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Yamaha YK120X, YK180X Overview, Periodic inspection includes Daily inspection 6-month inspection

Models: YK120X YK180X

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Periodic inspection includes:

CHAPTER 5 Periodic Inspection

1 Overview

Daily and periodic inspection of the YAMAHA robot is essential in order to ensure safe and efficient operation. This chapter describes the periodic inspection items and procedures for the YAMAHA YK120X series and YK180 series robots.

Periodic inspection includes:

•Daily inspection

•6-month inspection

•Replacing the speed reduction gear (harmonic drive) grease

Make sure that you thoroughly understand details of the inspection and follow the procedures and precautions explained in this chapter.

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Yamaha YK120X, YK180X owner manual Overview, Periodic inspection includes Daily inspection 6-month inspection

Contents

OWNERS MANUAL Page 1. Absolute Reset Before using the robot Be sure to read the following notes2. Setting the standard coordinates Error messages issued when robot & controller are connected RCX1423 Connection to the controller 2 Caution when turning off the robot controllerIM Company IntroductionClean Room Models YK120XC, YK150XC 1. Robot parameter has been changed. See section 4 in chapter2. Suction couplers have been added. See section 6 in chapter Installation CHAPTER 1 Using the Robot SafelyCHAPTER 2 Functions CHAPTERCHAPTER 4 Adjustment Periodic Inspecition SpecificationsIncreasing the robot operating speed CHAPTERMEMO CHAPTER Using the Robot SafelyMEMO DANGER 1 Safety Information1 Observe the following cautions during automatic operation 2 Essential Caution ItemsFig. 1-1 Warning label Fig. 1-2 Warning label3 Follow the instructions on warning labels and in this manual Fig. 1-3 Warning labelRead owners manual and all warning labels before operation 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 fan18Protective bonding 22Be sure to make correct parameter settings19Always connect the robot to the specified controller 21Do not use the robot in locations subject to strong vibrations24Do 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 1 Overload detection 4 Robot Safety Functions2 Overheat detection 3 Soft limits5 Safety Measures for the System 6 Trial Operation 7 Work Within the Safeguard Enclosure 9 Adjustment and Inspection 8 Automatic Operation10 Repair and Modification 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 ManipulatorConnector for user wiring No.1 to Fig. 2-2 YK120X, YK150XCHAPTER 2 Functions User tubing 2 φ3Connector for user wiring No.1 to Fig. 2-3 YK120XC, YK150XCBall screw Linear busing shaft CHAPTER 2 FunctionsFig. 2-4 YK180X, YK220X CHAPTER 2 FunctionsViewed from direction A 2 Robot Controller Fig. 2-5 Robot controller for YK120X series YK120X, YK150XRCX142 3 Robot initialization number list Precautions during use 4 Parameters for Clean Room Models YK120XC, YK150XCTo purchasers of this robot Parameter changesMEMO CHAPTER InstallationMEMO Installation environments 1 Robot Installation ConditionsCHAPTER 3 Installation The maximum reaction force Installation baseF Xmax M 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 2 Installation 2-1 UnpackingFig. 3-2 Packed state 2-2 Checking the product Fig. 3-3 Product configurationsStandard Option2-3 Moving the robot Fig. 3-5 Installing the robot Installing the robot3 Protective Bonding Symbol 417-IEC-5019CHAPTER 3 Installation Fig. 3-6 Ground terminalYK120X, YK150X YK180X, YK220X4 Robot Cable Connection CHAPTER 3 Installation Fig. 3-7 Robot cable connectionsUser wiring 5 User Wiring and User TubingUser signal cable User tubing3 Signal wiring connections in the machine harness Connector pins 1 to 6 can be usedCHAPTER 3 Installation Arm side and base side connector supplied SM Connector SMR-6V-BManufacture BYM-001T-0.6Connecting 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 CHAPTER 3 Installation 7-1-1 Acceleration coefficient vs. moment of inertia YK120XW=0.1kg W=0.2kgCHAPTER 3 Installation W=0.4kgW=0.5kg CHAPTER 3 Installation 7-1-2 Acceleration coefficient vs. moment of inertia YK150XW=0.1kg W=0.2kgCHAPTER 3 Installation W=0.4kgW=0.5kg Acceleration coefficient vs. moment of inertia YK180X, YK220X 7-1-3CHAPTER 3 Installation W=0.1 to 0.4kg7-2 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 2 Moment of inertia of the chuck 4 Total weight3 Moment of inertia of workpiece 5 Total moment of inertiaFig. 3-23 Z-axis tip shape 7-4 Attaching the end effectorFXYmax FZmaxCHAPTER 3 Installation Fig. 3-24 Maximum load applied to end effector attachmentkgfcm Hole diameterMake sure that excessive force is not applied to the joints 7-5 Gripping force of end effector Table 3-3 Maximum acceleration during robot operationFig. 3-26 Maximum acceleration on end effector attachment 1 X and Y axes MEMO CHAPTER AdjustmentMEMO 1 Overview 2 Safety Precautions3 Adjusting the origin 3-1 Absolute reset method 3-1-1 YK120X series YK120X, YK150X 3-1-1-1 Sensor method R-axisFig. 4-1 View of R-axis from below 3-1-1-2 Stroke end method X-axis, Y-axis Fig. 4-2 Default origin position YK120X, YK150X, YK120XC, YK150XC CHAPTER 4 Adjustment139 ± 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 position3-1-2-3 Stroke end method Z-axis Never enter within the robot movement range during absolute resetCHAPTER 4 Adjustment Machine reference value = B/A ⋅ 100% 3-2 Machine referenceMachine reference Machine reference display on MPB screen3-3 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 Fig. 4-10 Adjustment of Y-axis machine reference Y-axis moveable mechanical stopper BA X-axis armBolt On back side of 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 Lower end urethane damper Ball screw Bolt Z-axis motor Spline nut CHAPTER 4 AdjustmentZ-axis upper-end mechanical stopper Bolt Upper end urethane damper1 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 NamesFig. 4-17 Positions for affixing the stickers CHAPTER 4 Adjustment+ Y - + R 7 Removing the Robot Covers YK120X, YK150X CHAPTER 4 AdjustmentYK120XC, YK150XC same on opposite sideYK180X, YK220X CHAPTER 4 AdjustmentY-axis arm upper cover qM3⋅6 ⋅4 wM3⋅6 ⋅4 eM3⋅6 ⋅4 Base front coverMEMO Periodic Inspecition 5-1 Replacement periodCHAPTER MEMO Periodic inspection includes Daily inspection 6-month inspection 1 Overview2 Precautions 3 Daily Inspection 1 Inspection to be performed with the controller turned off2 Inspection to be performed with the controller turned on 3 Adjustment and parts replacement Take the following precautions when performing 6-month inspection 4 Six-Month Inspection1 Inspection to be performed with the controller turned off ProcedureCHAPTER 5 Periodic Inspection 1 Bolt tightening torqueCheck for dust on the fan cover. Remove and clean if necessary 3 Adjustment and parts replacement2 Inspection to be performed with the controller turned on Check if the fan rotates normally5-1 Replacement period 5 Replacing the Harmonic Drive GreaseTable 5-1 Harmonic drive speed reduction ratio Page Recommended grease Use the following harmonic drive greaseSK-2 made by Harmonic Drive Systems Inc CHAPTER Increasing the robot operating speedMEMO 1 Increasing speed by arch motion 1 Increasing the robot operating speedq Gate motion Axis parameters - Arch positione 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 1 = 10000 ... X-axis OUT effective position pulses 4 Increasing the speed by the OUT effective position parameterOUTPOS 2 = 10000 ... Y-axis OUT effective position pulses OUTPOS 3 = 10000 ... Z-axis OUT effective position pulsesMEMO CHAPTER SpecificationsMEMO 1 Manipulator Basic specificationCHAPTER 7 Specifications 69.5mm1-2 External view and dimensions Fig. 7-1 YK120XCHAPTER 7 Specifications 139 113 CHAPTER 7 Specifications139 ± R120Fig. 7-2 YK150X CHAPTER 7 SpecificationsUser tool installation range 13 9 ± CHAPTER 7 SpecificationsCHAPTER 7 Specifications Fig. 7-3 YK120XCCHAPTER 7 Specifications CHAPTER 7 Specifications Fig. 7-4 YK150XC139 113 CHAPTER 7 SpecificationsFig. 7-5 YK180X CHAPTER 7 Specifications7-10 R75.7 CHAPTER 7 SpecificationsCHAPTER 7 Specifications Fig. 7-6 YK220X7-12 Viewed from direction CR109 CHAPTER 7 SpecificationsCHAPTER 7 Specifications 1-3 Robot inner wiring diagramY-axis motor Z-axis brakeRobot cable wiring table 1-4 Wiring tableCHAPTER 7 Specifications 7-15Machine harness wiring table CHAPTER 7 SpecificationsYellow Green Origin sensor wiring table Motor wiring tableBrake wiring table CHAPTER 7 SpecificationsCHAPTER 7 Specifications ConnectorBlue MEMO SCARA Robots OWNERS MANUAL