BJA23006

Grinding and deburring

Application
Standard specification

FA Robot Division
 Notes on Use of
Grinding and deburring applications

Insufficient daily maintenance described in the instruction manual for the grinding/deburring tool
may cause malfunction or shorten the product life due to wear, stain, etc.
CAUTIONThe warranty policy shall not apply to the case when the maintenance work described in the
instruction manual was not carried out properly even if during the guarantee period. In this case,
all repair work shall be charged.
In addition, please be aware that we will not compensate for any damage to your company caused
by the malfunction of the grinding/deburring tool if maintenance is not carried out.

(1) Note that the functions and performance described in this document are not 100% assured in
every user’s system. Therefore, take this document just as a reference when installing the
IMPORTANT system.
(2) Before installing the grinding/deburring tool, be sure to inform us of the composition information
on the peripheral jig and also prepare the sample workpiece that has the same groove
information (shape, size, angle, etc.), shape of the seam line, and surface condition (mill scale,
glaze, etc.) as the actual workpiece. And then make a request of the prior experiment to us.
We will carry out the application test and let users know the details if turned out applicable.
(3) We guarantee the performance within the range verified by the grinding/deburring tool for the
sample workpiece used in the prior experiment or any other workpiece with the identical
conditions as the sample workpiece.
(4) If the composition of peripheral jigs or the conditions of workpiece are different from the one
used in the prior experiment, the Grinding and deburring tool may not be applicable. In that
case, we will not guarantee the performance.
(5) If applying the grinding/deburring tool to the workpiece in which the prior experiment was not
conducted, users shall be responsible for the application. Although we could conduct the
onerous application test, we will not guarantee the specification users requested.
(6) We will not guarantee the conditions of the workpiece.
(7) The contents described in this document are subject to change without notice for the
improvement of products.
(8) The product specification may be partly different according to the system in which this product
is applied.
 Contents
Introduction ............................................................................................................................................................................ - 1 -
Chapter 1 System Configuration ............................................................................................................................................ - 7 -
1.1 Examples of Deburring Robot System Configuration ................................................................................... - 7 -
1.1.1 Composition and Equipment List of Deburring Robot System ............................................................... - 7 -
1.2 Example of Grinding Robot System Configuration ....................................................................................... - 9 -
1.2.1 Composition and Equipment List of Grinding Robot System .................................................................. - 9 -
1.2.2 Grinding tool controller ......................................................................................................................... - 10 -
1.2.3 Grinding tool cable ............................................................................................................................... - 10 -
1.2.4 Grinding tools ....................................................................................................................................... - 11 -
1.2.5 Tooling (BT30 shanks) ......................................................................................................................... - 12 -
1.2.6 Grinding wheel ..................................................................................................................................... - 12 -
1.3 Interface board........................................................................................................................................... - 13 -
Chapter 2 Standard specifications ........................................................................................................................................ - 14 -
2.1 Application scope ....................................................................................................................................... - 14 -
2.2 Software Specifications.............................................................................................................................. - 16 -
Chapter 3 Delivery Terms ..................................................................................................................................................... - 17 -
Chapter 4 Notes on Installation ............................................................................................................................................ - 18 -
4.1 Selection for Installation Location .............................................................................................................. - 18 -
4.2 Connecting the primary power supply ........................................................................................................ - 18 -
4.3 Installation of guarding fences and layout of peripheral equipment ........................................................... - 19 -
Chapter 5 Safety .................................................................................................................................................................. - 20 -
Chapter 6 Assurance............................................................................................................................................................ - 20 -
6.1 Guarantee Period ...................................................................................................................................... - 20 -
6.2 Assurance scope ....................................................................................................................................... - 20 -
6.3 Restriction of responsibility ........................................................................................................................ - 21 -
6.4 Services within the warranty period ........................................................................................................... - 21 -
Chapter 7 Periodic Inspection Schedule ............................................................................................................................... - 22 -
7.1 Robot inspection schedule ......................................................................................................................... - 22 -
7.2 Inspection items of peripheral equipment .................................................................................................. - 23 -
7.2.1 Grinding and deburring tools ................................................................................................................ - 23 -
7.2.2 Cooling water circulation unit ............................................................................................................... - 23 -
Chapter 8 Restrictions.......................................................................................................................................................... - 24 -
Introduction
<Features of grinding and deburring applications>
The grinding and deburring application is a product that can easily realize the automation of grinding and deburring
processes by controlling the processing tool from the robot.

■ Optimum processing by dedicated command for grinding and deburring

Dedicated commands for grinding and deburring are provided as standard. Various parameters required for
starting and ending processing can be taught from the teach pendant by a single command. Stable grinding
and deburring can be achieved by controlling the setting timing of parameters required for processing all at
once from the robot.

Processing start command <CTS> Processing end command <CTE>

Fig. 1 Teaching screen of dedicated command for grinding and deburring

■ Improved workability with one-touch key

Functions frequently used in grinding and deburring are assigned to software keys. It can be recalled with one
touch, and the number of operations of the teach pendant can be reduced, thus improving workability at the
manufacturing site.

Of the processing tool

Rotating ON/OFF

Of the processing tool

Switch

Teaching of processing start

command
In the direction of
rotation
Switch
Changing settings
related to grinding and
deburring
Fig. 2 One-touch key example

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■ Equipped with interface for each processing tool controller manufacturer as standard
Interfaces with major processing tool controller manufacturers are incorporated as standard.
Since the setup is completed simply by selecting the control method, the number of man-hours for starting
the grinding and deburring processing system is greatly reduced.

Fig. 3 Example of Interface Function Dedicated to Manufacturer of Processing Tool Controller

■ Monitoring of processing tool status

You can monitor the status of the processing tool at hand.
Items that can be monitored can be selected according to the processing tool, such as rotation speed, feed
rate, and pressure.

Fig. 4 Example of monitoring function of processing tool

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■ Simple teaching support function which can reduce teaching man-hours of program for grinding
The grinding pattern generation function, which enables easy teaching of grinding patterns of typical shapes,
is incorporated as standard.
Teaching man-hours are greatly reduced because the whole teaching position is automatically generated by
only teaching feature points such as a plane, a curved surface, and a polyhedron.

Teaching Features Generates overall teaching points

Flat surface
Curved surface
Polyhedron

Fig. 5 Grinding pattern generation function

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■ Stabilization of processing quality by active compliance control and pressure control
Active compliance control and pressure control can be performed by the active compliance controller
manufactured by PushCorp, Inc. Stable grinding and deburring can be achieved by compliance control in
accordance with the raised surface of the processed surface and by adjusting the pressing force in accordance
with rough and polishing processing.

Before processing Rough processing Polishing

Grinding
point
Grinding speed: 120cm/min
Material: Mild steel square pipe Grinding speed: 70cm/min Grinding frequency: 1 time
40 x 40 mm Grinding frequency: 2 times Abrasive material:
Bead height: 2mm Abrasive material: 3M TS disc 982C 80+ 3M Scotch Brite
Bead Width: 7mm Others: With slope function Lolock TS Metacon
DiskAM #180
Fig. 6 Pressure Control and Active Compliance Control

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■ Improvement of processing quality by controlling processing conditions smoothly
Processing conditions can be changed smoothly in the grinding section.
The finish of the processed surface is improved by changing the processing conditions smoothly according to
the area where the thickness changes gradually, such as the bead end.

The bead is
low.

Before grinding
Processing conditions changed No change in processing conditions

force reduction constant force

Force

Force
Time Time

Do not shave
too much. Scrape down
to the base
metal.

Grinding speed: 40cm/min Grinding speed: 40cm/min

Grinding frequency: 1 time Grinding frequency: 1 time
Initial pressure: 30N Initial pressure: 30N
End-Pressure: 10N End-Pressure: 30N

Fig. 7 Smooth control of processing conditions

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 ■ Improvement of processing efficiency by realizing the same movement as manual grinding
Equipped with a pattern operation function for widening the grinding range and flattening it.
Reproduces manual grinding operations in a variety of patterns, including linear functions, trigonometric
functions, and arcs.

Completion of
Start of grinding Completion
grinding of
operation
operation
Start of machining operation
operation

Abrasive processing tool

Teaching line Grinding

operation Material
Planarization of
processed surface

Fig. 8 Grinding weaving function

■ Monitoring of cutting load

When using a cutting tool such as milling, an increase in cutting load due to cutting tool wear is detected, an
alarm is output, and cutting conditions are automatically switched. This allows the cutting to continue while
the replacement cutting tool is being prepared.

Fig. 9 Cutting result of aluminum block with end mill

(Cutting Speed 1m/min, Cutting Depth 2mm, Dry Cutting)

<Restrictions>

Refer to Chapter 8 ”Restrictions”.

・Please contact our sales department if the composition of your request is not described in this
manual.
IMPORTANT

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Chapter 1 System Configuration

1.1 Examples of Deburring Robot System Configuration

1.1.1 Composition and Equipment List of Deburring Robot System

The components of the deburring tool controller are shown below.

Table 1.1.1 Example of Deburring Robot System Configuration (*1)

User's
Reference No. and part name (*2) Remarks
preparations
(1) Communication cable ✓ Prepare the cables according to the interface.
(2) Interface board Refer to Table 1.3.1 Interface board list
(3) Application software Standard on robot controller
(4) Deburring tool controller ✓ Dedicated Inverter/General-purpose Inverter
(5) Filter regulator ✓
(6) Air filter ✓ For air: Filtration rating 0.3 μm
(7) Deburring tool cable ✓ Power line, Signal line
(8) Air hose ✓ For cooling
(9) Deburring tool ✓ Spindle motor, cutting tool, etc.

*1: The configuration may change according to the processing requirements.

*2: For reference No., refer to Fig. 1.1.1. (1) and (4) to (9) are prepared by the user.

User’s preparations

Air

Fig. 1.1.1 Example of Deburring Robot System Configuration (example of applying the FD-NA20 manipulator)

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 Table 1.1.2 [Reference] Example of Deburring Robot Peripheral Configuration (*1)
Reference No. and part name (*2) User's preparations Remarks
(7) Deburring tool cable ✓ Power line, Signal line
(8) Air hose ✓ For cooling
(9) Deburring tool ✓ Spindle motor, cutting tool, etc.
(10) Hanger L6532B
(11) Hanger L7419B
(12) Mounting bracket ✓
(13) Balancer ✓

*1: The configuration may change according to the processing requirements.

*2: For reference No., refer to Fig. 1.1.2. (7) to (9), (12) and (13) are User's preparations.

User’s preparations

Fig. 1.1.2 [Reference] Example of Deburring Robot Peripheral Configuration

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 1.2 Example of Grinding Robot System Configuration

1.2.1 Composition and Equipment List of Grinding Robot System

The basic configuration of the active compliance controller manufactured by PushCorp, Inc. is shown below.

Table 1.2.1 Example of Grinding Robot System Configuration (*1)

Reference No. and part name
Drawing No. Remarks
(*2)
(1) Ethernet cable L23328B 5m
(2) Interface board EtherNet/IP I/F (Slave) (see Table 1.3.1)
(3) Application software Standard on robot controller
AS controller manufactured by Aichi Sangyo co., Ltd.
(4) Grinding tool controller
(see Table 1.2.2)
(5) Cooling water circulation unit U6350 PU-701
(6) Air flow controller (*4) L24783F
10m(, 15m, 20m)
(7) Grinding tool cable
Power cable, control cable, etc. (see Table 1.2.4)
The air piping from the air flow regulator to the factory
(8) Air hose L24783F
piping is prepared by the user.
(9) Water hose L7689J
(10) Mounting bracket L12227A
spindle motor and active compliance controller (*3)
(11) Grinding tools
(see Table 1.2.5 and Table 1.2.6)
User's
(12) Tooling (BT30 shanks) Include a collet
preparations
User's
(13) Grinding wheel
preparations
(14) Emergency stop Cable L24788B 5m(, 10m, 15m)

*1: The configuration may change according to the processing requirements.

*2: For reference No., refer to Fig. 1.2.1. (12) and (13) are prepared by the user.
*3: Manufactured by PushCorp, Inc (Standard Specification),
Aichi Sangyo co., Ltd. (Auto Tool Changer Specification).
*4: Includes (8). The air hose to the factory piping is prepared by the user.

User’s preparations

Air

Fig. 1.2.1 Example of Grinding Processing System Configuration (Example of applying the FD-B100 Manipulator)

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 1.2.2 Grinding tool controller
The components of the grinding tool controller are shown below.
These components are integrated into AS controller.

Table 1.2.2 AS Controller Components (manufactured by Aichi Sangyo co., Ltd.)

No. Name Drawing No. Specifications
(4)-1 Interface unit L24783B Model :PushCorpAS-200 V-N
Servo amplifier for spindle
(4)-2 L24783C Model :S724-03131
unit
Controller for active
(4)-3 L24783D Model: FCUFLEX
compliance control
ANYBUS ETHERNET/IP
(4)-4 L24783E Model: Unit for PAR04288(FCUFLEX)
Module

Use the following 5 m cable for connection to the FD19 controller.

If the cable length is insufficient, use 10 m or 15 m.

Table 1.2.3 Components of the cable between FD19 controller and AS controller
No. Name Drawing No. Specifications
(1) Ethernet cable L23328□ □：B 5m
：C 10m
(14) Emergency stop Cable L24788□ ：D 15m

Ethernet
Cable

Emergency
stop Cable

FD19 controller AS controller

Fig. 1.2.2 Connecting to AS controller

1.2.3 Grinding tool cable

The components of the grinding tool cable are shown below.
Select the cable length according to the layout. The smallest bend radii are 125mm.

Table 1.2.4 Grinding Tool Cable Components (manufactured by Aichi Sangyo co., Ltd.)
No. Name Drawing No. Specifications
Communication cable for
(7)-1 L24784□
Spindle motor □ : B 10m
Power cable for Spindle : C 15m
(7)-2 L24785□
motor : D 20m
Control cable for Active
(7)-3 L24786□
compliance controller

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 1.2.4 Grinding tools
The components of the grinding tool are shown below. The components differ between the Standard
Specification and the Auto Tool Changer Specification. Select the one that best suits your grinding application.

Table 1.2.5 Grinding Tool (Standard Specification) Components (*1) (manufactured by PushCorp, Inc.)
No. Name Drawing No. Specifications
Model :STC1503-BT30
Speed: 60 to 15000rpm
(11)-
Spindle motor L24781B Rated power: 2.2kW, Rated torque: 3.5N･m
1
Body weight: 12.7kg, shanks: BT30 standard
Cooling method: Water cooling (*2)
Model: AFD310-2-02967, mounting: Horizontal
(11)- Active compliance Set Pressure: 1 to 267N, Accuracy: ± 1.0N
L24782B
2 controller Stroke length :20mm
Max. loading weight: 27.2kg, body weight: 5.5kg
Model :ASM01114
(11)- Bracket for Spindle motor
L24787B Connection of spindle motor to active compliance
3 installation
controller
*1: In addition to these, there are also components that are compatible with high loads, extended strokes and ER collets.
*2: Connect the cooling water circulation unit and use the product within the optimum motor temperature range (50°C to
60°C).
Check the cooling capacity of the cooling water circulation unit when changing the high load or components.

Spindle motor Active compliance controller

Bracket for Spindle motor installation

Fig. 1.2.3 Grinding tool(Standard Specification)

Table 1.2.6 Grinding Tool (Auto Tool Changer Specification) Components (*1) (manufactured by Aichi Sangyo co., Ltd.)
No. Name Drawing No. Specifications
Auto Tool Changer Specification
Model :STC1503-BT30(SWR0500-T)
Spindle motor
(11)- Speed: 60 to 15000rpm
(Auto Tool Changer L24781C
4 Rated power: 2.2kW, Rated torque: 3.5N･m
Specification)
Body weight: 12.7kg, shanks: BT30 standard
Cooling method: Water cooling (*2)
Auto Tool Changer Specification
Active compliance
Model: AFD310-2-02967(SWR0500-MF)
(11)- controller
L24782C Mounting: Horizontal, Set Pressure: 1 to 267N
5 (Auto Tool Changer
Accuracy: ± 1.0N,Stroke length :20mm
Specification)
Max. loading weight: 27.2kg, body weight: 5.5kg
*1: In addition to these, there are also components that are compatible with high loads, extended strokes and ER collets.
*2: Connect the cooling water circulation unit and use the product within the optimum motor temperature range (50°C to
60°C).
Check the cooling capacity of the cooling water circulation unit when changing the high load or components.

Active compliance
controller

Auto Tool Changer Spindle motor

Fig. 1.2.4 Grinding tool (Auto Tool Changer Specification)

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1.2.5 Tooling (BT30 shanks)
Tooling is prepared by the user.
Prepare the tooling corresponding to BT30 shank standard.
Also consider the installation of the grinding wheel and prepare the collet.

1.2.6 Grinding wheel

The grinding wheel is prepared by the user.
Prepare a collet that can be attached to the tool folder.

Be sure to conduct preliminary application experiments when selecting a grinding wheel. For details, contact our
sales department.

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 1.3 Interface board
An interface board is provided for connecting the robotic controller and the processing tool controller with a digital
I/O or various fieldbuses. Cables connected to these interface boards are prepared by the user.
For example, if the connection method is digital I/O, prepare boards for the required number of input/output
points from (1) and (2). For fieldbus, prepare the corresponding boards from (3) to (8) and (9).

Table 1.3.1 Interface board list

Interface board (*1) Product name Drawing No. Specification
(1) Arc I/F board-type (*4) - - Digital I/O, 8 inputs/8 outputs
Digital I/O, input/input 32 points,
Relay unit #1 L23424A
output/output 32 points
I/O board (*3) L23517A One relay unit can be connected
(2) Relay-unit (*4) Relay unit #2 L23425A Extension Digital I/O, 32 inputs/32 outputs
Cable flange L23548M For cable φ9-19
Cable flange L23548N For cable φ6-12
PCIe riser board L23400V
Base substrate L24187B
(3) DeviceNet I/F Supports master module and slave module
Master module L23595M
Slave module L9851S
PCIe riser board L23400V
(4) CC-Link I/F kits Supports master module and slave module
CC-Link I/F kits L23594C
PCIe riser board L23400V
(5) CC-Link IE I/F kits Supports master module and slave module
CC-Link IE I/F kits L23965C
PCIe riser board L23400V
Base substrate L24187B
(6) ProfiBus I/F kits Supports master module and slave module
Master module L9890M
Slave module L9890S
PCIe riser board L23400V
Base substrate L24187B Supports scanner modules and adapter
(7) EtherNet/IP I/F kits
Scanner module L9477M modules
Adapter module L9477S
PCIe riser board L23400V
(8) PROFINET (*2) Base substrate L24187B Supports slave modules
Slave module L22869S
Applicable cable diameter: φ6.4mm to
Cable flange L4800B84
(9) Cable flange • Bushing φ7.4mm
Cord bushing SR5P-4

*1: For robot controller. The interface board to be installed in the processing tool controller should be
prepared by the user.
*2: Only slave modules are supported. The master module is not supported.
*3: Two I/O boards are required when using the relay unit (drawing No. L23424A) and relay unit #2
(drawing No. L23425A).
*4: For the electric specifications, refer to "3.9 Signal Specifications of Optional Physical I/O board" in
the "Setup" (1L23400B) of the Instruction Manual.

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Chapter 2 Standard specifications

2.1 Application scope

Table 2.1.1 Applicable range for grinding and deburring applications
Item Specification
All FD series-robotics
Manipulator (Recommended) Robotic (*3) with three times or more payload
than the processing tool and fixed bracket total mass
Robot controller FD19 controller
General-purpose inverters corresponding to Table 2.1.2
Corresponding processing tool
Or dedicated inverter (*1) of the spindle motor manufacturer
controller
Or dedicated controllers (*7)
Digital I/O
Processing tool connection method
Fieldbus (*2)
Maximum number of units connected Processing tool controller 1 per robot controller
Usage Dry roughing cutting (*4), dry deburring (*4), dry grinding (*4)
*1: The inverters that can be connected are E4000 controllers (Table 2.1.2 A) manufactured by
NAKANISHI Inc. and the inverter V1000manufactured by YASKAWA Electric Corp. (Table 2.1.2
B and C). Inverters with the same interface specifications can be connected. If you have any
questions about the devices that can be connected, contact our sales department.
*2: See Table 1.3.1 for the corresponding fieldbus.
*3: The required payload will increase or decrease depending on the cutting conditions and cutting load.
*4: Contact our sales department if you wish to have a wet (liquid or spray, such as cooling or lubrication)
environment.
*7: Active compliance control requires AS controller manufactured by Aichi Sangyo co., Ltd.

Table 2.1.2 Connectable Processing Tool Controller Interface Specifications

Contact
Function
Direction Name combination
ON OFF A B C
Processing tool
Start/Stop rotation Stop ✔
rotation
Forward rotation of
Forward start/stop Stop ✔
processing tool
Reverse rotation
Reverse start/stop Stop ✔
of processing tool
Rotational direction Reverse rotation Forward
Input ✔ ✔
setup direction direction
signal Processing tool
Start of rotation - ✔
rotation
Stop - Stop ✔
Velocity selection
Binary data of speed number ✔ ✔
(*5)
Speed setting (*6) Binary data of rotational speed ✔
Processing tool
Rotating Stop ✔ ✔ ✔
Output rotating
signal Rotational
- Discrepancy ✔ ✔ ✔
coincidence
*5: Speed number registered in the dedicated/general-purpose inverter.
e.g., No.0=8000r/min, No.1=10000r/min, No.2=12000r/min
*6: The setting range and minimum setting unit conform to the specifications of the processing tool
controller.

The specifications of AS controller are shown below.

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 Table 2.1.3 AS controller (manufactured by Aichi Sangyo co., Ltd.)
Item Specification
Power supply 3Φ AC200V±10%
Maximum power capacity 4kVA
Environ Ambient
+10 to +50℃
mental temperature
resistanc Ambient
5 to 85%RH (non-condensing)
e humidity
Air specifications More than 0.62MPa to 0.69MPa, 56L/min
Dimensions (W×D×H) 600 × 400 × 800 (mm)
Mass About 48kg

The specifications of the cooling water circulation unit are shown below.

Table 2.1.4 Cooling water circulation unit (PU-701)

Item Specification
Rated input voltage
AC200V (single phase)
(number of phases)
Input voltage range 180 to 220V
Rated frequency 50/60 Hz sharing
Rated input 0.25kVA (50Hz) / 0.33kVA (60Hz)
Discharge volume 11L/min (50Hz) / 13L/min (60Hz)
Maximum delivery
0.43MPa (50Hz) / 0.53MPa (60Hz)
pressure
Cooling capacity 1.20kW (50 / 60 Hz)
Pump head 20m
Cooling method Radiator forced cooling
Rated duty Continuous (at rated input voltage)
Tank capacity 6L
Dimensions (W×D×H) 352 × 530 × 350 (mm)
Mass 18kg (without coolant)

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 2.2 Software Specifications
Table 2.2.1 Grinding and deburring application software specifications

Item Specification

FN465 CTS Starts of grinding and deburring

Dedicated commands
FN466 CTE Ends of grinding and deburring

Direct value method Set rotation speed.

Rotational speed output
teaching method
Slope control of
processing conditions
Speed number
Set speed number for processing tool controller.
selection method
・The processing parameters (rotational speed, pressure (*2), etc.) are gently
changed at the start and end of processing.
・How to specify the slope section: Time (second), Distance (mm)

Air control Air ON/OFF can be controlled when processing starts and ends.

Processing conditions
Teaching method
Monitoring of cutting load
Grinding pattern
generation function
Direct value method Teaching the processing conditions at the direct value.
File specification Teaching processing conditions with the condition file
method number.
Load monitoring Current value monitoring of grinding and deburring tools.
Continue to stop immediately or change the processing
Overload detection
conditions.
Plane, curved, and polyhedron

Grinding weaving Linear, trigonometric, and circular

Processing tool selection, grinding and deburring processing constant setting,
grinding and deburring processing condition setting, Processing start command
Dedicated softkeys
(CTS), Processing end command (CTE), Processing tool rotation ON/OFF,
Rotation direction switching, grinding and deburring monitor
Detects the following abnormal conditions to stop the robot and display the error.
・Abnormalities and warnings from the processing tool
Safety function ・Rotation stop detection during processing
・Sequence control timeout with processing tool
・No processing condition file
Number of rotations that
1 to 100,000r/min (1 r/min units) (*1)
can be taught
*1: This is the rotation speed that can be taught by the dedicated command for grinding and deburring.
Actual RPM and minimum setting unit (resolution) conforms to the specifications of your
processing tool controller.
*2: Controls the active compliance controller manufactured by PushCorp, Inc.

Table 2.2.2 Processing applications suitable for each function

Processing applications
Item
Grinding Polishing Cutting Deburring
Monitoring of cutting load ✓
Slope control of
✓ ✓ ✓ ✓
processing conditions
Grinding pattern
✓ ✓
generation function
Grinding weaving ✓ ✓
Active Compliance Control
✓ ✓
and Pressure Control

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Chapter 3 Delivery Terms
Delivery of the grinding and deburring processing systems is basically carried out by ex-works at the designated factory.
Note that users shall be charged for any installation work.

Delivery conditions outside Japan may vary depending on the country or region where the
product is used. Contact us for details.
IMPORTANT

[Example]
･ Connection with the robot and robot controller, operation check, and grinding check with a standard test piece

Adjustment work to operate the grinding and deburring system for the customer's work
will be charged separately. However, this work will be completed when the performance
is demonstrated to the specifications. (The grinding and deburring tool performance may
CAUTIONnot always demonstrate the maximum specification depending on the workpiece type and
conditions of performance.)
Note that we will not guarantee the processing quality.

･ Cost for adding the grinding and deburring applications to the existent robot system
･ Discharging and carrying-in work by using the facilities of either your company or OTC-DAIHEN
･ Wiring and piping of the OTC-DAIHEN-manufactured jigs, I/F check, and interlocking trial operation
･ Teaching work, processing conditions adjustment, operator education, etc.

The customer is requested to perform the following work.

･ Foundation work of installation location for the grinding and deburring system and jigs (including both your company
and OTC-DAIHEN manufactured)
･ Installation work of grinding and deburring processing systems and jigs (including both your company and OTC-
DAIHEN manufactured)
･ Powering of the grinding and deburring system, primary wiring and piping of the air, and their protection work
･ Wiring and piping work for connecting the jig and jig controller prepared by your company with the grinding and
deburring processing system.

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Chapter 4 Notes on Installation
It is essential to properly install the robot for sustaining the functions and safely using the unit. Also, the
environment surrounding the installation location does not only have an influence on the life duration of equipment
but also is essential to secure the operator's safety.

4.1 Selection for Installation Location

Install this product in a location that meets all the following conditions.

Table 4.1.1 Check items for installation location

(1) □ No direct sunlight and the ambient temperature of 0 to 45°C throughout the year.

(2) □ The ambient humidity of RH80% or lower.

□
(3) Minimal dust, dirt, lampblack, water, etc.
□
(4) No flammable or corrosive liquid, gas, and other substances.
□ Vibration or shock transmitted to the robot controller and sensor one caused by operating the peripheral
(5)
equipment is 4.9 m/sec２ or less.
□
(6) No electrical noise sources (Plasma, high-frequency ionizer, etc.)
□
(7) Locations where the controller is isolated from cutting powder, cutting fluid, water, and mist oil.

4.2 Connecting the primary power supply

To ensure safety, be sure to carry out the grounding work.

To prevent the possibility of electric shock, turn off the power supply source before
installing the product.

Turn OFF the primary power and the breaker of robot controller.
Make sure that the primary power voltage agrees with the voltage specification of robot
controller. The voltage of robot controller is indicated beside the breaker.
WARNING

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4.3 Installation of guarding fences and layout of peripheral
equipment
Be sure to install a guarding fence around the robot and equipment (positioner, etc.) as shown in the figure
below to prevent persons from approaching the robot carelessly.

Be sure to install robot controllers, welders, and peripheral devices such as the operating
box, teach pendant and start box (option) outside the guarding fence.

Guarding fence

Guarding fence 1m or more

1m or more 1m or
more
Robot working range
Manipulator
Door

Operation box
Limit switch for turning off
the servo power when the 1m or more
door in the guard fence is Teach pendant
opened Processing tool controller
Robot controller Communication cables and control cables

Fig. 4.3.1 Example of guarding fence installation

The safety equipment, such as the external emergency stop switches, the safety plugs installed on the guarding
fence or the mat switches, must conform to the related safety standards.

When the installation place of robot controller is selected, note the following points.

(1) When installing the controller, leave a clearance of at least 100 mm between the controller and the wall behind
it in order to ensure proper ventilation inside the robot controller. At the rear side, secure a space of 400 mm
at least for external connection cable.
(2) To install a robot controller and welding power supply, etc. on a place two or more meters in height such as a
frame base, a foothold as described in Fig. 4.3.2 is required so that adjustment and maintenance, etc. can
be performed.

Fig. 4.3.2 Installation of robot controller

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Chapter 5 Safety
For handling a robot, comply with the rules and regulations for industrial robots.
For the handling of the processing tool, observe the contents described in the instruction manual of the equipment
manufacturer.

・For safety measures or emergency stop in the event of an error, perform wiring in which both the
robot and the processing tool stop.
IMPORTANT
・When connecting the emergency stop output of the robot controller to the processing tool controller,
supply power to CNEXIN1 from an external source. For the connection procedure, refer to "3.6.6
Emergency stop output connection (CNEXIN1:A15-B15, A16-B16)" in the Instruction Manual "Quick
Start" (1L23400A).

Chapter 6 Assurance

6.1 Guarantee Period

The guarantee period of target product is the shorter period of full 1 year after delivery and accumulated actual
operating time 2000 hours if it is not especially decided. (Note 1)
(Note 1): The accumulated actual operating time is the accumulated activation time of control power supply (AC200V).
The delivery date is defined as shown below.
- If our serviceman joins the deliver, the date when this equipment is started is decided as the starting date of
assurance.
- If our serviceman does not join the delivery, the delivery date at the location where we deliver this equipment
first is decided as the starting date of assurance.

6.2 Assurance scope

We will replace or repair the defective part of target product without charge at the place where the product is
purchased or delivered for the failure due to the responsibility on manufacturing, which is generated in proper
using status while the customer implements the periodical inspection described in the instruction manual within
the guarantee period.

However, the following cases are out of the assurance scope within the guarantee period, and the repair will be
implemented with charge.

(1) Failure caused by improper condition environment, handling and usage that are not described in the
instruction manual and catalog
(2) The fault is due to a reason other than our product.
(3) Failure due to the reason other than our product such as customer's equipment or software.
(4) Failure caused by the modification and repair implemented by party other than our company (including the
specified service shop).
(5) When the failure is caused by improper maintenance or replacement of consumable parts described in the
instruction manual and catalog (failure etc. caused by the use of goods other than genuine parts and parts
/ lubrication oil specified by our company)
(6) When the failure cannot be forecasted by the science / technology level as of purchase.
(7) Damage caused by natural disaster such as earthquake, fire, flood disaster or offence by third party and
the failure that has a roots in that damage.
(8) Failure caused by movement after delivery and defective storage.
(9) Sound, vibration, bleeding of oil, color degradation of coated surface, rust and slight dent on appearance
that have no problem in performance.
(10) Failure caused by transportation and construction work out of range of our construction.
(11) In case of reselling, assignment and lend-lease (including the rental equipment).
(12) Other case that conforms to above and consumable parts / service parts.
(13) When the assurance registration slip in which the customer name, installation date and manufacturing
number are described is not returned to our company.

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 However, the assurance here means the assurance of our product single unit, so the loss caused by the failure
of our company is not excluded from the range of assurance.

6.3 Restriction of responsibility

(1) We do not accept any responsibility on the opportunity loss, special loss, indirect loss caused by this equipment,
or accident compensation, damage other than out product.
(2) For the programmable this equipment, we do not accept any responsibility on the programming implemented
by person other than our company and the result caused by that programming.
(3) We do not accept any responsibility on the processing quality when this equipment is used.
(4) If this equipment is repaired or the parts are replaced, it is sometimes necessary to repair or adjust the existing
teaching program or parameter, however, please note that we do not accept any responsibility on those works.
(5) This assurance is applied only when this equipment is installed in Japan.
For the transaction and use outside Japan, please contact us.
(This warranty is valid only in Japan.)
(6) Deadline for supplying the robot maintenance parts described in the guarantee card is 7 years from the
discontinuation date of the product, and that for repairing is for 10 years.

6.4 Services within the warranty period

(1) If a failure is generated or for the periodical inspection, please contact us (including the specified service shop).
(2) In case of repair, be sure to show the guarantee card to the serviceman.
(3) If you have lost the guarantee card, we may charge you for service within the guarantee period, so keep it in a
safe place.
(4) The burden of expense for the servicing is decided as shown below.
(A) When the target product is incompatible
When we assess that the repair in the field (limited in Japan) is necessary within the guarantee period
above, the repair by dispatching the engineer will be implemented without charge.
(B) When the incompatibility is caused by other than target product.
The cost required for separating the incompatibility will be charted separately.
(C) When the cause of incompatibility cannot be identified.
If the incompatible part cannot be identified or the defect cannot be restaged after implementing the certain
separating work, we will consult with the customer on it.

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Chapter 7 Periodic Inspection Schedule
Regular inspections are essential for safe and efficient operation of grinding and deburring processes.

7.1 Robot inspection schedule

Perform the periodic inspection in accordance with the following schedule.

Be sure to overhaul in either a period of whole 6 years or 30,000 cumulative operating hours after delivery,
whichever is shorter.
The inspection and maintenance period is estimated, supposing the manipulator only for Arc welding use. For
more frequent use such as handling operation, that period may be shorter. Contact to our engineers for details.

3yr
Maintenanc
1yr 1yr 1yr
Inspection Inspection Inspection
3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths 3mths
Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection Inspection
DailyInspection

0 3mths 6mths 9mths 1yr 15mths 18mths 21mths 2yr 27mths 30mths 33mths 3yr ～

Deadline for Supplying/ Repairing the Robot Maintenance Parts

Deadline for supplying the robot maintenance parts is guaranteed for 7 years from the
discontinuation date of the product, and that for repairing is for 10 years.
IMPORTANTFor the detailed information about discontinuation date of the product, please see the
guidance on the maintenance parts in our website: https://www.daihen.co.jp/en/ .
※Repair of the maintenance parts is provided for the above period of time in principle, however,
we will support our customers as long as the stock is available. We will make our every effort
to secure the required maintenance parts. However, please note that it may be occasionally
unavailable due to the external factors such as the market situation even during the
guaranteed period.

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7.2 Inspection items of peripheral equipment
For the periodic inspection of grinding and deburring tools, etc., refer to the instruction manual of the equipment
manufacturer.

7.2.1 Grinding and deburring tools

The following shows the periodic inspection items when an active compliance controller (manufactured by
PushCorp, Inc.) is used.
Refer to the manual of the active compliance controller or the spindle motor for details of the inspection items.

Table 7.2.1 Inspection items (grinding and deburring tools)

Daily Weekly monthly
No. Inspection points
inspection inspection inspection
Check the abrasive material at the end of the grinding tool and
1 ✓
the disc for wear or damage.
Check the discs and abrasives on the tip of the grinding tool are
2 ✓
not loose.
3 Wipe the entire spindle clean and keep it clean. ✓
Check that the connectors of the spindle motor and active
4 ✓
compliance controller are not bent or damaged.
Check whether the spindle motor rotates smoothly and whether
5 ✓
the active compliance control moves up and down smoothly.
6 Wipe off BT30 taper shaft cleanly to keep it clean. ✓

7 Check for bent or damaged air and water hoses. ✓

✓: Required Inspection Items, Blank: Items that can be omitted

7.2.2 Cooling water circulation unit

The following are the periodic inspection items of the cooling water circulation unit (PU-701).
Refer to the instruction manual of the cooling water circulation unit (PU-701) for more information on the inspection
items.

Table 7.2.2 Inspection items (Cooling water circulation unit)

Daily monthly 6 months
No. Inspection points
inspection inspection inspection
1 Is the grinding tool or hose clogged? ✓

2 Is there enough cooling water in the tank? ✓

3 Is there any abnormal vibration, beat, or smell? ✓

Does the fan rotate smoothly when the power switch is turned
4 ✓
on?
5 Is there any malfunction with the switch? ✓

6 Clean the radiator fan, filter and hose interior ✓

7 Clean the tank and replace with new cooling water. ✓

✓: Required Inspection Items, Blank: Items that can be omitted

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Chapter 8 Restrictions
This chapter describes precautions for using the grinding and deburring applications.
(1) The processing accuracy differs depending on the type of processing tool, material, robot model, etc.
Therefore, the desired cutting performance may not be obtained. Be sure to conduct an application
experiment in advance.
(2) Shift instructions (Fn52 SHIFTR, Fn58 SHIFTA) cannot be used in combination with the
following functions:
Touch sensor, laser sensor, other groove position recognition sensor, seam tracking (manual
copying)
(3) Note that neglect of the teaching and maintenance operation described in the instruction manual may
cause insufficient grinding tool performance. And it may cause a failure.
(4) Note that devices not purchased from us will not be supported.
(5) The following processing tools cannot monitor the cutting load.
 Processing tools that do not support fieldbus
 Processing tools that cannot monitor the spindle motor current value
(6) OTC-DAIHEN is not responsible for the processing conditions.

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 ● The specifications, structure, and others are subject to change without prior notice
for the purpose of improvement in the product quality. For confirmation, be sure to
check the latest specifications prior to ordering.

Standard Specification for Grinding and Deburring Applications

August 1st edition, 2023