OTC DAIHEN FD-V20 Robot Mechanical Structure & Core Parts Analysis
In the OTC DAIHEN automation application system, the FD-V20 is a high-performance heavy-duty industrial robot featuring a 20kg high payload. It can not only carry heavy water-cooled servo welding torches for high-current welding but is also widely used in laser cutting, heavy workpiece handling, and grinding/picking applications. To cope with the massive dynamic inertia brought by the 20kg payload, its lower base (J1-J3 axes) utilizes ultra-high torque RV gearboxes (cycloidal gearboxes), while the upper arm (J4-J6 axes) is equipped with reinforced harmonic gearboxes and high-strength crossed roller bearings.
Because heavy-load operation generates extremely high mechanical frictional heat and torque loss, the dedicated lubricating grease inside the gearboxes of each axis (such as 100-0624, 2670-053, etc.) must be replaced with pressure release strictly according to the maintenance cycle. When performing routine major overhauls or extracting/replacing internal bus cables, please strictly follow the official factory exploded view and the parts list for each axis below. Do not mix different models of motors and grease:
📷 Figure 1: OTC DAIHEN FD-V20 Industrial Robot Complete Mechanical Parts Configuration Diagram
2. FD-V20 Core Parts Reference Table by Axis
For the convenience of the workshop equipment department, we have consolidated the power units, reduction units, and cable accessories of the J1 to J6 axes into a comprehensive global matrix table. Please carefully cross-reference the circled numbers in Figure 1 (*Note: In the original factory data, axes J4/J5/J6 share the No. ⑧ motor assembly*):
| Axis / Location | Image Ref. | Official Part Number | Standard Part Name | Function & Maintenance Notes |
|---|---|---|---|---|
| J1 Axis (Rotating Base) |
① | W-L02641 | AC Servomotor | Provides main power for wide-range horizontal base rotation. |
| ② | W-L02116 | Cycloidal Gearbox | High-rigidity, large-capacity base main reducer. | |
| ③ | 100-0624 | Lubricating Grease | Liquid anti-friction grease dedicated for RV/cycloidal gearboxes. | |
| J2 Axis (Lower Arm Pitch) |
④ | W-L02152 | AC Servomotor | Provides high-torque main power for lower arm forward/backward pitch. |
| ⑤ | W-L02117 | Cycloidal Gearbox | Core reducer bearing the extreme overturning moment of the 20kg payload. | |
| ③ | 100-0624 | Lubricating Grease | Liquid anti-friction grease dedicated for RV/cycloidal gearboxes. | |
| J3 Axis (Upper Arm Pitch) |
⑥ | W-L02641 | AC Servomotor | Provides main power for upper arm up/down pitch. |
| ⑦ | L10725F00 | Cycloidal Gearbox | Heavy-duty reducer driving the extension of the upper arm. | |
| ③ | 100-0624 | Lubricating Grease | Liquid anti-friction grease dedicated for RV/cycloidal gearboxes. | |
| J4 Axis (Arm Rotation) |
⑧ | W-L02151 | AC Servomotor | Provides main power for arm axial rotation. |
| ⑨ | W-L02113 | Harmonic Gearbox | Compact flexspline harmonic reducer. | |
| ⑩ | W-L02551 | Crossed Roller Bearing | Precision bearing carrying the 20kg dynamic lateral turnover torque. | |
| ⑪ | 2670-053 | Lubricating Grease | Flexible high-viscosity lubricating grease dedicated for harmonic gearboxes. | |
| ⑱ | 100-1491 | Lubricating Grease | Supplemental grease for crossed roller bearing and local applications. | |
| J5 Axis (Wrist Pitch) |
⑧ | W-L02151 | AC Servomotor | Controls the up/down pitch of the wrist and heavy fixtures. |
| ⑬ | W-L02114 | Harmonic Gearbox | Reinforced high-precision harmonic reducer for the wrist. | |
| ⑭ | W-L02028 | Timing Belt (J5) | Toothed transmission synchronous belt connecting motor and gearbox. | |
| ⑰ | 100-1516 | Sealant | Original factory high-temperature anaerobic sealant for leakage prevention. | |
| ⑪ | 2670-053 | Lubricating Grease | Dedicated flexspline lubricating grease for harmonic gearboxes. | |
| J6 Axis (Flange Rotation) |
⑧ | W-L02151 | AC Servomotor | Controls the high-speed rotation of the end flange. |
| ⑮ | W-L02115 | Harmonic Gearbox | Zero-backlash harmonic drive for end flange. | |
| ⑯ | W-L02029 | Timing Belt (J6) | End axis synchronous toothed transmission belt. | |
| ⑰ | 100-1516 | Sealant | Anti-oil leakage sealant for end cover. | |
| ⑪ | 2670-053 | Lubricating Grease | Dedicated anti-friction grease for end high-frequency friction pair. | |
| Cables & Accessories (Global) |
— | L10485F00 | Cable Assembly (1) | Highly flexible main axis cable from the rear of the rack to the upper arm. |
| — | L10485G00 | Cable Assembly (2) | Dedicated highly flexible flying leads for J5 and J6 axis communication inside the upper arm. | |
| — | L10485B00 | J5, J6 Axis Unit Assembly | Wrist mechanical housing and drive comprehensive assembly. | |
| ⑲ | W-L01399 | Battery (Encoder) | Backup lithium battery pack maintaining the mechanical zero coordinates of the encoders. |
* Note: Items with an “Image Ref.” of “—” in the table represent wiring harness components hidden inside the main body, which cannot be visually indicated in the external skeleton exploded view. Please perform disassembly and replacement according to the original factory manual.
💡 FD-V20 20kg Heavy-Duty Robot Overhaul & Maintenance Red Card Warnings:
- Heavy-Duty Gearbox Grease Replacement (Forced Pressure Release to Prevent Oil Burst): The V20 model’s high payload of up to 20kg causes the cycloidal gearboxes (RV gearboxes) of its base and lower arm to generate astonishing heat during operation, often keeping the cavity in a high-pressure state. When injecting new grease (e.g., 100-0624) into the J1-J3 axes, you must absolutely open both the inlet and outlet ports simultaneously, and let each axis of the robot run continuously without load at 20%-30% low speed for 30 minutes after injection to thoroughly “release pressure”. If the oil plug is forcibly sealed without fully exhausting the high-pressure air inside the cavity, the rapidly expanding air will instantly burst the servo motor’s skeleton oil seal, causing grease backflow and completely burning out the motor coils.
- J5/J6 Axis Belt Abnormal Fatigue & Tension Measurement: The FD-V20 frequently handles heavy laser welding heads or handling fixtures. During highly dynamic interpolation emergency stops, the massive inertia of the heavy tooling is directly transmitted to the timing belts of the J5/J6 axes (
W-L01945/W-L02029), causing the belts to experience a severe “whiplash effect”. When replacing belts during maintenance, never rely on experience to press them; a professional sonic tension meter must be used to accurately adjust them to the Hz frequency baseline specified in the official maintenance manual. Being too loose will inevitably lead to tooth jumping and crashes, while being too tight will crush the motor bearings. - Encoder Battery (W-L01399) Live Hot-Swap Rule: The No. ⑲ battery located at the rear of the base maintains the spatial absolute position system of the robot’s 6 axes. Never unplug the old battery connector while the main power to the control cabinet is disconnected! Once unplugged during a power outage, all encoder origin coordinate parameters will instantly clear to zero. When replacing the
W-L01399battery, the control system must remain powered on, and the new battery must be plugged in immediately after removing the old one.
🛠️ Get Real-Time Quotes for FD-V20 Robot Motors, Gearboxes & Cables
The health of a heavy-payload industrial robot’s “skeleton and transmission mechanism” directly determines the safety and precision of the machining process. Simply provide the required official part numbers (e.g., W-L02641 Motor, W-L02117 Cycloidal Gearbox, W-L01399 Battery), and our automated spare parts system will quickly match and output an accurate, ready-to-ship quote for you. Whether you need original factory Cycloidal/Harmonic grease for routine maintenance or internal highly flexible cable assemblies for a major overhaul, feel free to contact us directly: