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Yamaha YK120X, YK180X owner manual Chapter, Using the Robot Safely

Models: YK120X YK180X

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CHAPTER 1

CHAPTER 1

Using the Robot Safely

1	Safety Information	1-1
2	Essential Caution Items	1-2
3	Special Training for Industrial Robot Operation	1-10
4	Robot Safety Functions	1-11
5	Safety Measures for the System	1-12
6	Trial Operation	1-13
7	Work Within the Safeguard Enclosure	1-14
8	Automatic Operation	1-15
9	Adjustment and Inspection	1-15
10	Repair and Modification	1-15
11	Warranty	1-16
12	CE Marking	1-18

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Yamaha YK120X, YK180X owner manual Chapter, Using the Robot Safely

Contents

OWNERS MANUAL Page Error messages issued when robot & controller are connected RCX142 Before using the robot Be sure to read the following notes1. Absolute Reset 2. Setting the standard coordinates3 Connection to the controller 2 Caution when turning off the robot controllerIM Company Introduction2. Suction couplers have been added. See section 6 in chapter Clean Room Models YK120XC, YK150XC1. Robot parameter has been changed. See section 4 in chapter CHAPTER CHAPTER 1 Using the Robot SafelyInstallation CHAPTER 2 FunctionsCHAPTER 4 Adjustment CHAPTER SpecificationsPeriodic Inspecition Increasing the robot operating speedMEMO CHAPTER Using the Robot SafelyMEMO DANGER 1 Safety InformationFig. 1-2 Warning label 2 Essential Caution Items1 Observe the following cautions during automatic operation Fig. 1-1 Warning labelRead owners manual and all warning labels before operation 3 Follow the instructions on warning labels and in this manualFig. 1-3 Warning label 7 Provide safety measures for end effector gripper, etc 6 Use caution when releasing the Z-axis vertical axis brake13Use the following caution during inspection of controller 12Cautions for removing Z-axis brake or Z-axis motor17Do not remove, alter or stain the warning labels 15Use caution not to touch the controller rear panel cooling fan21Do not use the robot in locations subject to strong vibrations 22Be sure to make correct parameter settings18Protective bonding 19Always connect the robot to the specified controller24Do not apply excessive force to each section 27Caution when turning off the robot controller28Take the following precautions when transporting the robot 3 Special Training for Industrial Robot Opera- tion 3 Soft limits 4 Robot Safety Functions1 Overload detection 2 Overheat detection5 Safety Measures for the System 6 Trial Operation 7 Work Within the Safeguard Enclosure 10 Repair and Modification 9 Adjustment and Inspection8 Automatic Operation 11 Warranty CHAPTER 1 Using the Robot Safely CHAPTER 1 Using the Robot Safely 12 CE MarkingCHAPTER FunctionsMEMO Fig. 2-1 Manipulator movement 1 Robot ManipulatorUser tubing 2 φ3 Fig. 2-2 YK120X, YK150XConnector for user wiring No.1 to CHAPTER 2 FunctionsCHAPTER 2 Functions Fig. 2-3 YK120XC, YK150XCConnector for user wiring No.1 to Ball screw Linear busing shaftViewed from direction A Fig. 2-4 YK180X, YK220XCHAPTER 2 Functions RCX142 2 Robot ControllerFig. 2-5 Robot controller for YK120X series YK120X, YK150X 3 Robot initialization number list Parameter changes 4 Parameters for Clean Room Models YK120XC, YK150XCPrecautions during use To purchasers of this robotMEMO CHAPTER InstallationMEMO Installation environments 1 Robot Installation ConditionsCHAPTER 3 Installation M Xmax Installation baseThe maximum reaction force F XmaxDo not place the robot on a moving installation base. Excessive loads will be applied to the robot arm by movement of the installation base, resulting in dam- age to the robot Fig. 3-2 Packed state 2 Installation2-1 Unpacking Option Fig. 3-3 Product configurations2-2 Checking the product Standard2-3 Moving the robot Fig. 3-5 Installing the robot Installing the robot3 Protective Bonding Symbol 417-IEC-5019YK180X, YK220X Fig. 3-6 Ground terminalCHAPTER 3 Installation YK120X, YK150X4 Robot Cable Connection CHAPTER 3 Installation Fig. 3-7 Robot cable connectionsUser tubing 5 User Wiring and User TubingUser wiring User signal cableCHAPTER 3 Installation 3 Signal wiring connections in the machine harnessConnector pins 1 to 6 can be used BYM-001T-0.6 SM Connector SMR-6V-BArm side and base side connector supplied ManufactureConnecting a suction hose YK120XC, YK150XC 7-1 R-axis tolerable moment of inertia and acceleration coeffi- cient 7 Attaching The End EffectorDepending on the Z-axis position, vibration may occur when the X, Y or R-axis moves. If this happens, reduce the X, Y or R-axis acceleration to an appropri- ate level W=0.2kg 7-1-1 Acceleration coefficient vs. moment of inertia YK120XCHAPTER 3 Installation W=0.1kgW=0.5kg CHAPTER 3 InstallationW=0.4kg W=0.2kg 7-1-2 Acceleration coefficient vs. moment of inertia YK150XCHAPTER 3 Installation W=0.1kgW=0.5kg CHAPTER 3 InstallationW=0.4kg W=0.1 to 0.4kg 7-1-3Acceleration coefficient vs. moment of inertia YK180X, YK220X CHAPTER 3 Installation7-2 Equation for moment of inertia calculation 3 Moment of inertia for cylinder part 5 When the objects center line is offset from the rotation center 7-3 Example of moment of inertia calculation 5 Total moment of inertia 4 Total weight2 Moment of inertia of the chuck 3 Moment of inertia of workpieceFZmax 7-4 Attaching the end effectorFig. 3-23 Z-axis tip shape FXYmaxHole diameter Fig. 3-24 Maximum load applied to end effector attachmentCHAPTER 3 Installation kgfcmMake sure that excessive force is not applied to the joints Fig. 3-26 Maximum acceleration on end effector attachment 7-5 Gripping force of end effectorTable 3-3 Maximum acceleration during robot operation 1 X and Y axes MEMO CHAPTER AdjustmentMEMO 1 Overview 2 Safety Precautions3 Adjusting the origin Fig. 4-1 View of R-axis from below 3-1 Absolute reset method 3-1-1 YK120X series YK120X, YK150X3-1-1-1 Sensor method R-axis 3-1-1-2 Stroke end method X-axis, Y-axis 139 ± Fig. 4-2 Default origin position YK120X, YK150X, YK120XC, YK150XCCHAPTER 4 Adjustment CHAPTER 4 Adjustment 3-1-1-3 Stroke end method Z-axisside 3-1-2 YK180X series YK180X, YK220X 3-1-2-1 Sensor method R-axis3-1-2-2 Sensor method X-axis, Y-axis Fig. 4-5 Default origin positionCHAPTER 4 Adjustment 3-1-2-3 Stroke end method Z-axisNever enter within the robot movement range during absolute reset Machine reference display on MPB screen 3-2 Machine referenceMachine reference value = B/A ⋅ 100% Machine reference3-3 Absolute reset procedures 3-3-1 Sensor method R-axis 7 Since the message Reset ABS encoder OK? is displayed, check that there are not any obstacles in the robot movement range, and press the F4 key YES 3-3-2 Stroke end method X and Y axes of YK120X, YK150X 8 After the absolute reset is completed, check that the X-axis and Y-axis ma- chine reference value displayed on the MPB is within the absolute reset tol- erance range 40 to 3-3-3 Stroke end method Z-axis 3-3-4 Sensor method X and Y axes of YK180X, YK220X CHAPTER 4 Adjustment 3-4 Adjusting the machine reference 3-4-1 YK120X series YK120X, YK150X 3-4-1-1 Adjusting the R-axis machine reference YK120X, YK150XFig. 4-7 Adjustment of R-axis machine reference View from below 3-4-1-2 Adjusting the R-axis machine reference YK120XC, YK150XC Fig. 4-8 Adjustment of R-axis machine reference 3-4-1-3 Adjusting the X-axis machine reference X-axis arm X-axis fixed mechanical stopper B A Bolt Fig. 4-9 Adjustment of X-axis machine reference3-4-1-4 Adjusting the Y-axis machine reference Bolt On back side of arm Fig. 4-10 Adjustment of Y-axis machine referenceY-axis moveable mechanical stopper BA X-axis arm The point data must be reset after adjusting the machine reference 3-4-1-5 Adjusting the Z-axis machine referenceWhen machine reference5% CHAPTER 4 Adjustment Section3-4-2 YK180X series YK180X, YK220X 3-4-2-1 Adjusting the R-axis machine reference YK180X, YK220X12 Perform the absolute reset from outside the safeguard enclosure 3-4-2-2 Adjusting the X-axis machine reference B A Bolt X-axis dog X-axis Sensor Fig. 4-13 Adjustment of X-axis machine reference3-4-2-3 Adjusting the Y-axis machine reference Fig. 4-14 Adjustment of Y-axis machine reference 3-4-2-4 Adjusting the Z-axis machine reference Prop up the Z-axis with a support stand before beginning the work Bolt Upper end urethane damper CHAPTER 4 AdjustmentLower end urethane damper Ball screw Bolt Z-axis motor Spline nut Z-axis upper-end mechanical stopper1 Setting the X-axis and Y-axis soft limits 4 Setting the Soft Limits7 Set the soft limits to within the figure for the X-axis andY-axis encoder pulses that you noted above in step 5. This software limit setting must be made from outside the safeguard enclosure Make this setting from outside the safeguard enclosure 5 Setting the Standard Coordinates A B X Y Z R 6 Affixing Stickers for Movement Directions and Axis Names+ Y - + R Fig. 4-17 Positions for affixing the stickersCHAPTER 4 Adjustment 7 Removing the Robot Covers same on opposite side CHAPTER 4 AdjustmentYK120X, YK150X YK120XC, YK150XCBase front cover CHAPTER 4 AdjustmentYK180X, YK220X Y-axis arm upper cover qM3⋅6 ⋅4 wM3⋅6 ⋅4 eM3⋅6 ⋅4MEMO CHAPTER Periodic Inspecition5-1 Replacement period MEMO Periodic inspection includes Daily inspection 6-month inspection 1 Overview2 Precautions 2 Inspection to be performed with the controller turned on 3 Daily Inspection1 Inspection to be performed with the controller turned off 3 Adjustment and parts replacement Take the following precautions when performing 6-month inspection 4 Six-Month Inspection1 Bolt tightening torque Procedure1 Inspection to be performed with the controller turned off CHAPTER 5 Periodic InspectionCheck if the fan rotates normally 3 Adjustment and parts replacementCheck for dust on the fan cover. Remove and clean if necessary 2 Inspection to be performed with the controller turned onTable 5-1 Harmonic drive speed reduction ratio 5-1 Replacement period5 Replacing the Harmonic Drive Grease Page SK-2 made by Harmonic Drive Systems Inc Recommended greaseUse the following harmonic drive grease CHAPTER Increasing the robot operating speedMEMO Axis parameters - Arch position 1 Increasing the robot operating speed1 Increasing speed by arch motion q Gate motione Arch motion Making the arch position value larger Robot parameters - Axis tip weight in Chapter 4 Programming manual = 80 ....... Returns the tolerance to the default value OUTPOS 3 = 10000 ... Z-axis OUT effective position pulses 4 Increasing the speed by the OUT effective position parameterOUTPOS 1 = 10000 ... X-axis OUT effective position pulses OUTPOS 2 = 10000 ... Y-axis OUT effective position pulsesMEMO CHAPTER SpecificationsMEMO 69.5mm Basic specification1 Manipulator CHAPTER 7 SpecificationsCHAPTER 7 Specifications 1-2 External view and dimensionsFig. 7-1 YK120X R120 CHAPTER 7 Specifications139 113 139 ±User tool installation range Fig. 7-2 YK150XCHAPTER 7 Specifications 13 9 ± CHAPTER 7 SpecificationsCHAPTER 7 Specifications Fig. 7-3 YK120XCCHAPTER 7 Specifications CHAPTER 7 Specifications Fig. 7-4 YK150XC139 113 CHAPTER 7 Specifications7-10 Fig. 7-5 YK180XCHAPTER 7 Specifications R75.7 CHAPTER 7 SpecificationsViewed from direction C Fig. 7-6 YK220XCHAPTER 7 Specifications 7-12R109 CHAPTER 7 SpecificationsZ-axis brake 1-3 Robot inner wiring diagramCHAPTER 7 Specifications Y-axis motor7-15 1-4 Wiring tableRobot cable wiring table CHAPTER 7 SpecificationsYellow Green Machine harness wiring tableCHAPTER 7 Specifications CHAPTER 7 Specifications Motor wiring tableOrigin sensor wiring table Brake wiring tableBlue CHAPTER 7 SpecificationsConnector MEMO SCARA Robots OWNERS MANUAL