Yaskawa Motoman HC10DTP Quick Start Guide

Part Number: 194649-1CD
Revision:
1
MOTOMAN-HC10DTP
Quick Start Guide
Using the Smart Pendant
• Manipulator Type: YR-1-06VXCP10-A00
(Built-In Air Hoses, Ethernet and I/O Cables Specification)
• Applicable Robot Controllers: YRC1000/YRC1000micro
• Smart Pendant Type: JZRCR-APP30-1
MANUAL NO. HW2480565 1
Unpacking and
Checking the Product
1
Transportation and
Installation
Connecting
the Robot Controller
Turning ON the Robot Controller
Power Supplies
2
Controlling the Manipulator
5
Mounting and Wiring
the Hand
6
Settings
7
Programming
8
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3
4
2
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Table of Contents
i.
Before Using the Product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
i.1
i.2
i.3
Introduction to This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
i.1.1
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
i.1.2
Precautions for Safely Using a Collaborative Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
i.1.3
Applicable Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
i.1.4
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Notes for Safe Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
i.2.1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
i.2.2
Visual Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
i.2.3
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
i.3.1
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
i.3.2
Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1. Unpacking and Checking the Product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1
Unpacking the Shipping Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2
Checking the Received Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.1
Components in a Basic Robot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2
Manipulator Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3
YRC1000 Robot Controller Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.4
YRC1000micro Robot Controller Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.5
Verifying the Order Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Transportation and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1
Transporting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2
Installing the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.1
Required Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.2
Strength of the Installation Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.3
Fixing the Manipulator to the Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.4
Grounding the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2.3
Transporting the YRC1000 Robot Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4
Installing the YRC1000 Robot Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5
Transporting the YRC1000micro Robot Controller . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6
Installing the YRC1000micro Robot Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3. Connecting the Robot Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1
3.2
Connecting the YRC1000 Robot Controller and Other Devices . . . . . . . . . . . . . . . 36
3.1.1
Connecting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.2
Connecting the Primary Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1.3
Connecting the Smart Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connecting the YRC1000micro Robot Controller and Other Devices . . . . . . . . . . 43
3.2.1
Connecting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2.2
Connecting the Primary Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2.3
Connecting the Smart Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4. Turning ON the Robot Controller Power Supplies . . . . . . . . . . . . . . . . . . . . . 49
4.1
4.2
Turning ON/OFF and Checking the Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . 50
4.1.1
Turning ON the Main Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1.2
Checking Operation of the Emergency Stop Button and Servo Power . . . . . . . . . . . . . . . . . . . . . . . . . 51
Corrective Actions for Alarms at Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2.1
Correcting Alarm 6022 EXTERNAL FORCE ESTIMATION ERROR and Alarm 6004 ESCAPE
FROM CLAMPING ERROR(PFL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2.2
Correcting Alarm 4107 OUT OF RANGE(ABSO DATA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5. Controlling the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1
Moving the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1.1
Jogging Each Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1.2
Jogging Parallel to the TCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1.3
Direct Teach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6. Mounting and Wiring the Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4
6.1
Required Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.2
Mounting the Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.3
Connecting the Air Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.4
Connecting the I/O Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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7. Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.1
Temporarily Disabling the Collaborative Operation Function . . . . . . . . . . . . . . . . . 84
7.2
Configuring a Tool File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.3
Checking the Home Positions of the Torque Sensors and Setting the Home
Positions Again . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.3.1
Checking the Home Positions of the Torque Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.3.2
Setting the Home Positions of the Torque Sensors Again . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.4
Setting External Force Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.5
Configuring the Speed Limit Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.6
Enabling the Collaborative Operation Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
8. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.1
Explanation of the Sample Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.1.1
8.2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Creating a Program with Direct Teach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.2.1
Creating a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.2.2
Registering Manipulator Positions in the Program Using Direct Teach . . . . . . . . . . . . . . . . . . . . . . . . 122
8.2.3
Adding and Changing Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.2.4
Confirming Operation Step by Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.2.5
Running the Created Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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6
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i
Before Using the Product
i.1
i.2
i.3
Introduction to This Manual..................................................................................... 8
i.1.1
Intended Audience ............................................................................................ 8
i.1.2
Precautions for Safely Using a Collaborative Robot..................................... 8
i.1.3
Applicable Products.......................................................................................... 9
i.1.4
Related Manuals ................................................................................................ 9
Notes for Safe Operation ........................................................................................ 11
i.2.1
Safety Information ............................................................................................11
i.2.2
Visual Aids ........................................................................................................11
i.2.3
General Precautions ....................................................................................... 12
Using This Manual.................................................................................................... 13
i.3.1
Terms ................................................................................................................ 13
i.3.2
Trademarks ...................................................................................................... 13
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7
i.1 Introduction to This Manual
i.1
Introduction to This Manual
i.1.1
Intended Audience
This manual is for customers who are using a YASKAWA collaborative robot for the first time.
This manual describes the necessary operations in order, from installing the collaborative robot to teaching pickand-place operation.
Read and understand this manual to ensure the correct usage of the product. Keep this manual in a safe place so
that it can be referred to whenever necessary.
Note:
Assume that items not described in this manual are either prohibited or not possible.
General items related to safety are described in chapter 1 "Safety" in the instructions for the robot controller that
will be used. Carefully read and understand the instructions before reading this manual and use the product
correctly.
i.1.2
Precautions for Safely Using a Collaborative Robot
A collaborative robot cannot be used safely as-is and without a safety fence when delivered. The customer
(including the system integrator) must conduct risk assessments and implement risk reduction measures on their
own, and then check if potential hazards have been eliminated.
8
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i.1 Introduction to This Manual
i.1.3
Applicable Products
This manual describes the following products.
Product
Robot Controller
i.1.4
Type
Specifications
YRC1000
ERAR-1000-06VX8-***
−
YRC1000micro
ERBR-100-06VX8-***
−
Manipulator
YR-1-06VXCP10-A00
Built-in air hoses, Ethernet and I/O cables
specification
Smart Pendant
JZRCR-APP30-1
−
Related Manuals
The following manuals describe the precautions, control functions, usage procedures, and troubleshooting procedures when using a robot in detail.
Refer to these manuals for detailed procedures on using the product.
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9
i.1 Introduction to This Manual
Manual No. *1
Category
Manual Name
Overview
YRC1000
Manipulator
MOTOMAN-HC10DTP
Instructions
MOTOMAN-HC10DTP
Maintenance Manual
MOTOMAN-HC10DTP
Setup Guide
Robot Controller YRC1000/YRC1000micro
Collaborative Operation Instructions
YRC1000/YRC1000micro
Supplementary Instructions for HC Series
YRC1000/YRC1000micro
Notes for Safe Operation
YRC1000/YRC1000micro
Maintenance Manual
YRC1000/YRC1000micro
Options Instructions for Inform Language
YRC1000/YRC1000micro
Options Instructions for Concurrent I/O
YRC1000/YRC1000micro
Instructions
YRC1000/YRC1000micro
Alarm Codes
YRC1000
micro
Describes information about the
manipulator, such as basic specifications, installation, and spare parts.
HW2480390
Describes the maintenance procedures
for the manipulator, such as precautions for inspections and procedures
for replacing parts.
HW2480452
Describes the setup procedures and
manuals for users to refer to when
installing the manipulator for the first
time after the product has been
delivered.
HW2380355
Describes information on collaborative
operation functions and configuration
procedures.
HW1484764
Describes the differences between
standard robots and collaborative
robots in the following main robot controller manuals.
HW1484756
• Instructions
• Maintenance Manual
• Instructions for Functional Safety
Function
HW1485285
Describes the residual risks and safety
precautions when using a robot.
R-AN-A308
R-AN-A309
Describes the maintenance procedures
for the robot controller, such as periodic inspections and procedures for
replacing parts.
RE-CHOA114
RE-CHOA115
Describes the instructions used by the
robot controller.
RE-CKI-A466 RE-CKI-A468
Describes concurrent I/O, which is an
I/O control function in the robot
controller.
RE-CKI-A467 RE-CKI-A469
Describes the following items in
details:
• Robot safety precautions
• Robot controller specifications,
installation, and wiring
• Robot control functions
Describes the causes of and corrective
actions for alarms.
RE-CTOA221
RE-CTOA222
RE-CERA600
RE-CERA601
(Major Alarms) (Minor Alarms)
YRC1000/YRC1000micro
Instructions for Smart Pendant
*1
10
Describes detailed information on
Smart Pendant functions and operating
procedures.
HW1485509
Read the manual for the robot controller that will be used.
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i.2 Notes for Safe Operation
i.2
Notes for Safe Operation
i.2.1
Safety Information
To prevent personal injury and equipment damage in advance, the following signal words are used to indicate
safety precautions in this manual. The signal words are used to classify the hazards and the degree of damage or
injury that may occur if a product is used incorrectly. Information marked as shown below is important for safety.
Always read this information and heed the precautions that are provided.
DANGER
Indicates precautions that, if not heeded, are likely to result in loss of life, serious injury, or
fire.
WARNING
Indicates precautions that, if not heeded, could result in loss of life, serious injury, or fire.
CAUTION
Indicates precautions that, if not heeded, could result in relatively serious or minor injury, or
in fire.
NOTICE
Indicates precautions that, if not heeded, could result in property damage.
i.2.2
Visual Aids
The following aids are used to indicate certain types of information for easier reference.
Indicates precautions or restrictions that must be observed. Also indicates alarm displays and other precautions that will not
result in machine damage.
Important
Indicates definitions of difficult terms or terms that have not been previously explained in this manual.
Term
Information
Indicates supplemental information to deepen understanding or useful information.
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11
i.2 Notes for Safe Operation
i.2.3
General Precautions
• Figures provided in this manual are typical examples or conceptual representations. There may be differences between them and actual
wiring, circuits, and products.
• The products shown in illustrations in this manual are sometimes shown with their covers or protective guards removed to illustrate
detail. Always replace all covers and protective guards before the product is used.
• If a new copy of this manual is required because it has been lost or damaged, contact your nearest YASKAWA representative or one of
the offices, and inform them of the manual number.
• This manual is subject to change without notice for product improvements, specifications changes, and improvements to the manual
itself. The manual number of this manual will be updated and revisions issued when changes are made.
• Any and all quality guarantees provided by YASKAWA are null and void if the customer modifies the product in any way. YASKAWA
disavows any responsibility for damages or losses that are caused by modified products.
12
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i.3 Using This Manual
i.3
Using This Manual
i.3.1
Terms
"MOTOMAN" is the product name for industrial robots manufactured by YASKAWA.
MOTOMAN consists of a manipulator, which is the robot itself, a robot control panel, a Smart Pendant, and a
manipulator cable.
Interpret the devices described in this manual as shown below.
Device
i.3.2
Name in This Manual
Robot
Manipulator
Robot control panel
Robot controller
Trademarks
The product names and company names used in this manual are the trademarks or registered trademarks of the
respective company. TM and the ® mark do not appear with product or company names in this manual.
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i.3 Using This Manual
14
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1
Unpacking and Checking the Product
1.1
Unpacking the Shipping Crate .............................................................................. 16
1.2
Checking the Received Products......................................................................... 17
1.2.1 Components in a Basic Robot System ......................................................... 17
1.2.2 Manipulator Accessories................................................................................ 18
1.2.3 YRC1000 Robot Controller Accessories....................................................... 18
1.2.4 YRC1000micro Robot Controller Accessories............................................. 19
1.2.5 Verifying the Order Numbers ......................................................................... 19
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1.1 Unpacking the Shipping Crate
1.1
Unpacking the Shipping Crate
CAUTION
Always remove the manipulator from the crate using two or more workers.
There is a risk of back injury due to the mass of the manipulator and a risk the manipulator may fall over
and be damaged.
NOTICE
When the manipulator and controller are received in a shipping crate, unpack them in a level
location near the installation location of the manipulator.
If the products are unpacked in an unstable location, there is a risk the manipulator and robot controller may
fall over and be damaged.
The Smart Pendant may also be dropped and damaged.
The mass of the manipulator is 48 kg. Always remove the manipulator from the crate using two or more workers.
16
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1.2 Checking the Received Products
1.2
Checking the Received Products
Confirm that all of the ordered products have been received.
Components in a Basic Robot System
Name
Standard/Option
Manipulator
Remarks
Standard component
Includes accessories.
YRC1000
Standard component
Includes spare parts.
YRC1000micro
Standard component
Includes spare parts.
Smart Pendant
Standard component
Mode selector key (2 keys)
Manipulator cables (3 types)
Standard component
Connects the manipulator and robot controller.
Robot controller
YRC1000
or YRC1000micro
Unpacking and Checking the Product
1.2.1
• Manipulator cable
• Torque sensor cable (TQ)
• Switch/lamp cable (SW)
CD-ROM (connected to a USB port)
Standard component
Contains PDF copies of the manuals.
1
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17
1.2 Checking the Received Products
1.2.2
Manipulator Accessories
Purpose
Name
Installing the manipulator
Quantity
Hexagon socket head cap screw
M12 (length: 45 mm)
4
Spring washer
M12
4
Washer
M12
4
Home positioning of the manipulator's Pin
S-axis
HW1407797-5-85
1
Transporting the manipulator
Shipping bracket
HW1307411-1
1
Hexagon socket head cap screw
M8 (length: 25 mm)
2
Conical spring washer
M8
2
Union
KQ2F06-01N
6
Grease replenishment for the
manipulator
1.2.3
Type/Specifications
YRC1000 Robot Controller Accessories
1.
Replacement Fuses
Name
Quantity
10-A fuse
2.
2
Specifications
Type
10 A, 500 VAC
FNQ-10 10A, 500VAC
10 A, 600 VAC
SC-10 10A, 600VAC
Glass cartridge fuse
1
3.15 A, 250 V
02173.15P 3.15A, 250V
Micro fuse
1
1.0 A, 250 V
HM10 1.0A, 250V
Quantity
Type
Tools for Wiring
Name
Wiring tool for WAGO
connectors
2
231-131
Wiring tool for WAGO
connectors
1
734-230
Wiring tool for WAGO terminal
block
1
210-119SB
Information
1. The fuses are replacement parts. Refer to the following manual for details on replacement procedures.
YRC1000 Maintenance Manual (Manual No.: RE-CHO-A114)
2. Use the wiring tool for WAGO connectors when connecting wires to the control power supply unit and
general-purpose I/O circuit board in the robot controller. Refer to the following manual for details on
wiring procedures.
YRC1000 Instructions (Manual No.: RE-CTO-A221)
18
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1.2 Checking the Received Products
1.2.4
YRC1000micro Robot Controller Accessories
1.
Parts for Connecting the Primary Power Supply
Cable clamps, power outlet plugs, and power wires (cables) are not included with the product. The customer is
responsible for these parts.
Important
Quantity
Name
L-shaped angled plug for the primary
power supply cable
1
CE05-8A18-10SD-D-BAS(R1)
End bell
1
CE3057-10A-1-D
Part for Short-Circuiting the Safety Signals
Quantity
Name
1
Dummy connector (Safety) for short-circuiting the safety signals
1.2.5
Type
CBL-AR001
Unpacking and Checking the Product
2.
Type
Verifying the Order Numbers
WARNING
Verify the order numbers on the robot and robot controller are the same. Each robot was
configured with unique home position data at the factory. Use extra caution when installing
multiple robots.
There is a risk of injury or damage due to malfunction.
Verify that the order numbers on the nameplates of the manipulator and robot controller
match.
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19
1.2 Checking the Received Products
20
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2
Transportation and Installation
2.1
Transporting the Manipulator................................................................................ 22
2.2
Installing the Manipulator ...................................................................................... 25
2.2.1 Required Items................................................................................................. 25
2.2.2 Strength of the Installation Surface .............................................................. 25
2.2.3 Fixing the Manipulator to the Floor ............................................................... 26
2.2.4 Grounding the Manipulator ............................................................................ 27
2.3
Transporting the YRC1000 Robot Controller .................................................... 28
2.4
Installing the YRC1000 Robot Controller ........................................................... 29
2.5
Transporting the YRC1000micro Robot Controller ......................................... 31
2.6
Installing the YRC1000micro Robot Controller ................................................ 32
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21
2.1 Transporting the Manipulator
2.1
Transporting the Manipulator
Mass: 48 kg (including the shipping bracket)
Table 2.1 Required Items
Name
Remarks
Phillips screwdriver
For mounting and removing the casing cover.
Hex key
For removing the shipping bracket.
Torque wrench
For mounting and removing the casing cover and mounting the shipping
bracket.
Hanging tool
Example: Wire or nylon sling.
Shipping bracket (1 bracket), type: HW1307411-1
Included with the manipulator. These parts are all contained in the same bag as
the transportation parts.
Hexagon socket head cap screw M8 (length: 25 mm) (2
screws)
Conical spring washer M8 (2 washers)
When moving the manipulator to another location, such as when changing the production line, set the manipulator to the
following transportation posture.
Important
A
Casing cover
C
• Hexagon socket head cap screw M8 (length: 25 mm) (2
screws)
• Conical spring washer M8 (2 washers)
B
Shipping bracket
D
Position of the center of gravity
Table 2.2 Angle and Pulses of Each Axis When Shipped from the Factory
22
Axis
Pulses
Angle
S
0
0°
L
0
0°
U
-211268
-90°
R
0
0°
B
0
0°
T
0
0°
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2.1 Transporting the Manipulator
1.
Remove the manipulator casing cover.
2.
Mount the shipping bracket using the hexagon socket head cap screws and conical
spring washers to where the casing cover was removed. Tightening torque: 24.5 N∙m
(2.5 kgf∙m)
Shipping bracket
B
• Hexagon socket head cap screw M8 (length: 25 mm)
(2 screws)
• Conical spring washer M8 (2 washers)
Transportation and Installation
A
2
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23
2.1 Transporting the Manipulator
3.
Pass the hook of the hanging tool through the two holes on the shipping bracket, hoist
the manipulator with a crane, and transport it to the installation location.
4.
5.
Remove the shipping bracket.
Mount the casing cover. Tightening torque: 1.2 N∙m (0.12 kgf∙m)
Carefully store the transportation parts (shipping bracket, hexagon socket head cap screws, and conical spring
washers) that were removed. The transportation parts are required when moving and transporting the manipulaImportant tor again.
24
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2.2 Installing the Manipulator
2.2
Installing the Manipulator
WARNING
Do not use the manipulator when it is not fixed to the installation surface with bolts.
The manipulator may fall over and cause injury or damage.
Required Items
Name
Hexagon socket head cap screw
*1
*2
2.2.2
Type/Specifications
Quantity
*1
M12 (length: 45 mm)
4
Spring washer *1
M12
4
Washer *1
M12
4
Baseplate *2
A thickness of 32 mm or greater is recommended.
1
Anchor bolt *2
M12 or larger is recommended.
4
Included with the manipulator.
Not provided by YASKAWA.
Strength of the Installation Surface
The installation of the manipulator is critical for maintaining appropriate functionality. Design and construct a
base that can fully withstand the maximum reaction force of the manipulator.
Ensure the installation surface of the manipulator has a flatness of 0.5 mm or lower. If the flatness of the installation surface
is poor, the manipulator may deform and lose appropriate functionality.
Important
Transportation and Installation
2.2.1
2
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25
2.2 Installing the Manipulator
Table 2.3 Manipulator Installation Reaction Force/Torque
When Rotating Horizontally
Reaction Force FH
During an emergency stop 2600 N
During acceleration/
deceleration
2.2.3
Torque MH
Reaction Force FV
Torque MV
1842 N∙m
932 N
1842 N∙m
(265 kgf)
(188 kgf∙m)
(95 kgf)
(188 kgf∙m)
834 N
559 N∙m
343 N
696 N∙m
(85 kgf)
(57 kgf∙m)
(35 kgf)
(71 kgf∙m)
Fixing the Manipulator to the Floor
1.
2.
26
When Rotating Vertically
Fix the baseplate to the floor with the anchor bolts.
Fix the manipulator to the baseplate with the hexagon socket head cap screws. (4
screws) Tightening torque: 84 N∙m (8.6 kgf∙m)
A
Hexagon socket head cap screw M12 (length: 45 mm) (4
screws)
D
Manipulator base
B
Spring washer M12 (4 washers)
E
Baseplate (with a thickness of 32 mm or greater is
recommended)
C
Washer M12 (4 washers)
F
Anchor bolt (M12 or larger is recommended)
A
Baseplate
C
Hole for mounting body: φ14 (4 places)
B
Reference hole: φ8H7
–
–
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2.2 Installing the Manipulator
Grounding the Manipulator
Ground the manipulator to a ground resistance of 100 Ω or less in accordance with all relevant local and national
electrical codes. Connect the manipulator directly to the ground wire.
Table 2.4 Required Items
Name
Remarks
5.5 mm2 or larger ground wire
This part is not provided by YASKAWA.
Spanner/wrench
For tightening the grounding bolt.
• Do not share the ground wire for the manipulator with any other ground wires or grounding electrodes, such as those for
electrical power, motors, or welders.
Important • Ground the manipulator in accordance with all relevant local and national electrical codes when using metallic ducts, metallic conduits, or cable trays to install cables.
WARNING
Always connect the ground terminal to a grounding electrode with a resistance of 100 Ω or
less.
There is a risk of fire or electric shock.
A
Bolt M8 (for grounding)
Included on the manipulator.
B
Transportation and Installation
2.2.4
Ground wire (5.5 mm2 or larger)
2
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27
2.3 Transporting the YRC1000 Robot Controller
2.3
Transporting the YRC1000 Robot Controller
The mass of the YRC1000 robot controller depends on the model as given below.
Table 2.5 YRC1000 Robot Controller Mass
YRC1000 Robot Controller Model
Small-capacity model
Specifications
Approx. Mass (kg)
Specification for Japan
60
Specification for Asia, North America, and
Europe
70
As a basic rule, use a crane when transporting the YRC1000 robot controller.
NOTICE
Transport the product so that it is not exposed to excessive vibration or shock.
Performance will be affected because this product is a precision machine.
Table 2.6 Required Items
Name
Eye bolt
Included with the robot controller when shipped from the factory.
Hanging tool
This part is not provided by YASKAWA. Select a wire or nylon sling according to the mass of the robot
controller.
1.
The eye bolts are attached to the robot controller when shipped from the factory. Check
again that the eye bolts have been fastened before transporting the manipulator.
2.
Pass the hanging tool through the eye bolts, hoist the robot controller with a crane, and
transport it to the installation location.
A
28
Remarks
45° or wider
B
Eye bolt M12 (4 bolts)
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2.4 Installing the YRC1000 Robot Controller
Installing the YRC1000 Robot Controller
A bracket for fixing the robot controller is not provided by YASKAWA. The recommended bracket is given
below.
Information
Refer to the following manual for details on the installation environment of the robot controller.
YRC1000 Instructions (Manual No.: RE-CTO-A221)
Table 2.7 Required Items (Recommended Items)
Name
Mounting screw
Recommended Specifications
Quantity
Remarks
Tightening torque: 45 N∙m
(4.6 kgf∙m)
M12 (length: 20 mm)
Note:
4
Select the screws based on a thread length of 14 mm for the
sides of the robot controller.
Fixing bracket
–
Hole φ14 (2 places)
Plate thickness 6 mm
4
Use the screw holes (M12) on the sides of the robot controller to fix it to the floor or a
pedestal.
Transportation and Installation
2.4
2
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29
2.4 Installing the YRC1000 Robot Controller
Ensure space to open the robot controller door for inspection.
Important
A
Wall
C
Robot controller door
B
Robot controller
–
–
For the work space during maintenance, install the YRC1000 robot controller in a location with a gap of approximately 300 mm or greater from the walls.
Important
A
30
Front side of robot controller
B
Side of robot controller
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2.5 Transporting the YRC1000micro Robot Controller
Transporting the YRC1000micro Robot Controller
The mass of the YRC1000micro robot controller depends on the specifications as given below.
Table 2.8 YRC1000micro Robot Controller Mass
YRC1000micro Robot Controller Specifications
Approx. Mass (kg)
Specification for Japan, North America, and Asia
16.5
Specification for Europe
20
When transporting the YRC1000micro robot controller, use a cart or have two workers lift and carry the robot
controller from its bottom. Be careful not expose the product to excessive vibration or shock during transport.
Note:
Use a lifter to lower the product from a rack or shelf.
Transportation and Installation
2.5
2
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31
2.6 Installing the YRC1000micro Robot Controller
2.6
Installing the YRC1000micro Robot Controller
A bracket for fixing the robot controller is not provided by YASKAWA.
Figure 2.1 Installation Example of the YRC1000micro Robot Controller
Information
Refer to the following manual for details on the installation environment of the robot controller.
YRC1000micro Instructions (Manual No.: RE-CTO-A222)
Table 2.9 Required Items
Name
Mounting screw
Quantity
Specifications
M5
Remarks
12
Material: Mild steel or a stronger material
4
Prepare fixing brackets according to the
mounting method of the robot controller.
Note:
Select screws with a thread length that is the thickness of
the fixing bracket + 5 mm or less.
Fixing bracket
NOTICE
If the thread length of the mounting screws exceeds the thickness of the mounting bracket +
5 mm, the components inside the robot controller may be damaged.
Use the screw holes M5 (8 places) on the sides of the robot controller to fix it to the floor or
a pedestal.
Side Mounted
Left Side View
Horizontally Mounted
Front Side View
Right Side View
A M5 tapped holes (hole depth: 5 mm) (4 places)
32
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2.6 Installing the YRC1000micro Robot Controller
1. Ensure the following space when the YRC1000micro robot controller lays flat (horizontally mounted).
Important
Space for Manipulator Cable
Top Side View
Left Side View
Front Side View
2. Ensure the following space when the YRC1000micro robot controller is side mounted.
Space for Manipulator Cable
Front Side View
Right Side View
Transportation and Installation
Top Side View
2
Information
The YRC1000micro robot controller is free-standing. Install the robot controller so that it is not exposed to excessive shock.
Refer to the mounting procedures in the following manual when side mounting the robot controller.
YRC1000micro Instructions (Manual No.: RE-CTO-A222)
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33
2.6 Installing the YRC1000micro Robot Controller
34
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3
Connecting the Robot Controller
3.1
Connecting the YRC1000 Robot Controller and Other Devices................... 36
3.1.1 Connecting the Manipulator........................................................................... 36
3.1.2 Connecting the Primary Power Supply......................................................... 39
3.1.3 Connecting the Smart Pendant...................................................................... 42
3.2
Connecting the YRC1000micro Robot Controller and Other
Devices........................................................................................................................ 43
3.2.1 Connecting the Manipulator........................................................................... 43
3.2.2 Connecting the Primary Power Supply......................................................... 46
3.2.3 Connecting the Smart Pendant...................................................................... 47
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35
3.1 Connecting the YRC1000 Robot Controller and Other Devices
3.1
Connecting the YRC1000 Robot Controller and Other
Devices
Symbol
3.1.1
Name
Symbol
Name
A
Primary power supply cable
F
Smart Pendant
B
Robot controller
G
Pendant connection cable
C
Manipulator cables (3 types)
H
Ground wire
D
Manipulator
I
Grounding equipment (earth)
E
Baseplate
J
Primary power supply
Connecting the Manipulator
Table 3.1 Required Items
Name
Specifications
Quantity
Manipulator cable
1
Torque sensor cable
1
Switch/lamp cable
1
Power supply cable *1
Power outlet plug *1
Power requirement 1.0 kVA
Cable size 3.5 mm2
3
Remarks
Included with the manipulator.
Robot controller breaker capacity: 15 A
1
Ground wire *1
1
Earth leakage breaker *2
1
–
Phillips screwdriver
1
–
Flat head screwdriver
1
–
*1
*2
Not provided by YASKAWA.
Refer to the following manual for selecting the earth leakage breaker.
YRC1000 Instructions (Manual No.: RE-CTO-A221)
36
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1.
Connecting the Robot Controller
3.1 Connecting the YRC1000 Robot Controller and Other Devices
Connect the 1BC connector on the manipulator cable to the manipulator.
Insert the manipulator cable into the 1BC connector, and turn the connector lever on the manipulator
cable side to the locked position to connect the connector.
3
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37
3.1 Connecting the YRC1000 Robot Controller and Other Devices
38
2.
Use the same procedure to connect the X1 connector on the manipulator cable to the
robot controller.
3.
Connect the switch/lamp cable to the [SW] connector on the manipulator and the [-X74]
connector on the robot controller.
Turn the tip of the cable connector with the arrow in the direction of the arrow to lock the cable.
4.
Use the same procedure to connect the torque sensor cable to the [TQ] connector on
the manipulator and the [-X73] connector on the robot controller.
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3.1 Connecting the YRC1000 Robot Controller and Other Devices
Connecting the Primary Power Supply
1.
Using a flat head screwdriver, rotate the door lock of the robot controller 90 degrees
clockwise.
2.
Turn the main power supply switch to the OFF position.
3.
Open the robot controller door.
Connecting the Robot Controller
3.1.2
3
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39
3.1 Connecting the YRC1000 Robot Controller and Other Devices
4.
Pull the breaker cover straight off.
5.
Connect the ground wire to the ground terminal (M6 screw).
Power requirement: 1.0 kVA
Cable size (for flexible cable (3 cores)): 3.5 mm2
Breaker capacity: 15 A
Note:
1. The ground wire is not provided by YASKAWA.
2. Ground the robot controller to a ground resistance of 100 Ω or less in accordance with all relevant local and national electrical codes.
• Ground resistance of 100 Ω or less (200 to 240 VAC specification)
• Ground resistance of 10 Ω or less (380 to 480 VAC specification)
• Always use an earth leakage breaker for a ground resistance of 100 Ω or less. Refer to the following manual
for details.
Important
YRC1000 Instructions (Manual No.: RE-CTO-A221)
• Do not share the ground wire for the robot controller with any other ground wires or grounding electrodes,
such as those for electrical power, motors, or welders.
• Ground the robot controller in accordance with all relevant local and national electrical codes when using metallic ducts, metallic conduits, or cable trays to install cables.
40
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6.
Connect the primary power supply.
7.
Mount the breaker cover.
8.
Close the robot controller door and turn the door lock 90 degrees counterclockwise.
Connecting the Robot Controller
3.1 Connecting the YRC1000 Robot Controller and Other Devices
3
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41
3.1 Connecting the YRC1000 Robot Controller and Other Devices
Install a dedicated breaker for the robot controller to the primary power supply.
Important
3.1.3
Connecting the Smart Pendant
Connect the Smart Pendant cable to the robot controller.
Insert the cable into the connector so that the arrow on connector of the robot controller is lined up with the triangle mark
on the connector of the cable.
Important
42
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3.2 Connecting the YRC1000micro Robot Controller and Other Devices
Connecting the YRC1000micro Robot Controller and
Other Devices
Symbol
3.2.1
Name
Symbol
Name
A
Primary power supply cable
F
Smart Pendant
B
Robot controller
G
Pendant connection cable
C
Manipulator cables (3 types)
H
Ground wire
D
Manipulator
I
Grounding equipment (earth)
E
Baseplate
J
Primary power supply
Connecting the Manipulator
Table 3.2 Required Items
Name
Specifications
Quantity
Remarks
Manipulator cable
1
Torque sensor cable
1
Switch/lamp cable
1
Dummy connector for short-circuiting the safety signals
1
L-shaped angled plug for the primary power supply cable
1
End bell
1
Straight plug for the primary power supply cable
1
Must be purchased separately if the robot controller is side mounted.
Power supply cable *1
3
Robot controller circuit protector capacity: 16 A
Cable clamp *1
Power requirement 1.0 kVA
Cable size 3.5 mm2
Included with the robot controller.
1
Power outlet plug *1
1
Ground wire *1
1
Circuit protector
1
Phillips screwdriver
1
*1
Included with the manipulator.
Connecting the Robot Controller
3.2
3
–
Not provided by YASKAWA.
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43
3.2 Connecting the YRC1000micro Robot Controller and Other Devices
1.
Connect the 1BC connector on the manipulator cable to the manipulator.
Insert the manipulator cable into the 1BC connector, and turn the connector lever on the manipulator
cable side to the locked position to connect the connector.
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3.2 Connecting the YRC1000micro Robot Controller and Other Devices
Use the same procedure to connect the X1 connector on the manipulator cable to the
robot controller.
3.
Connect the switch/lamp cable to the [SW] connector on the manipulator and the [-X74]
connector on the robot controller.
Turn the tip of the cable connector with the arrow in the direction of the arrow to lock the cable.
4.
Use the same procedure to connect the torque sensor cable to the [TQ] connector on
the manipulator and the [-X73] connector on the robot controller.
Connecting the Robot Controller
2.
3
5.
Connect the dummy connector for short-circuiting the safety signals to the SAFETY
connector on the robot controller.
Always connect the dummy connector for short-circuiting the safety signals. If this connector is not connected,
protective stops and external emergency stops will occur.
Important
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45
3.2 Connecting the YRC1000micro Robot Controller and Other Devices
3.2.2
Connecting the Primary Power Supply
1.
Connect the L-shaped angled plug for the primary power supply to the power supply
connector on the robot controller.
2.
Connect the primary power supply to the robot controller.
Note:
Confirm that the circuit protector of the robot controller is turned OFF.
Note:
A straight type plug is required if the robot controller is side mounted.
A
Power supply connector
C
Cable clamp
B
L-shaped angled plug
–
–
Table 3.3 Power Supply Connector (ACIN) Pin Assignments on the YRC1000micro (Three-Phase
Power Supply)
Pin No.
Signal Name
Description
A
L1
AC input (L1/R phase)
B
L2
AC input (L2/S phase)
C
L3
AC input (L3/T phase)
D
P.E.
Protective grounding
Table 3.4 Power Supply Connector (ACIN) Pin Assignments on the YRC1000micro (Single-Phase
Power Supply)
46
Pin No.
Signal Name
Description
A
L1
AC input (L1/R phase)
B
N.C.
No connection
C
L3
AC input (L3/T phase)
D
P.E.
Protective grounding
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3.2 Connecting the YRC1000micro Robot Controller and Other Devices
Install separate breakers for the primary power supply.
Important
Connecting the Smart Pendant
Connect the cable to the [-X81] connector on the robot controller.
Note:
Confirm that the pins of the robot controller and cable connectors are aligned before inserting the connector.
When the Smart Pendant is not used, attach the connector for short-circuiting the Smart Pendant safety signals to the [-X81]
connector on the robot controller. The robot controller will not start if this connector is not attached.
Important
Connecting the Robot Controller
3.2.3
3
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47
3.2 Connecting the YRC1000micro Robot Controller and Other Devices
48
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4
Turning ON the Robot Controller
Power Supplies
This chapter describes the how to turn ON/OFF the robot controller power supplies, how to check the
power supplies, and how to reset alarms that may occur when the power supplies are turned ON.
4.1
Turning ON/OFF and Checking the Power Supplies ....................................... 50
4.1.1 Turning ON the Main Power Supply .............................................................. 50
4.1.2 Checking Operation of the Emergency Stop Button and Servo
Power ................................................................................................................ 51
4.2
Corrective Actions for Alarms at Initial Startup ............................................... 54
4.2.1 Correcting Alarm 6022 EXTERNAL FORCE ESTIMATION ERROR and
Alarm 6004 ESCAPE FROM CLAMPING ERROR(PFL)................................ 54
4.2.2 Correcting Alarm 4107 OUT OF RANGE(ABSO DATA)................................ 56
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49
4.1 Turning ON/OFF and Checking the Power Supplies
4.1
Turning ON/OFF and Checking the Power Supplies
The main power supply and servo power are required to move the manipulator. Before moving the manipulator,
first turn ON/OFF these power supplies and check the correct operation of the emergency stop button.
4.1.1
Turning ON the Main Power Supply
1.
Turn ON the main power supply to the robot controller.
YRC1000
2.
YRC1000micro
Confirm that the startup window is displayed on the Smart Pendant.
It will take approximately three minutes until the window is displayed.
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4.1 Turning ON/OFF and Checking the Power Supplies
The main power supply is working correctly when the startup window is displayed.
Refer to the following section if an alarm is displayed on the Smart Pendant.
4.2 Corrective Actions for Alarms at Initial Startup on page 54
4.1.2
Checking Operation of the Emergency Stop Button and Servo
Power
Confirm the operation to turn ON/OFF the servo power, and confirm that the servo power is canceled when the
emergency stop button is pressed.
1.
Confirm that the collaborative operation LED on the manipulator is lit in green.
Turning ON the Robot Controller Power Supplies
This concludes the procedure.
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51
4.1 Turning ON/OFF and Checking the Power Supplies
Information
• A green lit LED means collaborative operation is enabled. Enabled is the default setting. If the LED is not
lit, the subsequent operations cannot be performed.
• When using the YRC1000micro robot controller, protective stop and external emergency stop alarms will
occur if the connector for short-circuiting the safety signals is not connected to the robot controller. Refer to
the following section for details.
1.2.1 Components in a Basic Robot System on page 17
2.
Tap {SERVO} to turn ON the servo.
3.
Confirm that the servo power is turned ON and {SERVO} is green.
The correct operation of servo power ON can be confirmed.
4.
Press the emergency stop button.
YRC1000
There is an emergency stop button on the YRC1000.
YRC1000micro
There is an emergency stop button on the Smart Pendant.
The emergency stop button on the Smart Pendant can also be
used.
Note:
The YRC1000micro is not equipped with an emergency stop
button.
5.
Confirm that {SERVO} changes back to blue.
A blue {SERVO} means the servo power has been turned OFF.
52
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4.1 Turning ON/OFF and Checking the Power Supplies
6.
Turn the emergency stop button in the direction of the arrows to reset the emergency
stop.
YRC1000
YRC1000micro
or
Turning ON the Robot Controller Power Supplies
This concludes the procedure.
4
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53
4.2 Corrective Actions for Alarms at Initial Startup
4.2
Corrective Actions for Alarms at Initial Startup
The following alarms may occur when the manipulator is first started.
If the following alarms occur, take the corrective actions described in the reference section.
Alarm No.
Alarm Name
Possible Cause
6022
• A large force was applied when the power supply to the
robot controller was turned ON.
EXTERNAL FORCE ESTIMATION ERROR
• The home positions of the torque sensors have greatly
deviated.
6004
ESCAPE FROM CLAMPING ERROR(PFL)
• The manipulator cannot perform the escape operation
because a large force was applied when the power supply
to the robot controller was turned ON.
• The manipulator cannot perform the escape operation
because the home positions of the torque sensors have
greatly deviated.
OUT OF RANGE(ABSO
DATA)
• The motor axis became misaligned when the power supply was turned OFF.
• There is a difference that exceeds the allowable range in
the position of the motor axis when the power supply
was turned OFF and when it was turned ON.
4107
Reference Section
4.2.1 Correcting Alarm
6022 EXTERNAL
FORCE ESTIMATION
ERROR and Alarm 6004
ESCAPE FROM
CLAMPING ERROR
(PFL) on page 54
4.2.2 Correcting Alarm
4107 OUT OF RANGE
(ABSO DATA) on page
56
Escape Operation :
The operation in which the manipulator automatically moves in a safe direction from a clamped state.
Term
4.2.1
Correcting Alarm 6022 EXTERNAL FORCE ESTIMATION ERROR
and Alarm 6004 ESCAPE FROM CLAMPING ERROR(PFL)
Use the following procedure to reset alarm 6022 EXTERNAL FORCE ESTIMATION ERROR or alarm 6004
ESCAPE FROM CLAMPING ERROR(PFL) that occurs when the manipulator is first started.
Information
If multiple alarms occur, use this procedure to reset both alarm 6022 and alarm 6004 in a single operation.
(1) Reset the Alarm
If an alarm occurs, the ERROR lamp on the Smart Pendant will be lit, an alarm window similar to the following
will be displayed, and the resume switch will be lit.
Select {RESET} to reset the alarm.
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4.2 Corrective Actions for Alarms at Initial Startup
(2) Change Security to {Safety}
1.
From the status bar, select {MENU} - {Security: Edit}.
2.
On the Security Access window, tap {SAFETY}.
3.
Enter the password and tap {ACCESS}.
Turning ON the Robot Controller Power Supplies
To change the home position settings of the torque sensors, change the security access level to {Safety}.
Note:
The default password is set to "5555555555555555" (enter "5" 16 times).
(3) Set the Home Positions of the Torque Sensors Again
If the home positions of the torque sensors have deviated, such as due to receiving a large shock, erroneous
detections will occur, such as a small external force being detected as a large external force.
4
To prevent erroneous detections, set the home positions of the torque sensors again.
Refer to the following section for the procedure to set the home positions of the torque sensors again.
7.3.2 Setting the Home Positions of the Torque Sensors Again on page 99
When the home position of the torque sensor is set again, press the resume switch on the manipulator.
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4.2 Corrective Actions for Alarms at Initial Startup
This concludes the procedure.
4.2.2
Correcting Alarm 4107 OUT OF RANGE(ABSO DATA)
Use the following procedure to reset alarm 4107 OUT OF RANGE(ABSO DATA) that occurs when the manipulator is first started.
(1) Reset the Alarm
If an alarm occurs, the ERROR lamp on the Smart Pendant will be lit, an alarm window similar to the following
will be displayed, and the resume switch will be lit.
Select {RESET} to reset the alarm.
(2) Change Security to {SAFETY}
To confirm the position of the manipulator, change the security access level to {SAFETY}.
1.
56
From the status bar, select {MENU} - {Security: Edit}.
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4.2 Corrective Actions for Alarms at Initial Startup
2.
On the Security Access window, tap {SAFETY}.
3.
Enter the password and tap {ACCESS}.
Note:
The default password is set to "5555555555555555" (enter "5" 16 times).
(3) Confirm the Position of the Manipulator
Turning ON the Robot Controller Power Supplies
In the current state, there is a large difference between the position of the manipulator when the power supply
was turned OFF and when the power supply was turned ON. The alarm occurred because of this difference in
positions.
Confirm the position according to the rest of this procedure to eliminate this difference.
1.
If the resume switch on the manipulator is lit, press the resume switch.
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57
4.2 Corrective Actions for Alarms at Initial Startup
2.
From the status bar, select {MENU} - {Robot Settings} - {Robot Configuration}.
3.
Tap {SERVO} on the status bar to turn ON the servo.
The button will turn green when the servo is turned ON.
4.
Confirm that {Robot Position Confirm} is selected.
{CONFIRM POSITION} will be displayed and the orange box will flash. However, this will be disabled if the robot position is incorrect.
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4.2 Corrective Actions for Alarms at Initial Startup
Press and hold {GO TO POSITION}.
When the robot moves to and reaches the confirmed position, {CONFIRM POSITION} will be
enabled.
Turning ON the Robot Controller Power Supplies
5.
4
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59
4.2 Corrective Actions for Alarms at Initial Startup
Information
The second home position posture is shown below.
The manipulator will automatically stop at the second home position posture.
6.
Tap {CONFIRM POSITION}.
The robot position will be confirmed and a confirmation message will be displayed.
7.
Confirm that the confirmation message was displayed.
This concludes the procedure. Jobs can be run and the operations to move to previous teaching points can be
used again.
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5
Controlling the Manipulator
This chapter describes jogging operations to move manipulator axes and direct teach operations to store
operating positions in the manipulator.
5.1
Moving the Manipulator .......................................................................................... 62
5.1.1 Jogging Each Axis .......................................................................................... 62
5.1.2 Jogging Parallel to the TCP............................................................................ 65
5.1.3 Direct Teach ..................................................................................................... 67
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61
5.1 Moving the Manipulator
5.1
Moving the Manipulator
This section describes the basic operations to move the manipulator.
Operation
Menu Name
Description
Reference Section
Jogging Each Axis
Joint
The operation to move each axis of the manipulator independently.
5.1.1 Jogging Each Axis on page 62
Jogging Parallel to the
TCP
World
The operation to move in parallel to the X-axis,
Y-axis, and Z-axis that are defined based on the
manipulator.
5.1.2 Jogging Parallel to the TCP
on page 65
Direct Teach
Hand Guiding
The operation to manually move the manipulator to the desired position and store that
position.
5.1.3 Direct Teach on page 67
The manipulator achieves continuous motion
by moving between the recorded positions.
5.1.1
Jogging Each Axis
Jogging is the most basic manipulator operation.
Use the following procedure to move the desired axis of the manipulator.
1.
Confirm that the collaborative operation lamp is lit in green.
Information
If the lamp is not lit, the collaborative operation function is disabled. Refer to the following section and enable the collaborative operation function.
7.6 Enabling the Collaborative Operation Function on page 111
2.
Change the mode switch to MANUAL (TEACH) mode, and set the operation mode to
teach mode.
3.
Tap {SERVO} on the status bar to turn ON the servo.
The button will turn green when the servo is turned ON.
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5.1 Moving the Manipulator
Tap the operation mode icon on the status bar and select {Joint}.
5.
Tap the operation speed icon on the status bar and select the operation speed.
Controlling the Manipulator
4.
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63
5.1 Moving the Manipulator
6.
Press the jog keys on the programming panel to move the manipulator.
This concludes the procedure.
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5.1 Moving the Manipulator
Jogging Parallel to the TCP
The tip of the manipulator moves in parallel to the X-axis, Y-axis, and Z-axis set for the manipulator base.
Use the following procedure to move the tip of the manipulator in the desired direction.
1.
Confirm that the collaborative operation lamp is lit in green.
Information
If the lamp is not lit, the collaborative operation function is disabled. Refer to the following section and enable the collaborative operation function.
7.6 Enabling the Collaborative Operation Function on page 111
2.
Change the mode switch to MANUAL (TEACH) mode, and set the operation mode to
teach mode.
3.
Tap {SERVO} on the status bar to turn ON the servo.
The button will turn green when the servo is turned ON.
4.
Tap the operation mode icon on the status bar and select {World}.
Controlling the Manipulator
5.1.2
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65
5.1 Moving the Manipulator
66
5.
Tap the operation speed icon on the status bar and select the operation speed.
6.
Press the jog keys on the programming panel to move the manipulator.
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5.1 Moving the Manipulator
• X-Axis, Y-Axis, and Z-Axis Directions That Are Defined Based on the Manipulator
• Relationship between Smart Pendant Jog Keys and Manipulator Movement
Information
The illustration on the left is the view from directly above the manipulator.
5.1.3
Direct Teach
Hand guiding mode is the operation to manually move the manipulator to the desired position and store that position. For hand guiding mode, select {XYZ + TOOL}. The manipulator can be manually moved in the X, Y, and
Z directions.
Controlling the Manipulator
This concludes the procedure.
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67
5.1 Moving the Manipulator
1.
Confirm that the collaborative operation LED is lit in green.
Information
If the LED is not lit, the collaborative operation function is disabled. Refer to the following section and enable the collaborative operation function.
7.6 Enabling the Collaborative Operation Function on page 111
2.
Change the mode switch to MANUAL (TEACH) mode, and set the operation mode to
teach mode.
3.
Tap {SERVO} on the status bar to turn ON the servo.
The button will turn green when the servo is turned ON.
4.
68
Tap the operation mode icon on the status bar and select {Hand Guiding}.
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5.1 Moving the Manipulator
5.
If the operation speed is set to low speed, the following message will be displayed.
Select {CHANGE TO HIGH SPEED}.
Information
If set to low speed, teaching precision will fall because a strong force will be required to manually move the
manipulator. An alarm will occur if the manipulator is pushed too hard.
Select {XYZ + TOOL}.
7.
Confirm that the manipulator can be manually moved while the [MOVE] button on the
manipulator is pressed.
Information
Controlling the Manipulator
6.
Refer to the following section for details on creating a program (registering a job).
8.2.1 Creating a Program on page 117
8.
While the [MOVE] button on the manipulator is pressed, manually move the arm of the
manipulator to the location to be taught.
Information
9.
5
If the arm speed feels fast, tap the [MOVE] button twice (double-click), and then move the arm when all
three buttons are flashing. The arm will move slowly, and it will be easier to make fine adjustments because
the feeling of arm coasting will be reduced.
Release the [MOVE] button on the manipulator.
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69
5.1 Moving the Manipulator
10. Press the [TEACH] button on the manipulator.
The position of the manipulator will be saved when the [TEACH] button is pressed.
Confirm that the saved content was inserted into the job program on the Smart Pendant.
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5.1 Moving the Manipulator
11. Return to step 8 and repeat the steps until the series of manipulator movements is
completed.
Controlling the Manipulator
This concludes the procedure.
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71
5.1 Moving the Manipulator
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6
Mounting and Wiring the Hand
6.1
Required Items .......................................................................................................... 74
6.2
Mounting the Hand................................................................................................... 75
6.3
Connecting the Air Hoses ...................................................................................... 79
6.4
Connecting the I/O Cables ..................................................................................... 80
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73
6.1 Required Items
6.1
Required Items
This manual describes the required preparations and installation work for the manipulator based on the following
hand.
• Air gripper for collaborative robots manufactured by SMC (type: JMHZ2-16D-X7400B-DTP-N)
Table 6.1 Hands and Hand Accessories
Name
Quantity
Remarks
Hand (air gripper)
1
–
Protective cover (valve side)
1
–
Protective cover (switch side)
1
–
Hexagon socket head cap screw M4 (length:
10 mm)
4
For attaching protective covers
Parallel pin (diameter: 6 mm, length: 10 mm)
1
For positioning the hand
Hexagon socket head cap screw M6 (length:
23 mm)
4
For mounting the hand
Polyurethane tube
1
Outside diameter: φ4, length: 2 m
Accessory cable
1
For connecting the hand to the manipulator
One-touch fitting (KQ2L04-M5A1)
2
–
One-touch fitting (KQ2L06-08A)
1
–
One-touch fitting (KQ2H04-06A)
1
–
Table 6.2 Tools for Connecting the Air Hoses
Name
Quantity
Remarks
Union (for air inlet)
2
Air inlet on manipulator: M5 tapped hole
Union (for air outlet)
2
Air outlet on manipulator: outside diameter φ8
Air hose
4
–
Air supply equipment
1
–
Table 6.3 Tools for Connecting the I/O Cable
Name
Quantity
Remarks
General-purpose I/O terminal block
1
–
General-purpose I/O cable
1
–
I/O cable
1
–
Table 6.4 Tools
Name
74
Quantity
Remarks
Hex key (M4)
1
–
Hex key (M6)
1
–
Flat head screwdriver
1
For adjusting the fingers exhaust throttle valves
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6.2 Mounting the Hand
Mounting the Hand
1.
Jog the robot arm to a position that makes it easier to mount the hand.
Refer to the following section for details on jogging.
5.1.1 Jogging Each Axis on page 62
2.
3.
4.
Turn OFF the power supply to the robot controller and peripheral devices.
Confirm that the collaborative operation LED on the manipulator are not lit.
Insert the parallel pin into the flange surface of the T-axis of the manipulator.
Mount the hand aligned with the parallel pin to the manipulator and fix with the hexagon socket head
cap screws M6 (length: 23 mm). Tightening torque: 5.2 N∙m (0.53 kgf∙m)
Mounting and Wiring the Hand
6.2
A
Parallel pin
C
Hexagon socket head cap screw M6 (length: 23 mm)
B
Flange surface of the T-axis of the manipulator
–
–
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75
6.2 Mounting the Hand
5.
6.
76
Attach the protective covers to the hand and fix with the hexagon socket head cap
screws M4 (length: 10 mm). Tightening torque: 1.0 N∙m (0.10 kgf∙m)
A
Hexagon socket head cap screw M4 (length: 10 mm)
C
Protective cover (valve side)
B
Protective cover (switch side)
–
–
Connect the cable to the hand. Connect the cable connectors by first checking that the
positioning key is aligned for both the hand-side and cable-side connectors.
A
Connector for cable connection
C
Positioning key on hand-side connector
B
Accessory cable
–
–
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6.2 Mounting the Hand
Connect the cable to the manipulator. Connect the cable to the I/O cable connector (S)
on the manipulator. Connect the cable connectors by first checking that the positioning
key is aligned for both the manipulator-side and cable-side connectors.
A
8.
I/O cable connector (S)
B
Positioning key
Connect the unions (included with the hand) to the air outlets on the T-axis flange of the
manipulator, and connect the air hoses.
Information
This note describes the adjustment method of the fingers opened/closed position.
The fingers section at the tip of the hand is set by default to respond at the opened limit and closed limit of
the fingers. The fingers opened/closed position can be adjusted by changing the position of the auto switches.
Fix the auto switches at the optimal positions for the shape of the workpiece.
A
Fingers opened limit detection position
B
Fingers closed limit detection position
Mounting and Wiring the Hand
7.
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77
6.2 Mounting the Hand
Information
This note describes the adjustment method of the fingers opening/closing speed.
Insert the flat head screwdriver into the throttle opening adjustment slot on the exhaust throttle valve and
adjust the throttle opening.
Adjust the throttle openings of both exhaust throttle valves to be the same amount. Operation may be unstable if the difference between the throttle openings is too great.
78
A
Exhaust throttle valve (for adjusting the opening speed of the fingers)
C
Enlarged view of the exhaust throttle valve
B
Exhaust throttle valve (for adjusting the closing speed of the fingers)
D
Throttle opening adjustment slot (use a flat
head screwdriver)
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6.3 Connecting the Air Hoses
Connecting the Air Hoses
The customer must prepare the air supply source, unions, and air hoses for driving the air gripper.
1.
Remove the plugs in the AIR1 and AIR2 inlets on the S-base part of the manipulator, and
then connect the unions.
A
2.
3.
AIR1 inlet
B
AIR2 inlet
Connect the air hoses to the unions.
Connect the air hoses to the air supply equipment.
Mounting and Wiring the Hand
6.3
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79
6.4 Connecting the I/O Cables
6.4
Connecting the I/O Cables
To perform the hand open/close fingers operation, the manipulator and robot controller must be connected
through the general-purpose I/O terminal block. Use the following connection example as a reference.
Note:
The connection example in this manual assumes the robot controller I/O is the NPN type (standard specification).
The customer must prepare the following connections:
Important
• Connecting the I/O cable to the general-purpose I/O terminal block
• Connecting the general-purpose I/O terminal block to the connector for the I/O cable on the S-base part of the manipulator
Information
80
Refer to the manual that is included with the end effector for the open/close fingers operation using simulated output for
I/O from the pendant.
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Mounting and Wiring the Hand
6.4 Connecting the I/O Cables
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81
6.4 Connecting the I/O Cables
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7
Settings
This chapter describes the configuration procedures for the settings of the collaborative robot.
7.1
Temporarily Disabling the Collaborative Operation Function ...................... 84
7.2
Configuring a Tool File............................................................................................ 91
7.3
Checking the Home Positions of the Torque Sensors and Setting the
Home Positions Again ............................................................................................ 98
7.3.1 Checking the Home Positions of the Torque Sensors ................................ 98
7.3.2 Setting the Home Positions of the Torque Sensors Again ......................... 99
7.4
Setting External Force Limits..............................................................................105
7.5
Configuring the Speed Limit Function..............................................................108
7.6
Enabling the Collaborative Operation Function............................................. 111
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83
7.1 Temporarily Disabling the Collaborative Operation Function
7.1
Temporarily Disabling the Collaborative Operation
Function
The collaborative operation function must be disabled to temporarily disable external force monitoring and speed
limits by collaborative operation.
WARNING
There is a risk of injury to the operator when the PFL function is disabled. Perform this operation only after a thorough risk assessment has been conducted.
When collaborative operation is disabled, the stop function when contact is made by PFL
function and the escape from clamping function are also disabled. Always enable the collaborative operation function after the following settings are changed.
• Tool settings
• Torque sensor home position
• Speed limit
• External force limits
Use the following procedure to disable the collaborative operation function.
Information
1.
84
Alarm 6003 "UNDEFINED SPEED LIMIT(PFL)" may be displayed during the procedure. The alarm can be reset by
tapping {RESET} on the alarm window.
From the status bar, select {MENU} - {Security: Edit}.
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7.1 Temporarily Disabling the Collaborative Operation Function
2.
On the Security Access window, select {SAFETY}.
3.
Enter the password and select {ACCESS}.
Note:
The default password is set to "5555555555555555" (enter "5" 16 times).
Select {MENU} - {Safety Settings} - {Safety Logic Circuit}.
Settings
4.
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85
7.1 Temporarily Disabling the Collaborative Operation Function
5.
Find the line on which the output (right side of the window) is set to "MSOUT54 (Collaborative op. request)". (Found on the first line of the user circuits in the default state.)
Refer to the following manual for details on the setting procedure for the safety logic circuit.
YRC1000/YRC1000micro Instructions For Smart Pendant (Manual. No.: HW1485509)
Signal Name
Description
Enables and disables collaborative operation
MS-OUT54
6.
• ON: Collaborative operation enabled
• OFF: Collaborative operation disabled
Tap the contact at the left edge of the relevant line (default state: FSBIN01).
The selected contact will be displayed as follows, and the Details pane will be displayed at the bottom
of the window.
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7.1 Temporarily Disabling the Collaborative Operation Function
Tap {Input Type}.
Settings
7.
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87
7.1 Temporarily Disabling the Collaborative Operation Function
8.
Select {Normally Closed contact}.
9. Confirm that the MSOUT54 collaborative operation request signal is OFF.
10. Confirm that there are no mistakes in the safety logic circuit, and then tap
{READBACK}.
11. Tap {WRITE}.
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7.1 Temporarily Disabling the Collaborative Operation Function
Readback
Term
Readback is the operation used to check if the data that was configured in the safety circuit board and PFL circuit board is correct.
Data related to safety functions is redundantly stored in the memory on the safety circuit board and PFL circuit
board. The readback operation is required when data is changed on windows such as the safety function condition setting windows and tool windows.
①: A setting value is changed with the pendant.
②: The setting value is transferred to the PFL and FSU.
③: Answer data is sent from the PFL and FSU to the CPU (readback).
④: The CPU value and answer data value are compared.
⑤: The setting value that was sent from the CPU is stored in the PFL and FSU.
Alarm 6003 "UNDEFINED SPEED LIMIT(PFL)" may be displayed. Tap {RESET} to reset the alarm.
Settings
Important
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89
7.1 Temporarily Disabling the Collaborative Operation Function
12. MSOUT54 will be disabled, and the PFL function will be disabled. The collaborative
operation LED on the manipulator will go out.
This concludes the procedure.
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7.2 Configuring a Tool File
Configuring a Tool File
In collaborative operation mode, the external force is calculated by canceling the tool mass. For this reason, the
tool installed on the manipulator and the mass and position of the center of gravity of the workpiece to transport
must be configured in advance. The configured content is managed by selection number.
The tool selection number must also be changed at each step of the manipulator program in accordance with
changes in the status of the hand.
Example: When Grasping and Lifting a Workpiece on a Table with the Hand
• When the workpiece is not grasped, the tool mass is the mass of the hand only.
• When the workpiece is grasped and lifted, the tool mass is the mass of the hand and workpiece.
This section describes the configuration procedure that uses the automatic measurement for the tool load and the
center of gravity, which can be used to easily configure a tool file.
Automatic measurement for the tool load and the center of gravity can be used only when the manipulator is installed at an
installation angle in relation to the ground of 0°.
Important
To estimate the mass property of the tool load, move the manipulator to the home position (U-axis, B-axis, and
R-axis: level to the ground), and operate the U-axis, B-axis, and T-axis.
To correctly estimate the tool mass, position of the center of gravity, and moment of inertia, disconnect cables and wiring
that are connected to the tool so that no unnecessary loads are applied to the tool.
Important
Use the following procedure to configure a tool file.
1.
Confirm that the workpiece is at hand.
Information
Settings
7.2
Prepare the workpiece in advance because it will be used in the rest of this procedure.
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91
7.2 Configuring a Tool File
2.
Confirm that the collaborative operation LED is not lit.
If the collaborative operation LED is lit, the collaborative operation function is enabled. Refer to the
following section for the operating procedure to disable the function.
7.1 Temporarily Disabling the Collaborative Operation Function on page 84
Information
3.
4.
Always disable the collaborative operation function before continuing with the rest of this procedure. The
subsequent operations may not correctly function if the collaborative operation function is enabled.
Select {MENU} - {Robot Settings} - {Tools}.
Select tool number {0} with the cursor.
The Tool Detail Panel for tool number {0} will be displayed.
Information
Data can be set in a maximum of 64 tool files. Information can be freely set in any tool file. Tool coordinates
number 0 is selected here to make the procedure easier to understand.
5.
Tap {ESTIMATE} at the corner of the weight properties area on the Tool Detail Panel.
6.
When the next message is displayed, tap {CHANGE ACTIVE TOOL}.
A dialog box will be displayed if the current tool differs from the tool that was selected in the list. These tools
must match to perform the tool load estimation.
Important
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7.2 Configuring a Tool File
7.
Tap {Properties to Estimate} and select {Weight + Center of Gravity + Inertia}.
8.
Tap {SERVO}.
The background color will change to orange.
9.
Squeeze the enable switch on the Smart Pendant.
{SERVO} will change to green and the servo ON state will be set.
Settings
10. Tap {Hold to Estimate Tool Load} to start estimating.
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93
7.2 Configuring a Tool File
11. Select {CHANGE TO HIGH SPEED}.
12. The manipulator will move to the reference position. Press and hold {Hold to Estimate
Tool Load} until the following message is displayed.
The progress of automatic estimation will be displayed as a percentage.
The following message may be displayed if the finger that was tapping the menu was removed while the estimation operation was running. Tap {Hold to Estimate Tool Load} again.
Important
13. Repeat the tool load estimations according to the messages until the estimations of all
axes are completed.
14. When the following message is displayed, the tool load estimation for tool number 0 is
completed.
15. Remove the finger from the enable switch on the Smart Pendant.
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7.2 Configuring a Tool File
16. Confirm that the tool mass was set.
Settings
17. If there were no errors in the estimations, tap {Send & Review Data}.
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95
7.2 Configuring a Tool File
18. Tap {READBACK}.
19. Select {Comparison Result}.
20. Check the readback results.
Note:
If the data is the same between the robot controller CPU and circuit board, the configuration was correctly completed. If the data
is not the same, {Comparison Result} will display "***" instead of a value. In this case, what data was not updated on which circuit board must be checked.
21. Tap {WRITE}.
The measurement data will be registered in the tool file.
This concludes only the procedure to register the information for the hand in tool coordinates number
00.
Next, register the information for the hand and workpiece when the workpiece is grasped and lifted in
tool coordinates number 01.
Proceed to the next step.
22. Select tool number 1.
23. Set the hand to grasp the workpiece, and return to step 4 and repeat the configuration
procedure in this state.
Register the tool file with the hand grasping the workpiece in tool number 01.
The method to make the hand grasp the workpiece (method to open/close the hand) depends on the
type of hand. Refer to the manual for the hand for the detailed operating procedure.
24. When tool file configuration is completed, remove the workpiece from the hand.
This concludes the procedure.
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7.2 Configuring a Tool File
Tool Center Point (TCP)
Term
The tool center point is the offset position from the wrist flange of the tool to the tip of the tool. For a simple tool, this is the
offset in the X/Y/Z directions only. If necessary, a rotational offset can also be set.
When the tool center point is set, the manipulator can be operated in an orthogonal direction with the correct position set as
the center point. Positions can also be taught with the correct offset from the manipulator base.
Orientation of Tool Tip
The orientation of the tool tip is the amount of TCP rotation from the wrist flange of the tool. Tool rotation is entered in
degrees.
Settings
Term
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
7.3
Checking the Home Positions of the Torque Sensors
and Setting the Home Positions Again
The torque sensors built into the manipulator require regular inspections because deviations in the measured values will occur when the environment changes or the manipulator is mistakenly used, such as when the manipulator accidentally collides with something.
Information
Keeping a continuous record of the current torque values is recommended after the manipulator is installed. When the
user changes the system (e.g., changes the tool), move the manipulator to the same posture each time, and record the current values of {Joint Data} on the Force/Torque Watch window. The user can compare this recorded data to the current
values.
The following four conditions must be met when the allowable values and current values of torque are compared.
• The tool number matches the currently installed tool.
• The tool information is correct.
• When checking torque values, the values are recorded when the robot is set to the same posture (e.g., home position
posture) each time.
• The current values of {Joint Data} do not exceed the values listed below.
If the values of the axes are larger than the torque values listed in the following table, adjust the torque sensors.
If values exceed the values in the following table, the external force estimation will be greatly affected. For this reason,
adjusting the torque sensor for the relevant axis is highly recommended.
Axis
S
L
U
R
B
T
Torque Value 27.0 N·m
27.0 N·m
12.0 N·m
3.0 N·m
3.0 N·m
3.0 N·m
CAUTION
Even if the torque by external force is lower than the values given in the table above, adjust the
torque sensors when there is a problem with the operation of the PFL function or escape from
clamping function.
7.3.1
Checking the Home Positions of the Torque Sensors
To check the status of the torque sensors, regularly open the Force/Torque Watch window with the manipulator
set to the same posture and with the same load, record the torque values by external force of each axis, and check
if the difference between the values is growing larger from when the manipulator first started being used.
Use the following procedure to check the values.
1.
98
Select {MENU} - {Safety Settings} - {Force/Torque Watch}.
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
2.
Tap {Joint Values} and check the torque values by external force of each axis.
3.
Compare the current values to the values when the manipulator first started being used
and check if the difference between the values is growing larger.
Information
Recording these values each day is recommended because these values must be checked regularly.
This concludes the procedure.
If the values exceed the thresholds as a result of the comparison, adjust the torque sensors according to the following procedure.
Setting the Home Positions of the Torque Sensors Again
If the home positions of the torque sensors are checked and the threshold values were exceeded, the home positions of the torque sensors must be set again. Use the following procedure.
1.
Tap the tool icon and select tool #0.
Information
2.
Select the tool file for the tool that is currently installed. In this example, number 0 is selected because the
tool file for the currently installed tool is set to tool number 0.
Select {MENU} - {Safety Settings} - {Torque Sensor Calibration}.
Settings
7.3.2
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
100
3.
Tap {CALIBRATE ALL TORQUE SENSORS}.
4.
When the following message is displayed, select {YES, CALIBRATE}.
5.
The following message will be displayed.
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
Tap {READBACK}.
Settings
6.
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
7.
Tap {Comparison Result} and confirm that there are no problems in the values that were
written.
This concludes the configuration procedure if the comparison result values match.
However, if the values do not match, {Comparison Result} will display "***". In this case, what data
was not updated on the PFL circuit board must be checked.
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
8.
Tap {WRITE}.
The data that was configured will be transferred to and saved in the robot controller.
Squeeze the enable switch on the smart pendant to set the servo ON state.
Settings
9.
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
10. Tap {VERIFY CALIBRATION}.
The current values of the torque sensors will be displayed.
Check the values. If there are no problems, tap {OK} on the confirmation dialog.
If there are problems with the current values, perform calibration again.
This concludes the procedure.
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7.4 Setting External Force Limits
Setting External Force Limits
The manipulator has an external force monitor function. This function stops the manipulator according to the
external force that is applied to the manipulator.
The manipulator will stop when the preset external force limits are exceeded.
The external force limits (TCP resultant force and each X/Y/Z axis direction external force) are set to 100 N by
default.
Up to 32 external force limits can be set.
Information
The resume switch on the manipulator will be lit during external force monitoring.
Use the following procedure to configure the external force limits that stop the manipulator. This example shows
the procedure to set the external force limits (TCP resultant force and each X/Y/Z axis direction external force)
to 90 N.
1.
From the status bar, select {MENU} - {Safety Settings} - {Safety Functions}.
Settings
7.4
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7.4 Setting External Force Limits
106
2.
Tap {Detect by TCP 100N}.
3.
Tap {100 N} for resultant.
4.
Enter "90" and tap {Enter}.
5.
Repeat steps 3 and 4 and set Fx, Fy, and Fz to 90 N.
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7.4 Setting External Force Limits
6.
Tap {READBACK}.
7.
Tap {WRITE}.
Settings
This concludes the procedure.
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107
7.5 Configuring the Speed Limit Function
7.5
Configuring the Speed Limit Function
The speed limit function performs monitoring to ensure the manipulator control points do not exceed the set
speed. The monitored control points are the TCP (tool center point) and FCP (flange center point).
The default speed limit provides no guarantees regarding manipulator safety. Always conduct a risk assessment and configure the speed limit again based on those results.
Important
TCP speed 250 mm/s is the default setting.
The speed limit function has two monitor types: speed limit and stop monitor.
Monitor Type
Description
The TCP speed and FCP speed are monitored to ensure the set speed is not exceeded.
Speed limit
When the speed limit is enabled, the teaching speed at that time is first lowered to the speed limit
if the teaching speed is faster than the speed limit. The time until monitoring is started from when
the conditions file becomes valid can be set in the conditions file as the detection delay time.
If an error was detected for the monitoring result, power to the motor is turned OFF using machine
safety. An alarm also occurs to provide notification of the error.
Stop monitor
The stop position of the TCP or FCP is monitored to confirm that the points do not move.
Use the following procedure to configure the speed limit function. This example shows the procedure to set the
speed limit value to 100 mm/s.
1.
From the status bar, select {MENU} - {Safety Settings} - {Safety Functions}.
The Safety Function Settings window will be displayed.
2.
108
Tap {speed limit for collaborative op}.
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7.5 Configuring the Speed Limit Function
Select "Speed Limit" under Monitor Type, and tap the speed {250.0 mm/sec}.
4.
Enter "100" and tap {Enter}.
Settings
3.
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109
7.5 Configuring the Speed Limit Function
5.
Tap {READBACK}.
6.
Tap {WRITE}.
This concludes the procedure.
Information
110
When configuring the stop monitor settings, select "Stop Monitor" under Monitor Type, and then set {Position Tolerance} and {Detection Delay Time}.
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7.6 Enabling the Collaborative Operation Function
Enabling the Collaborative Operation Function
To configure the collaborative operation function, the collaborative operation function was temporarily disabled.
Therefore, when the collaborative operation function configuration shown in "7.2 Configuring a Tool File on
page 91" to "7.5 Configuring the Speed Limit Function on page 108" is completed, the collaborative operation
function must be enabled.
Use the following procedure to enable the collaborative operation function.
1.
From the status bar, select {MENU} - {Security: Edit}.
2.
On the Security Access window, select {SAFETY}.
3.
Enter the password and select {ACCESS}.
Note:
The default password is set to "5555555555555555" (enter "5" 16 times).
Settings
7.6
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111
7.6 Enabling the Collaborative Operation Function
112
4.
Select {MENU} - {Safety Settings} - {Safety Logic Circuit}.
5.
Select the input relay with the input type that was set to {NORMALLY CLOSED} when
the collaborative operation function was temporarily disabled.
6.
Select {Normally Open contact} for the input type.
7.
Confirm that the MSOUT54 collaborative operation request signal is ON.
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7.6 Enabling the Collaborative Operation Function
8.
Confirm that there are no mistakes in the safety logic circuit, and then tap
{READBACK}.
9.
Tap {WRITE}.
10. The collaborative operation function will be enabled. Confirm that the collaborative
operation LED on the manipulator is lit in green.
When tool file number 1 is set, the collaborative operation LED will not be lit because the collaborative operation function is disabled inside the manipulator. First perform the following operation, and then confirm again
Important that the collaborative operation LED is lit.
Reset Procedure
Jog the tip of the manipulator approximately 5 mm.
Move a driven axis (e.g., B-axis) instead of a rotary axis (e.g., T-axis).
Refer to the following section for details on jogging.
Settings
5.1.1 Jogging Each Axis on page 62
This concludes the procedure.
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7.6 Enabling the Collaborative Operation Function
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8
Programming
This chapter describes how to create a program according example movements and how to move the
manipulator using that program.
8.1
Explanation of the Sample Program.................................................................. 116
8.1.1 Overview..........................................................................................................116
8.2
Creating a Program with Direct Teach .............................................................. 117
8.2.1 Creating a Program ........................................................................................117
8.2.2 Registering Manipulator Positions in the Program Using Direct
Teach............................................................................................................... 122
8.2.3 Adding and Changing Programming .......................................................... 125
8.2.4 Confirming Operation Step by Step ............................................................ 136
8.2.5 Running the Created Program ..................................................................... 139
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115
8.1 Explanation of the Sample Program
8.1
Explanation of the Sample Program
8.1.1
Overview
In this chapter, a program that moves the position of a workpiece from the left edge to the right edge will be
created.
An illustration that shows the workpiece positions and the path of the tip of the manipulator is shown below, as
well as the sample program that achieves this motion.
This program uses the tool shown below. The following four signals must be connected to open and close this
tool.
Appearance of Tool
Signal Name
Signal Application
Open fingers signal
Used for the open hand instruction.
Close fingers signal
Used for the close hand instruction.
Auto switch output (fingers opened) signal
Used for confirmation of the hand opened sensor.
Auto switch output (fingers closed) signal
Used for confirmation of the hand closed sensor.
The descriptions for this program assume the above signals have been connected as described in the following
section.
6.4 Connecting the I/O Cables on page 80
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8.2 Creating a Program with Direct Teach
8.2
Creating a Program with Direct Teach
This section describes the procedure to create a sample program using direct teach. The description is split into
the following steps.
Step
Applicable Device
Reference Section
1
Creating a Program
Smart Pendant
8.2.1 Creating a Program on page
117
2
Registering Manipulator Positions in the
Program Using Direct Teach
Manipulator
8.2.2 Registering Manipulator Positions in the Program Using Direct
Teach on page 122
3
Adding and Changing Programming
Smart Pendant
8.2.3 Adding and Changing Programming on page 125
4
Confirming Operation Step by Step
Smart Pendant
8.2.4 Confirming Operation Step by
Step on page 136
5
Running the Created Program
Smart Pendant
8.2.5 Running the Created Program
on page 139
Creating a Program
To use direct teach, a program must be created (job registered) in advance.
1.
Turn ON the main power supply to the robot controller.
YRC1000
YRC1000micro
Programming
8.2.1
Task
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117
8.2 Creating a Program with Direct Teach
2.
Wait approximately three minutes, and confirm that the startup window is displayed on
the Smart Pendant.
3.
Confirm that the collaborative operation lamp is lit in green.
Information
If the lamp is not lit, the collaborative operation function is disabled. Refer to the following section and enable the collaborative operation function.
7.6 Enabling the Collaborative Operation Function on page 111
4.
Change the mode switch to MANUAL (TEACH) mode, and set the operation mode to
teach mode.
5.
Tap {SERVO} on the status bar to turn ON the servo.
The button will turn green when the servo is turned ON.
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8.2 Creating a Program with Direct Teach
6.
Tap the operation mode icon on the status bar and select {Hand Guiding}.
7.
If the operation speed is set to low speed, the following message will be displayed.
Select {CHANGE TO HIGH SPEED}.
Information
From the status bar, select {MENU} - {Job List} - {+ NEW JOB}.
Programming
8.
If set to low speed, a strong force will be required to manually move the manipulator. An alarm will occur if
the manipulator is pushed too hard. The low speed setting is convenient for fine movements.
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119
8.2 Creating a Program with Direct Teach
9.
120
Enter a name in {Job Name}. "SAMPLE" is used in this manual.
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8.2 Creating a Program with Direct Teach
Programming
10. Confirm the job name and press {SAVE ALL}.
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121
8.2 Creating a Program with Direct Teach
11. Select the SAMPLE job that was created from the job list and tap {EDIT}.
Confirm that the job name that was registered is displayed.
This concludes the procedure. Proceed to the next step.
8.2.2
Registering Manipulator Positions in the Program Using Direct
Teach
Register the manipulator positions in the program using direct teach.
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8.2 Creating a Program with Direct Teach
1.
Confirm that the following procedure was completed.
8.2.1 Creating a Program on page 117
2.
Confirm again that the collaborative operation LED is lit in green.
Information
If the LED is not lit, the collaborative operation function is disabled. Refer to the following section and enable the collaborative operation function.
7.6 Enabling the Collaborative Operation Function on page 111
3.
Confirm again that the operation mode is teach mode.
Note:
If the teach mode icon is not displayed on the status bar, change the mode switch to MANUAL (TEACH) mode.
4.
Tap {SERVO} on the status bar to turn ON the servo.
The button will turn green when the servo is turned ON.
Information
While the [MOVE] button on the manipulator is pressed, move the manipulator to position (1).
Information
6.
If the arm speed feels fast, tap the [MOVE] button twice (double-click), and then move the arm when all
three buttons are flashing. The arm will move slowly, and it will be easier to make fine adjustments because
the feeling of arm coasting will be reduced.
Release the [MOVE] button on the manipulator.
Programming
5.
When using direct teach, the servo ON state will be maintained even if the enable switch on the back of the
Smart Pendant is not squeezed.
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8.2 Creating a Program with Direct Teach
7.
Press the [TEACH] button on the manipulator.
The position of the manipulator will be registered as line number 2 when the [TEACH] button is
pressed.
Information
8.
"Joint Move Speed=5.00(%)" will be displayed because the position is registered with the default instruction
and speed.
While the [MOVE] button on the manipulator is pressed, move the manipulator from
position (1) to position (2).
9. Release the [MOVE] button on the manipulator.
10. Press the [TEACH] button on the manipulator.
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8.2 Creating a Program with Direct Teach
The position of the manipulator will be registered as line number 3 when the [TEACH] button is
pressed.
11. Repeat steps 8 to 10 and register positions (3) to (10) in the program.
The line numbers that are registered and the descriptions of positions (1) to (10) are shown below.
For the positions in (4) and (8), register the same position as the previous step in order to switch the
tool information.
Manipulator Position
Information
Line No.
Description of Position
(1)
2
Start job position
(2)
3
Above grasp workpiece position
(3)
4
Grasp workpiece position
(4)
5
Grasp workpiece position
(5)
6
Above grasp workpiece position
(6)
7
Above release workpiece position
(7)
8
Release workpiece position
(8)
9
Release workpiece position
(9)
10
Above release workpiece position
(10)
11
End job position
The speed of manipulator motion, opening and closing the hand, the tool files, and other settings are configured after this procedure. This procedure registers the positions of the manipulator only.
This concludes the procedure. Proceed to the next step.
Adding and Changing Programming
Instructions can be added to and changed in the program in which the manipulator positions were registered.
This section describes the following four operations.
Programming
8.2.3
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125
8.2 Creating a Program with Direct Teach
Operation
Reference Section
Set the Start Job Position (Line No. 2) and End Job Position (Line
No. 11) to the Same Location
(1) Set the Start Job Position (Line No. 2) and End Job Position
(Line No. 11) to the Same Location on page 126
Change the Motion and Speed of the Manipulator
(2) Change the Motion and Speed of the Manipulator on page
127
Add Instructions to Close and Open the Hand
(3) Add Instructions to Close and Open the Hand on page 130
Change the Tool File
(4) Change the Tool File on page 134
(1) Set the Start Job Position (Line No. 2) and End Job Position (Line No.
11) to the Same Location
Setting the same position for the start job position (line number 2) and end job position (line number 11) is
recommended.
Each position that was registered with direct teach is a position that was registered by sight, so there will be slight
deviations in the positions. For this reason, use the following procedure to set the start job position (line number
2) and end job position (line number 11) to the same position.
1.
Confirm that the following procedure was completed.
8.2.2 Registering Manipulator Positions in the Program Using Direct Teach on page 122
2.
Select line number 2 on the Smart Pendant.
3.
Tap {GO TO POINT}.
The manipulator will move to position (1).
Information
126
If the movement speed seems slow or fast, tap the operation speed icon on the status bar and change the operation speed.
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8.2 Creating a Program with Direct Teach
4.
Select line number 11 on the Smart Pendant, and tap {RE-TEACH}.
The position of line number 11 will be set to the same position as line number 2.
This concludes the procedure. Proceed to the next step.
(2) Change the Motion and Speed of the Manipulator
The manipulator motions registered with direct teach are all registered with the "Joint Move Speed=5.00 (%)"
instruction and speed.
The program described in this manual uses the Joint Move instruction and Linear Move instruction depending on
the position where the manipulator moves. The differences between these instructions are described below.
Instruction
Manipulator Path
Linear Move
The manipulator moves along a linear path.
Joint Move
The path of the manipulator is not limited to a straight line.
The sample program uses the Linear Move instruction for the steps before and after the motion to close and open
the hand. The sample program uses the Joint Move instruction for all other steps.
To recreate the sample program, change the instructions and speeds. Use the following procedure.
Confirm that the following procedure was completed.
8.2.2 Registering Manipulator Positions in the Program Using Direct Teach on page 122
Programming
1.
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127
8.2 Creating a Program with Direct Teach
128
2.
Move the Smart Pendant cursor to line number 2.
3.
Tap the instruction and set the motion (instruction) from the start position (home position) to step 1.
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8.2 Creating a Program with Direct Teach
Tap {Speed} and enter the speed from the start position (home position) to step 1.
5.
Tap {Enter}.
Programming
4.
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129
8.2 Creating a Program with Direct Teach
6.
Repeat steps 2 to 5 and change the following instructions and speeds as shown in the
table.
Manipulator Position
Line No.
Instruction and Speed
(1)
2
JointMove Speed=10.00 (%)
(2)
3
JointMove Speed=25.00 (%)
(3)
4
LinearMove Speed=1000.0 (mm/sec)
(4)
5
LinearMove Speed=1000.0 (mm/sec)
(5)
6
LinearMove Speed=1000.0 (mm/sec)
(6)
7
JointMove Speed=25.00 (%)
(7)
8
LinearMove Speed=1000.0 (mm/sec)
(8)
9
LinearMove Speed=1000.0 (mm/sec)
(9)
10
LinearMove Speed=1000.0 (mm/sec)
(10)
11
JointMove Speed=25.00 (%)
This concludes the procedure. Proceed to the next step.
(3) Add Instructions to Close and Open the Hand
At position (4) in the sample program, the manipulator will close the hand and grasp the workpiece. At position
(8), the manipulator will open the hand and release the workpiece.
The instructions to close and open the hand are not in the program that was created up to this point. These
instructions must be added to the program.
Three instructions are required to close the hand, and three instructions are required to open the hand.
• Close the Hand
Instruction
DigitalOut Output#(7)
Off
DigitalOut Output#(8) On
Description
Turns OFF output signal #(7).
Output #(7) on the manipulator is the open fingers signal.
Turns ON output signal #(8).
Output #(8) on the manipulator is the close fingers signal.
Waits until input signal #(8) is turned ON.
Wait Input#(8) = On
Input #(8) on the manipulator is the auto switch output (fingers closed) signal. This signal provides confirmation of the hand closed sensor.
• Open the Hand
Instruction
DigitalOut Output#(8)
Off
DigitalOut Output#(7) On
Description
Turns OFF output signal #(8).
Output #(8) on the manipulator is the close fingers signal.
Turns ON output signal #(7).
Output #(7) on the manipulator is the open fingers signal.
Waits until input signal #(7) is turned ON.
Wait Input#(7) = On
130
Input #(7) on the manipulator is the auto switch output (fingers opened) signal. This signal provides confirmation of the hand opened sensor.
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8.2 Creating a Program with Direct Teach
Use the following procedure.
1.
Confirm that the following procedure was completed.
(2) Change the Motion and Speed of the Manipulator on page 127
2.
Tap {COMMANDS} at the bottom of the Smart Pendant window, and tap {I/O}.
3.
Select line number 5, and tap {DigitalOut} at the bottom of the window.
Information
The instruction will be added to the line below the cursor position. Place the cursor on line number 5 here.
Programming
First, the procedure to add the DigitalOut instruction to close the hand at position (4) will be described.
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8.2 Creating a Program with Direct Teach
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4.
Tap {Output#} that was added to line number 6 on the Smart Pendant, enter "7", and
then tap {Enter}.
5.
Tap {On} for line number 6 on the Smart Pendant, and select {Off}.
6. Repeat steps 3 to 5 and set line number 7 to "DigitalOut Output#(8) On".
7. Repeat steps 3 to 5 and set line number 8 to "Wait Input#(8) = On".
8. Repeat steps 3 to 5 and set line number 13 to "DigitalOut Output#(8) Off".
9. Repeat steps 3 to 5 and set line number 14 to "DigitalOut Output#(7) On".
10. Repeat steps 3 to 5 and set line number 15 to "Wait Input#(7) = On".
The line numbers at which to add the instructions and the details of those instructions are shown next.
Programming
8.2 Creating a Program with Direct Teach
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8.2 Creating a Program with Direct Teach
This concludes the procedure. Proceed to the next step.
(4) Change the Tool File
The sample program grasps the workpiece and moves it to a different location. For this reason, the tool file with
the information for when the hand is not grasping the workpiece and the tool file with the information for when
the hand is grasping the workpiece must be changed in the program.
Use the following procedure.
1.
Confirm that the following procedure was completed.
(3) Add Instructions to Close and Open the Hand on page 130
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8.2 Creating a Program with Direct Teach
2.
Create the following two tool files.
• Information for when the hand is not grasping the workpiece
• Information for when the hand is grasping the workpiece
Refer to the following section for details on creating a tool file.
7.2 Configuring a Tool File on page 91
Select line number 5 on the Smart Pendant, and tap {GO TO POINT}.
Programming
3.
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8.2 Creating a Program with Direct Teach
4.
Tap the tool number icon on the status bar, select {#1: Tool1}, and then tap {RETEACH}.
The tool number of line number 5 will change to [1].
Information
5.
If the tool numbers are not displayed in the window, tap {
box.
} at the top right and select the {Tool #} check
Repeat steps 3 to 4 and set the tool number on line numbers 9 to 11 to {#1: Tool1}.
This concludes the procedure. Proceed to the next step.
8.2.4
Confirming Operation Step by Step
When creating the program is completed, confirm the operation of the manipulator while stepping through the
created program (operation step by step).
1.
2.
Confirm that nobody is near the manipulator.
3.
Tap {SERVO} on the status bar to turn ON the servo.
Change the mode switch to MANUAL (TEACH) mode, and set the operation mode to
teach mode.
The button will turn green when the servo is turned ON.
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4.
Select line number 2 on the Smart Pendant, and tap {GO TO POINT}.
5.
6.
Confirm that the manipulator moves according to the created program.
Run the program up to line number 5 with steps 4 and 5 to confirm the operation of the
manipulator.
The hand must be opened and closed for line numbers 6 to 8 and 13 to 15. Use the following operation
to open and close the hand.
Programming
8.2 Creating a Program with Direct Teach
8
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8.2 Creating a Program with Direct Teach
7.
Tap {TEST/RUN JOB} at the bottom of the Smart Pendant window, and select {Test}.
8.
Press and hold {TEST START}.
The manipulator will start operation.
The job will start from the line where the cursor was placed. The line can be selected in teach mode.
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9.
Run the program up to the end with steps 5 and 8 to confirm the operation of the
manipulator.
This concludes the procedure.
Running the Created Program
Run the program that was created using direct teach, and confirm that the manipulator moves as expected.
1.
2.
Confirm that nobody is near the manipulator.
3.
Tap {SERVO} on the status bar to turn ON the servo.
Change the mode switch to AUTOMATIC (PLAY) mode, and set the operation mode to
play mode.
The button will turn green when the servo is turned ON.
4.
Tap {TEST/RUN JOB} at the bottom of the Smart Pendant window, and select {Run}.
Programming
8.2.5
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8.2 Creating a Program with Direct Teach
5.
Press and hold {RUN}.
The manipulator will start operation.
The job will start from the line where the cursor was placed. The line can be selected in teach mode.
6.
Confirm that the manipulator moves according to the created program.
Information
140
• While the job is running, press {STOP} or {PAUSE} to stop or pause the job.
• The servo power remains ON when {PAUSE} is pressed, but the servo power is turned OFF when {STOP}
is pressed.
• To cancel {CONTINUOUS}, select {ONE CYCLE} during job playback.
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7.
Press the emergency stop button.
YRC1000
There is an emergency stop button on the YRC1000.
YRC1000micro
There is an emergency stop button on the Smart Pendant.
The emergency stop button on the Smart Pendant can also be
used.
Note:
The YRC1000micro is not equipped with an emergency stop
button.
Confirm that {SERVO} changes back to blue.
A blue {SERVO} means the servo power has been turned OFF.
Programming
8.
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8.2 Creating a Program with Direct Teach
9.
Turn the emergency stop button in the direction of the arrows to reset the emergency
stop.
YRC1000
YRC1000micro
or
10. Turn OFF the main power supply to the robot controller.
YRC1000
YRC1000micro
This concludes the procedure.
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Revision History
Date of
Publication
July 2023
November 2021
Rev. No.
<1>
-
Section
Revised Contents
Front cover
Changed contents
1.2.1
Changed contents of "Components in a Basic Robot System".
1.2.3
Changed contents of "YRC1000 Robot Controller Accessories".
2.1
Changed contents of "Transporting the Manipulator".
2.2.3
Changed contents of "Fixing the Manipulator to the Floor".
2.3
Changed contents of "Transporting the YRC1000 Robot Controller".
4.2.1
Changed contents of "Correcting Alarm 6022 EXTERNAL FORCE ESTIMATION ERROR and Alarm 6004 ESCAPE
FROM CLAMPING ERROR(PFL)".
Chapter 6
Changed contents of "Mounting and Wiring the Hand".
Chapter 8
Changed contents of "Programming".
-
First edition
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MOTOMAN-HC10DTP
Quick Start Guide
Using the Smart Pendant
C 2021 YASKAWA ELECTRIC CORPORATION
Published by YASKAWA
July 2023 21-11
MANUAL NO.
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