The Omron i4L robot is a selective compliance assembly robot arm (SCARA) designed for automated motion control in factory environments, particularly for material handling operations. It is capable of high-speed, high-precision motion for payloads up to 5 kg, featuring a compact design and flexible programmability.
Function Description:
The i4L robot is an integrated system that operates with EtherCAT communications, allowing seamless integration with other networked devices, safety devices, vision systems, motion equipment, and discrete I/O. It is controlled by an NJ501 Robot Integrated CPU Unit, which provides both PLC functionality and robot control. The robot can be mounted on a horizontal (table mount) or vertical (wall mount) surface without additional adapters. It features a multi-colored LED light dome for status indication, with an integrated brake release button. Mounting points are available for external equipment like cameras and solenoid valves. Pass-through electrical and pneumatic ports extend from the robot base to the outer link for end-of-arm tooling. The Primary Interface Panel centralizes cable connections, while a Secondary Interface Panel on the outer link provides connections for end-of-arm tooling. Built-in, optically isolated I/O offers 17 inputs and 12 outputs, expandable with optional IO Blox units. Work envelope limits can be adjusted with configurable hard-stop points for joints 1, 2, and 3.
Important Technical Specifications:
- Payload: 2 kg rated, 5 kg maximum.
- Reach: Available in 350 mm (i4-350L), 450 mm (i4-450L), and 550 mm (i4-550L) configurations.
- Z-axis Stroke: 180 mm for i4-350L, i4-450L, and i4-550L; also available in 350 mm for i4-550L (350 mm Z).
- Cycle Time: 0.57 s (i4-350L), 0.54 s (i4-450L, i4-550L) for continuous path with straight-line motion cycle (25 mm up, 305 mm over, 25 mm down, and back along the same path, 2 kg payload, 20°C ambient temperature, no joint 4 rotation).
- Downward Push Force (burst with no load): 150 N.
- Repeatability at 100% speed: X, Y: 0.01 mm; Joint 3: 0.01 mm; Joint 4: 0.01°.
- Joint Speeds (maximum): Joint 1: 456 degrees/s; Joint 2: 456 degrees/s; Joint 3: 800 mm/s; Joint 4: 6000 degrees/s.
- Joint Ranges: Joint 1: ±136°; Joint 2: ±136° (i4-350L), ±148° (i4-450L, i4-550L); Joint 3: 180 mm (i4-350L, i4-450L, i4-550L), 350 mm (i4-550L 350 mm Z); Joint 4: ±360°.
- Electrical Specifications:
- Control Power: 24 VDC ±10%, 5 A / 120 W maximum, user-supplied 5 A in-line fuse, 0.75 mm² to 2.5 mm² wire size.
- High Power: 48 VDC ±10%, 15 A / 720 W rated (20 A / 960 W maximum), 2.5 mm² wire size.
- XIO Connector I/O: 12 inputs (sinking/sourcing, 0-30 VDC operational range, 2.5-6 mA ON state current), 8 outputs (sourcing, 24 VDC ±10%, 0.7 A per channel max).
- TIO Connector I/O: 5 inputs, 4 outputs (similar electrical characteristics to XIO).
- Belt Encoder: Line driver pulse input (A, B, Z signals), 2-5 VDC ON voltage, 100 µA input current, 5 VDC ±10% output rating (1 A max).
- Environmental Specifications:
- Ambient Operating Temperature: 5 to 40°C.
- Storage Temperature: –25 to 55°C.
- Humidity: 5 to 90%, non-condensing.
- Altitude: 2000 m maximum.
- Pollution Degree: 2.
- Protection Class: IP20 / NEMA Type 1.
- EtherCAT Communication: 100BASE-TX, 100 Mbits/s, line, daisy chain, and branching topology, 100 m max transmission distance between nodes, 2 ms or 4 ms communication cycle.
- Mounting Hardware Torque: Socket Head Cap Screw (M8 x 1.25 mm, Class 10.9 or 12.9): 30-32 N-m.
Usage Features:
- Control Modes: Supports Manual mode (for commissioning, teaching, setup, speed limited to 250 mm/sec) and Automatic mode (for normal operation at maximum speed).
- High Power Operations: Robot motion is enabled by supplying 48 VDC High Power, which can be controlled via the Front Panel, connected PC (Sysmac Studio), user program (V+ keyword POWER), or T20 pendant. High Power is automatically disabled if safety circuits are not satisfied or a fault occurs.
- Brake Operation: Joints 3 and 4 have mechanical brakes. Brakes are released by supplying 24 VDC Control Power and pressing the built-in brake release button or a remote brake release signal via the XIO connector. Joints 1 and 2 do not have brakes.
- Jogging: Manual jogging is performed during setup or teaching, with reduced speed and acceleration limits. Can be executed in world, tool, or joint modes using software or a T20 pendant.
- Robot Positioning: Includes Joint Zero Position (inner and outer links fully extended, quill retracted) and Ready Position (programmable via READY keyword).
- Arm Configurations: Supports both Left Arm and Right Arm configurations, selectable via RIGHTY/LEFTY keywords, to optimize for the work area.
- Collision Avoidance: Obstacles can be defined in software to prevent collisions with the robot base, flyover assembly, cables, connectors, walls, or other objects.
- EtherCAT Node ID Setting: Configurable via hardware switches on the robot interface panel or through Sysmac Studio software.
Maintenance Features:
- Periodic Maintenance:
- Safety Functions: Check E-Stop, enable and key switches, and barrier interlocks every 6 months.
- Fastener Torques: Check mounting screws (30-32 N-m), external equipment fasteners (2.5 N-m for M4, 4.5 N-m for M5), and hardstop screws (17 N-m for Joint 1 & 2, 4.5 N-m for Joint 3 clamp collar) every 3 months. Initial check after 72 hours of operation, then every 3 months.
- Safety and Warning Labels: Check weekly.
- High Power Indicator: Check operation weekly.
- Oil Leaks: Inspect around robot joints every 3 months.
- Joint 3 Lubrication: Lubricate quill every 3 months or 150 km of travel using THK AFF Grease (part number 20950-000). Requires removal of tool flange and outer link cover.
- Encoder Backup Batteries: Replace every 2 to 4 years, or when a low battery alarm is present. Requires 24 VDC Control Power to be present during replacement to maintain joint position data.
- Cleaning: Clean exterior of the robot as needed, especially around robot joints. Avoid organic solvents.
- Bellows Inspection: Check weekly for cracks, wear, or damage.
- Non-periodic Maintenance:
- Tool Flange Replacement: Procedure involves removing the old flange, aligning the new one with the z-axis quill, applying thread lock, and tightening screws to specified torques (1.1 N-m for setscrew, 2.5 N-m for socket-head screws).
- Troubleshooting: Fault detection via V+ programs, LED indicator, or Sysmac Studio. Emergency Stop troubleshooting using jumper plugs (XFP, XUSR, XMCP) to bypass and isolate safety devices. Error messages are provided with explanations and corrective actions.
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