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Chapter 1

USING THE ROBOT SAFELY

Contents

Special Training for Industrial Robot Operation 1-8

Safety Measures for the System

Work Within the Safeguard Enclosure

10. Repair and Modification

Содержание XY-X series

Страница 1: ...r s Manual ENGLISH E E40 Ver 1 02 NXY YAMAHA CARTESIAN ROBOT XY X series IM Operations 882 Soude Naka ku Hamamatsu Shizuoka 435 0054 Japan URL http www yamaha motor jp robot index html YAMAHA MOTOR CO LTD ...

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Страница 3: ...the Safeguard Enclosure 1 11 8 Automatic Operation 1 11 9 Adjustment and Inspection 1 12 10 Repair and Modification 1 12 11 Warranty 1 13 12 CE Marking 1 14 Chapter 2 INSTALLATION 1 Installation bolt types 2 1 2 Installation bolt nominal length 2 1 3 Tightening torque 2 2 4 Installation methods 2 2 Chapter 3 PROTECTIVE CONNECTIONS 1 Ground terminal 3 1 2 Ground wire 3 2 3 Wiring methods 3 2 3 1 Gr...

Страница 4: ...arrier type 5 1 1 1 Wiring piping to the single arm robot 5 1 1 2 Wiring piping to the double arm robot 5 3 1 3 Cable carrier specifications 5 6 Chapter 6 PERIODIC INSPECTIONS 1 Before beginning work 6 1 2 Periodic inspection 6 3 2 1 Daily inspection 6 3 2 2 Three month inspection 6 3 2 3 Six month inspection 6 4 2 4 Three year inspection 6 4 3 Replenishing grease to the linear guide 6 5 4 Repleni...

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

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Страница 7: ...HE ROBOT OPERATOR BYSTANDERS OR PERSONS SERVICING THE ROBOT cCAUTION Failure to follow CAUTION instructions may result in injury to the robot operator bystanders or persons servicing the robot or damage to the robot and or robot controller nNOTE Explains the keypoint in the operation in a simple and clear manner Refer to the user s manual by any of the following methods to operate or adjust the ro...

Страница 8: ... Install a safeguard enclosure to keep all personnel from entering within the movable range of the robot and suffering injury due to being struck by moving parts Install a safety interlock that triggers emergency stop when the door or panel is opened Install safeguards so that no one can enter inside except from doors or panels equipped with safety interlocks The warning label 1 are supplied with ...

Страница 9: ... contents before attempting installation and operation of the robot Before starting robot operation be sure to reread the procedures and cautions related to the work as well as the descriptions in this chapter Chapter 1 Using the Robot Safely Never install adjust inspect service or operate the robot in any manner that does not comply with the instructions in this manual Improper installation or op...

Страница 10: ...etc wWARNING END EFFECTORS MUST BE DESIGNED AND MANUFACTURED SO THAT THEY CREATE NO HAZARDS FOR EXAMPLE A WORKPIECE THAT COMES LOOSE EVEN IF POWER ELECTRICITY AIR PRESSURE ETC IS SHUT OFF OR A POWER FLUCTUATION OCCURS IF THERE IS A POSSIBLE DANGER THAT THE OBJECT GRIPPED BY THE END EFFECTOR MAY FLY OFF OR DROP THEN PROVIDE APPROPRIATE SAFETY PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE WEIGHT TE...

Страница 11: ... REPLACED WHILE THE AIR IS SUPPLIED THE PARTS OR AIR COULD SCATTER TURN THE CONTROLLER POWER OFF STOP THE AIR SUPPLY AND RELEASE ALL RESIDUAL PRESSURE FROM THE PNEUMATIC DEVICES BEFORE STARTING WORK THE Z AXIS WILL NATURALLY DROP SO PROP IT UP WITH A SUPPORT STAND ETC BEFORE STOPPING THE AIR SUPPLY 12 Use caution when disassembling and replacing the motor wWARNING WHEN DISASSEMBLING OR ASSEMBLING ...

Страница 12: ...uble Possible Danger Damage to machine harness or robot cable Electrical shock malfunction of robot Damage to exterior of robot Flying outward of damaged parts during robot operation Abnormal operation of robot positioning error excessive vibration etc Malfunction of robot Z axis brake trouble Dropping of load 16 Use caution not to touch the controller rear panel cooling fan wWARNING INJURY MAY OC...

Страница 13: ...OCK 20 Be sure to make correct parameter settings Part 1 cCAUTION Always input the correct parameters matching the payload and stroke working envelope before operating the robot 21 Be sure to make correct parameter settings Part 2 cCAUTION When using a rotary axis RF RH etc the robot must be operated with the tolerable moment of inertia and correct acceleration coefficients according to the tip ma...

Страница 14: ...ir has received appropriate training and also has the skills needed to perform the job correctly and safely Since YAMAHA Cartesian robot XY series falls 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 teaching programming movement check inspection adj...

Страница 15: ...ctions these mechanical stoppers prevent the axis from exceeding the movable range Note that the movable range is the area limited by the mechanical stoppers No mechanical stopper is provided on the R axis 5 Z axis vertical axis brake An electromagnetic brake is installed on the Z axis to prevent the Z axis from dropping when the servo power is shut off This brake is working when the controller po...

Страница 16: ...ible by everyone around the robot e Place a sign to keep the operator or other personnel from entering the movable range 2 Check the following points before turning the controller ON q Is the robot securely and correctly installed w Are the electrical connections to the robot correct e Are items such as air pressure correctly supplied r Is the robot correctly connected to peripheral devices t Have...

Страница 17: ...tomatic operation 2 Never enter the movable range of the robot while within the safeguard enclosure 8 Automatic Operation 1 Check the following before starting automatic operation q No one is within the safeguard enclosure w The programming unit or tools etc are in their specified location e The alarm or error lamps etc on the robot and peripheral devices do not flash r The safeguard enclosure is ...

Страница 18: ...NTENANCE UNLESS DESCRIBED IN THIS MANUAL UNEXPECTED ACCIDENTS OR TROUBLES MAY OTHERWISE RESULT 10 Repair and Modification wWARNING DO NOT ATTEMPT ANY REPAIR PART REPLACEMENT OR MODIFICATION UNLESS DESCRIBED IN THIS MANUAL THESE MATTERS REQUIRE TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE WORK HAZARDS 9 Adjustment and Inspection ...

Страница 19: ...ata and other internal data that were changed or created by the user Failures resulting from the following causes are not covered by warranty repair 1 Damage due to earthquakes storms floods thunderbolt fire or any other natural or man made disasters 2 Troubles caused by procedures prohibited in this manual 3 Modifications to the robot and or related product not approved by YAMAHA or YAMAHA sales ...

Страница 20: ...THE ROBOT SAFELY 12 CE Marking Refer to the following YAMAHA robot controller user s manuals for details on the related CE Marking for export to or use in EU regions CE marking supplement manual for RCX series 12 CE Marking ...

Страница 21: ...Chapter 2 INSTALLATION Contents 1 Installation bolt types 2 1 2 Installation bolt nominal length 2 1 3 Tightening torque 2 2 4 Installation methods 2 2 ...

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Страница 23: ...t 1 Installation bolt types Use the installation bolt with a hexagon socket head cap screw M6 strength 8 8T 2 Installation bolt nominal length cCAUTION Do not use washers or spring washers with the tightening bolt The bolt head could interfere with the linear guide s bearings and be damaged When using method A determine the nominal length so that the length of the screw from the robot bottom is 9m...

Страница 24: ... USE THE DESIGNATED BOLT AND SECURELY TIGHTEN IT WITH THE CORRECT TORQUE FAILURE TO OBSERVE THIS COULD CAUSE THE ROBOT POSITION TO DEVIATE AND COULD ALSO LEAD TO SERIOUS ACCIDENTS Method A 1 Open a φ6 5 through hole on the installation base s robot installation surface For machining positions refer to the external view and dimensions in the catalog or website www yamaha motor co jp global industri...

Страница 25: ... cover End cover 1 Top cover 3 Secure the robot to the base with the specified bolts utilizing the mounting holes in the bottom of the robot frame While moving the table slider secure the robot to the base using all the mounting holes in the bottom of the robot frame M6 hex wrench wWARNING TIGHTEN THE BOLTS SECURELY TO THE CORRECT TORQUE FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE POSITIONING ERR...

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Страница 27: ...Chapter 3 PROTECTIVE CONNECTIONS Contents 1 Ground terminal 3 1 2 Ground wire 3 2 3 Wiring methods 3 2 3 1 Grounding to the single arm robot 3 2 3 2 Grounding to the double arm robot 3 3 ...

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Страница 29: ...ING THE GROUND TO PREVENT ELECTRICAL SHOCKS WHEN USING A TOOL OR WORKPIECE HAVING POWER WHICH COULD CONTACT THE ROBOT DUE TO A FAILURE OR THE SPECIFICATIONS THE USER MUST PROVIDE PROPER GROUNDING SINCE THE ROBOT DOES NOT HAVE A GROUND TERMINAL FOR THOSE DEVICES 1 Ground terminal Single arm robot Grounding terminal is on the external face of the X axis wiring box X axis wiring box Ground terminal D...

Страница 30: ...ng tongue terminal and M4 small screw with spring washer and then tighten M4 small screw with spring washer Ring tongue terminal Lock washer cCAUTION Accurately insert the lock washer between the ring tongue terminal and robot Proper continuity may not be secured if the lock washer is dislocated Take care not to catch the harness and ground wire from the X axis with the cover of X axis wiring box ...

Страница 31: ... the double arm robot 1 Remove the M4 bolts 2 pcs on the top of the X wiring box and open the cover by sliding toward the robot 2 Connect the ground wire to the ground terminal attached in the X axis wiring box Ground terminal Ground wire 3 Wiring methods ...

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Страница 33: ...Chapter 4 INSTALLING THE TOOL Contents 1 Single arm type double arm type 2 axis model 4 1 2 ZFH single arm type double arm type 4 2 3 ZFL single arm type double arm type 4 3 ...

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Страница 35: ...e Y axis slider Install the user tool onto the Y axis slider using these holes M5 coarse thread tap holes are also opened on the slider side Use these to fix light loads other than the tool such as a wiring retainer There is a step on the top of the slider The actual tool installation surface is the shaded section shown in the drawing Select the nominal length of the tool fixing bolt so that the f...

Страница 36: ... the slider s workpiece installation surface The tap depth is 9mm There is a step on the top of the slider The actual tool installation surface is the shaded section shown in the drawing 62 100 112 SEC A A 31 28 31 70 10 5 9 1 A A 4 M5x0 8 Depth 9 2 F5H7 Depth 8 Tolerance between knock 0 02 cCAUTION If the bolt fitting length is 9mm or more from the installation surface the bolt will contact the b...

Страница 37: ...der to fix light loads other than the tool such as a wiring retainer There is a step on the top of the slider Select the nominal length of the tool fixing bolt so that the fitting length of the screw fixing the tool is 8mm or more 12mm or less 70 2 F5H7 Depth15 8 6 M5x0 8 Depth12 110 100 Tolerance between knock 0 02 43 70 156 70 0 02 9 9 18 120 50 10 6 M5x0 8 Depth 9 9 1 Stroke cover cCAUTION If t...

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Страница 39: ...Chapter 5 USER WIRING AND USER PIPING Contents 1 Cable carrier type 5 1 1 1 Wiring piping to the single arm robot 5 1 1 2 Wiring piping to the double arm robot 5 3 1 3 Cable carrier specifications 5 6 ...

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Страница 41: ...rovided between the Z and R axes Lay the wiring and piping to the tool using these ducts A 0 3sq 10 core flexible cable is wired from the X axis wiring box to the final axis wiring box and can be used freely The wiring and piping methods for a 2 axis arm type are explained below as an example 1 1 Wiring piping to the single arm robot cCAUTION Wiring layout must be designed in the unoccupied area 1...

Страница 42: ...Set the outer lids back in the original position after finishing the wiring layout 3 Fix the wiring materials with Insulock ties as necessary Insulock base must be attached See the photograph below for the machining position 1 Cable carrier type ...

Страница 43: ...e arm robot cCAUTION Wiring layout must be designed in the unoccupied area 1 Remove the outer lids on the cable carrier by using a flat tip screwdriver The outer lids do not have to be removed if the connectors are not attached to the wiring materials 1 Cable carrier type ...

Страница 44: ...Set the outer lids back in the original position after finishing the wiring layout 3 Fix the wiring materials with Insulock ties as necessary Insulock base must be attached See the photograph below for the machining position 1 Cable carrier type ...

Страница 45: ...5 5 Chapter 5 USER WIRING AND USER PIPIN 4 A bundle of wires can be set either left or right of the robot 1 Cable carrier type ...

Страница 46: ...l wire F10 1 Power wire F7 6 Signal wire F8 2 Power wire F9 8 User wiring area User wiring area 29 35 120 100 70 Power wire F9 8 Signal wire F10 1 User wiring area cCAUTION Harness and air tube must be laid in the unoccupied area Do not set the user wiring piping in the YAMAHA robot cable domain When setting the harness and air tube into the cable carrier make sure that the total cross sectional a...

Страница 47: ... beginning work 6 1 2 Periodic inspection 6 3 2 1 Daily inspection 6 3 2 2 Three month inspection 6 3 2 3 Six month inspection 6 4 2 4 Three year inspection 6 4 3 Replenishing grease to the linear guide 6 5 4 Replenishing grease to the ball screw 6 6 ...

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Страница 49: ...F THE CONTROLLER AND THE EXTERNAL SWITCH BOARD DO NOT TOUCH INTERNAL PARTS OF THE CONTROLLER FOR 5 SECONDS AFTER THE CONTROLLER HAS BEEN TURNED OFF WHEN ONLY MAKING ELECTRICAL INSPECTIONS AND REQUIRING NO MECHANICAL MOVEMENT OF THE ROBOT KEEP THE EMERGENCY STOP BUTTON PRESSED USE ONLY LUBRICANT AND GREASES SPECIFIED BY YAMAHA SALES OFFICE OR REPRESENTATIVE USE ONLY PARTS SPECIFIED BY YAMAHA SALES ...

Страница 50: ...NTACT WITH SKIN DO NOT TAKE ORALLY OR EAT EATING WILL CAUSE DIARRHEA AND VOMITING HANDS AND FINGERS MIGHT BE CUT WHEN OPENING THE GREASE CONTAINER SO USE PROTECTIVE GLOVES KEEP OUT OF THE REACH OF CHILDREN DO NOT HEAT THE GREASE OR PLACE NEAR AN OPEN FLAME SINCE THIS COULD LEAD TO SPARKS AND FIRES EMERGENCY TREATMENT IF GREASE GETS IN THE EYES WASH LIBERALLY WITH PURE WATER FOR ABOUT 15 MINUTES AN...

Страница 51: ...ection Check the following points every 3 months and apply grease if needed Checkpoints Check items Notes Ball screw linear guide ball bushing Check for dust buildup or debris Clean if necessary Apply grease after cleaning Check to see if the ball screw linear guide and ball bushing are lubricated not dry Apply grease if necessary Standard robots Albania No 2 Shell Daphne Eponex No 2 Idemitsu Clea...

Страница 52: ...se Check if connectors are loose Greasing to ball screw nut section and linear guide Apply grease every 6 months to ball screw nut and linear guide Recommended grease Albania No 2 Shell Daphne Eponex No 2 Idemitsu See 4 3 in this chapter Slider On long stroke robots check the slider inside the top cover for wear or damage every 6 months cCAUTION Using grease other than those recommended by YAMAHA ...

Страница 53: ...mended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu cCAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as indicated in the delivery specification drawings etc 1 Turn the controller power OFF When the ZFL unit is attached for the 3rd axis the replenishment wo...

Страница 54: ...the slider to the motor side and then start the work 5 Install the stroke cover 6 Confirm the surrounding safety and then turn the controller power ON 4 Replenishing grease to the ball screw The X axis Y axis and Z axis use a ball screw Grease must be replenished to this ball screw periodically Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu cCAUTION When designated by YAMA...

Страница 55: ...Remove the stroke cover of the axis to which grease is to be replenished Refer to section 1 Installation for details on removing the X axis cover 5 Install the grease nipple onto the ball screw flange 6 Using a grease gun replenish grease from the grease nipple X axis Y axis Sufficient grease has been replenished when new grease starts to seep out from the clearance between the ball screw nut and ...

Страница 56: ...eproduced 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 Cartesian Robot User s Manual NXY XY X series ...

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