulation Using the real machine (online) or simulations on RT ToolBox3, this function estimates the parts replacement time or the recommended maintenance time when specific motion patterns (robot programs) are repeated. Maintenance simulation estimates the following items. 1) Number of years up to the time of replenishing grease 2) Number of years up to the time of timing belt replacement 3) Recommended number of years up to the maintenance time for overhauling parts (Of reduction gear, bearing, ball screw, and ball spline, the part for which there is the shortest...
  • Page 21 When RT ToolBox3 mini is used, simulation on RT ToolBox3 cannot be used. Caution The recommended number of years up to the replacement/maintenance time output by this function is the value calculated when the specified operation is repeated. Also, the result may vary depending on the performance of the personal computer used and the load status.

  • Page 22: Consumption Degree Calculation Function

    2.1.2 Consumption degree calculation function This function calculates the consumption degree [%] of robot components based on the actual operating status (motor speed, load status, and others), and calculates the period up to maintenance/inspection or overhaul. Consumption Degree [%] is calculated based on the recommended maintenance time of each part as 100 [%].
  • Page 23 Notification Notification content · [Consumption Status] (maintenance parts): Output for each part, for each joint axis · [Consumption Status] (overhaul parts): Output for each part, for each joint axis · Servo ON Time Notification method Setting how to notify RT ToolBox3 Preventive Maintenance screen (3.2.1.
  • Page 24 Caution [About the robot controller] • When using this function by upgrading from a non-compatible controller software version to a compatible controller software version, the consumption degree during the period of the non-compatible software version is not added up, thus the result of consumption degree calculation function cannot be the correct value.
  • Page 25 << MEMO >> Basic specifications 15...

  • Page 26: Target Models/Target Axes

    2.1.3 Target models/target axes (1) Consumption degree calculation function/maintenance simulation The table below shows the joint axes for which target parts of the consumption degree calculation function of each robot type are used. (Compatible robots are the standard models only.) ...
  • Page 27 (5) RH-3FRHR Joint axis J1axis J2 axis J3 axis J4 axis    Grease Maintenance parts Timing belt       Reduction gear    Bearing Overhaul parts Ball screw  Ball spline  *3：The RH-3FRHR series uses a ball screw/spline but this function assumes that the J3 axis uses a ball screw and the J4 axis uses a ball spline.

  • Page 28: How To Utilize The Preventive Maintenance Function

    How to utilize the preventive maintenance function The preventive maintenance function assumes the following usages. (1) At system startup It is possible to estimate the replacement time of maintenance parts or the recommended maintenance time of overhaul parts when an operation pattern of the robot is repeated using "Maintenance Simulation". This function can be used for planning a maintenance schedule when starting up a system.
  • Page 29 << MEMO >> Basic specifications 19...

  • Page 30: Startup And Initial Settings

    3. Startup and initial settings This section describes the procedure to start the preventive maintenance function. Validation of the preventive maint enance function (3.1) 1. Turn off the power of the robot controller. 2. Insert the "MELFA Smart Plus Card" or "MELFA Smart Plus Card Pack"...

  • Page 31: Enabling The Preventive Maintenance Function

    Enabling the preventive maintenance function Insert the "MELFA Smart Plus Card" into the robot controller and set parameters. Turn off the power of the robot controller. CR800-D type Switch 1) Turn off the switch of the earth leakage circuit breaker. CR800-R/Q type 1) Turns off the power of the robot CPU system.
  • Page 32 Turn on the power of the robot controller. CR800-D type Switch 1) Turn on the switch of the earth leakage circuit breaker. 2) The POWER lamp of the robot controller lights. CR800-R/Q type 1) Turn on the switch of the earth leakage circuit breaker.
  • Page 33 Restart the robot controller. CR800-D type 1) Turn off the switch of the earth leakage circuit breaker. 2) Turn on the switch of the earth leakage circuit breaker. CR800-R/Q type 1) Turns off the power of the robot CPU system. 2) Turn off the switch of the earth leakage circuit breaker.

  • Page 34: Initial Setting Of The Preventive Maintenance Function

    Initial setting of the preventive maintenance function Set how to notify when consumption of parts is detected. Specify the notification method (presence of warning/signal output, notification day) when the warnings occurr. If you have not set the notification method, upon starting the preventive maintenance function, the [Setting] - [Synthesis] screen appears.

  • Page 35: Setting Signals

    3.2.2 Setting signals Set signal numbers when you wish to use signal input/output to implement notification when consumption or parts is detected, reset the consumption degree, or pause warning occurrence/signal output. For dedicated input/output signals of the preventive maintenance function, refer to "14 Dedicated input/output signals".

  • Page 36: Setting Of Maintenance Simulation

    Setting of maintenance simulation In order to use "Maintenance Simulation" for the simulation of RT ToolBox3, the function code and parameter of the MELFA Smart Plus card need to be set to RT ToolBox3. This section explains the procedure for setting the function code of the MELFA Smart Plus card to RT Toolbox3, which is not connected to the robot controller where the MELFA Smart Plus card has been installed.
  • Page 37 Set the function code of the MELFA Smart Plus card. Next, enter the function code obtained in Step 1 to the RT ToolBox3 that performs the maintenance simulation. 1) Start RT ToolBox3 that performs the maintenance simulation. At that time, click the right button of the mouse on the desktop icon of RT ToolBox3 and select "Implement as administrator"...
  • Page 38 Check that the preventive maintenance function is enabled. 1) Change the operation mode to . If parameter setting in Step 3 is performed using , start up Simulation once again. (The "PMENA" parameter requires rebooting.) 2) From the project tree, expand [Maintenance] and check that [Preventive Maintenance] is displayed.
  • Page 39 << MEMO >> Startup and initial settings 29...

  • Page 40: Basic Screen Structure

    4. Basic screen structure The "Total Score" screen is displayed first when starting the preventive maintenance function. This screen displays the total evaluation result of the consumption degree calculation function. RT ToolBox3 project tree 1) Preventive Maintenance [Preventive Maintenance] is displayed under [Maintenance] of the project tree.
  • Page 41 (1) Total score The screen that is displayed first when starting the preventive maintenance function. This screen displays the total evaluation result of the consumption degree calculation function, and maintenance messages. For details, refer to "5 Total score". (2) Consumption degree calculation The screen indicates the consumption degree of each part and each joint axis of maintenance parts and overhaul parts calculated by the consumption degree calculation function.

  • Page 42: Total Score

    5. Total score The "Total Score" screen is displayed first when starting the preventive maintenance function. This screen displays the total evaluation result of the consumption degree calculation function. Total score (1) Consumption degree calculation (2) Preventive maintenance message (1) Consumption degree calculation The Consumption Degree area indicates the total score (Consumption Degree [%] and Up to Maintenance) of maintenance parts (grease, timing belt), and the total score (Consumption Degree [%]) of overhaul parts (reduction gear, bearing, ball screw, ball spline), and the accumulated servo ON...
  • Page 43 (3) Preventive maintenance message When the consumption status of the target part exceeds the notification day you specified, the preventive maintenance message according to the status is displayed; check the message content and take measures. For preventive maintenance messages and measures, refer to "9 When consumption occurred". Total score 33...

  • Page 44: Consumption Degree Calculation Function

    6. Consumption degree calculation function This function calculates the consumption degree [%] of robot components based on the actual operating status (motor speed, load status, and others), and calculates the period up to maintenance/inspection or overhaul. The screen indicates the consumption degree of each joint axis of maintenance parts and overhaul parts calculated by the consumption degree calculation function.
  • Page 45 (2) Preventive maintenance message This field displays preventive maintenance messages according to the part status. When the remaining time exceeds the notification day, an appropriate preventive maintenance message is displayed; check the message content and take measures. For preventive maintenance message and measures, refer to "9.When consumption occurred".
  • Page 46 Caution Depending on the operating status at startup, correct results may not be obtained at the beginning due to fluctuations until sufficient data is accumulated. Correctly set hand work conditions (weight, center of gravity, shape) actually used. Caution If the settings differ from the actual robot settings, the consumption degree cannot be calculated correctly.

  • Page 47: Operating Information

    7. Operating information The Operating Information screen is used to manage and display the integration time and accumulation count from the time when the previous overhaul was carried out. The integration time and accumulation count data are reset when "Reset operation at overhaul implementation"...

  • Page 48: Maintenance Simulation

    8. Maintenance simulation This function estimates the parts replacement time or the recommended maintenance time when a specific motion pattern (robot program) is repeated using a real machine (online) or simulations on RT ToolBox3. Maintenance simulation estimates the following items. 1) Number of years up to the time of replenishing grease 2) Number of years up to the time of timing belt replacement 3) Recommended number of years up to the recommended maintenance time for overhauling parts...
  • Page 49 Caution When RT ToolBox3 mini is used, simulation on RT ToolBox3 cannot be used. The recommended number of years up to the replacement/maintenance time output by this function is the value calculated when the specified operation is repeated. Also, the result may vary depending on the performance of the personal computer used and the load status.

  • Page 50: Cycle" Operation

    "1 Cycle" operation This operation is performed in the simulation mode of the RT ToolBox3. Specify the start line and end line of the robot program to estimate the parts replacement/ the recommended maintenance time based on its 1 Cycle operation pattern. [Note] When an actual machine is connected, the "1 Cycle"...
  • Page 51 Move the current position of the robot to the robot operation start position of 1 Cycle operation. If the current position of the robot is not at the start position of 1 Cycle operation, if 1 Cycle operation starts, the robot moves to the operation start position first. Since that operation is included in the calculation by the maintenance simulation, calculation cannot give the correct 1 Cycle operation result.
  • Page 52 Select "1 Cycle". 1) Select "1 Cycle" on the Maintenance Simulation screen. Maintenance Simulation screen 1 Cycle Select the execution program. 1) Click [Program Selection] on the Maintenance Simulation screen. 2) The "Select Robot Program" screen opens; select the program to run the simulation and click the "OK"...
  • Page 53 Select the start line and end line of the program. 1) The Select Program Line Number Select Program Line Number screen screen appears. 2) Select the start line and end line. Enter the line number in the input Click to input line box at the right side of Start Line numbers.
  • Page 54 The simulation results are displayed. The simulation results are displayed when operation from the start line to end line specified in Step 5 is repeated. 1) When program operation ends, the maintenance simulation results are displayed. The displayed results are estimated results based on the value of "Operation Time of a Day" and "Working Days in a Month".

  • Page 55: Program Operation

    Program operation Run a program online or in the simulation mode of RT ToolBox3. While running a robot program automatically, the pats replacement/ the recommended maintenance time is estimated for operation from when the start button is pressed to when the end button is pressed is repeated.
  • Page 56 Select the "Program" for the estimation method. (Simulation only) 1) When running a program in simulation mode, select "Program" on the Maintenance Simulation screen. [Note] When an actual machine is connected, the "1 Cycle" button and "Program" button are not displayed.
  • Page 57 End the maintenance simulation. 1) When a series of operations for performing maintenance simulation have been executed, click the "End" button on the Maintenance Simulation screen. The maintenance simulation ends and the Maintenance Simulation result screen appears. (Even though the "End" button is clicked, the robot continues operation.) Maintenance Simulation screen Maintenance simulation 47...
  • Page 58 The simulation results are displayed. The maintenance simulation result displayed is when the operation from clicking the "Start" button in Step 4 to clicking the "End" button in Step 5 is repeated. 1) When program operation ends, the maintenance simulation results are displayed. The displayed results are estimated results based on the value of "Operation Time of a Day"...
  • Page 59 << MEMO >> Maintenance simulation 49...

  • Page 60: When Consumption Occurred

    When consumption occurred When the consumption status of the target part exceeded the notification day you specified, an error number and error message corresponding to the status are displayed. Preventive maintenance message is also displayed in the maintenance message field on the RT ToolBox3 Preventive Maintenance screen. This section explains the content and measures corresponding to each error number and preventive maintenance message;...

  • Page 61: Overhaul Parts

    (2) Timing belt Error number C.713n Error message Timing belt replacement period RT ToolBox3 The timing belt (Jn axis) consumption degree exceeded the warning number of preventive days remaining. Please check the details and prepare for timing belt replacement. maintenance message Measures Replace the timing belt.
  • Page 62 (2) Bearing Error number C.715n Error message Overhaul period (bearing) RT ToolBox3 The bearing (Jn axis) consumption degree exceeded the warning number of days preventive remaining. Please check the details and prepare for overhaul. maintenance message Measures Perform overhaul of the robot body. For selection of replacement parts and overhaul implementation timing, consult with our service affiliated company.

  • Page 63: Servo On Time

    9.1.3 Servo ON time (* n in the table indicates the axis numbers (1 to 6). Error number C.7110 Error message Overhaul period (servo on time) RT ToolBox3 The servo on time exceeded the warning number of days remaining. preventive Please check the details and prepare for overhaul.

  • Page 64: Maintenance

    10. Maintenance On the maintenance screen, you can reset the consumption degree, or can specify backup/restore and pausing of warning occurrence/warning signal output during maintenance. In addition, you can check the maintenance log. 1) Start preventive maintenance. 2) Click [Maintenance] to expand the menu; the maintenance functions are displayed. 3) Click [Warning Pause], [Maintenance Reset], [Backup], or [Maintenance Log], to switch the main screen.

  • Page 65: Warning Pause

    10.1 Warning Pause Displays the list of warning and warning signals that are occurring or paused. Usually, the alarm of consumption degree calculation is notified at the intervals you set. If you desire to stop notification (alarm, dedicated output signal), you can temporarily disable at this stage. Warning Pause screen (2) Warning (3) Signal Output...

  • Page 66: Maintenance Reset

    10.2 Maintenance Reset When part replacement, grease replenishing, or overhaul was performed, the information of the axes for which maintenance was performed accumulated in the controller needs to be reset. On the Maintenance Reset screen, you can reset the information held by the controller such as the consumption degrees calculated by the consumption degree calculation function.

  • Page 67: Backup And Restore

    10.3 Backup and restore You can back up or restore preventive maintenance information held in the controller. To replace the robot body or robot controller only, you need to perform backup/restore of the preventive maintenance information to migrate the preventive maintenance information. For backup/restore of the preventive maintenance information, click [Maintenance] - [Backup] of the preventive maintenance function.

  • Page 68: Backup (Robot  Personal Computer)

    10.3.1 Backup (robot  personal computer) Save the preventive maintenance information in the robot controller to a file on a personal computer. When clicking the [Backup] button, a time stamp folder (folder name: "YYmmdd-HHMMSS") is automatically created in the [Maintenance] - [PMBackup] folder directly under the project and the backup data is saved in that folder.

  • Page 69: Restore (Personal Computer  Robot)

    10.3.2 Restore (personal computer  robot) Transfer the information backed up on the personal computer to the robot controller. To restore preventive maintenance information, from the folder selection dialog box, select the folder you wish to restore. If there is missing backup data, an error message is displayed and restore is interrupted. The following describes how to restore preventive maintenance information.

  • Page 70: Maintenance Log

    10.4 Maintenance Log Display the recorded maintenance log. 10.4.1 Maintenance Log screen The preventive maintenance function stores 10 maintenance log items of the past. Upon executing maintenance reset, item, date & time, consumption degree [%] and accumulation count are recorded. On the Maintenance Log screen, the recorded log is displayed.

  • Page 71: Data To Be Recorded In The Maintenance Log

    10.4.2 Data to be recorded in the maintenance log After performing grease replenishing, timing belt replacement, or robot overhaul, upon resetting the consumption degree of each part, the reset date & time, consumption degree [%] at the time of reset, and reset count are recorded in the maintenance log.

  • Page 72: Batch Management Of Maintenance Information

    11. Batch management of maintenance information Explains how to collectively manage maintenance information of the entire production line with the host system. Robots in the factory 11.1 Functional overview Maintenance information used in the preventive maintenance function is compatible with the data output in communication protocol MelfaRXM.ocx, SLMP.

  • Page 73: Output Data

    11.2 Output data Output data Target Unit Robot status variable Parameter Robot body serial number Character C_RBSerial RBSERIAL string Power ON time h (hours) M_PowOnTime TIMPOWON Servo ON time h (hours) M_SrvOnTime TIMSRVON Operation time Basic data h (hours) M_PrgTime TIMPRG Actual operation time h (hours)

  • Page 74: Request Id (Melfarxm.ocx) Specified By Requestservice

    Output data Target Unit Robot status variable Parameter − − Specify data to get LOGPMNO Piece − M_PMLogGrs Grease Character C_PMLogGrs LOGPMGRS string Piece − M_PMLogBlt Timing belt Character C_PMLogBlt LOGPMBLT string Piece − M_PMLogDec Reduction gear Character C_PMLogDec LOGPMDEC string Maintenance Log Piece...
  • Page 75 << MEMO >> Batch management of maintenance information 65...

  • Page 76: Robot (System) Status Variables

    12. Robot (system) status variables 12.1 Robot (system) status variable list Consumption degree calculation function Variable name Overview Function Robot body serial number C_RBSerial Returns the serial number of the robot body. Controller serial number C_RCSerial Returns the serial number of the robot controller ...
  • Page 77 Variable name Overview Function Consumption degree (mechanism M_PMCsmMnt Returns the overall consumption degree of the total (maintenance parts)) maintenance part (grease and timing belt). [%] Consumption degree M_PMCsmOH Returns the overall consumption degree of the (mechanism total (overhaul parts)) overhaul part (decelerator, bearing and ball screw / ball spline).

  • Page 78: Melfa Smart Plus

    Variable name Overview Function Notification pause status (grease) M_PMRptGrs Returns the stop status of warning / signal output, of grease consumption of the specified axis. Notification pause status M_PMRptBlt Returns the stop status of warning / signal output, of (timing belt) timing belt consumption of the specified axis.

  • Page 79: Consumption Degree Calculation Function

    12.2 Consumption degree calculation function 12.2.1 Serial number C_RBSerial: Robot body serial number [Function] Returns the serial number of the robot body. [Format] Example) = C_RBSerial() [Terminology] Specify the string variable to assign. Set the mechanism number.
  • Page 80 C_RCSerial: Controller serial number [Function] Returns the serial number of the robot controller. [Format] Example) = C_RCSerial [Terminology] Specify the string variable to assign. [Sample] 1 C1$ = C_RCSerial 'The serial number of the robot controller is set in C1$. [Explanation] (1) Returns the serial number of the robot controller.

  • Page 81: Operating Information

    12.2.2 Operating information M_PowOnTime: Power ON time [Function] Returns the cumulative time of power supply ON of robot controller from a last overhaul. [hour] [Format] Example) = M_PowOnTime [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PowOnTime 'The cumulative time of power ON of the robot controller is set in M1.
  • Page 82 M_SrvOnTime: Servo ON time [Function] Returns the cumulative time of servo ON of the robot body from a last overhaul. [hour] [Format] Example) = M_SrvOnTime [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_SrvOnTime 'The cumulative servo ON time of the robot body (mechanism 1) is set in M1.
  • Page 83 M_PrgTime: Operation time [Function] Returns the cumulative time of the operating time of the robot controller from a last overhaul. [hour] [Format] Example) = M_PrgTime [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PrgTime 'The operation time of the robot controller is set in M1.
  • Page 84 M_MovTime: Actual operation time [Function] Returns the cumulative time of the moving time of the robot body from a last overhaul. [hour] [Format] Example) = M_MovTime [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_MovTime 'The actual operation time of the robot body (mechanism 1) is set in M1.
  • Page 85 M_SrvOnNum: Servo ON count [Function] Returns the cumulative count of the servo ON of the robot body from a last overhaul. [Format] Example) = M_SrvOnNum [Terminology] Specify the joint type variable to assign. [Sample] 1 M1 = M_SrvOnNum 'The servo ON count of the robot body (mechanism 1) is set in M1.
  • Page 86 M_MtRotNum: Motor cumulative rotation count [Function] Returns the cumulative number of rotations of the motor of the robot body from a last overhaul of the specified axis. [Format] Example) = M_MtRotNum() [Terminology] Specify the joint type variable to assign. ...

  • Page 87: Maintenance Log

    12.2.3 Maintenance Log M_PMLogGrs: Maintenance count (grease) [Function] Returns the maintenance count (reset count) of the grease of the specified axis. [Format] Example) = M_PMLogGrs() [Terminology] Specify the numeric variable to assign. Specify the joint axis for which to get a log. (1 to 6) When omitted, 1 is used.
  • Page 88 M_PMLogBlt: Maintenance count (timing belt) [Function] Returns the maintenance count (reset count) of the timing belt of the specified axis. [Format] Example) = M_PMLogBlt() [Terminology] Specify the numeric variable to assign. Specify the joint axis for which to get a log. (1 to 6) When omitted, 1 is used.
  • Page 89 M_PMLogDec: Maintenance count (reduction gear) [Function] Returns the maintenance count (reset count) of the decelerator of the specified axis. [Format] Example) = M_PMLogDec() [Terminology] Specify the numeric variable to assign. Specify the joint axis for which to get a log. (1 to 6) When omitted, 1 is used.
  • Page 90 M_PMLogBrg: Maintenance count (bearing) [Function] Returns the maintenance count (reset count) of the bearing of the specified axis. [Format] Example) = M_PMLogBrg() [Terminology] Specify the numeric variable to assign. Specify the joint axis for which to get a log. (1 to 6) When omitted, 1 is used.
  • Page 91 M_PMLogBss: Maintenance count (ball screw/ball spline) [Function] Returns the maintenance count (reset count) of the ball screw / ball spline of the specified axis. [Format] Example) = M_PMLogBss() [Terminology] Specify the numeric variable to assign. ...
  • Page 92 M_PMLogOH: Maintenance count (overhaul (servo ON time)) [Function] Returns the maintenance count (reset count) of the overhaul. [Format] Example) = M_PMLogOH [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PMLogOH 'The maintenance count of overhaul is set in M1. [Explanation] (1) Returns the maintenance count (reset count) of overhaul for the robot body (mechanism 1).
  • Page 93 C_PMLogGrs: Maintenance log (grease) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the grease. [Format] Example) = C_PMLogGrs(, ) [Terminology] Specify the string variable to assign. ...
  • Page 94 C_PMLogBlt: Maintenance log (timing belt) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the timing belt. [Format] Example) = C_PMLogBlt(, ) [Terminology] Specify the string variable to assign. ...
  • Page 95 C_PMLogDec: Maintenance log (reduction gear) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the decelerator. [Format] Example) = C_PMLogDec(, ) [Terminology] Specify the string variable to assign. ...
  • Page 96 C_PMLogBrg: Maintenance log (bearing) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the bearing. [Format] Example) = C_PMLogBrg(, ) [Terminology] Specify the string variable to assign. ...
  • Page 97 C_PMLogBss: Maintenance log (ball screw/ball spline) [Function] Returns the maintenance log data (the reset date and time, the consumption degree when resetting) of the ball screw / ball spline. [Format] Example) = C_PMLogBss(, ) [Terminology] Specify the string variable to assign. ...
  • Page 98 C_PMLogOH: Maintenance log (overhaul (servo ON time)) [Function] Returns the maintenance log data (the reset date and time, the cumulative time of servo ON when resetting) of the overhaul. [Format] Example) = C_PMLogOH() [Terminology] Specify the string variable to assign. ...

  • Page 99: Consumption Degree

    12.2.4 Consumption degree M_PMCsmMnt: Consumption degree (mechanism total (maintenance parts)) [Function] Returns the overall consumption degree of the maintenance part (grease and timing belt). [%] [Format] Example) = M_PMCsmMnt [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PMCsmMnt 'The overall consumption degree of the maintenance parts is set in M1.
  • Page 100 M_PMCsmOH: Consumption degree (mechanism total (overhaul parts)) [Function] Returns the overall consumption degree of the overhaul part (decelerator, bearing and ball screw / ball spline). [%] [Format] Example) = M_PMCsmOH [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PMCsmOH 'The overall consumption degree of the overhaul parts is set in M1.
  • Page 101 M_PMCsmGrs: Consumption degree (grease) [Function] Returns the consumption degree of the grease of the specified axis. [%] [Format] Example) = M_PMCsmGrs() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 102 M_PMCsmBlt: Consumption degree (timing belt) [Function] Returns the consumption degree of the timing belt of the specified axis. [%] [Format] Example) = M_PMCsmBlt() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 103 M_PMCsmDec: Consumption degree (reduction gear) [Function] Returns the consumption degree of the decelerator of the specified axis. [%] [Format] Example) = M_PMCsmDec() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 104 M_PMCsmBrg: Consumption degree (bearing) [Function] Returns the consumption degree of the bearing of the specified axis. [%] [Format] Example) = M_PMCsmBrg() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 105 M_PMCsmBss: Consumption degree (ball screw/ball spline) [Function] Returns the consumption degree of the ball screw / ball spline of the specified axis. [%] [Format] Example) = M_PMCsmBss() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count.
  • Page 106 M_PMRmnMnt: Remaining time (mechanism total (maintenance parts)) [Function] Returns the remaining time until maintenance of the maintenance part (grease and timing belt). [hour] [Format] Example) = M_PMRmnMnt [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PMRmnMnt 'The remaining time up to the maintenance of the maintenance part is set in M1.
  • Page 107 M_PMRmnSrv: Remaining time (servo ON time) [Function] Returns the remaining time until specified time of an overhaul of the cumulative time of servo ON. [hour] [Format] Example) = M_PMRmnSrv [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PMRmnSrv 'The remaining time up to overhaul of the overhaul part is set in M1.

  • Page 108: Consumption Status

    12.2.5 Consumption status M_PMStsMnt: Consumption status (mechanism total (maintenance parts)) [Function] Returns the consumption status of the maintenance part (grease and timing belt). [Format] Example) = M_PMStsMnt [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PMCsmMnt 'The overall consumption degree of the maintenance parts is set in M1.
  • Page 109 M_PMStsOH: Consumption status (mechanism total (overhaul parts)) [Function] Returns the consumption status of the overhaul part (decelerator, bearing and ball screw / ball spline). [Format] Example) = M_PMStsOH [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PMStsOH 'The consumption status of the overhaul part is set in M1.
  • Page 110 M_PMStsGrs: Consumption status (grease) [Function] Returns the consumption status of grease of the specified axis. [Format] Example) = M_PMStsGrs() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 111 M_PMStsBlt: Consumption status (timing belt) [Function] Returns the consumption status of timing belt of the specified axis. [Format] Example) = M_PMStsBlt() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 112 M_PMStsDec: Consumption status (reduction gear) [Function] Returns the consumption status of decelerator of the specified axis. [Format] Example) = M_PMStsDec() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 113 M_PMStsBrg: Consumption status (bearing) [Function] Returns the consumption status of bearing of the specified axis. [Format] Example) = M_PMStsBrg() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 114 M_PMStsBss: Consumption status (ball screw/ball spline) [Function] Returns the consumption status of ball screw / ball spline of the specified axis. [Format] Example) = M_PMStsBss() [Terminology] Specify the numeric variable to assign. Specify the joint axis to get the cumulative rotation count. (1 to 6) When omitted, 1 is used.
  • Page 115 M_PMStsSrv: Consumption status (servo ON time) [Function] Returns the arrival status to the specified time of an overhaul of the cumulative time of servo ON. [Format] Example) = M_PMStsSrv [Terminology] Specify the numeric variable to assign. [Sample] 1 M1 = M_PMStsSrv 'The arrival status to the specified overhaul time is set in M1.

  • Page 116: Notification

    12.2.6 Notification M_PMRptGrs: Notification pause status (grease) [Function] Returns the stop status of warning / signal output, of grease consumption of the specified axis. [Format] Example) = M_PMRptGrs [Terminology] Specify the numeric variable to assign. ...
  • Page 117 M_PMRptBlt: Notification pause status (timing belt) [Function] Returns the stop status of warning / signal output, of timing belt consumption of the specified axis. [Format] Example) = M_PMRptBlt [Terminology] Specify the numeric variable to assign. ...
  • Page 118 M_PMRptDec: Notification pause status (reduction gear) [Function] Returns the stop status of warning / signal output, of decelerator consumption of the specified axis. [Format] Example) = M_PMRptDec [Terminology] Specify the numeric variable to assign. Specify the joint axis for which to get a log.
  • Page 119 M_PMRptBrg: Notification pause status (bearing) [Function] Returns the stop status of warning / signal output, of bearing consumption of the specified axis. [Format] Example) = M_PMRptBrg [Terminology] Specify the numeric variable to assign. Specify the joint axis for which to get a log.
  • Page 120 M_PMRptBss: Consumption status (ball screw/ball spline) [Function] Returns the stop status of warning / signal output, of ball screw / ball spline consumption of the specified axis. [Format] Example) = M_PMRptBss [Terminology] Specify the numeric variable to assign. ...
  • Page 121 M_PMRptSrv: Notification pause status (servo ON time) [Function] Returns the stop status of warning / signal output, of arrival status to the specified time of an overhaul of the cumulative time of servo ON. [Format] Example) = M_PMRptSrv [Terminology] ...

  • Page 122: Melfa Smart Plus

    12.3 MELFA Smart Plus 12.3.1 MELFA Smart Plus card M_SmartPlus: MELFA Smart Plus function usage status [Function] Refer to the available status of each function of MELFA Smart Plus. [Format] Example) = M_SmartPlus() [Terminology] Specify the numeric variable to assign. 0 : Disabled 1 : Enabled ...
  • Page 123 C_SmartPlus: MELFA Smart Plus function name [Function] Returns the function name of MELFA Smart Plus. [Format] Example) = C_SmartPlus() [Terminology] Specify the character string variable to assign. Calibration assistance / Robot temperature compensation / Coordinated control for additional axes / Preventive Maintenance Extended function of MELFA-3D Vision /...

  • Page 124: Parameter

    13. Parameter 13.1 Common to preventive maintenance functions Parameter Number of Factory Parameter Details explanation name elements setting Pause method of PMSTPWAY Integer 1 Specify the pause method of warning occurrence warning or warning signal output of the preventive occurrence maintenance function.

  • Page 125: Consumption Degree Calculation Function

    13.2 Consumption degree calculation function 13.2.1 Setting parameters Number Parameter Parameter Details explanation Factory setting name elements Warning PMWNGDAY Integer 2 Specify the warning remaining number of days (30, 16) remaining and operation time of a day of the preventive number of maintenance function.

  • Page 126: Data Acquisition Parameter

    13.2.2 Data acquisition parameter The following operations are possible using the data acquisition parameters of the consumption degree calculation function. Get the integration time and accumulation count from the previous overhaul. (Total) Get the consumption degree [%] of the target part. (Total/for each joint axis) Get the remaining time [h] to the recommended maintenance time of the target part.
  • Page 127 Parameter Number of Attribute Parameter Details explanation name elements Consumption degree of the Consumption degree of the preventive preventive maintenance maintenance function (grease) function (grease) (Up to three decimal places) Real CSMPMGRS number 8 * "-1" when the preventive maintenance function is disabled, and "0"...
  • Page 128 Parameter Number of Attribute Parameter Details explanation name elements Consumption status of the STSPMMNT Integer 1 Consumption status of the preventive preventive maintenance maintenance function (mechanism total function (mechanism total (maintenance parts)) (maintenance parts)) -1: The preventive maintenance function is disabled 0: The remaining time exceeded the warning occurrence remaining time.
  • Page 129 Parameter Number of Attribute Parameter Details explanation name elements Consumption status of the STSPMSRV Integer 1 Consumption status of the preventive preventive maintenance maintenance function (servo ON time (at function (servo ON time (at overhaul implementation)) overhaul implementation)) The meaning of the value is the same as that of the mechanism total (maintenance parts) (STSPMMNT).

  • Page 130: Operation Parameters

    13.2.3 Operation parameters The following operations are possible using the parameters for operation of the consumption degree calculation function. Reset consumption degree reset of the target part. (For each joint axis) Pause occurrence of warnings until consumption degree reset of the target part. (For each joint axis) Get the consumption degree warning occurrence status or pause status of the target part.
  • Page 131 Parameter Number of Attribute Parameter Details explanation name elements Resets total accumulated data related to the Operating information RSTPMOH Integer 1 operating information (integration time, (integration time, accumulation count) of the preventive accumulation count) total accumulated data reset maintenance function. (Used at the time of overhaul.) In order to prevent mis-operation, the value upon reading is [-1] (out of setting range).
  • Page 132 Parameter Number of Attribute Parameter Details explanation name elements Consumption degree Specifies pause of warning RPTPMDEC Integer 8 (reduction gear) occurrence/warning signal output of the consumption degree (reduction gear) of Specifying pause of each joint axis. warning occurrence/warning * The meaning of reading and writing is the signal output same as that of grease (RPTPMGRS).
  • Page 133 Parameter Number of Attribute Parameter Details explanation name elements Specifying data to get LOGPMNO Integer 2 Specifies the data to get the maintenance log maintenance log of the preventive maintenance function. It is possible to get specified data (log number, joint axis number) for each part using the following virtual parameters.
  • Page 134 Parameter Number of Attribute Parameter Details explanation name elements Getting maintenance log LOGPMOH Character Gets maintenance log (overhaul) data. (overhaul) data string 6 Element 5: Servo ON time [h] at reset (integer) * If a log number with which there is no recorded data or nonexistent joint axis number is specified, the output becomes as follows:...
  • Page 135 < MEMO >> Parameter 125...

  • Page 136: Dedicated Input/Output Signals

    14. Dedicated input/output signals This section describes dedicated input/output signals related to the preventive maintenance function. To use those signals, from the Preventive Maintenance screen, click the [Setting] - [Signal] screen and (Note 1) assign a signal number to the respective parameter. For the setting procedure for signal numbers, refer to "3.
  • Page 137 Signal number at factory Parameter Signal default Category Function name level CR800-R/Q CR800-D -1 (No -1 (No − − Input meaning), meaning), Maintenance warning of preventive maintenance (grease) PMSIGGRS Outputs the effect that the remaining time − Output (remaining recommended maintenance time) of the grease exceeded the warning occurrence detection level.
  • Page 138 Signal number at factory Parameter Signal default Category Function name level CR800-R/Q CR800-D Consumption degree reset of preventive maintenance (grease) − Input Resets the grease consumption degree information. PMRSTGRS * The reset target axis is specified in IODATA or DIODATA using the axis bit pattern.
  • Page 139 Signal number at factory Parameter Signal default Category Function name level CR800-R/Q CR800-D Pause of warning and warning signal output (grease) − Input * The pause target axis is specified in IODATA or PMSTPGRS DIODATA using the axis bit pattern. Pause of unspecified axes is canceled.

  • Page 140: Troubleshooting

    15. Troubleshooting 15.1 Error number list This section describes the cause and countermeasure to take for the error numbers when errors related to the preventive maintenance function occurs. In event of an error, refer to this chapter and take appropriate action. For other error numbers described in this chapter, refer to the separate volume, "Troubleshooting in CR800 Series Controller Instruction Manual".

  • Page 141: Consumption Degree Calculation Function

    15.1.2 Consumption degree calculation function In case the remaining time up to the recommended replacement/maintenance time of each part or the remaining time up to the specified overhaul time exceeded the remaining time of warning occurrence specified by the "PMWNGDAY" parameter, or the setting of the dedicated output signal is incorrect, the following warnings will occur.
  • Page 142 Error number Causes of the error and its countermeasures Upper four Lower five digits digits Error Illegal parameter (PMSIGGRS) message Cause The parameter setting is illegal Measures Correct the parameter Error Illegal parameter (PMSIGBLT) message Cause The parameter setting is illegal Measures Correct the parameter Error...
  • Page 143 Error number Causes of the error and its countermeasures Upper four Lower five digits digits Error Illegal parameter (PMRSTNEW) message Cause The parameter setting is illegal Measures Correct the parameter Error Illegal parameter (PMSTPGRS) message Cause The parameter setting is illegal Measures Correct the parameter Error...

  • Page 144: Melfa Smart Plus Card

    15.1.3 MELFA Smart Plus card Indicates the error number related to the MELFA Smart Plus card. Error number Error cause and measures Error message Cannot use the MELFA Smart Plus. L3780 Cause Invalid MELFA Smart Plus. Measures Check the MELFA Smart Plus card or parameter. Error message Cannot use the MELFA Smart Plus.
  • Page 146 Sep., 2018 MEE Printed in Japan on recycled paper. Specifications are subject to change without notice.

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