YASKAWA DX200 Instructions Manual
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YASKAWA DX200 Instructions Manual

For hand guiding function
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See also: Operator's Manual , Instruction Manual
DX200/YRC1000 OPTIONS
INSTRUCTIONS
FOR HAND GUIDING FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX200/YRC1000 OPTIONS INSTRUCTIONS FOR HAND GUIDING FUNCTION DX200
INSTRUCTIONS
DX200 OPERATOR'S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
DX200 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY BOARD OPERATION
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR'S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY FUNCTION
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
186984-1CD
0
MANUAL NO.
HW1485706
1/58

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Summary of Contents for YASKAWA DX200

  • Page 1 Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN- INSTRUCTIONS DX200/YRC1000 OPTIONS INSTRUCTIONS FOR HAND GUIDING FUNCTION DX200 INSTRUCTIONS DX200 OPERATOR’S MANUAL (for each purpose) DX200 MAINTENANCE MANUAL...
  • 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 HW1485706 NOTES FOR SAFE OPERATION Read this manual carefully before installation, operation, maintenance, or inspection of the DX200/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 Before operating the manipulator, make sure the servo power is turned off by pressing the emergency stop button on the front door of the DX200/YRC1000, on the programming pendant, and on the hand guiding device respectively. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.
  • 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 DX200/YRC1000 controller, the DX200 programming pendant or the YRC1000 programming pendant, and the power cables.
  • Page 6 START, HOLD, or EMERGENCY STOP. (For YRC1000, the button names are denoted as symbols) Displays The menu displayed in the programming pendant is denoted with { }. e.g. {JOB} <DX200> <YRC1000> Start button Hold button Start button* Hold button* Mode switch...
  • Page 7 HW1485706 Description of the Operation Procedure In the explanation of the operation procedure, the expression “Select • • •” means that the cursor is moved to the object item and [SELECT] is pressed, or that the item is directly selected by touching the screen. Registered Trademark In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or...

  • Page 8: Table Of Contents

    HW1485706 Contents 1 Introduction ............................. 1-1 2 Hand Guiding Function ........................2-1 2.1 Usage Conditions of Hand Guiding Function..............2-1 2.2 Overview of Hand Guiding Function .................. 2-1 2.3 System Configuration of Hand Guiding Function............... 2-2 2.3.1 System Configuration for Using Hand Guiding Device of Handle Type....2-4 2.3.2 System Configuration for Using Hand Guiding Device of Grip Type ....
  • Page 9 HW1485706 Contents 4.4.2.1 Translation Mode ..................4-5 4.4.2.2 Rotation Mode ..................4-5 4.4.3 Force Sensor/ I/O Input ..................4-6 4.4.3.1 Force Sensor Input Mode................ 4-6 4.4.3.2 I/O Input Mode ..................4-6 4.5 Calibration of Force Sensor ....................4-7 4.6 Register Output Function....................4-8 5 Risk Assessment ..........................

  • Page 10: Introduction

    HW1485706 Introduction Introduction The hand guiding function enables to realize the collaboration work between people and robots. Therefore, make sure to perform the risk assessment for the whole robot system before using this function since the safety for the collaborative operation depends on the robot system. For the risk assessment, refer to chapter 5 “Risk Assessment”...

  • Page 11: Hand Guiding Function

    HW1485706 Hand Guiding Function Usage Conditions of Hand Guiding Function Hand Guiding Function This chapter describes the overview and the system configuration of the hand guiding function. Usage Conditions of Hand Guiding Function The usage conditions of the hand guiding function are as follows. •...

  • Page 12: System Configuration Of Hand Guiding Function

    HW1485706 Hand Guiding Function System Configuration of Hand Guiding Function System Configuration of Hand Guiding Function The hand guiding function consists of two patterns depending on the hand guiding device to use. 1. Hand guiding device of the handle type with both hands operation 2.
  • Page 13 HW1485706 Hand Guiding Function System Configuration of Hand Guiding Function Locations of the screw holes on the force sensor HW1485706 13/58...

  • Page 14: System Configuration For Using Hand Guiding Device Of Handle Type

    This jig connects the robot with the force sensor and the hand guiding device. *Prepared by the customer. Force sensor Force sensor designated by YASKAWA Hand guiding device Hand guiding device of the handle type Presence detection sensor A safety laser scanner and a light curtain, etc.

  • Page 15: System Configuration For Using Hand Guiding Device Of Grip Type

    This jig connects the robot with the force sensor and the hand guiding device. *Prepared by the customer. Force sensor Force sensor designated by YASKAWA Hand guiding device Hand guiding device of the grip type Presence detection sensor A safety laser scanner and a light curtain, etc.

  • Page 16: Connection For Hand Guiding Device

    Each switch of the hand guiding device in the controller is connected as follows. The signals of the following table cannot be used for other purposes. Switch Connection terminal block Terminal Signal name Contents DX200 YRC1000 Emergency stop Machine safety Safety terminal EXESP1+ External emergency switch...

  • Page 17: Connection For Presence Detection Sensor

    Connect them by using the safety relay, etc. depending on the output signal specifications of the presence detection sensor. Device Connection terminal block Terminal Signal name Contents DX200 YRC1000 Presence detection Functional safety Expansion safety XIN2_1+ Functional safety sensor...

  • Page 18: Speed Limiting Function

    2.6.1 Setting of Speed Limiting Function For details of setting procedures for the functional safety, refer to the following instruction manuals. DX200: DX200 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY BOARD OPERATION (HW1481991) YRC1000: YRC1000 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY FUNCTION (HW1483576)

  • Page 19: Setup Of Hand Guiding Function

    HW1485706 Setup of Hand Guiding Function Setup of Hand Guiding Function This chapter describes the setup procedures of the hand guiding function. The following items to setup are required to be prepared by the customers. Item Details Filter setting Setting of the smoothing filter coefficient to the force sensor value Setting of speed upper limit Setting of the moving speed limit of the...

  • Page 20: Filter Setting

    HW1485706 Setup of Hand Guiding Function Filter Setting Filter Setting When using the hand guiding function, the robot may repeat unintentional acceleration or deceleration caused by unstable input value of the force sensor because of the time differences which occur in starting a robot operation after applying force by the user or the influence of the force sensor interlocking with the hand operation.

  • Page 21: Setting Of Speed Coefficient

    HW1485706 Setup of Hand Guiding Function Setting of Speed Coefficient Setting of Speed Coefficient A coefficient of the robot moving speed of the hand guiding function can be set by variables. [Speed Coefficient: Large] A robot moves in a large force. [Speed Coefficient: Small] A robot moves in a small force.

  • Page 22: Setting Of Operation Angle Limit

    HW1485706 Setup of Hand Guiding Function Setting of Operation Angle Limit Setting of Operation Angle Limit The operation angle to the rotation can be limited so that the robot is prevented from contacting the external device when operating a robot by using the hand guiding function.

  • Page 23: Setting Of Area Limit

    10000 -10000 10000 -10000 For the detail setting method of the cubic interference area, refer to DX200 INSTRUCTIONS or YRC1000 INSTRUCTIONS. Ladder setting Connect the set cubic interference area specific output signal (#50080 - #50157) and the auxiliary relay (#70201 - #70206) for the area limit with the concurrent ladder setting.

  • Page 24: Tool Setting

    HW1485706 Setup of Hand Guiding Function Tool Setting (Setting example when the area in the X- direction is limited using the cubic interference area 1) Cubic interference area 1 Concurrent ladder Cubic interference area 1 specific output signal Signal of X direction minimum position exceeded When the TCP (tool center point) intrudes the cubic interference area 1, the hand guiding function stops the robot from moving to X- direction.

  • Page 25: Tool Coordinate System And Sensor Coordinate System

    HW1485706 Setup of Hand Guiding Function Setting of Sensor Mounting Angle Perform chapter 3.6 “Tool Setting” before this setting. If the value except for the possible values is input, when the general output 4081 (#15110) of the hand guiding function enable signal is turned ON, the following alarm is displayed.

  • Page 26: Calculating Setting Value Of Sensor Mounting Angle

    HW1485706 Setup of Hand Guiding Function Setting of Sensor Mounting Angle 3.7.2 Calculating Setting Value of Sensor Mounting Angle The angle when the tool coordinate is rotated so as to match the sensor coordinate is the input value. The clockwise viewed from the arrow is the forward direction.

  • Page 27: Setting Example Of Sensor Mounting Angle

    HW1485706 Setup of Hand Guiding Function Setting of Sensor Mounting Angle 3.7.3 Setting Example of Sensor Mounting Angle I084 (X): 0 I085 (Y): 0 I086 (Z): 45 I084 (X): 0 I085 (Y): 0 I086 (Z): 135 I084 (X): 0 I085 (Y): 0 I086 (Z): -135 I084 (X): 0 I085 (Y): 0...
  • Page 28 HW1485706 Setup of Hand Guiding Function Setting of Sensor Mounting Angle I084 (X): 0 I085 (Y): 180 I086 (Z): 135 I084 (X): 180 I085 (Y): 0 I086 (Z): 45 I084 (X): 180 I085 (Y): 0 I086 (Z): 135 I084 (X): -90 I085 (Y): 45 I086 (Z): 0 I084 (X): -90...
  • Page 29 HW1485706 Setup of Hand Guiding Function Setting of Sensor Mounting Angle I084 (X): -90 I085 (Y): -135 I086 (Z): 0 I084 (X): -90 I085 (Y): -45 I086 (Z): 0 I084 (X): 90 I085 (Y): 45 I086 (Z): 0 I084 (X): 90 I085 (Y): 135 I086 (Z): 0 I084 (X): 90...
  • Page 30 HW1485706 Setup of Hand Guiding Function Setting of Sensor Mounting Angle I084 (X): 90 I085 (Y): -45 I086 (Z): 0 I084 (X): 90 I085 (Y): 45 I086 (Z): 90 I084 (X): 90 I085 (Y): -45 I086 (Z): 90 I084 (X): -90 I085 (Y): -45 I086 (Z): -90 I084 (X): -90...
  • Page 31 HW1485706 Setup of Hand Guiding Function Setting of Sensor Mounting Angle I084 (X): -90 I085 (Y): 45 I086 (Z): 90 I084 (X): -90 I085 (Y): 135 I086 (Z): 90 I084 (X): -90 I085 (Y): -135 I086 (Z): 90 I084 (X): -90 I085 (Y): -45 I086 (Z): 90 I084 (X): 0...

  • Page 32: Setting Confirmation Of Sensor Mounting Angle

    HW1485706 Setup of Hand Guiding Function Setting of Sensor Mounting Angle 3.7.4 Setting Confirmation of Sensor Mounting Angle Refer to the following procedures to confirm whether the sensor mounting angle is set correctly. 1. Refer to chapter 4.6 “Register Output Function” to enable the register output function.

  • Page 33: Hand Guiding Function Execution Procedures

    HW1485706 Hand Guiding Function Execution Procedures Execution Conditions of Hand Guiding Function Hand Guiding Function Execution Procedures This chapter describes the execution procedures of the hand guiding function. Execution Conditions of Hand Guiding Function Executing the hand guiding function is required to satisfy the following conditions.

  • Page 34: Job Creation For Hand Guiding Function Execution

    HW1485706 Hand Guiding Function Execution Procedures Job Creation for Hand Guiding Function Execution Job Creation for Hand Guiding Function Execution There are two commands in the job necessary for executing the hand guiding function. • Turn the general output 4081 (#15110) OFF to ON. •...

  • Page 35: Mode

    HW1485706 Hand Guiding Function Execution Procedures Mode Mode There are following three mode switching functions in the hand guiding function. The robot operation methods and moving methods differ depending on the combination of each mode. Table 4-1: Mode Signal name Signal status Mode Overview General input...

  • Page 36: Inching Mode

    HW1485706 Hand Guiding Function Execution Procedures Mode 4.4.1.2 Inching Mode The inching mode allows the robot to move only for the set moving amount when applying force to the hand guiding device or when the I/O for the moving operation is ON by an I/O input. The followings describe each input mode.

  • Page 37: Translation/Rotation

    HW1485706 Hand Guiding Function Execution Procedures Mode 4.4.2 Translation/Rotation The robot operation method can be switched in the translation and the rotation. It is not possible to use the translation and the rotation simultaneously. 4.4.2.1 Translation Mode Follow the input (the force sensor input and the I/O input) to move the robot to the translation direction.

  • Page 38: Force Sensor/ I/O Input

    HW1485706 Hand Guiding Function Execution Procedures Mode 4.4.3 Force Sensor/ I/O Input The command method to the robot can be selected from the input from the force sensor and the I/O input such as a switch. 4.4.3.1 Force Sensor Input Mode Follow the force sensor input operation mounted on the hand guiding device to move the robot.

  • Page 39: Calibration Of Force Sensor

    HW1485706 Hand Guiding Function Execution Procedures Calibration of Force Sensor Calibration of Force Sensor Even if not applying force to the hand guiding device, the value of the force sensor will not be 0 due to the influence of gravity. Measure the value of the force sensor with not applying force to the hand guiding device.

  • Page 40: Register Output Function

    HW1485706 Hand Guiding Function Execution Procedures Register Output Function Register Output Function Setting the variable I074 to 1 allows the following information to output to the register. Variable Variable name Value range Initial value I074 Register output 0 - 1 If the value except for possible values is input, when the general output signal 4081 (#15110) is turned ON, the following alarm is displayed.
  • Page 41 HW1485706 Hand Guiding Function Execution Procedures Register Output Function Table 4-2: Register output list Register Contents Current X direction external force value (Calibration result is reflected.) [N] + 10000 Current Y direction external force value (Calibration result is reflected.) [N] + 10000 Current Z direction external force value (Calibration result is reflected.) [N] + 10000 Current Rx direction external force value...

  • Page 42: Risk Assessment

    HW1485706 Risk Assessment Assumed Risk Risk Assessment This chapter describes the assumed risk and risk reduction measures in an application of the hand guiding function. Assumed Risk This chapter describes the assumed risk on the collaborative operation of the hand guiding function. Other risks may also occur depending on the conditions such as a tool or environment.

  • Page 43: Risk Reduction Measures

    An intrusion of other workers to the work area during the hand guiding operation is detected, and the robot can be stopped. The safety measures described here are only examples. NOTE YASKAWA does not guarantee safety. HW1485706 43/58...

  • Page 44: User Variables And General I/O Signals To Be Used With Hand Guiding Function

    HW1485706 User Variables and General I/O Signals to be Used with Hand Guiding Function User Variable List User Variables and General I/O Signals to be Used with Hand Guiding Function User Variable List The user variables to be used with the hand guiding function are shown in table 6-1 “User Variable List”...
  • Page 45 HW1485706 User Variables and General I/O Signals to be Used with Hand Guiding Function User Variable List Table 6-1: User Variable List Variable Variable name Contents Unit Range Initial value I073 Filter coefficient Force value filtering coefficient 1 - 50 I074 Register output Register output switching...

  • Page 46: General I/O Signal List

    HW1485706 User Variables and General I/O Signals to be Used with Hand Guiding Function General I/O Signal List General I/O Signal List The general I/O signals to be used with the hand guiding function are shown in table 6-2 “General I/O List” . The I/O signals described in table 6-2 are used in the hand NOTE guiding function, and therefore they should not be used for...

  • Page 47: Ladder Program

    HW1485706 User Variables and General I/O Signals to be Used with Hand Guiding Function Ladder Program Ladder Program In addition to the standard ladder program, the ladder program for the hand guiding function is added upon shipment. The added ladder program for the hand guiding is as follows. This ladder program is a part of the system ladder, and therefore it cannot be edited.

  • Page 48: Troubleshooting

    HW1485706 Troubleshooting Robot Operating Method when Force Sensor Disconnected Troubleshooting This chapter describes the trouble handling method to be assumed for the hand guiding function. Robot Operating Method when Force Sensor Disconnected When retracting the robot while Alarm 0831 "force sensor communication state error"...
  • Page 49 HW1485706 Troubleshooting Robot Operating Method when Force Sensor Disconnected 3. Change the setting of “FORCE SEONSOR” for R1 from “○” (valid) to “- ” (invalid). 4. After pressing [ENTER], the confirmation dialog shows up. Select {YES} and press [ENTER]. 5. After setting to the safety mode, select in the following order: {FILE} - {INITIALIZE} - 'Functional Safety Board FLASH Reset'.
  • Page 50 HW1485706 Troubleshooting Robot Operating Method when Force Sensor Disconnected 6. After pressing [ENTER], the confirmation dialog shows up. Select {YES} and press [ENTER]. 7. After setting to the safety mode, select in the following order: {FILE} - {INITIALIZE} - 'Machine Safety Board FLASH Reset'. 8.

  • Page 51: Enabling Force Sensor

    HW1485706 Troubleshooting Robot Operating Method when Force Sensor Disconnected 7.1.2 Enabling Force Sensor 1. Start up the controller in the maintenance mode, and set the mode to the management mode. Select in the following order: {SYSTEM} - {SETUP} - {OPTION BOARD}. Move the cursor to “Interface466102” to open the Interface466102 setting window.
  • Page 52 HW1485706 Troubleshooting Robot Operating Method when Force Sensor Disconnected 3. Change the setting of “FORCE SEONSOR” for R1 from “-” (invalid) to “○” (valid). 4. After pressing [ENTER], the confirmation dialog shows up. Select {YES} and press [ENTER]. 5. After setting to the safety mode, select in the following order: {FILE} - {INITIALIZE} - 'Functional Safety Board FLASH Reset'.
  • Page 53 HW1485706 Troubleshooting Robot Operating Method when Force Sensor Disconnected 6. After pressing [ENTER], the confirmation dialog shows up. Select {YES} and press [ENTER]. 7. After setting to the safety mode, select in the following order: {FILE} - {INITIALIZE} - 'Machine Safety Board FLASH Reset'. 8.

  • Page 54: Robot Operating Method When Hand Guiding Device Disconnected

    HW1485706 Troubleshooting Robot Operating Method When Hand Guiding Device Disconnected Robot Operating Method When Hand Guiding Device Disconnected When the hand guiding device is not connected, the external emergency stop signal is always open and becomes in an emergency stop state. When operating the robot in the state that the hand guiding device is disconnected, follow the procedures below to short-circuit the emergency stop signal.

  • Page 55: Troubleshooting

    MotoPlus is deleted. Select {SYSTEM} - {VERSION} under the main menu, and press [PAGE] to confirm that the following MotoPlus is registered. HandGuiding AP018MP □□.□□A(JP)-□□ □ represents the version number. If the MotoPlus is deleted, contact your YASKAWA representatives. HW1485706 55/58...

  • Page 56: Alarm List

    (2) If an alarm occurs again, + Cause save the CMOS.BIN on the are shown. maintenance mode and contact Cause: your YASKAWA representative 1: ROM error about the situation such as 16: Watch-dog operating procedures when the Timeout is detected.
  • Page 57 HW1485706 Alarm List Table 8-1: Alarm List (Sheet 2 of 2) Alarm Alarm name Details Cause Countermeasure 8000 Parameter Setting Sub-code: xx Software Refer to chapter 6.1 “User error The number 0xx of the (Setting error) Variable List” , and set the I-variable is shown as the variable to the correct value.
  • Page 58 FOR HAND GUIDING FUNCTION 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 ) Yaskawastrasse 1, 85391 Allershausen, Germany...

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