Yaskawa Motoman HC20DTP Dust-proof/Drip-proof Quick Start Guide

MOTOMAN-HC20DTP
Dust-Proof/Drip-Proof Specification
Quick Start Guide
Using the Programming Pendant
• Manipulator Type: YR-1-06VXCP20-B00
(Built-In Air Hoses, Ethernet and I/O Cables Specification)
• Applicable Robot Controllers: YRC1000/YRC1000micro
• Programming Pendant Type: JZRCR-APP01-1
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MANUAL NO. 200351-1CD
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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3
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 Programming 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 Programming 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 .............................................................. 53
4.2.1
Correcting Alarm 6022 EXTERNAL FORCE ESTIMATION ERROR and Alarm 6004 ESCAPE
FROM CLAMPING ERROR(PFL).................................................................................................................... 53
4.2.2
Correcting Alarm 4107 OUT OF RANGE(ABSO DATA) ............................................................................... 58
5. Controlling the Manipulator .................................................................................... 63
5.1
Moving the Manipulator ..................................................................................................... 64
5.1.1
Jogging Each Axis (Joint Coordinate System) ............................................................................................... 64
5.1.2
Cartesian Jogging .............................................................................................................................................. 66
5.1.3
Direct Teach ....................................................................................................................................................... 69
6. Mounting and Wiring the Hand .............................................................................. 75
4
6.1
Required Items ................................................................................................................... 76
6.2
Mounting the Hand ............................................................................................................ 77
6.3
Connecting the Air Hoses ................................................................................................. 81
6.4
Connecting the I/O Cables ............................................................................................... 82
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7. Settings ..................................................................................................................... 85
7.1
Temporarily Disabling the Collaborative Operation Function ...................................... 86
7.2
Configuring a Tool File ...................................................................................................... 89
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 ......................................................................................... 102
7.5
Configuring the Speed Limit Function .......................................................................... 106
7.6
Enabling the Collaborative Operation Function ...........................................................111
8. Programming ......................................................................................................... 113
8.1
Explanation of the Sample Program ............................................................................. 114
8.1.1
8.2
Overview .......................................................................................................................................................... 114
Creating a Program with Direct Teach ......................................................................... 115
8.2.1
Creating a Program ........................................................................................................................................ 115
8.2.2
Registering Manipulator Positions in the Program Using Direct Teach .................................................... 117
8.2.3
Adding and Changing Programming............................................................................................................. 122
8.2.4
Confirming Operation Step by Step .............................................................................................................. 133
8.2.5
Running the Created Program ...................................................................................................................... 134
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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-1000-06VXH25-***
−
YRC1000micro
ERBR-100-06VXH12-***
−
Manipulator
YR-1-06VXCP20-B00
Built-in air hoses, Ethernet and I/O cables
specification
Programming pendant
JZRCR-APP01-1
−
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
Manipulator
Manual Name
MOTOMAN-HC20DTP
Instructions
Dust-Proof/Drip-Proof Specification
MOTOMAN-HC20DTP
Maintenance Manual
Dust-Proof/Drip-Proof Specification
MOTOMAN-HC20DTP
Setup Guide
Robot Controller
YRC1000/YRC1000micro
Collaborative Operation Instructions
YRC1000/YRC1000micro
Supplementary Instructions for HC Series
Overview
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
Operator’s Manual
YRC1000/YRC1000micro
Instructions
YRC1000/YRC1000micro
Alarm Codes
(Major Alarms) (Minor Alarms)
*1
1
YRC1000
micro
Describes information about the
manipulator, such as basic specifications, installation, and spare parts.
HW2480394
Describes the maintenance procedures
for the manipulator, such as precautions for inspections and procedures
for replacing parts.
HW2480456
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.
HW2380361
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
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
• Instructions
• Maintenance Manual
• Instructions for Functional Safety
Function
YRC1000/YRC1000micro
YRC1000
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 operating methods and
procedures for the programming
pendant.
RE-CSOA051
RE-CSOA058
RE-CTOA221
RE-CTOA222
RE-CERA600
RE-CERA601
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.
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.
Indicates definitions of difficult terms or terms that have not been previously explained in this manual.
Information Indicates supplemental information to deepen understanding or useful information.
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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.
1
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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 programming 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
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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
1.1 Unpacking the Shipping Crate
1.1
Unpacking the Shipping Crate
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 programing pendant may also be dropped and damaged.
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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.
Programming pendant
Standard component
–
Pendant connection cable
Standard component
–
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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1
1.2 Checking the Received Products
1.2.2
Manipulator Accessories
Purpose
Name
Installing the manipulator
Type/Specifications
Hexagon socket head cap screw
Quantity
M16 (length: 50 mm)
4
M16
4
M16
4
KQ2F06-01N
6
*trivalent chromate*
Spring washer
*stainless steel*
Washer
*stainless steel*
Grease replenishment for the
manipulator
1.2.3
Union
YRC1000 Robot Controller Accessories
1.
Replacement Fuses
Name
10-A fuse
2.
Quantity
Specifications
Type
2
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
Tools for Wiring
Name
Quantity
Type
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
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)
1
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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.
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
Dummy connector (Safety) for short-circuiting the safety signals
1.2.5
1
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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1
1.2 Checking the Received Products
2
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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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2
2.1 Transporting the Manipulator
2.1
Transporting the Manipulator
Mass: 160 kg (including the shipping brackets)
Table 2.1 Required Items
Name
Remarks
Hex key
For removing the shipping brackets.
Torque wrench
For mounting the shipping brackets.
However, this is not necessary because the shipping brackets are mounted to the manipulator
when shipped from the factory.
Hanging tool
Example: Wire or nylon sling.
Be sure to use a hanging tool for a four-wire sling with a length of 2000 mm or longer.
Shipping bracket (4 brackets)
Hexagon socket head cap screw
Included with the manipulator. The manipulator is shipped from the factory with these parts
mounted as the transportation parts.
• M10 (length: 35 mm) (4 screws)
• M8 (length: 20 mm) (4 screws)
• M4 (length: 16 mm) (2 screws)
Spring washer M10 (4 washers)
Washer M10 (4 washers)
Conical spring washer
• M8 (4 washers)
• M4 (2 washers)
When moving the manipulator to another location, such as when changing the production line, set the manipulator to the
following transportation posture.
A
Shipping bracket 1 (type: HW1308958-1)
E
LIGHTLON #510 (single-sided adhesive processing, 50 mm × 90
mm)
Two sheets pasted on top of each other on shipping bracket 4.
B
Shipping bracket 2 (type: HW1308959-1)
F
Hanging tool (for four-wire sling with a length of 2000 mm or
longer)
Continued on next page.
2
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1.1 Transporting the Manipulator
Continued from previous page.
C
Shipping bracket 3 (type: HW1308960-2)
G
Position of the center of gravity
D
Shipping bracket 4 (type: HW2401666-1)
-
-
Table 2.2 Angle and Pulses of Each Axis When Shipped from the Factory
Pulses
Angle
S
0
0°
L
-76585
-20°
U
-186473
-67°
R
0
0°
B
321596
137°
T
0
0°
The transportation parts (shipping brackets, hexagon socket head cap screws, spring
washers, washers, and conical spring washers) are mounted to the manipulator when it
is shipped from the factory. Check again that the hexagon socket head cap screws have
been fastened before transporting the manipulator.
A
Shipping bracket 1 (type: HW1308958-1)
E
• Hexagon socket head cap screw M10 (length: 35
mm) (2 screws)
• Spring washer M10 (2 washers)
• Washer M10 (2 washers)
Tightening torque: 48 N∙m (4.9 kgf∙m)
B
Shipping bracket 2 (type: HW1308959-1)
F
• Hexagon socket head cap screw M8 (length: 20 mm)
(2 screws)
• Conical spring washer M8 (2 washers)
Tightening torque: 24.5 N∙m (2.5 kgf∙m)
C
Shipping bracket 3 (type: HW1308960-2)
G
• Hexagon socket head cap screw M4 (length: 16 mm)
(2 screws)
• Conical spring washer M4 (2 washers)
Tightening torque: 2.8 N∙m (0.29 kgf∙m)
D
Shipping bracket 4 (type: HW2401666-1)
-
-
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2
Transportation and Installation
1.
Axis
2
2.1 Transporting the Manipulator
2.
Pass the hook of the hanging tool through the holes in each of the two places on shipping bracket 1 and shipping bracket 2, hoist the manipulator with a crane, and transport
it to the installation location.
3.
Remove the shipping brackets.
Carefully store the transportation parts (shipping brackets, hexagon socket head cap screws, spring washers,
washers, and conical spring washers) that were removed. The transportation parts are required when moving
and transporting the manipulator again.
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1.2 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
*1
*2
1.2.2
Type/Specifications
Quantity
Hexagon socket head cap screw *trivalent chromate* *1
M16 (length: 50 mm)
4
Spring washer *stainless steel* *1
M16
4
Washer *stainless steel* *1
M16
4
Baseplate *2
A thickness of 40 mm or greater is
recommended.
1
Anchor bolt *2
M16 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.
Transportation and Installation
1.2.1
2
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2
2.2 Installing the Manipulator
Table 2.3 Manipulator Installation Reaction Force/Torque
When Rotating Horizontally
Reaction Force FH
During an emergency stop 4120 N
During acceleration/
deceleration
1.2.3
Torque MH
Reaction Force FV
Torque MV
4591 N∙m
2502 N
6121 N∙m
(420 kgf)
(468 kgf∙m)
(255 kgf)
(624 kgf∙m)
1275 N
1373 N∙m
834 N
2296 N∙m
(130 kgf)
(139 kgf∙m)
(85 kgf)
(234 kgf∙m)
Fixing the Manipulator to the Floor
1.
2.
2
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: 206 N∙m (21 kgf∙m)
A
Hexagon socket head cap screw M16 *trivalent chromate* (length:
50 mm) (4 screws)
D
Manipulator base
B
Spring washer M16 *stainless steel* (4 washers)
E
Baseplate (with a thickness of 40 mm or greater is
recommended)
C
Washer M16 *stainless steel* (4 washers)
F
Anchor bolt (M16 or larger is recommended)
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2.2 Installing the Manipulator
A
B
Reference hole: ϕ12H7
Reamed hole depth: 12
C
Hole for mounting body: ϕ18 (4 places)
–
–
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
1.2.4
Baseplate
Ground wire (5.5 mm2 or larger)
2
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2
1.3 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.
2.
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.
Pass the hanging tool through the eye bolts, hoist the robot controller with a crane, and
transport it to the installation location.
A
2
Remarks
45° or wider
B
Eye bolt M12 (4 bolts)
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1.4 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.
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
M12 (length: 20 mm)
Note:
Select the screws based on a thread length of 14 mm for the
sides of the robot controller.
Fixing bracket
Quantity
4
Hole ϕ14 (2 places)
Plate thickness 6 mm
Remarks
Tightening torque: 45 N∙m
(4.6 kgf∙m)
–
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
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2
2.4 Installing the YRC1000 Robot Controller
Ensure space to open the robot controller door for inspection.
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.
A
3
Front side of robot controller
B
Side of robot controller
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1.5 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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3
1.6 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
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)
3
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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).
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.
Top Side View
Space for Manipulator Cable
Front Side View
Right Side View
Transportation and Installation
Important
2
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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3
2.6 Installing the YRC1000micro Robot Controller
3
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3
Connecting the Robot Controller
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 Programming 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 Programming Pendant .............................................................. 47
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3
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
A
Primary power supply cable
B (6)
Symbol
Name
F (10)
Programming pendant
Robot controller
G
Pendant connection cable
C (1, 2, & 3) Manipulator cables (3 types)
H
Ground wire
D (15)
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)
1
Torque sensor cable (2)
1
Switch/lamp cable (3)
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)
3
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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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3
3.1 Connecting the YRC1000 Robot Controller and Other Devices
3
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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3
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.
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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
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4
3.1 Connecting the YRC1000 Robot Controller and Other Devices
Install a dedicated breaker for the robot controller to the primary power supply.
3.1.3
Connecting the Programming Pendant
Use the cable to connect the robot controller and programming pendant.
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.
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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
A
Primary power supply cable
B (6)
Symbol
Name
F (10)
Programming pendant
Robot controller
G
Pendant connection cable
C (1, 2, & 3) Manipulator cables (3 types)
H
Ground wire
D (15)
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)
1
Torque sensor cable (2)
1
Switch/lamp cable (3)
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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4
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.
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4
3.2 Connecting the YRC1000micro Robot Controller and Other Devices
3.2.2
Connecting the Primary Power Supply
1.
2.
Connect the L-shaped angled plug for the primary power supply to the power supply
connector on the robot controller.
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)
4
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.
Connecting the Programming 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 programming pendant is not used, attach the connector for short-circuiting the programming pendant safety signals to the [-X81] connector on the robot controller. The robot controller will not start if this connector is not attached.
Connecting the Robot Controller
3.2.3
3
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4
3.2 Connecting the YRC1000micro Robot Controller and Other Devices
4
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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
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 ................................................ 53
4.2.1
Correcting Alarm 6022 EXTERNAL FORCE ESTIMATION ERROR and
Alarm 6004 ESCAPE FROM CLAMPING ERROR(PFL) .................................... 53
4.2.2
Correcting Alarm 4107 OUT OF RANGE(ABSO DATA) ................................... 58
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4
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 programming pendant.
It will take approximately three minutes until the window is displayed.
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 programming pendant.
4.2 Corrective Actions for Alarms at Initial Startup on page 53
This concludes the procedure.
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1.1 Turning ON/OFF and Checking the Power Supplies
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 lamp on the manipulator is lit in green.
• A green lit lamp means collaborative operation is enabled. Enabled is the default setting. If the lamp is not
lit, the subsequent operations cannot be performed.
• If the dummy connector is not connected, protective stops and external emergency stops will occur. Connect the dummy connector when the manipulator is stopped. Refer to the following section for details on
the dummy connector.
1.2.4 YRC1000micro Robot Controller Accessories on page 19
2.
Confirm that the mode key on the programming pendant is set to TEACH.
3.
Press [SERVO ON READY] on the programming pendant, and confirm that the [SERVO
ON] lamp is lit in green.
The [SERVO ON] lamp lit in green means the servo power has been turned ON.
Turning ON the Robot Controller Power Supplies
4.1.2
4
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5
4.1 Turning ON/OFF and Checking the Power Supplies
4.
Press the emergency stop button.
YRC1000 & YRC1000micro E-Stop button
The emergency stop button on the programming pendant can also be used.
5.
Confirm that the [SERVO ON] lamp on the programming pendant goes out.
The [SERVO ON] lamp not lit means the servo power has been turned OFF.
6.
Turn the emergency stop button in the direction of the arrows to reset the emergency
stop.
YRC1000 & YRC100micro E-Stop button
This concludes the procedure.
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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
EXTERNAL FORCE ESTIMATION ERROR
• A large force was applied when the power supply to the
robot controller was turned ON.
• 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.
4107
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.
6022
Reference Section
4.2.1 Correcting Alarm
6022 EXTERNAL
FORCE ESTIMATION
ERROR and Alarm 6004
ESCAPE FROM
CLAMPING ERROR
(PFL) on page 53
4.2.2 Correcting Alarm
4107 OUT OF RANGE
(ABSO DATA) on page
58
Escape Operation :
The operation in which the manipulator automatically moves in a safe direction from a clamped state.
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.
If multiple alarms occur, use this procedure to reset both alarm 6022 and alarm 6004 in a single operation.
If an alarm occurs, an alarm window similar to the following will be displayed, and the resume switch will be lit.
Turning ON the Robot Controller Power Supplies
4.2.1
1.
4
Check the axes on which the alarms occurred.
For alarm 6022, write down the axes on which the alarms occurred because these axes will be required
later.
Check the axes on which the alarms occurred with the numeric value of the subcode. Axes with the
subcode value "1" are the axes on which the alarms occurred.
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5
4.2 Corrective Actions for Alarms at Initial Startup
The relationship between subcode and axis is as follows:
Subcode
Relevant Axis
[
0
0
No rele- No relevant
vant
axis
axis
0
0
T-axis
B-axis
_
1
0
0
1
R-axis
U-axis
L-axis
S-axis
]
In the above screenshot, the alarms occurred on the R-axis and S-axis.
2.
Select {RESET} on the programming pendant.
The alarm will be reset.
To change the settings, change the security mode to {SAFETY MODE}. Proceed to the next step.
3.
Select {Main Menu} - {SYSTEM INFO} - {SECURITY} on the programming pendant.
The SECURITY window will be displayed.
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4.2 Corrective Actions for Alarms at Initial Startup
4.
Select {SAFETY MODE} for the mode, enter the password, and select [ENTER].
The default password is "5555555555555555" (enter "5" 16 times).
The security mode will be set to safety mode.
The rest of this procedure is the operation to 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.
Set the home positions of the torque sensors again according to the rest of this procedure to prevent
erroneous detections.
Select {Main Menu} - {SAFETY FUNC.} - {TORQUE SENSOR ORG POS} on the programming pendant.
Turning ON the Robot Controller Power Supplies
5.
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5
4.2 Corrective Actions for Alarms at Initial Startup
6.
Select the axes on which the alarms occurred.
• The home position of the torque sensor will be set again for the axes selected here.
• To select all axes, select {EDIT} at the top of the window - {SELECT ALL AXIS}.
A confirmation window will be displayed.
7.
5
Select {YES}.
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4.2 Corrective Actions for Alarms at Initial Startup
The procedure assumes that {YES} is selected when nothing has been set for the tool information.
If this operation is performed after tool information was set, select {ROBOT} - {TOOL} to display the
TOOL COORDINATE window. Confirm that the tool information is correct, and then select {YES}.
9.
Select {READBACK} - {WRITE}.
A confirmation window will be displayed when transferring and saving the configured data to the robot
controller is completed.
Select {YES}.
Turning ON the Robot Controller Power Supplies
8.
This concludes the procedure.
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5
4.2 Corrective Actions for Alarms at Initial Startup
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.
If an alarm occurs, an alarm window similar to the following will be displayed on the programming pendant.
1.
Select {RESET} on the programming pendant.
The alarm will be reset.
To change the settings, change the security mode to {SAFETY MODE}. Proceed to the next step.
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4.2 Corrective Actions for Alarms at Initial Startup
2.
Select {Main Menu} - {SYSTEM INFO} - {SECURITY} on the programming pendant.
The SECURITY window will be displayed.
3.
Select {SAFETY MODE} for the mode, enter the password, and select [ENTER].
The security mode will be set to safety mode.
The rest of this procedure is the operation to confirm the position of the manipulator.
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.
4.
If the resume switch on the manipulator is lit, press the resume switch to make it not lit.
Turning ON the Robot Controller Power Supplies
The default password is "5555555555555555" (enter "5" 16 times).
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5
4.2 Corrective Actions for Alarms at Initial Startup
6
5.
Select {Main Menu} - {ROBOT} - {SECOND HOME POS} on the programming pendant.
6.
Confirm that the mode key on the programming pendant is set to TEACH, and press
[SERVO ON READY].
The servo power will be turned ON, and the [SERVO ON] lamp will be lit in green.
7.
If "ALARM 4511 OUT OF RANGE(DROP-VALUE)" is displayed, first press {RESET}, and
then press [SERVO ON READY] on the programming pendant to turn ON the servo
power again.
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4.2 Corrective Actions for Alarms at Initial Startup
8.
Press and hold [FWD] while the [SERVO ON] lamp is lit on the programming pendant.
While [FWD] is pressed and held, the manipulator will move to the second home position posture.
The second home position posture is shown below.
The manipulator will automatically stop at the second home position posture, and it will no longer
move even if [FWD] is pressed.
Confirm that the manipulator stopped at the second home position posture, and then
select {DATA} - {CONFIRM POSITION} on the programming pendant.
Turning ON the Robot Controller Power Supplies
9.
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6
4.2 Corrective Actions for Alarms at Initial Startup
10. Confirm that the "Home position checked" confirmation message was displayed.
This concludes the procedure.
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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 ........................................................................................... 64
5.1.1
Jogging Each Axis (Joint Coordinate System) .................................................. 64
5.1.2
Cartesian Jogging..................................................................................................... 66
5.1.3
Direct Teach ............................................................................................................... 69
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6
5.1 Moving the Manipulator
5.1
Moving the Manipulator
This section describes the basic operations to move the manipulator.
Operation
Reference Section
Jogging Each Axis (Joint CoordiThe operation to move each axis of the manipulator independently.
nate System)
5.1.1 Jogging Each Axis
(Joint Coordinate System) on
page 64
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 Cartesian Jogging on
page 66
Cartesian Jogging
Direct Teach
5.1.1
Description
The operation to manually move the manipulator to the desired position and store that position.
The manipulator achieves continuous motion by moving between the
recorded positions.
5.1.3 Direct Teach on page
69
Jogging Each Axis (Joint Coordinate System)
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 LED is lit in green.
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.
6
Set the mode key on the programming pendant to TEACH.
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5.1 Moving the Manipulator
3.
Press [SERVO ON READY].
The [SERVO ON] lamp will be lit in green and the servo power will be turned ON.
4.
Press [TOOL SEL COORD] until the icon on the window changes to the joint coordinates system icon.
5.
Press MANUAL SPEED [FAST] or [SLOW] to change the speed at which the manipulator
moves as required.
Controlling the Manipulator
Selecting medium speed at first is recommended to make it easier to check the movement of the manipulator.
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6
5.1 Moving the Manipulator
6.
Press the axis keys on the programming pendant, and confirm the manipulator axis
moves that corresponds to the pressed key.
This concludes the procedure.
5.1.2
Cartesian Jogging
The operation to move in parallel to the X-axis, Y-axis, and Z-axis that are defined based on the manipulator.
Use the following procedure.
1.
Confirm that the collaborative operation LED is lit in green.
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
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5.1 Moving the Manipulator
2.
Set the mode key on the programming pendant to TEACH.
3.
Press [SERVO ON READY].
The [SERVO ON] lamp will be lit in green and the servo power will be turned ON.
Press [TOOL SEL COORD] until the icon on the window changes to the Cartesian coordinates system icon.
5.
Press MANUAL SPEED [FAST] or [SLOW] to change the speed at which the manipulator
moves as required.
Controlling the Manipulator
4.
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6
5.1 Moving the Manipulator
Selecting medium speed at first is recommended to make it easier to check the movement of the manipulator.
6.
Press the axis keys on the programming pendant, and confirm the manipulator moves
in the direction that corresponds to the pressed key.
• X-Axis, Y-Axis, and Z-Axis Directions That Are Defined Based on the Manipulator
• Relationship between Programming Pendant Axis Keys and Manipulator Movement
The illustration on the left is the view from directly above the manipulator.
This concludes the procedure.
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5.1 Moving the Manipulator
Direct Teach
Direct teach is the operation to manually move the manipulator to the desired position and store that position.
Use the following procedure.
1.
Confirm that the collaborative operation LED is lit in green.
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.
Set the mode key on the programming pendant to TEACH.
3.
Press MANUAL SPEED [FAST] or [SLOW] to change the speed at which the manipulator
moves as required.
Controlling the Manipulator
5.1.3
Selecting high speed is recommended to make it easier to move the manipulator.
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6
5.1 Moving the Manipulator
7
4.
Select {EASY}.
5.
Move the switch to {Hand Guiding Settings}.
6.
Press {MODE} until the manipulator operation mode changes to the mode to select.
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5.1 Moving the Manipulator
Details on the operation modes are shown below. The axes that can be moved are displayed in green.
The displayed changes each time {MODE} is pressed.
Operation Mode
Description
Icon
The TCP moves while the manipulator is fixed in the tool posture.
XYZ + Tool
RBT
Only the R-axis, B-axis, and T-axis move.
JOINT
Each axis moves.
Move the {Turn Hand Guiding On/Off} switch to {ON}.
Controlling the Manipulator
7.
The tool rotates according to the external force torque applied to the
T-axis.
Direct teach mode will be enabled.
The maximum speed at which the robot can be moved during direct teach is limited to the manual speed during teach mode that is currently set.
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7
5
5.1 Moving the Manipulator
8.
Press [SERVO ON READY] on the programming pendant.
The [SERVO ON] lamp will be lit in green and the servo power will be turned ON.
When using direct teach, the servo ON state will be maintained even if the enable switch on the back of the
programming pendant is not squeezed.
9.
Select {Main Menu} - {JOB} - {CREATE NEW JOB}.
The NEW JOB CREATE window will be displayed.
10. Enter the job name and select {EXECUTE}.
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5.1 Moving the Manipulator
11. Confirm that the manipulator can be manually moved while the [MOVE] button on the
manipulator is pressed.
12. While the [MOVE] button on the manipulator is pressed, manually move the arm of the
manipulator to the location to be taught.
If the arm speed feels fast, tap (double-click) the [MOVE] button twice, 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.
13. Release the [MOVE] button on the manipulator.
14. Press the [TEACH] button on the manipulator.
The position of the manipulator will be saved when the [TEACH] button is pressed.
The saved content will be displayed on the programming pendant. The step number will be automatically added.
15. 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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5.1 Moving the Manipulator
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6
Mounting and Wiring the Hand
6.1
Required Items .......................................................................................................... 76
6.2
Mounting the Hand ................................................................................................... 77
6.3
Connecting the Air Hoses ....................................................................................... 81
6.4
Connecting the I/O Cables ...................................................................................... 82
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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
7
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 (Joint Coordinate System) on page 64
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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7
6.2 Mounting the Hand
5.
6.
7
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.
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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6.2 Mounting the Hand
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.
8
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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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:
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
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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6.4 Connecting the I/O Cables
Mounting and Wiring the Hand
YRC1000 Diagram
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8
6.4 Connecting the I/O Cables
YRC1000micro Diagram
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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 ....................... 86
7.2
Configuring a Tool File ............................................................................................ 89
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 .............................................................................. 102
7.5
Configuring the Speed Limit Function .............................................................. 106
7.6
Enabling the Collaborative Operation Function .............................................. 111
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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.
1.
Select {Main Menu} - {SYSTEM INFO} - {SECURITY} on the programming pendant.
The SECURITY window will be displayed.
2.
Select {SAFETY MODE} for the mode, enter the password, and select [ENTER].
The default password is "5555555555555555" (enter "5" 16 times).
The security mode will be set to safety mode.
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7.1 Temporarily Disabling the Collaborative Operation Function
3.
Select {Main Menu} - {SAFETY FUNC.} - {SAFETY LOGIC CIRCUIT}.
The SAFETY LOGIC CIRCUIT window will be displayed.
4.
To the left of line 1 "FSBIN01", select the blank, change this item to "NOT", and then
select {WRITE}.
5.
Confirm that there are no mistakes in the safety logic circuit, and then select {CONFIRM} and {YES}.
6.
Confirm that the collaborative operation lamp on the manipulator is not lit.
Settings
If alarm 6003 "UNDEFINED SPEED LIMIT(PFL)" is displayed, press {RESET} to reset the alarm.
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7.1 Temporarily Disabling the Collaborative Operation Function
7.
Confirm that the right side of {MS-OUT54} in the {OUTPUT} column is "○".
The following table gives the details of the MS-OUT54 output signal.
Signal Name
Description
Enables and disables collaborative operation
MS-OUT54
• ○ = OFF: Collaborative operation disabled
• ● = ON: Collaborative operation enabled
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°.
Use the following procedure to configure a tool file.
1.
Confirm that the workpiece is at hand.
Prepare the workpiece in advance because it will be used in the rest of this procedure.
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 86
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.
Settings
7.2
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7.2 Configuring a Tool File
3.
Select {Main Menu} - {ROBOT} - {TOOL} on the programming pendant.
The TOOL COORDINATE window will be displayed.
4.
Move the cursor to {00} under the {TOOL COORDINATE NO.} column, and press
[SELECT].
Data can be set in a maximum of 64 tool files. Information can be freely set in any tool file. Tool coordinates
number 00 is selected here to make the procedure easier to understand.
The TOOL COORDINATE window for tool coordinates number 00 will be displayed.
5.
9
Select {UTILITY} - {W.GRAV.POS MEASURE}.
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7.2 Configuring a Tool File
The W.GRAV.POS MEASURE window will be displayed.
6.
Press [SERVO ON READY] on the programming pendant, and confirm that the [SERVO
ON] lamp flashes green.
When the collaborative operation function is enabled, the [SERVO ON] lamp is lit when [SERVO ON
READY] is pressed. The [SERVO ON] lamp flashes here because the collaborative operation function is
temporarily disabled for the configuration procedure.
7.
While squeezing the enable switch on the back of the programming pendant with the
left hand (the [SERVO ON] lamp is lit on the programming pendant), press and hold
[FWD] until the manipulator stops.
The enable switch will turn OFF the servo if squeezed too firmly (when the [SERVO ON] lamp is not lit).
While [FWD] is pressed and held, the manipulator will move to the reference position to start
measurements.
The manipulator will automatically stop at the reference position to start measurements, and it will no
longer move even if [FWD] is pressed.
When the manipulator stops moving, press and hold [FWD] again while squeezing the
enable switch with the left hand.
The manipulator will move and the mass and position of the center of gravity measurements will start.
Press and hold [FWD] until the measurements are completed. It will take approximately three minutes
until the automatic measurements for all axes are completed.
The measurements will be canceled if [FWD] is released during the measurements (before the items change to
"●"). Redo the procedure from step 5.
Settings
8.
When the measurements are completed, the programming pendant will display "●" for all items. The
measurement results will also be displayed.
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9
7.2 Configuring a Tool File
Next, the inertia measurements will be taken. Proceed to the next step.
If the moment of inertia around the position of the center of gravity is sufficiently small in regard to the moment
of inertia found from the mass and position of the center of gravity, the measurements do not need to be taken.
However, if the moment of inertia of the tool itself is large (as a general rule, the external dimensions of the
tool are double the distance from the flange to the position of the center of gravity or larger), take the
measurements.
Example of When Measurements Are
Unnecessary
Measuring the moment of inertia around the position
of the center of gravity is not necessary because the
external dimensions of the tool are not large.
Example of When Measurements Are
Necessary
Measuring the moment of inertia around the position
of the center of gravity is necessary because the external dimensions of the tool are large.
Inertia :
Term
Also called moment of inertia. The moment of inertia is the amount of force required to rotate and stop an
object.
For example, a heavy tool with large dimensions will have a large amount of inertia, so a large force will be
required when the manipulator starts and stops moving the axis.
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7.2 Configuring a Tool File
9.
Press [SERVO ON READY] on the programming pendant, and confirm that the [SERVO
ON] lamp flashes green.
10. While squeezing the enable switch on the back of the programming pendant with the
left hand, press and hold [FWD] until the manipulator stops.
While [FWD] is pressed and held, the manipulator will move to reference position 1 to start
measurements.
The manipulator will automatically stop at the reference position to start measurements, and it will no
longer move even if [FWD] is pressed.
11. When the manipulator stops moving, press and hold [FWD] again while squeezing the
enable switch with the left hand.
The manipulator will move and the measurements of the inertia of B-axis 1 and B-axis 2 will start.
Press and hold [FWD] until the measurements are completed.
The measurements will be canceled if [FWD] is released during the measurements (before the items change to
"●"). Redo the procedure from step 9.
Settings
When the measurements are completed, the programming pendant will display "●" for the items. The
measurement results will also be displayed.
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9
7.2 Configuring a Tool File
12. While squeezing the enable switch on the back of the programming pendant with the
left hand, press and hold [FWD] until the manipulator stops.
While [FWD] is pressed and held, the manipulator will move to reference position 2 to start
measurements.
The manipulator will automatically stop at the reference position to start measurements, and it will no
longer move even if [FWD] is pressed.
13. When the manipulator stops moving, press and hold [FWD] again while squeezing the
enable switch with the left hand.
The manipulator will move and the measurements of the inertia of the T-axis will start. Press and hold
[FWD] until the measurements are completed.
The measurements will be canceled if [FWD] is released during the measurements (before the items change to
"●"). Redo the procedure from step 12.
When the measurements are completed, the programming pendant will display "●" for the items. The
measurement results will also be displayed.
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7.2 Configuring a Tool File
14. Select {REGISTER}, and select {YES} on the confirmation window.
The measurement results will be written to the robot controller.
Settings
Select {CANCEL} to display the TOOL window without registering the measurement data to the tool file.
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7.2 Configuring a Tool File
15. Select {READBACK} - {WRITE} - {YES} on the confirmation window.
The measurement data will be registered in the tool file.
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 programming 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.
This concludes only the procedure to register the information for the hand without a workpiece 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.
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7.2 Configuring a Tool File
16. Select {PAGE}.
The tool coordinates number of coordinates number 01 will be displayed.
17. 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.
18. When tool file configuration is completed, remove the workpiece from the hand.
Settings
This concludes the procedure.
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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.
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 on the monitor 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 on the monitor window 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
72.0 N·m
96.0 N·m
48.0 N·m
27.0 N·m
12.0 N·m
12.0 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 External Force Monitor window with the manipulator set to the same posture and with the same load, record the torque values by external force of each axis on the
right side of the window, 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.
9
Select {Main Menu} - {SAFETY FUNC.} - {ForceMonitor} on the programming pendant.
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
2.
Select {External Force}, 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.
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.
Press [SHIFT] and [TOOL SEL COORD] on the programming pendant at the same time.
2.
Use the cursor keys to place the cursor on tool number 0.
Select the tool file for the tool that is currently installed. In this example, tool number 0 is selected because
the tool file for the currently installed tool is set to tool number 0.
Settings
7.3.2
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
3.
Select {Main Menu} - {SAFETY FUNC.} - {TORQUE SENSOR ORG POS} on the programming pendant.
4.
Select {EDIT} - {SELECT ALL AXIS}.
A confirmation window will be displayed.
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7.3 Checking the Home Positions of the Torque Sensors and Setting the Home Positions Again
5.
Select {YES}.
To check the contents of the tool information that was set, select {ROBOT} - {TOOL}, and select tool number 0 on the TOOL NO. SELECT window. Confirm that the tool information is correct, and then select
{YES}.
6.
Select {READBACK} - {WRITE}.
A confirmation window will be displayed when transferring and saving the configured data to the robot
controller is completed.
Select {YES}.
Settings
7.
7
This concludes the procedure.
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101
7.4 Setting External Force Limits
7.4
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.
Use the following procedure to configure the external force limits that stop the manipulator.
This example shows the procedure to set external force limit 90 N in file number 2.
1.
Select {Main Menu} - {SAFETY FUNC.} - {EXTERNAL FORCE LIMIT} on the programming
pendant.
2.
Select the file number of the external force limit to set.
3.
Enter {COMMENT}.
When selected, the text entry window will be displayed for the comment. Touch {Enter} to confirm the
entered comment and return to the previous window.
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7.4 Setting External Force Limits
The content that was entered here will be displayed on the external force limit file selection window
(from step 2). A comment that briefly describes the setting is recommended.
Set {LIMIT(TCP)}.
Settings
4.
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7.4 Setting External Force Limits
5.
Select {READBACK} - {WRITE}.
If {READBACK} is not displayed, one of the previous settings was not configured. Check the settings.
6.
7.
A confirmation window will be displayed when transferring and saving the configured data to the robot
controller is completed.
Select {YES}.
Select {CONFIRM}.
{FILE SET STATUS} will change from "CONFIRMING" to "COMPLETED", and the setting will be
applied to the CPU in the robot controller.
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7.4 Setting External Force Limits
8.
Confirm that {FILE SET STATUS} is "COMPLETED".
The labels displayed in {FILE SET STATUS} and the meanings are shown below.
Label
9.
Description
SETTING
Immediately after initialization or the data is being set.
CONFIRMING
{WRITE} was pressed after the data was set and the data was transferred to the robot
controller.
COMPLETED
{CONFIRM} was pressed after the external force limit was confirmed.
To set multiple external force limits, return to step 2 and repeat the settings.
Up to 32 external force limits can be set, but keep the number of valid files to five or less. Six or more files can
be valid at the same time, but the external force judgments may take more time than normal.
If all external force monitor files are invalid, the external force monitor function will be disabled.
Settings
This concludes the procedure.
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105
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).
TCP speed 250 mm/s is the default setting.
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.
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.
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.
Speed limit
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 TCP speed 100 mm/s in file number 30.
1.
106
Select {Main Menu} - {SAFETY FUNC.} - {SPEED LIMIT} on the programming pendant.
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7.5 Configuring the Speed Limit Function
2.
Select the speed limit file number to set.
3.
Enter {COMMENT}.
When selected, the text entry window will be displayed for the comment. Touch {Enter} to confirm the
entered comment and return to the previous window.
Settings
The content that was entered here will be displayed on the speed limit file selection window (from step
2). A comment that briefly describes the setting is recommended.
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7.5 Configuring the Speed Limit Function
108
4.
Set {LIMIT SPEED}.
5.
Set {DETECTION DELAY TIME} as required.
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7.5 Configuring the Speed Limit Function
6.
Set {FILE VALID COND} to "VALID".
7.
Select {READBACK} - {WRITE}.
If {READBACK} is not displayed, one of the previous settings was not configured. Check the settings.
A confirmation window will be displayed when transferring and saving the configured data to the robot
controller is completed.
Select {YES}.
Settings
8.
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7.5 Configuring the Speed Limit Function
9.
Confirm that the configured file is valid.
This concludes the procedure.
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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 89" to "7.5 Configuring the Speed Limit Function on page 106" is completed, the collaborative operation
function must be enabled.
Use the following procedure to enable the collaborative operation function.
1.
Select {Main Menu} - {SAFETY FUNC.} - {SAFETY LOGIC CIRCUIT}.
The SAFETY LOGIC CIRCUIT window will be displayed.
2.
To the left of line 1 "FSBIN01", select "NOT", make this item blank, and then select
{WRITE}.
3.
Confirm that there are no mistakes in the safety logic circuit, and then select {CONFIRM} and {YES}.
Settings
7.6
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7.6 Enabling the Collaborative Operation Function
4.
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
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.
5.1.1 Jogging Each Axis (Joint Coordinate System) on page 64
5.
Confirm that the right side of {MS-OUT54} in the {OUTPUT} column is "●".
The following table gives the details of the MS-OUT54 output signal.
Signal Name
Description
Enables and disables collaborative operation
MS-OUT54
• ○ = OFF: Collaborative operation disabled
• ● = ON: Collaborative operation enabled
This concludes the procedure.
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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 .................................................................. 114
8.1.1
8.2
Overview .................................................................................................................. 114
Creating a Program with Direct Teach ............................................................... 115
8.2.1
Creating a Program................................................................................................ 115
8.2.2
Registering Manipulator Positions in the Program Using Direct
Teach......................................................................................................................... 117
8.2.3
Adding and Changing Programming................................................................. 122
8.2.4
Confirming Operation Step by Step ................................................................... 133
8.2.5
Running the Created Program ............................................................................ 134
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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 82
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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
Programming pendant
8.2.1 Creating a Program on page
115
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 117
3
Adding and Changing Programming
Programming pendant
8.2.3 Adding and Changing Programming on page 122
4
Confirming Operation Step by Step
Programming pendant
8.2.4 Confirming Operation Step by
Step on page 133
5
Running the Created Program
Programming pendant
8.2.5 Running the Created Program
on page 134
Creating a Program
To use direct teach, a program must be created (job registered) in advance.
The program that moves the robot is called a job.
1.
Confirm that the collaborative operation LED is lit in green.
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.
Set the mode key on the programming pendant to TEACH.
Programming
8.2.1
Task
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8.2 Creating a Program with Direct Teach
3.
Select {Main Menu} - {JOB} - {CREATE NEW JOB} on the programming pendant.
The NEW JOB CREATE window will be displayed.
4.
Press [SELECT] on the programming pendant.
5.
Touch the programming pendant screen, enter the name of the job, and touch {Enter}.
The NEW JOB CREATE window will be displayed again.
6.
Confirm {JOB NAME}, and press [ENTER].
{COMMENT}, {JOB FOLDER}, and {GROUP SET} can also be set, but the job will be registered with the
default settings here.
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8.2 Creating a Program with Direct Teach
The JOB CONTENT window will be displayed.
7.
Confirm that the job name that was registered is displayed.
When a job is created, the following two instructions are automatically inserted into the job.
• NOP: The first instruction of the program (start instruction).
• END: The last instruction of the program (end instruction).
This concludes the procedure. Proceed to the next step.
Registering Manipulator Positions in the Program Using Direct
Teach
Register the manipulator positions in the program using direct teach.
1.
Confirm that the following procedure was completed.
8.2.1 Creating a Program on page 115
Programming
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8.2 Creating a Program with Direct Teach
2.
Confirm again that the collaborative operation LED is lit in green and the mode key on
the programming pendant is set to TEACH.
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
11
3.
Select {EASY}.
4.
Move the switch to {Hand Guiding Settings}.
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8.2 Creating a Program with Direct Teach
5.
Press {MODE} until {HAND GUIDING} becomes {XYZ + TOOL}.
6.
Set {Turn Hand Guiding On/Off} to {ON}.
Direct teach mode will be enabled.
The maximum speed at which the manipulator can be moved during direct teach is limited to the manual
speed during teach mode that is currently set.
Press [SERVO ON READY] on the programming pendant.
The [SERVO ON] lamp will be lit in green and the servo power will be turned ON.
When using direct teach, the servo ON state will be maintained even if the enable switch on the back of the
programming pendant is not squeezed.
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Programming
7.
8
8.2 Creating a Program with Direct Teach
8.
While the [MOVE] button on the manipulator is pressed, move the manipulator to position (1).
If the arm speed feels fast, tap (double-click) the [MOVE] button twice, 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.
9. Release the [MOVE] button on the manipulator.
10. Press the [TEACH] button on the manipulator.
The position of the manipulator will be registered as step 1 when the [TEACH] button is pressed.
"MOVJ VJ=0.78" will be displayed because the position is registered with the default instruction and speed.
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8.2 Creating a Program with Direct Teach
11. While the [MOVE] button on the manipulator is pressed, move the manipulator from
position (1) to position (2).
12. Release the [MOVE] button on the manipulator.
13. Press the [TEACH] button on the manipulator.
The position of the manipulator will be registered as step 2 when the [TEACH] button is pressed.
14. Repeat steps 11 to 13 and register positions (3) to (10) in the program.
Programming
The step 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.
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8.2 Creating a Program with Direct Teach
Manipulator Position
Step
Description of Position
(1)
0001
Start job position
(2)
0002
Above grasp workpiece position
(3)
0003
Grasp workpiece position
(4)
0004
Grasp workpiece position
(5)
0005
Above grasp workpiece position
(6)
0006
Above release workpiece position
(7)
0007
Release workpiece position
(8)
0008
Release workpiece position
(9)
0009
Above release workpiece position
(10)
0010
End job position
The motion and speed of the manipulator, 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.
8.2.3
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.
Operation
Reference Section
Set the Start Job Position (Step 1) and End Job Position (Step 10) to
the Same Location
(1) Set the Start Job Position (Step 1) and End Job Position
(Step 10) to the Same Location on page 122
Change the Motion and Speed of the Manipulator
(2) Change the Motion and Speed of the Manipulator on page
124
Add Instructions to Close and Open the Hand
(3) Add Instructions to Close and Open the Hand on page 128
Change the Tool File
(4) Change the Tool File on page 131
(1) Set the Start Job Position (Step 1) and End Job Position (Step 10) to
the Same Location
Setting the same position for the start job position (step 1) and end job position (step 10) is recommended.
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8.2 Creating a Program with Direct Teach
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 (step 1) and
end job position (step 10) 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 117
2.
Move the cursor to step 1 by pressing the cursor keys on the programming pendant,
and confirm the cursor is flashing.
If the cursor is not flashing, the manipulator is at the step 1 position. Proceed to the step 4.
3.
Press [SERVO ON READY], and press and hold [FWD] while the [SERVO ON] lamp is lit.
Press and hold [FWD] until the step 1 cursor changes from flashing to solid.
Programming
If the movement speed seems slow or fast, press MANUAL SPEED [FAST] or [SLOW] to change the speed
at which the manipulator moves.
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8.2 Creating a Program with Direct Teach
4.
Move the cursor to step 10 by pressing the cursor keys on the programming pendant.
5.
Press [MODIFY] - [ENTER] on the programming pendant.
The position of step 10 will be set to the same position as step 1.
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 MOVJ instruction at the set
speed.
The program described in this manual uses the MOVL instruction and MOVJ instruction depending on the position where the manipulator moves. The differences between these instructions are described below.
Instruction
Manipulator Path
MOVL
The manipulator moves along a linear path.
MOVJ
The path of the manipulator is not limited to a straight line.
The sample program uses the MOVL instruction for the steps before and after the motion to close and open the
hand. The sample program uses the MOVJ instruction for all other steps.
To recreate the sample program, change the instructions and speeds. Use the following procedure.
1.
Confirm that the following procedure was completed.
8.2.2 Registering Manipulator Positions in the Program Using Direct Teach on page 117
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8.2 Creating a Program with Direct Teach
2.
Move the cursor to the instruction on step 1 by pressing the cursor keys on the programming pendant.
3.
Press [SELECT].
The cursor will be displayed in the instruction area.
Press [SHIFT] and the cursor key at the same time.
The instruction will change as follows each time the cursor key is pressed.
MOVJ → MOVL → MOVC → MOVS → (pattern repeats)
Programming
4.
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8.2 Creating a Program with Direct Teach
5.
126
When the instruction changes to "MOVJ", press the right cursor key.
The cursor will be displayed in the numeric value area.
6.
Press [SELECT], enter "10.00" for the speed with the number buttons, and then touch
{Enter}.
7.
Confirm the instruction and numeric value, and then press [ENTER].
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8.2 Creating a Program with Direct Teach
8.
Confirm that the instruction and speed for step 1 have changed.
9.
Repeat steps 2 to 8 and change the following instructions and speeds as shown in the
table.
Manipulator Position
Step
Description of Position
0001
MOVJ VJ=10.00
(2)
0002
MOVJ VJ=25.00
(3)
0003
MOVL V=100.0
(4)
0004
MOVL V=100.0
(5)
0005
MOVL V=100.0
(6)
0006
MOVJ VJ=25.00
(7)
0007
MOVL V=100.0
(8)
0008
MOVL V=100.0
(9)
0009
MOVL V=100.0
(10)
0010
MOVJ VJ=25.00
Programming
(1)
This concludes the procedure. Proceed to the next step.
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8.2 Creating a Program with Direct Teach
(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.
The descriptions here assume the hand has been installed and wired as described in the following section.
6 Mounting and Wiring the Hand on page 75
• Close the Hand
Instruction
DOUT OT#(7) OFF
DOUT OT#(8) ON
Description
Turns OFF output signal #7.
OT#(7) on the manipulator is the open fingers signal.
Turns ON output signal #8.
OT#(8) on the manipulator is the close fingers signal.
Waits until input signal #8 is turned ON.
WAIT IN#(8)=ON
IN#(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
DOUT OT#(8) OFF
DOUT OT#(7) ON
Description
Turns OFF output signal #8.
OT#(8) on the manipulator is the close fingers signal.
Turns ON output signal #7.
OT#(7) on the manipulator is the open fingers signal.
Waits until input signal #7 is turned ON.
WAIT IN#(7)=ON
IN#(7) on the manipulator is the auto switch output (fingers opened) signal. This signal provides confirmation of the hand opened sensor.
Use the following procedure.
1.
Confirm that the following procedure was completed.
(2) Change the Motion and Speed of the Manipulator on page 124
First, the procedure to add the DOUT instruction to close the hand at position (4) will be described.
2.
Move the cursor to line number 0004 by pressing the cursor keys on the programming
pendant, and confirm the cursor is not flashing.
The instruction will be added to the line below the cursor position. Place the cursor on line number 0004
here.
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3.
Press [INFORM LIST] on the programming pendant, and touch {IN/OUT} - {DOUT} on the
window.
"DOUT" will be displayed at the bottom of the window.
Move the cursor to "#(1)" with the cursor keys on the programming pendant, enter "7",
and touch {Enter}.
Programming
4.
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8.2 Creating a Program with Direct Teach
5.
Move the cursor to "ON" with the cursor keys on the programming pendant, and press
[SELECT] to toggle ON/OFF.
6.
Press [INSERT] - [ENTER] on the programming pendant.
The DOUT instruction will be added to line number 0005.
7.
Repeat steps 2 to 6 and add/set the rest of the instructions.
The line numbers at which to add the instructions and the details of those instructions are shown next.
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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 128
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 89
Press the cursor keys on the programming pendant to place the cursor on the step with
the tool number to change.
Place the cursor on step 1 here because the tool number of step 1 will be changed from 01 to 00.
Programming
3.
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8.2 Creating a Program with Direct Teach
If the tool number column is not displayed, touch {DISPLAY} - {ENABLE TOOL NO}.
4.
Press [SERVO ON READY], and press and hold [FWD] while the [SERVO ON] lamp is lit.
Press and hold [FWD] until the step 1 cursor changes from flashing to solid.
5.
Press [SHIFT] + [TOOL SEL COORD] to display the TOOL NO. SELECT window, and
place the cursor on the tool number to change.
6.
Press [MODIFY] and [ENTER] at the same time.
The tool number of the program will be changed.
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8.2 Creating a Program with Direct Teach
7.
Repeat steps 3 to 6 and change the tool numbers as shown in the table.
Manipulator Position
Step
Tool No.
(1)
0001
00
(2)
0002
00
(3)
0003
00
(4)
0004
01
(5)
0005
01
(6)
0006
01
(7)
0007
01
(8)
0008
00
(9)
0009
00
(10)
0010
00
This concludes the procedure. Proceed to the next step.
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.
Set the mode key on the programming pendant to TEACH.
Move the cursor on the programming pendant window to the first line (line number
0000) of the program that was created.
Programming
8.2.4
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8.2 Creating a Program with Direct Teach
4.
Press [SERVO ON READY].
The [SERVO ON] lamp will be lit in green and the servo power will be turned ON.
5.
Press and hold [FWD].
The manipulator will move according to the programmed content on the line number of the cursor.
6.
7.
Confirm that the manipulator moves according to the created program.
8.
While pressing [INTERLOCK] on the programming pendant, press [FWD].
9.
Run the program up to the end with steps 5 and 8 to confirm the operation of the
manipulator.
Run the program up to line number 0004 with steps 5 and 6 to confirm the operation of
the manipulator.
The hand must be opened and closed for line numbers 0005 to 0007 and 0012 to 0014. Use the following operation to open and close the hand.
This concludes the procedure.
8.2.5
Running the Created Program
When confirming the operation of the manipulator is completed with step operation, run the program that was
created for one cycle, and confirm that the manipulator moves as expected.
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8.2 Creating a Program with Direct Teach
1.
2.
Confirm that nobody is near the manipulator.
3.
Touch {JOB} - {CYCLE} on the programming pendant, and press [SELECT].
4.
Use the cursor keys to place the cursor on "CYCLE", and press [SELECT].
5.
Confirm that the icon on the programming pendant window changed to "CYCLE".
Programming
Move the cursor on the programming pendant window to the first line (line number
0000) of the program that was created.
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8.2 Creating a Program with Direct Teach
6.
Set the mode key on the programming pendant to PLAY.
7.
Press [SERVO ON READY].
The [SERVO ON] lamp will be lit in green and the servo power will be turned ON.
8.
Press the start button.
The start button will be lit, and the manipulator will start operation.
9. Confirm that the manipulator moves according to the created program.
10. Press the emergency stop button.
YRC1000 & YRC1000micro E-Stop button
There is an emergency stop button on the programming pendant.
Continued on next page.
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8.2 Creating a Program with Direct Teach
Continued from previous page.
11. Confirm that the [SERVO ON] lamp on the programming pendant goes out.
The [SERVO ON] lamp not lit means the servo power has been turned OFF.
12. Turn the emergency stop button in the direction of the arrows to reset the emergency
stop.
YRC1000 & YRC1000micro E-Stop button
13. Turn OFF the main power supply to the robot controller.
YRC1000
YRC1000micro
Programming
This concludes the procedure.
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MOTOMAN-HC20DTP
Dust-Proof/Drip-Proof Specification
Quick Start Guide
Using the Programming Pendant
C 2024 YASKAWA ELECTRIC CORPORATION
Published by YASKAWA
November 2024 21-12
MANUAL NO.
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