Yamaha | F8 | User`s manual | Yamaha F8 User`s manual

YAMAHA SINGLE-AXIS ROBOT
FLIP-X series
F8/F8L/F8LH
User’s Manual
ENGLISH
E
YAMAHA MOTOR CO., LTD.
IM Operations
882 Soude, Naka-ku, Hamamatsu, Shizuoka 435-0054.Japan
URL http://www.yamaha-motor.jp/robot/index.html
E43-Ver. 2.03
Thank you for purchasing this YAMAHA single-axis robot F8/F8L/F8LH.
Before using this robot, read the following notes and set the origin position.
The F8/F8L/F8LH single-axis robots use absolute position detectors that do not require
return-to-origin after turning on the controller power. However, when the controller
power is turned on in the following cases, return-to-origin must be performed just the very
first time.
(1) When robot cable was first connected after delivery from YAMAHA.
(2) When robot cable was disconnected from the controller and then reconnected.
(3) When no absolute battery is connected.
(4) When a motor or cable was replaced.
At this point, any of the following errors is issued immediately after controller power
is turned on, but this is not a malfunction. The controller will operate normally by
restarting.
When using an SR1 controller:
15 : FEEDBACK ERROR 2
23 : ABS.BAT.L-VOLTAGE
24 : ABS.DATA.ERROR
… etc.
When using an RCX240, RCX222 controller:
17.81 : D?.ABS.battery wire breakage
17.92 : D?.Resolver disconnected during power off
17.93 : D?.Position backup counter overflow
… etc.
When using an TS-X controller:
82 ENCODER ERROR
83 ABS. ENCODER ERR.
8A ABS. BATTERY ERR.
8B ABS. COUNT ERROR
8D ABS. OVERFLOW ERR.
… etc.
Before using the F8/F8L/F8LH single-axis robots (Be sure to read the following notes.)
Before using the F8/F8L/F8LH single-axis robots
(Be sure to read the following notes.)
Setting the origin position
Before using the F8/F8L/F8LH single-axis robots (Be sure to read the following notes.)
Set the origin position by referring to the following section in the robot controller user's
manual.
When using an SR1 controller:
See "9.1.1 Return-to-origin by the search method" in Chapter 9 of the "HPB
Operation Guide" section.
When using an RCX240 controller:
See "11.9 Absolute reset" in Chapter 4.
When using an RCX222 controller:
See "11.8 Absolute reset" in Chapter 4.
When using an TS-X controller:
See "6.2 Origin search (return-to-origin)" in "6. Operating the robot" of the "HT1
Operation Guide" section.
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CAUTION
Changing the origin position to the opposite side of the initial position may
cause a position shift or robot breakdowns, so use caution.
Avoid changing the origin detection method since it is dangerous in some
cases. If the origin position must be changed, please consult our sales office
or dealer.
General Contents
General Contents
Introduction
Chapter 1 Using the Robot Safely
1-1
Safety information
1-1
1-2
Essential precautions
1-3
1-3
Industrial robot operating and maintenance personnel 1-10
1-4
Robot safety functions
1-10
1-5
Safety measures for the system
1-11
1-6
Trial operation
1-11
1-7
Work within the safety enclosure
1-12
1-8
Automatic operation
1-13
1-9
Warranty
1-14
Chapter 2 Product Overview
2-1
Checking the product
2-1
2-2
Robot part names
2-1
Chapter 3 Installation and Connections
3-1
Carrying the robot
3-1
3-2
Robot installation conditions
3-2
3-2-1
3-2-2
Installation environments
Installation base
3-3
Installing the robot
3-5
3-4
Connecting the robot to the controller
3-7
3-5
Setting the operating conditions
3-5-1
3-5-2
3-5-3
Payload
Maximum speed setting
Duty
3-2
3-3
3-10
3-10
3-11
3-11
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Chapter 4 Periodic Inspection and Maintenance
General Contents
4-1
Before beginning work
4-1
4-2
Periodic inspection
4-3
4-2-1
4-2-2
4-2-3
4-2-4
Daily inspection
Three-month inspection
Six-month inspection
Three-year inspection
4-3
4-3
4-4
4-4
4-3
Applying grease
4-5
4-4
Replacing the motor
4-6
Chapter 5 Troubleshooting
5-1
If you suspect trouble
5-1-1
5-1-2
Positioning error
Feedback error
5-1
5-1
5-2
Chapter 6 Specifications
6-1
Main unit specifications
6-1-1
6-1-2
6-1-3
F8 6-1
F8L
F8LH
6-2
AC servo motor specifications
6-2-1
6-2-2
AC servo motor termination
Brake cable specifications
6-3
Robot cables
6-3-1
6-3-2
6-3-3
6-3-4
Robot
Robot
Robot
Robot
6-1
6-4
6-9
cables
cables
cables
cables
(SR1)
(TS-X)
(RCX222/240)
(RDX)
6-12
6-12
6-13
6-14
6-14
6-15
6-16
6-18
Appendix
ii
About machine reference
i
Moment of inertia calculation
ii
Introduction
• This user's manual should be used with the robot and considered an integral part of
it. When the robot is moved, transferred or sold, send this manual to the new user
along with the robot. Be sure to explain to the new user the need to read through this
manual.
• Specifications of robot models other than standard models may be omitted in this
manual if they are common to those of standard models. In this case, refer to the
specifications of standard models.
• For details on specific operation of the robot, refer to the separate user’s manual for the
robot controller being used.
NOTES
◆ The contents of this manual are subject to change without prior notice.
◆ While every effort has been made to ensure the contents of this manual are
correct, please contact us if you find any part of this manual to be unclear,
confusing or inaccurate.
YAMAHA MOTOR CO., LTD.
IM Operations
Introduction
The YAMAHA single-axis robots F8/F8L/F8LH is an industrial robot that uses the absolute
positioning method as standard and has improved ease of use, resistance to environmental
conditions, and maintenance work. A wide varaiety of product lineup allows you to select
the desired robot model that best matches your application.
This user's manual describes the safety measures, handling, adjustment and maintenance
of the F8/F8L/F8LH robots for correct, safe and effective use.
Be sure to read this manual carefully before installing the F8/F8L/F8LH robots. Even after
you have read this manual, keep it in a safe and convenient place for future reference.
MEMO
Chapter 1
Using the Robot Safely
Contents
1-1 Safety information
1-1
1-2 Essential precautions
1-3
1-3 Industrial robot operating and maintenance personnel 1-10
1-4 Robot safety functions
1-10
1-5 Safety measures for the system
1-11
1-6 Trial operation
1-11
1-7 Work within the safety enclosure
1-12
1-8 Automatic operation
1-13
1-9 Warranty
1-14
1-1 Safety information
1-1
Safety information
Warning symbols and signal words used in this manual are classified as explained below.
Make sure that you fully understand the meaning of each symbol and comply with the
instructions.
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DANGER
FAILURE TO FOLLOW DANGER INSTRUCTIONS WILL RESULT IN SEVERE INJURY OR
DEATH TO THE ROBOT OPERATOR, BYSTANDERS OR PERSONS INSPECTING OR
REPAIRING THE ROBOT.
WARNING
FAILURE TO FOLLOW WARNING INSTRUCTIONS COULD RESULT IN SEVERE INJURY
OR DEATH TO THE ROBOT OPERATOR, BYSTANDERS OR PERSONS INSPECTING
OR REPAIRING THE ROBOT.
CAUTION
Failure to follow CAUTION instructions may result in injury to the robot
operator, bystanders or persons inspecting or repairing the robot, or
damage to the robot and/or robot controller.
NOTE
Explains the key point in the operation in a simple and clear manner.
Reference
Gives useful information related to the robot operation.
1-1
1
Using the Robot Safely
Industrial robots are highly programmable, mechanical devices that provide a large degree
of freedom when performing various manipulative tasks. To ensure correct and safe use of
YAMAHA industrial robots, carefully read this manual and make yourself well acquainted
with the contents. FOLLOW THE WARNINGS, CAUTIONS AND INSTRUCTIONS included
in this manual. Failure to take necessary safety measures or mishandling due to not
following the instructions in this manual may result in trouble or damage to the robot and
injury to personnel (robot operator or service personnel) including fatal accidents.
1-1 Safety information
Refer to the user's manual by any of the following methods to operate or adjust the robot
safely and correctly.
1
1. Operate or adjust the robot while referring to the printed version of the user's
manual (available for an additional fee).
Using the Robot Safely
2. Operate or adjust the robot while viewing the CD-ROM version of the user's
manual on your computer screen.
3. Operate or adjust the robot while referring to a printout of the necessary pages
from the CD-ROM version of the user's manual.
It is not possible to list all safety items in detail within the limited space of
this manual. So it is essential that the user have a full knowledge of basic
safety rules and also that the operator makes correct judgments on safety
procedures during operation.
For specific safety information and standards, refer to the applicable local
regulations and comply with the instructions. This manual and warning labels
supplied with or attached to the robot are written in English. Unless the
robot operators or service personnel understand English, do not permit them
to handle the robot.
* Cautions regarding the official language of EU countries
For equipment that will be installed in EU countries, the language used for the
user's manuals, CE declarations, and operation screen characters is English only.
Warning labels only have pictograms or else include warning messages in English.
In the latter case, Japanese messages might be added.
1-2
1-2 Essential precautions
1-2
Essential precautions
(1)
Obser ve the following cautions during automatic operation.
• Install a safeguard (safety enclosure) to keep any person from entering within the
movement range of the robot and suffering injury due to being struck by moving
parts.
• Install a safety interlock that triggers emergency stop when the door or panel is
opened.
• Install a safety enclosure so that no one can enter inside except from doors or
panels equipped with safety interlocks.
• Warning labels 1 are supplied with the robot and should be affixed to conspicuous
spots on doors or panels equipped with safety interlocks.
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DANGER
SERIOUS INJURY OR DEATH WILL RESULT FROM IMPACT WITH MOVING ROBOT.
• KEEP OUTSIDE OF GUARD DURING OPERATION.
• LOCK OUT POWER BEFORE APPROACHING ROBOT.
Warning label 1
DANGER
Serious injury or death
will result from impact
with moving robot.
• Keep outside of guard
during operation.
• Lock out power before
approaching robot.
(2)
Use caution to prevent hands or fingers from being pinched or crushed.
Warning label 2 is affixed to the robot.
Use caution to prevent hands or fingers from being pinched or crushed by the moving
parts when carrying the robot or during teaching.
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WARNING
MOVING PARTS CAN PINCH OR CRUSH.
KEEP HANDS AWAY FROM ROBOT ARMS.
1-3
1
Using the Robot Safely
Particularly important cautions for handling or operating the robot are described below. In
addition, precautions during installation, operation, inspection and maintenance are also
provided in each chapter. Be sure to comply with these instructions to ensure safe use of
the robot.
1-2 Essential precautions
Warning label 2
1
WARNING
Using the Robot Safely
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
(3)
Follow the instructions on warning labels and in this manual.
• Be sure to read the warning labels and this manual carefully and make sure you
thoroughly understand their contents before attempting installation and operation
of the robot.
• Before starting robot operation, be sure to reread the procedures and cautions
relating to your work as well as descriptions in this chapter (Chapter 1, "Using the
Robot Safely").
• Never install, adjust, inspect or service the robot in any manner that does not
comply with the instructions in this manual.
• The warning labels 3 are supplied with the robot and should be affixed to the robot
or conspicuous spots near the robot.
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WARNING
IMPROPER INSTALLATION OR OPERATION CAN RESULT IN SERIOUS INJURY OR
DEATH.
READ THE USER'S MANUAL AND ALL WARNING LABELS BEFORE OPERATION.
Warning label 3
WARNING
Improper installation or operation
can result in serious injury or
death.
Read user's(owner’s)
manual and all warning labels
before operation.
1-4
1-2 Essential precautions
(4)
Do not remove, alter or stain the warning labels.
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Do not use the robot in environments containing inflammable gas, etc.
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(6)
WARNING
• THIS ROBOT WAS NOT DESIGNED FOR OPERATION IN ENVIRONMENTS WHERE
INFLAMMABLE OR EXPLOSIVE SUBSTANCES ARE PRESENT.
• DO NOT USE THE ROBOT IN ENVIRONMENTS CONTAINING INFLAMMABLE
GAS, DUST OR LIQUIDS. EXPLOSIONS OR FIRE MIGHT OTHERWISE RESULT.
Do not use the robot in locations possibly subject to electromagnetic interference,
etc.
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(7)
1
WARNING
AVOID USING THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC
INTERFERENCE, ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY
INTERFERENCE. MALFUNCTIONS MIGHT OTHERWISE OCCUR.
Use caution when releasing the brake of a vertical use robot.
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WARNING
THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE BRAKE IS RELEASED, CAUSING
A HAZARDOUS SITUATION.
• PRESS THE EMERGENCY STOP BUTTON AND PROP UP THE VERTICAL AXIS
WITH A SUPPORT STAND BEFORE RELEASING THE BRAKE.
• BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL
AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM
DIRECT TEACH.
1-5
Using the Robot Safely
(5)
WARNING
IF WARNING LABELS ARE REMOVED OR DIFFICULT TO SEE, THEN ESSENTIAL
PRECAUTIONS MIGHT NOT BE TAKEN, RESULTING IN ACCIDENTS.
• DO NOT REMOVE, ALTER OR STAIN THE WARNING LABELS ON THE ROBOT.
• DO NOT ALLOW THE WARNING LABELS TO BE HIDDEN BY DEVICES INSTALLED
ONTO THE ROBOT BY THE USER.
• PROVIDE PROPER LIGHTING SO THAT THE SYMBOLS AND INSTRUCTIONS ON
THE WARNING LABELS CAN BE CLEARLY SEEN EVEN FROM OUTSIDE THE
SAFETY ENCLOSURE.
1-2 Essential precautions
(8)
Provide safety measures for end effector (gripper, etc.).
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1
Using the Robot Safely
(9)
WARNING
• END EFFECTORS MUST BE DESIGNED AND MANUFACTURED SO THAT THEY
CREATE NO HAZARDS (FOR EXAMPLE, A WORKPIECE THAT COMES LOOSE)
EVEN IF POWER (ELECTRICITY, AIR PRESSURE, ETC.) IS SHUT OFF OR POWER
FLUCTUATIONS OCCUR.
• IF THERE IS A POSSIBLE DANGER THAT THE OBJECT GRIPPED BY THE END
EFFECTOR MAY FLY OFF OR DROP, THEN PROVIDE APPROPRIATE SAFETY
PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE, WEIGHT,
TEMPERATURE AND CHEMICAL PROPERTIES.
Use caution when removing the motor. (Vertical use robots)
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WARNING
THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE MOTOR IS RELEASED,
CAUSING A HAZARDOUS SITUATION.
• TURN OFF THE ROBOT CONTROLLER AND PROP UP THE VERTICAL AXIS WITH
A SUPPORT STAND BEFORE REMOVING THE MOTOR.
• BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL
AXIS PARTS AND INSTALLATION BASE.
(10) Be careful not to touch the motor and peripheral parts when hot.
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WARNING
The motor and speed reduction gear casing are extremely hot after
automatic operation, so burns may occur if these are touched.
Before handling these parts during inspection or servicing, turn off the
controller, wait for a while and check that the parts have cooled.
(11) Take the following safety precautions during inspection of controller.
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1-6
WARNING
• WHEN YOU NEED TO TOUCH THE TERMINALS OR CONNECTORS ON THE
OUTSIDE OF THE CONTROLLER DURING INSPECTION, ALWAYS FIRST TURN OFF
THE CONTROLLER POWER SWITCH AND ALSO THE POWER SOURCE IN ORDER
TO PREVENT POSSIBLE ELECTRICAL SHOCK.
• NEVER TOUCH ANY INTERNAL PARTS OF THE CONTROLLER.
• REFER TO THE "YAMAHA ROBOT CONTROLLER USER'S MANUAL" FOR
PRECAUTIONS ON HANDLING THE CONTROLLER.
1-2 Essential precautions
(12) Use caution not to touch the controller cooling fan.
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WARNING
• BODILY INJURY MAY OCCUR FROM COMING INTO CONTACT WITH THE
COOLING FAN WHILE IT IS ROTATING.
• WHEN REMOVING THE FAN COVER FOR INSPECTION, FIRST TURN OFF THE
CONTROLLER AND MAKE SURE THE FAN HAS STOPPED.
1
Using the Robot Safely
(13) Consult us for corrective action when the robot is damaged or malfunctions occur.
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WARNING
IF ANY PART OF THE ROBOT IS DAMAGED OR ANY MALFUNCTION OCCURS,
CONTINUING THE OPERATION MAY BE VERY DANGEROUS. PLEASE CONSULT
YOUR YAMAHA SALES OFFICE OR DEALER FOR CORRECTIVE ACTION.
Damage or Trouble
Possible Danger
Damage to machine harness or robot cable
Electrical shock, malfunction of robot
Damage to exterior of robot
Flying outwards of damaged parts
during robot operation
Abnormal operation of robot
(positioning error, excessive vibration, etc.)
Malfunction of robot
Z-axis brake trouble
Dropping of load
(14) Protective bonding
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WARNING
BE SURE TO GROUND THE ROBOT AND CONTROLLER TO PREVENT ELECTRICAL
SHOCK.
(15) Be sure to make correct parameter settings.
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CAUTION
The robot must be operated with correct tolerable moment of inertia and
acceleration coefficients according to the manipulator tip mass and
moment of inertia. If these are not correct, drive unit service life may end
prematurely, and damage to robot parts or residual vibration during
positioning may result.
(16) Follow the specified procedures when installing, adjusting or inspecting the robot.
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WARNING
ALWAYS FOLLOW THE SPECIFIED PROCEDURES WHEN INSTALLING, ADJUSTING
OR INSPECTING THE ROBOT. NEVER ATTEMPT ANY PROCEDURE NOT DESCRIBED
IN THIS MANUAL.
1-7
1-2 Essential precautions
(17) Do not attempt any repair, parts replacement and modification.
1
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Using the Robot Safely
WARNING
DO NOT ATTEMPT ANY REPAIR, PARTS REPLACEMENT AND MODIFICATION
UNLESS DESCRIBED IN THIS MANUAL.
THESE WORKS REQUIRE TECHNICAL KNOWLEDGE AND SKILL, AND MAY ALSO
INVOLVE WORK HAZARDS.
(18) Location for installing the controller and the programming box or Handy Terminal
The robot controller, programming box, and Handy Terminal should be installed at a
location that is outside the robot movement range yet where it is easy to operate and
view the robot performing tasks.
(19) Protect electrical wiring and hydraulic/pneumatic hoses as needed.
Install a cover or similar item to protect the electrical wring and hydraulic/pneumatic
hoses from possible damage.
(20) Install an operation status light.
Install an operation status light (signal light tower, etc.) at an easy-to-see position so
the operator will know whether the robot is merely stopped or is in emergency-error
stop.
(21) Clean work tools, etc.
Work tools such as welding guns and paint nozzles which are mounted in the robot
arm will preferably be cleaned automatically.
(22) Provide adequate lighting.
Make sure to provide enough lighting to ensure safety during work.
(23) Prevent the gripped object from flying outwards.
If the object or workpiece gripped by the robot might fly outward or drop and create
a hazard to the operator, then protective equipment should be installed by taking the
size, weight, temperature and chemical properties of the object into account.
(24) Draw up "work instructions" and makes sure the operator learns them well.
Decide on "work instructions" for the following items in cases where personnel
must work within the robot movement range to perform teaching, maintenance or
inspection. Make sure the workers know these "work instructions" well.
(1) Robot operating procedures needed for tasks such as startup procedures and
handling switches
(2) Robot speeds used during tasks such as teaching
(3) Methods for workers to signal each other when two or more workers perform
tasks
(4) Steps that the worker should take when a problem or emergency occurs
1-8
1-2 Essential precautions
(5) Steps to take after the robot has come to a stop when the emergency stop device
was triggered, including checks for cancelling the problem or error state and
safety checks in order to restart the robot.
1. Show a display on the operator panel
2. Ensure the safety of workers performing tasks within the robot movement range
3. Clearly specify position and posture during work
Position and posture where worker can constantly check robot movements and
immediately move to avoid trouble if an error/problem occurs
4. Install noise prevention measures
5. Use methods for signaling operators of related equipment
6. Use methods to decide that an error has occurred and identify the type of error
Implement the "work instructions" according to the type of robot, installation
location, and type of work task.
When drawing up the "work instructions", make an effort to include opinions from
the workers involved, equipment manufacture's technicians, and workplace safety
consultants, etc.
(25) Display a sign on operation panel during work
Display an easy to understand sign or message on the programming box, Handy
Terminal, and operation panel during the job task, to prevent anyone other than the
operators for that job task from mistakenly operating a start or selector switch. If
needed, take other measures such as locking the cover on the operation panel.
(26) Make daily and periodic inspections.
(1) Always make sure that daily and periodic inspections are performed, and make
a pre-work check to ensure there are no problems with the robot or related
equipment. If a problem or abnormality is found, then promptly repair it or take
other measures as necessary.
(2) When you make periodic inspections or repairs, make a record and store it for at
least 3 years.
1-9
1
Using the Robot Safely
(6) In cases other than above, the following actions should be taken as needed to
prevent hazardous situations due to sudden or unexpected robot operation or
faulty robot operation, as listed below.
1-3 Industrial robot operating and maintenance personnel
1-3
1
Industrial robot operating and maintenance personnel
Using the Robot Safely
Operators or persons who handle the robot such as for teaching, programming, movement
check, inspection, adjustment, and repair must receive appropriate training and also have
the skills needed to perform the job correctly and safely. They must read the user's manual
carefully to understand its contents before attempting the robot operation.
Tasks related to industrial robots (teaching, programming, movement check, inspection,
adjustment, repair, etc.) must be performed by qualified persons who meet requirements
established by local regulations and safety standards for industrial robots.
1-4
(1)
Robot safety functions
Overload detection
This function detects an overload applied to the motor and shuts off the servo power.
(2)
Overheat detection
This detects an abnormal temperature rise in the controller driver and shuts off the
servo power.
If an overload or overheat error occurs, take the following measures.
1. Insert a timer in the program.
2. Reduce the acceleration coefficient.
(3)
Soft limits
Soft limits can be set on each axis to limit the working envelope in manual operation
after return-to-origin and during automatic operation.
Note: The working envelope is the area limited by soft limits.
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(4)
WARNING
SOFT LIMITS MUST BE SET WITHIN THE MOVEMENT RANGE (MECHANICAL
STOPPER). IF THE SOFT LIMIT IS SET OUTSIDE THE MOVEMENT RANGE, THE ROBOT
AXIS MAY COLLIDE WITH THE MECHANICAL STOPPER AT HIGH SPEED, CAUSING
THE OBJECT GRIPPED BY THE END EFFECTOR TO FLY OR DROP AND THE ROBOT
TO MALFUNCTION.
Mechanical stoppers
If the servo power is suddenly shut off during high-speed operation by emergency
stop or safety functions, these mechanical stoppers prevent the axis from exceeding
the movement range.
Note: The movement range is the area limited by mechanical stoppers.
1-10
1-5 Safety measures for the system
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1
Vertical axis brake
An electromagnetic brake is installed on the vertical use robot to prevent the vertical
axis from sliding down when servo power is turned off. This brake is working when
the controller is off or the vertical axis servo power is off even when the controller is
on.
The vertical axis brake can be released with the programming box or Handy Terminal
or in the program when the controller power is turned on.
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1-5
WARNING
THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE BRAKE IS RELEASED, CREATING
A HAZARDOUS SITUATION.
• PRESS THE EMERGENCY STOP BUTTON AND PROP THE VERTICAL AXIS WITH A
SUPPORT STAND BEFORE RELEASING THE BRAKE.
• USE CAUTION NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL
AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM
DIRECT TEACH.
Safety measures for the system
Since the robot is commonly used in conjunction with an automated system, dangerous
situations are more likely to occur from the automated system than from the robot
itself. Accordingly, appropriate safety measures must be taken on the part of the system
manufacturer according to the individual system. The system manufacturer should provide
a proper instruction manual for safe, correct operation and servicing of the system.
1-6
Trial operation
After making installations, adjustments, inspections, or maintenance or repairs to the
robot, make a trial run using the following procedures.
(1)
If a safety enclosure has not yet been provided right after installation of the robot,
rope off or chain off around the movement area of the manipulator in place of the
safety enclosure, and obser ve the following points.
1. Use sturdy, stable posts which will not fall over easily.
2. The rope or chain should be easily visible by everyone around the robot.
3. Place a sign to keep the operator or other personnel from entering the movement
range of the manipulator.
1-11
Using the Robot Safely
(5)
WARNING
ROBOT MOVEMENT WILL NOT STOP IMMEDIATELY AFTER THE SERVO POWER
SUPPLY IS SHUT OFF BY EMERGENCY STOP OR OTHER SAFETY FUNCTIONS.
1-7 Work within the safety enclosure
(2)
Check the following points before turning on the controller.
1. Is the robot securely and correctly installed?
1
2. Are the electrical connections to the robot correct?
3. Are items such as air pressure correctly supplied?
Using the Robot Safely
4. Is the robot correctly connected to peripheral equipment?
5. Have safety measures (safety enclosure, etc.) been taken?
6. Does the installation environment meet the specified standards.
(3)
After the controller is turned on, check the following points from outside the safety
enclosure.
1. Does the robot start and stop as intended? Can the operation mode be selected
correctly?
2. Does each axis move as intended within the soft limits?
3. Does the end effector move as intended?
4. Are the signal transmissions to the end effector and peripheral equipment correct?
5. Does emergency stop work?
6. Are the teaching and playback functions normal?
7. Are the safety enclosure and interlock working as intended?
8. Does the robot move correctly during automatic operation?
1-7
Work within the safety enclosure
(1) Work within the safety enclosure
When work is required inside the safety enclosure, always turn off the controller and
place a sign indicating that the robot is being adjusted or serviced in order to keep
any other person from touching the controller switch or operation panel, except for
the following cases.
1) Soft limit settings
2) Teaching
For item 1), follow the precautions and procedure for each section. To perform item 2),
refer to the description in (2) below.
(2)
Teaching
When performing teaching within the safety enclosure, comply with the instructions
listed below.
1) Check or perform the following points from outside the safety enclosure.
1. Make sure that no hazards are present within the safety enclosure by a visual
check.
2. Check that the programming box or Handy Terminal operates correctly.
1-12
1-8 Automatic operation
3. Check that no failures are found in the robot.
4. Check that emergency stop works correctly.
1
5. Select teaching mode and prohibit automatic operation.
1-8
Automatic operation
Automatic operation described here includes all operations in AUTO mode.
(1)
Check the following before starting automatic operation.
1. No one is within the safety enclosure.
2. The programming box, Handy Terminal and tools are placed in their specified
positions.
3. The alarm or error lamps on the robot and peripheral equipment do not flash.
4. The safety enclosure is securely installed with safety interlocks actuated.
(2)
Obser ve the following during automatic operation or in cases where an error occurs.
1)After automatic operation has started, check the operation status and signal light to
ensure that the robot is in automatic operation.
2) Never enter the safety enclosure during automatic operation.
3) If an error occurs in the robot or peripheral equipment, observe the following
procedure before entering the safety enclosure.
1. Press the emergency stop button to set the robot to emergency stop.
2. Place a sign on the start switch, indicating that the robot is being inspected in
order to keep any other person from touching the start switch and restarting the
robot.
1-13
Using the Robot Safely
2) Never enter the movement range of the manipulator while within the safety
enclosure.
1-9 Warranty
1-9
1
Warranty
The YAMAHA robot and/or related product you have purchased are warranted against the
defects or malfunctions as described below.
Using the Robot Safely
Warranty description
: If a failure or breakdown occurs due to defects in materials
or workmanship in the genuine parts constituting this
YAMAHA robot and/or related product within the warranty
period, then YAMAHA will repair or replace those parts
free of charge (hereafter called "warranty repair").
Warranty Period
: The warranty period ends when any of the following
applies:
(1) After 18 months (one and a half year) have elapsed from
the date of shipment
(2) After one year has elapsed from the date of installation
(3) After 2,400 hours of operation
Exceptions to the Warranty : This warranty will not apply in the following cases:
(1) Fatigue arising due to the passage of time, natural
wear and tear occurring during operation (natural fading
of painted or plated surfaces, deterioration of parts
subject to wear, etc.)
(2) Minor natural phenomena that do not affect the
capabilities of the robot and/or related product (noise
from computers, motors, etc.).
(3) Programs, point data and other internal data that were
changed or created by the user.
Failures resulting from the following causes are not covered by warranty repair.
1) Damage due to earthquakes, storms, floods, thunderbolt, fire or any other natural
or man-made disasters.
2) Troubles caused by procedures prohibited in this manual.
3) Modifications to the robot and/or related product not approved by YAMAHA or
YAMAHA sales representatives.
4) Use of any other than genuine parts and specified grease and lubricants.
5) Incorrect or inadequate maintenance and inspection.
6) Repairs by other than authorized dealers.
1-14
1-9 Warranty
1-15
1
Using the Robot Safely
YAMAHA MOTOR CO., LTD. MAKES NO OTHER EXPRESS OR IMPLIED WARRANTIES,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE. THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS
IN LIEU OF ALL EXPRESSED OR IMPLIED WARRANTIES, INCLUDING WARRANTIES OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR WARRANTIES ARISING
FROM A COURSE OF DEALING OR USAGE OF TRADE.
YAMAHA MOTOR CO., LTD. SOLE LIABILITY SHALL BE FOR THE DELIVERY OF THE
EQUIPMENT AND YAMAHA MOTOR CO., LTD. SHALL NOT BE LIABLE FOR ANY
CONSEQUENTIAL DAMAGES (WHETHER ARISING FROM CONTRACT, WARRANTY,
NEGLIGENCE OR STRICT LIABILITY). YAMAHA MOTOR CO., LTD. MAKES NO
WARRANTY WHATSOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED
BY YAMAHA MOTOR CO., LTD.
MEMO
1-16
Chapter 2
Product Over view
Contents
2-1 Checking the product
2-1
2-2 Robot part names
2-1
2-1 Checking the product
2-1
Checking the product
After unpacking, make sure that all components and accessories are included (as specified
in your order). Also check the product for any damage on the exterior which might have
occurred during shipping.
If there are any missing parts or damage due to shipping, please notify your YAMAHA
sales office or representative immediately.
2-2
Product Overview
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2
WARNING
• ALWAYS USE TWO OR MORE PEOPLE TO TAKE THE ROBOT UNIT OUT OF THE
PACKAGE. EACH PERSON SHOULD GRIP THE ROBOT UNIT NEAR ONE END
FROM THE LOWER SIDE. CARRY WITH THE ROBOT FACING UPWARD (SLIDER
SIDE UPWARDS).
• WHEN UNPACKING, CAREFULLY HOLD THE ROBOT NOT TO DROP IT. IF THE
ROBOT FALLS, SERIOUS INJURY MAY OCCUR OR THE ROBOT MAY BE
DAMAGED.
Robot part names
Robot part names
Top cover
Side cover
Slider
End cover
Robot cable (motor wires)
Robot cable (I/O signal wires)
2-1
MEMO
2-2
Chapter 3
Installation and Connections
Contents
3-1 Carrying the robot
3-1
3-2 Robot installation conditions
3-2
3-2-1 Installation environments
3-2-2 Installation base
3-2
3-3
3-3 Installing the robot
3-5
3-4 Connecting the robot to the controller
3-7
3-5 Setting the operating conditions
3-5-1 Payload
3-5-2 Maximum speed setting
3-5-3 Duty
3-10
3-10
3-11
3-11
3-1 Carr ying the robot
3-1
Carr ying the robot
Always use two people to carry the robot unit. Each person should grip the robot unit near
one end from the lower side and carry with the load well balanced. Carry with the robot
facing upward (slider side upwards).
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[Never try this when moving!]
• DO NOT CARRY BY HOLDING THE SLIDER.
• DO NOT CARRY BY HOLDING THE CABLE.
• DO NOT CARRY BY GRIPPING THE END COVER.
• DO NOT CARRY BY HOLDING THE TOP COVER.
3-1
3
Installation and Connections
WARNING
ALWAYS OBSERVE THE FOLLOWING PRECAUTIONS WHEN CARRYING THE
ROBOT.
• REMOVE ANY AND ALL OBJECTS SUCH AS HANDS AND GRIPPERS ATTACHED
TO THE ROBOT SLIDER BEFORE MOVING THE ROBOT. THE SLIDER WILL LOSE
BALANCE IF MOVED WITH OBJECTS STILL ATTACHED AND CAUSE INJURIES.
• KEEP THE ROBOT BALANCED AND DON'T LET IT TILT WHILE MOVING IT. IF THE
ROBOT TILTS, THE SLIDER MAY MOVE UNDER ITS OWN WEIGHT CAUSING
SERIOUS INJURIES SUCH AS CRUSHED FINGERS.
• MOVE THE SLIDER SO THAT BALL NUT SECTION IS POSITIONED IN THE NEAR
CENTER OF THE ROBOT BEFORE CARRYING THE ROBOT. FAILURE TO DO SO
MAY CAUSE THE BALL SCREW TO SWING OR VIBRATE LARGELY WHILE
CARRYING THE ROBOT.
• NEVER ATTEMPT TO HOLD THE ROBOT IN ANY OF THE FOLLOWING MANNERS.
3-2 Robot installation conditions
3-2
Robot installation conditions
3-2-1 Installation environments
Be sure to install the robot in the following environments.
Items
3
Specifications
Allowable ambient
temperature
0 to 45°C
Allowable ambient humidity
35 to 85% RH (no condensation)
Altitude
0 to 1000 meters above sea level
Installation and Connections
Avoid installing near water, cutting water, oil, dust,
metallic chips and organic solvent.
Avoid installation near corrosive gas and corrosive
materials.
Ambient environments
Avoid installation in atmosphere containing inflammable
gas, dust and liquid.
Avoid installation near objects causing electromagnetic
interference, electrostatic discharge and radio frequency
interference.
Vibration
Do not subject to impacts or vibrations.
Working space
Allow sufficient space margin to perform jobs (teaching,
inspection, repair, etc.)
For detailed information on how to install the robot controller, refer to the separate
"YAMAHA Robot Controller User's Manual".
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3-2
WARNING
AVOID INSTALLING THE ROBOT IN LOCATIONS WHERE THE AMBIENT
CONDITIONS MAY EXCEED THE ALLOWABLE TEMPERATURE OR HUMIDITY, OR IN
ENVIRONMENTS WHERE EXCESSIVE MOISTURE, CORROSIVE GASES, METALLIC
POWDER OR DUST ARE GENERATED. MALFUNCTIONS, FAILURES OR SHORT
CIRCUITS MAY OTHERWISE RESULT.
WARNING
• THIS ROBOT WAS NOT DESIGNED FOR OPERATION IN ENVIRONMENTS
WHERE INFLAMMABLE OR EXPLOSIVE SUBSTANCES ARE PRESENT.
• DO NOT USE THE ROBOT IN ENVIRONMENTS CONTAINING INFLAMMABLE
GAS, DUST OR LIQUIDS.
EXPLOSIONS OR FIRE COULD OTHERWISE RESULT.
3-2 Robot installation conditions
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WARNING
AVOID USING THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC
INTERFERENCE, ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY
INTERFERENCE. MALFUNCTIONS MAY OTHERWISE OCCUR.
WARNING
DO NOT USE THE ROBOT IN LOCATIONS SUBJECT TO EXCESSIVE VIBRATION.
ROBOT INSTALLATION BOLTS MAY OTHERWISE BECOME LOOSE CAUSING THE
ROBOT TO FALL OVER.
3
To mount the robot, use an installation base that satisfies the following conditions.
(1)
The installation base is subjected to a great deal of stress while the robot is in
operation. Prepare a sufficiently rigid and stable installation base, taking into account
the robot weight including the end effector (gripper) and workpiece.
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(2)
WARNING
IF THE INSTALLATION BASE IS NOT SUFFICIENTLY RIGID AND STABLE, VIBRATION
(RESONANCE) MAY OCCUR DURING OPERATION, CAUSING ADVERSE EFFECTS
ON THE ROBOT WORK.
The installation base surface must be machined within a flatness of ±0.05mm/500mm.
c
CAUTION
The robot positioning accuracy or the service life might be reduced if the
installation surface precision is insufficient.
3-3
Installation and Connections
3-2-2 Installation base
3-2 Robot installation conditions
(3)
Use an installation base of sufficient size to match the robot body so that the robot
can be installed with the specified number of bolts. Avoid installing the robot with
less than the specified number of bolts or installing the robot closer to one end as
shown at the lower right.
Robot installation example
3
Installation and Connections
Installation base
Good example
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n
3-4
Installation base
Bad example
WARNING
WHEN INSTALLING THE ROBOT, ALWAYS USE ALL THE MOUNTING HOLES DRILLED
IN THE BOTTOM OF THE ROBOT. USING LESS THAN THE SPECIFIED NUMBER OF
BOLTS TO INSTALL THE ROBOT MAY CAUSE VIBRATION AND POOR POSITIONING
ACCURACY. THIS MAY ALSO RESULT IN POSITIONING ERRORS AND REDUCED
SERVICE LIFE IN THE WORST CASES.
NOTE
Positions of robot mounting holes differ according to the stroke length of
each robot. Refer to the dimensional outlines shown in "6-1 Main unit
specifications".
3-3 Installing the robot
3-3
Installing the robot
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1) Drill and tap M5 holes into the surface of the installation base.
Refer to the dimensional outlines shown in "6-1 Main unit specifications" in Chapter
6 for drilling positions.
2) Remove the three screws securing the robot top cover and remove the top cover.
Move the slider to a position where the mounting holes in the bottom of the robot are
not hidden under the slider.
Top cover
3) Secure the robot to the installation base with the specified bolts. The specified bolts
and tightening torque are shown below.
Bolt
Hex socket-head M5
bolt, Strength: 8.8T
Length: 20mm or more
Tightening torque
60kgf•cm to 90kgf•cm
M5 hex wrench
4) After installing the robot, reattach the top cover.
3-5
3
Installation and Connections
WARNING
• BEFORE INSTALLING THE ROBOT, ALWAYS MAKE SURE THAT THE ROBOT
CONTROLLER IS NOT CONNECTED TO THE ROBOT OR THE POWER TO THE
CONTROLLER IS OFF. SERIOUS ACCIDENTS MAY OCCUR IF THE ROBOT
STARTS TO OPERATE DURING INSTALLATION.
• BE SURE TO USE THE BOLTS OF THE SPECIFIED SIZE AND LENGTH AND TIGHTEN
THEM SECURELY TO THE CORRECT TORQUE IN THE CORRECT POSITIONS.
FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE ROBOT VIBRATIONS,
POSITION ERRORS AND SERIOUS ACCIDENTS.
• DO NOT USE A BOLT LONGER THAN THE SPECIFIED LENGTH SINCE IT MAY
INTERFERE WITH THE INTERNAL PARTS OF THE ROBOT AND CAUSE
MALFUNCTIONS.
3-3 Installing the robot
● Protective bonding
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WARNING
ALWAYS GROUND THE ROBOT AND CONTROLLER UNIT TO PREVENT ELECTRICAL
SHOCK.
Always use the ground terminal (M4 screw) on the robot unit to make ground connection.
The ground terminal location is shown below.
3
Installation and Connections
Ground terminal
Robot cable
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CAUTION
• A secure ground connection (less than 100-ohm resistance to ground) is
recommended.
• Use electrical wire thicker than AWG14 (2mm2) as the ground wire.
WARNING
ALWAYS TURN OFF THE POWER TO THE CONTROLLER BEFORE MAKING THE
GROUND CONNECTION.
Provide a terminal marked "PE" as the protective conductor for the entire system, and
connect it to an external protective conductor. Also securely connect the ground terminal
on the robot frame to the protective conductor.
(Symbol 417-IEC-5019)
3-6
3-4 Connecting the robot to the controller
3-4
Connecting the robot to the controller
Connect the robot cables to the mating connectors on the controller as shown. Refer to
the robot controller user's manual for the controller connectors.
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3
Installation and Connections
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WARNING
• BEFORE CONNECTING THE CABLES, CHECK THAT THERE ARE NO BENDS OR
BREAKS IN THE ROBOT CABLE CONNECTOR PINS AND THAT THE CABLES ARE
NOT DAMAGED. CONTACT FAILURE MAY CAUSE ROBOT MALFUNCTIONS.
• ALWAYS MAKE SURE THAT THE POWER TO THE ROBOT CONTROLLER IS OFF
BEFORE CONNECTING THE ROBOT CABLES TO THE CONTROLLER.
CAUTION
After connecting the robot cable intermediate connectors together, fit the
connector hoods together securely.
Intermediate connector (motor wire)
Intermediate connector (signal wire)
1) Connect the robot cables (motor and signal wires) to the mating connectors coming
out from the robot.
Robot cable
connector
(signal wire)
Robot cable
connector
(motor wire)
3-7
3-4 Connecting the robot to the controller
2) After making the connections, fit the connector hoods together securely.
Hood
3
Installation and Connections
3-8
3-4 Connecting the robot to the controller
● Robot cable connections (when connected to SR1)
HPB
SR1
ERR
PWR
MOTOR
HPB
U
V
W
I/O
BAT
AC IN
ROB I/O
L
N
L1
N1
RGEN
P
Robot cable (power cable)
SAFETY
N
3
SHORT:
AC100V
OPEN:
AC200V
Robot cable (signal cable)
Hood
Installation and Connections
Single-axis robot
F8/F8L/F8LH
* After making connections,
fasten the hoods securely.
System Configurations
ERR
PWR
MOTOR
RS-232C or
communication control
(communication cable)
HPB
U
V
W
Resolver signal
Motor power
RS-232C
communication control
SD memory card
(option)
I/O
BAT
AC IN
ROB I/O
L
L1
N1
RGEN
P
SAFETY
N
SHORT:
AC100V
OPEN:
AC200V
Input
16 general-purpose pins
7 custom-purpose pins
Output 16 general-purpose pins
3 custom-purpose pins
I/O control
(24V power
supply built-in)
N
Servo control
SD
MEMORY
CARD
Robot controller SR1
Programming box
HPB (option)
PC
POPCOM
communication software
Power supply
AC100~115/200~230V
p10%
External control
(PLC)
Single-axis robot
F8/F8L/F8LH
The controller is supplied with the robot as
a standard unit.
The programming box HPB is optional.
3-9
3-5 Setting the operating conditions
3-5
Setting the operating conditions
3-5-1 Payload
Optimal acceleration for the YAMAHA single-axis robots is automatically determined by
setting the controller payload parameters. Set the total weight of the workpiece and the
end effectors such as grippers attached to the robot slider in the payload parameter as
shown below.
3
c
Installation and Connections
CAUTION
Be sure to enter an accurate value when making this setting, since a
mistake will cause troubles such as vibration or a shorter machine service
life span.
● To set the payload parameter
Use the following method when setting the payload parameter on a single-axis robot
controller (SR1). If other controllers (RCX240, RCX222, TS-X) are used, refer to their
respective user's manual.
1) Connect the HPB to the SR1 controller
and turn on the controller power. The
initial menu then appears on the HPB.
2) Press
(SYS) on the initial menu
screen.
[MENU]
select menu
The SYS (system) mode screen
appears.
1EDIT2OPRT3SYS 4MON
3) Press
(PRM) to enter the
parameter setting mode.
The SYS-PRM mode screen appears.
4) Select the parameter group.
Press
(AXIS) to select the axis
parameter.
The current setting for PRM100 (Robot
type) appears on the screen.
[SYS]
select menu
1PRM 2B.UP3INIT4next
[SYS−PRM]
select menu
1AXIS2DATA3SYS14SYS2
[SYS−PRM−AXIS]
PRM100 = _
4040
robot type
read only
The robot type No. displayed on the
screen shows an example of model F10.
3-10
3-5 Setting the operating conditions
5) Display PRM112 (payload).
Press the
keys to scroll up or
down the parameter list and select the
parameter you want to set.
6) Set the parameter.
Enter the parameter value with the
number keys and press
.
[SYS−PRM−AXIS]
PRM112 = _
10 [Kg]
payload
range 0→MAX
3
3-5-2 Maximum speed setting
In operation of a single-axis robot with a long stroke ball screw, resonance of the ball
screw may occur. In this case, the maximum speed must be reduced to an appropriate
level. The maximum speed can be reduced by lowering the SPEED setting in automatic
operation or by programming. Use the desired method that matches your application.
Refer to Chapter 6, "Specifications" for information on how to set the maximum speed
according to the stroke length.
If the maximum speed does not reach a hazardous level, reducing the speed is
unnecessary even when a robot has a long stroke axis.
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CAUTION
Do not operate the robot if the ball screw is vibrating. The ball screw may
otherwise wear out prematurely.
3-5-3 Duty
To achieve maximum service life for the YAMAHA single-axis robots, it is recommended
to operate the robot within the allowable duty (50%). The duty is calculated as follows:
Duty (%) =
Operation time
s100
Operation time + Non-operation time
If the robot duty is too high, an error such as "overload" or "overheat" may occur. In this
case, increase the stop time to reduce the duty.
3-11
Installation and Connections
The parameter setting range is shown
on the bottom line of the screen.
When setting is complete, the cursor
moves back to the beginning of the
parameter data.
[SYS−PRM−AXIS]
PRM112 = 10_[Kg]
payload
range 0→MAX
MEMO
3-12
Chapter 4
Periodic Inspection and Maintenance
Contents
4-1 Before beginning work
4-1
4-2 Periodic inspection
4-3
4-2-1
4-2-2
4-2-3
4-2-4
Daily inspection
Three-month inspection
Six-month inspection
Three-year inspection
4-3
4-3
4-4
4-4
4-3 Applying grease
4-5
4-4 Replacing the motor
4-6
4-1 Before beginning work
4-1
Before beginning work
Periodic inspection and maintenance are essential to ensure safe and efficient operation
of YAMAHA robots. This chapter describes periodic inspection items and procedures for
the F8/F8L/F8LH. Before beginning work, read the precautions below and also in Chapter
1 "Using the Robot Safely" and follow the instructions.
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4
WARNING
• WHEN THE ROBOT DOES NOT NEED TO BE OPERATED DURING ADJUSTMENT
OR MAINTENANCE, ALWAYS TURN OFF THE CONTROLLER AND THE
EXTERNAL SWITCH BOARD.
• DO NOT TOUCH INTERNAL PARTS OF THE CONTROLLER FOR 10 MINUTES
AFTER THE CONTROLLER HAS BEEN TURNED OFF.
• WHEN ONLY MAKING ELECTRICAL INSPECTIONS AND REQUIRING NO
MECHANICAL MOVEMENT OF THE ROBOT, KEEP THE EMERGENCY STOP
BUTTON PRESSED.
• USE ONLY LUBRICANT AND GREASES SPECIFIED BY YAMAHA SALES OFFICE
OR REPRESENTATIVE.
• USE ONLY PARTS SPECIFIED BY YAMAHA SALES OFFICE OR REPRESENTATIVE.
TAKE SUFFICIENT CARE NOT TO ALLOW ANY FOREIGN MATTER TO
CONTAMINATE THEM DURING ADJUSTMENT, PARTS REPLACEMENT OR
REASSEMBLY.
• DO NOT MODIFY ANY PARTS ON THE ROBOT OR CONTROLLER.
MODIFICATION MAY RESULT IN UNSATISFACTORY SPECIFICATIONS OR
THREATEN OPERATOR SAFETY.
• WHEN ADJUSTMENT OR MAINTENANCE IS COMPLETE, RETIGHTEN THE BOLTS
AND SCREWS SECURELY.
• DURING ROBOT ADJUSTMENT OR MAINTENANCE, PLACE A SIGN
INDICATING THAT THE ROBOT IS BEING ADJUSTED OR SERVICED TO PREVENT
OTHERS FROM TOUCHING THE CONTROL KEYS OR SWITCHES. PROVIDE A
LOCK ON THE SWITCH KEYS OR ASK SOMEONE TO KEEP WATCH AS NEEDED.
4-1
Periodic Inspection and Maintenance
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DANGER
IF THE INSPECTION OR MAINTENANCE PROCEDURE CALLS FOR OPERATION OF
THE ROBOT, STAY OUT OF THE WORKING AREA OF THE ROBOT DURING
OPERATION. DO NOT TOUCH ANY PARTS INSIDE THE CONTROLLER.
KEEP WATCHING THE ROBOT MOVEMENT AND SURROUNDING AREA SO THAT
THE OPERATOR CAN PRESS THE EMERGENCY STOP BUTTON IF ANY DANGER
OCCURS.
4-1 Before beginning work
When applying grease to the ball screw and linear guide, take the following precautions.
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4
Periodic Inspection and Maintenance
4-2
WARNING
PRECAUTIONS WHEN HANDLING GREASE:
• INFLAMMATION MAY OCCUR IF THIS GETS IN THE EYES.
BEFORE HANDLING THE GREASE, WEAR YOUR SAFETY GOGGLES TO ENSURE
THE GREASE WILL NOT COME IN CONTACT WITH THE EYES.
• INFLAMMATION MAY OCCUR IF THE GREASE COMES INTO CONTACT WITH
SKIN. BE SURE TO WEAR PROTECTIVE GLOVES TO PREVENT CONTACT WITH
SKIN.
• DO NOT TAKE ORALLY OR EAT. (EATING WILL CAUSE DIARRHEA AND
VOMITING.)
• HANDS AND FINGERS MIGHT BE CUT WHEN OPENING THE GREASE
CONTAINER, SO USE PROTECTIVE GLOVES.
• KEEP OUT OF THE REACH OF CHILDREN.
• DO NOT HEAT THE GREASE OR PLACE NEAR AN OPEN FLAME SINCE THIS
COULD LEAD TO SPARKS AND FIRES.
EMERGENCY TREATMENT:
• IF GREASE GETS IN THE EYES, WASH LIBERALLY WITH PURE WATER FOR ABOUT
15 MINUTES AND CONSULT A PHYSICIAN FOR TREATMENT.
• IF GREASE COMES IN CONTACT WITH THE SKIN, WASH AWAY COMPLETELY
WITH SOAP AND WATER.
• IF TAKEN INTERNALLY, DO NOT INDUCE VOMITING BUT PROMPTLY CONSULT
A PHYSICIAN FOR PROPER TREATMENT.
4-2 Periodic inspection
4-2
Periodic inspection
4-2-1 Daily inspection
Check the following points on a daily basis, before and after robot operation.
Checkpoints
Check items
Cables
Check for damage, dent
and excessively tight
bends.
Ball screw, bearing
Check for unusual vibration
and noise.
Motor
Check for unusual vibration
and noise, and for
abnormal temperature rise.
Notes
Replace if needed.
4
4-2-2 Three-month inspection
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Periodic Inspection and Maintenance
Take the following precautions when performing 3-month inspection.
WARNING
THE SLIDER OF VERTICAL USE ROBOT WILL SLIDE DOWN WHEN THE BRAKE IS
RELEASED, CAUSING A HAZARDOUS SITUATION. DO NOT RELEASE THE BRAKE
WHEN LUBRICATING VERTICAL USE ROBOT PARTS.
Check the following points every 3 months and apply grease if needed.
Checkpoints
Ball screw, linear
guide, ball bushing
Check items
• Check for dust buildup or debris.
Clean if necessary. Apply grease
after cleaning.
Notes
See "4-3" in this
chapter.
• Check to see if the ball screw,
linear guide and ball bushing are
lubricated (not dry). Apply grease
if necessary.
Standard robots:
Albania No. 2 (Shell)
Daphne Eponex No. 2 (Idemitsu)
Clean room robots:
LG-2 (NSK)
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CAUTION
Using grease other than those recommended by YAMAHA might shorten the
service life of the ball screw, linear guide and linear bushing shaft.
4-3
4-2 Periodic inspection
4-2-3 Six-month inspection
Take the following precautions when performing 6-month inspection.
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WARNING
THE SLIDER OF VERTICAL USE ROBOT WILL SLIDE DOWN WHEN THE BRAKE IS
RELEASED, CAUSING A HAZARDOUS SITUATION. DO NOT RELEASE THE BRAKE
WHEN LUBRICATING THE VERTICAL USE ROBOT PARTS.
Check the following points every 6 months and adjust or replace parts if needed.
Checkpoints
4
Check items
Major bolts and
screws on robot
Check for looseness. Tighten
if loose.
Ball screw, linear
guide
• Check the ball screw and
linear guide for backlash.
Tighten if necessary.
Periodic Inspection and Maintenance
• Check for vibration during
operation. Tighten bolts if
necessary to secure drive
unit and/or shaft.
Notes
Consult us if problem
cannot be solved or
there is backlash due to
wear.
• Check for backlash due to
wear.
Controller
• Check if terminals are loose.
• Check if connectors are
loose
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Greasing to ball
screw/nut section
and linear guide
Apply grease every 6 months
to ball screw/nut and linear
guide.
Recommended grease
Albania No. 2 (Shell)
Daphne Eponex No. 2
(Idemitsu)
Slider
On long-stroke (750mm or
more) robots, check the slider
inside the top cover for wear
or damage every 6 months.
See "4-3" in this
chapter.
CAUTION
Using grease other than those recommended by YAMAHA might shorten the
service life of the ball screw and linear guide.
4-2-4 Three-year inspection
Check the following points every 3 years or more often if the robot is used frequently.
Checkpoints
Ball screw/nut
section and linear
guide
4-4
Check items
Check ball screw/nut and
linear guide for backlash due
to wear.
Notes
Consult us if abnormal
condition is found.
4-3 Applying grease
4-3
Applying grease
When applying grease to the ball screw according to periodic inspection, follow the
procedure below. Grease can be applied to the guide sliding section using the grease
nipples. Prepare a grease gun in this case.
1) Make sure that the power to the controller is off.
2) Apply grease by either of the following methods.
● Linear guide
When using the grease nipples, apply grease into the two grease nipples on the left
and right side of the slider (4 grease nipples for F8LH). Then move the table slider
back and forth to help spread the grease around.
Grease gun
● Ball screw
1) Remove the screws securing the robot top cover and remove the top cover.
(For how to remove the top cover, refer to "3-3 Installing the robot".)
2) Apply grease by hand to the ball screw and move the table slider back and forth
to help spread the grease around.
Ball screw
3) Reattach the top cover and end covers.
4-5
Periodic Inspection and Maintenance
Grease nipple
4
4-4 Replacing the motor
4-4
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Replacing the motor
CAUTION
A positional shift occurs by replacing the motor. It is therefore necessary to
perform return-to-origin and set point data again after replacing the motor.
When removing the parts, note their positional relation and assembly order.
1) Turn off the controller power.
2) Remove the three screws securing the robot top cover and remove the top cover.
(For how to remove the top cover, refer to "3-3 Installing the robot".)
4
3) Remove the two screws securing each side cover and remove the side covers.
Periodic Inspection and Maintenance
Side cover
4) Remove the four screws securing the end cover on the motor side and remove the
end cover.
End cover
4-6
4-4 Replacing the motor
5) Remove the four screws securing the motor cover and remove the motor cover.
Motor cover
Motor cover
6) Remove the ground wire.
4
7) Remove the four bolts securing the motor and remove the motor.
Periodic Inspection and Maintenance
Motor
Motor
8) Remove the wave washer and flat washer.
c
CAUTION
When removing the motor, the flat washer might be left in the bearing inside
the motor, so use caution.
Wave washer
Flat washer
4-7
4-4 Replacing the motor
9) Remove the four bolts securing the rotor and pull out the rotor.
Rotor
10) Install the new rotor.
4
11) Install the wave washer and flat washer in the correct order.
Periodic Inspection and Maintenance
12) Install the new motor.
13) Reassemble in the reverse order (steps 11 to 2).
4-8
Rotor
4-4 Replacing the motor
● Checking the grid position (for SR1)
1) Press
(OPRT) on the initial menu
screen.
[MENU]
select menu
1EDIT2OPRT3SYS 4MON
2) Press
(ORG).
[OPRT]
select menu
1ORG 2STEP3AUTO
3) Press
(yes) to perform return-to-
origin.
To cancel the operation, press
4) This screen appears during return-toorigin.
Pressing
4
1yes 2no
[OPRT−ORG−SEARCH]
searching ...
during operation stops the
robot and displays a message. Then
pressing
returns to the screen of 2).
5) When return-to-origin ends normally,
the machine reference value appears
on the bottom right of the screen.
6) Press
[OPRT−ORG−SEARCH]
origin complete
grid position 50%
to display the grid position.
4-9
Periodic Inspection and Maintenance
(no).
[OPRT−ORG−SEARCH]
ORG search OK ?
MEMO
4-10
Chapter 5
Troubleshooting
Contents
5-1 If you suspect trouble
5-1-1 Positioning error
5-1-2 Feedback error
5-1
5-1
5-2
5-1 If you suspect trouble
5-1
If you suspect trouble
If an error such as a positioning error or feedback error occurs, check the following points
to find the solution before you determine the robot or controller has malfunctioned. If
the trouble still exists even after checking these points, please contact us with a detailed
description of the trouble.
5-1-1 Positioning error
Position deviates.
The position deviates after
moving the robot or set up
of workpiece tool.
Operation was correct,
but position deviates.
Robot bumped into something,
or there are traces of bumping
into (rubbing against) something.
5
Are cables correctly wired?
Are connectors correctly fitted?
No
No
Troubleshooting
Yes
Is cable broken?
Replace
the cable
Yes
(1) Check tool and workpiece for warping.
(2) Check robot alignment.
Check wiring and
connectors.
No
Are the robot, tools and
workpiece correctly installed?
Mechanical
cause
No
Yes
Check installation
method.
Check for looseness of
robot mechanical parts.
Does the position return
after return-to-origin operation?
Yes
(1) Check for looseness of
mechanical parts. Retighten
if necessary.
(2) Replace mechanical parts.
Yes
Electrical cause
Is there a large source of
noise nearby?
No
Take measures
against noise.
Check or replace the motor, cable and controller.
5-1
5-1 If you suspect trouble
5-1-2 Feedback error
Feedback error
No
Any foreign matter
caught inside?
No
Much mechanical
friction?
Turn power off and
check for friction
by moving manually
Yes
No
Adjust mechanical alignment
Is brake installed?
Yes
Is brake sound
heard when turning power
on and off?
Yes
Recheck
No
Replace motor (with brake)
Repair
No
Replace power supply unit or
repair defective parts
Initialize parameters
No
Yes
Is there electrical
discontinuity?
5
No
Repair
Is 24V supplied to
brake?
Yes
Are parameters for
controller and robot OK?
Yes
Is there electrical
discontinuity?
Are wiring and connector
securely connected?
No
No
Securely connect wiring and connector
Yes
Troubleshooting
Are connector pins
securely inserted?
When feedback error is occurring, perform
continuity check
(1) Check motor power supply lines U, V and W
(2) Check encoder signal lines for phases A and B
Is wiring live?
No
Yes
Securely insert pins or
repair defective pins
Is motor resistance
OK?
No
Replace motor since motor has shorted or burnt out
Yes
Take noise reduction
measures
Is motor encoder
OK?
Yes
Yes
No
5-2
Is external
noise large?
Yes
Is controller
hardware OK?
No
Replace motor
(1) Check position shift by repetitive accuracy
measurement
(2) If replacement motor is available, check by
exchanging the motors
(1) If replacement controller is available, check by
exchanging the controllers
Chapter 6
Specifications
Contents
6-1 Main unit specifications
6-1-1 F8
6-1-2 F8L
6-1-3 F8LH
6-1
6-4
6-9
6-2 AC servo motor specifications
6-2-1 AC servo motor termination
6-2-2 Brake cable specifications
6-3 Robot cables
6-3-1
6-3-2
6-3-3
6-3-4
Robot
Robot
Robot
Robot
6-1
cables
cables
cables
cables
(SR1)
(TS-X)
(RCX222/240)
(RDX)
6-12
6-12
6-13
6-14
6-14
6-15
6-16
6-18
6-1 Main unit specifications
6-1
Main unit specifications
6-1-1 F8
● Basic specifications
Motor output AC (W)
100
Repeated positioning accuracy (mm)
±0.02
1
Ball screw φ12 (Class C10)
Deceleration mechanism
Ball screw lead (mm)
20
12
6
1200
720
360
Horizontal installation
12
20
40
Vertical installation
–
4
8
84
141
283
Maximum speed (mm/sec)
Maximum payload
(kg)
2
Rated thrust (N)
Stroke (mm)
Total length (mm)
150 to 800 (50 pitch)
Horizontal installation
Stroke length + 286
Vertical installation
Stroke length + 316
Maximum cross-section outside
dimensions (mm)
W80×H65
Cable length (m)
Controller
Robot driver
Standard : 3.5 Option: 5/10
Horizontal installation
SR1-X, TS-X, RCX222, RCX240
Vertical installation
SR1-X, TS-X, RCX222, RCX240
Horizontal installation
RDX-05-RBR1
Vertical installation
RDX-05-RBR1
6
Effective stroke
150
200
250
300
350
400
450
500
550
600
650
700
750
800
Lead 20
1200
1080 900
780
720
600
Maximum Lead 12
speed Lead 6
(mm/sec)
Speed
setting
720
648
540
468
432
360
360
324
270
234
216
180
–
● Static loading moment
90% 75% 65% 60% 50%
MY
(Unit: N•m)
MY
MP
MR
70
95
110
MP
MR
6-1
Specifications
1: Positioning repeatability in one direction.
2: When the stroke is longer than 600mm, the ball screw may resonate depending on the moving
range (critical speed). In this case, adjust to reduce the operating speed by referring to the
maximum speeds shown in the table below.
6-1 Main unit specifications
● Allowable overhang*
* Distance from the center on the top face of slider to the gravity center of the item being
carried. (This is calculated assuming that the service life of the guide is 10,000km.)
■ Horizontal installation
Horizontal installation
A
Lead 20
C
Lead 12
B
Lead 6
(Unit: mm)
A
B
C
5kg
197
76
120
10kg
100
32
54
12kg
85
25
43
5kg
364
89
188
10kg
203
39
87
15kg
139
22
51
20kg
103
14
33
10kg
403
43
113
20kg
214
16
43
30kg
140
6
20
40kg
113
0
8
■ Wall installation
Wall installation
6
Lead 20
Specifications
B
A
Lead 12
C
Lead 6
(Unit: mm)
A
B
C
5kg
104
67
174
10kg
37
23
72
12kg
27
15
55
5kg
171
81
340
10kg
69
32
172
15kg
33
15
100
20kg
15
6
55
10kg
94
36
369
20kg
25
9
157
30kg
0
0
14
40kg
0
0
0
■ Vertical installation
Vertical installation
Lead 12
C
A
Lead 6
6-2
(Unit: mm)
A
C
1kg
447
448
2kg
214
216
3kg
137
138
4kg
98
99
2kg
244
245
4kg
113
113
6kg
69
69
8kg
46
46
6.4
3.5
Cross-section E-E
148±1 (Note 1)
1.5
5
2
Grounding terminal (M4)
60
80
F: Detail of T-groove
6-3
150
436
0
100
8
240
3.6
200
486
0
150
8
290
3.9
250
536
1
100
10
340
4.2
300
586
1
150
10
390
4.4
350
636
2
100
12
440
4.7
400
686
2
150
12
490
5.0
450
736
3
100
14
540
5.3
500
786
3
150
14
590
5.6
Specifications
Effective stroke
L
A
B
C
D
Weight (kg) Note 5
E
L
100
Ax100
Greasing hole
F10H7 Plate thickness 10
(Note 4)
50
78
D
L+30 (with brake)
2-F5H7 Depth 10
4-M6 s 1.0 Depth 12
30 ±0.02
Effective stroke
B
(93) : When origin is on motor side
50
(68)
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
WARNING
93±3 : When origin is on
non-motor side
48±1
(Note1)
2
550
836
4
100
16
640
5.9
600
886
4
150
16
690
6.2
650
936
5
100
18
740
6.4
700
986
5
150
18
790
6.7
750
1036
6
100
20
840
7.0
800
1086
6
150
20
890
7.3
Note 4. When using this φ10 knock-pin hole to position the robot body, the knockpin must not protrude more than 10mm inside the robot body.
Note 5. Weight excluding brake. Weight of brake-equipped robots is 0.3kg heavier
than the weight of robots with no brake (shown in the table).
175 (with brake)
145
C-F5.5 See cross-section E-E. E
168
198 (with brake)
Note 1. Distance from both ends to the mechanical stopper.
Note 2. When installing the robot, do not use washers inside the robot body.
Note 3. Minimum bend radius of motor cable is R50 (50mm).
F9.5
65
Use M5 s0.8 hex socket
*Recommended plate nut: M3 (%6*t1.6)
head bolt with length
(under head) of 16mm or more.
5
F5.5
80
178±1 (with brake) (Note 1)
Approx. 210 (Motor cable length) 223±3 (with brake) : When origin is on motor side
(223) : When origin is on non-motor side
63.5
40
F
34
70
(Tolerance between
knocks±0.02)
50
R
Approx. 240 (Motor cable length) 193±3 : When origin is on motor side
(193) : When origin is on non-motor side
10H7
(Note 4)
● F8 Dimensions
6-1 Main unit specifications
6
6-1 Main unit specifications
6-1-2 F8L
● Basic specifications
Motor output AC (W)
100
Repeated positioning accuracy (mm)
±0.01
1
Ball screw φ15 (Class C7)
Deceleration mechanism
Ball screw lead (mm)
30
20
10
5
1800
1200
600
300
Horizontal installation
7
20
40
50
Vertical installation
–
4
8
16
56
84
169
339
Maximum speed (mm/sec)
Maximum payload
(kg)
2
Rated thrust (N)
Stroke (mm)
Total length (mm)
150 to 1050 (50 pitch)
Horizontal installation
Stroke length
+ 300
Stroke length + 292
–
Stroke length + 322
Vertical installation
Maximum cross-section outside
dimensions (mm)
W80×H65
Cable length (m)
Controller
Robot driver
6
Standard : 3.5 Option: 5/10
Horizontal installation
SR1-X, TS-X, RCX222, RCX240
Vertical installation
SR1-X, TS-X, RCX222, RCX240
Horizontal installation
RDX-05-RBR1
Vertical installation
RDX-05-RBR1
Specifications
1: Positioning repeatability in one direction.
2: When the stroke is longer than 700mm, the ball screw may resonate depending on the moving
range (critical speed). In this case, adjust to reduce the operating speed by referring to the
maximum speeds shown in the table below.
Effective stroke
150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050
Lead 20
1200
1020 900 780 720 660 600 540 480
Maximum Lead 10
speed Lead 5
(mm/sec)
Speed
setting
600
510 450 390 360 330 300 270 240
300
255 225 195 180 165 150 135 120
–
85% 75% 65% 60% 55% 50% 45% 40%
High lead type: Lead 30
Effective stroke
150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050
Maximum Lead 30
speed
SPEED
(mm/sec)
setting
1800
1530 1350 1170 1080 990 900 810 720
–
85% 75% 65% 60% 55% 50% 45% 40%
● Static loading moment
MY
(Unit: N•m)
MY
MP
MR
70
95
110
MP
MR
6-4
6-1 Main unit specifications
● Allowable overhang*
* Distance from the center on the top face of slider to the gravity center of the item being
carried. (This is calculated assuming that the service life of the guide is 10,000km.)
■ Horizontal installation
Horizontal installation
Lead 30
A
Lead 20
C
B
Lead 10
Lead 5
(Unit: mm)
A
B
C
5kg
112
80
80
7kg
78
43
49
5kg
211
108
147
10kg
116
45
69
15kg
76
24
39
20kg
58
14
26
10kg
251
56
122
20kg
121
20
46
30kg
74
8
20
40kg
35
0
6
20kg
249
23
62
30kg
170
10
29
40kg
138
4
12
50kg
51
0
0
6
■ Wall installation
Wall installation
B
Lead 20
A
C
Lead 10
Lead 5
A
B
C
5kg
55
57
77
7kg
21
19
34
5kg
119
89
176
10kg
38
26
69
15kg
7
0
16
20kg
0
0
0
10kg
85
39
202
20kg
7
0
30
30kg
0
0
0
40kg
0
0
0
20kg
19
7
140
30kg
0
0
0
40kg
0
0
0
50kg
0
0
0
Specifications
Lead 30
(Unit: mm)
6-5
6-1 Main unit specifications
■ Vertical installation
Vertical installation
Lead 20
C
Lead 10
A
Lead 5
6
Specifications
6-6
(Unit: mm)
A
C
2kg
236
240
4kg
106
110
2kg
310
311
4kg
141
143
6kg
85
86
8kg
57
58
5kg
123
124
10kg
47
48
15kg
22
22
16kg
19
19
1.5
5
2
Grounding terminal (M4)
60
80
6.4
3.5
Cross-section E-E
160±1 (Note 1)
F: Detail of T-groove
186 (with brake)
156
6-7
150
442
0
100
8
240
3.9
200
492
0
150
8
290
4.2
250
542
1
100
10
340
4.5
300
592
1
150
10
390
4.8
350
642
2
100
12
440
5.1
400
692
2
150
12
490
5.4
450
742
3
100
14
540
5.7
500
792
3
150
14
590
6.1
Specifications
Effective stroke
L
A
B
C
D
Weight (kg) Note 5
L
100
Ax100
Greasing hole
F10H7 Plate thickness 10
(Note 4)
50
78
L+30 (with brake)
2-F5H7 Depth 10
4-M6 s 1.0 Depth 12
30 ±0.02
D
Effective stroke
B
50
(63)
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
WARNING
88±3 : When origin is on
non-motor side
44±1
(Note 1)
(88) : When origin is on motor side
2
550
842
4
100
16
640
6.4
600
892
4
150
16
690
6.7
650
942
5
100
18
740
7.0
700
992
5
150
18
790
7.3
750
1042
6
100
20
840
7.6
800
1092
6
150
20
890
7.9
850
1142
7
100
22
940
8.2
900
1192
7
150
22
990
8.5
950
1242
8
100
24
1040
8.8
1000
1292
8
150
24
1090
9.2
1050
1342
9
100
26
1140
9.5
Note 4. When using this φ10 knock-pin hole to position the robot body, the knockpin must not protrude more than 10mm inside the robot body.
Note 5. Weight excluding brake. Weight of brake-equipped robots is 0.3kg heavier
than the weight of robots with no brake (shown in the table).
E
179
C-F5.5 See cross-section E-E. E
209 (with brake)
Note 1. Distance from both ends to the mechanical stopper.
Note 2. When installing the robot, do not use washers inside the robot body.
Note 3. Minimum bend radius of motor cable is R50 (50mm).
9.5
65
Use M5 s0.8 hex socket
*Recommended plate nut: M3 (%6*t1.6)
head bolt with length
(under head) of 16mm or more.
5
5.5
80
190±1 (with brake) (Note 1)
Approx. 210 (Motor cable length) 234±3 (with brake) : When origin is on motor side
(234) : When origin is on non-motor side
63.5
40
F
34
70
(Tolerance between
knocks±0.02)
50
R
Approx. 240 (Motor cable length) 204±3 : When origin is on motor side
(204) : When origin is on non-motor side
10H7
(Note 4)
● F8L Dimensions
6-1 Main unit specifications
6
1.5
5
2
Grounding terminal (M4)
60
80
Approx. 240 (Motor cable length)
65
6.4
3.5
Cross-section E-E
F: Detail of T-groove
164
Effective stroke
L
A
B
C
D
Weight (kg)
150
450
0
100
8
240
3.9
200
500
0
150
8
290
4.2
250
550
1
100
10
340
4.5
300
600
1
150
10
390
4.8
350
650
2
100
12
440
5.1
400
700
2
150
12
490
5.4
450
750
3
100
14
540
5.7
500
800
3
150
14
590
6.1
100
Ax100
Greasing hole
L
2-F5H7 Depth 10
F10H7 Plate thickness 10
(Note 4)
50
78
D
Effective stroke
4-M6 s 1.0 Depth 12
30 ±0.02
50
B
50
(63)
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
WARNING
(88) : When origin is on motor side
90.5±4: When origin is on
non-motor side
44±1
2
550
850
4
100
16
640
6.4
600
900
4
150
16
690
6.7
650
950
5
100
18
740
7.0
700
1000
5
150
18
790
7.3
750
1050
6
100
20
840
7.6
800
1100
6
150
20
890
7.9
850
1150
7
100
22
940
8.2
900
1200
7
150
22
990
8.5
950
1250
8
100
24
1040
8.8
1000
1300
8
150
24
1090
9.2
1050
1350
9
100
26
1140
9.5
Note 4. When using this φ10 knock-pin hole to position the robot body, the knockpin must not protrude more than 10mm inside the robot body.
E
C-F5.5 See cross-section E-E. E
187
165.5±1
212±4 : When origin is on motor side
(209.5) : When origin is on non-motor side
Note 1. Distance from both ends to the mechanical stopper.
Note 2. When installing the robot, do not use washers inside the robot body.
Note 3. Minimum bend radius of motor cable is R50 (50mm).
9.5
80
Use M5 s0.8 hex socket
*Recommended plate nut: M3 (%6*t1.6)
head bolt with length
(under head) of 16mm or more.
5
5.5
63.5
40
F
34
70
(Tolerance between
knocks±0.02)
6-8
R
6
10H7
(Note 4)
Specifications
● F8L Dimensions (High lead type: Lead 30)
6-1 Main unit specifications
6-1 Main unit specifications
6-1-3 F8LH
● Basic specifications
Motor output AC (W)
100
Repeated positioning accuracy (mm)
±0.01
1
Ball screw φ15 (Class C7)
Deceleration mechanism
Ball screw lead (mm)
Maximum speed (mm/sec)
Maximum payload
(kg)
2
Horizontal installation
Rated thrust (N)
20
10
5
1200
600
300
30
60
80
84
169
339
Stroke (mm)
150 to 1050 (50 pitch)
Total length (mm)
Stroke length + 368
Maximum cross-section outside
dimensions (mm)
W80×H65
Cable length (m)
Controller
Robot driver
Standard : 3.5 Option: 5/10
Horizontal installation
SR1-X, TS-X, RCX222, RCX240
Vertical installation
SR1-X, TS-X, RCX222, RCX240
Horizontal installation
RDX-05-RBR1
Vertical installation
RDX-05-RBR1
1: Positioning repeatability in one direction.
2: When the stroke is longer than 650mm, the ball screw may resonate depending on the moving
range (critical speed). In this case, adjust to reduce the operating speed by referring to the
maximum speeds shown in the table below.
6
150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050
Lead 20
1200
1020 900 780 720 660 600 540 480 420
Maximum Lead 10
speed Lead 5
(mm/sec)
Speed
setting
600
510 450 390 360 330 300 270 240 210
300
255 225 195 180 165 150 135 120 105
–
85% 75% 65% 60% 55% 50% 45% 40% 35%
● Static loading moment
MY
(Unit: N•m)
MY
MP
MR
128
163
143
MP
MR
6-9
Specifications
Effective stroke
6-1 Main unit specifications
● Allowable overhang*
* Distance from the center on the top face of slider to the gravity center of the item being
carried. (This is calculated assuming that the service life of the guide is 10,000km.)
■ Horizontal installation
Horizontal installation
Lead 20
A
Lead 10
C
B
6
Lead 5
(Unit: mm)
A
B
C
10kg
573
256
176
20kg
334
116
81
30kg
279
70
50
20kg
629
137
111
40kg
479
57
47
60kg
382
30
25
20kg
1094
148
127
40kg
851
63
54
60kg
714
34
29
80kg
601
20
17
■ Wall installation
Wall installation
(Unit: mm)
Specifications
A
Lead 20
B
Lead 10
A
C
Lead 5
6-10
B
C
10kg
147
215
515
20kg
53
75
255
30kg
20
29
160
20kg
80
99
545
40kg
15
19
270
60kg
0
0
0
20kg
96
112
1005
40kg
22
26
604
60kg
0
0
0
80kg
0
0
0
6.4
3.5
1.5
5
2
Grounding terminal (M4)
80
60
Cross-section E-E
F: Detail of T-groove
169
6-11
150
518
0
150
8
290
4.7
200
568
1
100
10
340
5.0
250
618
1
150
10
390
5.3
300
668
2
100
12
440
5.6
350
718
2
150
12
490
5.9
400
768
3
100
14
540
6.2
450
818
3
150
14
590
6.6
500
868
4
100
16
640
6.9
Specifications
Effective stroke
L
A
B
C
D
Weight (kg)
Effective stroke
100
Ax100
D
L
2-Greasing hole
2-F5H7 Depth 10
8-M6 s 1.0 Depth 12
30 ±0.02
F10H7 Plate thickness 10
(Note 4)
50
154
120
50
B
50
(76)
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
WARNING
(126) : When origin is on motor side
126±3 : When origin is on
non-motor side
44±1
(Note 1)
2
550
918
4
150
16
690
7.2
600
968
5
100
18
740
7.5
650
1018
5
150
18
790
7.8
700
1068
6
100
20
840
8.1
750
1118
6
150
20
890
8.4
800
1168
7
100
22
940
8.7
850
1218
7
150
22
990
9.0
900
1268
8
100
24
1040
9.3
950
1318
8
150
24
1090
9.7
1000
1368
9
100
26
1140
10.0
1050
1418
9
150
26
1190
10.3
Note 3. Minimum bend radius of motor cable is R50 (50mm).
Note 4. When using this φ10 knock-pin hole to position the robot body, the knockpin must not protrude more than 10mm inside the robot body.
E
C-F5.5 See cross-section E-E. E
192
160±1 (Note 1)
Note 1. Distance from both ends to the mechanical stopper.
Note 2. When installing the robot, do not use washers inside the robot body.
9.5
65
Use M5 s0.8 hex socket
*Recommended plate nut: M3 (%6*t1.6)
head bolt with length
(under head) of 16mm or more.
5
5.5
F
34
80
70
(Tolerance between
knocks±0.02)
63.5
40
242±3 : When origin is on motor side
(242) : When origin is on non-motor side
R
Approx. 240 (Motor cable length)
10H7 (Note 4)
● F8LH Dimensions
6-1 Main unit specifications
6
6-2 AC servo motor specifications
6-2
AC ser vo motor specifications
6-2-1 AC ser vo motor termination
■ Connector specifications
No.
Parts
Type No.
Maker
Qty
Notes
1
Servo motor
1
2
Receptacle housing
SMR-07V-B
JST
1
CN1 (7 polarities)
3
Pin contact
BYM-001T-P0.6
JST
9
CN1, CN2
4
Plug housing
176273-1
AMP
1
CN3 (4 polarities)
5
Receptacle
175156-2
AMP
4
CN3
6
Receptacle housing
SMR-02V-B
JST
1
CN2 (2 polarities)
7
Plug housing
SMR-02V-BC
JST
1
CN4 (2 polarities)
8
Socket contact
BHF-001T-0.8BS
JST
2
CN4
9
Round terminal
1.25-M4
1
■ Connector wiring
Connector
6
Specifications
CN1
Pin No.
Signal
Wire Color
Connection
1
S2
Yellow
2
S4
Blue
3
S1
Red
4
S3
Black
5
R1
White
6
R2
Green
7
Shield
Black *1
1
BK
Brown
1
2
BK
Gray
2
1
U
Red
2
V
White
3
W
Black
4
CG
Yellow/Green
P
Motor
CN2
Motor
M
CN3
*1: Heat shrinkable tube
PI
CN1
BK
CN4
6-12
MO
CN2
CN3
6-2 AC servo motor specifications
6-2-2 Brake cable specifications
■ Connector specifications
No.
Parts
Type No.
Maker
Qty
Note
1
Brake parts
1
2
Receptacle housing
SMR-02V-B
JST
1
CN1
3
Pin contact
BYM-001T-P0.6
JST
9
CN1
■ Connector wiring
Connector
Pin No.
Signal
Wire Color
1
S1
Yellow (black)
2
S2
Yellow (black)
CN1
BK
CN1
6
Specifications
6-13
6-3 Robot cables
6-3
Robot cables
6-3-1 Robot cables (SR1)
■ Signal cable
To robot
To controller
P
BK
ORG
PIN
Parts
1
1
Resolver
S4
2
2
Orange
S1
3
3
Green
S3
4
4
Brown
R1
5
5
Grey
R2
6
6
Red
6
D.G
9
7
Clear
Specifications
Parts
Signal
PIN
Controller CN1
S2
Connection
BK+
17
1
BK-
18
2
ORG
12
2
24V
13
1
White
GND24
15
3
Blue/Red
Brake
Wire
0.3sq
Blue
SPMCU-14K
Shield
Black
Yellow
ORG
Pink
■ Power cable
To controller
6-14
To robot
Parts
Signal
PIN
Connection
PIN
Parts
Wire
Motor wire
FG
1
4
0.75sq
Yellow/Green
U
2
1
0.75sq
Red
V
4
2
0.75sq
White
W
3
3
0.75sq
Black
6-3 Robot cables
6-3-2 Robot cables (TS-X)
■ Signal cable
To robot
To controller
P
BK
ORG
Parts
Signal
PIN
Controller CN1
S2
Connection
PIN
Parts
Wire
1
1
Resolver
S4
2
2
Orange
S1
3
3
Green
S3
4
4
Brown
R1
5
5
Grey
R2
6
6
Red
FG
7
7
BK+
13
1
BK-
14
2
ORG
12
2
24V
11
1
White
GND24
10
3
Blue/Red
0.3sq
Blue
SPMCU-14(K)
Drain wire
Brake
6
Black
Specifications
Yellow
ORG
Pink
■ Power cable
To controller
To robot
Parts
Signal
PIN
Connection
PIN
Parts
Wire
Motor wire
FG
1
4
0.75sq
Yellow/Green
U
2
1
0.75sq
Red
V
4
2
0.75sq
White
W
3
3
0.75sq
Black
6-15
6-3 Robot cables
6-3-3 Robot cables (RCX222/240)
P1
BK1
M1
X Z
ORG1
P2
BK2
YR
XZ
M1
Y R
ORG2
M2
6
Specifications
6-16
M2
6-3 Robot cables
Signal
Resolver
Brake
Connector
No.
P1
1
1
S4
2
2
S1
3
3
S3
4
4
R1
5
5
R2
6
DG
S2
MB+
BK1
MB-
Connection
No.
Connector
0.3sq
Twisted pair
Resolver
Yellow
6
0.3sq
Twisted pair
7
7
Drain wire
1
14
2
16
0.3sq
Twisted pair
White
0.3sq
Twisted pair
Purple
9
ORG
2
12
GND24
3
13
1
19
S4
2
20
S1
3
21
S3
4
22
R1
5
23
R2
6
DG
MB+
BK2
MB-
0.3sq
Twisted pair
0.3sq
Twisted pair
White
Blue
Blue
Brown
Red
White
0.3sq
Twisted pair
Green
Yellow
24
0.3sq
Twisted pair
7
25
Drain wire
1
32
2
White
White
Blue
34
0.3sq
Twisted pair
White
0.3sq
Twisted pair
Purple
ORG2
Sensor
White
24V
1
27
ORG
2
30
GND24
3
31
HLIM
10
GND24
11
HLIM
28
GND24
29
1
2
V
2
W
FG
0.3sq
Twisted pair
Blue
Brown
Green
Green
0.75sq
Red
3
0.75sq
White
3
4
0.75sq
4
1
0.75sq
1
2
0.75sq
Black
Yellow/
Green
Red
V
2
3
0.75sq
White
W
3
4
0.75sq
FG
4
1
0.75sq
Black
Yellow/
Green
U
U
M1
M2
M1
M2
6-17
6
Specifications
Brake
1
P2
White
Green
24V
S2
Red
0.3sq
Twisted pair
ORG1
Sensor
Wire
6-3 Robot cables
6-3-4 Robot cables (RDX)
■ Signal cable
To robot
molex
To controller
P
BK
ORG
Signal
Encoder
Connector
No.
Connection
6
Connector
P
S2
5
1
S4
6
2
S1
7
3
Wire
Blue
Orange
Green
0.3sq
Twisted pair
S3
8
4
R1
1
5
Grey
R2
2
6
Red
F.G.
Brake
No.
7
BK+
1
1
BK-
2
2
Brown
Drain wire
BK
Blue
Orange
Specifications
ORG
0.3sq
Twisted pair
24V
3
1
ORG
4
2
Grey
GND24
5
3
Red
Green
■ Power cable
U
V
W
FG
Signal
Motor wire
6-18
U
Connector
No.
M
1
Connection
Connector
Round
terminal
Wire Color
Red
V
2
White
W
4
Black
FG
3
Yellow/Green
Appendix
Contents
About machine reference
i
Moment of inertia calculation
ii
About machine reference
n
Appendix
The position detector built into the motor issues a "0" pulse each time the motor
rotates 1/4th of one turn. When return-to-origin is performed, a difference in distance
occurs between the position where the origin signal is detected and the point at
which the next "0" pulse is received. This is called the machine reference and is
usually expressed as a percent, with 100% being equal to 1/4th of one turn of the
motor. (See the figure below.)
The machine reference value must be within the allowable range (25 to 75%) to
maintain axis movement repeatability.
The optional programming box (HPB or RPB) or Handy Terminal (HT1) is needed
to check the machine reference value. The machine reference value is displayed on
the LCD screen of the programming box or Handy Terminal when return-to-origin is
complete. (See the figure below.)
NOTE
The F8/F8L/F8LH robots use an absolute type position detector. There is no need to
perform return-to-origin each time the robot controller is turned on and readjust the
machine reference value. If for some reason the machine reference adjustment
becomes necessary, please contact YAMAHA sales office or dealer.
Machine reference
Origin signa
Origin detection
signal
Machine reference
(Stroke end detection)
Machine reference
(Origin dog detection)
Zero signal
Pulse
1/4th of one turn of motor
Machine reference value display examples
[OPRT−ORG−SEARCH]
origin complete
Origin search
NRM [01]
Method: TORQUE
Direction:
CCW search
Origin
Coordinates:
OK
Ref. = 50 %
machine ref. 50%
SR1 * In the screen illustration below, a section of the screen
shown by the ∼
∼ marks is omitted.
RUN:Origin search start
128.00 mm
Current pos.
TS-X
MANUAL>RST.ABS 50%[MG][S0H0J]
Machine reference(%)
M1= 32 M2= 40 M3= 49
M4= 40 M1 M2 M3 M4 M5
RCX Series (Multiple FLIP-X control)
i
Moment of inertia calculation
Appendix
c
CAUTION
The robot must be operated with correct tolerable moment of inertia and
acceleration coefficients according to the manipulator tip mass and
moment of inertia. If this is not observed, premature end to the life of the
drive units, damage to the robot parts or residual vibration during positioning
may result.
Usually the R axis load is not a simple form, and the calculation of the moment of inertia
is not easy.
As a method, the load is replaced with several factors that resemble a simple form for
which the moment of inertia can be calculated. The total of the moment of inertia for
these factors is then obtained.
The objects and equations often used for the calculation of the moment of inertia are
shown below.
1.
Moment of inertia for cylinder
The moment of inertia (J) for a cylinder having a rotation center such as shown below
is given by
J=
RPD4 h
32g
R
g
W
m
2.
WD2
8g
2
mD
=
8
=
(kgf.cm.sec2)
(kgm2)
h
: Density (kg/cm3)
: Gravitational acceleration (cm/sec2)
: Weight of cylinder (kgf)
: Mass of cylinder (kg)
D
Moment of inertia for rectangular parallelepiped
The moment of inertia (J) for a rectangular parallelopiped having a rotation center as
shown below is given by
J=
Rabc (a2 + b2) W (a2 + b2)
2
=
(kgf.cm.sec )
12g
12g
m (a2 + b2)
=
(kgm2)
12
R : Density (kg/cm3)
g : Gravitational
acceleration (cm/sec2)
W : Weight of prism (kgf)
m : Mass of prism (kg)
ii
c
1/2a
b
a
3.
When the object’s center line is offset from the rotation center.
J=
RPD4 h
32g
2
2
RPD hx2
4g
+
Wx
g
WD
8g
=
mD2
2
2
+ mx (kgm )
8
W
m
e
g
+
center line
rotation
center
2
=
Appendix
The moment of inertia (J) when the center of the cylinder is offset by a distance "x"
from the rotation center as shown below is given by
(kgf.cm.sec2)
h
: Weight of cylinder (kgf)
: Mass of cylinder (kg)
: Density (kg/cm3)
: Gravitational acceleration (cm/sec2)
D
x
In the same manner, the moment of inertia (J) of a prism as shown below is given by
J=
Rabc (a2 + b2)
12g
W (a2 + b2)
=
+
12g
=
+
Rabcx2
g
Wx2
g
center line
2
(kgf.cm.sec )
m (a2 + b2)
2
2
+ mx (kgm )
12
c
W : Weight of prism (kgf)
m : Mass of prism (kg)
x
b
a
iii
Revision record
Manual version Issue date
Description
Ver. 2.01
Jun. 2009
Clerical error corrections.
Ver. 2.02
Dec. 2009
Some explanations were corrected or added in "Chapter 1 Using
the Robot Safely".
Ver. 2.03
Aug. 2010
Clerical error corrections, etc.
User's Manual
FLIP-X series
Single-axis Robot
F8/F8L/F8LH
Aug. 2010
Ver. 2.03
This manual is based on Ver. 2.03 of Japanese manual.
© YAMAHA MOTOR CO., LTD.
IM Operations
All rights reserved. No part of this publication may be reproduced in
any form without the permission of YAMAHA MOTOR CO., LTD.
Information furnished by YAMAHA in this manual is believed to be
reliable. However, no responsibility is assumed for possible
inaccuracies or omissions. If you find any part unclear in this manual,
please contact YAMAHA or YAMAHA sales representatives.
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