YASKAWA YRC1000 Operator's Manual
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YASKAWA YRC1000 Operator's Manual

For spot welding using air gun
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See also: Operator's Manual , Instruction Manual
YRC1000
OPERATOR'S MANUAL
FOR SPOT WELDING USING AIR GUN
Upon receipt of the product and prior to initial operation, read these instructions below
thoroughly, and retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR'S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
The YRC1000 operator's manual above corresponds to specific usage. Be sure to use the appropriate manual.
The YRC1000 operator's manual above consists of "GENERAL" and "SUBJECT SPECIFIC".
The YRC1000 alarm codes above consists of "MAJOR ALARMS" and "MINOR ALARMS".
182902-1CD
0
MANUAL NO. RE-CSO-A055
1 of 56

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Summary of Contents for YASKAWA YRC1000

  • Page 1 YRC1000 MAINTENANCE MANUAL YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS) The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual. The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”. The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.
  • Page 2 If such modification is made, the manual number will also be revised. • If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.
  • Page 3 Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the YRC1000. In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”, or “NOTICE”. Indicates an imminently hazardous DANGER situation which, if not avoided, will result in death or serious injury.
  • Page 4 Immediately press an emergency stop button whenever there is a problem. The emergency stop buttons are located on the front panel of the YRC1000 and on the right of the programming pendant. Read and understand the Explanation of the Warning Labels before operating the manipulator.
  • Page 5 Definition of Terms Used Often in This Manual The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables.
  • Page 6 Descriptions of the programming pendant keys, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters or its Pendant /Symbol Keys symbol printed on them are denoted with [ ]. ex. [ENTER] Axis Keys [Axis Key] and [Numeric Key] are generic /Numeric Keys...

  • Page 7: Table Of Contents

    Contents 1 Spot Welding Application Using an Air Gun..................1-1 1.1 System Overview of Spot Welding System Using an Air Gun ........... 1-1 1.2 Function Keys ........................1-3 1.3 Teaching ..........................1-5 1.3.1 Manual Spot Welding Function................1-5 1.3.1.1 Manual Dry Spotting................1-5 1.3.1.2 Stroke Switching ..................
  • Page 8 Contents 1.6.5.2 Output Allocation Window ..............1-38 1.6.5.3 Pseudo Input Signal Window..............1-39 1.6.6 Allocation Signal Meanings................. 1-40 1.6.7 Monitor Function for Spot Welding Equipment ........... 1-42 1.6.8 Spot Welding Exclusive Signal Allocation List ............ 1-43 1.7 Instruction List........................1-47 viii 8 of 56...

  • Page 9: Spot Welding Application Using An Air Gun

    Spot Welding Application Using an Air Gun System Overview of Spot Welding System Using an Air Gun Spot Welding Application Using an Air Gun System Overview of Spot Welding System Using an Air Gun An I/O signal diagram of a typical spot welding system is shown below. Fig.
  • Page 10 Spot Welding Application Using an Air Gun System Overview of Spot Welding System Using an Air Gun • STROKE CHANGE (level) Select the stroke of the gun. • In case of single solenoid: Change by 1 signal • In case of double solenoid: Change by 2 signal For details on signal contents, refer to chapter 1.6 Spot Gun Motion Control.

  • Page 11: Function Keys

    Spot Welding Application Using an Air Gun Function Keys Function Keys Each function used for spot welding is allocated on [Numeric Key]s of the programming pendant. These keys become available when the WORK HOME POSITION is on the display. Displays the MANUAL SPOT window. Displays the WORK HOME POSITION window.
  • Page 12 Spot Welding Application Using an Air Gun Function Keys Instruction to change the stroke to the short open position when using a double stroke gun: Displays the STROKE SHORT instruction in the input buffer. The SHORT OPEN POSITION SETTING window appears the first time the key is pressed.

  • Page 13: Teaching

    Spot Welding Application Using an Air Gun Teaching Teaching In order to use the air gun function, first perform teaching as described below. 1.3.1 Manual Spot Welding Function To perform manual spot welding, carry out the following operation. 1. Press [0/MANUAL SPOT] of [Numeric Key]s. 2.

  • Page 14: Welding On/Off

    Spot Welding Application Using an Air Gun Teaching 1.3.1.3 Welding On/Off Press [INTERLOCK] and [WELD ON/OFF] simultaneously in the teach mode to turn on or off the welding ON/OFF signal to all connected welders. A user message appears when the welding ON/OFF signal is turned ON in the teach mode.

  • Page 15: Resetting Alarms

    Spot Welding Application Using an Air Gun Teaching 1.3.1.4 Resetting Alarms The alarm reset signal to all connected welders remains ON while [INTERLOCK] and [WELD ALM RESET] are being pressed simultaneously. The welding conditions, gun pressure and weld request are reset with this function. The output destination must be allocated in the spot input/output allocation information window before this function is used.

  • Page 16: Registering Work Instructions

    Spot Welding Application Using an Air Gun Teaching 1.3.2 Registering Work Instructions The function keys [GUNCL](GUNCL instruction), [SPOT](SPOT instruction), [SHORT OPEN]/[FULL OPEN](STROKE instruction) can be used for registering the work instructions. The STRWAIT instruction is registered using [INSTRUCTION LIST]. Table 1-1: Registering Work Instructions Specific Keys Instructions [GUN CLOSE]...

  • Page 17: Guncl Instruction

    Spot Welding Application Using an Air Gun Teaching 1.3.2.1 GUNCL Instruction This is the dry spotting instruction. It performs dry spotting for the specified time. The gun performs dry spotting then returns to the start position after the time-up timer counts out. Use this instruction when spotting is required, such as after automatic tip dressing or automatic tip replacement.
  • Page 18 Spot Welding Application Using an Air Gun Teaching Operation Procedure  1. Move the cursor to the line before the place where the GUNCL instruction is to be registered. 2. Press [2/GUN CLOSE] or [INSTRUCTION LIST]. 3. Select the {GUNCL} instruction. –...

  • Page 19: Spot Instruction

    Spot Welding Application Using an Air Gun Teaching 1.3.2.2 SPOT Instruction This instruction starts the spot welding sequence. It outputs the gun pressure signal then executes the welding sequence appropriate for the gun type. The function key [SPOT] can be used for its registration. The condition number used for the registration of the spot instruction is a value set on the manual spot condition window.
  • Page 20 Spot Welding Application Using an Air Gun Teaching Specifies the operation mode of the second gun at two-gun con- trol. Specifies the open status before and after welding in the case of double stroke. Do not set when only one gun is used. Setting data is the same as shown in the table in (2).
  • Page 21 Spot Welding Application Using an Air Gun Teaching Examples  The sequence of the SPOT instruction is started from the short open 0.5 seconds before the manipulator reaches the position of step 5. After completion of the sequence, the status becomes full open to move to the execution of step 6.

  • Page 22: Stroke Instruction

    Spot Welding Application Using an Air Gun Teaching 1.3.2.3 STROKE Instruction This is an instruction to alternate short open and full open of a double stroke gun at any time other than welding. It executes the stroke changes sequence with an X double stroke mechanical stopper type gun, and with the other double stroke guns, it changes the change signal to full open or to short open status.
  • Page 23 Spot Welding Application Using an Air Gun Teaching Operation Procedure  1. Move the cursor to the line before the place where the STROKE instruction is to be registered. 2. Press [-/SHORT OPEN], [3/FULL OPEN], or [INSTRUCTION LIST]. – The “STROKE GUN#(1) SHORT” instruction appears in the input buffer line when [-/SHORT OPEN] is pressed;...

  • Page 24: Strwait Instruction

    Spot Welding Application Using an Air Gun Teaching 1.3.2.4 STRWAIT Instruction This is an instruction to verify the double stroke gun status short open or full open, at any time other than welding. It waits until a signal to verify full open or short open is turned ON.

  • Page 25: Setting Welding Conditions (For Air Gun)

    Spot Welding Application Using an Air Gun Setting Welding Conditions (for Air Gun) Setting Welding Conditions (for Air Gun) 1.4.1 Settings for Manual Spot Welding  Manual Spot Window A. TWO GUN CONTROL Specifies whether the simultaneous control is turned ON or OFF when using two guns.
  • Page 26 Spot Welding Application Using an Air Gun Setting Welding Conditions (for Air Gun) Operation Procedure  1. Press [0/MANUAL SPOT] of [Numeric Key]s. 2. Select the desired mode. 3. Select the item to be set. 1-18 26 of 56...

  • Page 27: Spot Welder Condition Data Setting

    Spot Welding Application Using an Air Gun Setting Welding Conditions (for Air Gun) 1.4.2 Spot Welder Condition Data Setting The spot welder condition data file makes the welder-related settings using the welding sequence I/O signal control method.  Welder Condition Window A.
  • Page 28 Spot Welding Application Using an Air Gun Setting Welding Conditions (for Air Gun) START SIGNAL PRESSURE WELD COND COMMAND OUTPUT TIME WELDING CONDITION WELDING COMMAND WELD COMPLETE C. WELD INST OUTPUT TIME When “WELD INST OUTPUT TYPE” is specified as “PULSE” or “START SIGNAL”, set the welder condition signal to the pulse output time.
  • Page 29 Spot Welding Application Using an Air Gun Setting Welding Conditions (for Air Gun) Operation Procedure  1. Select {SPOT WELDING} under the main menu. 2. Select {WELDER CONDITION}. 3. Select the item to be set. 1-21 29 of 56...

  • Page 30: Spot Gun Condition Data File

    Spot Welding Application Using an Air Gun Setting Welding Conditions (for Air Gun) 1.4.3 Spot Gun Condition Data File Set the type of a gun, the number of the welder to be used, etc. for welding gun numbers 1 to 8. ...
  • Page 31 Spot Welding Application Using an Air Gun Setting Welding Conditions (for Air Gun) H. OPEN STROKE OUT DELAY TIME Specifies the timing to change the stroke change signal to the short- open status after the gun pressure instruction is output (ON) when a mechanical stopper type gun is used.
  • Page 32 Spot Welding Application Using an Air Gun Setting Welding Conditions (for Air Gun) Operation Procedure  1. Select {SPOT WELDING} under the main menu. 2. Select {GUN CONDITION}. – The GUN CONDITION window is displayed. 3. Select the item to be set. 1-24 32 of 56...

  • Page 33: Spot Welding Diagnosis

    Spot Welding Application Using an Air Gun Spot Welding Diagnosis Spot Welding Diagnosis 1.5.1 Spot Welding Diagnosis Window This window shows the maintenance information for tip replacement. It shows the set number of welds to tip replacement and the number currently completed.

  • Page 34: Tip Hit Count Clear

    Spot Welding Application Using an Air Gun Spot Welding Diagnosis 1.5.1.2 Tip Hit Count Clear 1. Select {SPOT WELDING} under the main menu. 2. Select {WELD DIAGNOSIS}. – The SPOT WELD DIAGNOSIS window appears. 3. Select {CLEAR CURRENT POS} from {DATA}. 4.

  • Page 35: Spot Gun Motion Control

    Spot Welding Application Using an Air Gun Spot Gun Motion Control Spot Gun Motion Control As regards to the guns for each stroke methods, the motion control described in chapter 1.6.1 "Gun Motion Control" can be executed. The following gun types are available: •...

  • Page 36: C Type Gun

    Spot Welding Application Using an Air Gun Spot Gun Motion Control FULL OPEN WELD FULL OPEN Stroke change  FULL OPEN WELD 1.6.1.2 C Type Gun  Single stroke SHORT OPEN WELD SHORT OPEN  Double stroke SHORT OPEN WELD SHORT OPEN FULL OPEN WELD...
  • Page 37 Spot Welding Application Using an Air Gun Spot Gun Motion Control SHORT OPEN WELD FULL OPEN FULL OPEN WELD FULL OPEN  Stroke change FULL OPEN SHORT OPEN 1-29 37 of 56...

  • Page 38: Process Timing

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.2 Process Timing 1.6.2.1 OPERATION MODE = 0 (SINGLE GUN, OPEN → WELDING → OPEN)  Gun Motion Control (With X gun, C gun, single type) Signal Control Order Manipulator starts moving by welding completion (Input) signal when "GUN OPEN"...

  • Page 39: (Short Open → Welding → Short Open)

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.3 OPERATION MODE = 1 (SHORT OPEN → WELDING → SHORT OPEN)  Gun Motion Control (With C gun double stroke) (With X gun double stroke, cylinder type) Signal Control Order Manipulator starts moving by welding completion (Input) signal when "GUN OPEN"...

  • Page 40: (Short Open → Welding → Full Open)

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.3.1 OPERATION MODE = 2 (SHORT OPEN → WELDING → FULL OPEN)  Gun Motion Control (With C gun double stroke) (With X gun double stroke, cylinder type) Signal Control Order Manipulator Movement Welding Instruction Turns ON/OFF welding instruction, welding...

  • Page 41: (Full Open → Welding → Short Open)

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.3.2 OPERATION MODE = 3 (FULL OPEN → WELDING → SHORT OPEN)  Gun Motion Control (With C gun double stroke) (With X gun double stroke, cylinder type) Signal Control Order Manipulator Movement Welding Instruction Turns ON/OFF welding instruction, welding condition...

  • Page 42: (Full Open → Welding → Full Open)

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.3.3 OPERATION MODE = 4 (FULL OPEN → WELDING → FULL OPEN)  Gun Motion Control (With C gun double stroke) (With X gun double stroke, cylinder type) Signal Control Order Manipulator Movement Turns ON/OFF welding instruction, welding condition Welding Instruction...

  • Page 43: Stroke Change Control Method

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.4 Stroke Change Control Method 1.6.4.1 Single Gun, C Double Gun, X Double Cylinder Gun When OPEN (SHORT) is specified, change the stroke change signal (general output) to short open; when FULL OPEN (LONG) is specified, change the stroke change 1 signal (general output) to full open.
  • Page 44 Spot Welding Application Using an Air Gun Spot Gun Motion Control When FULL OPEN (LONG) is Specified  Process Timing Stroke Change Signal Control Order Response Time Manipulator Movement Pressure Instruction (Output) Stopper Type Stroke Full Open Output Delay Time (when pressure Stroke Change 1 detection OFF) (Output)

  • Page 45: I/O Allocation

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.5 I/O Allocation The I/O necessary for each welder can be set in the general-purpose I/O signal. The following signals are specified on the pseudo input signal window. • Timer Cooling Water Error •...

  • Page 46: Output Allocation Window

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.5.2 Output Allocation Window 1. Select {SPOT WELDING} under the main menu. 2. Select {I/O ALLOCATION}. – The input allocation window appears. 3. Select {DISPLAY} from {DATA}. 4. Select {ALLOCATE OUTPUT}. –...

  • Page 47: Pseudo Input Signal Window

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 5. Specify the signal number. – Input the numerical value of the desired signal number, and press [ENTER]. • Be sure to confirm that the allocated general-purpose sig- nal is not used in the job. If it is used in the job, the signal is duplicated and the job does not operate normally.

  • Page 48: Allocation Signal Meanings

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.6 Allocation Signal Meanings Table 1-2: Robot Controller Input Signal Signal Content Source Standard Setting WELD COMPLETE This signal specifies that welding has been completed. Welder IN13 When the welding command manual spot operation is executed, it is used as a confirmation signal.
  • Page 49 Spot Welding Application Using an Air Gun Spot Gun Motion Control Table 1-3: Robot Controller Output Signal Signal Content Source Standard Setting WELD COND Specifies the welding condition for the welder. Welder OUT19 (Level Signal) Binary/discrete (bit number) can be selected as the used from 4 output format Corresponding to 255 conditions or less (Parity Bit...

  • Page 50: Monitor Function For Spot Welding Equipment

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.7 Monitor Function for Spot Welding Equipment Table 1-4: Function List Function Content Signal Method of Use Condition AIR PRESS LOW When the air pressure is low and Normal: OFF This signal can be used during the Input Signal this signal turns on, an alarm...

  • Page 51: Spot Welding Exclusive Signal Allocation List

    Spot Welding Application Using an Air Gun Spot Gun Motion Control 1.6.8 Spot Welding Exclusive Signal Allocation List  :Connector :Connector and terminal block Table 1-5: Spot Welding Exclusive Signal Allocation List (20010 to 20037) Input Input Signal Name Signal Method No Allocation Set Allocation Set...
  • Page 52 Spot Welding Application Using an Air Gun Spot Gun Motion Control :Connector  :Connector and terminal block Table 1-6: Spot Welding Exclusive Signal Allocation List (30010 to 30037) Output Input Signal Name Signal Method No Allocation Set Allocation Set Number 30010 DURING RUNNING DURING RUNNING...
  • Page 53 Spot Welding Application Using an Air Gun Spot Gun Motion Control :Connector  :Connector and terminal block Table 1-7: Spot Welding Exclusive Signal Allocation List (20040 to 20067) Output Input Signal Name Signal Method No Allocation Set Allocation Set Number 20040 ...
  • Page 54 Spot Welding Application Using an Air Gun Spot Gun Motion Control  :Connector  :Connector and terminal block Table 1-8: Spot Welding Exclusive Signal Allocation List (30040 to 30067) Output Input Signal Name Signal Method No Allocation Set Allocation Set Number 30040 ...

  • Page 55: Instruction List

    Spot Welding Application Using an Air Gun Instruction List Instruction List Data variables are denoted in parentheses “<>”. If multiple items are shown in one section, select one of the items. Table 1-9: Spot Welding Instructions GUNCL Function Presses a gun. Format GUN # (<gun No.>) T=<gun pressing time (sec.)>...
  • Page 56 FOR SPOT WELDING USING AIR GUN HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802 YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Europe GmbH Robotics Divsion )

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