Operator s Manual for Handling

Transcription

1 Motoma XRC 2001 Cotroller Operator s Maual for Hadlig Part Number: Release Date: November 28, 2006 Documet Status: Fial Motoma, Icorporated 805 iberty ae West Carrollto, OH TE: (937) FAX: (937) Hour Service Hotlie: (937)

2 COMPETE OUR ONINE SURVEY Motoma is committed to total customer satisfactio! Please give us your feedback o the techical mauals you received with your Motoma robotic solutio. To participate, go to the followig website: The iformatio cotaied withi this documet is the proprietary property of Motoma, Ic., ad may ot be copied, reproduced or trasmitted to other parties without the expressed writte authorizatio of Motoma, Ic by MOTOMAN All Rights Reserved Because we are costatly improvig our products, we reserve the right to chage specificatios without otice. MOTOMAN is a registered trademark of YASKAWA Electric Maufacturig.

3 TABE OF CONTENTS Sectio Page 1 INTRODUCTION SAFETY XRC OPERATOR S MANUA FOR BEGINNERS XRC OPERATOR S MANUA FOR HANDING MOTOMAN i XRC Operator s Maual for Hadlig

4 NOTES XRC Operator s Maual for Hadlig ii MOTOMAN

5 SECTION 1 INTRODUCTION 1.1 About this Documet The XRC Operator s Maual for Hadlig provides iformatio about hadlig applicatios for Motoma robots usig the XRC cotroller, icludig job teachig, playback, ad editig. Also icluded is iformatio about the robot istructio set, user variables, alarm/error messages ad special robot settigs (e.g., tool costat, user coordiates, etc.). This maual is iteded to teach basic cotroller ad robot operatio ad programmig to operators, programmers, egieers, ad maiteace persoel who desig, istall, use, ad maitai a Motoma robotic system. Power users performig advaced programmig ad operatio of the cotroller may eed the XRC Iform II maual (P/N ). Please cotact your salesma directly, or the Motoma service staff at (937) , to order the XRC Iform II maual. This maual is orgaized as follows: SECTION 1 INTRODUCTION Geeral iformatio about this maual, a list of referece documets, ad customer service iformatio. SECTION 2 SAFETY Provides iformatio for the safe use ad operatio of Motoma products. SECTION 3 OPERATOR S MANUA FOR BEGINNERS Provides a itroductio to the XRC cotroller ad programmig pedat icludig basic operatig istructios i teachig, playback, ad editig modes. The hadlig sectio provides job examples ad gives basic istructios for settig coditio files ad performig hadlig operatios. SECTION 4 OPERATOR S MANUA FOR HANDING Provides detailed iformatio about the XRC cotroller ad programmig pedat; maipulator coordiates; ad teachig, playback, ad editig modes. The hadlig sectio discusses specific keys, teachig, cotrollig peripheral devices, ad I/O sigal iformatio. 1.2 Referece to Other Documetatio For additioal iformatio refer to the followig: Cocurret I/O Parameters Maual (P/N ) Operator s Maual for Geeral Purpose (P/N ) Motoma UP6, XRC 2001 Maipulator Maual (P/N ) Motoma UP20, XRC 2001 Maipulator Maual (P/N ) Motoma UP50, XRC 2001 Maipulator Maual (P/N ) Motoma UP130/165, XRC 2001 Maipulator Maual (P/N ) MOTOMAN 1-1 XRC Operator s Maual for Hadlig

6 INTRODUCTION 1.3 Customer Service Iformatio If you are i eed of techical assistace, cotact the Motoma service staff at (937) Please have the followig iformatio ready before you call: Robot Type (UP6, UP130, UP165, etc.) Applicatio Type (weldig, hadlig, etc.) Robot Serial Number (located o the back side of the robot arm) Robot Sales Order Number (located o back side of XRC cotroller) XRC Operator s Maual for Hadlig 1-2 MOTOMAN

7 SECTION 2 SAFETY 2.1 Itroductio It is the purchaser's resposibility to esure that all local, couty, state, ad atioal codes, regulatios, rules, or laws relatig to safety ad safe operatig coditios for each istallatio are met ad followed. We suggest that you obtai ad review a copy of the ANSI/RIA Natioal Safety Stadard for Idustrial Robots ad Robot Systems. This iformatio ca be obtaied from the Robotic Idustries Associatio by requestig ANSI/RIA R The address is as follows: Robotic Idustries Associatio 900 Victors Way P.O. Box 3724 A Arbor, Michiga TE: 313/ FAX: 313/ Ultimately, the best safeguard is traied persoel. The user is resposible for providig persoel who are adequately traied to operate, program, ad maitai the robot cell. The robot must ot be operated by persoel who have ot bee traied! We recommed that all persoel who ited to operate, program, repair, or use the robot system be traied i a approved Motoma traiig course ad become familiar with the proper operatio of the system. This safety sectio addresses the followig: Stadard Covetios (Sectio 2.2) Geeral Safeguardig Tips (Sectio 2.3) Mechaical Safety Devices (Sectio 2.4) Istallatio Safety (Sectio 2.5) Programmig Safety (Sectio 2.6) Operatio Safety (Sectio 2.7) Maiteace Safety (Sectio 2.8) MOTOMAN 2-1 XRC Operator s Maual for Hadlig

8 SAFETY 2.2 Stadard Covetios This maual icludes iformatio essetial to the safety of persoel ad equipmet. As you read through this maual, be alert to the four sigal words: DANGER WARNING CAUTION NOTE Pay particular attetio to the iformatio provided uder these headigs which are defied below (i descedig order of severity). DANGER! Iformatio appearig uder the DANGER captio cocers the protectio of persoel from the immediate ad immiet hazards that, if ot avoided, will result i immediate, serious persoal ijury or loss of life i additio to equipmet damage. WARNING! Iformatio appearig uder the WARNING captio cocers the protectio of persoel ad equipmet from potetial hazards that ca result i persoal ijury or loss of life i additio to equipmet damage. CAUTION! Iformatio appearig uder the CAUTION captio cocers the protectio of persoel ad equipmet, software, ad data from hazards that ca result i mior persoal ijury or equipmet damage. NOTE: Iformatio appearig i a NOTE captio provides additioal iformatio which is helpful i uderstadig the item beig explaied. XRC Operator s Maual for Hadlig 2-2 MOTOMAN

9 2.3 Geeral Safeguardig Tips SAFETY All operators, programmers, plat ad toolig egieers, maiteace persoel, supervisors, ad ayoe workig ear the robot must become familiar with the operatio of this equipmet. All persoel ivolved with the operatio of the equipmet must uderstad potetial dagers of operatio. Geeral safeguardig tips are as follows: Improper operatio ca result i persoal ijury ad/or damage to the equipmet. Oly traied persoel familiar with the operatio of this robot, the operator's mauals, the system equipmet, ad optios ad accessories should be permitted to operate this robot system. Do ot eter the robot cell while it is i automatic operatio. Programmers must have the teach pedat whe they eter the robot cell. Improper coectios ca damage the robot. All coectios must be made withi the stadard voltage ad curret ratigs of the robot I/O (Iputs ad Outputs). The robot must be placed i Emergecy Stop (E-STOP) mode wheever it is ot i use. I accordace with ANSI/RIA R15.06, sectio ad , use lockout/tagout procedures durig equipmet maiteace. Refer also to Sectio (29CFR, Part 1910), Occupatioal Safety ad Health Stadards for Geeral Idustry (OSHA). 2.4 Mechaical Safety Devices The safe operatio of the robot, positioer, auxiliary equipmet, ad system is ultimately the user's resposibility. The coditios uder which the equipmet will be operated safely should be reviewed by the user. The user must be aware of the various atioal codes, ANSI/RIA R15.06 safety stadards, ad other local codes that may pertai to the istallatio ad use of idustrial equipmet. Additioal safety measures for persoel ad equipmet may be required depedig o system istallatio, operatio, ad/or locatio. The followig safety measures are available: Safety feces ad barriers ight curtais Door iterlocks Safety mats Floor markigs Warig lights Check all safety equipmet frequetly for proper operatio. Repair or replace ay o-fuctioig safety equipmet immediately. MOTOMAN 2-3 XRC Operator s Maual for Hadlig

10 SAFETY 2.5 Istallatio Safety Safe istallatio is essetial for protectio of people ad equipmet. The followig suggestios are iteded to supplemet, but ot replace, existig federal, local, ad state laws ad regulatios. Additioal safety measures for persoel ad equipmet may be required depedig o system istallatio, operatio, ad/or locatio. Istallatio tips are as follows: Be sure that oly qualified persoel familiar with atioal codes, local codes, ad ANSI/RIA R15.06 safety stadards are permitted to istall the equipmet. Idetify the work evelope of each robot with floor markigs, sigs, ad barriers. Positio all cotrollers outside the robot work evelope. Wheever possible, istall safety feces to protect agaist uauthorized etry ito the work evelope. Elimiate areas where persoel might get trapped betwee a movig robot ad other equipmet (pich poits). Provide sufficiet room iside the workcell to permit safe teachig ad maiteace procedures. 2.6 Programmig Safety All operators, programmers, plat ad toolig egieers, maiteace persoel, supervisors, ad ayoe workig ear the robot must become familiar with the operatio of this equipmet. All persoel ivolved with the operatio of the equipmet must uderstad potetial dagers of operatio. Programmig tips are as follows: Ay modificatios to PART 1 of the cotroller PC ca cause severe persoal ijury or death, as well as damage to the robot! Do ot make ay modificatios to PART 1. Makig ay chages without the writte permissio of Motoma will VOID YOUR WARRANTY! Some operatios require stadard passwords ad some require special passwords. Special passwords are for Motoma use oly. YOUR WARRANTY WI BE VOID if you use these special passwords. Back up all programs ad jobs oto a floppy disk wheever program chages are made. To avoid loss of iformatio, programs, or jobs, a backup must always be made before ay service procedures are doe ad before ay chages are made to optios, accessories, or equipmet. The cocurret I/O (Iput ad Output) fuctio allows the customer to modify the iteral ladder iputs ad outputs for maximum robot performace. Great care must be take whe makig these modificatios. Double-check all modificatios uder every mode of robot operatio to esure that you have ot created hazards or dagerous situatios that may damage the robot or other parts of the system. XRC Operator s Maual for Hadlig 2-4 MOTOMAN

11 SAFETY Improper operatio ca result i persoal ijury ad/or damage to the equipmet. Oly traied persoel familiar with the operatio, mauals, electrical desig, ad equipmet itercoectios of this robot should be permitted to operate the system. Ispect the robot ad work evelope to be sure o potetially hazardous coditios exist. Be sure the area is clea ad free of water, oil, debris, etc. Be sure that all safeguards are i place. Check the E-STOP butto o the teach pedat for proper operatio before programmig. Carry the teach pedat with you whe you eter the workcell. Be sure that oly the perso holdig the teach pedat eters the workcell. Test ay ew or modified program at low speed for at least oe full cycle. 2.7 Operatio Safety All operators, programmers, plat ad toolig egieers, maiteace persoel, supervisors, ad ayoe workig ear the robot must become familiar with the operatio of this equipmet. All persoel ivolved with the operatio of the equipmet must uderstad potetial dagers of operatio. Operatio tips are as follows: Be sure that oly traied persoel familiar with the operatio of this robot, the operator's mauals, the system equipmet, ad optios ad accessories are permitted to operate this robot system. Check all safety equipmet for proper operatio. Repair or replace ay ofuctioig safety equipmet immediately. Ispect the robot ad work evelope to esure o potetially hazardous coditios exist. Be sure the area is clea ad free of water, oil, debris, etc. Esure that all safeguards are i place. Improper operatio ca result i persoal ijury ad/or damage to the equipmet. Oly traied persoel familiar with the operatio, mauals, electrical desig, ad equipmet itercoectios of this robot should be permitted to operate the system. Do ot eter the robot cell while it is i automatic operatio. Programmers must have the teach pedat whe they eter the cell. The robot must be placed i Emergecy Stop (E-STOP) mode wheever it is ot i use. This equipmet has multiple sources of electrical supply. Electrical itercoectios are made betwee the cotroller, exteral servo box, ad other equipmet. Discoect ad lockout/tagout all electrical circuits before makig ay modificatios or coectios. All modificatios made to the cotroller will chage the way the robot operates ad ca cause severe persoal ijury or death, as well as damage the robot. This icludes cotroller parameters, ladder parts 1 ad 2, ad I/O (Iput ad Output) modificatios. Check ad test all chages at slow speed. MOTOMAN 2-5 XRC Operator s Maual for Hadlig

12 SAFETY 2.8 Maiteace Safety All operators, programmers, plat ad toolig egieers, maiteace persoel, supervisors, ad ayoe workig ear the robot must become familiar with the operatio of this equipmet. All persoel ivolved with the operatio of the equipmet must uderstad potetial dagers of operatio. Maiteace tips are as follows: Do ot perform ay maiteace procedures before readig ad uderstadig the proper procedures i the appropriate maual. Check all safety equipmet for proper operatio. Repair or replace ay ofuctioig safety equipmet immediately. Improper operatio ca result i persoal ijury ad/or damage to the equipmet. Oly traied persoel familiar with the operatio, mauals, electrical desig, ad equipmet itercoectios of this robot should be permitted to operate the system. Back up all your programs ad jobs oto a floppy disk wheever program chages are made. A backup must always be made before ay servicig or chages are made to optios, accessories, or equipmet to avoid loss of iformatio, programs, or jobs. Do ot eter the robot cell while it is i automatic operatio. Programmers must have the teach pedat whe they eter the cell. The robot must be placed i Emergecy Stop (E-STOP) mode wheever it is ot i use. Be sure all safeguards are i place. Use proper replacemet parts. This equipmet has multiple sources of electrical supply. Electrical itercoectios are made betwee the cotroller, exteral servo box, ad other equipmet. Discoect ad lockout/tagout all electrical circuits before makig ay modificatios or coectios. All modificatios made to the cotroller will chage the way the robot operates ad ca cause severe persoal ijury or death, as well as damage the robot. This icludes cotroller parameters, ladder parts 1 ad 2, ad I/O (Iput ad Output) modificatios. Check ad test all chages at slow speed. Improper coectios ca damage the robot. All coectios must be made withi the stadard voltage ad curret ratigs of the robot I/O (Iputs ad Outputs). XRC Operator s Maual for Hadlig 2-6 MOTOMAN

13 YASKAWA YASNAC XRC OPERATOR S MANUA FOR BEGINNERS Upo receipt of the product ad prior to iitial operatio, read these istructios thoroughly, ad retai for future referece. MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUA MOTOMAN- INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR S MANUA YASNAC XRC OPERATOR S MANUA FOR BEGINNERS The YASNAC XRC operator s mauals above correspod to specific usage. Be sure to use the appropriate maual. YASKAWA MANUA NO. RE-CSO-A011 1

14 MANDATORY This maual explais the various compoets of the YASNAC XRC system ad geeral operatios. Read this maual carefully ad be sure to uderstad its cotets before hadlig the YASNAC XRC. Geeral items related to safety are listed i the Setup Maual Sectio 1: Safety. To esure correct ad safe operatio, carefully read the Setup Maual before readig this maual. CAUTION Some drawigs i this maual are show with the protective covers or shields removed for clarity. Be sure all covers ad shields are replaced before operatig this product. The drawigs ad photos i this maual are represetative examples ad differeces may exist betwee them ad the delivered product. YASKAWA may modify this model without otice whe ecessary due to product improvemets, modificatios, or chages i specificatios. If such modificatio is made, the maual umber will also be revised. If your copy of the maual is damaged or lost, cotact a YASKAWA represetative to order a ew copy. The represetatives are listed o the back cover. Be sure to tell the represetative the maual umber listed o the frot cover. YASKAWA is ot resposible for icidets arisig from uauthorized modificatio of its products. Uauthorized modificatio voids your product s warraty. ii

15 NOTES FOR SAFE OPERATION Read this maual carefully before istallatio, operatio, maiteace, or ispectio of the YASNAC XRC. I this maual, the Notes for Safe Operatio are classified as WARNING, CAUTION, MANDATORY, or PROHIBITED. WARNING CAUTION Idicates a potetially hazardous situatio which, if ot avoided, could result i death or serious ijury to persoel. Idicates a potetially hazardous situatio which, if ot avoided, could result i mior or moderate ijury to persoel ad damage to equipmet. It may also be used to alert agaist usafe practices. MANDATORY Always be sure to follow explicitly the items listed uder this headig. PROHIBITED Must ever be performed. Eve items described as CAUTION may result i a serious accidet i some situatios. At ay rate, be sure to follow these importat items. NOTE To esure safe ad efficiet operatio at all times, be sure to follow all istructios, eve if ot desigated as CAUTION ad WARNING. iii

16 WARNING Before operatig the maipulator, check that servo power is tured off whe the emergecy stop buttos o the playback pael or programmig pedat are pressed. Whe the servo power is tured off, the SERVO ON READY lamp o the playback pael ad the SERVO ON ED o the programmig pedat are tured off. Ijury or damage to machiery may result if the emergecy stop circuit caot stop the maipulator durig a emergecy. The maipulator should ot be used if the emergecy stop buttos do ot fuctio. Emergecy Stop Butto Oce the emergecy stop butto is released, clear the cell of all items which could iterfere with the operatio of the maipulator. The tur the servo power ON. Ijury may result from uitetioal or uexpected maipulator motio. TURN Release of Emergecy Stop Always set the Teach ock before eterig the robot work evelope to teach a job. Operator ijury ca occur if the Teach ock is ot set ad the maipulator is started from the playback pael. Observe the followig precautios whe performig teachig operatios withi the workig evelope of the maipulator : - View the maipulator from the frot wheever possible. - Always follow the predetermied operatig procedure. - Esure that you have a safe place to retreat i case of emergecy. Improper or uiteded maipulator operatio may result i ijury. Cofirm that o persos are preset i the maipulator s work evelope ad that you are i a safe locatio before: - Turig o the YASNAC XRC power - Movig the maipulator with the programmig pedat - Ruig check operatios - Performig automatic operatios Ijury may result if ayoe eters the workig evelope of the maipulator durig operatio. Always press a emergecy stop butto immediately if there are problems.the emergecy stop butto is located o the right side of both the YASNAC XRC playback pael ad programmig pedat. iv

17 CAUTION Perform the followig ispectio procedures prior to coductig maipulator teachig. If problems are foud, repair them immediately, ad be sure that all other ecessary processig has bee performed. -Check for problems i maipulator movemet. -Check for damage to isulatio ad sheathig of exteral wires. Always retur the programmig pedat to the hook o the XRC cabiet after use. The programmig pedat ca be damaged if it is left i the maipulator s work area, o the floor, or ear fixtures. Read ad uderstad the Explaatio of the Alarm Display i the Setup Maual before operatig the maipulator. Defiitio of Terms Used Ofte i This Maual The MOTOMAN maipulator is the YASKAWA idustrial robot product. The maipulator usually cosists of the cotroller, the playback pael, the programmig pedat, ad supply cables. I this maual, the equipmet is desigated as follows. Equipmet Maual Desigatio YASNAC XRC Cotroller YASNAC XRC Playback Pael YASNAC XRC Programmig Pedat XRC Playback Pael Programmig Pedat v

18 Descriptios of the programmig pedat ad playback pael keys, buttos, ad displays are show as follows: Equipmet Maual Desigatio Programmig Pedat Character Keys Symbol Keys Axis Keys Number Keys Keys pressed simultaeously Displays The keys which have characters prited o them are deoted with [ ]. ex. [ENTER] The keys which have a symbol prited o them are ot deoted with [ ] but depicted with a small picture. ex. page key The cursor key is a exceptio, ad a picture is ot show. Axis Keys ad Number Keys are geeric ames for the keys for axis operatio ad umber iput. Whe two keys are to be pressed simultaeously, the keys are show with a + sig betwee them, ex. [SHIFT]+[COORD] The meu displayed i the programmig pedat is deoted with { }. ex. {JOB} Playback Pael Buttos Playback pael buttos are eclosed i brackets. ex. [TEACH] o the playback pael Descriptio of the Operatio Procedure I the explaatio of the operatio procedure, the expressio "Select " meas that the cursor is moved to the object item ad the SEECT key is pressed. vi

19 1 INTRODUCTION 1.1 XRC Overview Butto Descriptios Programmig Pedat Key Descriptios Named Keys Symbol Keys Axis Keys ad Number Keys Simultaeously Pressed Keys Scree Descriptios Operatio Sequece TURNING THE POWER ON 2.1 Turig O the Mai Power Startup Diagostics Whe Startup Diagostics are Complete Turig o the Servo Power Durig Play Mode Durig Teach Mode TEACHING 3.1 Maipulator Motio Joit Coordiates Rectagular Coordiates Move Istructios ad Steps Teachig Preparatio Before Teachig Teachig Teachig a Job Step 1 -- Start Positio Step 2 -- Near the Work Start ocatio Step 3 -- Work Start ocatio Step 4 -- Work Ed Positio Step 5 -- Positio Away From Workpiece ad Fixture Step 6 -- Near the Start Positio Esurig the First ad ast Step are Idetical Path Cofirmatio Correctig a Job Before Correctig a Job Chage the Positio Data Add a Step Delete a Step Chagig the Speed Betwee Steps vii

20 4 PAYBACK 4.1 Preparatio Prior to Playback Playback ARC WEDING 5.1 Example Job Teachig Procedure Teachig Procedure Items Operatio Method Step 2 -- Near Weldig Start ocatio Step 3 -- Weldig Start Positio Step 4 -- Weldig Ed Coditio Settig Weldig Coditios Registratio of Weldig Coditio Settig Other Parameters Shieldig Gas Flow Rate Weldig Test Check Ru Weldig Executio Adjustmets for Weldig Defects HANDING 6.1 Example Job Usage of HAND Istructio Fuctio SP (sigle-soleoid) P (double-soleoid) P (triple soleoid) Istructio ad Additioal Items Teachig Procedure Teachig Poits Operatio Procedure Step 2 -- Near Grippig Positio (before grippig) Step 3 -- Grippig Positio Step 4 -- Near Grippig Positio (after grippig) Step 6 -- Near Release Positio (before releasig) Step 7 -- Release Assistace Positio Step 8 -- Release Positio Step 9 -- Near Release Positio (after release) Hadlig Test Speed imitatio Drive Hadlig Executio viii

21 7 GENERA PURPOSE 7.1 Example Job Teachig Procedure Teachig Poits Operatio Procedure Step 2 -- Near cuttig positio Step 3 -- Cuttig Start Positio Step 4 -- Cuttig Ed Positio Cuttig Test Speed imitatio Drive Cuttig Executio SPOT WEDING 8.1 Example Job Settig Weldig Coditios Settig Spot Weldig Gu Coditio Files Settig Weldig Coditio for the Welder Teachig Procedure Teachig Procedure Items Operatio Procedure Step 2 -- Near Weldig Start Positio Step 3 -- Weldig Start Positio Weldig Test Check Ru Weldig Executio TURNING THE POWER OFF 9.1 Turig the Servo Power Off (Emergecy Stop) Turig the Mai Power Off ix

22 x

23 1.1 XRC Overview 1 INTRODUCTION 1.1 XRC Overview The mai power switch ad the door lock are located o the frot of the XRC cotroller. The programmig pedat hags from a hook located o the top right frot face of the cotroller. The playback pael ca be foud mouted o the cabiet door of the cotroller. Fid iformatio for setup, istallatio, ad coectio of the XRC system by referrig to the MOTOMAN Setup Maual. 1-1

24 1.2 Butto Descriptios 1.2 Butto Descriptios Playback pael buttos are eclosed i brackets throughout this maual. TEACH [TEACH] o the playback pael 1-2

25 1.3 Programmig Pedat 1.3 Programmig Pedat Programmig Pedat 1-3

26 1.4 Key Descriptios 1.4 Key Descriptios Named Keys The keys which have a ame o them are deoted with [ ]. ENTER is show as [ENTER] ad TEACH OCK is show as [TEACH OCK]. The umber keys have additioal fuctios alog with their umber values. Dual fuctio keys are used i the cotext of the operatio beig performed. For example: described i text as [1] or [TIMER]. 1 TIMER may be Symbol Keys The keys which have a symbol o them are ot deoted with [ ] but depicted with a small picture excepted the cursor key. It is deoted as Cursor. Cursor Reserved Display Key Direct Ope Key Page Key Area Key Axis Keys ad Number Keys The axis key ad umber key are deoted with Axis Operatio Keys ad Number Keys whe all of the keys are show at oe time. X- S- X+ S+ Y- - Z- U- Y+ + Z+ U+ y B- z T- x R- Axis Operatio x R+ y B+ z T TIMER 0. - REF PNT Number Simultaeously Pressed Keys Whe two keys are pressed simultaeously, these keys are deoted through combiig with + such as [SHIFT]+[COORD]. 1-4

27 1.5 Scree Descriptios 1.5 Scree Descriptios Meu items show i the programmig pedat display are deoted with { }. JOB EDIT DISPAY UTIITY I the case of the above meu, each item is show as {JOB}, {EDIT}, {DISPAY}, ad {UTI- ITY}. The items of the pull dow meu are show i the same maer, e.g. {Reame Job}. JOB EDIT DISPAY J: SEECT JOB S:*** R1 CA MASTER JOB CREATE NEW JOB RENAME JOB COPY JOB DEETE JOB UTIITY C S Four scree views are used i this maual to illustrate the programmig pedat displays. Full Scree View Upper Scree View Middle Scree View ower Scree View 1-5

28 1.6 Operatio Sequece 1.6 Operatio Sequece The followig basic sequece is used to operate the maipulator.. 1. Tur o the XRC cotroller. 2. Teach a job o the robot. 3. Replay the job o the maipulator. (called playback ) 4. Whe fiished, tur off the power. Be sure to follow the proper shutdow sequece as described i Sectio

29 2.1 Turig O the Mai Power 2 TURNING THE POWER ON Whe turig o the power, always tur o the mai power supply first ad the the servo power supply. Esure that the area aroud the maipulator is safe before turig o the power. 2.1 Turig O the Mai Power To tur o the mai power, flip the mai power switch o the frot of the XRC to the ON positio. Startup diagostics will begi automatically Startup Diagostics The startup diagostics are performed whe the XRC mai power is tured o, ad the startup display is show o the programmig pedat scree. YASNAC XRC PERFORMING SYSTEM DIAGNOSIS Copyright (c) : YASKAWA EECTRIC CORPORATION Whe Startup Diagostics are Complete Whe the power is tured off, the XRC saves all coditio data, icludig: Mode of operatio Cycle Called job (active job if the XRC is i the play mode; edit job if the XRC is i the teach mode) ad the cursor positio i the job. 2-1

30 2.2 Turig o the Servo Power 2.2 Turig o the Servo Power Durig Play Mode 1. Whe the safety guard is closed, press [SERVO ON READY] o the playback pael to tur o the servo power supply. This butto lights. SERVO ON READY NOTE Whe the safety guard is ope, the servo power supply caot be tured o Durig Teach Mode 1. Press [SERVO ON READY] o the playback pael to tur o the servo power supply. The butto will light whe the servo power is tured o. SERVO ON READY 2. Press [TEACH OCK] to eter the teach mode. TEACH OCK 3. The servo power is tured o ad [SERVO ON READY] o the playback pael lights whe the operator grips the deadma switch. SUPPE- MENT Servo Power ON/OFF --- Deadma Switch Whe the operator squeezes the deadma switch, the servo power turs ON. However, if the operator squeezes the switch util a click is heard, the servo power will tur OFF. 2-2

31 2.2 Turig o the Servo Power NOTE Whe usig the playback pael, programmig pedat, or exteral sigal to perform emergecy stop, the servo power o operatio from the deadma switch is cacelled. Whe turig the power back o, follow the previously listed istructios. 2-3

32 2.2 Turig o the Servo Power 2-4

33 3.1 Maipulator Motio 3 TEACHING 3.1 Maipulator Motio The robot is geerally operated usig two types of coordiates: joit coordiates ad rectagular coordiates. Press the axis operatio keys o the programmig pedat to move each axis of the maipulator Joit Coordiates 3-1

34 3.1 Maipulator Motio 3-2

35 3.1 Maipulator Motio Rectagular Coordiates (This figure shows directio oly (ot positio) of rectagular coordiates.) 3-3

36 3.1 Maipulator Motio Move Istructios ad Steps The maipulator uses job istructios to move ad execute playback. This is called a move istructio. The destiatio positio, the iterpolatio method, the play speed, etc. are registered i the move istructio. The reaso it is called a move istructio is that the mai istructio begis with MOV i the INFORM II laguage used by the XRC. <Example> MOVJ VJ=50.00 MOV V=1122 P=1 From oe move istructio to the ext move istructio is oe step. Step 1 is 001 ad step 2 is 002. The ext step is 003, ad so o. Positio of Step1 correspods to the positio registered i the move istructio of Step umber 001 (S:001). <Example> Refer to the job cotet display i the followig. Whe executig playback, the maipulator moves betwee Step 1 ad Step 2, ad the play speed is registered i Step 2 s move istructio. After the maipulator reaches Step 2, the maipulator the executes the TIMER istructio followed by the DOUT istructio, ad the cotiues o to Step 3. Step Number ie Number J:JOB-A S:002 R1 TOO: MOVJ VJ= MOV V= TIMER T= DOUT OT#(1) ON 0009 MOVJ VJ=50.00 Step 1 Step 2 Step 3 3-4

37 3.2 Teachig 3.2 Teachig Preparatio Before Teachig Perform the followig tasks before startig to teach. Eable the operatio of the playback pael. Set the operatio mode to teach mode. Set the teach lock. Eter the job ame. 1. Cofirm that [REMOTE] o the playback pael is ot lit. If the lamp is lit, press [REMOTE] to tur it off so that the playback pael will be ready to operate. REMOTE 2. Eter the teach mode by pressig [TEACH] o the playback pael. TEACH 3. Press [TEACH OCK]. [TEACH OCK] will light idicatig the Teach ock is tured o. The operatio mode ad cycle caot be chaged usig the playback pael or a exteral iput device. Playback caot be performed. Also, if [TEACH OCK] is ot lit, the servo power supply caot be tured o usig the deadma switch. 4. Select {JOB} uder the top meu, ad select {CREATE NEW JOB} i the sub meu. The iput lie is displayed. TEACH OCK T O P ME NU JOB ARC WEDING VARIABE OUT SEECT IN IN/OUT ROBOT SYSTEM INFO TOP MENU JOB CREATE NEW JOB SEECT JOB MASTER JOB JOB CAPACITY SEECT! {JOB} Sub Meu 3-5

38 3.2 Teachig 5. After the ew job display is show, press [SEECT]. JOB EDIT DISPAY NEW JOB CREATE R1 JOB NAME : COMM.: GROUP SET : R1 UTIITY C S SEECT EXEC CANCE! 6. The word TEST is used i this example job ame. To eter the letters for TEST, press the page key to show the followig display. APHABET R1 A B C D E F G H I J K M N O P Q R S T U V W X Y Z =! \" % & ' ( ),. _ C S > _ 7. Move the cursor to T ad press [SEECT]. Do the same to eter E, S, ad T. SEECT APHABET R1 A B C D E F G H I J K M N O P Q R S T U V W X Y Z =! \" % & ' ( ),. _ C S >TEST 8. Press [ENTER] to register. JOB EDIT NEW JOB CREATE JOB NAME : TEST COMM.: GROUP SET : R1 DISPAY R1 UTIITY C S ENTER EXEC CANCE! 3-6

39 3.2 Teachig 9. Move the cursor to EXEC ad press [SEECT]. The job TEST is registered i the XRC memory ad the job is displayed. The NOP ad END istructios are automatically registered. SEECT JOB EDIT DISPAY UTIITY JOB CONTENT R1 J: TEST S: 000 R1 TOO: 0000 NOP 0001 END => MOVJ VJ=0.78! SUPPE- MENT Characters Which Ca Be Used for Job Names Job ames ca be created from umbers, letters from the alphabet, or registered characters. The iput display for each character is displayed whe the page key is pressd durig the operatio betwee 5 ad 6. Up to eight alphaumeric characters ca be used. 3-7

40 3.2 Teachig Teachig Teachig a Job A job is a work program that describes the tasks that the maipulator will execute. Jobs are created usig a robot programmig laguage called INFORM II. The followig example will istruct you how to teach the maipulator all of the steps from Poit A to Poit B of the followig workpiece. This job ca be completed i 6 steps. Actual work is ot performed here. 3-8

41 3.2 Teachig Step 1 -- Start Positio Always be sure the maipulator is i a safe work area before operatio. 1. Grip the deadma switch ad the servo power will tur o. The maipulator ca the be operated. 2. Move the maipulator to the desired positio usig the axis operatio keys. Be sure the positio is safe ad that the work area is appropriate for the job to be programmed. 3. Select joit motio by pressig [MOTION TYPE]. Joit istructio MOVJ... will be displayed i the iput buffer lie. => MOVJ VJ=0.78 MOTION TYPE 4. Move the cursor to the lie umber 0000 ad press [SEECT]. J: TEST S: 000 R1 TOO: * 0000 NOP 0001 END SEECT 5. The iput buffer lie is displayed. Move the cursor to the right to VJ=*.**, which shows the speed. While pressig [SHIFT] simultaeously, move the cursor up ad dow (to higher ad lower play speeds) util the desired speed is specified. SHIFT => MOVJ VJ= Press [ENTER]. Step1 (ie 0001) is registered NOP 0001 MOVJ VJ= END ENTER 3-9

42 3.2 Teachig Step 2 -- Near the Work Start ocatio Defie the maipulator work pose. 1. Move the maipulator to the workig positio usig the axis operatio keys. 2. Press [ENTER]. Step 2 (ie 0002) is registered NOP 0001 MOVJ VJ= MOVJ VJ= END ENTER Step 3 -- Work Start ocatio Move the maipulator to the work start locatio as i Step 2 pose. 1. Chage to medium speed by pressig [FST] or [SW] util M is displayed i the status area. JOB EDIT JOB CONTENT DISPAY R1 UTIITY 2. Do ot release the pose i Step 2. Press [COORD] to select the rectaglar coordiates. Move the maipulator to the weldig start locatio usig the axis operatio keys. M C S FST MAN SPD SW COORD JOB EDIT JOB CONTENT DISPAY R1 M UTIITY C S 3. Move the cursor to the lie umber 0002 ad press [SEECT]. SEECT 3-10

43 3.2 Teachig 4. The iput buffer lie is displayed. Move the cursor to the right to VJ=*.**, which shows the speed. While pressig [SHIFT] simultaeously, move the cursor up ad dow (to higher ad lower play speeds) util the desired speed is specified. Set the speed 12.50%. SHIFT => MOVJ VJ= Press [ENTER]. Step 3 (ie 0003) is registered NOP 0001 MOVJ VJ= MOVJ VJ= MOVJ VJ= END ENTER Step 4 -- Work Ed Positio Specify the work ed positio. 1. Move the maipulator to the work ed positio with the axis operatio keys. While the maipulator is movig, keep a wide eough distace to esure it will ot strike the workpiece. There is o eed to follow the work lie too closely. 2. Press [MOTION TYPE] to select liear motio (MOV). => MOV V=66 MOTION TYPE 3. Move the cursor to the lie umber 0003 ad press [SEECT]. => MOV V=66 SEECT 4. The iput buffer lie is displayed. Move the cursor to the right to V=*.**, which shows the speed. While pressig [SHIFT] simultaeously, move the cursor up ad dow (to higher ad lower play speeds) util the desired speed is specified. Set the speed to 138 cm/mi. SHIFT => MOV V=

44 3.2 Teachig 5. Press [ENTER]. Step 4 (ie 0004) is registered NOP 0001 MOVJ VJ= MOVJ VJ= MOVJ VJ= MOV V= END ENTER Step 5 -- Positio Away From Workpiece ad Fixture Move the maipulator to a positio where it will ot strike the workpiece or fixture. 1. Chage the speed to high speed by pressig [FST] or [SW]. JOB EDIT DISPAY UTIITY H JOB CONTENT R1 FST MAN SPEED NOTE This butto oly affects teachig speed. Whe the job is played, the job will execute at the speed defied i Step Move the maipulator with the axis operatio keys to a positio where it will ot strike the fixture. 3. Press [MOTION TYPE] to set to the joit motio type (MOVJ). => MOVJ VJ=12.50 MOTION TYPE 4. Move the cursor to lie umber 0004 ad press [SEECT]. => MOVJ VJ=12.50 SEECT 3-12

45 3.2 Teachig 5. The iput buffer lie is displayed. Move the cursor to the right to V=*.**, which shows the speed. While pressig [SHIFT] simultaeously, move the cursor up ad dow (to higher ad lower play speeds) util the desired speed is specified. Set the speed to 50%. SHIFT => MOVJ VJ= Press [ENTER]. Step5 (ie 0005) is registered NOP 0001 MOVJ VJ= MOVJ VJ= MOVJ VJ= MOV V= MOVJ VJ= END ENTER Step 6 -- Near the Start Positio Move the maipulator ear the start positio. 1. Move the maipulator ear the start positio with the axis operatio keys. 2. Press [ENTER]. Step6 (ie 0006) is registered NOP 0001 MOVJ VJ= MOVJ VJ= MOVJ VJ= MOV V= MOVJ VJ= MOVJ VJ= END ENTER 3-13

46 3.2 Teachig Esurig the First ad ast Step are Idetical The maipulator has stopped at Step 6, which should be very close to Step1. It is possible to move directly from the weldig ed positio of Step 5 to Step1, so the maipulator ca begi the ext weldig job quickly ad efficietly. The followig operatio will make Step 6 (ed positio) ad Step1 (start positio) idetical. 1. Move the cursor to Step1 (ie 0001) NOP 0001 MOVJ VJ= MOVJ VJ= Press [FWD]. The maipulator will move to Step1. FWD 3. Move the cursor to Step 6 (ie 0006) MOVJ VJ= MOVJ VJ= END 4. Press [MODIFY]. MODIFY 5. Press [ENTER]. This will chage the positio of Step 6 to be the same as Step1. ENTER Path Cofirmatio The job is ow complete. Try to check each step separately to esure there are o problems. 1. Move the cursor to Step 1 (ie 0001) NOP 0001 MOVJ VJ= MOVJ VJ=

47 3.2 Teachig 2. Chage to medium speed by pressig [FST] or [SW]. JOB EDIT JOB CONTENT DISPAY R1 3. Press [FWD] to cofirm each step executed by the maipulator. Each time [FWD] is pressed, the maipulator moves oe step. M UTIITY C S FST MAN SPD SW FWD 4. Whe you fiish step cofirmatio, move the cursor to the begiig of the job. 5. Ru all the steps cotiuously. Hold dow [INTEROCK] ad press [TEST START]. The maipulator plays back all the steps cotiuously ad stops whe oe cycle is fiished. INTER OCK + TEST START Did the maipulator move exactly as you expected? Proceed to the ext sectio to chage the positio ad speed of the job steps Correctig a Job CAUTION After the job is corrected, cofirm the path. Before Correctig a Job Cofirm the maipulator s motio i each step. If ay positio modificatio or addig or deletig of steps is ecessary, display the job cotet first with the followig procedure. 1. Select {JOB} uder the top meu ad {JOB} uder the sub meu. T O P ME NU JOB OUT ARC WEDING VARIABE SEECT IN IN/OUT ROBOT SYSTEM INFO JOB CREATE NEW JOB SEECT JOB MASTER JOB SEECT Cofirm that the teach lock is o. 3-15

48 3.2 Teachig Chage the Positio Data Chage the positio registered i Step Move the maipulator to Step 2 (ie 0002) by pressig [FWD]. FWD 2. Move the maipulator to the modified positio with the axis operatio keys. 3. Press [MODIFY]. MODIFY 4. Press [ENTER]. The step s positio data is chaged. ENTER Add a Step Add a ew step betwee Step 5 ad Step Move the maipulator to Step 5 (ie 0005) by pressig [FWD] MOV V= MOVJ VJ= MOVJ VJ= END FWD 2. Move the maipulator to the positio at which you wish to add a step usig the axis operatio keys. 3-16

49 3.2 Teachig 3. Press [INSERT]. INSERT 4. Press [ENTER]. The step is added. Whe a step is added, the umberig is automatically adjusted to cout the ew step MOV V= MOVJ VJ= MOVJ VJ= MOVJ VJ= END ENTER Delete a Step Delete the step you just added. 1. Move the maipulator to Step 6 (ie 0006) by pressig [FWD] MOV V= MOVJ VJ= MOVJ VJ= MOVJ VJ= END FWD 2. Make sure the cursor is o the step you wish to delete, ad press [DEETE]. DEETE 3. Press [ENTER]. The step is deleted MOV V= MOVJ VJ= MOVJ VJ= END ENTER 3-17

50 3.2 Teachig SUPPE- MENT Whe Error 2070: Set Robot Exactly to Taught Positio Occurs Whe the operator presses [ENTER] durig the previous operatio, a error ca occur i some cases. The error occurs because the maipulator has ot bee moved exactly to the taught positio. Cacel the error by pressig [CANCE] ad press [FWD] to move the maipulator. If the cursor i the display is blikig, the robot is ot i the taught positio. Chagig the Speed Betwee Steps Chage the maipulator speed. Slow the speed betwee Step 3 ad Step Move the cursor to Step Move the cursor to the istructio ad press [SEECT]. SEECT 3. The iput buffer lie is displayed. Move the cursor to the right to V=138, which shows the speed. While pressig [SHIFT] simultaeously, move the cursor up ad dow (to higher ad lower play speeds) util the desired speed is specified. Set the speed to 66cm/mi. SHIFT => MOV V=66 4. Press [ENTER]. The speed is chaged. ENTER 3-18

51 4.1 Preparatio Prior to Playback 4 PAYBACK 4.1 Preparatio Prior to Playback Before executig maipulator playback, release the teach lock. 1. Press [TEACH OCK]. After pressig the butto, be sure [TEACH OCK] lights. TEACH OCK NOTE To ru the program from the begiig of the job, perform the followig operatio. Move the cursor to the begiig of the job. Move the maipulator close to Step 1 with the axis operatio keys. Whe playback is ready to begi, the maipulator begis to move from the Step Playback Begi operatio oly after esurig there is o oe i the workig evelope of the maipulator. 1. Press [PAY] o the playback pael. PAY 2. Press [START] o the playback pael. The maipulator will perform oe complete taught cycle ad the stop. START How did it go? Did the maipulator perform exactly as you expected? 4-1

52 4.2 Playback 4-2

53 5.1 Example Job 5 ARC WEDING 5.1 Example Job The figure below shows a example of weldig a workpiece with a explaatio of each step. Example Job INE INSTRUCTION EXPANATION 0000 NOP 0001 MOVJ VJ=25.00 Moves maipulator to waitig positio. (Step 1) 0002 MOVJ VJ=25.00 Moves maipulator ear weldig start positio. (Step 2) 0003 MOVJ VJ=12.50 Moves maipulator to weldig start positio. (Step 3) 0004 ARCON Specifies maipulator arc start MOV V=50 Moves maipulator to weldig ed positio. (Step 4) 0006 ARCOF Specifies maipulator arc ed MOVJ VJ=25.00 Moves maipulator to positio a safe distace away from equipmet. (Step 5) 0008 MOVJ VJ=25.00 Moves maipulator to waitig positio. (Step 6) 0009 END 5.2 Teachig Procedure Teachig Procedure Items The teachig procedure is explaied i Step 2 (weldig pose defiitio) ad the weldig procedure is explaied i Step 3 (weldig start) ad Step 4 (weldig ed). 5-1

54 5.2 Teachig Procedure NOTE Step 1 ad 6, which are both the waitig positio, are adjusted to a safe positio where the robot does ot collide with the workpiece ad the fixture, etc. Esure that the legth of the wire is the same durig teachig ad playback. The appropriate wire legth ca be determied by usig the ichig procedure. Whe the maipulator comes i cotact with the workpiece durig the teachig procedure, exted the wire mm ad cut at a appropriate legth. After teachig is completed, cofirm the weldig path with [FWD] ad [BWD] Operatio Method Step 2 -- Near Weldig Start ocatio Defie the pose of the weldig torch. 1. Usig the axis operatio keys, specify the correct posture for the maipulator to begi weldig. 2. Press [ENTER]. Step 2 is registered NOP 0001 MOVJ VJ= MOVJ VJ= END ENTER Step 3 -- Weldig Start Positio Move the weldig torch to the weldig start locatio with the pose as show i Step 2, ad register the ARCON istructio. 1. Chage to medium speed by pressig [FST] or [SW] util M is displayed i the status area. JOB EDIT DISPAY UTIITY M JOB CONTENT R1 FST MAN SPD SW 2. Move the maipulator to the weldig start positio with the axis operatio keys. At this time, do ot release the pose iput i Step Move the cursor to the lie umber ad press [SEECT]. => MOV VJ=50.00 SEECT 5-2

55 5.2 Teachig Procedure 4. The iput buffer lie is displayed. Move the cursor to the right to VJ=*.**, which shows the speed. While pressig [SHIFT] simultaeously, move the cursor up ad dow (to higher ad lower play speeds) util the desired speed is specified. Set the speed 12.50%. SHIFT => MOVJ VJ= Press [ENTER]. Step 3 is registered NOP 0001 MOVJ VJ= MOVJ VJ= MOVJ VJ= END ENTER 6. Press [ARCON]. ARCON is displayed i the iput buffer lie. => ARCON Press [ENTER]. The ARCON istructio is registered. 8 ARCON ENTER Step 4 -- Weldig Ed Coditio Specify the weldig ed positio. 1. Move the maipulator to the weldig ed positio with the axis operatio keys. While the maipulator is movig, keep a wide eough distace to esure it will ot strike the workpiece. There is o eed to follow the work lie too closely. 2. Set the motio type to liear motio type (MOV) by pressig [MOTION TYPE]. => MOV V=66 MOTION TYPE 3. Move the cursor to the lie umber ad press [SEECT]. => MOV V=66 SEECT 4. The iput buffer lie is displayed. Move the cursor to the right to V=66, which shows the speed. Set to 50 cm/mi with the umber keys

56 5.3 Settig Weldig Coditios 5. Press [ENTER]. Step 4 is registered NOP 0001 MOVJ VJ= MOVJ VJ= MOVJ VJ= ARCON 0005 MOV V= END ENTER 6. Press [ARCOF]. ARCOF is displayed i the iput buffer lie. => ARCOF Press [ENTER]. The ARCOF istructio is registered. 5 ARCOF ENTER 5.3 Settig Weldig Coditios Registratio of Weldig Coditio There are two ways to register the weldig coditio, the oe way is usig the arc start coditio file ad the other way is usig the additioal items of the ARCON istructio. The latter way is described here. See "OPERATOR S MANUA FOR ARC WEDING" for the arc start coditio file. 1. Move the cursor to the ARCON istructio ad press [ENTER]. The ARCON istructio is displayed i the iput buffer lie. Press [SEECT]. The detail edit display is show. ENTER SEECT 5-4