Manuals / Yamaha / Computer Equipment / Robotics

Yamaha YK120X, YK180X Automatic Operation, Adjustment and Inspection, Repair and Modification

Models: YK120X YK180X

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8 Automatic Operation

CHAPTER 1 Using the Robot Safely

8 Automatic Operation

Automatic operation described here includes all operations in AUTO mode.

(1)Check the following before starting automatic operation.

1.No one is within the safeguard enclosure.

2.The programming unit and tools are in their specified locations.

3.The alarm or error lamps on the robot and peripheral equipment do not flash.

4.The safeguard enclosure is securely installed with safety interlocks ac- tuated.

(2)Observe the following during automatic operation or in cases where an error occurs.

1)After automatic operation has started, check the operation status and warn- ing lamp to ensure that the robot is in automatic operation.

2)Never enter the safeguard enclosure during automatic operation.

3)If an error occurs in the robot or peripheral equipment, observe the fol- lowing procedure before entering the safeguard enclosure.

1.Press the emergency stop button to set the robot to emergency stop.

2.Place a sign on the start switch, indicating that the robot is being in- spected in order to keep any other person from touching the start switch and restarting the robot.

9 Adjustment and Inspection

Do not attempt any installation, adjustment, inspection or maintenance unless it is described in this manual.

10 Repair and Modification

Do not attempt any repair, parts replacement and modification unless described in this manual. These works require technical knowledge and skill, and may also involve work hazards.

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Yamaha YK120X, YK180X owner manual Automatic Operation, Adjustment and Inspection, Repair and Modification

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 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 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 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 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 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 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 shaftFig. 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 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 2 Installation 2-1 UnpackingFig. 3-2 Packed state 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 cable3 Signal wiring connections in the machine harness Connector pins 1 to 6 can be usedCHAPTER 3 Installation 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=0.1kgCHAPTER 3 Installation W=0.4kgW=0.5kg W=0.2kg 7-1-2 Acceleration coefficient vs. moment of inertia YK150XCHAPTER 3 Installation W=0.1kgCHAPTER 3 Installation W=0.4kgW=0.5kg 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 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 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 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 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 NamesFig. 4-17 Positions for affixing the stickers CHAPTER 4 Adjustment+ Y - + R 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 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 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 on5-1 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 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 Specifications1-2 External view and dimensions Fig. 7-1 YK120XCHAPTER 7 Specifications R120 CHAPTER 7 Specifications139 113 139 ±Fig. 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 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 SpecificationsMachine harness wiring table CHAPTER 7 SpecificationsYellow Green CHAPTER 7 Specifications Motor wiring tableOrigin sensor wiring table Brake wiring tableCHAPTER 7 Specifications ConnectorBlue MEMO SCARA Robots OWNERS MANUAL