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Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
147855-1
June 17, 2003
1
Final
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Table of Contents
Related Manuals for YASKAWA Motoman ArcWorld IV-6200 XHD DR2C
Summary of Contents for YASKAWA Motoman ArcWorld IV-6200 XHD DR2C
- Page 1 /QVQOCP :4% %QPVTQNNGT #TE9QTNF +8 :*& &4% 5[UVGO /CPWCN HQT 725GTKGU 4QDQVU Part Number: 147855-1 Release Date: June 17, 2003 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...........................iv LIST OF TABLES ..........................v INTRODUCTION About this Document ....................1-1 System Overview ......................1-2 1.2.1 System Layout ....................1-3 1.2.2 Major Components ..................1-3 1.2.3 Optional Equipment ..................1-3 Reference to Other Documentation................1-4 Customer Service Information .................. -
Page 4: Section Page
Section Page 3.6.4 Safety Light Curtains ..................3-14 3.6.5 ENABLE Switch ..................... 3-14 3.6.6 Interlocked Cell Door ..................3-15 3.6.7 Interference Cubes ..................3-15 3.6.8 Brake Release ....................3-15 3.6.9 Emergency Stops (E-STOPS) ................ 3-16 INSTALLATION Materials Required......................4-1 4.1.1 Customer-Supplied Items ................ - Page 5 Section Page 4.14 Installing the Light Curtain System................4-31 4.14.1 Light Curtain Installation ................4-31 4.14.2 Installing the Light Curtain Cable ..............4-32 4.15 Installing the Operator Station ..................4-33 4.15.1 Connecting the Operator Station ..............4-33 4.16 Connecting the Power....................4-34 4.17 System Check –...
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Page 6: List Of Figures
LIST OF FIGURES Figure Page Figure 1-1 System Layout......................1-2 Figure 3-1 DR2C XRC 2001 Controller – R1 and R2 ..............3-1 Figure 3-2 External Axis Cabinet Components ................3-2 Figure 3-3 XRC 2001 Playback Panel..................3-3 Figure 3-4 Programming Pendant ....................3-4 Figure 3-5 RS-232C Serial Port.................... - Page 7 LIST OF FIGURES (continued) Figure Page Figure 4-32 Install Top Door Rail ....................4-29 Figure 4-33 Install Final Door Rail....................4-30 Figure 4-34 Securing the Arc Curtains ..................4-30 Figure 4-35 Light Curtain Sensor Installation................4-31 Figure 4-36 Light Curtain Alignment/Cable Routing..............4-32 Figure 4-37 Operation Station Installation ..................
- Page 8 NOTES ArcWorld IV-6200 XHD DR2C System Manual MOTO MAN...
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Page 9: Introduction
SECTION 1 INTRODUCTION The ArcWorld IV-6200 XHD DR2C (Dual Robot, Two Controller) cell 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 ArcWorld IV-6200 XHD DR2C cell features two Motoman arc welding robots, two XRC 2001 controllers with menu-driven arc welding application software, two complete welding packages, a 180-degree reciprocating plane... -
Page 10: System Overview
INTRODUCTION System Overview The ArcWorld IV-6200 XHD DR2C provides a complete arc welding solution in a standardized configuration. The system is designed around two Motoman arc welding robots, two XRC 2001 controllers functioning as one, and includes two complete welding packages. A dual-station, 180-degree reciprocating positioner with rotating headstock allows an operator to prepare and set up parts on one side while the robot welds on the other side. -
Page 11: System Layout
INTRODUCTION 1.2.1 System Layout The robotic cell is fully enclosed by safety fencing and an interlocking door. If the operator stands in the path of the light curtain, the positioner will not cycle. All operator controls, including those on the XRC 2001 controllers and welding power supplies, are accessible from outside the robotic enclosure. -
Page 12: Reference To Other Documentation
INTRODUCTION Reference to Other Documentation For additional information refer to the following: • Motoman UP6 Manipulator Manual (P/N 145960-1) • Motoman UP20 Manipulator Manual (P/N 145965-1) • Motoman UP20-6 Manipulator Manual (P/N 145962-1) • Motoman MRM2-750 S3X Positioner Manual (P/N 147988-1) •... -
Page 13: 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 14: 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 15: 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 16: Installation Safety
SAFETY Installation Safety Safe installation is essential for protection of people and equipment. 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 17: Operation Safety
SAFETY • Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this robot should be permitted to operate the system. • Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. -
Page 18: 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 19: Equipment Description
SECTION 3 EQUIPMENT DESCRIPTION UP-series Robot Description The Motoman UP6, UP20, and UP20-6 robots and the XRC 2001 robotic controller represent state-of-the-art technology in robotics today. The six-axis UP6 robot has a payload of 6 kg (13.2 lbs). It features a 1,373-mm (54.05-inch) reach and has a relative positioning accuracy of ±... -
Page 20: Top-Mount External Axis Cabinet
EQUIPMENT DESCRIPTION DR2C Conversion The DR2C can be reconfigured from the dual robot system, with the Master XRC 2001 controlling system operation, to two separate robotic systems with independent control (see Motoman DR2C Conversion Instructions, XRC 2001 P/N 146822-1). For more information, please call the Motoman service staff at (937) 847-3200. -
Page 21: Playback Panel
EQUIPMENT DESCRIPTION 3.2.2 Playback Panel The playback panel (see Figure 3-3) 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. ALARM MODE INDICATOR BUTTONS E-STOP SERVO ON MODE... -
Page 22: Programming Pendant
EQUIPMENT DESCRIPTION Edit Lock The EDIT LOCK key switch, when turned on, prevents editing of system/ controller files and programs. The operator is limited to only viewing files and jogging the robot axes. The EDIT LOCK key can only be removed from the lock when it is in the ON position. - Page 23 EQUIPMENT DESCRIPTION Emergency Stop (E-STOP) The E-STOP button on the programming pendant is connected in series with the system Emergency Stop circuit. Pressing the E-STOP button interrupts this circuit and stops all system operation. Status Area The Status Area shows system status via the following symbols: •...
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Page 24: Figure 3-5 Rs-232C Serial Port
EQUIPMENT DESCRIPTION Area Key The Area key moves the cursor to the different areas of the display screen. Cursor Key The Cursor key is an 8-way, directional key that moves up, down, left or right to highlight a desired item that can then be chosen using the SELECT key. SELECT Key The SELECT key is used to choose the item currently highlighted by the cursor. -
Page 25: Brake Release
EQUIPMENT DESCRIPTION 3.2.4 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 the operator to release the automatic brakes on the robot in case of an emergency or robot failure. - Page 26 EQUIPMENT DESCRIPTION EMERGENCY STOP (E-STOP) Pressing an E-STOP button or interrupting a door interlock stops all system operation. Brakes are applied to the robot and all servo power is removed from the system. The system E-STOP lights illuminate and all positioner motion is stopped. The operator station E-STOP, the robot E-STOP, and the sliding door interlocks are connected in series in the Emergency Stop circuit.
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Page 27: Mrm2-750 S3X Positioner
EQUIPMENT DESCRIPTION RESET Pressing RESET clears a minor alarm or error. The RESET button is connected to the robot alarm reset input and is always active. SERVO ON The SERVO ON pushbutton enables servo power. In TEACH mode, the SERVO ON pushbutton operates only when the ENABLE switch on the programming pendant is held in. -
Page 28: Welding Ground System
EQUIPMENT DESCRIPTION Table 3-1 Positioner Specifications - continued Conditions Specifications Welding Capacity 2 x 920A (60%) Positioning Accuracy ± 0.1 mm (± .003 in.) Maximum Unbalance 300 kg (661 lbs) Distance between headstock 3.0 meters (118 in.) and tailstock 3.4.1 Welding Ground System The welding ground system consists of four spring-loaded copper brushes that contact a copper disc inside each headstock assembly. -
Page 29: Welding Equipment
EQUIPMENT DESCRIPTION Welding Equipment In its standard configuration, the ArcWorld IV-6200 XHD DR2C system includes a power source, wire feeder, torch, and torch mount. Optional equipment, including water circulators, Com-Arc units, and torch tenders may be included to enhance performance. 3.5.1 Wire Feeder The wire feeder in the welding package is selected to match the welder. -
Page 30: Power Sources
EQUIPMENT DESCRIPTION 3.5.4 Power Sources Motoman offers several different power sources for use with the ArcWorld IV- 6200 XHD DR2C system, depending on your system’s application. The following are some of the more common power sources used (see Figure 3-8). For more specific information, refer to the vendor manual that came with your system. -
Page 31: Safety Features
EQUIPMENT DESCRIPTION Safety Features The ArcWorld system includes a total safety environment. When all standard safety precautions are taken, the safety equipment helps to ensure safe operation of the robotic cell. The ANSI/RIA R15.06 Robot Safety Standard stipulates the user is responsible for safeguarding. -
Page 32: Arc Screens
EQUIPMENT DESCRIPTION 3.6.2 Arc Screens WARNING! Although the arc curtain blocks dangerous arc radiation, never look directly at the arc without protective eye wear! Two arc screens are used on the ArcWorld IV-6200 XHD DR2C cell. The first are the metal arc shields on the positioner. These shields block arc radiation and sparks from the welding operation. -
Page 33: Interlocked Cell Door
EQUIPMENT DESCRIPTION 3.6.6 Interlocked Cell Door A safety interlock on the cell entrance door prevents entry into the cell during PLAY mode. Opening the cell door with the robot in PLAY causes servo power to be removed and brakes applied to the robot. All positioner motion is stopped. To turn servos back on and resume job, proceed as follows: 1. -
Page 34: Emergency Stops (E-Stops)
EQUIPMENT DESCRIPTION 3.6.9 Emergency Stops (E-STOPS) Emergency E-STOPS are operator-actuated devices that, when activated, immediately stop all system operation. Brakes are applied to the robot and all servo power is removed from the system. The system E-STOP lights illuminate and all positioner motion is stopped. The following is a list of their locations: •... -
Page 35: Installation
SECTION 4 INSTALLATION The ArcWorld IV-6200 XHD DR2C system can be installed easily in just a short time by three workers. The more people involved (within reason), the more quickly installation can be completed. Follow established safety procedures at all times throughout the installation process. -
Page 36: Cell Components
INSTALLATION 4.1.3 Cell Components There are six major components that make up the ArcWorld IV-6200 XHD DR2C cell (see Figure 4-1). The component names and quantities are as follows: Component Description Robot Common Base Auxiliary Equipment Base Positioner Programming Base Fence Operator Station PROGRAMMING... -
Page 37: Site Preparation
INSTALLATION Site Preparation To prepare your site, proceed as follows: 1. Clear the floor space needed for the unit (see Figure 4-2). 5894 mm (19.34 ft) 6069 mm (19.91 ft) Figure 4-2 Area Needed for Installation NOTE: It is recommended to keep an additional 2 to 3 m (8 to 10 ft.) of clear distance on all sides of your system. -
Page 38: Shipment Inspection
INSTALLATION Shipment Inspection After components are unloaded, inspect them for shipping damage. If needed, carefully remove protective plastic wrapping from components. NOTE: If damage is found, notify shipper immediately. Steps for Installation The procedures below are the sequence of steps to complete installation. •... -
Page 39: Installing The Positioner
INSTALLATION WASHER ANCHOR LEVELING BOLT Figure 4-4 Floor Anchors Installing the Positioner The positioner is anchored to the concrete floor at the front of the cell (see Figure 4-1). 4.6.1 Unpacking the Positioner WARNING! The positioner weighs 3992 kg (8800 lbs). Make sure the lifting devices used to move the positioner are capable of safely handling this much weight, or damage to equipment or injury to personnel can result. -
Page 40: Positioner Leveling
INSTALLATION SCREWS POSITIONER BEAM LONG POSITIONER SHIPPING BRACKET SHORT POSITIONER SHIPPING BRACKETS SCREWS Figure 4-5 Positioner Shipping Brackets 2. Remove the long positioner shipping bracket. 3. Use a M24 socket/wrench to remove the four screws securing both short shipping brackets to the positioner beam. 4. -
Page 41: Installing The Robot Common Base
INSTALLATION 3. Vacuum concrete dust from holes. 4. Prepare 1/2-inch anchors (factory-supplied) with accompanying washer and nut (see Figure 4-4) for each anchor location. 5. Using a hammer, drive an anchor into each drilled hole until the washer stops at the leveling bolt. 6. -
Page 42: Figure 4-8 Robot Common Base Leveling Points
INSTALLATION 3. Fasten the robot common base to the positioner beam using hardware removed in Step 1. WARNING! Metal bands are under tension and, when cut, may cause injury. Be cautious when cutting the metal bands. 4. Cut bands securing the floor cover plate and remove it from the robot common base. -
Page 43: Removing The Robot Shipping Brackets - Up20/Up20-6
INSTALLATION 4.7.1 Removing the Robot Shipping Brackets – UP20/UP20-6 CAUTION! Failure to remove shipping brackets from robot before operating the cell may result in damage to the robot drive mechanisms. The UP20 and UP20-6 robots have two yellow shipping brackets (see Figure 4-9) to stabilize it during shipping. -
Page 44: Installing The Programming Platforms
INSTALLATION Installing the Programming Platforms WARNING! The total weight of the platforms and accessories is 120 kg (264.5 lbs). Make sure the lifting devices used to move these objects are capable of safely handling this much weight. A programming platform must now be installed on the left and right side (see Figure 4-10) of the robot common base. -
Page 45: Installing The Auxiliary Equipment Common Base
INSTALLATION 6. Insert a 1/2-inch concrete drill bit through the center of each leveling bolt (see Figure 4-3) and drill holes (at least four inches deep into concrete) for anchors. 7. Vacuum concrete dust from holes. 8. Prepare a 1/2-inch anchor (factory-supplied) with accompanying washer and nut (see Figure 4-4) for each anchored location. -
Page 46: Figure 4-12 Aec Base Installation Location
INSTALLATION .6 m (2 ft) PROGRAMMING PLATFORM AUXILARY EQUIPMENT COMMON BASE .6 m (2 ft) HEADSTOCK Figure 4-12 AEC Base Installation Location WARNING! The AEC base weighs 1600 kg (3520 lbs). Be sure that your lifting device is capable of handling this much weight or damage to the equipment or injury to personnel can result. -
Page 47: Connecting The Cables
INSTALLATION 4.10 Connecting the Cables After components are level and securely in place, unwrap the cables and connect them according to the cable diagram included in the system drawing package. All cables are labeled to match the labels at the connection points. 4.10.1 Cable Routing It is important to keep cables covered/hidden as much as possible. -
Page 48: Connecting The Programming Pendant Cable
INSTALLATION DANGER! • 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 15.24 m (50 ft) of other sources of noise (i.e., GTAW arc starters, plasma cutters, induction furnaces, high-power-resistance... -
Page 49: Figure 4-14 Ground Welding Cable On Positioner
INSTALLATION 4. Connect one end of second welding ground cable to the Welder 2 negative (-) terminal (see Figure 4-15). Check that the connection is tight. 5. Connect the other end of the Welder 2 ground cable to the WELD 2 grounding bolt located on the side of the headstock cabinet (see Figure 4-14). -
Page 50: Connecting The Positioner Air Line
INSTALLATION Positive Cables The positive welding cables (R1 and R2) are wrapped in leather and wire-tied to each robot. One end of each positive cable is properly connected to the robot. CAUTION! Do not remove the leather wrapping or damage to the cables could result. -
Page 51: Figure 4-16 Connecting The Controller To The Robot
INSTALLATION GREASE INSERT EXTERNAL AIR INPUT 3BC-A NOT USED 1BC-A 2BC-A FROM CONTROLLER Figure 4-16 Connecting the Controller to the Robot Use Table 4-1 to identify cables used for each robot and its function. Table 4-1 Cable Connections Cable Connection Cable Function 1BC-A Robot encoder communication... -
Page 52: Connecting The Positioner Cables
INSTALLATION 4.10.7 Connecting the Positioner Cables The positioner headstock uses a cable interface panel for cable connections. The cable interface panel is placed inside the housing cabinet for shipping. To install the interface panel and connect positioner cables to it, proceed as follows: 1. -
Page 53: Installing The Fence
INSTALLATION 4.11 Installing the Fence 4.11.1 Unpacking The fencing that makes up the welding cell’s protective walls is shipped on its own skid with all the hardware needed for installation (see Figure 4-18). METAL BANDING WOOD SHIPPING SKID Figure 4-18 Crated Fencing Skid WARNING! Metal bands are under tension and, when cut, may cause injury. -
Page 54: Locate Special Fence Posts
INSTALLATION DOOR REAR REAR CELL FENCE RAIL WALL WALL DOOR POST PLATFORM WALL PLATFORM WALL REAR SHORT POSITIONER REAR SHORT WALL POSITIONER WALL REAR REAR POSITIONER POSITIONER WALL WALL MIDDLE POSITIONER MIDDLE POSITIONER WALL AND QUICK WALL AND QUICK ACCESS WALL ACCESS WALL FRONT FRONT... -
Page 55: Figure 4-20 Left Side Fence Wall Assembly - Steps A And B
INSTALLATION STEP A CONNECT POSTS TO REAR WALL REAR FENCE WALL POST PLATFORM WALL STEP B CONNECT POST TO PLATFORM WALL Figure 4-20 Left Side Fence Wall Assembly – Steps A and B 2. Have an assistant raise the rear wall and hold steady at permanent location (see Figure 4-19). -
Page 56: Figure 4-22 Fence Anchor Points - Left Side
INSTALLATION SECURE ROBOT COMMON FENCE BASE PROGRAMMING HERE PLATFORM SECURE FENCE HERE ANCHOR FENCE HERE ANCHOR FENCE HERE ANCHOR FENCE HERE Figure 4-22 Fence Anchor Points – Left Side 7. Connect a fence post to rear short positioner wall (see Figure 4-23, Step C). STEP C REAR SHORT CONNECT POST TO REAR... -
Page 57: Figure 4-24 Connect Quick-Access Wall - Left Side
INSTALLATION 8. Raise the rear short positioner wall and connect perpendicularly to the installed section. Use Figure 4-19 as a guide for fence wall orientation. 9. Raise the rear positioner wall and connect perpendicularly to the rear short positioner wall. Use Figure 4-19 as a guide for fence wall orientation. 10. -
Page 58: Anchor Remaining Fence To Floor - Left Side
INSTALLATION STEP F CONNECT POST TO LIGHT CURTAIN LIGHT CURTAIN WALL WALL FENCE POST Figure 4-25 Left Fence Wall Assembly – Step F 16. Raise the light curtain wall and connect perpendicularly to front positioner wall. Use Figure 4-19 as a guide for fence wall orientation. 17. -
Page 59: Installing Right Side Of Fence
INSTALLATION 4.11.6 Installing Right Side of Fence Before installation, place all fence wall components on floor around the cell. Use Figure 4-19 as a guide for fence wall orientation. To install the fence for right side of ArcWorld IV-6200 XHD DR2C cell, proceed as follows: WARNING! Assembling the fence requires at least two people to accomplish safely. -
Page 60: Figure 4-27 Fence/Post Connections - Right Side
INSTALLATION FENCE POST REAR WALL PLATFORM WALL Figure 4-27 Fence/Post Connections – Right Side 5. Align the holes in fence post feet with holes in programming platform and robot common base, adjust if necessary (see Figure 4-28). 6. Secure assembled fence section to the programming platform and robot common base using factory-supplied M16 x 30 screws (M24 wrench/socket). -
Page 61: Figure 4-29 Right Fence Wall Assembly - Steps C Through E
INSTALLATION STEP C CONNECT POST TO REAR REAR SHORT SHORT POSITIONER WALL POSITIONER WALL REAR POSITIONER WALL STEP D CONNECT POSTS TO MIDDLE MIDDLE POSITIONER POSITIONER WALL WALL FENCE POST FRONT POSITIONER STEP E WALL CONNECT POST TO FRONT POSITIONER WALL Figure 4-29 Right Fence Wall Assembly –... -
Page 62: Figure 4-30 Connect Quick-Access Wall - Right Side
INSTALLATION MIDDLE POSITIONER WALL TAILSTOCK HOUSING T-BRACKET SCREW QUICK-ACCESS WALL Figure 4-30 Connect Quick-Access Wall – Right Side 15. Connect a fence post to light curtain wall (see Figure 4-31, Step F). LIGHT CURTAIN WALL STEP F CONNECT POST TO LIGHT CURTAIN WALL FENCE POST... -
Page 63: Anchor Remaining Fence To Floor - Right Side
INSTALLATION 4.11.7 Anchor Remaining Fence to Floor – Right Side Remaining cell walls are anchored using provided 3/8-inch concrete anchors. Holes must be drilled into concrete. See Figure 4-22 for fence anchor points. Do not floor-anchor either light curtain fence post located in front of positioner. They will be anchored into the cement after the light curtains are properly aligned. -
Page 64: Installing The Arc Curtains
INSTALLATION STOP BOLT DOOR RAIL CLAMP Figure 4-33 Install Final Door Rail 4. Install stop bolt and tighten clamp. 5. Ensure cell walls are square. 4.13 Installing the Arc Curtains WARNING! Do not install the arc curtains until after the cell walls have been secured to the base and anchored to the floor. -
Page 65: Installing The Light Curtain System
INSTALLATION 2. Make sure there are no gaps between arc curtains. 3. Install door wall arc curtain on inside of door wall using supplied wire ties and eyelets in curtain. 4.14 Installing the Light Curtain System For the light curtains to work effectively, they must be properly aligned and facing each other with no obstructions. -
Page 66: Installing The Light Curtain Cable
INSTALLATION 3. Set the light curtain guard against the fencing in the correct position (see system prints) and hold in place. 4. Use a pen to mark the four spots on arc curtain where mounting screws will be installed. 5. Use a knife or other sharp object to make small holes at the marked spots. 6. -
Page 67: Installing The Operator Station
INSTALLATION 4.15 Installing the Operator Station Motoman recommends anchoring the operator station to the floor. To install the operator station, proceed as follows: 1. Unload operator station from shipping platform. 2. Carefully remove protective plastic wrapping from operator station. 3. Inspect operator station for shipping damage. NOTE: If damage is found, notify shipper immediately. -
Page 68: Connecting The Power
INSTALLATION 2. Connect one end of the operator station cable to the connection on the R1 controller labeled OPERATION STATION. 3. Route the other end of the operator station cable to the operator station (see Figure 4-37). 4. Connect operator station cable to the operator station. 4.16 Connecting the Power Incoming 3-Phase Power... -
Page 69: System Check - Before System Power Up
INSTALLATION 4.17 System Check – Before System Power Up Verify the following steps have been completed before System Power Up: 1. Check that both shipping brackets (if applicable) have been removed from each robot (see Section 4.7.1). 2. Check that the positioner shipping brackets have been removed from the positioner (see Section 4.6.2). -
Page 70: Installing The Swingarm Guards
INSTALLATION 4. Push an anchor through holes in fence post feet and into drilled holes until it stops. A hammer may be needed. 5. Anchor the cell walls to the floor by tightening nut. ANCHOR ANCHOR FENCE FENCE HERE HERE Figure 4-38 Anchoring the Light Curtain Fence 4.19.3 Installing the Swingarm Guards... -
Page 71: System Check - After Power Up
INSTALLATION 1. Place the swingarm guard against the fencing as shown in Section 4-39 and hold in place. 2. Use a pen to mark the four spots on arc curtain where screws will be installed. 3. Use a knife or other sharp object to make small holes at the marked spots. 4. -
Page 72: Installing The Tooling And Fixtures
INSTALLATION 4.21 Installing the Tooling and Fixtures Your ArcWorld IV-6200 XHD DR2C system is now ready for the installation of tooling and fixtures for your application. Installation of tooling and fixtures should be performed by personnel who are familiar with the operation of this system. Tooling and fixtures are supplied by the customer. -
Page 73: Operation
SECTION 5 OPERATION The ArcWorld IV-6200 XHD DR2C is a fully integrated robotic gas metal arc welding (GMAW) cell. The Master job setup, and the sub-jobs programmed within it, determine how the robot performs the welding operation or other tasks. The robots weld parts on one side of the 180-degree reciprocating positioner, while the operator loads or unloads parts on the opposite side. -
Page 74: I/O Assignment
OPERATION With the programming pendant, the operator can develop a series of jobs for the robots. You can program the robots independently, the station axis independently, or the robots and station axis together. You must select the axis combination when teaching the job initially (see Section 5.1.4). -
Page 75: Table 5-2 Xrc 2001 User Outputs
OPERATION Table 5-1 XRC 2001 User Inputs - continued Input Assignment Description IN#017 SWEEP LOCK ENGAGED TAILSTOCK Signal from switch S1S in positioner tailstock IN#018 SWEEP LOCK DISENGAGED TAILSTOCK Signal from switch S1R in positioner tailstock IN#019 SWEEP LOCK ENGAGED HEADSTOCK Signal from switch S1S in positioner headstock IN#020... -
Page 76: Sweeping The Positioner
OPERATION 5.1.2 Sweeping the Positioner CAUTION! Sweeping the positioner manually from the pendent may result in the fixtures/tooling hitting the ground. Care must be taken by the operator to avoid this from happening. NOTE: In order to sweep the positioner, the robots must be in the Safe position (Cube 23 and Cube 24). MANUAL mode on the controller allows the positioner to sweep without activating the robots. -
Page 77: Programming Specific Jobs
OPERATION CAUTION! Do Not use S1 or S4 for any reason. Use S2 for Side A or S3 for Side B. Misuse will create a SERVO TRACKING ERROR. b) Check status screen to ensure S2 for Side A or S3 for Side B is displayed. c) Press S+ or S- (X+ or X-) motion keys on programming pendant to move headstock. - Page 78 OPERATION Valid Axes Combinations for Non-synchronous Motion R1 + S2 = Robot 1 + A-side headstock R1 + S3 = Robot 1 + B-side headstock R2 + S2 = Robot 2 + A-side headstock R2 + S3 = Robot 2 + B-side headstock Non-Valid Axes Combinations S1 + S4 = Main Trunion + Positioner sweeping (all axes on positioner) S2 + S4 = A-side headstock + Positioner sweeping (all axes on positioner)
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Page 79: Daily Operation
OPERATION Robot Motion with the Headstock Stationary – Non-synchronous Motion 1. Program robot position without moving positioner axis. 2. Set motion type and speeds in normal fashion; 3. Select GROUP AXIS as R1 only. Rotation of the Headstock During Welding – Synchronous Motion The controller can coordinate motion with the external axis. -
Page 80: Safety Circuit Check
OPERATION 9. Make sure the air supply reads 0.04 cmm at 620.5 kPa (1.5 scfm at 90 psi). 10. Set ENABLE/DISABLE switch on operator station to DISABLE. 11. Press TEACH mode button on controller playback panel of R1 controller. 12. Place robots in Safe position (Cube 23 and Cube 24). 5.2.2 Safety Circuit Check Test each of the following safety circuit items daily for proper operation. -
Page 81: Selecting Weld Job (Initial Setup Only)
OPERATION 5.2.4 Selecting Weld Job (Initial Setup Only) CAUTION! Selecting the wrong job can cause unexpected robot motion. Care must be taken to ensure proper job is selected. 1. In the Sweep A (or B) Job, select the line that states, “PStart Job:Test A (or B) sub 2.”... -
Page 82: Shutdown
OPERATION 6. Press the CYCLE START button on operator station. The CYCLE LATCHED light comes on. The robots finish welding and return to Safe Position (Cube 23 and Cube 24). After welding cycle is completed, the positioner sweeps returning welded parts outside cell and placing newly loaded, unwelded parts in the robot work area. -
Page 83: E-Stop Recovery
OPERATION Table 5-3 User Messages User Message Indication Remedy Move Robot to Home Robots not in Home when trunion sweep Move Robot to Home/Safe position. is required. Table 5-4 Alarm Messages Alarm Indication Remedy Shot Pin Sensor Fault with proximity switch Adjust or replace sensor. -
Page 84: Shock Sensor Recovery
OPERATION a) Release E-STOP key on operator station, programming pendant, or R1 controller playback panel. b) Step out of light curtain. c) Clear Shock Sensor condition (see Section 5.3.3). 2. Press SERVO ON READY key on operator station, programming pendant, or playback panel. -
Page 85: Using The Brake Release
OPERATION 5.3.4 Using the Brake Release A brake release control panel is located on front of each controller. Each axis brake is controlled by an individual axis button. Simultaneously pressing the ENABLE button and one of these axis buttons releases the indicated axis. To release the brakes, proceed as follows: 1. - Page 86 OPERATION NOTES ArcWorld IV-6200 XHD DR2C System Manual 5-14 MOTOMAN...
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Page 87: Maintenance
SECTION 6 MAINTENANCE Maintenance/Troubleshooting All maintenance intervals serve as guidelines only. Adjust the frequency of maintenance to suit your specific work conditions. Robots For troubleshooting and maintenance procedures for the UP6, UP20, and UP20-6 robot and controller, refer to the manipulator manual that came with your system. Positioner Quick-access fence walls protect the headstock and tailstock housings. - Page 88 MAINTENANCE NOTES ArcWorld IV-6200 XHD DR2C System Manual MOTOMAN...
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Page 89: Index
INDEX C (continued) About this Document Coordinated System Symbols Alarm Lamp, Operator Station Cylindrical Joint Alarm Message 5-11 Tool Illegal Motion S4 5-11 User Frame Low Air Pressure 5-11 World Shot Pin Sensor 5-11 Cursor Key SR_Relay Fault 5-11 Customer Service Information Alarm Symbol, System Status Customer-Supplied Items Alarm/Error... - Page 90 INDEX General Safeguarding Tips Job Configurations GMAW Torch 3-11 JOB, Icon Menu Joint Symbol, Coordinated System High Symbol, Speed Setting Hold Keypad Hold Symbol, System Status Keypad, Numeric Hold, Operator Station Leveling/Shipping Bolts I/O Assignment Light Curtain Alignment 4-35 Icons, Pendant Light Curtain Alignment/Fence Anchoring 4-35 ARC WELDING...
- Page 91 INDEX O (continued) R (continued) Override the Alarm 5-11 Rotating the Headstock Rotation of the Positioner During Air-Cut Moves Rotation of the Positioner During Welding Payload, Robot RS-232C Serial Port Perform Operation Cycle Running/Start Symbol, System Status Periodic Maintenance Playback Box Alarm Safety Edit Lock...
- Page 92 INDEX S (continued) Sweeping the Positioner XRC 2001 Controllers – R1 and R2 Symbols, Programming Pendant, Status Area Synchronized Motion Synchronous, Station System Check After Power Up 4-37 Before System Power Up 4-35 SYSTEM INFO, Icon Menu System Layout System Overview System Power Up 4-35 System Recovery...