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Denso SMT7 Instruction Manual

Denso SMT7 Instruction Manual

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ROBOT
SMT7 CONTROLLER
INSTRUCTION MANUAL
(SUPPLEMENT)

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  • Page 1 ROBOT SMT7 CONTROLLER INSTRUCTION MANUAL (SUPPLEMENT)
  • Page 2 Copyright © DENSO WAVE INCORPORATED, 2005-2010 All rights reserved. No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher. Specifications are subject to change without prior notice. All products and company names mentioned in this book are trademarks or registered...
  • Page 3 Preface Thank you for purchasing our SMT7 controller. The SMT7 controller controls the positioning mechanism driven by an AC servomotor, e.g., X-Y table. This manual is a supplement to the robot instruction manuals. Read through this manual in conjunction with manuals for robot systems configured with the RC7M controller, which are given on the next page.

  • Page 4: How The Documentation Set Is Organized

    & inspection procedures. STARTUP HANDBOOK Introduces you to the DENSO robot system and guides you through connecting the robot unit and controller with each other, running the robot with the teach pendant, and making and verifying a program. This manual is a comprehensive guide to starting up your robot system.

  • Page 5: Safety Precautions

    The maximum distance that the robot, end-effector, and workpiece can travel after the software motion limits are set defines the boundaries of the motion space of the robot. (The "motion space" is DENSO WAVE-proprietary terminology.) Operating space: Refers to the portion of the restricted space that is actually used while performing all motions commanded by the task program.
  • Page 6 This section provides safety precautions to be observed for the 1. Introduction robot system. The installation shall be made by qualified personal and should confirm to all national and local codes. 2. Warning Labels The robot unit and controller have warning labels. These labels alert the user to the danger of the areas on which they are pasted.
  • Page 7 SAFETY PRECAUTIONS 3. Installation Precautions 3.1 Insuring the proper installation environment The standard and cleanroom types have not been designed to For standard type and withstand explosions, dust-proof, nor is it splash-proof. cleanroom type Therefore, it should not be installed in any environment where: (1) there are flammable gases or liquids, (2) there are any shavings from metal processing or other conductive material flying about,...
  • Page 8 The robot controller, teach pendant and mini-pendant should be 3.3 Control devices installed outside the robot's restricted space and in a place outside the robot's where you can observe all of the robot’s movements and operate restricted space the robot easily. Pressure gauges, oil pressure gauges and other gauges should 3.4 Positioning of gauges be installed in an easy-to-check location.
  • Page 9 SAFETY PRECAUTIONS A safety fence should be set up so that no one can easily enter 3.9 Setting-up a safety the robot's restricted space. fence (1) The fence should be constructed so that it cannot be easily moved or removed. (2) The fence should be constructed so that it cannot be easily damaged or deformed through external force.
  • Page 10 Never modify the robot unit, robot controller, teach pendant or 3.11 No robot modification other devices. allowed If your robot uses welding guns, paint spray nozzles, or other 3.12 Cleaning of tools end-effectors requiring cleaning, it is recommended that the cleaning process be carried out automatically.
  • Page 11 SAFETY PRECAUTIONS 4. Precautions Touching the robot while it is in while Robot is operation can lead to serious Warning Running injury. Please ensure the fol- lowing conditions maintained that cautions listed from Section 4.1 and onwards are followed when any work is being performed.
  • Page 12 4) Implementation of measures for noise prevention 5) Signaling methods for workers of related equipment 6) Types of malfunctions and how to distinguish them Please ensure "working regulations" are appropriate to the robot type, the place of installation and to the content of the work. Be sure to consult the opinions of related workers, engineers at the equipment manufacturer and that of a labor safety consultant when creating these "working regulations".
  • Page 13 SAFETY PRECAUTIONS Before disassembling or replacing pneumatic parts, first release 4.5 Release of residual air any residual air pressure in the drive cylinder. pressure 4.6 Precautions for test Whenever possible, have the worker stay outside of the robot's restricted space when performing test runs. runs (1) At start-up 4.7 Precautions for...
  • Page 14 Industrial Robots and Robot Systems--General Safety Requirements ISO10218-1: 2006 Robots for industrial environments--Safety requirements--Part 1: Robot NFPA 79: 2002 Electrical Standard for Industrial Machinery 8. Battery Recycling DENSO Robot uses lithium batteries. Discard batteries according to your local and national recycling law.

  • Page 15: Table Of Contents

    4.8 Joint Exclusive Operations..........................71 4.8.1 Performing CALSET Operation on Each Joint ................... 4.8.2 Releasing or locking brakes ........................ 4.8.3 Direct Teaching Mode ......................... 4.8.4 Resetting Encoder ..........................4.8.5 Operating Extended-Joints ........................4.8.6 Programmed Operation in SMT7 (Description of arm groups) ............
  • Page 16 4.9 Joint Parameter Configuration Commands ......................83 4.9.1 Single-Joint Servo Data Monitor Commands (Library)..............4.9.2 Operation Termination Commands (Library)..................4.9.3 Internal Servo Data Get Commands....................Chapter 5 Installation and Wiring ..........................91 5.1 Installation of Controller ............................. 91 5.1.1 Installation Site Conditions ......................... 5.1.2 Installing the Controller ........................

  • Page 17: Chapter 1 Overview

    Chapter 1 Overview Chapter 1 Overview System Configuration The SMT7 is a controller that controls the positioning mechanism driven by an AC servomotor, e.g., X-Y table. Shown below is a system configuration sample using the SMT7 controller. First, move the X-Y table using the teach pendant to store the position into the controller memory.

  • Page 18: Standard Items Contained In The Package

    Standard Items Contained in the Package The items listed in the table below are contained in the product package. Standard Items Item Qty. SMT7 controller (Note 1) Power supply cable (5m) Instruction manuals (Manual pack CD) 1 set NetwoRC CD...

  • Page 19: Optional Items

    Chapter 1 Overview Optional Items The table below lists the optional items. Optional Items (1) Item Remarks Part No. AC servomotor (Standard type, 50W, Without brake) SGMAH-A5A1A-DH1* 410627-0210 AC servomotor (Standard type, 50W, With brake) SGMAH-A5A1A-DH2* 410627-0160 AC servomotor (Standard type, 100W, Without brake) SGMAH-01A1A-DH1* 410627-0220 AC servomotor (Standard type, 100W, With brake)
  • Page 20 Chapter 1 Overview Optional Items (2) Item Remarks Part No. Encoder backup battery 1 unit per a motor 410611-0030 (8 m) Includes Nos. 7-1 and 7-2. 410149-0940 Standard I/O cable set (15 m) Includes Nos. 7-1 and 7-2 410149-0950 (8 m) 410141-2700 I/O cable for "Mini I/O"...
  • Page 21 410006-0800 EtherNet/IP function Board manufacturer: Hilscher GmbH Added when the board is purchased as a 410006-0810 spare part Model: CIFX 50-RE\DENSO Extension only upon controller shipment Optional function for memory extension 410006-0320 (3.25 to 5.5 MB) Controller protection box 410181-0090...

  • Page 22: Controller Specification

    Chapter 1 Overview Controller Specification The table below lists the specifications of the SMT7 controller. Specifications of SMT7 Controller (1) Item Specifications Applicable motor AC servomotors specified in Section 1.3. (For details, see Chapter 3.) RC7M-SMT6AA :NPN I/O RC7M-SMT6AA-P :PNP I/O...
  • Page 23 Chapter 1 Overview Specifications of SMT7 Controller (2) Item Specifications Motor cable, encoder cable 4 m, 6 m, 12 m (Connected to the controller via the branch cable.) (option) Cables 8 m, 15 m I/O cable (option) (For Mini I/O, HAND I/O, Optional board for parallel I/O and SAFETY I/O)

  • Page 24: Outer Dimensions Of The Controller

    Chapter 1 Overview Outer Dimensions of the Controller The figure below shows the outer dimensions of the SMT7. Outer dimensions...

  • Page 25: Names Of The Controller Components

    Chapter 1 Overview Names of the Controller Components The following figures show the names of the SMT7 components. Front Panel Rear side (air exhaust) Front panel Air intake filters Connector No. Marking Name RS-232C Serial interface connector USB connector (2 lines)
  • Page 26 Chapter 1 Overview "THE SETPRM LIST" of the SMT7 The SMT7 is customized for motors specified by each customer in both hardware and software at the factory. The allowable combination of the controller's axes and motor types is printed in (2) SUBASSEMBLY on the "THE SETPRM LIST" labeled on the top of the controller.

  • Page 27: Precautions For Safe Use Of The Robot System

    Precautions for Safe Use of the Robot System NOTE: This section provides safety precautions to be taken when you configure the robot system with the SMT7 controller. For details, refer to the ISO 10218-1:2006, Safety Requirements. [1] For the mechanism to be driven (1) If the mechanism involves a risk of bodily injury to workers, set up a safety fence to prevent danger.

  • Page 28: Chapter 2 Engineering Design Of Servo Mechanism

    Chapter 2 Engineering Design of Servo Mechanism Chapter 2 Engineering Design of Servo Mechanism Designing the Servo Mechanism 2.1.1 Example of the Mechanism The mechanism is classified into a linear movement section and a revolving arm section as shown in Fig. 2-1. Load Motor Gear...

  • Page 29: Design Example (High-Speed Transfer Equipment)

    Chapter 2 Engineering Design of Servo Mechanism 2.1.3 Design Example (High-Speed Transfer Equipment) Sliding resistance Fig. 2-2. High-speed transfer equipment [Designing conditions] 1) Table design specification Table weight = 40 kg Transferred object weight = 20 kg (Max) Max. stroke = 700 mm Fast feed speed = 1000 mm/sec (60 m/min)
  • Page 30 Chapter 2 Engineering Design of Servo Mechanism [Selection of screw shaft dia., lead and nut] Selection of lead (l) From the max. speed of DC motor  1000 60    20 (mm) 3000 Select from among accuracy large lead products of 20 mm or longer lead. Temporary selection of thread length Ls = max.
  • Page 31 Chapter 2 Engineering Design of Servo Mechanism Therefore, from equation (1)    ≧ 10 (mm) where = Max. stroke + Nut length/2 + Shaft end allowance = 700 + 50 + 100 = 850 (mm) = 15.1 dr = 14.4 (mm) dm ...
  • Page 32 Chapter 2 Engineering Design of Servo Mechanism 4-1) Average load F , Average rpm N When shaft direction load is changed, find the average load which may give the life equal to the fatigue life under changing load conditions, and calculate the life. (a) When load and rpm are divided step-by-step (Fig.
  • Page 33 Chapter 2 Engineering Design of Servo Mechanism (c) When load is changed like a sine curve (Fig. 2-7) Average load F can be approximately achieved by the following equation. Fig. 6 In case of (a) F ≒0.65F ··············································· (6) In case of (b) F ≒0.75F Fig.
  • Page 34 Chapter 2 Engineering Design of Servo Mechanism When selecting a ball screw, it is not economical to make its fatigue life uselessly long because the ball screw must be so much big. For reference, general target value of fatigue life is shown bellow. Machine tool 20,000 hours Industrial machine...
  • Page 35 Chapter 2 Engineering Design of Servo Mechanism (b) Shaft direction clearance Repeat positioning accuracy: ± 0.010 (mm) Min. resolution: 0.01 mm/pulse From the above, Shaft direction clearance: T clearance 0.005 (mm) or less Table 2-2. Combination of accuracy grade and shaft direction clearance Unit: mm Shaft direction clearance...

  • Page 36: Notes For Designing

    Chapter 2 Engineering Design of Servo Mechanism 2.1.4 Notes for Designing The sliding resistance of the mechanism controlled by the SMT7 should be as follows. Sliding resistance (torque conversion)  0.2 motor rated torque (T ) × [ 1 ] Sliding resistance of ball screw...
  • Page 37 Chapter 2 Engineering Design of Servo Mechanism Motor rated torque (T Refer to motor catalog. Evaluation        ≦   : Friction torque by external load (Nm) : Friction torque by pre-load (Nm) : Motor rated torque (Nm) : The number of gear A teeth : The number of gear B teeth...

  • Page 38: Knowledge Required For Selection Of Servomotors

    Kt = Torque constant (See motor catalog) (Nm/Ao٠p) ٠٠٠٠٠ (2) Or this is shown by the "Instantaneous max. torque" in the motor catalog. [Note] > T shall be formed. However, drive torque T shall be designed within 2.5 times of motor rated torque as SMT7.
  • Page 39 Chapter 2 Engineering Design of Servo Mechanism Calculation and evaluation of effective torque When the servomotor moves like fig. 2-10 pattern, the effective torque (T ) of 1 cycle is achieved by the following equation.    ·············································································(3)  ...
  • Page 40 Chapter 2 Engineering Design of Servo Mechanism Calculation of total inertia moment (I) (conversion into the motor shaft's) (a) Revolving arm (Fig. 2-11). I (Nms ) = (I (RG1 RG2) ··············· (Deceleration 2 step part) × × + (I (RG1) ·······················...
  • Page 41 Chapter 2 Engineering Design of Servo Mechanism (c) Calculation of rotor inertia moment (I ) (Fig. 2-13)        ····································································· Equation (6) (Nms ) Where D : Outer diameter (m) d : Inner diameter (m) h : Thickness (m) ...
  • Page 42 Chapter 2 Engineering Design of Servo Mechanism Friction torque of transmission system, etc. (T Divide the friction torque of the slide part, seal, speed reducer, etc. by deceleration ratio to make the quotient as the friction torque in conversion into the motor shaft. Especially be sure to know that the transmission mechanism friction torque before deceleration is directly applied to the motor.
  • Page 43 Chapter 2 Engineering Design of Servo Mechanism (c) Example of Corioli's force (Fc) When an object (W) on the revolving shaft moves at V speed, corioli's force (Fc) which is in proportion  to the double of the product of W, revolving shaft angular speed ( ) and speed (V ) occurs in the vertical ...

  • Page 44: Chapter 3 Choosing Ac Servomotors

    Chapter 3 Choosing AC Servomotors Chapter 3 Choosing AC Servomotors There are 20 types of AC servomotors available to the SMT7 controller. This chapter provides the reference data for motor selection. AC Servomotors 3.1.1 List of AC Servomotors The table below lists AC servomotors available to the SMT7.

  • Page 45: Cable End Treatment Of Ac Servomotors When Shipped

    Chapter 3 Choosing AC Servomotors 3.1.2 Cable End Treatment of AC Servomotors When Shipped When shipped, the cable ends of an AC servomotor are treated with connector housings as shown below. Cable End Treatment of AC Servomotor Shipped...

  • Page 46: Motor Characteristics Lists

    Chapter 3 Choosing AC Servomotors 3.1.3 Motor Characteristics Lists The main characteristics of each motor are listed below. (1) Motor characteristics of standard type Motor model SGMAH-A5A SGMAH-01A SGMAH-02A SGMAH-04A SGMAH-08A Rated output r/min 3000 Rated revolving speed Maximum revolving speed r/min 5000 Rated torque...
  • Page 47 Chapter 3 Choosing AC Servomotors (2) Motor characteristics of flat type Motor model SGMPH-01A SGMPH-02A SGMPH-04A SGMPH-08A SGMPH-15A 1500 Rated output r/min 3000 Rated revolving speed r/min 5000 Maximum revolving speed Rated torque 0.318 0.637 1.27 2.39 4.77 0.955 1.91 3.82 7.16 14.3...

  • Page 48: Specification Details

    Chapter 3 Choosing AC Servomotors 3.1.4 Specification Details (1) Performance Item Specifications Heat resistance Allowable ambient temperature Running: 0C to +40C In storage: -20C to +80C Dampproof Allowable ambient humidity 20% to 80% RH (No dew condensation allowed) Insulation resistance 10 M...
  • Page 49 Chapter 3 Choosing AC Servomotors (4) Allowable shaft load Motor Radial load Thrust load (F1) (F2) Part No. Model Capacity 410627-0210 SGMAH-A5A1A-DH1* 410627-0160 SGMAH-A5A1A-DH2* 410627-0220 SGMAH-01A1A-DH1* 100W 410627-0170 SGMAH-01A1A-DH2* 100W 410627-0230 SGMAH-02A1A-DH1* 200W 245N 410627-0180 SGMAH-02A1A-DH2* 200W 245N 410627-0240 SGMAH-04A1A-DH1* 400W 245N 410627-0190...
  • Page 50 Chapter 3 Choosing AC Servomotors (5) Lead wire colors and signals Motor lead wires Motor side Name White Blue Green/Yellow E (FG) Brake lead wires Brake side Name Black Brake Black Brake Encoder lead wires Encoder side Name Remarks Orange Twisted pair wires White /Orange COMMON...

  • Page 51: External Dimensions Of Ac Servomotors

    Chapter 3 Choosing AC Servomotors External Dimensions of AC Servomotors ■Standard type without brake [50W or 100W] Motor model Rated Approx Part No. Remarks SGMAH - output weight 410627-0210 A5A1A - DH1 102.0 77.0 44.0 Dia. 2.5, Depth 5 0.4 kg (1) Assembly accuracy conforms to Japan 410627-0220 01A1A - DH1...
  • Page 52 Chapter 3 Choosing AC Servomotors ■Standard type with brake [50W or 100W] Motor model Rated Approx Part No. Remarks SGMAH - output weight 410627-0160 A5A1A - DH2 133.5 108.5 44.0 Dia. 2.5, Depth 5 0.7 kg (1) Assembly accuracy conforms to Japan 410627-0170 01A1A - DH2 100W...
  • Page 53 Chapter 3 Choosing AC Servomotors ■Standard type without brake [200W, 400W or 750W] Motor model Rated Approx Part No. Remarks SGMAH- output weight 410627-0230 02A1A–DH1 200W 126.5 96.5 62.5 Dia. 5, Depth 8 1.1 kg 410627-0240 04A1A–DH1 400W 154.5 124.5 90.5 Dia.
  • Page 54 Chapter 3 Choosing AC Servomotors ■Standard type with brake [200W, 400W or 750W] Motor model Rated Approx Part No. Remarks SGMAH- output weight 410627-0180 02A1A–DH2* 200W 166.0 136.0 62.5 Dia. 5, Depth 8 1.6 kg 410627-0190 04A1A–DH2* 400W 194.0 164.0 90.5 Dia.
  • Page 55 Chapter 3 Choosing AC Servomotors ■Flat type without brake [100W, 200W, 400W, 750W or 1.5kW] Motor model Rated Approx Part No. Remarks SGMPH- output weight 410627-0310 01A1A–DH1* 100W 87.0 62.0 42.5 12.5 10.55 Dia. 3, Depth 6 0.7 kg 410627-0320 02A1A–DH1* 200W 97.0...
  • Page 56 Chapter 3 Choosing AC Servomotors ■Flat type with brake [100W, 200W, 400W, 750W or 1.5kW] Motor model Rated Approx Part No. Remarks SGMPH- output weight 410627-0260 01A1A–DH2* 100W 116.0 91.0 42.5 12.5 10.55 Dia. 3, Depth 6 0.9 kg 410627-0270 02A1A–DH2* 200W 128.5...

  • Page 57: Chapter 4 Configuring The Joint Parameters

    Chapter 4 Configuring the Joint Parameters Chapter 4 Configuring the Joint Parameters To use joints, you need to configure joint parameters beforehand. There are three types of joint parameters as described below, which can be configured by using the teach pendant. (1) Path configuration parameters, which are provided for motion definitions (including speed, acceleration, and range of motion) of joints.
  • Page 58 Chapter 4 Configuring the Joint Parameters (3) Press [F7 Path]. The path configuration window appears as shown below. (4) Select the target joint (J1 in this example) by using the cursor keys or jog dial. Press [OK]. The path configuration parameters window appears as shown below. Change the path configuration parameters and press [OK].
  • Page 59 Chapter 4 Configuring the Joint Parameters List of Path Configuration Parameters Factory Controller Parameter name Entry range Unit Description Remarks default restart Boundless rotation 0 or 1 To rotate the motor 32768 Needed Setting this times or more in the same parameter to "1: (0: Limited, direction, set this parameter...

  • Page 60: Servo Configuration Parameters

    Chapter 4 Configuring the Joint Parameters Servo Configuration Parameters (1) Call up the Joint Settings window. Access: Top Screen—[F2 Arm]—[F12 Maint.]—[F7 Joints] (2) On the Joint Settings window shown above, press [F8 Servo]. The servo configuration window appears as shown below. Select the target joint (J1 in this example) by using the cursor keys or jog dial.
  • Page 61 Chapter 4 Configuring the Joint Parameters (3) Press [OK]. The servo configuration parameters window appears as shown below. Change the servo configuration parameters and press [OK]. Note: For the detailed procedure, refer to "Detailed Description of Joint Parameter Setting." The servo configuration parameters are listed in the table below. Note: Some parameters will take effect after the controller is restarted.
  • Page 62 Chapter 4 Configuring the Joint Parameters List of Servo Configuration Parameters (2) Entry Factory Controller Parameter name Unit Description Remarks range default restart Positional loop gain 1 min. Set the response of the The positioning loop Not needed position control system. gain can be Increasing the value will converted in unit by...

  • Page 63: Arm Configuration Parameters

    Chapter 4 Configuring the Joint Parameters Arm Configuration Parameters (1) Call up the Joint Settings window. Access: Top Screen—[F2 Arm]—[F12 Maint.]—[F7 Joints] (2) Press [F2 ArmSet]. The ArmSet window appears as shown below. List of Arm Configuration Parameters Factory Controller Parameter name Entry range Unit...

  • Page 64: Setting The Speed Reduction Rate In Manual Operation

    Chapter 4 Configuring the Joint Parameters 4.3.1 Setting the Speed Reduction Rate in Manual Operation The speed reduction rate in manual operation can be limited to 10% or below of that in automatic operation. This section provides the reduction rate calculation procedure using the maximum composite tool-end speed and the target speed in manual operation.

  • Page 65: Outputting A List Of Joint Parameter Settings (Using Wincapsiii)

    Chapter 4 Configuring the Joint Parameters Outputting a List of Joint Parameter Settings (Using WINCAPSIII) WINCAPSIII can display a list of joint parameter settings on the PC screen and output it in CSV format. If you log on to WINCAPSIII as Programmer or higher level, you can configure the following parameters in the Joint Setting window.

  • Page 66: Detailed Description Of Joint Parameter Setting

    Chapter 4 Configuring the Joint Parameters Detailed Description of Joint Parameter Setting The path configuration parameters and servo configuration parameters should be configured with joints being connected to motors. (1) Resetting the encoder The encoder is not connected with a backup battery at the time of shipment, so the error message "J* encoder system down"...
  • Page 67 Chapter 4 Configuring the Joint Parameters (3) When a joint keeps on rotating in the same direction, the current value might jump (overflow) suddenly and greatly. Performing an absolute motion in this state moves the joint to the position different from the specified one. (4) In a boundless rotation motion command, the effective number of digits is 7.
  • Page 68 Chapter 4 Configuring the Joint Parameters (2-2) Setting the motion conditions Set the motion-relation parameters--sliding/rotary joint structure, motor rotation direction, motor maximum speed, motor acceleration time, gear ratio or lead, motion limit detection, positive motion limit, negative motion limit, and CALSET reference position.
  • Page 69 Chapter 4 Configuring the Joint Parameters (3) Setting the servo configuration parameters For the calling-up procedure of the servo configuration parameters window, refer to Section 4.2. (3-1) Setting the joint motion Set the joint motion to "1: Valid." (3-2) Setting the torque limits Set the torque limits in each of Auto and Manual modes.
  • Page 70 Chapter 4 Configuring the Joint Parameters (3-3) Checking the encoder axis number, power module slot number, and motor capacity Checks that the encoder axis number and power module slot number match the joint number. Also, check that the motor capacity is selected correctly. After completion of steps (1) to (3), restart the controller.
  • Page 71 Chapter 4 Configuring the Joint Parameters (4) Checking the wiring (4-1) Checking the brake wiring If the motor has a brake, release the brake and check that the brake of all joints will be released. For the brake releasing procedure, refer to Section 4.8.2 "Releasing or locking brakes."...

  • Page 72: Configuring Motors As Robot Joints Or Extended-Joints

    Chapter 4 Configuring the Joint Parameters Configuring Motors as Robot Joints or Extended-Joints The motors connected to the controller can be configured as robot joints or extended-joints. Any or all of joints 1 to 4 can be configured as robot joints. (In version 2.7 or earlier, all of four joints J1 to J4 are fixed as robot joints.) Robot joints can be driven by robot motion commands enabling CP motion (linear and circular).

  • Page 73: Extended-Joints

    Chapter 4 Configuring the Joint Parameters 4.6.2 Extended-Joints A single extended-joint is configured as shown below. It can execute only PTP motion. A MOVE command is not available for extended-joints, so use DRIVEA and DRIVE commands to drive extended-joints. Example of configuration realized in extended-joint motion 4.6.3 Usable Functions in Robot and Extended-Joint Motion (Examples) Usable functions in...

  • Page 74: Configuring Robot Joints

    4.6.4 Configuring Robot Joints The SMT7 controller is capable of controlling a maximum of eight joints (incl. optional extended-joints) that can be configured as robot joints or extended-joints. Up to four joints can be selectively configured as robot joints using the teach pendant or in WINCAPSIII with the following procedures.

  • Page 75: Gain Tuning Of Each Joint

    Chapter 4 Configuring the Joint Parameters Gain Tuning of Each Joint In Section 4.5, you have set the motion conditions of each joint and checked the motion of the mechanism connected to each joint motor in manual mode. After that, proceed to the gain tuning for the servo system.

  • Page 76: Auto Gain Tuning

    Chapter 4 Configuring the Joint Parameters 4.7.1 Auto Gain Tuning To implement auto gain tuning, the mechanism to be connected to the joint motor should satisfy the requirements given in Section 4.7.1.1 below. Otherwise, some errors may occur and the auto gain tuning process may be interrupted. If such happens, implement manual gain tuning.
  • Page 77 Chapter 4 Configuring the Joint Parameters (5) Select the mechanical rigidity, referring to the rigidity reference values listed below. Types of Torque Transmission Mechanisms Mechanical Rigidity Ball screw direct connection 4 to 8 Ball screw with transmission mechanism 3 to 7 Timing belt 3 to 6 Gear or rack &...
  • Page 78 Chapter 4 Configuring the Joint Parameters (6) Select whether the gravity offset torque should be enabled or disabled. If an unbalanced load applies to the motor, be sure to enable the gravity offset torque. NOTE: If you disable gravity offset torque when the motor undergoes any unbalanced load, then the joint will drop in the gravity direction, causing an error.
  • Page 79 Chapter 4 Configuring the Joint Parameters (8) In the dialog box shown below, confirm the conditions and press OK. In the confirmation window, press OK. Then auto gain tuning will start. The motor rotates in CCW and CW directions alternately two times each direction in two sequences to calculate a temporary servo loop gain.

  • Page 80: Manual Gain Tuning

    Chapter 4 Configuring the Joint Parameters 4.7.2 Manual Gain Tuning You can manage the following parameters for manual gain tuning: (1) Positioning loop gain (2) Positioning loop feed forward gain (3) Positioning error allowance (4) Speed linear gain (5) Speed loop integral gain (6) Torque control filter (7) Torque offset The block diagram for the servo system is shown below.
  • Page 81 Chapter 4 Configuring the Joint Parameters 4.7.2.1 Parameter details (1) Positioning loop gain Set the response of the positioning loop. The positioning loop gain is a dimensionless number, so it may be converted to the (1/s) unit according to the following formula: Positioning loop gain x 125/256 (1/s) (Formula 4.7-1)
  • Page 82 Chapter 4 Configuring the Joint Parameters The drive current system gain is as listed below. Motor Model Motor rated output Drive Current System Gain SGMAH-A5A1A 1.852E-05 SGMAH-01A1A 100W 3.004E-05 SGMAH-02A1A 200W 7.144E-05 SGMAH-04A1A 400W 1.093E-04 SGMAH-08A1A 750W 1.979E-04 SGMPH-01A1A 100W 3.421E-05 SGMPH-02A1A 200W...
  • Page 83 Chapter 4 Configuring the Joint Parameters 4.7.2.2 Monitor of single-joint servo data This function allows you to monitor a specified joint servo data currently set in the controller with graphs in real-time. (1) Monitoring capability This function is capable of handling up to 1,250 samples of data at once. If the sampling interval is set to 1ms, then you may monitor the servo data for 1.25 seconds.
  • Page 84 Chapter 4 Configuring the Joint Parameters (4) Graphing the monitored data The single joint servo log function in WINCAPSIII can graph the monitored data on a PC screen. (4.1) Read monitored data To receive single joint servo log data from the controller, use the data transfer function in WINCAPSIII as follows.
  • Page 85 Chapter 4 Configuring the Joint Parameters 4.7.2.3 Operating procedure for manual gain tuning (1) Initializing positioning loop gain First set the positioning loop gain to almost the same value of that calculated from natural frequency of the connected mechanism. If the natural frequency is 20 Hz, set the positioning loop gain to 41 which equals to 20 ...
  • Page 86 Chapter 4 Configuring the Joint Parameters (9) Checking operations of the connected mechanism in full motion range and in full speed range Run the connected mechanism in the full motion range while changing the speed gradually. If any abnormal noises or vibrations occur at some particular points, then check whether the mechanism slides evenly.

  • Page 87: Joint Exclusive Operations

    Chapter 4 Configuring the Joint Parameters Joint Exclusive Operations 4.8.1 Performing CALSET Operation on Each Joint ■ From the teach pendant (1) Call up the Maintenance Functions (Arm) window. Access: Top Screen―[F2 Arm]―[F12 Maint.]―[F6 CALSET] Select a joint to be CALSET and press [OK]. CALSET on the selected joint will start.

  • Page 88: Releasing Or Locking Brakes

    Chapter 4 Configuring the Joint Parameters 4.8.2 Releasing or locking brakes ■ From the teach pendant (1) Call up the Brake Release Settings window. Access: Top Screen―[F2 Arm]―[F12 Maint.]―[F3 Brake] (2) Select the target brake. (3) Press [F5 ON/OFF], and the indicator color of the selected brake will change from black to green if locked or from green to black if released.
  • Page 89 Chapter 4 Configuring the Joint Parameters ■ From the mini-pendant (1) Press [BRAKE] to call up the "BrakeSetting" window shown below. (2) Choose an arbitrary joint with the up and down cursor keys. (You can vertically scroll the screen with those keys.) Then press [OK].

  • Page 90: Direct Teaching Mode

    (Usual teaching requires the motor to be turned ON.) Note 1: In the SMT7, the system has no air balance cylinder on the Z-axis, so the operation procedure for the direct teaching mode differs from that of the conventional 4-axis robots.
  • Page 91 Chapter 4 Configuring the Joint Parameters ■ From the mini-pendant (Starting/ending the direct teaching mode) Access: [AUX]―[Arm Aux.]―[Direct.] (1) Select [Direct] and press [OK]. (2) A confirmation screen whether "Direct Mode Start OK?" or "Direct Mode end OK?" appears. (3) Press [OK]. The direct teaching mode starts or ends. NOTE: In the direct teaching mode, the "D"...

  • Page 92: Resetting Encoder

    Chapter 4 Configuring the Joint Parameters 4.8.4 Resetting Encoder You need to reset encoders and perform CALSET if: - Error 6411 or 6422 occurs due to first use of AC servomotors, or run-down encoder backup batteries, or - Error 6771 or 6772 occurs due to a great impact applied to the robot when the power is off.

  • Page 93: Operating Extended-Joints

    Chapter 4 Configuring the Joint Parameters ■ From the mini-pendant Access: [AUX]—[ArmAux]—[EncRst] (1) The "Select Joint" screen appears, prompting you to choose the joint to reset the related encoder. (2) Select the target joint. (3) Press [OK] to start resetting the encoder on the target joint. 4.8.5 Operating Extended-Joints For the operating procedures for the manual operation of extended-joints, for taking...

  • Page 94: Programmed Operation In Smt7 (Description Of Arm Groups)

    Chapter 4 Configuring the Joint Parameters 4.8.6 Programmed Operation in SMT7 (Description of arm groups) ■ Concept of an arm group An arm group is a set of semaphores for joints to be driven. Specifying an arm group using a TAKEARM command allows a task to get arm semaphores and execute motion commands.
  • Page 95 Chapter 4 Configuring the Joint Parameters ■ Releasing the currently held arm group To release the currently held arm group, execute a GIVEARM command. An occurrence of an error or program termination automatically releases the currently held arm group. For details about the GIVEARM, refer to the Programmer's Manual I, Section 14.3 "Arm Semaphore."...
  • Page 96 Chapter 4 Configuring the Joint Parameters ■ Motion commands requiring an arm group The following commands require an arm group. If a task holding no arm group attempts to execute any of the following motion commands, an error will occur. Before execution of those commands, get an arm group by using the TAKEARM command.
  • Page 97 Chapter 4 Configuring the Joint Parameters Note: A program can get the same arm group repeatedly. Example: PROGRAM PRO1 TAKEARM 1 TAKEARM 1 'Possible to get Arm Group 1 'even after getting it on the earlier 'line ■ From the teach pendant (1) Call up the "ArmGroup Settings"...
  • Page 98 Chapter 4 Configuring the Joint Parameters ■ Notes for command execution from the specified line The specifications about command execution from the specified line are detailed in the Setting-up Manual, Section 3.3, "Teach Check Mode (TP/MP), [ 4 ]." (1) Making effective the arm group previously obtained by TAKEARM If a command on the specified program line is executed, an arm group obtained by a TAKEARM command on the earlier line will automatically take effect.

  • Page 99: Joint Parameter Configuration Commands

    Chapter 4 Configuring the Joint Parameters Joint Parameter Configuration Commands 4.9.1 Single-Joint Servo Data Monitor Commands (Library) SetMonitorCond Function Sets the monitoring conditions for single-joint servo data monitor. Syntax SetMonitorCond(<JntNumber>,<MonitorData1>,<MonitorData2>, <SampInterval>) Description SetMonitorCond sets the joint number to be monitored, monitor data (up to 2 types allowed per command), and sampling interval in ms as monitoring conditions.
  • Page 100 Chapter 4 Configuring the Joint Parameters StartSrvMonitor Function Starts monitoring single-joint servo data. Syntax StartSrvMonitor Description StartSrvMonitor fetches a maximum of 1250 samples of single-joint servo data until StopSrvMonitor executes. Macro definition Not needed. Related commands ClearSrvMonitor, SetMonitorCond, and StopSrvMonitor Notes (1) If the total number of data samples monitored in a monitoring cycle is 1250 or less, all data may be monitored.
  • Page 101 Chapter 4 Configuring the Joint Parameters StopSrvMonitor Function Stops monitoring single-joint servo data. Syntax StopSrvMonitor Description In duration from execution of StartSrvMonitor to that of StopSrvMonitor, a maximum of 1250 samples of data may be obtained. Macro definition Not needed. Related commands ClearSrvMonitor, SetMonitorCond, and StartSrvMonitor Notes...
  • Page 102 Chapter 4 Configuring the Joint Parameters ClearSrvMonitor Function Initializes the pointer of data obtained by the single-joint servo data monitor function. Syntax ClearSrvMonitor Description ClearSrvMonitor initializes the pointer of data already obtained and starts monitoring new data up to 1250 samples. Macro definitions Not needed.

  • Page 103: Operation Termination Commands (Library)

    Chapter 4 Configuring the Joint Parameters 4.9.2 Operation Termination Commands (Library) MotionSkip Function Aborts running motion commands. Syntax MotionSkip Description MotionSkip aborts motion commands running in the task in which the MotionSkip executes. Macro definition Not needed. Related commands GetJntData and GetSrvData Notes (1) Execute this command in a TAKEARMed task that holds an arm semaphore.
  • Page 104 Chapter 4 Configuring the Joint Parameters MotionComp Function Judges whether execution of running motion commands is complete. Syntax MotionComp(<MotionCommandComplete>) Description If MotionComp judges that execution of running motion commands is complete, then it returns "1" in <MotionCommandComplete>. This command checks motion commands running in the task in which the MotionComp executes.

  • Page 105: Internal Servo Data Get Commands

    Chapter 4 Configuring the Joint Parameters 4.9.3 Internal Servo Data Get Commands GetSrvData Function Gets the internal servo data of robot joints. Syntax <InternalServoData> = GetSrvData(<DataNumber>) Description GetSrvData gets the internal servo data specified by <DataNumber> into <InternalServoData>. <InternalServoData> is a joint type data of robot. <DataNumber should be any of the following: <DataNumber>...
  • Page 106 Chapter 4 Configuring the Joint Parameters GetJntData Function Gets the internal servo data of a specified joint. Syntax <JntInternalServoData> = GetJntData(<DataNumber>,<JntNumber>) Description GetJntData gets the internal servo data (specified by <DataNumber>) of a joint specified by <JntNumber> into <JntInternalServoData>. <JntInternalServoData>.is a floating point type data of the specified joint. <DataNumber>...

  • Page 107: Chapter 5 Installation And Wiring

    Chapter 5 Installation and Wiring Chapter 5 Installation and Wiring Installation of Controller 5.1.1 Installation Site Conditions Install the controller in conditions as shown in the table below. Installation Site Condition Requirements Item Requirements Ambient temperature 0 to 40℃ during operation –10 to 60℃...

  • Page 108: Installing The Controller

    4 mm in length. If they exceed 4 mm, the nut-welded holes may be damaged. (2) Fix the controller at all of the five nut-welded holes. Location of Mounting Screw Holes (on the bottom of the SMT7 controller)
  • Page 109 Caution: <Wall-mounted installation> The controller has not the air filter on the side of air outlet. Therefore, install the controller as shown in the figure below. <Stand-alone Installation > <Wall-mounted Installation > Installation of SMT7...

  • Page 110: Wiring Between Controller And Motor

    Chapter 5 Installation and Wiring Wiring between Controller and Motor For wiring between the SMT7 controller and the motor, use optional parts listed Section 1.3 "Optional Items." For details about wiring, refer to the Supplement for Extended-Joints Support. 5.2.1 Connecting Motor Cable Motor cables with the length of 4, 6, and 12 m are available as options.

  • Page 111: Connecting Encoder Cable

    Encoder cables with the length of 4, 6, and 12 m are available as options. Connect the encoder cable to the SMT7 controller via the encoder branch cable. Note: Secure the FG terminal of the encoder branch cable to the original screw on the SMT7 controller shown in the figure below.

  • Page 112: Encoder Backup Battery

    Chapter 5 Installation and Wiring 5.2.3 Encoder Backup Battery Connect a lithium battery to the encoder to memorize the position data by the absolute position encoder circuit as shown on the figure below. Encoder backup battery circuit The figure below shows the optional encoder backup battery. Use one battery per single axis.

  • Page 113: Caution For Wiring

    Chapter 5 Installation and Wiring 5.2.4 Caution for Wiring The figure below shows the wiring example when a motor is connected to the SMT7. Absolute value encoder transmits data in serial communication. So, securely connect shield or F.G. (1) Secure the FG terminal of the encoder branch cable to the original screw on the controller.

  • Page 114: Wiring Of Primary Power Source

    Chapter 5 Installation and Wiring Wiring of Primary Power Source Observe the following precautions when wiring the primary power source of the controller: (1) Connect the robot power cable to a power source separate from the welder power source. (2) Ground the protective grounding wire (green/yellow) of the robot power cable securely.
  • Page 115 Chapter 5 Installation and Wiring (7) Prepare wires of an appropriate capacity for the 200VAC main line and other cables according to the tables given below. Power Supply Specifications of the SMT7 Controller (at full IPM boards) Pin assignment on power connector (CN6) Item...
  • Page 117 Please feel free to send your comments regarding any errors or omissions you may have found, or any suggestions you may have for generally improving the manual. In no event will DENSO WAVE INCORPORATED be liable for any direct or indirect damages resulting from the application of the information in this manual.

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