YASKAWA RM2-755-RDR Instructions Manual
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YASKAWA RM2-755-RDR Instructions Manual

YASKAWA RM2-755-RDR Instructions Manual

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RM2-755-RDR POSITIONER
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and
retain for future reference
YASKAWA INSTRUCTIONS
MOTOMAN RM2-755-RDR POSTIONER INSTRUCTIONS
YASKAWA MH(T)-SERIES SIGMA-5 POSITIONER MANUAL
CONTROLLER MANUAL ASSEMBLY
OPERATOR'S MANUAL (GENERAL) (SUBJECT SPECIFIC)
MAINTENANCE MANUAL
ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
The operator's manual above correspond to specific usage.
Be sure to use the appropriate manual.
Part Number:
183523-1CD
Revision:
1
1 of 104

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Summary of Contents for YASKAWA RM2-755-RDR

  • Page 1 INSTRUCTIONS Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain for future reference YASKAWA INSTRUCTIONS MOTOMAN RM2-755-RDR POSTIONER INSTRUCTIONS YASKAWA MH(T)-SERIES SIGMA-5 POSITIONER MANUAL CONTROLLER MANUAL ASSEMBLY OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC) MAINTENANCE MANUAL ALARM CODES (MAJOR ALARMS) (MINOR ALARMS) The operator’s manual above correspond to specific usage.
  • Page 2 YASKAWA customers to assist in the operation of Motoman robots, related equipment and software This manual is 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...
  • Page 3 It is important that users operate the equipment in accordance with this instruction manual and any additional information which may be provided by YASKAWA. Address any questions regarding the safe and proper operation of the equipment to Customer Support. Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the manipulator.
  • Page 4 183523-1CD RM2-755-RDR Postioner Safety Notes for Safe Operation Even items described as “CAUTION” may result in a serious accident in some situations. WARNING • This instruction manual is intended to explain mainly the mechanical part of the Positioner concerning the actual operations, proper maintenance, and inspection.
  • Page 5 183523-1CD RM2-755-RDR Postioner Safety Notes for Safe Operation WARNING • Before operating the Positioner, check that servo power is turned OFF by pressing the EMERGENCY STOP buttons. When servo power is turned OFF, the SERVO ON LED on the Programming Pendant is turned OFF.
  • Page 6 The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product. YASKAWA is not responsible for incidents arising from unauthorized modifications to its products. Unauthorized modification voids the product warranty.
  • Page 7 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 8 183523-1CD RM2-755-RDR Postioner Explanation of Safety Labels Notes for Safe Operation Explanation of Safety Labels The following labels are attached to the Positioner (refer to Fig. 3). Always follow the safety labels. Also, an identification label with important information is placed on the body of the Positioner.
  • Page 9 Do not make any modifications to the Controller unit. Making any changes without the written permission from YASKAWA will void the warranty. • Some operations require standard passwords and some require special passwords.
  • Page 10 183523-1CD RM2-755-RDR Postioner Explanation of Safety Labels Safeguarding Tips Safeguarding Tips CAUTION Anyone working near the system must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation.
  • Page 11 NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR REPAIR THE EQUIPMENT! We recommend approved YASKAWA training courses for all personnel involved with the operation, programming, or repair of the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules.
  • Page 12 Explanation of Safety Labels Definition of Terms Used Often in This Manual Definition of Terms Used Often in This Manual The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of a Positioner, Manipulator, Controller, the Programming Pendant, and supply cables.

  • Page 13: Table Of Contents

    183523-1CD RM2-755-RDR Postioner Table of Contents Table of Contents 1 Introduction ............................. 1-1 1.1 About this Document ......................1-1 1.2 System Overview....................... 1-2 1.2.1 Positioner Configuration ..................1-3 1.2.2 Welding Ground System..................1-4 1.2.3 Major Components ....................1-4 1.2.4 Optional Equipment ....................1-4 1.3 Reference Documentation ....................
  • Page 14 183523-1CD RM2-755-RDR Postioner Table of Contents 3 Wiring .............................. 3-1 3.1 Grounding .......................... 3-1 3.2 Cable Connection ......................3-2 3.2.1 Connection to the Positioner................. 3-2 3.2.2 Connection to the Controller ................. 3-3 4 Basic Specifications ........................4-1 4.1 Basic Specifications List ....................4-1 4.2 Part Names and Working Axes..................
  • Page 15 183523-1CD RM2-755-RDR Postioner Table of Contents 6.11 Positioner Home Position ....................6-12 6.11.1 Positioner Headstock..................6-12 6.11.1.1 Setting the Main Axis (S1) to Home (Zero) Position ......6-12 6.11.1.2 Defining Trunnion Axis (S1) “A-Side” ..........6-12 6.11.2 Setting the Tooling Axis (S2 & S3) to Home (Zero) Position ......6-14 6.11.2.1 “Re-Homing”...

  • Page 16: Introduction

    183523-1CD RM2-755-RDR Postioner Introduction 1.1 About this Document Introduction About this Document This manual provides the following information: Chapter 1 Introduction  Provides general information about the Positioner system and components and customer support contact information. Chapter 2 Installation ...

  • Page 17: System Overview

    183523-1CD RM2-755-RDR Postioner Introduction 1.2 System Overview System Overview The Positioner is for a variety of applications that require precise parts movement. Normally the Positioner is in a work cell arrangement with one or more Manipulators and Controllers. The Positioner is a two-station headstock/tailstock (HS/TS) Positioner.

  • Page 18: Positioner Configuration

    183523-1CD RM2-755-RDR Postioner Introduction 1.2 System Overview A tooling plate multiple angle control feature allows the programmer to define the angle of the tooling presented to the operator (with a resolution of infinite degrees). This improves load station ergonomics and part tacking (see Fig.

  • Page 19: Welding Ground System

    Reference Documentation For additional information on individual components of the Positioner, refer to the following documentation that is included with the system: • YASKAWA Positioner Manual (P/N 183523-1CD) • Controller Manual • Maintenance Manual for Controller • Operator's Manual for the application •...

  • Page 20: Customer Support Information

    183523-1CD RM2-755-RDR Postioner Introduction 1.4 Customer Support Information Customer Support Information If assistance is needed with any aspect of the Positioner, contact Customer Support at the following 24-hour telephone number: (937) 847-3200 For routine technical inquiries, feel free to contact Customer Support at the following e-mail address: techsupport@motoman.com...

  • Page 21: Installation

    183523-1CD RM2-755-RDR Postioner Installation Installation WARNING • The Positioner must be installed by qualified personnel who are familiar with the installation and setup of this type of Positioner. Failure to use a qualified personnel for installation and setup can result in serious injury or death.

  • Page 22: Contents Confirmation

    183523-1CD RM2-755-RDR Postioner Installation 2.1 Contents Confirmation Contents Confirmation Confirm the contents of the delivery when the product arrives. NOTICE Notify shipping agent immediately, if there is any shipping damage. Standard delivery includes the following items (information for the content of optional goods is given separately): 2.1.1 Major Components...

  • Page 23: Materials Required

    183523-1CD RM2-755-RDR Postioner Installation 2.2 Materials Required Materials Required This section identifies customer-supplied items and tools required to complete installation. 2.2.1 Customer-Supplied Items • Servo motion control unit • Incoming power supply • Two earth ground cables with two earth ground stakes 2.2.2 Customer-Supplied Items...

  • Page 24: Positioner Installation

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation Positioner Installation CAUTION • Do not start operating the Positioner or turn ON power before firmly anchoring. The Positioner may overturn and cause injury or damage if Positioner is not firmly anchored. 2.3.1 Site Preparation CAUTION •...

  • Page 25: Location

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation 2.3.1.1 Location CAUTION • Install the Positioner in a location where the Positioner with a jig does not hit against anything such as the wall or the safeguarding Failure to observe this caution may result in damage.
  • Page 26 Fig. 2-1: Mounting the Positioner to the Floor 4X Ø25 THRU 8X M20 X 2.5 THRU +0.7 12X Ø20 THRU 1190.0 1240 25.0 25.0 25.0 50.0 50.0 90.0 140.0 230.0 250.0 410.0 280.0 450.0 500.0 550.0 227.0 "A" and "B" DIMENSIONS "A"...

  • Page 27: Shipping Bolts And Bracket

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation 2.3.2 Shipping Bolts and Bracket The Positioner is attached to a wooden shipping skid at the factory, prior to shipment to the customer. The customer is responsible for removing the Positioner from the shipping skid and inspecting for shipping damage.

  • Page 28: Transporting Method

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation 2.3.3 Transporting Method WARNING • Sling applications and crane or forklift operations must be performed by authorized personnel only. Failure to observe this caution could result in serious injury or death. • Never place any part of your body under a suspended load or move a suspended load over any part of another person’s body.

  • Page 29: Using An Overhead Crane

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation 2.3.3.1 Using an Overhead Crane CAUTION • Check that the eyebolts are securely fastened on Positioner. • Use a wire rope strong enough to withstand this weight. Refer to Table 4-1 “Positioner Technical Specifications” on page 4-1 for the weight of the Positioner and other included documentation to ensure the wire rope is strong enough to withstand this weight.

  • Page 30: Using Forklifts

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation 2.3.3.2 Using Forklifts Two forklifts can be used with the forklift pockets when the Positioner is in the shipping position and the shipping lifting bracket is installed (see Fig. 2-5). Be sure that the Positioner is fixed with shipping bolts and bracket before transposition, and lift in the posture as shown in Fig.

  • Page 31: Setting Headstock

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation 2.3.4.1 Setting Headstock 1. Place leveling bolt plates under each M20 leveling bolts so that the bolts do not rest on the concrete. • There should be approximately 6.35mm between the top of the leveling bolt plate and the underside of the headstock.

  • Page 32: Setting Tailstock

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation • After the top of the headstock is level, the fourth leveling bolt can be turned down to just contact the jack bolt plate. 4. Lag the two outer most holes of the headstock column to the floor.

  • Page 33: Mounting The Positioner On The Floor

    183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation Fig. 2-8: Distance Between Points on Tailstock and Headstock SECTION A-A SECTION B-B 6. Check the elevation of the headstock to tailstock using a self leveling laser. NOTICE The Z-beam dowel pin is the recommended reference. The laser should hit both dowel pins at the same elevation 7.
  • Page 34 183523-1CD RM2-755-RDR Postioner Installation 2.3 Positioner Installation Positioner Installation and Lagging Requirements  • The customer is responsible for reviewing the data in “Equipment Anchoring” to determine all equipment lagging requirements. • The customer is responsible for determining the adequacy of the foundation in the area where the proposed Positioner equipment will be located.

  • Page 35: Customer-Supplied Tooling Fixtures

    (Refer to section 1.4 “Customer Support Information” on page 1-5). NOTICE The customer shall supply all tooling fixtures for the Positioner. YASKAWA recommends application of a corrosion/rust preventive compound to tooling fixtures located in a high-humidity environment. Installation of Safeguarding WARNING •...

  • Page 36: Responsibility For Safeguarding (Iso10218)

    183523-1CD RM2-755-RDR Postioner Installation 2.5 Installation of Safeguarding CAUTION • Before turning ON the power, check to be sure that all shipping bolts and brackets are removed. Failure to observe this caution may cause in damage to the major driving parts.

  • Page 37: Wiring

    183523-1CD RM2-755-RDR Postioner Wiring 3.1 Grounding Wiring WARNING • Ground resistance must be 100Ω or less. Failure to observe this warning may result in fire or electric shock. • Before wiring, make sure to turn OFF the primary power supply, and put up a warning sign.

  • Page 38: Cable Connection

    183523-1CD RM2-755-RDR Postioner Wiring 3.2 Cable Connection Cable Connection There are two cables for connecting the Positioner to the Controller; a power cable and an encoder cable. Connect these cables to the Positioner base connectors and the Controller respectively. Refer to Fig.

  • Page 39: Connection To The Controller

    183523-1CD RM2-755-RDR Postioner Wiring 3.2 Cable Connection 3.2.2 Connection to the Controller CAUTION • Check numbers on both the cable and the Controller before connecting. Failure to observe this caution may cause damage to the Controller and cables. 1. Check the numbers on both the cables and Controller connectors.

  • Page 40: Basic Specifications

    183523-1CD RM2-755-RDR Postioner Basic Specifications 4.1 Basic Specifications List Basic Specifications Basic Specifications List CAUTION • Check numbers on both the cable and the Controller before connecting. Failure to observe this caution may cause damage to the Controller and cables.
  • Page 41 183523-1CD RM2-755-RDR Postioner Basic Specifications 4.1 Basic Specifications List SPECIFICATION UNITS RM2-755-RDR Max. Tooling Envelope Ø1300 Max. Tooling Sweep Ø2675 E-Stop Response 0.561 30.17 183523-1CD 41 of 104...

  • Page 42: Part Names And Working Axes

    183523-1CD RM2-755-RDR Postioner Basic Specifications 4.2 Part Names and Working Axes Part Names and Working Axes Fig. 4-1: Part Names and Working Axes TAILSTOCK SWING ARM ASSY TAILSTOCK ASSY ARC SHIELD ASSY HEADSTOCK DRIVE ASSY HEADSTOCK SWINGARM ASSY HEADSTOCK DRIVE ASSY...

  • Page 43: Dimensions And Working Envelope

    Dimensions and Working Envelope Fig. 4-3: Dimensions and Working Envelope Ø2675 MAX TOOLING SWEEP Ø1300 MAX TOOLING ENVELOPE 2522 1185 ROBOT SIDE SWEEP 25° CENTER 1446 475 MAX. 1476 TOOLING WORK SWEEP OPERATOR SIDE LOAD 22 TOOLING SWEEP CLEARANCE 43 of 104...

  • Page 44: Load Specifications And Jig Mounting

    183523-1CD RM2-755-RDR Postioner Load Specifications and Jig Mounting 5.1 Details of Fixture Mounting Load Specifications and Jig Mounting Details of Fixture Mounting The fixture mounting dimensions are shown in the figures below. It is a requirement that the fixture be located with the 16mm dowel and attached with 4 x M12 bolts (10.9 or 8.8 grade)

  • Page 45: Maintenance And Troubleshooting

    Failure to observe this caution may result in injury from unexpected turning of the table. NOTICE The motor and reducer are not recommended for field service. The unit should be returned to YASKAWA for repairs to these components. 183523-1CD 45 of 104...

  • Page 46: Inspection Interval

    Grease with YASKAWA P/N 132412-1, Reducer Molywhite RE00 Positioner Main Axis Speed Reducer 20,000 H Grease with YASKAWA P/N 132412, Moly-White RE00 Tailstock Main Sweep Axis Bearing Monthly Grease with YASKAWA P/N 180144-1, Mobil CM-P, Lithium Complex. Apply grease with a grease gun thru the two grease fittings on each side.
  • Page 47 183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.1 Inspection Interval Table 6-2: Inspection Parts and Grease Used Grease Used YASKAWA Part Number Inspected Parts Moly-White RE00 132412-1 Speed reducers of all axes Mobil CM-P, Lithium 180144-1 Tailstock swingarm main axis Complex...

  • Page 48: Battery Pack Replacement

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.2 Battery Pack Replacement Battery Pack Replacement If a battery alarm occurs in the Controller, replace the battery according to the following procedure. CAUTION • Do not remove power from the main power supply.

  • Page 49: Grease Replenishment/Exchange For Speed Reducers

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.3 Grease Replenishment/Exchange for Speed Reducers Grease Replenishment/Exchange for Speed Reducers 6.3.1 Tooling Axes Reducer 1. Remove the button head screws in the vent located in the flat surface at the top of the drive assembly.

  • Page 50: Tailstock Lubrication

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.3 Grease Replenishment/Exchange for Speed Reducers 6.3.2 Tailstock Lubrication The lubrication of the swingarm main axis bearing and the motomount axis bearing are required to be lubricated monthly. 6.3.2.1 Swingarm Main Swing Axis Apply Mobil CM-P grease to the grease fitting by using a standard grease gun and pressing the lever 10 times (1.25 g x 10).

  • Page 51: General Cleaning

    Use compressed air or vacuum, and a bristle brush (if required). NOTICE YASKAWA recommends application of a corrosion/rust preventive compound to tooling fixtures located in a high-humidity environment. Sigma-5 Servomotors The Sigma-5 servomotors (1 sweep axis, 2 tooling plate axis) are sealed units and have no parts that need inspection or replacement on a regular basis.

  • Page 52: Main (Sweep) Axis Reduction Gear Unit (Rdr-320C)

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.7 Main (Sweep) Axis Reduction Gear Unit (RDR–320C) Main (Sweep) Axis Reduction Gear Unit (RDR–320C) The main (sweep) axis Reduction Gear Unit (RDR–320C) is located on the Main Drive Housing Assembly (see Fig. 1-1 “Positioner Assembly” on page 1-2).

  • Page 53: Weld Ground Brush Replacement

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.9 Welding Ground System 6.9.2 Weld Ground Brush Replacement To replace the grounding brush(s) proceed as follows: 1. Shut down cell using main disconnect. 2. Remove the back panel of the drive assembly. 3. Use a flathead screwdriver to disconnect the brush cable(s) from the ground post (Fig.
  • Page 54 183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.9 Welding Ground System 5. Slide the old brush out of the housing and replace it with the new one. Fig. 6-6: Brush Assembly BRUSH SQUEEZE LEVERS and ROTATE UPWARD BRUSH HOLDER 6. Squeeze the brush retaining spring and push the brush against the faceplate then release.

  • Page 55: Ac Servomotor Encoder Back-Up Battery

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.10 AC Servomotor Encoder Back-Up Battery 6.10 AC Servomotor Encoder Back-Up Battery The main (sweep) axis and tooling (orbital) axes Sigma-5 servomotors all incorporate an external Lithium-Ion “keep alive” battery pack that maintains encoder positioning data in system memory, should the main cables between the Positioner and Controller be disconnected .

  • Page 56: Positioner Home Position

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.11 Positioner Home Position 6.11 Positioner Home Position Home Position Definition:  • S1 with Side B at Robot & Side A at Operator • S2 Tooling Down (At Operator Side) • S3 Tooling Up (At Robot Side) 6.11.1 Positioner Headstock...
  • Page 57 183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.11 Positioner Home Position Table 6-3: Positioner Headstocks Position Variables Variable Value Descriptions Variable Name EX040 -180.000° S1 A-Side At Robot S1 A-Side @Robot EX041 0.000° S2 Tooling At Robot S2 @Robot EX042 -180.000°...

  • Page 58: Setting The Tooling Axis (S2 & S3) To Home (Zero) Position

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.11 Positioner Home Position 6.11.2 Setting the Tooling Axis (S2 & S3) to Home (Zero) Position 1. Using the Programming Pendant, place the robotic system into MANAGEMENT mode. 2. Jog the S1 axis into the Positioner hard stop with S3 tooling at robot, and S3 tooling side up and level in the horizontal plane.

  • Page 59: Re-Homing" Tooling Axes S2 & S3 To Flat At The Robot And Operator

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.11 Positioner Home Position 6. Press {TOP MENU} on the programming pendant. 7. Cursor to {ROBOT} and press [SELECT]. 8. Cursor to {HOME POSITION} and press [SELECT]. 9. Press [PAGE OVER] to {S3} (indicated in top right corner of Programming Pendant display panel).

  • Page 60: Troubleshooting

    183523-1CD RM2-755-RDR Postioner Maintenance and Troubleshooting 6.12 Troubleshooting 6.12 Troubleshooting 6.12.1 Positioner Table 6-4: Troubleshooting Symptom Probable Cause Corrective Action Motor does not start Loose connection Check all wire connections. Incorrect wiring Check that system has been wired correctly. Overload Reduce load or reduce unbalanced load.

  • Page 61: Recommended Spare Parts

    (Refer to section 1.4 “Customer Support Information” on page 1-5). To order spare parts or replacement parts for the Positioner, please contact Customer Support (Refer to section 1.4 “Customer Support Information” on page 1-5). Table 7-1: Spare Parts for the RM2-755-RDR Postioner Rank Part No's. Name...

  • Page 62: Performance Charts

    183523-1CD RM2-755-RDR Postioner Appendix A A.1 Performance Charts Appendix A Performance Charts A.1.1 Positioner Assembly Rated Peak Holding Torque (N*m)= Load CG Offcenter from Tooling Plate r (mm) Rated W (kgf) Max W (kgf) Holding Torque; Load CG Offcenter (from Tooling Pl...

  • Page 63: Illustrated Parts List

    183523-1CD RM2-755-RDR Postioner Appendix B B.1 Illustrated Parts List Appendix B B.1 Illustrated Parts List The Illustrated Parts List (IPL) contains illustrations (exploded views) and associated parts list tables that show detail parts of a particular component, assembly, or subassembly.

  • Page 64: Parts List Table Structure

    183523-1CD RM2-755-RDR Postioner Appendix B B.1 Illustrated Parts List B.1.5 Parts List Table Structure Each figure’s parts list table contains the following data columns – FIGURE AND ITEM NUMBER  An entry in this column gives the item number for a part shown in the associated illustration (exploded view).
  • Page 65 Fig. B-1: Positioner Major Assemblies — 2.0M DETAIL T 65 of 104...
  • Page 66 DESCRIPTION ITEM P/N DESCRIPTION 180047-1 PLATE,STRIKER,LEVELING SCREW 183341-1 POSITIONER ASSY,RM2-755-RDR,2.0M,W/O 180130-1 COVER,Z-BEAM,END,LH,MAIN DRIVE,W/STUDS,RM2- SWITCHES,SLIP RINGS,AND AIR 183343-1 DRIVE ASSY,MAIN AXIS,RM2-755-RDR,W/O 155235-2 LABEL, PATENT IDENTIFICATION SWITCHES 169718-1 COVER, CABLES, HEADSTOCK SWINGARM, RM2- 163892-1 DRIVE ASSY,MH555 HEADSTOCK,W/MOTOMOUNT 755SL 164218-3 BEAM, Z-SPREADER 166355-1...
  • Page 67 LABEL, MOVING PARTS, HORIZONTAL 471359-1 LABEL, ROBOT WARNING, HORIZONTAL 471378-1 LABEL,ARC FLASH,HORIZONTAL, 159257-1 LABEL,ARCWORLD, 173483-1 LABEL,YASKAWA, 110 X 675, WHITE 472268-18 LABEL, CAPACITY, WEIGHT, 755kg 173463-1 FITTING,PLUG,37° FLARED,3/8" 145790-3 FITTING_SWIVEL_FEMALE-PIPE 145759-3 HOSE, 1/2 ID, 250 PSI, BLACK, USE W/PUSH-LOK 5400...
  • Page 68 Fig. B-2: Positioner Major Assemblies — 3.0M DETAIL T 68 of 104...
  • Page 69 ITEM P/N DESCRIPTION 183342-1 POSITIONER ASSY,RM2-755-RDR,3.0M,W/O 155235-2 LABEL, PATENT IDENTIFICATION SWITCHES,SLIP RINGS,AND AIR 169718-1 COVER, CABLES, HEADSTOCK SWINGARM, RM2- 183343-1 DRIVE ASSY,MAIN AXIS,RM2-755-RDR,W/O 755SL SWITCHES 166355-1 PIN,DOWEL,PULL,M20 x 40,HARDENED STEEL,NF 164218-1 BEAM, Z-SPREADER DIN7979D,M6 INTERNAL THRD 163900-1 ARM ASSY, SWING, TAILSTOCK 131274-4 SCREW,HHC,M16X40,ZP,CLASS 8.8...
  • Page 70 LABEL, MOVING PARTS, HORIZONTAL 471359-1 LABEL, ROBOT WARNING, HORIZONTAL 471378-1 LABEL,ARC FLASH,HORIZONTAL 159257-1 LABEL,ARCWORLD, 173483-1 LABEL,YASKAWA, 110 X 675, WHITE 472268-18 LABEL, CAPACITY, WEIGHT, 755kg 173463-1 FITTING,PLUG,37° FLARED,3/8" 145790-3 FITTING_SWIVEL_FEMALE-PIPE 145759-3 HOSE, 1/2 ID, 250 PSI, BLACK, USE W/PUSH-LOK 6400...
  • Page 71 Fig. B-3: Main Axis Drive Assy 71 of 104...
  • Page 72 Table B-3: Main Drive Headstock Swing Arm Assembly ITEM P/N DESCRIPTION 180117-1 PLATE,ADAPTER,MAIN DRIVE OUTPUT TO ITEM P/N DESCRIPTION SWINGARM,RM2-755,RDR 183343-1 DRIVE ASSY,MAIN AXIS,RM2-755-RDR,W/O 130532-9 SCREW,SHC,M16X110,CLASS12.9 SWITCHES 132619-3 SCREW,FHSC,M8X20, 183618-1 HOUSING,COLUMN,MAIN DRIVE,RM2-755-RDR 132620-1 SCREW,FHSC,M6X16 180286-1 HOUSING,HEADSTOCK SWINGARM,RM2-755,RDR 158942-27 LABEL,PRODUCT IDENTIFICATION,RM2-755,RDR...
  • Page 73 Fig. B-4: Main Drive Assembly 73 of 104...
  • Page 74 Table B-4: Main Drive Assembly ITEM P/N DESCRIPTION 163892-1 DRIVE ASSY,MH555 HEADSTOCK,W/MOTOMOUNT 163838-1 HOUSING, HEADSTOCK, TOOLING DRIVE 163879-1 PLATE, FACE, TOOLING DRIVE W/MOTOMOUNT 164116-1 BLOCK ASSY, HEADSTOCK, MOTOMOUNT 132616-3 SCREW,HHC,M8 X 16 470617-1 WASHER,CONICAL SPRING,GTS8 164485-1 BRUSH ASSY, GROUND, MTG BRKT, 3 POS 151594-5 REDUCER, RV, RV-80E 407248-7...
  • Page 75 Fig. B-5: Tailstock Swing Arm Assembly 75 of 104...
  • Page 76 Table B-5: Tailstock Swing Arm Assembly ITEM P/N DESCRIPTION 163900-1 ARM ASSY, SWING, TAILSTOCK CSW 4/16/15 RM2- 755/1255SL 163840-1 HOUSING,TAILSTOCK SWINGARM 164890-1 HOUSING ASSY, TAILSTOCK ADAPTER, MOTOMOUNT 165038-1 SHAFT, BEARING, TAILSTOCK SWINGARM 163886-1 BEARING,SPHERICAL,PILLOW BLOCK,2.437 ID 157188-1 RETAINER, TAILSTOCK SWINGARM 132619-3 SCREW, FHSC, M8x1.25 X 20 130532-2...

  • Page 77: Glossary

    183523-1CD RM2-755-RDR Postioner Appendix C Appendix C Glossary 3D Graphic Display Function The 3D Graphic Display Function (this will be called 3D Display Function) is that, a 3D model of the Manipulator is displayed on the programming pendant window, and the current value of the Manipulator can be confirmed.
  • Page 78 183523-1CD RM2-755-RDR Postioner Appendix C ANSI/RIA R15.06-2012 American National Standard for Industrial Robots and Robot Systems This standard provides guidelines for the manufacture and integration of Industrial Robots and Robot Systems with emphasis on their safe use, the importance of risk assessment and establishing personnel safety. This...
  • Page 79 183523-1CD RM2-755-RDR Postioner Appendix C Computer Aided Design (CAD) Computer Aided Design (CAD). Computer graphic applications designed to allow engineering of objects (or parts), which are to be manufactured. A computer is used as a tool to design schematics and produce blueprints, which enable the accurate production of the object.
  • Page 80 183523-1CD RM2-755-RDR Postioner Appendix C Centrifugal Force When a body rotates about an axis other than one at it's center of mass, it exerts an outward radial force called centrifugal force upon the axis, which restrains it from moving in a straight tangential line. To offset this force, the robot must exert an opposing torque at the joint of rotation.
  • Page 81 183523-1CD RM2-755-RDR Postioner Appendix C Continuous Path Describes the process where by a robot is controlled over the entire path traversed, as opposed to a point-to-point method of traversal. This is used when the trajectory of the end-effector is most important to provide a smooth movement, such as in spray painting etc.
  • Page 82 183523-1CD RM2-755-RDR Postioner Appendix C Cubic Interference Area This area is a rectangular parallelepiped, which is parallel to the base coordinate, Manipulator coordinate or user coordinate. The Controller judges whether the current position of the Manipulator’s TCP is inside or outside this area, and outputs this status as a signal.
  • Page 83 183523-1CD RM2-755-RDR Postioner Appendix C Drop Delivery A method of introducing an object to the workplace by gravity. Usually, a chute or container is so placed that, when work on the part is finished, it will fall or drop into a chute or onto a conveyor with little or no transport by the robot.
  • Page 84 183523-1CD RM2-755-RDR Postioner Appendix C Expandability Being able to add resources to the system, such as memory, larger hard drive, new I/O card, etc. External Force Limit The threshold limit where the robot moves to or retains position, even when external forces are applied (provided that forces do not exceed limits that would cause an error).
  • Page 85 183523-1CD RM2-755-RDR Postioner Appendix C Functional Safety Unit (FSU) The Functional Safety Unit (FSU) is a component of the Manipulator Controller that provides programmable safety functions that enable collaborative operation of the robot. As these safety functions are programmable, the FSU allows the minimization of nearby overall equipment footprint, as well as human accessible areas.
  • Page 86 Manipulator, and a computer Controller that gives detailed movement instructions. INFORM The robot programming language for YASKAWA robots. INFORM language allows the robot user to: instruct the robot to use its basic capabilities to fulfill a defined set of expectations and also to describe to the robot, through a definition of parameters and conditions, what the expectations are in some given situations or scenarios.
  • Page 87 183523-1CD RM2-755-RDR Postioner Appendix C Integrator A company that provides value added services that results in creation of automation solutions by combining a robot and other automation and controls equipment to create an automation solution for end users. Intelligent Robot A robot that can be programmed to make performance choices contingent on sensory inputs with little or no help from human intervention.
  • Page 88 183523-1CD RM2-755-RDR Postioner Appendix C Joint A part of the Manipulator system, which allows a rotation and/or translational degree of freedom of a link of end-effector. Joint Interpolated Motion A method of coordinating the movement of the joints, such that all joints arrive at the desired location simultaneously.
  • Page 89 183523-1CD RM2-755-RDR Postioner Appendix C Linear Motion Type Is a method of path interpolation that commands the movement of the robot by moving each joint in a coordinated motion so that all axis arrive to the position at the same time. The path of the Tool Control Point (TCP) is predictable and will be linear.
  • Page 90 Self-contained component of a package. This component may contain sub-components known as sub-modules. Motomount YASKAWA proprietary mounting block allowing for limited play on multiple axis Motion Axis The line defining the axis of motion either linear or rotary segment of a Manipulator.
  • Page 91 183523-1CD RM2-755-RDR Postioner Appendix C Orientation The angle formed by the major axis of an object relative to a reference axis. It must be defined relative to a three dimensional coordinate system. Angular position of an object with respect to the robot's reference system.
  • Page 92 183523-1CD RM2-755-RDR Postioner Appendix C Performance Level d (PLd) ISO Performance Level (PL) “d” means that the average probability of dangerous failure per hour of the safety related parts of the control system falls within = 10-7 to < 10-6. Additionally, other factors such as proper installation, maintenance and protection against environmental factors also apply.
  • Page 93 183523-1CD RM2-755-RDR Postioner Appendix C Playback Operation Playback is the operation by which the taught job is played back. This function is used to decide where to resume the playback on the start operation after suspending the playback and moving the cursor or selecting other jobs.
  • Page 94 See "Inductive Sensor". Pulse Coordinates YASKAWA robots define robot joint axes position in degrees for revolute joints. Pulse is also another way to specify robot joint position, and it does so in robot motor encoder pulse counts.
  • Page 95 183523-1CD RM2-755-RDR Postioner Appendix C Real-time System A computer system in which the computer is required to perform its tasks within the time restraints of some process simultaneously with the system it is assisting. The computer processes system data (input) from the...
  • Page 96 183523-1CD RM2-755-RDR Postioner Appendix C Risk Assessment The process of evaluating the intended use of a machine or system for foreseeable hazards and then determining the level of risk involved for the tasks identified. Risk Mitigation A secondary step in the risk assessment process that involves reducing the level of risk for the identified tasks, by applying risk reduction measures in order to eliminate or mitigate the hazards.
  • Page 97 FSU generated signals. The safety logic circuit is programmed via an intuitive user interface that is supported on the YASKAWA programming pendant. It enables to set up the logical operations, such as stopping the Manipulator or outputting a signal if the servos are on.
  • Page 98 183523-1CD RM2-755-RDR Postioner Appendix C Servo Motor An electrical power mechanism used to effect motion or maintains position of the robot (for example, a motor which converts electrical energy to effect motion of the robot) (R15.07). The motor responds to a signal received from the control system and often incorporates an encoder to provide feedback to the control loop.
  • Page 99 183523-1CD RM2-755-RDR Postioner Appendix C SLURBT SLURBT are terms that YASKAWA Motoman uses to describe each axis of the robot for convenience. The definition of each value is as follows: S – Swing or Swivel L – Lower Arm U – Upper Arm R –...
  • Page 100 183523-1CD RM2-755-RDR Postioner Appendix C Teach To program a Manipulator arm by manually guiding it through a series of motions and recording the position in the robot Controller memory for playback. Teach Lock While the Teach Lock is set, the mode of operation is tied to the Teach Mode and the machines cannot be played back using either [START] or external input.
  • Page 101 183523-1CD RM2-755-RDR Postioner Appendix C Tool Center Point (TCP) The Tool Center Point (TCP) defines the tip of the current tool as defined relative to the tool flange. For example, for a welding robot, the TCP will generally be defined at the tip of the welding gun. After defining and configuring the TCP, the robot motion will be defined relative to this frame (i.e., rotation in the Rx direction would cause rotation around the X-axis...
  • Page 102 183523-1CD RM2-755-RDR Postioner Appendix C User Coordinate Setting User coordinates are defined by three points that have been taught to the Manipulator through axis operations. These three defining points are ORG, XX, and XY, as shown in the diagram below. These three points of positional data are registered in a user coordinate file.
  • Page 103 183523-1CD RM2-755-RDR Postioner Appendix C World Coordinates A reference coordinate system in which the Manipulator arm moves in linear motions along a set of Cartesian or rectangular axes in X, Y, and Z directions. The shape of the work envelope forms a rectangular figure.
  • Page 104 INSTRUCTIONS YASKAWA ELECTRIC CORPORATION 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu, 806-0004, Japan Phone: +81-93-645-7703 Fax: +81-93-645-7802 http://www.yaskawa.co.jp 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 http://www.motoman.com YASKAWA EUROPE GmbH (ROBOTICS DIVISION) Yaskawastrasse 1, 85391, Allershausen, Germany Phone: +49-8166-90-100 Fax: +49-8166-90-103 http://www.yaskawa.eu.com...

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