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User's Manual

SCARA Robot

YK-XG

series

Jul. 2008
Ver. 1.08

This manual is based on Ver. 1.08 of Japanese manual.

© YAMAHA MOTOR CO., LTD.
IM Company

All rights reserved. No part of this publication may be reproduced in
any form without the permission of YAMAHA MOTOR CO., LTD.
Information furnished by YAMAHA in this manual is believed to be
reliable. However, no responsibility is assumed for possible
inaccuracies or omissions. If you find any part unclear in this manual,
please contact YAMAHA or YAMAHA sales representatives.

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Summary of Contents for YK-X Series

Page 1: ...User s Manual ENGLISH E YAMAHA SCARA ROBOT E35 Ver 1 08 YK XG YK X series ...

Page 2: ......

Page 3: ...g the next absolute reset 2 Setting a position OTHER than the robot arm extended position the origin position adjusted at the factory prior to shipment as the origin position 1 To set the robot arm extended position the origin position adjusted at the factory prior to shipment as the origin position Absolute Reset TheYK XG series robots only require the absolute reset to be performed once when the...

Page 4: ... the Reference Coordinates in Chapter 4 of this manual and also to Setting the Reference Coordinates in the YAMAHA Robot Controller User s Manual Robot malfunctions vibration noise may occur if the reference coordinates are not set correctly Even though there is no problem with the robot the following error messages are issued when the robot and controller are connected and power first turned on A...

Page 5: ... and effective use Be sure to read this manual carefully before installing the robot Even after you have read this manual keep it in a safe and convenient place for future reference This instruction manual should be used with the robot and considered an integral part of it When the robot is moved transferred or sold send this manual to the new user along with the robot Be sure to explain to the ne...

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Page 7: ...10 Repair and Modification 1 13 11 Warranty 1 14 12 CE Marking 1 16 CHAPTER 2 Functions 1 Robot Manipulator 2 1 2 Robot Controller 2 3 3 Robot initialization number list 2 4 CHAPTER 3 Installation 1 Robot Installation Conditions 3 1 1 1 Installation environments 3 1 1 2 Installation base 3 2 2 Installation 3 4 2 1 Unpacking 3 4 2 2 Checking the product 3 5 2 3 Moving the robot 3 6 2 3 1 Moving the...

Page 8: ...H YK700XG YK800XG YK900XG YK1000XG 3 31 8 Working Envelope and Mechanical Stopper Positions for Maximum Working Envelope 3 33 CHAPTER 4 Adjustment 1 Overview 4 1 2 Safety Precautions 4 1 3 Adjusting the origin 4 2 3 1 Absolute reset method 4 3 3 1 1 Sensor method X axis Y axis and R axis 4 3 3 1 2 Stroke end method Z axis 4 3 3 2 Machine reference 4 4 3 3 Absolute reset procedures 4 5 3 3 1 Sensor...

Page 9: ...eriod 5 9 5 2 Basic replacement procedure for harmonic drive and precautions 5 10 5 2 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 5 12 CHAPTER 6 Increasing the robot operating speed 1 Increasing the robot operating speed 6 1 CHAPTER 7 Specifications 1 Manipulator 7 1 1 1 Basic specification 7 1 1 2 Robot inner wiring diagram 7 2 1 3 Wiring table 7 3 ...

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Page 11: ...aining for Industrial Robot Operation 1 8 4 Robot Safety Functions 1 9 5 Safety Measures for the System 1 10 6 Trial Operation 1 11 7 Work Within the Safeguard Enclosure 1 12 8 Automatic Operation 1 13 9 Adjustment and Inspection 1 13 10 Repair and Modification 1 13 11 Warranty 1 14 12 CE Marking 1 16 ...

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Page 13: ... or repairing the robot CAUTION Failure to follow CAUTION instructions may result in injury to the robot opera tor a bystander or a person inspecting or repairing the robot or damage to the robot and or robot controller NOTE Explains the key point in the operation in a simple and clear manner Refer to the instruction manual by any of the following methods to operate or adjust the robot safely and ...

Page 14: ...stall safeguards so that no one can enter inside except from doors or panels equipped with safety interlocks The warning labels shown in Fig 1 1 are supplied with the robot and should be affixed to a conspicuous spot on doors or panels equipped with safety interlocks DANGER Serious injury or death will result from impact with moving robot Keep outside of guard during operation Lock out power befor...

Page 15: ...as well as descriptions in this chapter Chapter 1 Using the Robot Safely Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual WARNING Improper installation or operation can result in serious injury or death Read user s manual and all warning labels before installation or operation Improper Installation or operation can result in ...

Page 16: ...the Z axis vertical axis brake WARNING The Z axis will slide down when the Z axis brake is released causing a hazard ous situation Press the emergency stop button and prop up the Z axis with a support stand before releasing the brake Use caution not to let your body get caught between the Z axis and installa tion base when releasing the brake to perform direct teach 8 Provide safety measures for e...

Page 17: ...struction is removed causing injury such as pinched or crushed hands Turn off the controller and reduce the air pressure before attempting to re move the obstruction Before reducing the air pressure place a support stand under the Z axis because it will drop under its own weight 11 Use caution on Z axis movement when air supply is stopped 2 axis robots with air driven Z axis WARNING The Z axis may...

Page 18: ...er to the YAMAHA Robot Con troller User s Manual 15 Consult us for corrective action when the robot is damaged or malfunction occurs WARNING If any part of the robot is damaged or any malfunction occurs continuous op eration may be very dangerous Please consult YAMAHA dealer for corrective action If the following damages or troubles exist These dangers can happen Damage to machine harness or robot...

Page 19: ...be operated with correct tolerable moment of inertia and accel eration coefficients according to the manipulator tip mass and moment of iner tia If this is not observed premature end to the life of the drive units damage to the robot parts or residual vibration during positioning may result 20 Do not use the robot for tasks requiring motor thrust CAUTION Avoid using the YK XG series robots for tas...

Page 20: ...in spection adjustment and repair has received appropriate training and also has the skills needed to perform the job correctly and safely Since the YK XG series robots fall under the industrial robot category the user must observe local regulations and safety standards for industrial robots and provide special training for every person involved in robot related tasks teach ing programming movemen...

Page 21: ...is the area lim ited by mechanical stoppers The movement ranges of the X axis arm can be limited as needed by use of mechanical stoppers On theY axis arm mechanical stoppers are fixed at both ends of the maxi mum movement range The Z axis has a mechanical stopper at the upper end and lower end No mechanical stopper is provided on the R axis WARNING Axis movement will not stop immediately after the...

Page 22: ...n gerous situations are more likely to occur from the automated system than from the robot itself Accordingly appropriate safety measures must be taken on the part of the system manufacturer according to the individual system The system manufacturer should provide a proper instruction manual for safe correct opera tion and servicing of the system ...

Page 23: ...roller 1 Is the robot securely and correctly installed 2 Are the electrical connections to the robot correct 3 Are items such as air pressure correctly supplied 4 Is the robot correctly connected to peripheral equipment 5 Have safety measures safeguard enclosure etc been taken 6 Does the installation environment meet the specified standards 3 After the controller is turned on check the following p...

Page 24: ...ter 4 4 Teaching For items 1 to 3 follow the precautions and procedure for each section To perform item 4 refer to the description in 2 below 2 Teaching When performing teaching within the safeguard enclosure comply with the instructions listed below 1 Check or perform the following points from outside the safeguard enclo sure 1 Make sure that no hazards are present within the safeguard enclosure ...

Page 25: ...p 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 i...

Page 26: ...ty will not apply in the following cases 1 Fatigue arising due to the passage of time natural wear and tear occurring during op eration natural fading of painted or plated surfaces deterioration of parts subject to wear etc 2 Minor natural phenomena that do not affect the capabilities of the robot and or related product noise from computers motors etc 3 Programs point data and other internal data ...

Page 27: ...IES INCLUDINGWARRAN TIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR WARRANTIES ARISING FROM A COURSE OF DEALING OR USAGE OF TRADE YAMAHA MOTOR CO LTD SOLE LIABILITY SHALL BE FOR THE DE LIVERY OF THE EQUIPMENT ANDYAMAHA MOTOR CO LTD SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES WHETHER ARISING FROM CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY YAMAHA MOTOR CO LTD MAKES NOWARRANTY...

Page 28: ...Robot Safely 12 CE Marking When the YAMAHA robots are exported to or used in EU European Union countries refer to the separate YAMAHA Robot Controller User s Manual or CE marking manual for related information about CE marking ...

Page 29: ...CHAPTER 2 Functions 1 Robot Manipulator 2 1 2 Robot Controller 2 3 3 Robot initialization number list 2 4 ...

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Page 31: ...ig 2 1 By attaching different types of end effector gripper to the end of the arm a wide range of tasks can be performed with high precision at high speeds The and signs show the direction of axis movement when the jog keys on the programming unit are pressed standard setting at the factory Fig 2 2 on the subsequent pages show part names and functions of each robot model Y axis arm Y axis X axis a...

Page 32: ...s speed reduction gear Y axis arm Y axis motor X axis arm Y axis mechanical stopper Warning label 3 X axis motor Tapped hole and screw for user X axis speed reduction gear X axis movable mechanical stopper Warning label 1 Warning label 2 on opposite side User tubing 1 φ6 black User tubing 2 φ6 red User tubing 3 φ6 blue M4 ground terminal Robot cable D sub connector for user wiring No 1 to 20 Seria...

Page 33: ...eparate YAMAHA Robot Controller User s Manual RCX142 MOTOR XM YM ZM RM PWR SRV ERR SAFETY MPB COM STD DIO RGEN ACIN P N L N ROB I O XY ROB I O ZR OP 1 OP 3 OP 2 OP 4 200 230V 50 60Hz MAX 2500VA BATT ZR XY MODEL SER NO MANUFACTURED FACTORYAUTOMATIONEQUIPMENT MADEINJAPAN 注意 CAUTION 取扱説明書参照 READ INSTRUCTION MANUAL RCX142 Fig 2 3 Robot controller ...

Page 34: ...nderstand the proce dure When the controller is initialized the ARM LENGTH and OFFSET PULSE settings in the axis parameters will be erased making the standard coordi nate settings invalid For details on standard coordinates see 5 Setting the Standard Coordinates in Chapter 4 If you do not want to change the origin position by initializing make a note of the ARM LENGTH and OFF SET PULSE settings be...

Page 35: ...ration coefficient vs moment of inertia YK500XG 3 17 6 1 2 Acceleration coefficient vs moment of inertia YK600XG 3 17 6 1 3 Acceleration coefficient vs moment of inertia YK600XGH 3 18 6 1 4 Acceleration coefficient vs moment of inertia YK700XG YK800XG 3 18 6 1 5 Acceleration coefficient vs moment of inertia YK900XG YK1000XG 3 19 6 2 Equation for moment of inertia calculation 3 20 6 3 Example of mo...

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Page 37: ...r oil filtration 40µm or less Allow sufficient space margin to perform jobs teaching inspection repair etc For detailed information on how to install the robot controller refer to the sepa rate YAMAHA Robot Controller User s Manual WARNING Avoid installing the robot in locations where the ambient conditions may ex ceed the allowable temperature or humidity or in environments where water corrosive ...

Page 38: ...llation base vibration resonance may occur during operation causing detrimental effects on the manipulator work 1 Prepare a sufficiently rigid and stable installation base taking account of the robot weight including the end effector gripper workpiece and reaction force while the robot is operating The maximum reaction force see Fig 3 1 applied to the X axis and Z axis of each robot during operati...

Page 39: ...mount must be installed fac ing down and in a level position except ceiling mount models which should be installed with the base mount facing up 3 Tap holes into the surface of the installation base For machining dimensions and positions refer to the external view and dimensions shown in the catalog or website www yamaha motor co jp global industrial robot 4 Securely fix the installation base on t...

Page 40: ...rate it The equipment and tools used for moving the robot should be serviced daily The YK XG series robot comes packed with a robot controller and accessories according to the order specifications Using a carrying cart dolly or forklift move the package to near the installation base Take sufficient care not to apply shocks to the equipment when unpacking it YK500XG YK600XG YK600XGH YK700XG YK800XG...

Page 41: ...0XG YK800XG YK900XG YK1000XG A B X Y Z R RCX142 MOTOR XM YM ZM RM PWR SRV ERR SAF ETY MPB COM STD DIO RGE N ACIN P N L N ROB I O XY ROB I O ZR OP 1 OP 3 OP 2 OP 4 200 230V 50 60H z MA X 2 500 VA MODEL SER NO MANUFAC TURED FACTORY AUTOMATIO N EQUIPMENT MADE IN JAPAN CAUT ION READ INSTRU CTION MANUA L BAT T ZR XY Robot manipulator YK XG series CD ROM User s Manual or User s Manual RCX142controller W...

Page 42: ...robot may lose balance while being carried and topple over causing accidents CAUTION When moving the robot by equipment such as cranes that require a license only properly qualified personnel may operate it The equipment and tools used for moving the robot should be serviced daily To move a robot for example the YK500XG correctly and safely follow the procedure below See Fig 3 4 Use the same proce...

Page 43: ... the hoist carefully to move to the installation base The angle between each rope and the arm surface should be kept at 45 degrees or more 9 Slightly lower the robot on the installation base and temporarily secure it by tightening the bolts For tightening torque to secure the robot firmly see the next section 2 4 Installing the robot 10 Remove the rope eyebolts and arm clamp stay Screw the bolts i...

Page 44: ...tightened correctly the robot might fall over during operation causing a serious accident Robot Model YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG M10 M12 71Nm 720kgfcm 128Nm 1310kgfcm Bolts Used Tightening torque Tightening torque Depth of tapped holes in installation base Iron installation base Bolt diameter 1 5 or more Aluminum installation base Bolt diameter 3 or more Recommended ...

Page 45: ...otec tive conductor See Fig 3 6 for example of the YK500XG Symbol 417 IEC 5019 2 When the end effector uses an electrical device which if it malfunctions might make contact with the power supply the user must provide proper grounding on his own responsibility TheYK XG series robots do not have a ground terminal for this purpose 3 For details on protective bonding on the robot body to comply with C...

Page 46: ...3 10 CHAPTER 3 Installation Ground symbol M4 Ground terminal Fig 3 6 Ground terminal ...

Page 47: ... is inadequate or if there are contact failures in the pins the robot may malfunction causing a hazardous situation Reconfirm that each connector is securely installed before turning on the controller To attach the PI connector securely tighten the screws supplied with the robot Take caution not to apply an excessive load to the connectors due to stress or tension on the cables Lay out the cables ...

Page 48: ...r tubing φ6 3 tubes Robot models for custom specifications may have different wiring or tub ing The specifications of the user wires and air tubes are shown below Always observe the specifications 30V 1 5A 0 2mm2 Yes User Wiring Rated voltage Allowable current Nominal cross section area of conductor Shield User Tubing Maximum pressure Outer diameter inner diameter Fluid 0 58MPa 6Kgf cm2 φ6mm φ4mm ...

Page 49: ...1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Signal User signal line Shield Flame Ground NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 Connector I O Arm side Connection Connector I O Base side FG Color Brown Red Orange Blue Violet Grey White Black Brown Red Orange Blue Brown Red Orange Blue Violet Grey White Black Green Green Robots models with non standard specifications m...

Page 50: ...s to the shield wire If this task is omitted noise may cause malfunction of the robot Securely attach the D sub connector supplied with the robot into the D sub connector on the robot side by tightening the screws on the connector hood If this connector comes loose or comes off malfunction may result Avoid fastening the user cable or tube with the machine harness as this may lead to harness breaka...

Page 51: ...robot Using other types may result in contact failure DB C2 J9R DB 25S NR DB 25P NR YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Robot model D sub connector on arm side D sub connector on base side Hood Manufacturer Japan Aviation Electronics Industry Limited D sub connectors supplied with robot 5 To check the operation and signal transmission between the end effector and the controll...

Page 52: ...nts to 62 as can be seen from Fig 3 9 Be sure to select an optimum tip mass and acceleration coefficient param eters that meet the mass of the load and moment of inertia before using the robot To make settings for the tip mass and acceleration coefficient refer to the separate YAMAHA Robot Controller User s Manual 3 Methods for calculating the moment of inertia of the load are shown in Sec tion 6 ...

Page 53: ...AR Ir kgm2 Jr kgm2 80 60 40 20 0 0 0 05 0 5 0 1 1 0 0 15 1 5 0 2 2 0 0 25 2 5 0 3 3 0 0 04 0 4 Fig 3 9 m 1 to 10kg 6 1 2 Acceleration coefficient vs moment of inertia YK600XG 100 AX AY AR Ir kgm2 Jr kgm2 80 60 40 20 0 0 0 05 0 5 0 1 1 0 0 15 1 5 0 2 2 0 0 25 2 5 0 3 3 0 0 03 0 3 Fig 3 10 m 1 to 10kg ...

Page 54: ... AR Ir kgm2 Jr kgfcmsec2 80 60 40 20 0 0 0 2 2 0 0 4 4 0 0 6 6 0 0 8 8 0 1 0 10 0 0 03 0 3 Fig 3 11 m 1 to 20kg 6 1 4 Acceleration coefficient vs moment of inertia YK700XG YK800XG 100 AX AY AR Ir kgm2 Jr kgfcmsec2 80 60 40 20 0 0 0 2 2 0 0 4 4 0 0 6 6 0 0 8 8 0 1 0 10 0 0 02 0 2 Fig 3 12 m 1 to 20kg ...

Page 55: ...PTER 3 Installation 6 1 5 Acceleration coefficient vs moment of inertia YK900XG YK1000XG 100 AX AY AR Ir kgm2 Jr kgfcmsec2 80 60 40 20 0 0 0 2 2 0 0 4 4 0 0 6 6 0 0 8 8 0 1 0 10 0 0 07 0 7 Fig 3 13 m 1 to 20kg ...

Page 56: ...1 Moment of inertia for material particle The equation for the moment of inertia for a material particle that has a rota tion center such as shown in Fig 3 14 is as follows This is used as an approximate equation when x is larger than the object size x J Wx g 2 kgfcmsec2 g Gravitational acceleration cm sec2 m Mass of material particle kg Eq 3 1 I mx2 kgm2 W Weight of material particle kgf Fig 3 14...

Page 57: ...2 ρ Density kg m3 kg cm3 g Gravitational acceleration cm sec2 m Mass of cylinder kg W Weight of cylinder kgf kgfcmsec2 kgm2 Fig 3 16 4 Moment of inertia for prism The equation for the moment of inertia for a prism that has a rotation center as shown in Fig 3 17 is given as follows J ρ abc a b 12g W a b 12g 2 2 Eq 3 4 a c b 1 2a 2 2 I ρ abc a b 12 m a b 12 2 2 2 2 kgfcmsec2 kgm2 ρ Density kg m3 kg ...

Page 58: ...celeration cm sec2 m Mass of cylinder kg W Weight of cylinder kgf kgfcmsec2 kgm2 Fig 3 18 In the same manner the moment of inertia of a cylinder as shown in Fig 3 19 is given by W 4g Eq 3 6 D 4 h 3 2 2 h D x Cneter line J ρπ D h 16g 2 D 4 h 3 2 2 ρπ D h x 4g 2 2 Wx g 2 I ρπ D h 16 2 D 4 h 3 2 2 ρπ D h x 4 2 2 m 4 D 4 h 3 2 2 mx2 kgfcmsec2 kgm2 Fig 3 19 In the same manner the moment of inertia of a...

Page 59: ...lowing three factors assuming that the load mate rial is steel and its density ρ is 0 0078kg cm3 10cm 2cm 2cm R axis 1cm 1cm 2cm 2cm 4cm 6cm 4cm Stay Chuck Workpiece Fig 3 21 1 Moment of inertia of the stay From Fig 3 22 the weight of the stay Ws is given as follows Ws ρabc 0 0078 12 2 2 0 37 kgf The moment of inertia of the stay Js is then calculated from Eq 3 7 Js 0 37 122 22 0 37 52 0 014 kgfcm...

Page 60: ...4cm R axis 3 Moment of inertia of workpiece When the workpiece form resembles that shown in Fig 3 24 the weight of the workpiece Ww is Ww ρπD2 h 0 0078π 22 4 4 4 0 098 kgf The moment of inertia of the workpiece Jw is then calcu lated from Eq 3 5 Jw 0 097 22 0 097 102 8 980 980 0 010 kgfcmsec2 Fig 3 24 10cm 4cm R axis 2cm 4 Total weight The total weight W is calculated as follows W Ws Wc Ww 0 84 kg...

Page 61: ...r will not come off when the loads listed in Table 3 1 are applied The user s end effector that attaches to the robot must have adequate strength and rigidity as well as gripping force to prevent positioning errors Table 3 1 shows the maximum load that can be applied to the end effector attachment of each robot model Recommended methods for attaching end effectors are shown in Table 3 2 and Fig 3 ...

Page 62: ...00XG YK800XG YK900XG YK1000XG End effector attachment area Fig 3 25 WARNING The tapped hole see Figs 3 25 provided on the lower part of the end effec tor attachment should be used only for preventing the end effector from com ing loose Do not fasten the end effector just by using this tapped hole If the end effec tor is fastened only with this tapped hole it may come loose from the attach ment dur...

Page 63: ...idents or injuries The end effector attachment must have sufficient rigidity versus the loads listed in Table 3 1 If this rigidity is inadequate the end effector may vibrate during robot operation causing bad effects on the manipulator operation FRmax End effector Stay FxYmax Fzmax MRmax Mmax Fig 3 26 Maximum load applied to end effector attachment Table 3 2 Robot Model YK500XG YK600XG YK600XGH YK...

Page 64: ...3 28 CHAPTER 3 Installation Hole diameter Bolt Slot Spline shaft End effector or stay Fig 3 27 ...

Page 65: ...unt equal to the offset versus the arm length When the R axis rotates during operation this acceleration ARmax must be taken into account Table 3 4 Maximum acceleration during robot operation Robot Model YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Amax m sec2 AXYmax m sec2 Azmax m sec2 ARmax rad sec2 98 48 57 280 104 41 57 280 78 60 38 176 96 60 38 176 101 51 38 176 95 51 38 176 95 5...

Page 66: ... If the maximum movement range is too large compared to the actual work range or the manipulator might interfere with peripheral units then the movement range can be limited as out lined below The X axis mechanical stopper positions may slightly differ depending on machining precision WARNING Always turn off the controller before changing the movement range with me chanical stoppers CAUTION When t...

Page 67: ...all the mechanical stopper bolt and washer at the position that determines the desired movement range by tightening the bolt to the torque specified in Table 3 5 Reinstall the screw plug you removed into the position where the X axis stopper bolt was installed 6 Check that the movement range is limited by the mechanical stoppers as desired 7 Go outside the safeguard enclosure 8 Check that no one i...

Page 68: ...movable mechanical stopper 43 12 87 132 Fig 3 29 X axis movable mechanical stopper position Screw plug X axis stopper bolt Washer YK500XG YK600XG 1 washer YK600XGH YK700XG YK800XG YK900XG YK1000XG 2 washers Fig 3 30 Changing the X axis mechanical stopper position ...

Page 69: ...R 5 0 0 R 8 2 a R64 d R 1 7 1 1 3 2 1 4 7 R300 R 2 5 R25 c 113 100 288 R55 b 165 Z300mm stroke Z200mm stroke Z axis lower end mechanical stopper position Z axis upper end mechanical stopper position 8mm rise during Z axis return to origin Working envelope Interference position a Base front panel b Base side panel c Base rear panel d Base corners Interference position a Base front panel b Base side...

Page 70: ...end mechanical stopper position Z axis upper end mechanical stopper position 8mm rise during Z axis return to origin Working envelope Interference position a Base front panel b Base side panel c Base rear panel d Base corners Interference position a Base front panel b Base side panel c Base rear panel d Base corners Maximum movement range X axis mechanical stopper 132 Y axis mechanical stopper 147...

Page 71: ...wer end mechanical stopper position Z axis upper end mechanical stopper position 6mm rise during Z axis return to origin Working envelope Interference position a Base front panel b Base side panel c Base rear panel d Base corners Interference position a Base front panel b Base side panel c Base rear panel d Base corners Maximum movement range X axis mechanical stopper 132 Y axis mechanical stopper...

Page 72: ... Z axis upper end mechanical stopper position 6mm rise during Z axis return to origin Z axis lower end mechanical stopper position Working envelope Interference position a Base front panel b Base side panel c Base rear panel d Base corners Interference position a Base front panel b Base side panel c Base rear panel d Base corners Maximum movement range X axis mechanical stopper 132 Y axis mechanic...

Page 73: ...stopper position Z axis upper end mechanical stopper position 6mm rise during Z axis return to origin Z400mm stroke Z200mm stroke Working envelope Interference position a Base front panel b Base side panel c Base rear panel d Base corners Interference position a Base front panel b Base side panel c Base rear panel d Base corners Maximum movement range X axis mechanical stopper 132 Y axis mechanica...

Page 74: ...m stroke Z200mm stroke Z axis upper end mechanical stopper position 6mm rise during Z axis return to origin Working envelope Interference position a Base front panel b Base side panel c Base rear panel d Base corners Interference position a Base front panel b Base side panel c Base rear panel d Base corners Maximum movement range X axis mechanical stopper 132 Y axis mechanical stopper 152 Do not o...

Page 75: ...echanical stopper position 6mm rise during Z axis return to origin Z axis lower end mechanical stopper position Working envelope Interference position a Base front panel b Base side panel c Base rear panel d Base corners Interference position a Base front panel b Base side panel c Base rear panel d Base corners Maximum movement range X axis mechanical stopper 132 Y axis mechanical stopper 152 Do n...

Page 76: ...ical stop pers so use caution 3 Interference positions where a load might touch the robot within the maxi mum movement range and their radii are shown in the figure Here a b c and d are the respective interference positions with the base front panel base side panel base rear panel and the base corners The Z axis spline may touch the base or the Y axis arm may touch the wire har ness before the rob...

Page 77: ...ation maxi mum payload maximum speed Robot model YK500XG YK600XG YK600XGH YK700XG to YK800XG 5mm 5mm Lower end 5mm 5mm Upper end Z axis 12 12 Y axis 9 9 X axis Note Here deg is the overrun angle at the X axis and Y axis joints 1 If the X axis Y axis or Z axis mechanical stopper is deformed or dam aged by impacts please contact our sales office or dealer Using the de formed or damaged mechanical st...

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Page 79: ... Stroke end method Z axis 4 7 3 4 Changing the origin position and adjusting the machine reference 4 8 3 4 1 Sensor method 4 9 3 4 1 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 4 9 3 4 2 Stroke end method 4 27 3 4 2 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 4 27 4 Setting the Soft Limits 4 31 5 Setting the Standard Coordinates 4 34 5 1 Standard coordinate setting ...

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Page 81: ...ing the robot is being adjusted to prevent others from touching the controller switch programming unit or operation panel 3 If a safeguard enclosure has not yet been provided right after installation of the robot rope off or chain off the movement area around the manipulator in place of a safeguard enclosure and observe the following points qUse stable posts which will not fall over easily wThe ro...

Page 82: ...gin direction or Motor direction were changed g Motor was replaced Motor wiring connector was removed h Data in the ALL data file extension ALL or parameter file extension PRM was written into the controller by way of the RS 232C The following sections explain how to perform absolute reset CAUTION If any of the above cases occur after installing the robot absolute reset must be performed again To ...

Page 83: ...4 2 before starting the return to origin operation Factory setting at shipment In this case press the STOP key to interrupt the return to origin operation move the target axis to the plus side of the origin and reperform the origin return operation If the return to origin operation is not interrupted the robot will continue the operation and may collide with the me chanical stopper or a peripheral...

Page 84: ...e value unit is displayed on the optional MPB screen Machine reference value B A 100 CAUTION The machine reference must be adjusted within a specified range to keep the repeatability precision of the absolute reset position The machine reference is factory adjusted prior to shipping If the origin position is changed the ma chine reference must be readjusted For information on how to adjust the ma ...

Page 85: ...s from touch ing the controller switch or operation panel 3 Set the controller to MANUAL mode if not in MANUAL mode 4 Press the F13 LOWER F3 key to select RST ABS 5 Select the axis for absolute reset X axis M1 Y axis M2 R axis M4 To perform absolute reset on all axes select ALL with the F11 LOWER F1 key CAUTION The Z axis of the stroke end method first rises during the absolute reset of all axes d...

Page 86: ...machine reference value is outside the recommended range then the next absolute reset may not be properly performed In this case refer to 3 4 Chang ing the origin position and adjusting the machine reference and make the necessary adjustments Return to origin is impossible from this area Origin position at shipment Return to origin direction Plus side Minus side Fig 4 2 ...

Page 87: ...set ABS encoder OK is displayed check that there are not any obstacles in the robot movement range and press the F4 key YES 7 After absolute reset is complete check that the adjustment machine refer ence value displayed on the MPB is within the absolute reset tolerance range 33 to 67 CAUTION Use the following procedure to display the adjustment machine reference value When adjusting the machine re...

Page 88: ...inate and point data must be reset If any machine reference is adjusted the origin position may change Before the adjustment mark off the reference mark at the current origin position on the main body of the robot After the machine reference is adjusted be sure to check that the origin position has not deviated If the origin position changes after the machine reference has been adjusted then the s...

Page 89: ...value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure 5 Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel 6 Turn off the controller and enter the safeguard enclosure 7 Mark off the reference mar...

Page 90: ...enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 13 Perform the absolute reset from outside the safeguard enclosure 14 After the absolute reset is completed read the machine reference value dis played on the MPB 15 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted...

Page 91: ...4 11 CHAPTER 4 Adjustment X axis origin sensor stay X axis origin sensor Bolt Cover q w Fig 4 3 b ...

Page 92: ...e safeguard enclosure and then turn on the controller 3 Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method 4 Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel 5 Turn off the controller and enter the safeguard enclosure 6...

Page 93: ...s completed read the machine reference value dis played on the MPB 19 If the machine reference value is in the range between 40 and 60 recom mended range then the origin position has been correctly changed Fully tighten the bolts to secure the X axis origin sensor stay If it is outside the recommended value then adjust the machine reference by referring to 1 1 Adjusting the X axis machine referenc...

Page 94: ...4 14 CHAPTER 4 Adjustment Elongated hole Bolt Cover Hex nut Dog X axis origin sensor stay Fig 4 5 a Bolt X axis arm Fig 4 5 b ...

Page 95: ...ommended Screw Lock LOCTITE 262 made by Henkel Corporation Fig 4 5 c Bolt Bolt Tightening torque kgfcm Tightening torque Nm M4 30 46 4 5 M5 40 92 9 0 Robot model YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Recommended Screw Lock LOCTITE 262 made by Henkel Corporation Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 Fig 4 5 d ...

Page 96: ...ange between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure 5 Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel 6 Turn off the controller and enter the safeguard enclosure 7 Mark off the reference mark at the current origin position on theY a...

Page 97: ...he safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 13 Perform the absolute reset from outside the safeguard enclosure 14 After the absolute reset is completed read the machine reference value dis played on the MPB 15 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been comple...

Page 98: ...4 18 CHAPTER 4 Adjustment Y axis origin dog Y axis origin sensor Y axis origin sensor stay Cover Bolt q w Fig 4 6 ...

Page 99: ...safeguard enclosure and then turn on the controller 3 Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method 4 Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel 5 Turn off the controller and enter the safeguard enclosure 6 R...

Page 100: ...completed read the machine reference value dis played on the MPB 19 If the machine reference value is in the range between 40 and 60 recom mended range then the origin position has been correctly changed Fully tighten the bolts to secure the Y axis origin sensor stay If it is outside the recommended value then adjust the machine reference by referring to 2 1 Adjusting the Y axis machine reference ...

Page 101: ...4 21 CHAPTER 4 Adjustment Cover Elongated hole Y axis origin sensor stay Bolt Fig 4 8 a ...

Page 102: ...4 22 CHAPTER 4 Adjustment Dog Hex nut Fig 4 8 b Bolt Y axis arm X axis arm Fig 4 8 c ...

Page 103: ...mmended Screw Lock LOCTITE 262 made by Henkel Corporation Fig 4 8 d Bolt Bolt Tightening torque kgfcm Tightening torque Nm M3 30 20 2 0 M4 30 46 4 5 Robot model YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Recommended Screw Lock LOCTITE 262 made by Henkel Corporation Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 Fig 4 8 e ...

Page 104: ...erating the controller or operation panel 6 Turn off the controller and enter the safeguard enclosure 7 Mark off the reference mark at the current origin position on the R axis area of the robot At this time be careful not to touch the tool at the tip of the robot arm so that the origin position does not shift 8 Remove the cover 9 Scribe a mark on the position of the R axis origin sensor stay 10 U...

Page 105: ...rd enclosure 14 After the absolute reset is completed read the machine reference value dis played on the MPB 15 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it 16 Reattach the cover after the adjustment is compl...

Page 106: ...4 26 CHAPTER 4 Adjustment R axis origin dog Bolt R axis origin sensor stay R axis origin sensor q w Cover Fig 4 9 ...

Page 107: ...at no one is inside the safeguard enclosure and then turn on the controller 2 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 3 Perform the Z axis absolute reset To perform the Z axis absolute reset see 3 3 Absolute reset procedures in Chapter 4 Make a note of the Z axis machine reference value CAUTION Use the following procedure...

Page 108: ...ges the machine reference value by 33 The machine reference value decreases by rotating the flange clockwise as viewed from top while it increases by rotating the flange counterclockwise Determine the flange position based on the Z axis machine reference value you made a note of so that the machine reference value is within 33 to 67 11 Tighten the bolts a little at a time in a diagonal pattern The...

Page 109: ...R 4 Adjustment 15 When the machine reference value is within the tolerance range lower the Z axis lower end damper until it makes tight contact with the holder and then reattach the cover Cover Rear cover Fig 4 10 ...

Page 110: ... hex socket head bolts strength class JIS B 1051 12 9 M3 12 Bolt Ball screw Z axis lower end damper Flat surface Z axis motor shaft located under the flange Flange Mark Fig 4 11 a Counterclockwise Counterclockwise Counterclockwise Clockwise Clockwise Clockwise Fig 4 11 b ...

Page 111: ...been changed Likewise in models where the mechanical stopper position cannot be changed reduce the soft limits to narrow the working envelope when the actual work ing range of the robot is small or the manipulator interferes with the periph eral equipment 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Press the emergency stop button on the MPB to set emerge...

Page 112: ...terferes with the peripheral equip ment reduce the Z axis plus soft limit pulses to narrow the working envelope 3 Setting the R axis soft limit To make this setting set emergency stop just as for the X axis andY axis or be sure to do this from outside the safeguard enclosure The R axis has no mechanical stoppers When the actual working range of the R axis is small or it interferes with the periphe...

Page 113: ...ft limits X Y and R axis speed reduction ratio and Z axis ball screw lead for each robot Operation angle distance vs number of resolver pulses Z axis X Y and R axis speed reduction ratio Robot model YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG X axis 80 80 Y axis 80 80 Z axis 20mm 20mm R axis 30 50 Lead 10mm 12mm 20mm 30mm Number of resolver pulses per lead movement 16384 16384 16384 ...

Page 114: ...ription of 4 Setting the Soft Limits in Chapter 4 3 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 4 Enter the safeguard enclosure while holding the MPB Stay outside the robot movement range at this time 5 Make the standard coordinate settings while referring to methods for Setting the Standard Coordinates as explained in the YA...

Page 115: ...the sleeve into the hole Then tighten the bolt just enough to hold the sleeve See Fig 4 14 7 Turn the X and Y axis arms so that they are nearly straight See Fig 4 15 Remove the cover and plate 8 Position the Y axis arm so that you can easily insert the pin into the sleeve through the elongated hole in the Y axis arm See Fig 4 16 Secure the pin with the bolt Tighten the bolt just enough to hold the...

Page 116: ...00 400 00 M1 X axis arm length M2 Y axis arm length 13 Enter the following values in 12 Offset pulse of axis parameters M1 X axis position pulse value you made a note of in step 11 M2 Y axis position pulse value you made a note of in step 9 Y axis position pulse value you made a note of in step 10 Round off the decimal part of the M2 value 2 14 After entering the parameters remove the pin bolt and...

Page 117: ...4 37 CHAPTER 4 Adjustment Bolt Sleeve Hole Fig 4 14 Bolt Plate Cover Bolt Fig 4 15 Y axis arm Bolt Pin Sleeve X axis arm Elongated hole Clockwise Counterclockwise Fig 4 16 ...

Page 118: ...hers from oper ating the controller switch 5 Enter the safeguard enclosure 6 Being careful not to move the origin positions attach stickers at conspicuous points on matching sides of components such as the robot arm of each axis base robot pedestal and end effector Affix stickers nearby showing the axis name and direction of movement Use a cloth moistened with alcohol to re move grease from the su...

Page 119: ...4 39 CHAPTER 4 Adjustment R End effector End effector Z Y X Fig 4 18 ...

Page 120: ...4 40 MEMO ...

Page 121: ...ns 5 2 3 Daily Inspection 5 3 4 Six Month Inspection 5 5 5 Replacing the Harmonic Drive 5 9 5 1 Replacement period 5 9 5 2 Basic replacement procedure for harmonic drive and precautions 5 10 5 2 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 5 12 ...

Page 122: ...MEMO ...

Page 123: ...on This chapter describes the periodic inspection items and procedures for the YAMAHA YK XG series robots Periodic inspection includes Daily inspection 6 month inspection Replacement of speed reduction gear harmonic drive Make sure that you thoroughly understand details of the inspection and follow the procedures and precautions explained in this chapter ...

Page 124: ...ance procedure calls for operation of the robot stay outside the safeguard enclosure 5 Place a sign indicating the robot is being inspected to keep others from oper ating the controller switch programming unit or operation panel 6 Use only the lubricants specified by YAMAHA or YAMAHA dealers 7 To check the operation after inspection refer to 6 Trial operation in Chapter 1 WARNING When you need to ...

Page 125: ...controller turned on 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller programming unit or operation panel 3 Check the following points from outside the safeguard enclosure Checkpoint Procedure Safeguard enclosure Check if the safeguard enclosure is in place Check...

Page 126: ...ller and then enter the safeguard enclosure to perform the necessary work After adjustment or replacement is fin ished again review the checkpoints outlined in 1 and 2 above 2 If repair or parts replacement is required for the robot or controller please contact your YAMAHA dealer This work requires specialized technical knowledge and skill so do not attempt it by yourself ...

Page 127: ...lace near an open flame since this could lead to sparks and fires Emergency Treatment If this grease gets in the eyes wash liberally with pure water for about 15 minutes and consult a physician for treatment If this grease comes in contact with the skin wash away completely with soap and water If taken internally do not induce vomiting but promptly consult a physician for treatment Disposing of gr...

Page 128: ...dirty Check for looseness at each terminal and connector on the panel See 4 in Chapter 3 Lubricate the Z axis spline shaft and ball screw nut after removing the old grease The specified grease is Alvania S2 SHOWA SHELL SEKIYU KK See Fig 5 1 Check for backlash If any abnormality is found contact YAMAHA dealer 1 Bolt tightening torque Bolt size Tightening torque kgfcm Tightening torque Nm M3 button ...

Page 129: ...5 7 CHAPTER 5 Periodic Inspection Cover Supply grease through the grease nipple Apply grease to the groove Lower the spline and apply grease to the groove Fig 5 1 ...

Page 130: ...ing points from outside the safeguard enclosure Checkpoint Procedure Cooling fan at rear of controller Check if the fan rotates normally Check if objects blocking the fan are located and remove if any are found Check for abnormal noise from the rotating fan If abnormal noise is heard visually check and remove the cause If no cause is found contact YAMAHA dealer Check for dust on the fan cover Remo...

Page 131: ...io is high or the robot is operated in environments at higher temperatures the harmonic drive should be replaced earlier Replacement period 8 4 108 n 60 h D N θ years where n Number of axis movements per minute θ Average turn per axis movement N Speed reduction ratio h Operation time per day D Operation days per year For example when the robot is used under the following conditions the replacement...

Page 132: ...es Inflammation may occur if they come into contact with skin Be sure to wear protective gloves to prevent contact with skin Do not take orally or eat Eating will cause diarrhea and vomiting Hands and fingers might be cut when opening the container so use protec tive gloves Keep out of the reach of children Do not heat them or place near an open flame since this could lead to sparks and fires Emer...

Page 133: ...do not scratch scar or dent these parts by dropping etc Such actions will damage the harmonic drive The specified performance cannot be maintained if any part of the harmonic drive is used in a damaged state This damage or wear may also lead to trouble with the harmonic drive Since a positional shift occurs after replacing the harmonic drive it is neces sary to make absolute reset standard coordin...

Page 134: ...ll length YK600XGH to YK1000XG For M5 installation diameter 9 53 outer diameter 17 or less 128mm approx at full length Hexagon bit YK500XG YK600XG For M4 installation diameter 6 35 YK600 to YK1000XG For M5 installation diameter 9 53 Replacement parts Parts name Type No YAMAHA Parts No Note Harmonic drive SHG 25 80 KBF M2110 000 q S90 JIS KN4 M2143 000 Top of harmonic drive O ring w Rubber wire dia...

Page 135: ...to let it drop see Fig 5 3 Items in parentheses apply to the YK600XGH and YK700XG to YK1000XG 8 Pull the motor out of the base while turning the X axis arm 9 Remove the wave generator from the motor shaft The wave generator is secured with a set screw 1 piece and keyway see Fig 5 6 A spacer and bolts need to be removed for YK600XGH and YK700XG to YK1000XG CAUTION A spacer is inserted between the w...

Page 136: ... not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of the groove 15 Apply harmonic grease to the new wave generator and flexible spline See Fig 5 7 for applying grease properly 16 Fit a new O ring e coated with harmonic grease into the O ring groove of the harmonic drive Apply small amount of Screw L...

Page 137: ... by hand slowly left and right through 45 If any jamming or catching is felt while moving the axis at this time then reassemble from the beginning See Fig 5 3 20 Reattach the connectors on the X axis motor power wire XM and resolver wire XP See Fig 5 2 Also reattach the X axis motor ring tongue terminal 21 Reattach the base robot pedestal front and rear covers 22 Go outside the safeguard enclosure...

Page 138: ...5 16 CHAPTER 5 Periodic Inspection M6 16 M5 16 X axis motor Base Fig 5 3 ...

Page 139: ...5 17 CHAPTER 5 Periodic Inspection M4 18 M5 40 O ring w YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG O ring w Fig 5 4 ...

Page 140: ...same position on the X axis arm as before Fig 5 5 M4 setscrew supplied with harmonic drive YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG M5 16 YK600XG YK700XG to YK1000XG only M4 setscrew supplied with harmonic drive Wave generator Harmonic drive Wave generator Harmonic drive Spacer Motor mating end face Do not remove this spacer Motor flange end face Motor flange end face Fig 5 6 ...

Page 141: ...d into this groove Never remove these temporarily tightened bolts The axis will otherwise deviate from center Apply grease to entire inner surface to the thickness equal to ball diameter Flexible spline Circular spline Wave generator Apply grease to sufficiently fill in the ball space Fig 5 7 ...

Page 142: ...P M2510 000 q S90 JIS KN4 M2143 000 Lower part of harmonic drive O ring w Rubber wire diameter 1 78mm Ring inner diameter 66 40mm 90990 17J030 For motor e Rubber wire diameter 1 3mm Ring inner diameter 66 50mm KN5 M257L 000 Supplied with harmonic drive YK600XGH YK700XG YK800XG YK900XG YK1000XG 2 Turn off the controller 3 Place a sign indicating that the robot is being inspected to keep others from...

Page 143: ...ut See Fig 5 11 12 Remove the Y axis harmonic drive from the top of the X axis arm CAUTION An O ring q is fitted to the upper surface of the X axis arm Replace this O ring with a new one 13 Fit a new O ring q coated with harmonic grease into the O ring groove of the X axis arm See Fig 5 11 14 Place the new harmonic drive on the X axis arm and secure it with the bolts you removed earlier At this po...

Page 144: ...XG to YK1000XG do not forget to insert a spacer 19 Fit a new O ring w to the motor and place the motor in theY axis arm while turning the Y axis joint Then tighten the bolts you removed earlier to temporarily secure the motor to the Y axis arm See Fig 5 9 On theYK600XGH andYK700XG toYK1000XG fit the new O ring w into the groove in the Y axis arm See Fig 5 12 CAUTION Do not allow the O ring to get ...

Page 145: ...5 23 CHAPTER 5 Periodic Inspection Cover Cover Y axis arm Disconnect this Y axis motor ring tongue terminal located inside the cover Fig 5 8 M5 12 M6 16 Y axis motor Fig 5 9 ...

Page 146: ...5 24 CHAPTER 5 Periodic Inspection M3 16 M4 18 X axis arm Fig 5 10 ...

Page 147: ...M3 30 M4 30 M3 30L M4 30L panhead bolt During reassembly reattach this bolt to the same position on the X axis arm as before M4 nut M5 nut O ring q Fig 5 11 M3 setscrew supplied with harmonic drive Wave generator Harmonic drive O ring w YK500XG YK600XG Fig 5 12 ...

Page 148: ...5 26 CHAPTER 5 Periodic Inspection M4 setscrew supplied with harmonic drive O ring w Wave generator Harmonic drive Do not forget to insert a spacer YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 5 12 ...

Page 149: ... Parts No Note Harmonic drive Edge seal SHF 20 50 KBP M1821 000 Lower part of harmonic drive O ring q S71 JIS KN3 M2159 000 w Rubber wire diameter 0 99mm Ring inner diameter 53 28mm V 28A N C KN3 M2144 000 KBP M1886 000 Supplied with harmonic drive e Rubber wire diameter 1 00mm Ring inner diameter 43 00mm 90990 17J036 Spline nut r Rubber wire diameter 1 30mm Ring inner diameter 53 00mm 90990 17J03...

Page 150: ... and pull out the R axis motor while turning the R axis See Fig 5 17 CAUTION An O ring r is placed between the R axis motor flange and the Y axis arm Replace this O ring with a new one See Fig 5 17 10 Loosen the two setscrews for the wave generator Pull the wave generator out of the R axis motor shaft See Fig 5 20 CAUTION An O ring t is placed between the R axis motor shaft and the wave generator ...

Page 151: ...to a torque of 2 0Nm 20kgfcm See Fig 5 19 b CAUTION Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of groove 17 Fit the O ring w coated with harmonic grease into the O ring groove of the new harmonic drive See Fig 5 18 Apply small amounts of Screw Lock to the bolts you removed earlier and tight...

Page 152: ...ut to secure the bearing Utilize the flat surfaces when tightening the U nut like you did to loosen it On the YK600XGH and YK700XG to YK1000XG do not forget to insert a spacer See Fig 5 15 21 Insert the spline and bearing through the holder and secure them with the bolts you removed earlier See Fig 5 14 22 Reconnect the R axis motor power wire RM and resolver wire RP Also reconnect the R axis moto...

Page 153: ...5 31 CHAPTER 5 Periodic Inspection Cover Disconnect this R axis motor ring tongue terminal located inside the cover Cover Fig 5 13 M5 14 Bearing mount plate Holder Spline Fig 5 14 ...

Page 154: ...cer Bearing Flat surface Bearing mount plate M5 14 Flat surface YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 5 15 V ring Degrease and make it tight contact with sleeve Sleeve Do not remove this sleeve from spline nut Spline nut Shaft O ring e M4 10 M5 14 Fig 5 16 ...

Page 155: ...5 33 CHAPTER 5 Periodic Inspection O ring r M5 14 M6 16 R axis motor Fig 5 17 ...

Page 156: ...5 34 CHAPTER 5 Periodic Inspection M3 14 M3 16 O ring w Fig 5 18 ...

Page 157: ...5 35 CHAPTER 5 Periodic Inspection M4 nut M3 30L panhead bolt M3 25 O ring w Harmonic drive Shaft O ring q YK500XG YK600XG Fig 5 19 a ...

Page 158: ...5 36 CHAPTER 5 Periodic Inspection M3 30 Shaft O ring q Harmonic drive O ring w M3 25 Dog YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 5 19 b ...

Page 159: ...Periodic Inspection R axis motor O ring t Wave generator Harmonic drive M4 setscrew M3 set screw supplied with harmonic drive Tightening torque YK500XG YK600XG 7kgfcm 0 7Nm YK600XGH to YK1000XG 17kgfcm 1 7Nm Fig 5 20 ...

Page 160: ...face seal lip End face seal lip Apply slight amount of grease to the lip only Remove all grease that remain inside the lip Harmonic grease Apply grease every around Be cautious about the amount of grease amounts of the grease applying to the area above and below the end face seal lip are different Below the end face seal lip apply grease as thick as the diameter of the wave generator ball Fig 5 21...

Page 161: ...CHAPTER 6 Increasing the robot operating speed 1 Increasing the robot operating speed 6 1 ...

Page 162: ...MEMO ...

Page 163: ... motion Using default arch position 2000 pulses From point P1 to P2 MOVE P P2 Z 0 Axis parameters Arch position M1 X axis arch position 2000 pulses M2 Y axis arch position 2000 pulses M3 Z axis arch position 2000 pulses M4 R axis arch position 2000 pulses When the Z axis moves upward from P1 and enters the M3 arch position range 2000 pulses prior to Z 0 the X Y and R axes begin to move When these ...

Page 164: ...positions in the program From point P1 to P2 and then to P3 ARCH 1 10000 X axis arch position pulses ARCH 2 20000 Y axis arch position pulses ARCH 3 20000 Z axis arch position pulses ARCH 4 20000 R axis arch position pulses MOVE P P2 Z 0 ARCH 1 2000 ARCH 2 2000 ARCH 3 2000 ARCH 4 2000 MOVE P P3 Z 100 Since the arch positions can be changed in the program optimizing the arch po sitions can further ...

Page 165: ...k closes WEIGHT 10 Changes the axis tip weight parameter to 10kg with workpiece MOVE P P3 Z 0 In the above program the acceleration can be set to a higher level by reducing the axis tip weight parameter to 5kg while the chuck does not grip any workpiece and then set to a lower level by changing the axis tip weight parameter to 10kg Compared to programs using an axis tip weight parameter left set a...

Page 166: ...ses MOVE P P2 TOLE 1 80 Returns the tolerance to the default value TOLE 2 80 TOLE 3 80 TOLE 4 80 MOVE P P3 When P2 is an escape point and does not need to be accurately positioned setting the tolerance parameter to a larger value allows the robot arm to pass through P2 quickly The larger the tolerance value for the positioning time the shorter the cycle time will be The maximum value of the tolera...

Page 167: ...n When all of the X Y Z and R axes enter the OUT effective position 10000 pulses prior to P2 the chuck starts closing By setting the OUT effective posi tion larger the chuck starts closing while the robot arm is still moving at an earlier point so that the chuck can grip the workpiece more quickly The default value of the OUT effective position is 2000 pulses Reference Relation between X Y R axis ...

Page 168: ...6 6 MEMO ...

Page 169: ...CHAPTER 7 Specifications 1 Manipulator 7 1 1 1 Basic specification 7 1 1 2 Robot inner wiring diagram 7 2 1 3 Wiring table 7 3 ...

Page 170: ...MEMO ...

Page 171: ...0XG 300mm 130 400mm 150 200 400mm 360 750W 400W 400W 200W 8 4m s 1020 s 0 02mm 0 01mm 0 005 YK800XG 400mm 130 400mm 150 200 400mm 360 750W 400W 400W 200W 9 2m s 1020 s 0 02mm 0 01mm 0 005 YK900XG 500mm 130 400mm 150 200 400mm 360 750W 400W 400W 200W 9 9m s 1020 s 0 02mm 0 01mm 0 005 YK1000XG 600mm 130 400mm 150 200 400mm 360 750W 400W 400W 200W 10 6m s 1020 s 0 02mm 0 01mm 0 005 1 Soft limit 2 Mec...

Page 172: ...G YM User tubing ZP FG XM YM XY ZM RM ZR Y axis resolver Y axis motor Z axis brake Z axis motor Z axis resolver R axis resolver R axis motor Y axis origin sensor R axis origin sensor ZBKG ZBKG ZM ZM ZP ZP RP RP RM RM RORG RORG YP YP YM YM YORG YORG IO Round terminal M4 ground terminal Round terminal User IO connector User tubing Machine harness X axis arm Y axis arm YK500XG YK600XG YK600XGH YK700X...

Page 173: ...sq XP Yellow Green YM XM Resolver W V U W V U 2 3 R1 R2 DG S2 S4 S1 S3 S3 24 23 22 21 20 19 6 6 5 5 7 4 3 2 1 4 3 2 1 R1 DG S2 7 7 5 6 Signal 2 1 1 3 2 3 2 1 Blue Brown Yellow White Red Black 3 2 4 FG 4 3 Connection Connector No Wire Color Connector No 25 S4 Resolver S1 R2 Round terminal 28 1 FG FG XY 11 Green 0 3sq 10 0 3sq Green 18 Gray 2 Red 0 15sq 29 HLIM GND24 HLIM GND24 Gray 2 Black 36 0 15s...

Page 174: ... green 2 Red Brightgreen 2 Black Pink 1 Black Orange 1 Red Orange 1 Black Gray 1 Red Gray 1 Black Sky blue 2 Red Sky blue 2 Black Pink 1 Red Sky blue 1 Black Green Green Brake 4 0 15sq Twisted pair 0 15sq Twisted pair 0 15sq Twisted pair 0 15sq Twisted pair 0 15sq Twisted pair 0 15sq Twisted pair 0 15sq Twisted pair 0 15sq Twisted pair ZM RM 1 FG FG 18 16 0 15sq 28 11 Green 0 3sq 10 0 3sq Green 29...

Page 175: ...range Shield 0 2mm2 Twisted pair 0 2mm2 Twisted pair 0 2mm2 Twisted pair 0 2mm2 Twisted pair 0 2mm2 Twisted pair 0 2mm2 Twisted pair Shield Shield 0 2mm2 Twisted pair 0 2mm2 Twisted pair 0 2mm2 Twisted pair Orange 0 2mm2 Brown Gray Red Brown White Red White Orange White Brown Black Red Black Orange Black White Brown Orange Red Blue Purple White Black Gray Gray Gray Green Green Green Frame ground S...

Page 176: ...ue Brown Red Black Black Red White Black Yellow Blue No 1 2 3 4 5 6 7 1 2 3 1 1 2 Connector XP YP ZP RP XM YM ZM RM Round terminal ZBK Z axis motor only Signal Connection Green Yellow Black Blue Black Brown Origin sensor wiring table 24V ORG 0V Brown Black Blue 1 2 3 XORG YORG RORG Signal Connection Color No Connector ...

Page 177: ...MEMO ...

Page 178: ...rved No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO LTD Information furnished by YAMAHA in this manual is believed to be reliable However no responsibility is assumed for possible inaccuracies or omissions If you find any part unclear in this manual please contact YAMAHA or YAMAHA sales representatives ...

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