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1、ABB RoboticsProduct Manual IRB 55003HNA015911-001 en Rev.03Product ManualIRB 55003HNA015911-001 en Rev.03First Edition: 08 December 2009Last Revised: 08 April 2011Product Manual, IRB 5500The information in this document is subject to change without notice and should not be construed as a commitment

2、by ABB. ABB assumes no responsibility for any errors that may appear in this document.Except as may be expressly stated anywhere in this document, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose

3、or the like.In no event shall ABB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third p

4、arties without express authority is strictly forbidden.Additional copies of this document may be obtained from ABB at its then current charge. Copyright 2009-2011 ABB All right reserved.ABB AS, Robotics Discrete Automation and MotionN-4349 BRYNE, NorwayProduct Manual, IRB 5500Table of ContentsProduc

5、t Manual, IRB 5500Product Manual, IRB 55003HNA015911-001 en Rev.0371 Introduction112 Safety133 System Description153.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153.2 Basic Design. . . . . .

6、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163.2.1 Design Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163.2.2 Component Identification .

7、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173.2.3 Purge Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183.2.4 Identification Plate . . . . . . . . . . . . . . .

8、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193.3 The Axis 3 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203.3.1 The Axis 3 Arm and Drive Unit . . . . . . . . . . . .

9、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203.3.2 The Hollow Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223.4 The Axis 2 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233.5 The Base and Foot Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253.5.1 The Base Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11、 . . . . . . . . . . . . . . . . . . . . . . . . . . .253.5.2 The Foot Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273.6 Axes Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12、 . . . . . . . . . . . . . . . . . . . . . . . . . .283.7 The Axes Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293.8 The Pneumatic Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13、. . . . . . . . . . . . . . . . . . . . . . . . . .303.9 Boards Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314 Technical Specifications334.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .

14、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334.2 Manipulator Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344.3 Manipulator Specifications . . . . . . . . . . . . . . . .

15、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354.4 Hollow Wrist Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384.5 Foot Unit Specifications . . . . . . . . . . . . . . . . . . .

16、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404.6 Pneumatic Cabinet Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414.7 Permitted Load on Arm. . . . . . . . . . . . . . . . . . . . . . . . .

17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424.8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .444.9 Working Area Drawings . . . . . . . . . . . . . . . . . . . . . . .

18、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464.10 Bending Backward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .535 Installation and Commissioning575.1 Introduction . . . . . . . . . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .575.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .575.1.2 Installation Guidelines . . . .

20、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .595.2 Positioning the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605.3 Mounting Base . . . . . . . . . . . . . . . . .

21、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .615.4 Mechanical Installation of Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655.4.1 Mechanical Installation of Manipulator Configurati

22、on A/B . . . . . . . . . . . . . . . . . . . . . . . . . . .665.4.2 Mechanical Installation of Manipulator Vertical Configuration A/B . . . . . . . . . . . . . . . . . . . . .695.5 Mechanical Installation of Pneumatic Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23、. . . . . .735.6 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .745.7 Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24、 . . . . .755.8 Working Area Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .765.8.1 Axis 1 Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25、.775.8.2 Axis 2 Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785.8.3 Axis 3 Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .795.8.4 Elbow

26、 Joint Limitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .805.9 Concluding Activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825.10 Mechanical Dism

27、ounting of Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .835.10.1 Mechanical Dismounting of Manipulator Configuration A/B . . . . . . . . . . . . . . . . . . . . . . . . .845.10.2 Mechanical Dismounting of Manipulator Vertical Configuration A

28、/B. . . . . . . . . . . . . . . . . . .865.11 Manipulator Configuration Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .886 Preventive Maintenance936.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .936.2 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .946.3 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .956.4 Testing the Axis Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .966.5 Lubricate Axis 3 Slewing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . .

31、 . . . . . . . . . . . . . . . . . . . . . . . . . . . .976.6 Lubricate Axis 3 Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .986.7 Lubricate Hollow Wrist1016.8 Check Oil Level in Gearboxes1027 Repair1057.1 Introduction

32、1057.2 Releasing Axis Brakes1077.2.1 Introduction1077.2.2 Brake Release Safety1087.2.3 Manually Releasing Axis Brakes1097.3 Base Unit Guidelines1137.3.1 Removal of Motors for Axes 1 and 21147.3.2 Installation of Motors for Axes 1 and 21187.3.3 Removal of Gearboxes for Axes 1 and 21227.3.4 Installati

33、on of Gearboxes for Axes 1 and 21257.3.5 Removal of Foot Unit1287.3.6 Installation of Foot Unit1317.3.7 Replace Oil for Axes 1 and 21337.4 Axis 2 Arm Guidelines1377.4.1 Removal of Axis 2 Arm1387.4.2 Installation of Axis 2 Arm1427.4.3 Removal of Motor for Axis 31457.4.4 Installation of Motor for Axis

34、 31487.4.5 Removal of Axis 3 Gear1517.4.6 Installation of Axis 3 Gear1547.4.7 Removal of Diaphragm for Axis 3 Gearbox1587.4.8 Installation of Diaphragm for Axis 3 Gearbox1607.4.9 Replace Oil for Axis 31627.5 Axis 3 Arm Guidelines1657.5.1 Removal of Axis 3 Arm1667.5.2 Installation of Axis 3 Arm1697.5

35、.3 Removal of Axis 3 Arm Drive Unit1737.5.4 Installation of Axis 3 Arm Drive Unit1767.5.5 Removal of Motors in Axis 3 Arm1797.5.6 Installation of Motors in Axis 3 Arm1827.5.7 Removal of Wrist Drive Shafts1867.5.8 Installation of Wrist Drive Shafts1897.5.9 Replace Oil for Axes 4, 5, 61937.6 Hollow Wr

36、ist Unit Guidelines1977.6.1 Removal of Wrist Unit1987.6.2 Installation of Wrist Unit2007.6.3 Removal of Wrist Inner Flexible Hose2027.6.4 Installation of Wrist Inner Flexible Hose2057.6.5 Replace Wrist Seals2077.7 Replacing Cable Unit2097.7.1 Removal of Cable Unit2107.7.2 Installation of Cable Unit2

37、177.8 Calibration Fixture Installation2257.8.1 Introduction2257.8.2 Fixture Calibration2267.8.3 Calibration Fixture Installation, Axes 1,2,32277.8.4 Calibration Fixture Installation, Hollow Wrist2298 Decommissioning2319 Reference Information2339.1 Introduction2339.2 Mounting Instructions for Bearing

38、s2349.3 Mounting Instructions for Seals2359.4 Instructions for Tightening Screw Joints2379.5 Safety Instructions for Replacing Oil in Gearboxes2399.6 Oil Type Specifications240Product Manual, IRB 5500This manual provides information and instructions for installation, replacing parts and performing p

39、reventive maintenance on the IRB 5500 robot.WARNING! Before performing any work described in this manual, the Safety Manual must be read and understood. Work must only be performed by skilled personnel with the proper training.The Safety Manual is included in the Software and Documentation DVD follo

40、wing each robot, and is also shipped with the robot as paper copy, included in the control cabinet.Product Manual, IRB 55003HNA015911-001 en Rev.0391 Introduction1 IntroductionAbout This ManualThis manual contains information on the following: Mechanical and electrical installation of the manipulato

41、r. Description of the design of the manipulator. Technical specifications for the manipulator. Maintenance of the manipulator. Mechanical and electrical repair of the manipulator.UsageThis manual should be used during: Installation. Maintenance work. Repair work.Product Manual, IRB 55003HNA015911-00

42、1 en Rev.0311Who Should Read This Manual?This manual is intended for: Installation personnel. Maintenance personnel. Repair personnel.PrerequisitesThe reader should: Be a trained maintenance and repair craftsman. Have the required knowledge of mechanical and electrical installation, maintenance and

43、repair work.ChapterDescription1. IntroductionThis chapter.2. SafetyInformation on safety.3. System DescriptionInformation on function and design of the manipulator.4. Technical SpecificationsSpecifications for the manipulator, working area drawings, calculating load on arm etc.5. Installation and Co

44、mmissioningInformation about installation of the manipulator.6. Preventive MaintenanceInformation about maintenance work, including maintenance schedules.7. RepairInformation about repair work, including brake release information and mounting of calibration fixture.8. DecommissioningGeneral informat

45、ion for decommissioning the manipulator.9. Reference InformationInformation such as mounting instructions for bearings and seals, screw tightening torques and oil types.Organization of ChaptersThe manual is organized in the following chapters:ReferencesFollowing manuals are referred to in this manua

46、l:ManualDescriptionSafety Manual 3HNA008924-001This manual must be read before any work on the robot is performed.Product Manual, Control Cabinet IRC5P 3HNA009834-001Includes information on installation of purge unit.Unit Description, Paint 3HNA012856-001Includes technical description of the units u

47、sed in the paint system.Unit Description, IRC5P 3HNA009628-001Includes technical description of the control system electronics etc.Operators Manual, IRC5P 3HNA008861-001Includes description of the calibration function and procedure for entering calibration data etc.Technical Reference Manual - System Parameters 3HAC17076Includes in