Yamaha YK-XR Series Installation Manual Download

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Summary of Contents for YK-XR Series

Page 1: ...EWFK155120 E66 Ver 1 20 YAMAHA SCARA ROBOT Installation Manual YK XR Series YK400XR ...

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Page 3: ...ers S 12 4 4 Moving and installation S 13 4 4 1 Precautions for robots S 13 4 4 2 Precautions for robot controllers S 14 4 5 Safety measures S 16 4 5 1 Safety measures S 16 4 5 2 Installing a safety enclosure S 17 4 6 Operation S 18 4 6 1 Trial operation S 18 4 6 2 Automatic operation S 20 4 6 3 Precautions during operation S 20 4 7 Inspection and maintenance S 22 4 7 1 Before inspection and maint...

Page 4: ...allation 2 3 2 1 Unpacking 2 3 2 2 Checking the product 2 4 2 3 Moving the robot 2 5 2 4 Installing the robot 2 6 3 Protective bonding 2 7 4 Robot cable connection 2 8 5 User wiring and user tubing 2 9 6 Attaching the end effector 2 11 6 1 Acceleration coefficient vs moment of inertia 2 11 6 1 1 R axis tolerable moment of inertia and acceleration coefficient 2 11 6 1 2 Parameter setting according ...

Page 5: ... X axis Y axis 3 4 2 2 Machine reference 3 5 2 3 Return to origin procedures 3 6 2 3 1 Stroke end method 3 6 2 3 2 Sensor method X axis Y axis 3 7 2 4 Adjusting the machine reference value 3 9 2 4 1 Stroke end method 3 9 2 4 2 Mark method 3 13 2 4 2 1 Absolute reset in servo on state re reset 3 14 2 4 2 2 Absolute reset in servo off state re reset 3 16 2 4 2 3 Absolute reset in servo on state new ...

Page 6: ...1 Increasing the robot operating speed 6 1 1 1 Increasing speed by arch motion 6 1 1 2 Increasing the speed with the WEIGHT statement 6 3 1 3 Increasing the speed by the tolerance parameter 6 4 1 4 Increasing the speed by the OUT effective position parameter 6 5 Chapter 7 Torque limit designated Z axis pushing action 1 Torque limit designated Z axis pushing action 7 1 Chapter 8 Specifications 1 Ma...

Page 7: ...n S 13 4 4 1 Precautions for robots S 13 4 4 2 Precautions for robot controllers S 14 4 5 Safety measures S 16 4 5 1 Safety measures S 16 4 5 2 Installing a safety enclosure S 17 4 6 Operation S 18 4 6 1 Trial operation S 18 4 6 2 Automatic operation S 20 4 6 3 Precautions during operation S 20 4 7 Inspection and maintenance S 22 4 7 1 Before inspection and maintenance work S 22 4 7 2 Precautions ...

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Page 9: ...l regulations and comply with the instructions Warning labels attached to the robots are written in English Japanese Chinese and Korean This manual is available in English or Japanese or some parts in Chinese Unless the robot operators or service personnel understand these languages do not permit them to handle the robot Cautions regarding the official language of EU countries For equipment that w...

Page 10: ...mbol and signal word and then read this manual w DANGER This indicates an immediately hazardous situation which if not avoided will result in death or serious injury w WARNING This indicates a potentially hazardous situation which if not avoided could result in death or serious injury c CAUTION This indicates a potentially hazardous situation which if not avoided could result in minor or moderate ...

Page 11: ...before entering the safety enclosure Instructions on this label Always install a safety enclosure to keep all persons away from the robot movement range and prevent injury from contacting the moving part of the robot Install an interlock that triggers emergency stop when the door or gate of the safety enclosure is opened The safety enclosure should be designed so that no one can enter inside excep...

Page 12: ...r operation may cause serious injury To avoid hazard Before installing or operating the robot read the manual and instructions on the warning labels and understand the contents 90K41 001290 Warning label 4 SCARA robots This label is not attached to omnidirectional type SCARA robots c CAUTION Do not remove the parts on which Warning label 4 is attached Doing so may damage the ball screw Instruction...

Page 13: ...7 controllers TS X TS P w WARNING Before touching the terminals or connectors on the outside of the controller turn off the power and wait at least 10 minutes to avoid burns or electrical shock Motors and heatsinks become hot during and shortly after operation so do not touch them c CAUTION Before using the controller be sure to read the manual thoroughly Be sure to ground the ground terminal Inst...

Page 14: ...label 9 single axis linear motor robots c CAUTION A magnetic scale is located inside this cover Bringing a magnet close to it may cause malfunction Instructions on this label To prevent the robot from operating improperly due to magnetic scale malfunction do not bring a strong magnet to the cover Do not bring tools close to the magnetic scale 90K41 001510 Warning label 10 single axis linear motor ...

Page 15: ... power supply to the controller read the manual carefully and make checks before beginning the work Connectors have an orientation Insert each connector in the correct direction 93005 X0 00 Warning label 12 single axis robots Cartesian robots Some robot models w WARNING If a load is applied to the motor cover this may cause breakage The robot may drop at installation causing personal injury Instru...

Page 16: ...lied with the robot and should be affixed to an easy to see location on the door or gate of the safety enclosure Warning label comes supplied with the robot and should be affixed to an easy to see location SCARA robots Cartesian robots Single axis robots Warning label 1 1 Warning label 2 1 2 Warning label 3 1 1 See Part names in each SCARA robot manual for label positions 2 This label is not attac...

Page 17: ...e units become hot so do not touch them Instructions by this symbol This indicates the area around this symbol may become very hot Motors heatsinks and regenerative units become hot during and shortly after operation To avoid burns be careful not to touch those sections 93008 X0 00 Caution symbol 333 c CAUTION Always read the manual carefully before using the controller Instructions by this symbol...

Page 18: ...eneral public In equipment intended to carry or transport people In environments which are subject to vibration such as onboard ships and vehicles Qualification of operators workers 222 Operators or persons who perform tasks for industrial robots such as teaching programming movement check inspec tion adjustment and repair must receive appropriate training and also have the skills needed to perfor...

Page 19: ...structions in this manual when grounding the linear conveyor module and installing the termination module Do not touch the motor of the linear conveyor module when it is on Always comply with the instructions in the manual when performing maintenance and be sure to turn off the power before starting maintenance tasks If cracked or broken plastic motor parts are found stop using the linear conveyor...

Page 20: ... power electricity air pressure etc is shut off or power fluctuations occur If the object gripped by the end effector might possibly fly off or drop then provide appropriate safety protection taking into account the object size weight temperature and chemical properties Provide adequate lighting 444 Provide enough lighting to ensure safety during work Install an operation status light 555 w WARNIN...

Page 21: ...le parts of the robot As instructed in Warning label 2 use caution to prevent hands or fingers from being pinched or crushed by movable parts when transporting or moving the robot For details on warning labels see 3 Warning labels in Safety instruc tions Take safety measures when moving robots 222 To ensure safety when moving a SCARA robot with an arm length of 500mm or more use the eyebolts that ...

Page 22: ...st be installed at a location that is outside the robot safety enclosure yet where it is easy to operate and view robot movement Install the robot controller in locations with enough space to perform work teaching inspection etc safely Limited space not only makes it difficult to perform work but can also cause injury Install the robot controller in a stable level location and secure it firmly Avo...

Page 23: ...correctly using the tool specified by the connector manufacturer c CAUTION When disconnecting the cable from the robot controller detach by gripping the connector itself and not by tugging on the cable Loosen the screws on the connector if fastened with the screws and then disconnect the cable Trying to detach by pulling on the cable itself may damage the connector or cables and poor cable contact...

Page 24: ...ollowing actions should be taken as needed to prevent hazardous situations due to sudden or unexpected robot operation or faulty robot operation as listed below Place a display sign on the operator panel Ensure the safety of workers performing tasks within the robot safety enclosure Clearly specify position and posture during work Specify a position and posture where worker can constantly check ro...

Page 25: ... damage and malfunction Do not touch or operate the robot controller or programming box with wet hands Touching or operating them with wet hands may result in electrical shock or breakdown Do not disassemble and modify 666 w WARNING Never disassemble and modify any part in the robot controller and programming box Do not open any cover Doing so may cause electrical shock breakdown malfunction injur...

Page 26: ...WAY sign to keep the operator or other personnel from entering within the movement range of the robot w WARNING Use sturdy stable posts which will not fall over easily The rope or chain should be easily visible to everyone around the robot Check the following points before turning on the controller 222 Is the robot securely and correctly installed Are the electrical connections to the robot wired ...

Page 27: ... SCARA robots Follow the precautions and procedure described in Setting the standard coordinates Soft limit settings SCARA robots Follow the precautions and procedure described in Setting the soft limits Cartesian robots Single axis robots Follow the precautions and procedure described in Soft limit in each controller manual Work with power turned on Teaching SCARA robots Cartesian robots Single a...

Page 28: ...ot to emergency stop 2 Place a sign on the start switch indicating that the robot is being inspected in order to keep other persons from restarting the robot 4 6 3 Precautions during operation When the robot is damaged or an abnormal condition occurs 111 w WARNING If unusual odors noise or smoke occur during operation immediately turn off power to prevent possible electrical shock fire or breakdow...

Page 29: ...op due to obstruction from peripheral equipment the Z axis may move suddenly after the obstruction is removed causing injury such as pinched or crushed hands Turn off the controller and reduce the air pressure before attempting to remove the obstruction Before reducing the air pressure place a support under the Z axis because the Z axis will drop under its own weight Be careful of Z axis movement ...

Page 30: ...ized technical knowledge and skills and may also involve hazards if attempted by an unskilled person This adjustment must be performed only by persons who have the required qualifications described in 2 Qualification of operators workers in section 4 1 of this Safety instructions Shut off all phases of power supply 333 w WARNING Always shut off all phases of the power supply externally before clea...

Page 31: ...robot since this may cause injury Devices that may malfunction due to magnetic fields must be kept away from this robot See 6 Cautions regarding strong magnetic fields in Safety instructions for detailed information on strong magnetic fields Use the following caution items when disassembling or replacing the pneumatic equipment 555 w WARNING Air or parts may fly outward if pneumatic equipment is d...

Page 32: ... regulations or entrust disposal to a licensed industrial waste disposal company We do not collect and dispose of the used batteries Disposal of packing boxes and materials 222 When disposing of packing boxes and materials use the correct disposal method in compliance with your local regula tions We do not collect and dispose of the used packing boxes and materials Strong magnet 333 w WARNING Stro...

Page 33: ...ontain parts generating strong magnetic fields which may cause bodily injury death or device malfunction Always comply with the following instructions Persons wearing medical electronic devices such as cardiac pacemakers or hearing aids must keep away from the linear single axis robot and linear conveyor Stay at least 100mm away Persons wearing ID cards purses and or wristwatches must keep away fr...

Page 34: ...he manipulator tip and the solenoid valves attached to the robot arms move To make the robot motion easier to understand the figures below only show the movement ranges of the tool attachment section tool and workpiece Please note that during actual operation the movement range includes all areas where the robot arms and any other parts move along with the robot Movement range Figure A Movement ra...

Page 35: ...d on the R axis YK TW series robots do not have mechanical stoppers intended to protect the human body due to the product characteristic of the orbit movement When it is necessary to restrict the arm rotation angle so as to ensure the safety install additional stopper separately Single axis robots Cartesian robots The linear movement axis has a mechanical stopper at both ends of the maximum moveme...

Page 36: ...perform the job correctly and safely They must also read the manual carefully to understand its contents before attempting the robot operation or maintenance Tasks related to industrial robots teaching programming movement check inspection adjustment repair etc must be performed by qualified persons who meet requirements established by local regulations and safety standards for industrial robots C...

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Page 38: ...rk sequence for working within the safety enclosure changed typing errors corrected etc Ver 1 02 Sep 2012 Description of warning labels was added descriptions of soft limits mechanical stoppers and work performed with vertical axis brake released were changed and residual risk description was added Ver 1 03 Dec 2012 Warning on restricting the robot moving speed was added and description of warning...

Page 39: ... causes other than the above that are not the fault or responsibility of YAMAHA The following cases are not covered under the warranty 1 Products whose serial number or production date month year cannot be verified 2 Changes in software or internal data such as programs or points that were created or changed by the customer 3 Products whose trouble cannot be reproduced or identified by YAMAHA 4 Pr...

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Page 41: ...Contents Before using the robot Be sure to read the following notes i Introduction iv Introduction ...

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Page 43: ...al axis names are called using alphabetic characters like X axis Y axis Z axis and so on So read this manual while referring to the robot external view and axis name correspondence table shown below External view of robot and axis name correspondence table X axis arm arm 1 Y axis arm arm 2 R axis axis 4 Z axis axis 3 X axis axis 1 Y axis axis 2 Y axis axis 2 23002 FK 00 RCX340 controller axis name...

Page 44: ...to origin methods in 2 Adjusting the origin in Chapter 3 of this manual and in Return to origin of the YAMAHA Robot Controller User s Manual Setting of standard coordinates is not required in the above case To set the standard coordinates with high accuracy refer to 4 Setting the standard coordinates in Chapter 3 of this manual and Setting the Standard Coordinates in the YAMAHA Robot Controller Us...

Page 45: ... Motion pattern factors If a motion approaching to the teaching point from a different direction is included during repetitive operation If the power is turned off or the robot is stopped before completing the motion or the moving speed is changed even when approaching to the teaching point from the same direction If the robot is moved to the teaching point using a hand system different from the h...

Page 46: ...ce for future reference This user s 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 new user the need to read through this manual For details about actual robot operation and programming refer to the YAMAHA Robot Controller User s Manual w Warning T...

Page 47: ...Chapter 1 Functions Contents 1 Robot manipulator 1 1 1 1 Manipulator movement 1 1 1 2 Part names 1 2 2 Robot controller 1 3 3 Robot initialization number list 1 4 ...

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Page 49: ...YK XR series robots can move as shown in the Fig below 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 box are pressed standard setting at the factory Manipulator movement X axis arm Y axis arm R axis Z axis X ax...

Page 50: ...or R axis motor Ball screw Machine harness Z axis spline Warning label 1 Warning label 2 Warning label 3 User wiring connector Numbers 1 to 10 are usable M4 ground terminal User tubing 1 φ4 black User tubing 2 φ4 red User tubing 3 φ4 blue User tubing 1 φ4 black User tubing 2 φ4 red User tubing 3 φ4 blue Tapped hole for user User wiring tubing through spline type Extension shaft for user wiring and...

Page 51: ...unctions 2 Robot controller The YK XR series robot comes supplied with a robot controller RCX340 For more details refer to the separate YAMAHA Robot Controller User s Manual Robot controller RCX340 23103 FK 00 ...

Page 52: ...optional c CAUTION Return to origin must be performed after reinitializing the controller Before reinitializing the controller read the descriptions in 2 Adjusting the origin in Chapter 3 and make sure you thoroughly understand the procedure When the controller is initialized the ARM LENGTH and OFFSET PULSE settings in the axis parameters will be erased making the standard coordinate settings inva...

Page 53: ...ing according to R axis moment of inertial of load 2 11 6 2 Equation for moment of inertia calculation 2 12 6 3 Example of moment of inertia calculation 2 15 6 4 Attaching the end effector 2 17 6 5 Gripping force of end effector 2 19 7 Limiting the movement range with X axis and Y axis mechanical stoppers 2 20 7 1 Installing the X axis Y axis additional mechanical stoppers 2 21 7 2 Robot overrun d...

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Page 55: ... 40μm or less Working space Allow sufficient space margin to perform jobs teaching inspection repair etc For detailed information on how to install the robot controller refer to the separate YAMAHA Robot Controller User s Manual w Warning Avoid installing the robot in locations where the ambient conditions may exceed the allowable temperature or humidity or in environments where water corrosive ga...

Page 56: ...the installation base is not sufficiently rigid and stable or a thin metallic plate is attached to the installation base vibration resonance during operation causing detrimental effects on the manipulator work 1 Prepare a robot installation base The maximum reaction force applied to the X axis and Z axis of each robot during operation is shown in the Table below These values are instantaneous forc...

Page 57: ...d personnel may operate it The equipment and tools used for moving the robot should be serviced daily The YK XR 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 Packed state Robot ma...

Page 58: ...40 Robot YK XR series A B X Y Z R Product configurations PBX programming box etc Robot manipulator Disc version of the User s Manual or User s Manual RCX340 controller Warning label 1 X axis additional stopper option Y axis additional stopper option Origin position stickers User wiring connector kit Connector 2 pcs Pin 30 pcs Standard Option Y axis standard coordinate setup jig Option X axis stand...

Page 59: ... 8 1 Fold the arms Take out the robot from the case or remove it from the pallet Fold the arms while referring to the Fig below Moving the robot Support Robot cable Robot main body Support 23219 FK 00 2 Place the robot on the base One work person holds the support of the robot main body with both hands and other work person holds the robot cable to place the robot on the base 3 Temporarily secure ...

Page 60: ...ng torque YK400XR M8 37Nm 380kgfcm 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 bolt JIS B 1176 hex socket head bolt or equivalent Strength class JIS B 1051 12 9 or equivalent Installing the robot Installation base Hex socket head bolt 23203 FK 00 n NOTE Knock holes for the positioning pin...

Page 61: ... IEC 5019 23201 F0 00 Example of grounding Ground symbol M4 Ground terminal 23204 FK 00 Use a ground cable with a conductor wire cross section of at least 2 0mm2 and a length within 1 meter c CAUTION 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 The YK XR series robo...

Page 62: ...and hazardous situations If the connector installation 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 ...

Page 63: ... 10 wires φ4 3 tubes Base Y arm Robot models for custom specifications may have different wiring or tubing The specifications of the user wires and air tubes are shown below Always observe the specifications User Wiring Rated voltage 30V Allowable current 1 0A Nominal cross section area of conductor 0 15mm2 Shield Yes User Tubing Maximum pressure 0 58MPa 6Kgf cm2 Outer diameter inner diameter φ4mm...

Page 64: ... tube prepared by the user as this may break the robot harness or user signal wires causing malfunction of the robot This will also result in poor positioning accuracy Make sure that user wiring and tubing connected with the user wiring connector and user tubing joint do not interfere with the robot get wound around the robot or led around when the robot moves The wiring and tubing could be damage...

Page 65: ...n kgm2 x 10 4 steps c CAUTION When the input value to the SCARA R axis inertia kgm2 x 10 4 parameter is small when compared to the actual load the warning is given from the controller When the load shape is large set a larger value for the SCARA R axis inertia kgm2 x 10 4 parameter Vibrations may occur in the R axis depending on the load status or operation pattern In this case make the input valu...

Page 66: ... equation for the moment of inertia for a material particle that has a rotation center such as shown in the Fig below is as follows This is used as an approximate equation when x is larger than the object size Moment of inertia for material particle x J Wx2 g kgfcmsec2 g Gravitational acceleration cm sec2 m Mass of material particle kg 1 I mx2 kgm2 W Weight of material particle kgf 23203 F0 00 2 M...

Page 67: ...s given as follows Moment of inertia for prism a c b 1 2a J ρabc a2 b2 12g W a2 b2 12g 4 I ρabc a2 b2 12 m a2 b2 12 kgfcmsec2 kgm2 ρ Density kg m3 kg cm3 g Gravitational acceleration cm sec2 m Mass of prism kg W Weight of prism kgf 23206 F0 00 5 When the object s center line is offset from the rotation center The equation for the moment of inertia when the center of the cylinder is offset by the d...

Page 68: ... 4 h2 3 ρπD2 h x2 4g Wx2 g I ρπD2 h 16 D2 4 h2 3 ρπD2 h x2 4 kgfcmsec2 m 4 D2 4 h2 3 mx2 kgm2 23208 F0 00 In the same manner the moment of inertia of a prism as shown in the Fig below is given by Moment of inertia of a prism a c b x Center line J ρabc a2 b2 12g W a2 b2 12g 7 ρabcx2 g Wx2 g I ρabc a2 b2 12 ρabcx2 m a2 b2 12 m Mass of prism kg W Weight of prism kgf kgfcmsec2 mx2 kgm2 23209 F0 00 ...

Page 69: ...sity ρ is 0 0078kg cm3 Example of moment of inertia calculation The chuck and workpiece are at a position offset by 10 cm from the R axis by the stay 10cm 2cm 2cm R axis 1cm 1cm 2cm 2cm 4cm 6cm 4cm Stay Chuck Workpiece 23210 F0 00 1 Moment of inertia of the stay Moment of inertia of the stay 12cm 2cm 2cm Center line 5cm R axis The weight of the stay Ws is given as follows Ws ρabc 0 0078 12 2 2 0 3...

Page 70: ... F0 00 3 Moment of inertia of workpiece Moment of inertia of workpiece 10cm 4cm R axis 2cm Ww ρπD2 h 0 0078π 22 4 4 4 0 098 kgf The moment of inertia of the workpiece Jw is then calculated from Eq 5 When the workpiece form resembles that shown in figure the weight of the workpiece Ww is Jw 0 097 22 0 097 102 8 980 980 0 010 kgfcmsec2 23213 F0 00 4 Total weight The total weight W is calculated as f...

Page 71: ...lied n NOTE When checking end effector operation refer to the section 4 6 1 Trial Operation in Chapter Safety Instructions of this manual The following shows the maximum load that can be applied to the end effector attachment of each robot model w Warning The end effector attachment must have adequate strength to withstand the loads listed in the Table below If the strength is insufficient the att...

Page 72: ... more 9 92 16 0 018 0 The following shows the details of the end effector attachment of each robot Details of end effector attachment 30 16 h7 0 018 0 Never loosen this bolt 23209 FK 00 For details about the depth of the tapped hole and recommended bolt see the Table below Depth of tapped hole Iron material base Bolt diameter 1 5 or more Aluminum material base Bolt diameter 3 0 or more Recommended...

Page 73: ...tor attachment the accelerations Amax and AXYmax become larger by an amount equal to the offset versus the arm length When the R axis rotates during operation this acceleration ARmax must be taken into account w Warning The gripping force of the end effector must have a sufficient extra margin of strength to prevent the workpiece from coming loose and flying off during robot operation If the gripp...

Page 74: ...mited When the robot is shipped from factory the movement range is set to the maximum level The movement range can be limited by shifting the X axis and Y axis mechanical stopper positions Follow the steps below to limit the movement range The following shows the mechanical stopper positions and movement range Mechanical stopper position and maximum movement position 150 Y axis standard stopper po...

Page 75: ...16 7 1 Installing the X axis Y axis additional mechanical stoppers Follow the steps below to install the X axis Y axis additional mechanical stoppers Use the bolts listed below to install optional mechanical stoppers No Part No Q ty Remarks Additional mechanical stopper parts in either one direction of X axis plus or minus direction 1 1 91312 08016 1 Stopper bolt Additional mechanical stopper part...

Page 76: ...t no one is inside the safety enclosure and then turn on the controller 8 Set the X axis soft limits in the plus direction When the stopper is installed in the minus direction set the soft limits in the minus direction c CAUTION Whether or not the X axis stops at a position before the stopper limited by the soft limit must be checked from the outside of the safety enclosure 9 Check that the X axis...

Page 77: ...um overrun amounts are listed below for normal operation maximum payload maximum speed X axis Y axis 2 1 Note Here deg is the overrun angle at the X axis and Y axis joints c CAUTION If the X axis or Y axis mechanical stopper is deformed or damaged due to an impact on the stopper please contact your distributor Continued use of the deformed or damaged stopper is very dangerous and so it must be rep...

Page 78: ...view and dimensions of Chapter 8 X and Y axes Do not use an area other than the working envelope for the work The working envelope described in this manual shows the robot working envelope in the no load state based on the robot front Working envelope 150 1 3 2 1 3 2 74 74 90 90 R115 150 23215 FK 00 ...

Page 79: ...movement range w Warning The robot cable user wiring or tubing may be damaged if the robot load interferes with them resulting in hazardous robot malfunctions Do not operate at points where the load may interfere with the robot cable user wiring or tubing Z axis mechanical stopper position 0 493 150 7 10 0 124 7 2 Z axis lower end mechanical stopper position Z axis upper end mechanical stopper pos...

Page 80: ...eral unit due to overrun during impacts with mechanical stopper Maximum overrun amounts are listed below for normal operation maximum payload maximum speed X axis Y axis Z axis Upper end Lower end 4 1 2mm 3mm Note Here deg is the overrun angle at the X axis and Y axis joints c CAUTION If an impact occurs with the mechanical stopper and the stopper is deformed or broken contact your distributor If ...

Page 81: ...the robot arms are fully extended while 3 types of tip mass 33 66 and 100 of maximum payload are loaded 10 30 50 70 90 XY axis stopping time Emergency stop is activated while the XY axis operates in the plus direction 1kg XY axis 2kg XY axis 3kg XY axis 0 20 40 60 80 100 0 00 0 05 0 10 0 15 0 20 0 25 0 30 0 35 0 40 0 45 XY axis stopping time sec Operation speed 23220 FK 00 10 30 50 70 90 XY axis s...

Page 82: ...operates in the plus direction Operation speed Z axis stopping time sec 1kg Z axis 2kg Z axis 3kg Z axis 23222 FK 01 0 2 4 6 8 10 12 14 16 18 20 0 10 20 30 40 50 60 70 80 90 100 Z axis stopping distance Emergency stop is activated while the Z axis operates in the plus direction Operation speed Z axis stopping distance mm 1kg Z axis 2kg Z axis 3kg Z axis 23223 FK 01 ...

Page 83: ...0 0166kgm2 R axis 2kg 0 0333kgm2 R axis 3kg 0 05kgm2 R axis Operation speed R axis stopping time sec 23224 FK 00 R arm stopping angle Emergency stop is activated while the R axis operates in the plus direction 1kg 0 0166kgm2 R axis 2kg 0 0333kgm2 R axis 3kg 0 05kgm2 R axis 0 50 100 150 200 250 300 0 10 20 30 40 50 60 70 80 90 100 Operation speed R axis stopping rotation angle 23225 FK 00 ...

Page 84: ...ows the outside diameters and quantities that can be added by considering the durability of the machine harness Installing the user wiring and tubing newly Clamp the user wiring and tubing with minimal tie band quantity so that the additional signal lines and tubes do not deviate If the clamp is too strong the machine harness may have faulty wiring φ D φ d Machine harness Signal line Air tube Tie ...

Page 85: ...ne R axis speed reduction unit or R axis motor Use an appropriate connector that passes through the spline with an inside diameter of φ11 Example of how to pass the wiring and tubing Clamp using nylon clamp etc Stay Extension shaft Clamp using nylon clamp etc Stay Junkosha s mechatro flat tube MF1 06 working length cm 10 0 1 0 1sq wire materials 10 pcs are included in the air tube outside diameter...

Page 86: ...e not secured firmly noise may occur the cover may drop and fly out your hand may be entangled in the drive unit during teaching or your hand may be in contact the hot drive unit causing burn To prevent such troubles strictly observe this caution YK400XR Base rear cover mounting bolt Hex socket head bolt M4 8 4 pcs YAMAHA s part No 91312 04008 Y axis arm cover YAMAHA s part No KDS M1314 000 Harnes...

Page 87: ... 2 2 Absolute reset in servo off state re reset 3 16 2 4 2 3 Absolute reset in servo on state new reset 3 19 2 4 2 4 Absolute reset in servo off state new reset 3 21 2 4 3 Sensor method X axis Y axis 3 23 3 Setting the soft limits 3 27 3 1 Setting the X axis and Y axis soft limits 3 27 3 2 Setting the Z axis soft limits 3 28 3 3 Setting the R axis soft limits 3 28 3 4 Relation between the X Y and ...

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Page 89: ... the robot is being adjusted to prevent others from touching the controller switch programming box PBX or operation panel If a safety enclosure has not yet been provided right after installation of the robot rope off or chain off the movement range around the manipulator in place of a safety enclosure and observe the following points 1 Use stable posts which will not fall over easily 2 The rope or...

Page 90: ...rformed 5 Parameters were initialized 6 Axis parameters Origin shift Return to origin method Return to origin direction or Motor axis polarity were changed 7 Motor was replaced Motor wiring connector was removed 8 Data in the ALL data file extension ALL or parameter file extension PRM was written into the controller by way of the Online command The following sections explain how to perform return ...

Page 91: ...R axis the return to origin operations of the Z axis and R axis are automatically performed continuously So pay special attention to the interference between the tip tool and robot or peripheral unit Default origin position 1 2 9 3 147 3 147 3 Plus side Plus side Minus side Minus side 23001 FK 00 c CAUTION The X and Y axes will move to the positions shown in Fig below during return to origin so ma...

Page 92: ... position exceeding the repeatability allowable value or at a position different from the previous absolute reset position the position deviation may occur Use the origin position stickers supplied with the product so that the origin position can be reproduced correctly within the allowable value In section 2 4 2 2 Absolute reset in servo off state re reset of this chapter the origin position repe...

Page 93: ...AUTION The machine reference must be adjusted within a specified range to keep the repeatability precision of the return to origin position The machine reference is factory adjusted prior to shipping If the origin position is changed the machine reference must be readjusted For information on how to adjust the machine reference refer to 2 Adjusting the origin in this Chapter When the temperature o...

Page 94: ...el 3 Display the ORIGIN RTN TRQ SENS screen on the PBX operation return to origin 24304 F0 00 Return to origin mode screen Step 3 4 4 Select an axis whose return to origin is performed Use the cursor keys to select an axis number whose return to origin is performed n NOTE As the return to origin operations of the Z axis and R axis are performed simultaneously you can select either axis number 3 or...

Page 95: ...1 Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller 2 Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel 3 Display the ORIGIN RTN TRQ SENS screen on the PBX operation return to origin Return to origin mode screen Step 3 4 24302 F...

Page 96: ...screen Check that the status is OK and that the machine reference value is within the return to origin tolerable range 25 to 75 24303 F0 00 Machine reference value checking procedure 1 Use the cursor keys on the initial screen to select Operation and press to display the operation menu 2 Select Origin Return and press to display the ORIGIN RTN TRQ SENS screen The return to origin completion status...

Page 97: ...rd coordinate and point data must be reset 2 4 1 Stroke end method The return to origin of the YK XR series uses the stroke end method The machine reference value was adjusted correctly at shipment So the readjustment is not needed during normal operation However if the machine reference value exceeds the return to origin tolerance range 25 to 75 for some reason follow the steps below to readjust ...

Page 98: ... reference value 7 Loosen the bolts that secure the speed reduction gear At this time it is enough to loosen the bolts Do not pull out the bolts A rattle is produced Utilize this rattle to turn the arm To increase the reference value turn the Y axis arm counterclockwise when viewed from the top of the robot Conversely to decrease the reference value turn the Y axis arm clockwise when viewed from t...

Page 99: ...the Z axis reference value loosen the bolts at 3 locations 23302 FK 00 w Shift the engagement between the motor pulley and belt tooth Shifting the belt engagement one tooth will change the machine reference value approximately 25 When shifting the pulley clockwise with the belt teeth left as they are the reference value will increase Conversely when shifting the pulley counterclockwise the referen...

Page 100: ...rigin refer to 2 3 Return to origin procedures in this Chapter u Check the Z axis machine reference value After the return to origin has been completed check that the machine reference value is within the return to origin tolerance range 25 to 75 If the adjustment machine reference value is outside the tolerance range 25 to 75 then repeat the procedure from step 9 again to readjust it i Turn off t...

Page 101: ...seen from a position beyond the robot movement range The origin position mark cannot be seen from a position beyond the robot movement range The robot can be guided to the new origin position by the servo drive from a position beyond the robot movement range The robot cannot be guided to the new origin position by the servo drive from a position beyond the robot movement range To 2 4 2 1 absolute ...

Page 102: ...Robot Controller User s Manual 1 Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller 2 Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel 3 Move to a position where the origin position sticker can be seen Move to a position where t...

Page 103: ...wable value See the figure below If the absolute reset is performed at a position exceeding the repeatability allowable value or at a position different from the previous absolute reset position the position deviation may occur When performing the absolute reset take appropriate measures so that the deviation between the origin position marks is put in the repeatability allowable value range corre...

Page 104: ...out how to operate the robot controller see the YAMAHA Robot Controller User s Manual 1 Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller 2 Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel 3 Enter the safety enclosure Enter the...

Page 105: ... from the previous absolute reset position the positional deviation may occur When performing the absolute reset take appropriate measures so that the deviation between the origin position marks is put in the repeatability allowable value range correctly The origin position repeatability allowable value of each axis is shown below Origin position repeatability allowable value axis Origin position ...

Page 106: ...r the return to origin position where the value of the selected axis on the PBX screen enters the range between 26 and 74 press the key If the value of the selected axis is not in the range between 26 and 74 the message Position reset malposition appears in the next operation and the absolute reset cannot be completed 9 Perform the absolute reset Press on the ORIGIN RTN MARK pop up screen to compl...

Page 107: ...Q SENS screen on the PBX operation return to origin 5 Display the ORIGIN RTN MARK screen Press MARK on the ORIGIN RTN TRQ SENS screen 6 Select an axis whose absolute reset is performed Use the cursor keys to select an axis number whose absolute reset is performed and then press 7 Perform the step movement Press the jog key to perform the step movement of the robot until the absolute reset position...

Page 108: ...ng next absolute reset The origin position repeatability allowable value of each axis is shown below Origin position repeatability allowable value axis Origin position repeatability allowable value X 0 72 Y 0 72 R 3 00 Positional relationship between origin position stickers Repeatability allowable value Origin position sticker Repeatability allowable value Origin position sticker Repeatability al...

Page 109: ...ne reference value When the robot is moved to a position where the absolute reset is performed check that the value of the selected axis is in the range between 26 and 74 on the PBX screen Normally this value is 50 8 Select an axis whose absolute reset is performed Use the cursor keys to select an axis number whose absolute reset is performed and then press The execution confirmation screen will p...

Page 110: ...an be understood securely during next absolute reset The origin position repeatability allowable value of each axis is shown below Origin position repeatability allowable value axis Origin position repeatability allowable value X 0 72 Y 0 72 R 3 00 Positional relationship between origin position stickers Repeatability allowable value Origin position sticker Repeatability allowable value Origin pos...

Page 111: ...n on the controller 2 Perform the return to origin Perform the return to origin from outside the safety enclosure For details about how to perform the return to origin refer to 2 3 Return to origin procedures in this Chapter 3 Check the machine reference value If the machine reference value displayed on the PBX is not in the range between 25 and 75 recommended range after the return to origin has ...

Page 112: ...dog 0 Secure the X axis origin sensor with the hex nut Secure the X axis origin sensor with the hex nut Tightening torque 5Nm 50kgfcm Tool KANON Nakamura Mfg Co Ltd Torque wrench N190SPK 13 q Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller w Perform the return to origin Perform the return to origin from outside the safety enclosure e Check th...

Page 113: ... refer to 2 3 Return to origin procedures in this Chapter 3 Check the machine reference value If the machine reference value displayed on the PBX is not in the range between 25 and 75 recommended range after the return to origin has been completed follow the steps below to adjust the machine reference value 4 Place a sign indicating the robot is being adjusted Place a sign indicating the robot is ...

Page 114: ...not collide with the dog 0 Secure the Y axis origin sensor with the hex nut Secure the Y axis origin sensor with the hex nut Tightening torque 5Nm 50kgfcm Tool KANON Nakamura Mfg Co Ltd Torque wrench N190SPK 13 q Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller w Perform the return to origin Perform the return to origin from outside the safety...

Page 115: ...ency stop status n NOTE For details about emergency stop and how to cancel the emergency stop see the YAMAHA Robot Controller User s Manual 3 Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel 4 Enter the safety enclosure while holding the PBX 5 Move the X axis and Y axis arms by ha...

Page 116: ...rom outside the safety enclosure or after the emergency stop button has been pressed in the same manner as the X axis and Y axis soft limits The R axis has no mechanical stoppers When the actual working range of the R axis is small or it interferes with the peripheral equipment reduce the R axis plus soft limit pulse and minus soft limit pulses to narrow the working envelope 3 4 Relation between t...

Page 117: ...djust the soft limits while referring to 3 Setting the soft limits 3 Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel 4 Enter the safety enclosure while holding the PBX At this time stay outside the robot movement range c CAUTION Never enter the robot movement range 5 Set the stan...

Page 118: ... the controller or operation panel 4 Enter the safety enclosure while holding the PBX 5 Insert the shaft 1 Make the adjustment so that the X axis arm and Y axis arm are aligned on an almost straight line 2 Adjust the arm positions so that the shaft enters the slot in the Y axis arm and the hole in the X axis arm without prying and then insert the shaft Installing the Y axis standard coordinate jig...

Page 119: ...GTH Enter the following values arm length values in the axis parameter ARM LENGTH A1 and A2 A1 X axis arm length A2 Y axis arm length 225 175 q Enter the axis parameter OFFSET PULSE Enter the values shown on the right in the axis parameter OFFSET PULSE Entering the Offset pulse values Step 11 Note Round off the decimal part of the A2 value A1 X axis position pulse value you have made a note of in ...

Page 120: ... may cause faulty operation and hazardous situations 1 Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller 2 Move the robot to the 0 pulse position n NOTE For details about how to move the robot to the 0 pulse position see 8 Point trace function in Chapter 3 of the RCX340 User s Manual 3 Turn off the controller 4 Place a sign indicating the robot...

Page 121: ...3 Robot settings 3 33 Sticker affixing positions example X X Y Y Y Y Y Y Z R 23305 FK 00 ...

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Page 123: ...Chapter 4 Periodic inspecition Contents 1 Overview 4 1 2 List of inspection items 4 2 ...

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Page 125: ...ogramming box PBX or operation panel Use only the lubricants specified by your distributor To check the operation after inspection refer to 4 6 1 Trial Operation in Chapter Safety Instructions of this manual n NOTE For precautions on handling the controller refer to the YAMAHA Robot Controller User s Manual Cautions on 6 month inspection w Warning The Z axis will slide down when the Z axis brake i...

Page 126: ... connection connector for looseness 2 Application of grease to Z axis spline and Z axis ball screw 3 Remove the old grease with a cloth rag and apply LG2 NSK Z axis ball screw and ball spline Check for play Inspection with the controller turned on Safeguard enclosure Check that the safeguard enclosure is located at its specified position Check that the emergency stop turns on when the safeguard en...

Page 127: ...riodic inspecition 4 3 Bolt tightening torque Bolt size Tightening torque kgfcm Tightening torque Nm M3 set screw 7 0 69 M4 set screw 17 1 7 M3 20 2 0 M4 46 4 5 M5 92 9 0 M6 156 15 3 M8 380 37 M10 459 45 0 ...

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Page 129: ...Chapter 5 Harmonic drive replacement period Contents 1 Overview 5 1 2 Replacement period 5 2 ...

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Page 131: ... below to determine the replacement period and replace the harmonic drive periodically Since the YK XR series robots listed below use long life harmonic grease it is not necessary to replace the harmonic grease w Warning Engineers who have the qualification in conformity with 2 Qualification of operators workers in section 4 1 of the Safety Guide must perform the harmonic drive replacement while r...

Page 132: ...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 period for the X ...

Page 133: ...Increasing the robot operating speed 6 1 1 1 Increasing speed by arch motion 6 1 1 2 Increasing the speed with the WEIGHT statement 6 3 1 3 Increasing the speed by the tolerance parameter 6 4 1 4 Increasing the speed by the OUT effective position parameter 6 5 ...

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Page 135: ... P2 MOVE P P3 MOVE P P4 Gate motion Z 0 P2 P1 P3 P4 23601 F0 Arch motion 222 From point P1 to P2 MOVE P P2 Z 0 Axis parameter arch pulse 1 arch pulse 2 ARCHP1 ARCHP2 ARCHP1 102400 pulses ARCHP2 102400 pulses The default arch pulse value is 9999999 pulses ARCHP1 ARCHP2 Obstacles Obstacles Arch motion Z 0 P1 P2 23602 F0 After the Z axis has moved up 102400 pulses from P1 the X Y and R axis start ope...

Page 136: ...44 Example From point P1 ARCHP1 140000 Arch pulse1 ARCHP2 140000 Arch pulse2 MOVE P P2 Z 0 ARCHP1 70000 Arch pulse1 ARCHP2 70000 Arch pulse2 MOVE P P3 Z 102400 Since the arch positions can be changed in the program optimizing the arch positions can further shorten the cycle time Arch motion Z 0 P1 P2 P3 Z 102400 Large arch pulse Small arch pulse 23603 F0 Example 2 Arch pulse designation using opti...

Page 137: ...the 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 tip weight parameter to 5kg while the chuck does not grip any workpiece and then set to a lower level by changing the tip weight parameter to 10kg while the chuck grips a workpiece Compared to programs using a tip weight parameter left set at 10kg this me...

Page 138: ...E 1 80 Decreases the tolerance at P3 TOLE 2 80 TOLE 3 80 TOLE 4 80 MOVE P P3 If P2 is a transit point whose location does not need to be specified precisely speed can be increased by increasing the tolerance of positioning at P2 Specifying a greater tolerance will produce increased sound and vibration when the robot is operating and will make the movement path irregular so pay attention to the sou...

Page 139: ...ng OUT effective position 23606 F0 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 position 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 Refere...

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Page 141: ...Chapter 7 Torque limit designated Z axis pushing action Contents 1 Torque limit designated Z axis pushing action 7 1 ...

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Page 143: ...iffer due to individual variance and sliding friction of the robot model The speed limit value shown in the table is one of the options of the PUSH statement and is the value to be entered as the movement speed DS of the axis If the speed limit value is 100 the movement speed will be 10 of the maximum speed For specific programming refer to the separate RCX340 Programming Manual Tip Load Weight kg...

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Page 145: ...Chapter 8 Specifications Contents 1 Manipulator 8 1 1 1 Basic specification 8 1 1 2 External view and dimensions 8 2 1 3 Robot inner wiring diagram 8 4 1 4 Wiring table 8 5 ...

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Page 147: ...Standard cycle time 3 0 45s R axis tolerable moment of inertia 4 0 05kgm2 without offset User wiring 0 2sq 10 User tubing Outer diameter φ4 3 Travel limit 1 Soft limit 2 Mechanical stopper X Y Z axis Robot cable Standard 3 5m Option 5m 10m Weight 17kg 1 This is the value at a constant ambient temperature 2 In the user wiring tubing through spline type option this value becomes 2kg 3 When moving a ...

Page 148: ...ype When performing return to origin move both the X axis and Y axis counterclockwise in advance from the position shown above M8 bolt for installation 4 bolts used Maximum 370 during arm rotation Maximum 600 during arm rotation Z axis lower end mechanical stopper position Keep enough space for the maintenance work at the rear of the base R27 Min cable bending radius Do not move the cable Z axis o...

Page 149: ...d through spline shaft 4 M3 0 5 through hole No phase relation to R axis origin As this hole is intended for the wiring tubing clamp do not attach a large load to it View of F X axis mechanical stopper position 134 Y axis mechanical stopper position 154 Working envelope User tubing 1 ϕ4 black User tubing 2 ϕ4 red User tubing 3 ϕ4 blue M4 ground terminal User wiring connector Numbers 1 to 10 are us...

Page 150: ... terminal User tubing User IO connector XM YM XY ZM RM ZR XORG XORG Y axis origin sensor FG RORG RORG YM ZM ZM RM RM XM XM YP YP ZP RP RP YORG YORG ZBK ZBK XP XP RM RP RP RM ZM ZBK YORG YORG RORG ZBK ZP ZP ZM YM YP YP YM FG YM ZP X axis motor X axis resolver R axis motor R axis resolver Z axis motor Z axis resolver Y axis motor Y axis resolver Z axis brake I O I O X axis origin sensor 23803 FK 00 ...

Page 151: ... Red 0 15sq S3 4 22 Bright green 2 Black Twisted pair R1 5 23 Pink 2 Red 0 15sq R2 6 24 Pink 2 Black Twisted pair DG 7 25 Gray 0 3sq FG FG 1 18 Gray 2 Red 0 15sq 36 Gray 2 Black 0 15sq HLIM 10 Gray 0 3sq GND24 11 HLIM 28 Gray 0 3sq GND24 29 Origin Sensor GND XORG 3 13 Sky blue 3 Red 0 15sq ORG 2 12 Sky blue 3 Black Twisted pair 24V 1 9 Pink 3 Red 0 15sq Origin Sensor 24V YORG 1 27 Pink 3 Black Twi...

Page 152: ...2 Black Twisted pair S1 3 21 Bright green 2 Red 0 15sq S3 4 22 Bright green 2 Black Twisted pair R1 5 23 Pink 2 Red 0 15sq R2 6 24 Pink 2 Black Twisted pair DG 7 25 Gray 0 3sq FG FG 1 18 Gray 2 Red 0 15sq 36 Gray 2 Black 0 15sq HLIM 10 Gray 0 3sq GND24 11 HLIM 28 Gray 0 3sq GND24 29 Origin Sensor 24V ZORG 3 13 Sky blue 3 Red 0 15sq ORG 2 12 Sky blue 3 Black Twisted pair GND 1 9 Pink 3 Red 0 15sq O...

Page 153: ...S3 4 4 Gray R1 5 5 Orange 0 2mm2 Twisted pair R2 6 6 Gray DG 7 7 Gray Shield Y axis motor U YM 1 1 YM Brown 0 75mm W 2 2 Red V 3 3 Orange Z axis motor U ZM 1 1 ZM Blue 0 75mm W 2 2 Purple V 3 3 Gray R axis motor U RM 1 1 RM Black 0 75mm W 2 2 Blue V 3 3 Red Z axis brake 1 ZBK 1 1 ZBK Purple 0 3mm Z axis brake 2 2 2 Gray 0 3mm User signal line IO 1 1 IO Brown 0 2mm2 2 2 Red 3 3 Orange 4 4 Blue 5 5 ...

Page 154: ...W PE Green Yellow Motor Round terminal PE Cable wiring table Motor Robot cable Signal No Connection No Wire S2 1 4 0 3sq Blue S4 2 6 Orange S1 3 3 Bright green S3 4 5 Brown R1 5 1 Gray R2 6 2 Red FG 7 Drain wire Origin sensor wiring table Signal Color Connection No Connector 24V Brown 1 XORG YORG ORG Black 2 0V Blue 3 ...

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Page 156: ...evision record Manual version Issue date Description Ver 1 00 Jul 2014 First edition Ver 1 01 Sep 2014 Clerical error corrections etc Ver 1 10 Nov 2014 In Chapter 2 9 Stopping time and stopping distance at emergency stop the graphs of Z axis were changed Ver 1 20 May 2015 In Chapter 2 6 Attaching the end effector was changed In Chapter 3 2 3 2 Sensor method X axis Y axis a caution statement was ad...

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Page 158: ...robot Robot manuals can be downloaded from our company website Please use the following for more detailed information YAMAHA MOTOR CO LTD IM Operations 882 Soude Nakaku Hamamatsu Shizuoka 435 0054 Japan Tel 81 53 460 6103 Fax 81 53 460 6811 ...

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