YASKAWA DX200 Instructions Manual
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YASKAWA DX200 Instructions Manual

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See also: Operator's Manual , Instruction Manual
TOUCHSENSE, ACCUFAST and
ACCUFAST
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
YASKAWA INSTRUCTIONS
DX200 OPERATOR'S MANUAL
DX200 MAINTENANCE MANUAL
DX100 OPERATOR'S MANUAL
DX100 MAINTENANCE MANUAL
NX100 OPERATOR'S MANUAL
NX100 MAINTENANCE MANUAL
The operator's manual above corresponds to specific usage. Be sure to use the appropriate manual.
II
WITH MACRO JOBS
Part Number:
Revision:
166153-1CD
1
1 of 124

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  • Page 1 WITH MACRO JOBS INSTRUCTIONS Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. YASKAWA INSTRUCTIONS DX200 OPERATOR’S MANUAL DX200 MAINTENANCE MANUAL DX100 OPERATOR’S MANUAL DX100 MAINTENANCE MANUAL NX100 OPERATOR’S MANUAL NX100 MAINTENANCE MANUAL The operator’s manual above corresponds 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 DX200/DX100/ NX100. • General items related to safety are listed in Section 1 of the DX200/ DX100/NX100 instructions. To ensure correct and safe operation, carefully read the section before reading this manual.
  • Page 4 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 5 Failure to observe this caution may result in electric shock or injury. • For disassembly or repair, contact your YASKAWA representative. • Do not remove the motor, and do not release the brake. Failure to observe these safety precautions may result in death or serious injury from unexpected turning of the manipulator's arm.
  • Page 6 166153-1CD Notes for Safe Operation TouchSense, AccuFast, and AccuFast with Macro Jobs WARNING • Before operating the manipulator, check that servo power is turned OFF by pressing the emergency stop button on the programming pendant. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is OFF.
  • Page 7 166153-1CD Notes for Safe Operation TouchSense, AccuFast, and AccuFast with Macro Jobs WARNING • Since detected voltage (200V), welding current, and welding voltage are applied to the starting point detecting unit, install the unit securely so that it does not fall. •...
  • Page 8 DX200/DX100/NX100 Instructions before operating the manipulator. Definition of Terms Used Often in This Manual The YASKAWA Motoman manipulator is an industrial robot product. The manipulator usually consists of the controller, the programming pendant, and supply cables. In this manual, the equipment is designated as follows:...
  • Page 9 166153-1CD Description of the Operation Procedure TouchSense, AccuFast, and AccuFast with Macro Jobs Descriptions of the programming pendant, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters Pendant printed on them are denoted with [ ].
  • Page 10 WARNING Label A Nameplate Nameplate: WARNING Label A: WARNING MOTOMAN TYPE Moving parts MASS PAYLOAD may cause ORDER NO. DATE injury SERIAL NO. YASKAWA ELECTRIC CORPORATION JAPAN WARNING Label B: WARNING Do not enter robot work area. 166153-1CD 10 of 124...
  • Page 11 166153-1CD Safeguarding Tips TouchSense, AccuFast, and AccuFast with Macro Jobs Safeguarding Tips All operators, programmers, maintenance personnel, supervisors, and 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 12 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 a standard passwords and some require special passwords.
  • Page 13 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 YASKAWA Customer Support.
  • Page 14 Macro Jobs system, please contact YASKAWA Customer Support at the following 24-hour telephone number: (937) 847-3200 For routine technical inquiries, you can also contact YASKAWA Customer Support at the following e-mail address: techsupport@motoman.com When using e-mail to contact YASKAWA Customer Support, please provide a detailed description of your issue, along with complete contact information.

  • Page 15: Table Of Contents

    166153-1CD Table of Contents TouchSense, AccuFast, and AccuFast with Macro Jobs Table of Contents 1 Introduction ............................. 1-1 1.1 Overview..........................1-1 1.1.1 Seam Finding ....................... 1-2 1.1.2 Macro Jobs ......................1-3 1.2 Features ..........................1-4 1.2.1 Improved Control ....................1-4 1.3 About this Document ......................
  • Page 16 166153-1CD Table of Contents TouchSense, AccuFast, and AccuFast with Macro Jobs 4 TCH Macro, Two Touch (2TCH) Routine..................4-1 4.1 Features..........................4-1 4.1.1 Limitations......................4-2 4.2 AutoTeach Mode........................ 4-3 4.3 Macro Job Setup........................ 4-5 4.4 Interface ..........................4-7 4.5 Programming Instructions ....................4-8 5 EDGE: Edge Finding Routine ......................
  • Page 17 166153-1CD Table of Contents TouchSense, AccuFast, and AccuFast with Macro Jobs 8 Programming Suggestions......................8-1 8.1 Orientation ......................... 8-1 8.1.1 AccuFast Orientation .................... 8-1 8.1.2 AccuFast II Orientation..................8-2 8.2 Perpendicular Search Paths ....................8-4 8.3 Pattern Type and AutoTeach Descriptions ................ 8-6 8.3.1 Pattern Type 0 ......................
  • Page 18 166153-1CD Table of Contents TouchSense, AccuFast, and AccuFast with Macro Jobs 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job..........9-4 9.6.1 Program the user Frame to be used by the Macro Manager Function's Robot Job ............9-5 9.6.2 Set and Program the AccuFast - TCP - UPDATER Robot Job ......

  • Page 19: Introduction

    166153-1CD Introduction TouchSense, AccuFast, 1.1 Overview and AccuFast with Macro Jobs Introduction Overview A macro job is a job that runs in the background of the robot controller. Seam finding macro jobs are used to locate deviated weld seams, gaps, and edges.

  • Page 20: Seam Finding

    166153-1CD Introduction TouchSense, AccuFast, 1.1 Overview and AccuFast with Macro Jobs 1.1.1 Seam Finding In the most basic seam finding application, the robot begins a search motion from a pre-programmed start robot position towards the next programmed robot position. When the weldment is detected, either by touchsense or laser, a signal is immediately sent to the robot controller.

  • Page 21: Macro Jobs

    166153-1CD Introduction TouchSense, AccuFast, 1.1 Overview and AccuFast with Macro Jobs  Touch Sense For most welding applications, seam finding is performed using touch sense. With this technique, electrical power is provided by a welding power supply or an external touch sense box to either the welding electrode (welding wire) or the gas nozzle.

  • Page 22: Features

    About this Document This manual is intended as an introduction and overview for personnel who are familiar with the operation of their YASKAWA robot model and robot programming. This User’s Manual provides a description of functionality, usage instructions, as well as application examples for the Touch Sense, AccuFast, and AccuFast II function using macro jobs.

  • Page 23: System Requirements

    All DX controller software versions supported • Macro Job function enabled Learning Seam Finding with Macro Jobs YASKAWA provides a variety of options to help you learn to use TouchSense, AccuFast, and AccuFast II with Macro Jobs, including training and technical support.

  • Page 24: Setup And Operation

    Setting of the SICK sensor set point(s) must be done prior to programming the first seam finding routine. The standard YASKAWA mounting location places the laser beam at an angle relative to the welding torch so that the laser passes within 30mm of the tip of the welding wire (30mm from the TCP of the welding torch).

  • Page 25: Setting The Q1 Focal Length

    166153-1CD Setup and Operation TouchSense, AccuFast, 2.2 AccuFast and AccuFast with Macro Jobs 2.2.1 Setting the Q1 Focal Length: 1. For each AccuFast in the system, turn on the specified output to open the AccuFast's door. The laser light should already be on and a laser dot should become visible.
  • Page 26 166153-1CD Setup and Operation TouchSense, AccuFast, 2.2 AccuFast and AccuFast with Macro Jobs 9. While maintaining servo power and the 30mm separation, momentarily press the “Set” button on the laser sensor to set the “Q1” focal length. Once pressed, the LED for Q1 should flash once. 10.

  • Page 27: Accufast Ii

    “drift” in measurement accuracy. The standard YASKAWA mounting location places the laser beam at an angle relative to the welding torch so that the laser passes within 80mm of the tip of the welding wire (80mm from the TCP of the welding torch).
  • Page 28 166153-1CD Setup and Operation TouchSense, AccuFast, 2.3 AccuFast II and AccuFast with Macro Jobs 5. Jog the robot away from the part in world coordinates Z-DIRECTION ONLY until a 30mm change in the Z direction is noted (This will result in a 30mm separation between the part contact tip).

  • Page 29: Using The Zero Shift Function (If Temperature Variance Is A Concern)

    166153-1CD Setup and Operation TouchSense, AccuFast, 2.3 AccuFast II and AccuFast with Macro Jobs 2.3.2 Using the Zero Shift Function (If Temperature Variance is a Concern) 1. Position the sensor beam at a known, fixed distance. This position must be stored in the robot controller, as it will be the position used for zeroing in the future.

  • Page 30: Job Setup

    The macro jobs have the following setup sections: Table 2-1: R1-TCH Instruction Explanation ‘----------------------------------------- ‘-----DX-------------------------------- Controller '- --ver.2.0.0 ------------------------- Version '- --Yaskawa America Inc.-------- '----Motoman Robotic Div.-------- ‘----2013May06; TL---------------- Revision Date/Developer ‘----------------------------------------- '- For use with Touch Sensing ' - and/or 1D laser sensor ‘ '----------------------------------------- '---- Setup Section ...
  • Page 31 166153-1CD Setup and Operation TouchSense, AccuFast, 2.4 Job Setup and AccuFast with Macro Jobs Instruction Explanation ' LB7 = userframe number Value of user frame to be created SET LB007 0 '----------------------------------------- '- Setup Section ... complete --- '---------------------------------------- '---Do not modify below here--- To access the parameters associated with the macro instruction, the macro instruction should first be inserted into the robot job.
  • Page 32 166153-1CD Setup and Operation TouchSense, AccuFast, 2.4 Job Setup and AccuFast with Macro Jobs 6. Cursor to the parameter to change and press [SELECT]. 7. Type in the value desired to use and then press [ENTER] (or press [MODIFY] > [ENTER] in the case of a robot position). The value changes from UNREGIST to REGIST.

  • Page 33: Autoteach

    166153-1CD Setup and Operation TouchSense, AccuFast, 2.5 AutoTeach and AccuFast with Macro Jobs AutoTeach The AutoTeach feature is used to define the robot positions at the exact location of the part. During initial teaching, the Robot Position 1 is programmed near the surface desired to detect. The macro job is then ran in AutoTeach mode.

  • Page 34: Tch Macro, One Touch (1Tch) Routine

    166153-1CD TCH Macro, One Touch (1TCH) Routine TouchSense, AccuFast, 3.1 Features and AccuFast with Macro Jobs TCH Macro, One Touch (1TCH) Routine Features This section describes the TCH macro using One Touch (1TCH) routine. When using the One Touch routine, the robot moves from Robot Position 1 towards a Robot Position 2, stopping when the surface of the part is detected.

  • Page 35: Limitations

    166153-1CD TCH Macro, One Touch (1TCH) Routine TouchSense, AccuFast, 3.1 Features and AccuFast with Macro Jobs 3.1.1 Limitations The AutoTeach perpendicular mode (Search Type is set to 2) defines a search motion that is perpendicular to a surface, but for some applications there may not be enough room to use this detection mode (ie.

  • Page 36: Autoteach Mode

    166153-1CD TCH Macro, One Touch (1TCH) Routine TouchSense, AccuFast, 3.2 AutoTeach Mode and AccuFast with Macro Jobs AutoTeach Mode With the TCH macro in 1TCH routine, AutoTeach mode defines the exact location of the Robot Position 2. When AutoTeach mode is set to 1, the robot moves from the starting position (Robot Position 1) to Robot Position 2 while searching for the surface of the part.

  • Page 37: Macro Job Setup

    Table 3-1: R1-TCH Macro Setup Instruction Explanation ‘----------------------------------------- ‘-----DX-------------------------------- Controller '- --ver.2.0.0 ------------------------- Version '- --Yaskawa America Inc.-------- '----Motoman Robotic Div.-------- ‘----2013May06; TL---------------- Revision Date/Developer ‘----------------------------------------- '- For use with Touch Sensing ' - and/or 1D laser sensor ‘ '----------------------------------------- '---- Setup Section ...
  • Page 38 166153-1CD TCH Macro, One Touch (1TCH) Routine TouchSense, AccuFast, 3.3 Macro Job Setup and AccuFast with Macro Jobs Instruction Explanation ' LB7 = userframe number Value of user frame to be created SET LB007 0 '----------------------------------------- '- Setup Section ... complete --- '---------------------------------------- '---Do not modify below here--- 4.

  • Page 39: Interface

    166153-1CD TCH Macro, One Touch (1TCH) Routine TouchSense, AccuFast, 3.4 Interface and AccuFast with Macro Jobs Interface The 1TCH macro instruction argument setting screen contains the following controls. Fig. 3-4: Argument Settings R1-TCH (1 Dimension Search) Table 3-3: Argument Settings R1-TCH (1 Dimension Search) Name Description Default...

  • Page 40: Programming Instructions

    166153-1CD TCH Macro, One Touch (1TCH) Routine TouchSense, AccuFast, 3.5 Programming Instructions and AccuFast with Macro Jobs Programming Instructions 1. While in TEACH mode, open the robot weld job and select: [INFORM LIST] > {MACRO} > {R1-TCH}. Fig. 3-5: R1-TCH 2.
  • Page 41 166153-1CD TCH Macro, One Touch (1TCH) Routine TouchSense, AccuFast, 3.5 Programming Instructions and AccuFast with Macro Jobs Cursor to Robot Position 1. Jog the robot to the desired seam finding start position (note: the distance between the Robot Position 1 and the surface of the part defines the search window, which impacts effectiveness and cycle time) and press [MODIFY] >...

  • Page 42: Tch Macro, Two Touch (2Tch) Routine

    166153-1CD TCH Macro, Two Touch (2TCH) Routine TouchSense, AccuFast, 4.1 Features and AccuFast with Macro Jobs TCH Macro, Two Touch (2TCH) Routine Features This section describes the TCH macro when using Two Touch routine. The two touch (Search Type = 2) routine of the TCH macro is used to detect the location of a weld joint using two contact positions.

  • Page 43: Limitations

    166153-1CD TCH Macro, Two Touch (2TCH) Routine TouchSense, AccuFast, 4.1 Features and AccuFast with Macro Jobs Fig. 4-2: Argument Settings The AutoTeach mode has two sequential modes: 1- First Detection and 2- Lap Detection. After teaching the exact location for Robot Position 1 and the approximate locations of Robot Position 2 and Robot Position 3, the R1-TCH macro instruction is placed into First Detection mode (Auto Teach 1).

  • Page 44: Autoteach Mode

    166153-1CD TCH Macro, Two Touch (2TCH) Routine TouchSense, AccuFast, 4.2 AutoTeach Mode and AccuFast with Macro Jobs AutoTeach Mode As stated previously, the AutoTeach feature defines the exact location of Robot Position 2 and Robot Position 3. When AutoTeach is set to mode 1, the robot detects the exact position for Robot Position 2.
  • Page 45 166153-1CD TCH Macro, Two Touch (2TCH) Routine TouchSense, AccuFast, 4.2 AutoTeach Mode and AccuFast with Macro Jobs Playback of the Search Type =2 routine uses simpler motion than that of the AutoTeach modes. The robot moves to the Robot Position 1, then moves while searching for the Robot Position 2 position, next moves up the Robot Position 3, and then moves toward the lap surface while searching.

  • Page 46: Macro Job Setup

    Table 4-1: R1-TCH Macro Setup Instruction Explanation ‘----------------------------------------- ‘-----DX-------------------------------- Controller '- --ver.2.0.0 ------------------------- Version '- --Yaskawa America Inc.-------- '----Motoman Robotic Div.-------- ‘----2013May06; TL---------------- Revision Date/Developer ‘----------------------------------------- '- For use with Touch Sensing ' - and/or 1D laser sensor ‘ '----------------------------------------- '---- Setup Section ...
  • Page 47 166153-1CD TCH Macro, Two Touch (2TCH) Routine TouchSense, AccuFast, 4.3 Macro Job Setup and AccuFast with Macro Jobs Instruction Explanation ' LB7 = userframe number Value of user frame to be created SET LB007 0 '----------------------------------------- '- Setup Section ... complete --- '---------------------------------------- '---Do not modify below here--- 4.

  • Page 48: Interface

    166153-1CD TCH Macro, Two Touch (2TCH) Routine TouchSense, AccuFast, 4.4 Interface and AccuFast with Macro Jobs Interface The R1-TCH macro instruction has the following controls in the argument setting screen. Fig. 4-5: Argument Settings R1-TCH (2 Dimension Search) Table 4-3: Argument Settings R1-TCH Name Description Default...

  • Page 49: Programming Instructions

    166153-1CD TCH Macro, Two Touch (2TCH) Routine TouchSense, AccuFast, 4.5 Programming Instructions and AccuFast with Macro Jobs Programming Instructions 1. While in TEACH mode, from a robot job select: [INFORM LIST] > {MACRO} >{R1-TCH}. Fig. 4-6: R1-TCH Macro 2. Insert R1-TCH macro instruction into job [ENTER] or [INSERT] > [ENTER].
  • Page 50 166153-1CD TCH Macro, Two Touch (2TCH) Routine TouchSense, AccuFast, 4.5 Programming Instructions and AccuFast with Macro Jobs 6. When the part surface is detected, the robot stops and a message is displayed at the bottom of the teach pendant screen prompting the user to Modify Robot Pos 2, set TEACH to 2.

  • Page 51: Edge: Edge Finding Routine

    166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.1 Features and AccuFast with Macro Jobs EDGE: Edge Finding Routine Features The EDGE macro is used to detect the location of an edge on a flat surface. Several different pattern types are available to assist in the detection of the surface’s edge.

  • Page 52: Limitations

    166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.2 Limitations and AccuFast with Macro Jobs Fig. 5-2: EDGE with Gap Detection Taught Location O r i g i n a l P r o g r a m a r t Middle of Gap v i a t e d...

  • Page 53: Macro Job Setup

    Jobs Macro Job Setup New systems from YASKAWA that includes either the Touch Sense option or the AccuFast or AccuFast II options, the EDGE routine should already be placed into the robot controller. To verify that the macro job is available in the controller (1) switch to MANAGEMENT mode and then, from the MAIN MENU, press {JOB} >...
  • Page 54 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.3 Macro Job Setup and AccuFast with Macro Jobs Instruction Explanation ' LI0 = non search speed Speed value for robot to use during air moves. Units mm/sec. SET LI000 3000 max= 3000 of user frame to be created.

  • Page 55: Interface

    166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.4 Interface and AccuFast with Macro Jobs Interface The EDGE macro instruction has the following controls inside the argument setting screen. Fig. 5-3: Argument Settings R1-Edge Table 5-2: Argument Settings R1-Edge Name Description Setting;...
  • Page 56 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.4 Interface and AccuFast with Macro Jobs Table 5-2: Argument Settings R1-Edge Name Description Setting; Setting: Allowable Range Default Step Offset Distance between steps/size of (0-100) each step of motion. Also, the distance between searches when searching for Robot Position 2 Depth...
  • Page 57 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.4 Interface and AccuFast with Macro Jobs When using Pattern Type 2 or Pattern Type 3, the EDGE mode uses three contact positions to detect the location and orientation of the part's surface, followed by a fourth touch to execute search motion perpendicular to the part surface.

  • Page 58: Programming

    166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.5 Programming and AccuFast with Macro Jobs Programming Programming consists of three elements: (1) insert macro instruction into robot job and set arguments, (2) teach exact position of Robot Positions (this is typically done semi-automatically using AutoTeach mode) and (3) setting the macro instruction to playback mode and deploying shift amounts for the weld path.
  • Page 59 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.5 Programming and AccuFast with Macro Jobs Verify arguments are set properly for the application. To modify arguments; cursor to argument, press [SELECT], type in the numerical data, and press [ENTER]. Set the value of the Pattern Type argument for desired application.

  • Page 60: Autoteach

    166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs AutoTeach As stated previously, the AutoTeach feature defines the exact location of the Robot Position 2 and Robot Position 3. When AutoTeach is set to mode 1, the robot detects the exact position for Robot Position 2. When AutoTeach is set to mode 2, the robot detects the exact position for Robot Position 3.

  • Page 61: Autoteach 1 (Robot Position 2)

    166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs 5.6.1 AutoTeach 1 (Robot Position 2) AutoTeach mode 1 locates the exact location for Robot Position 2 by executing the following sequence: 1. Robot will touch or drag the surface three times to define the location and orientation of the part's surface.
  • Page 62 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs  Examples The following diagrams show the AutoTeach function with each pattern type available: Fig. 5-8: Pattern Type 0, AutoTeach 1 Robot Position1 Robot Position 2 (Initial) Robot Position 2 (After AutoTeach1)
  • Page 63 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs Fig. 5-10: Pattern Type 2, AutoTeach 1 Robot Position 1 Robot Position 2 (Initial) Robot Position 2 (After AutoTeach1) Robot Position 3 Fig. 5-11: Pattern Type 3, AutoTeach 1 Robot Position 1 Robot Position 2 (Initial)
  • Page 64 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs Fig. 5-12: Pattern Type 4, AutoTeach 1 Robot Positon 1 Robot Position 2 (Initial) Robot Positon 2 (After AutoTeach1) Robot Position 3 Fig. 5-13: Pattern Type 5, AutoTeach 1 Robot Position 1 Robot Postion 2 (After AutoTeach1)

  • Page 65: Autoteach 2 (Robot Position 3)

    166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs 4. Save the above data to the robot job by pressing [ENTER] > [ENTER]. 5.6.2 AutoTeach 2 (Robot Position 3) AutoTeach mode 2 locates the exact location for Robot Position 3 by executing the following sequence: 1.
  • Page 66 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs  Parameters The Search Distance argument defines the allowable distance of the calculated shift amount. The robot develops search motion so it does not search excessively beyond the Search Distance amount. The exact definition of the Search Distance amount is shown in the following three figures: Fig.
  • Page 67 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs Fig. 5-19: EDGE with Gap Search Distance Robot Position 1 Robot Position 2 Detected Gap Robot Position 3  Examples The following diagrams show the AutoTeach function with each pattern type available: Fig.
  • Page 68 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs Fig. 5-21: Pattern Type 1, AutoTeach 2, Step Offset 0 Robot Postion 1 Depth Robot Position 2 Robot Position 3 (After AutoTeach2) Robot Position 3 (Initial) Fig.
  • Page 69 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs Fig. 5-23: Pattern Type 2, AutoTeach 2 Robot Position 1 Robot Position 2 Middle of Gap Robot Position 3 (Initial) Fig. 5-24: Pattern Type 3, AutoTeach 2, StepOffset = 0 Robot Position 1 Depth Robot Position 2...
  • Page 70 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs Fig. 5-25: Pattern Type 3, AutoTeach 2, Step Offset >0 Robot Position 1 Depth Robot Position 2 Middle of Gap Robot Position 3 (Initial) Fig. 5-26: Pattern Type 4, AutoTeach 2 Robot Position 1 Robot Positon 3 Robot Position 2...
  • Page 71 166153-1CD EDGE: Edge Finding Routine TouchSense, AccuFast, 5.6 AutoTeach and AccuFast with Macro Jobs Fig. 5-27: Pattern Type 5, AutoTeach 2, Step Offset = 0 Robot Postion 1 Depth Robot Postion 2 Robot Positon 3 (After AutoTeach2) Robot Positon 3 (Initial) Fig.
  • Page 72 Calculations (combining/partitioning shift amounts) may be needed in order to develop the necessary shift amount for NOTE the weld seam. Such calculations are outside the scope of this manual. YASKAWA offers training classes that covers these types of scenarios. 166153-1CD 5-22...

  • Page 73: R1 Circle: Circle Touch Routine

    166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.1 Features and AccuFast with Macro Jobs R1 CIRCLE: Circle Touch Routine Features The R1CIRCLE macro detects positional deviations for curved (constant radius) surfaces. A part’s center of curvature (i.e. the center of a circle) is calculated using three detected positions along the surface of the curved part.

  • Page 74: Limitations

    166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.2 Programming Requirements and AccuFast with Macro Jobs 6.1.4 Limitations The CIRCLE routine works only on circles that lie perpendicular to either the XY, YZ, or XZ plane. Cylinders/cylindrical surfaces where the axis of the cylinder is not perpendicular to the X, Y or Z axis of Base Frame are not supported by the macro.

  • Page 75: Job Setup

    Table 6-1: R1 Circle Macro Setup Instruction Explanation ‘----------------------------------------- ‘-----DX-------------------------------- Controller '- --ver.2.0.0 ------------------------- Version '- --Yaskawa America Inc.-------- '----Motoman Robotic Div.-------- ‘----2013May06; TL---------------- Revision Date/Developer ‘----------------------------------------- '- For use with Touch Sensing ' - and/or 1D laser sensor ‘...
  • Page 76 166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.3 Job Setup and AccuFast with Macro Jobs Instruction Explanation ‘ Dar Output for Diameter Diameter measurement of circle out put number ‘ Measurement Set LB003 99 '----------------------------------------- '- Setup Section ... complete --- '---------------------------------------- '---Do not modify below here--- '----------------------------------------...

  • Page 77: Interface

    166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.4 Interface and AccuFast with Macro Jobs Interface The R1CIRCLE macro instruction includes the following controls inside the argument setting screen. Fig. 6-2: Argument Settings R1Circle Table 6-3: Argument Settings R1Circle Argument Name Description Default Allowable Setting Range Setting...
  • Page 78 166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.4 Interface and AccuFast with Macro Jobs Table 6-3: Argument Settings R1Circle Argument Name Description Default Allowable Setting Range Setting Circle Diameter Diameter of circle being searched. The value of minimum of 1 this argument should be set to as close to the actual diameter of the curved surface as possible in order to provide for accurate qualification of the...

  • Page 79: Programming

    166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.5 Programming and AccuFast with Macro Jobs Programming 6.5.1 Programming AutoTeach for the R1CIRCLE Macro 1. Insert R1CIRCLE macro instruction into the robot job. The R1CIRCLE macro can be accessed from pressing [INFORM LIST] and then {MACRO}.

  • Page 80: Setup Macro Instruction And Detect Robot Position 1

    166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.5 Programming and AccuFast with Macro Jobs 6.5.1.1 Setup Macro Instruction and Detect Robot Position 1 1. Cursor to Auto Teach. Enter 1 in the input field and press [ENTER]. 2. Teach the initial positions for the three Robot Positions. Jog the robot to the approximate position of Robot Position 1 in the diagram below.
  • Page 81 166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.5 Programming and AccuFast with Macro Jobs Program the three robot positions at a consistent height. NOTE Avoid having one robot position lower or higher than the other two. Fig. 6-6: Consistent Programming Height INCORRECT CORRECT Program the initial robot position as close as possible to the...
  • Page 82 166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.5 Programming and AccuFast with Macro Jobs Set the Outside=0, Inside=1 parameter to the value correct for the part being programmed. If programming an inside circle, where the robot positions are programmed between the detection surface and the center of the circle, set this parameter to 1.

  • Page 83: Detect Robot Position 2

    166153-1CD R1 CIRCLE: Circle Touch Routine TouchSense, AccuFast, 6.5 Programming and AccuFast with Macro Jobs 6.5.1.2 Detect Robot Position 2 Open the Argument Setting screen by pressing [SELECT] > [SELECT] from the instruction side of the macro instruction. Modify Robot Position 2, set Auto Teach Mode to 2 and press [ENTER] >...

  • Page 84: Application Examples

    166153-1CD Application Examples TouchSense, AccuFast, 7.1 T-Joint and AccuFast with Macro Jobs Application Examples T-Joint In order to account for variations at the end of a part, a 1TCH routine in tandem with a 2TCH routine can account for three dimensional variation. This process uses the 1TCH routine to detect the edge of the plate.
  • Page 85 166153-1CD Application Examples TouchSense, AccuFast, 7.1 T-Joint and AccuFast with Macro Jobs The 1TCH routine, in this example, detects variations in the Part Variation direction shown in the figure. Results of 1TCH routine are saved to P variable P000. This shift amount is then used to shift the 2TCH routine. Fig.

  • Page 86: Cylinder To Plate

    166153-1CD Application Examples TouchSense, AccuFast, 7.2 Cylinder to Plate and AccuFast with Macro Jobs Cylinder to Plate The 1TCH routines used to detect vertical variations of the plate. This shift amount is then input into the R1CIRCLE routine, shifting this routine vertically.
  • Page 87 166153-1CD Application Examples TouchSense, AccuFast, 7.2 Cylinder to Plate and AccuFast with Macro Jobs Fig. 7-3: Part Variation The 1TCH routine, in this example, detects variations in the Part Variation direction shown in the figure. Results of 1TCH routine are saved to P variable P000.

  • Page 88: Programming Suggestions

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.1 Orientation and AccuFast with Macro Jobs Programming Suggestions Orientation 8.1.1 AccuFast Orientation Fig. 8-1: AccuFast Orientation (Lap Weld) Better Fig. 8-2: AccuFast Orientation (Reflective Surface) Reflective Surface Reflective Surface Not Ideal Better 166153-1CD 88 of 124...

  • Page 89: Accufast Ii Orientation

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.1 Orientation and AccuFast with Macro Jobs Fig. 8-3: Touch Sense Over AccuFast Use Touch Sense Instead of AccuFast 8.1.2 AccuFast II Orientation Fig. 8-4: AccuFast II Orientation (Lap Weld) Better 166153-1CD 89 of 124...
  • Page 90 166153-1CD Programming Suggestions TouchSense, AccuFast, 8.1 Orientation and AccuFast with Macro Jobs Fig. 8-5: AccuFast II Orientation (Reflective Surface) Reflective Surface Reflective Surface Not Ideal Better Fig. 8-6: Touch Sense Over AccuFast II Use Touch Sense Instead of AccuFast II 166153-1CD 90 of 124...

  • Page 91: Perpendicular Search Paths

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.2 Perpendicular Search Paths and AccuFast with Macro Jobs Perpendicular Search Paths Another often overlooked problem occurs when search motion is not perpendicular to the surface of the part, or when offsets are added together but the motions associated with these searches are not mutually perpendicular.
  • Page 92 166153-1CD Programming Suggestions TouchSense, AccuFast, 8.2 Perpendicular Search Paths and AccuFast with Macro Jobs  Keep search motion perpendicular to the surface of the part As long as the previous rule is not contradicted (where all search motion must be perpendicular to each other, when wishing to combine shift amounts), keep search motion perpendicular to the surface of the part.

  • Page 93: Pattern Type And Autoteach Descriptions

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs Pattern Type and AutoTeach Descriptions 8.3.1 Pattern Type 0 8.3.1.1 AutoTeach 1 AutoTeach 1 is used to redefine Robot Position 2. Fig. 8-9: Pattern Type 0, AutoTeach 1 Robot Position1 Robot Position 2 (Initial)

  • Page 94: Autoteach 0

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.1.3 AutoTeach 0 Fig. 8-11: Pattern Type 0, AutoTeach = 0 (Playback) Robot Position 1 O r i Robot Position 2 g i n v i a a l P t e d...

  • Page 95: Autoteach 2

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.2.2 AutoTeach 2 AutoTeach 2 is used to redefine Robot Position 3. Fig. 8-13: Pattern Type 1, AutoTeach 2 Robot Position 1 Depth Robot Position 2 Robot Position 3 (After AutoTeach2) Robot Position 3...

  • Page 96: Pattern Type 2

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.3 Pattern Type 2 8.3.3.1 AutoTeach 1 AutoTeach 1 is used to redefine Robot Position 2. Fig. 8-15: Pattern Type 2, AutoTeach 1 Robot Position 1 Robot Position 2 (Initial) Robot Position 2...

  • Page 97: Autoteach 0

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.3.3 AutoTeach 0 Fig. 8-17: Pattern Type 2, AutoTeach = 0 (Playback) Robot Position 1 Robot Position 2 O r i g i n a l P r o g r a m...

  • Page 98: Autoteach 2

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.4.2 AutoTeach 2 AutoTeach 2 is used to redefine Robot Position 3. Fig. 8-19: Pattern Type 3, AutoTeach 2 Robot Position 1 Depth Robot Position 2 Middle of Gap Robot Position 3 (Initial)

  • Page 99: Pattern Type 4

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.5 Pattern Type 4 8.3.5.1 AutoTeach 1 AutoTeach 1 is used to redefine Robot Position 2. Fig. 8-21: Pattern Type 4, AutoTeach 1 Robot Positon 1 Robot Position 2 (Initial) Robot Positon 2...

  • Page 100: Autoteach 0

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.5.3 AutoTeach 0 Fig. 8-23: Pattern Type 4, AutoTeach = 0 (Playback) Robot Position 1 v i a Robot Position 2 t e d 8.3.6 Pattern Type 5 8.3.6.1 AutoTeach 1 AutoTeach 1 is used to redefine Robot Position 2.

  • Page 101: Autoteach 2, Step Offset 0

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.6.2 AutoTeach 2, Step Offset 0 AutoTeach 2 is used to redefine Robot Position 3. Fig. 8-25: Pattern Type 5, AutoTeach 2, Step Offset = 0 Robot Postion 1 Depth Robot Postion 2...

  • Page 102: Autoteach 0

    166153-1CD Programming Suggestions TouchSense, AccuFast, 8.3 Pattern Type and AutoTeach Descriptions and AccuFast with Macro Jobs 8.3.6.4 AutoTeach 0 Fig. 8-27: Pattern Type 5, AutoTeach = 0 (Playback) Robot Position 1 Depth v i a t e d 166153-1CD 8-15 102 of 124...

  • Page 103: Target For Tcp Update For Accufast Or Accufast Ii

    Target for TCP Update for AccuFast or AccuFast II Requirements It is under the assumption that the user has knowledge of YASKAWA “Touch Sense, AccuFast, and AccuFast II Macro Jobs” functions; mostly the R1-EDGE macro instructions including its uses, programming procedure, and association parameter settings.

  • Page 104: Breakdown Of Procedure

    166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.4 Breakdown of Procedure and AccuFast with Macro Jobs  Semi-Automatic User needs to create a TCP (i.e Tool#1) for AccuFast or AccuFast II while it is mounted in its original location. This could be done using the traditional 5 point method.

  • Page 105: Detailed Usage

    166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.5 Detailed Usage and AccuFast with Macro Jobs Detailed Usage • Mount target on a secure surface. • Mount the target securely on a surface that is easily reachable by the robot.

  • Page 106: Adjust Settings Of Accufast - Tcp - Updater Robot Job

    166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job and AccuFast with Macro Jobs Adjust Settings of ACCUFAST - TCP - UPDATER robot job ‘Adjust setting values at the top of the robot job as needed for the application that AccuFast or AccuFast II is being used for.

  • Page 107: Program The User Frame To Be Used By The Macro Manager Function's Robot Job

    166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job and AccuFast with Macro Jobs Table 9-1: Parameters Variable Parameter Name Default Value Description LI003 P variable #; saved tool LI016 P variable #;...

  • Page 108: Set And Program The Accufast - Tcp - Updater Robot Job

    166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job and AccuFast with Macro Jobs 2. Program the XX and XY of the User Frame as shown Fig. 9-2 “Programing the XX and XY of the User Frame”.
  • Page 109 166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job and AccuFast with Macro Jobs 4. Change the necessary value for the application. • LI003 • Pvar# for Saved Tool •...
  • Page 110 166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job and AccuFast with Macro Jobs 5. Set the User Frame number used above in the first section of the instructions.
  • Page 111 166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job and AccuFast with Macro Jobs 7. Program the MOVJ positions labeled Program Position and the first R1-EDGE macro instruction labeled “Block, UF XX - Far.” It is recommended to program the MOVJ position in the same area that the Robot Position 1 or the R1-EDGE macro is programmed.
  • Page 112 166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job and AccuFast with Macro Jobs 8. Program the second R1-EDGE macro instruction labeled “Block, UF XX - Close.” It's recommended to program to program MOVJ position in the same area that the Robot Position 1 of the R1-EDGE macro is programmed.
  • Page 113 166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.6 Adjust Settings of ACCUFAST - TCP - UPDATER robot job and AccuFast with Macro Jobs 9. Program the third R1-EDGE macro instruction labeled “Block, UF XY.” It is recommended to program the MOVJ position in the same area that the Robot Position 1 of the R1-EDGE macro is programmed.

  • Page 114: Run The Robot Job In Train Mode

    166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.7 Run the Robot Job in Train Mode and AccuFast with Macro Jobs Run the Robot Job in Train Mode 1. Open the job named ACCUFAST - TCP - UPDATER - MASTER. 2.
  • Page 115 166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.7 Run the Robot Job in Train Mode and AccuFast with Macro Jobs 3. Set the ACCUFAST - TCP - UPDATER jobs ARGUMENT #1 to a value of 0, for Train mode. •...
  • Page 116 166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.7 Run the Robot Job in Train Mode and AccuFast with Macro Jobs 4. Set the ACCUFAST - TCP - UPDATER jobs ARGUMENT #2 to the B variable number desired to save the success/fail result to. Example: ARGUMENT #2 set to a value of 4, thus B004 is set to provide the success/fail status of the robot job.

  • Page 117: Run The Robot Job In Calc Mode

    166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.8 Run the Robot Job in Calc Mode and AccuFast with Macro Jobs Run the Robot Job in Calc Mode 1. Set the ACCUFAST - TCP - UPDATER job's ARGUMENT #1 to a value of 0, for the Calculate Offset Mode.

  • Page 118: Tcp Detection Mode (Optional)

    166153-1CD Target for TCP Update for AccuFast or AccuFast II TouchSense, AccuFast, 9.10 TCP Detection Mode (Optional) and AccuFast with Macro Jobs 9.10 TCP Detection Mode (Optional) 1. Open the job named ACCUFAST - TCP - UPDATER - MASTER. 2. Cursor to the CALL JOB:ACCUFAST - TCP - UPDATER instruction. 3.

  • Page 119: Arg Target Values

    166153-1CD Appendix A TouchSense, AccuFast, A.1 ARG Target Values and AccuFast with Macro Jobs Appendix A ARG Target Values Table A-1: ARG Values Value of Description Comment ARG.1 Calculate Offset The routines measures the calculated TCP offset and writes the “before” and “after” data into the Tool Files.

  • Page 120: Value B Variables

    166153-1CD Appendix B TouchSense, AccuFast, B.1 Value B Variables and AccuFast with Macro Jobs Appendix B Value B Variables The second argument (JOB ARGUMENT > ARG 2) of the robot job ACCUFAST - TCP - UPDATER sets the address of a B Variable. This B variable is given a value on the success/failure state of the robot job.

  • Page 121: Accufast Verify Routine (Optional Function

    166153-1CD Appendix C TouchSense, AccuFast, C.1 AccuFast Verify Routine (Optional Function) and AccuFast with Macro Jobs Appendix C AccuFast Verify Routine (Optional Function) C.1.1 Overview This a robot job that was written for the user to be able to see AccuFast is experiencing a “drift”...
  • Page 122 166153-1CD Appendix C TouchSense, AccuFast, C.1 AccuFast Verify Routine (Optional Function) and AccuFast with Macro Jobs 166153-1CD 122 of 124...

  • Page 123: Accufast Ii Recommended Spare Parts

    177098-1 Cable Assy, Accufast II Sensor YASKAWA 176906-1 Cable Assy, AccuFast II, Power, I/O YASKAWA 177315-1 Cable Assy, Amplifier, AccuFast II, Sensor Head YASKAWA 177326-1 Cable Assy, Air Valve, AccuFast II YASKAWA 176876-1 Valve, Air, 3-way, No, 24VDC 35A-AEA-DDAJ-1KG 176910-1...
  • Page 124 INSTRUCTIONS 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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