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/QVQOCP :4% %QPVTQNNGT
#TE 9QTNF.KVG
5[UVGO /CPWCN
HQT 58: 4QDQV
Part Number:
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Document Status:
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
142719-1
July 25, 2000
1
Final
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Table of Contents
Related Manuals for YASKAWA Motoman WorldLite-50
Summary of Contents for YASKAWA Motoman WorldLite-50
- Page 1 /QVQOCP :4% %QPVTQNNGT #TE 9QTNF.KVG 5[UVGO /CPWCN HQT 58: 4QDQV Part Number: 142719-1 Release Date: July 25, 2000 Document Version: Document Status: Final Motoman, Incorporated 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-Hour Service Hotline: (937) 847-3200...
- Page 2 Motoman, Inc. ©2003 by MOTOMAN All Rights Reserved Because we are constantly improving our products, we reserve the right to change specifications without notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
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Page 3: Table Of Contents
TABLE OF CONTENTS Section Page LIST OF FIGURES...........................iii LIST OF TABLES ..........................iii INTRODUCTION About this Document ....................1-1 System Overview ......................1-2 1.2.1 System Layout ....................1-2 1.2.2 Major Components ..................1-2 1.2.3 Optional Equipment ..................1-2 Reference to Other Documentation................1-4 Customer Service Information .................. - Page 4 EQUIPMENT DESCRIPTION (CONTINUED) Safety Features ......................3-9 3.6.1 Arc Shields ....................3-10 3.6.2 Fencing ......................3-10 3.6.3 Emergency Stops (E-STOPS) ................ 3-10 3.6.4 ENABLE Switch ..................... 3-10 3.6.5 Interlocked Cell Door ..................3-10 3.6.6 Interference Cubes ..................3-11 3.6.7 Brake Release Control ................... 3-11 INSTALLATION Materials Required......................
- Page 5 LIST OF FIGURES Figure Page Figure 1-1 System Layout ......................1-3 Figure 3-1 XRC Controller ......................3-1 Figure 3-2 XRC Playback Panel ....................3-2 Figure 3-3 Programming Pendant ....................3-3 Figure 3-4 RS-232C Serial Port ....................3-5 Figure 3-5 Enable Switch ....................... 3-5 Figure 3-6 Operator Station ......................
- Page 6 NOTES Arc-WorldLite 50 System Manual MOTO MAN...
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Page 7: Introduction
SECTION 1 INTRODUCTION The Arc-WorldLite 50 is part of the ArcWorld family of standardized arc welding solutions. It is a fully integrated welding system, and is supported from wire to weld by Motoman, Inc. The Arc-WorldLite 50 features a Motoman SV3X arc welding robot and XRC robot controller with menu-driven arc welding application software, complete welding package, stationary weld table, and a total safety environment. -
Page 8: System Overview
INTRODUCTION System Overview The Arc-WorldLite 50 provides a complete arc welding solution in a standardized configuration. The system is designed around a Motoman SV3X arc welding robot with XRC controller, and includes a complete welding package. A stationary weld table with protective operator door provides easy operator access to parts, and a safe welding environment. -
Page 9: Figure 1-1 System Layout
INTRODUCTION CELL DOOR XRC CONTROLLER ROBOT 1 6 X T LOC (OFF (ON) POWER SOURCE POSITIONER A T E A T E A L A A T E O L T I N P I C A I N D B L E A T I Ø... -
Page 10: Reference To Other Documentation
INTRODUCTION Reference to Other Documentation For additional information refer to the following: • Motoman SV3X Manipulator Manual (P/N 139067-1) • Motoman Operator's Manual for Arc Welding (P/N 142098-1) • Motoman Concurrent I/O Parameter Manual (P/N 142102-1) • Com-Arc III Instruction Manual (P/N 132753-1) •... -
Page 11: Safety
SECTION 2 SAFETY Introduction It is the purchaser's responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed. We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems. -
Page 12: Standard Conventions
SAFETY Standard Conventions This manual includes information essential to the safety of personnel and equipment. As you read through this manual, be alert to the four signal words: • DANGER • WARNING • CAUTION • NOTE Pay particular attention to the information provided under these headings which are defined below (in descending order of severity). -
Page 13: General Safeguarding Tips
SAFETY General Safeguarding Tips All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. General safeguarding tips are as follows: •... -
Page 14: Installation Safety
SAFETY Installation Safety Safe installation is essential for protection of people and equipment. The following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. -
Page 15: Operation Safety
SAFETY • Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc. • Be sure that all safeguards are in place. • Check the E-STOP button on the teach pendant for proper operation before programming. -
Page 16: Maintenance Safety
SAFETY Maintenance Safety All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Maintenance tips are as follows: •... -
Page 17: Equipment Description
SECTION 3 EQUIPMENT DESCRIPTION SV3X Robot Description The Motoman SV3X robot and Xtra Robotic Controller (XRC) represent state-of- the-art technology in robotics today. The six-axis SV3X robot has a payload of 3 kg (6.6 lbs). It features a 1,019 mm (40.1 in.) vertical reach and has a relative positioning accuracy of ±... -
Page 18: Playback Panel
EQUIPMENT DESCRIPTION 3.2.1 Playback Panel The playback panel (see Figure 3-2) contains the primary system controls and consists of the features described below. For more information, refer to the manipulator manual that came with your system. MODE ALARM/ERROR BUTTONS INDICATOR E-STOP SERVO ON MODE... -
Page 19: Programming Pendant
EQUIPMENT DESCRIPTION Hold The HOLD button is a normally closed, momentarily actuated switch. Pressing HOLD halts operation of the manipulator until another Start signal is sent. 3.2.2 Programming Pendant The programming pendant (see Figure 3-3) is the primary user interface for the system. - Page 20 EQUIPMENT DESCRIPTION Status Area The Status Area shows system status via the following symbols: • Active Robot, External Axis, or Base Axis R1, R2, R3; S1, S2, etc.; or B1, B2, etc. • Coordinate System Joint, World, Cylindrical, Tool, or User Frame •...
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Page 21: Figure 3-4 Rs-232C Serial Port
EQUIPMENT DESCRIPTION SELECT Key The SELECT key is used to choose the item currently highlighted by the cursor. TEACH LOCK Key The TEACH LOCK key locks operation of the robot with the programming pendant. Operation is not possible from the playback panel or operator station. Servo power can not be applied in TEACH mode unless TEACH LOCK is ON. -
Page 22: Brake Release
EQUIPMENT DESCRIPTION 3.2.3 Brake Release WARNING! Releasing brakes could cause personal injury or machine damage. Always support the axis to be released BEFORE you release it. The Brake Release Control is a safety feature that allows you to release the brakes on the robot in case of an emergency or robot failure. -
Page 23: Emergency Stop (E-Stop)
EQUIPMENT DESCRIPTION 3.3.2 Emergency Stop (E-STOP) The operator station E-STOP button is connected in series with the system Emergency Stop circuit. Pressing the E-STOP button interrupts this circuit and stops all system operation. Brakes are applied to the robot and all servo power is removed from the system. -
Page 24: Welding Equipment
EQUIPMENT DESCRIPTION Welding Equipment The ArcWorld system provides a complete complement of arc welding equipment. In its standard configuration, the ArcWorld system includes a power source, wire feeder, torch, and torch mount. Optional equipment including water circulators, Com-Arc units, and torch tenders may also be included with your system. 3.5.1 Power Sources Motoman offers several different power sources for use with the ArcWorld system... -
Page 25: Pwf Wire Feeder
EQUIPMENT DESCRIPTION Mobility The steel base that supports the power source for the Arc-WorldLite 50 system is mobile. Four casters enable the power source to be wheeled away from the welding cell for ease of service and installation. To remove the power source, remove the two bolts that fasten the base to the welding cell. -
Page 26: Arc Shields
EQUIPMENT DESCRIPTION 3.6.1 Arc Shields WARNING! Although the arc curtain blocks dangerous arc radiation, never look directly at the arc without protective eye wear! Two separate arc screens are used on the Arc-WorldLite 50. The first is the metal arc screen on the front of the weld table. These screens block arc radiation and sparks from the welding operation. -
Page 27: Interference Cubes
EQUIPMENT DESCRIPTION 3.6.6 Interference Cubes Cubic interference zones prevent interference between multiple manipulators or a manipulator and peripheral devices. The XRC monitors the robot tool center point (TCP) during operation. If the TCP enters one of the these software-defined interference zones, an output is turned on in the XRC. These outputs can be used to interlock the activity of other manipulators or peripheral devices. - Page 28 EQUIPMENT DESCRIPTION NOTES Arc-WorldLite 50 System Manual 3-12 MOTOMAN...
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Page 29: Installation
SECTION 4 INSTALLATION The Arc-WorldLite 50 system can be installed easily in just a short time by one or two workers. Follow established safety procedures at all times throughout the installation process. Failure to use safe work practices can result in damage to the equipment and injury to the workers. -
Page 30: Site Preparation
INSTALLATION Site Preparation To prepare your site, proceed as follows: 1. Clear the floor space needed for the unit (see Figure 4-1). NOTE: An additional 2.43 to 3.05 m (8 to 10 ft.) on all sides of is recommended. 2. Gather all customer-supplied items and required tools listed in Section 4.1. 2000 (6.56 ft) 2438... -
Page 31: Removing The Shipping Brackets
INSTALLATION SHIPPING BOLT LEVELING BOLT 16 X STOP EMERGE TEACH MODE PLAY SERVO READY START HOLD ALARM EDIT LOCK REMOTE (OFF) (ON) A T E A L A A T E A T E O L T I N P B L E I C A I N D... -
Page 32: Leveling And Securing The Cell
INSTALLATION Leveling and Securing the Cell After everything is in position, the equipment should be leveled and then secured to the floor. The lag bolts are shipped in the accessories box. Refer to your Motoman Robot manipulator manual for floor loading requirements. To level and secure the equipment, proceed as follows: 1. -
Page 33: Connecting The Water Circulator (Optional)
INSTALLATION WARNING! • If proper earth grounds cannot be provided, do not use the equipment! Serious injury or death can occur. • Do not place the MIG system within 50 feet of other sources of noise (i.e., GTAW arc starters, plasma cutters, induction furnaces, high-power-resistance spot... -
Page 34: Connecting The Gas/Air Services
INSTALLATION WATER OUT WATER IN TO POWER SOURCE Figure 4-5 Water Circulator Connections Connecting the Gas/Air Services The gas and air hoses for the Arc-WorldLite 100 are already connected when the unit is shipped. Gas and air services must be completed after the cell has been secured to the floor. -
Page 35: Connecting The Power
INSTALLATION Connecting the Power After all of the system components have been properly installed, power must be connected to the main disconnect. Conducting a Safety/Operation Check Before installing the tooling and fixtures for your application, take a few minutes to perform a safety/operation check. To conduct a safety/operation check, proceed as follows: 1. - Page 36 INSTALLATION NOTES Arc-WorldLite 50 System Manual MOTOMAN...
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Page 37: Operation
SECTION 5 OPERATION The Arc-WorldLite 50 is a fully integrated robotic GMAW welding cell. After production parts have been loaded onto the weld table, the operator door closes, servo power is applied allowing the robot to safely process the parts. The robot welds the parts and returns to the home position, the operator door opens removing servo power allowing the operator to safely remove the welded parts and load new production parts. -
Page 38: Daily Operation
OPERATION Table 5-1 XRC User Inputs Input Assignment IN#001 CYCLE START STATION A IN#002 LOWER DOOR IN#003 DOOR CLOSED STATION A IN#004 NOT USED IN#005 NOT USED IN#006 NOT USED IN#007-IN#016 NOT USED Table 5-2 XRC User Outputs Input Assignment OUT#001 LOWER DOOR OUT#002... -
Page 39: Robot Home Position
OPERATION 5.2.2 Robot Home Position To move the robot to the homehome position (Cube 24), proceed as follows: 1. Press TEACH mode button on XRC playback box. 2. Press SELECT on programming pendant. 3. Press SEL JOB (F4). 4. Using cursor keys, move cursor to R1home job and press ENTER. R1home job appears in display screen. -
Page 40: System Recovery
OPERATION System Recovery Under certain conditions you will be required to clear an alarm or error. Clearing an alarm or error requires different operator actions depending on the type. Different types of alarms and errors are described below. 5.3.1 Alarms and Errors Alarms and errors will cause the program to stop. -
Page 41: Shock Sensor Recovery
OPERATION 5.3.3 Shock Sensor Recovery The ArcWorld welding package includes a Motoman gun mount. This mount is designed to protect the torch from damage in case of a crash. A slight deflection of the torch activates a SHOCK SENSOR message, which triggers an E-STOP condition. - Page 42 OPERATION NOTES Arc-WorldLite 50 System Manual MOTOMAN...
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Page 43: Maintenance
SECTION 6 MAINTENANCE Periodic Maintenance For periodic maintenance procedures and schedules for the SV3X robot and the XRC controller, refer to the manipulator manual that came with your system. Table 6-1 provides a list of periodic maintenance to be performed on the Arc- WorldLite 50 cell. -
Page 44: Fuse And Circuit Breaker Protection
MAINTENANCE Fuse and Circuit Breaker Protection Tables 6-2 and 6-3 give the locations of fuses and circuit breakers that are significant to the operation of the total system. In most cases, spare fuses are placed in the accessory bag with the controller. WARNING! Replace fuses with those of the same type and rating. - Page 45 INDEX About this Document Gas/Air Services, Connecting Alarm/Error General Safeguarding Tips Alarms and Errors GMAW Torch ANSI/RIA Arc Shields 3-10 Hold Arc-WorldLite 52 Common Base, Installation Area Key I/O Assignment Installation Safety Brake Release Installation Section Brake Release Control 3-11 Interference Cubes 3-11 Introduction...
- Page 46 INDEX P (continued) S (continued) Symbol Power Sources Cylindrical, Coordinate System Mobility E-Stop, System Status Programming High, Manual Speed Programming Pendant Hold, System Status Programming Safety Inching, Manual Speed PWF Wire Feeder Joint, Coordinate System Low, Manual Speed Medium, Manual Speed Reach, Vertical Running/Start, System Status Reference to Other Documentation...