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175932-1CD

175932-1CD

EcoTrim ET-1024 System

1     Introduction
1.2  System Overview

1.2.2  Major Components

The EcoTrim-1024 System includes the following major components:

• Motoman MH24 manipulator (robot)

• DX200 controller 

• One MSR series rotary positioner 

• One Programming Pendant (located on the DX200 controller)

• Operator Station

• Ultrasonic Trimming (Standard) or Hybrid (Optional) tool

• Safety equipment:

• Heavy gauge, wire-mesh safety fencing 

• Dual-channel, interlocked safety light curtain system

• Dual-channel, interlocked work-cell entry doors

• Steel screen on the MSR rotary positioner

1.2.3  Theory of Operation and Safe Guarding

The DX200 EcoTrim-1024 cell is designed to accommodate a single 
MH24 robot.

• EcoTrim-1024 - Single MH24 robot with MSR-355 positioner 

 

or optional MSR-655.

The robot controller and Ultrasonic/Hybrid tool controls are located behind 
the cell. Two sliding doors with safety interlocks allow access from either 
side. The MH24 sits on a 610 mm raiser. 

The standard servo driven MSR positioner provides either a 60 inch 

 

(1500 mm) or optional 72 inch (1829 mm) H-Frame tabletop. The table 
comes programmed for two reciprocating positions (Side A/Side B). 
Based on the selected table, options are available for additional load 
positions, rotary brushes, slip-rings and hard-stops.

The functional safety unit (FSU) is included in the controller for monitoring 
the rotary table. Two FSU “Axis Range Limit” files monitor the table's 
position (within 1 degree) to determine if the table is at “Side A” or “Side 
B”. The status of these two “Axis Range Limit” files generate outputs 
FSUOUT#1 (“Side A @ Robot”) and FSBOUT#2 (“Side B @ Robot”). The 
controller outputs connect to the coils of two force-guided relays. The 
contacts of these relays (At Side A and Side B), or with the light curtain's 
“Clear” status to generate an element in the E-stop chain.

15 of 64

Содержание 175932-1CD

Страница 1: ...ons thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MH24 MANIPULATOR INSTRUCTIONS MSR 355 AND MSR 655 POSITIONER MANUAL EcoTrim ET 1024 SYSTEM MANUAL DX200 INSTRUCTIONS DX200 OPERATOR...

Страница 2: ...copyrighted property of Yaskawa and may not be sold or redistributed in any way You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF fil...

Страница 3: ...own with the protective covers or shields removed for clarity Be sure that all covers and shields are replaced before operating this product The drawings and photos in this manual are representative e...

Страница 4: ...responsible for providing adequately trained personnel to operate program and maintain the equipment NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE PROGRAM OR REPAIR THE EQUIPMENT We recommend approved Y...

Страница 5: ...azardous situation which if not avoided could result in death or serious injury to personnel WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious i...

Страница 6: ...xpected manipulator motion Figure 2 Release of EMERGENCY STOP Button TURN Observe the following precautions when performing teaching operations within the P point maximum envelope of the manipulator V...

Страница 7: ...ll include in the information for use the safeguards and mode selection required for collaborative operation CAUTION Perform the following inspection procedures prior to conducting manipulator teachin...

Страница 8: ...w the warnings on the labels Also an identification label with important information is placed on the body of the manipulator Prior to operating the manipulator confirm the contents Figure 3 Warning L...

Страница 9: ...ce Documentation 1 10 1 3 1 Location of Operations in Reference Documentation 1 11 1 4 Customer Support Information 1 14 2 Equipment Description 2 1 2 1 Robot Description 2 1 2 2 DX200 Controller 2 1...

Страница 10: ...erator Station Pedestal Option 3 6 3 5 Light Curtain Alignment 3 6 3 6 Cable Connections 3 7 3 6 1 Connection to Earth Ground 3 7 3 6 2 Connection to Local Electrical Service 3 8 3 7 Safety Operation...

Страница 11: ...1 Appendix A A 1 A 1 Checklist A 1 Appendix B B 1 B 1 EcoTrim ETU 1024 Pneumatics B 1 B 1 1 Standard EcoTrim ETU 1024 B 2 B 1 2 Optional EcoTrim ETU 1024 B 3 Appendix C C 1 C 1 Optional Equipment C 1...

Страница 12: ...4 System and its components a list of reference documents and customer service contact information chapter 2 Equipment Description This chapter provides a description of the major components of the Ec...

Страница 13: ...tive A dual channel safety light curtain system provides a sensing field in front of the rotary positioner through use of an infrared light beam Rotary positioner motion is prevented whenever an opera...

Страница 14: ...mpletely surrounds the EcoTrim 1024 work cell The equipment platform is located outside and to the rear of the work cell This arrangement allows most of the component wiring interconnects to be pre wi...

Страница 15: ...rid tool controls are located behind the cell Two sliding doors with safety interlocks allow access from either side The MH24 sits on a 610 mm raiser The standard servo driven MSR positioner provides...

Страница 16: ...roken when the table is out of position stopped or moving the External E Stop signal will open resulting in a category 1 stop in either Play or Teach Mode The integrator or end user may implement addi...

Страница 17: ...t s external axis keys on the pendant or by selecting the Sweep job and test starting through the job logic If the operator or another person enters the light curtain while teaching the cell the exter...

Страница 18: ...he operator can safely enter the light curtain to remove the processed part and begin installation of a new part into the fixture Assuming there are no faults or issues during the production of the pa...

Страница 19: ...ct connections for use in the external E Stop logic 1 2 3 4 Safety Logic Implementation 1 In Play Mode and Teach Mode FSU based Axis Range Limit functions generate At Side A B outputs which prevent th...

Страница 20: ...1 Introduction 1 2 System Overview 1 9 175932 1CD 175932 1CD EcoTrim ET 1024 System Fig 1 4 b S1 Side A at Robot Details Fig 1 4 c S1 Side B at Robot Details 20 of 64...

Страница 21: ...292 1CD Motoman Maintenance Manual for DX200 P N 165293 1CD Motoman DX200 Concurrent I O Manual P N 165294 1CD Motoman MSR 355 and MSR 655 Positioner Manual P N 169856 1CD Motoman DX200 For Cutting De...

Страница 22: ...p 3 Assembly Mounting Condition Positioner Chap 2 Manipulator Chap 3 Space Needed for Maintenance EcoTrim Chap 3 Connecting Power EcoTrim Chap 3 Waste Removal Controller Chap 1 Protective Measures by...

Страница 23: ...Throughout Manuals Test and Examination After Changing Components EcoTrim Chap 3 4 Instructions for Disconnecting Pendants Controller Chap 4 Instructions for Fault and Emergency Recovery EcoTrim Chap...

Страница 24: ...imits for Range of Motion EcoTrim Chap 2 Relevant Standards Included Outside Manuals Instruction on Synchronized Motion EcoTrim Chap 2 Programmed Limits Controller Chap 11 Robot Suitable for Integrati...

Страница 25: ...r Please have the following information ready before you call System EcoTrim 1024 System DX Series Robot MH24 Positioner MSR 355 and MSR 655 Primary Application Trimming Controller DX200 Software Vers...

Страница 26: ...Twist can rotate the trimming tool 200 degrees without cable interference For additional information on the Motoman MH24 robot please refer to the MH24 Manipulator Manual that is included with your E...

Страница 27: ...TENT 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 TEST01 TOOL CONTROL GROUP R1 S 0000 NOP SET B000 1 SET B001 0 MOVJ VJ 80 00 MOVJ VJ 80 00 DOUT OT 10 ON TIMER T 3 00 MOVJ VJ 80 00 MOVJ...

Страница 28: ...stand alone pedestal Fig 2 8 Optional Pedestal Operator Station NOTE The Programming Pendant s LCD display goes dark after a few minutes of inactivity Press any key to restore the screen Operator Sta...

Страница 29: ...ters the safety zone created by the light curtain system the Cycle Start command will unlatch and the positioner will not sweep 2 4 2 Emergency Stop E STOP Pressing the red Emergency Stop E STOP butto...

Страница 30: ...75932 1CD EcoTrim ET 1024 System 2 4 7 Reset The black Reset button is used to clear a minor alarm or error condition 2 4 8 Servo On The green Servo On push button turns servo power ON when the robot...

Страница 31: ...ng operation The MSR family uses a rotary motion to sweep each side of the circular turntable 180 from the operator s loading zone into the robot s work zone and back to the operator again The positio...

Страница 32: ...de tight against part fixtures for precise and repeatable cuts There are six different blades available but it is recommended to try the standard blade first The ultrasonic oscillator is cooled with c...

Страница 33: ...the light curtains With the EcoTrim ET 1024 System the safety light curtains are set up to protect personnel who might unintentionally enter the MSR rotary positioner area during the positioner sweep...

Страница 34: ...ction 1 3 2 7 5 Emergency Braking System The MH24 manipulator incorporates a series of brakes that are designed to protect the robot and other system components from damage in the event of a software...

Страница 35: ...of the EcoTrim ET 1024 System are included with your shipment There are however some required items that the customer must supply hand tools special anchor bolts etc These are not included with your s...

Страница 36: ...ith appropriate concrete bits Phillips and flat blade screwdrivers Hammers dead blow and steel Hammer non marring Socket sets SAE and Metric Air impact gun with 3 4 inch hex socket Open end wrench set...

Страница 37: ...t on all sides of the work cell to facilitate installation 2 Gather all customer supplied items and required tools refer to section 3 1 Fig 3 1 Installation Dimensions for the EcoTrim 1024 System WARN...

Страница 38: ...aded into the wooden platform see Fig 3 2 It may be necessary to hold the leveling screws in place with a suitable open end wrench while removing the shipping bolts Figure 3 2 Stabilizing and Lag Poin...

Страница 39: ...floor Use a suitable concrete drill bit and special anchor lag bolts refer to chapter 6 Anchor Requirements for the correct drill bit and anchor bolt Be sure to remove all concrete dust from the drill...

Страница 40: ...to the floor Use a suitable concrete drill bit and special anchor lag bolts refer to section 6 for the correct drill bit and anchor bolt Be sure to remove all concrete dust from the drilled hole befor...

Страница 41: ...specialized measuring equipment is usually required to get an accurate resistance to ground reading Consult a specialist in this field if required Connect robot and DX200 controller to the earth groun...

Страница 42: ...1 1 and Fig 2 5 and the system diagram supplied with the system WARNING Connection of the EcoTrim ET 1024 System to local electrical service must be done by a qualified licensed electrician Electrical...

Страница 43: ...ON see Fig 2 5 9 Check for correct operation of system E STOP push buttons 10 Check for correct operation of the system HOLD buttons on the Programming Pendant and Operation Station ROBOT HOLD Refer t...

Страница 44: ...System is now ready for the installation of tooling and fixtures for your particular application Personnel who are familiar with the operation of the EcoTrim ET 1024 System should do the installation...

Страница 45: ...rom that presented here however basic operation will be the same For additional programming procedures and information refer to the DX200 controller and operator documentation that is included with yo...

Страница 46: ...ng Pendant s Mode Select Switch set to REMOTE 3 Set the Operator Station s POSITIONER AUTO MANUAL switch to MANUAL mode and start the Control Master job see section 4 3 3 Normally the robot will not m...

Страница 47: ...cell doors are closed and operating properly and the door safety interlocks are engaged 4 Make sure that all E STOP buttons are released E STOP buttons are installed at the following locations Progra...

Страница 48: ...of the positioner with parts to be processed 2 The operator steps out of the safety zone created by the safety light curtain system and moves to the front of the Operator Station 3 The operator presse...

Страница 49: ...hat the robot is in HOME position 2 Turn off system servo power by pressing the E STOP button on the Operator Station pedestal or Programming Pendant 3 Select TEACH mode on the Programming Pendant 4 S...

Страница 50: ...red operation errors One example of this type of error is pressing the START button when the robot is not in PLAY mode Clear errors of this type by pressing the CANCEL button on the Programming Pendan...

Страница 51: ...ront of the MSR positioner that is protected by the safety light curtain system 2 Press the SERVO ON button on the Operator Station or Programming Pendant 3 Ensure that the Programming Pendant is in R...

Страница 52: ...order to move it To release the brakes proceed as follows 1 On the Programming Pendant select TEACH mode 2 Select ROBOT on the Programming Pendant touch screen 3 Select the BRAKE RELEASE option 4 Sel...

Страница 53: ...al Be advised that the maintenance intervals given in Table 5 1 are recommendations only Adjust the frequency and level to suit your specific equipment schedules and shop environment For periodic main...

Страница 54: ...UP50 SP80 Note 2 7 8 inch HVA Chemical Style Anchor Note 3 900 mm 35 in Length 900 mm 35 in Width 50 8 mm 2 in Thick 60 in x 60 in x 9 in Thick 4000 psi Reinforced Concrete ROBOTS UP120 UP130 UP165 S...

Страница 55: ...and the Hilti Anchor Design Program v3 3b 2 SP series robots require base plates and or risers to be level within 2 Grout if necessary 3 Reference source Hilti Product Technical Guide section 4 2 1 f...

Страница 56: ...n all Mnls Check Power Refer to Connections Controller Mnl Check Ground Refer to Grounding in all Mnls Check Water Refer to Operation and Vendor Mnls Check Air Refer to Manipulator and Vendor Mnls Che...

Страница 57: ...External Power Disconnect Refer to Turning OFF The Power Supply Check Teach Mode Refer to Teach Mode Controller Mnl Check Playback Mode Refer to Play Mode Controller Mnl Check Environment Refer to Lo...

Страница 58: ...Load Analysis Instructions on Synchronized Motion More than one piece of equipment Programmed Limits Collaborative Operation Declaration Robot is suitable for integration that includes Compliance Doc...

Страница 59: ...ist MARKINGS INCLUDED ON EQUIPMENT Business Name Address Info Machinery Designation and Type Year Built Explosive Proof Order Number Serial Number Other Markings on Equipment Vendor Machine Designatio...

Страница 60: ...ndix B B 1 EcoTrim ETU 1024 Pneumatics B 1 175932 1CD 175932 1CD EcoTrim ET 1024 System Appendix B B 1 EcoTrim ETU 1024 Pneumatics Fig B 1 EcoTrim ETU 1024 Pneumatics Location K K SECTION K K 1 5 60 o...

Страница 61: ...R VALVE MANIFOLD ASSY SET PRESSURE REGULATOR TO 60 PSI MIN MAX 55 65 PSI SET PRESSURE REGULATOR TO 40 PSI MIN MAX 36 43 PSI ULTRASONIC TRANSDUCER MOTOR COOLING ROUTER MOTOR COOLING ROUTER INDEX CYLIND...

Страница 62: ...OOL KIT FILTER REGULATOR SUPPLY AIR VALVE MANIFOLD ASSY SET PRESSURE REGULATOR TO 60 PSI MIN MAX 55 65 PSI ULTRASONIC TRANSDUCER MOTOR COOLING ULTRASONIC COMPLIANCE CYLINDER BLADE SHARPENER CYLINDER S...

Страница 63: ...or Single Edge Tip Tracing Style 174868 1 Tool Blade Fixing Screw Part Number Description 174482 1 Accessory Kit Blade Sensor Sharpening Alignment Includes 174474 1 174860 1 174457 1 174454 1 Stand an...

Страница 64: ...88 2858 Fax 86 10 6788 2878 YASKAWA SHOUGANG ROBOT Co Ltd 426 Udyog Vihar Phase IV Gurgaon Haryana India Fax 91 124 475 8542 Phone 91 124 475 8500 YASKAWA India Private Ltd Robotics Division YASKAWA E...

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