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YK120X_180X U/M English

1. 50 5 69 5 111 Use M4 bolt for installation T gt 425 Do not attach any wire or tube Bellows _ to this cable Doing so may reduce type suction coupler 3 positioning accuracy a t r i User tubing 1 43 l User tubing 2 03 Viewed from direction A i L 4247 Connector for user wiring No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector l SMR 6V B pin BYM 001T 0 6 or SYM 001T P0 6 supplied Use the YC12 crimping machine 4151 E P Wane 143 gt 125 Ha 113 88 Pp ay L 4024 laa y E Epa 4 O po 3 ji HT 28 f a b 3 e 15 9 i j 3 40 Suction coupler 96 Z axis 2t ee Onn position lt 19 66 J 53 for xy and R axis joints Maximum 10 mm rise k26 k 73 gl 50 J during Z axis stopper origin setting Fig 7 3 YK120XC 7 6 CHAPTER 7 Specifications 93 99 E eee Use M3 bolt for installation NOTE Le 1 Suction amount for suction coupler 1 25 Nl min Suction amount lower than this level cannot maintain the degree of cleanliness and higher than this level may damage the Z axis bellows 2 Suction amount for suction couplers 2 25 Nl min Simultaneous suction 58 through two 6 couplers is p
2. E Ro Morr AN User air tube User tubing 1 03 axi IARI I da a vettori User signal cable NO tY axis motor X axis mechanical stopper Vai T Yaris i OS pe a 4 nas User tubing 2 3 A cama a X axis arm y User tubing 1 3 caha X axis speed reduction gear R axis speed Y axis speed reduction gear reduction gear Z axis brake a 0 is spli P pH A Z axis spline J M3 ground terminal PAVOL CANE End effector attachment Connector for user wiring No 1 to 6 X axis motor userwining Serial label Warning label 3 e e AY User tap four positions Fig 2 2 YK120X YK150X 2 2 CHAPTER 2 Functions Connector for user wiring No 1 to 6 Warning label 2 Bellows Ballsorew Machine harness A N Linear busing shaft Bellows type suction coupler User tubing 2 03 Warning label 1 A IN Ves tubing 1 Y axis motor User toing 1 99 Z axis motor Viewed from direction A R axis motor X axis mechanical stopper mechanical stopper Ny 7 M3 ground terminal Layi l X axis speed Y axis
3. i 9 f 4 ff H i i j i Z axis brake Z axis brake 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 Brown Red 0 20mm Orange Blue ZM Gray 0 20mm Black White RM Purple 0 20mm Yellow Round terminal i H Round terminal LA 0 20mm Es FG Black Shield Y axis motor U Z axis motor ZM R axis motor RM O0 N 0 ND 0 ND O0 N 0 N 0 ND 7 16 CHAPTER 7 Specifications Motor wiring table YK120X YK150X Color Connection Connector S2 Yellow S4 Blue S1 Red Resolver s3 Black R1 White R2 Green SHIELD Black XP YP ZP RP U Red Vv White Ww Black Origin sensor wiring table Signal Connection XM YM ZM RM Connector Origin position sensor Brake wiring table Signal Connection RORG Connector Brake1 Brake2 ZBK 7 17 CHAPTER 7 Specifications Motor wiring table YK180X YK220X
4. Robot cable 3 5m option 5m 10m Weight 3 1kg 3kg 3 1kg Degree of cleanliness Class 10 0 1 y level during suction Suction amount 25N min 1 At constant ambient temperature measured when the robot arm was moved 7 times in the same direction a aa hes Maximum value Minimum value Repeatable positioning accuracy 2 There are limits to acceleration coefficient settings 7 1 CHAPTER 7 Specifications 1 2 External view and dimensions 58 5 96 5 Connector for user wiring No 1 to 6 usable socket contact RR F J S T Mfg Co Ltd SM connector SMR 6V B pin BYM 001T 0 6 or SYM 001T PO 6 supplied a Use the YC12 crimping machine S gt Q YE 2 2 J P a gE W 50 5 si 69 5 123 gt 7346 Maximum 355 during arm rotation 7316 Do not attach any wire or tube 3075 to these cables Doing so may reduce positioning accuracy 4245 4175 R axis sensor R axis origin dog 140 1139 123 4125 R19 111 T 410
5. Connection Connector s2 S4 S1 Resolver S3 R1 R2 j 1 1 4 T l i 1 l SHIELD XP YP ZP RP U Vv Ww Origin sensor wiring table Signal Connection XM YM ZM RM Connector Origin position sensor Brake wiring table Signal Connection RORG Connector Brake1 Brake2 ZBK 7 18 MEMO User s Manual YK X series VAMAHA Y K120X YKI150X saman Y K180X YK220X Jul 200 Ver 1 36 This manual is based on Ver 1 35 of Japanese manual YAMAHA MOTOR CO LTD IM Company All rights reserved No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO LTD Information furnished by YAMAHA in this manual is believed to be reliable However no responsibility is assumed for possible inaccuracies or omissions If you find any part unclear in this manual please contact YAMAHA or YAMAHA sales representatives
6. 11 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 12 Perform the absolute reset from outside the safeguard enclosure 13 After the absolute reset is completed read the machine reference value dis played on the MPB 14 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it B lt m p A Set screw 4 pieces Dog ring R axis Fig 4 8 Adjustment of R axis machine reference 4 22 CHAPTER 4 Adjustment AAA A A 3 4 1 3 Adjusting the X axis machine reference The adjustment method for the X axis machine reference is as follows 1 2 3 4 5 6 7 8 Prepare the necessary tools e Hex wrench set Check that no one is inside the safeguard enclosure and then turn on the controller Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure Place a sign indicating that the robot is being adjusted in order to keep other
7. 3 20 CHAPTER 3 Installation 7 1 2 Acceleration coefficient vs moment of inertia YK150X O Ax AY AR 0 00004 0 0004 100 80 60 40 20 0 00025 0 0025 y 0 0005 0 0010 0 0015 0 0020 Ir kgm 0 0 005 0 010 0 015 0 020 Jr kgfcmsec W 0 1kg O AX AY AR 0 00018 0 0018 100 80 60 40 20 a 0 0005 0 0010 0 0015 0 0020 Ir kgm2 0 0 005 0 010 0 015 0 020 Jr kgfcmsec W 0 2kg Ax Ay AR 100 80 60 40 20 y 9 0011 0 011 9 0 0005 0 0010 0 0015 0 0020 Ir kgm2 0 0 005 0 010 0 015 0 020 Jr kgfcmsec W 0 3kg 3 21 CHAPTER 3 Installation AAA AAA BA EN AR 0 00016 0 0016 100 80 60 40 20 0 0 0005 0 0010 0 0015 0 0020 Ir kgm2 0 0 005 0 010 0 015 0 020 Jr kgfcmsec AX AY AR 0 00005 0 0005 100 80 60 40 20 a 0 0005 0 0010 0 0015 0 0020 Ir kgm 0 0 005 0 010 0 015 0 020 Jr kgfcmsec2 W 0 5kg Fig 3 10 3 22 CHAPTER 3 Installation A A 7 1 3 Acceleration coefficient vs moment of inertia YK180X YK220X AX AY dde 0 0005 0 005 80 60 40 20 d 0 005 0 01 Ir kgm2 0 0 05 0 1 Jr kgfcmsec W 0 1 to 0 4kg AX AY AR 0 0005 0 005 100 4 80 60 40 20 0 0 005 0 01 Ir kgm2 0 0 05 0 1 Jr kgfcmsec 2 W 0 5 to 0 8kg Ax AY AR 100 0 0005 0 005 80 60 40 20 o 0 00
8. 6 Trial Operation After making installations adjustments inspections maintenance or repairs to the robot make a trial run using the following procedures 1 If a safeguard enclosure has not yet been provided right after installation of the robot rope off or chain off around the movement area of the manipulator in place of the safeguard enclosure and observe the following points 1 Use sturdy stable posts which will not fall over easily 2 The rope or chain should be easily visible by everyone around the robot 3 Place a sign to keep the operator or other personnel from entering the movement range of the manipulator Check the following points before turning on the controller 1 Is the robot securely and correctly installed 2 Are the electrical connections to the robot correct 3 Are items such as air pressure correctly supplied 4 Is the robot correctly connected to peripheral equipment 2 wa 5 Have safety measures safeguard enclosure etc been taken 6 Does the installation environment meet the specified standards 3 After the controller is turned on check the following points from outside the safeguard enclosure 1 Does the robot start and stop as intended Can the operation mode be selected correctly 2 Does each axis move as intended within the soft limits Does the end effector move as intended Bu Are the signal transmissions to the end effector and peripheral equipment correct Doe
9. Check for air leaks solenoid valve air cylinder Check drain Check air filter for clogging or damage Robot exterior Check for damage If a damage is found contact YAMAHA dealer 2 Inspection to be performed with the controller turned on 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller programming unit or operation panel 3 Check the following points from outside the safeguard enclosure Checkpoint Procedure Check if the safeguard enclosure is in place Safeguard enclosure Check if emergency stop is triggered when the door is opened Check if warning labels are affixed at the entrance and clearly visible Emergency stop device Press the emergency stop button to check if it works Check for abnormal movement and excessive vibration and noise If Robot t a any abnormal symptom is found contact YAMAHA dealer Check if the brake works to stop the Z axis from dropping more than Z axis brake operation 1 3mm from the stationary point If any abnormal operation is found contact YAMAHA dealer Visually check the Z axis movement when you press the emergency stop button from outside the safeguard enclosure and also when you turn off the controller 5 3 CHAPTER 5 Periodic Inspection ERA AAA AA AAA AAA AAA 3 Adjustment and parts replacement 1 Aft
10. in each figure respectively indicate the acceleration coefficients of the X axis Y axis and R axis The symbol Ir Jr is the moment of inertia of the load around the R axis and m is the tip mass Example YK120X Assume that the mass of the load installed to the R axis is 0 15kg and the moment of inertia around the R axis is 0 0005kgm 0 005kgfcmsec When the tip mass parameter is set to 0 2kg the robot can be operated by reducing the X Y and R axis acceleration coefficients to 50 as can be seen from Fig 3 9 Be sure to select an optimum tip mass and acceleration coefficient param eters that meet the mass of the load and moment of inertia before using the robot To make settings for the tip mass and acceleration coefficient refer to the separate YAMAHA Robot Controller User s Manual Methods for calculating the moment of inertia of the load are shown in Sec tion 6 2 however it is not easy to precisely figure out these values If a calculated value smaller than the actual moment of inertia is set residual vibrations may occur If this happens reduce the acceleration coefficient pa rameter even further AACAUTION The robot must be operated with correct tolerable moment of inertia and accel eration coefficients according to the manipulator tip mass and moment of iner tia Ifthis is not observed premature end to the life of the drive units damage to the robot parts or residual vibration during positioning ma
11. ing down and in a level position 3 Tap holes into the surface of the installation base Refer to 1 2 External view and dimensions in Chapter 7 for machining dimensions and positions 4 Securely fix the installation base on the floor with anchor bolts 3 3 CHAPTER 3 Installation Do not place the robot on a moving installation base Excessive loads will be applied to the robot arm by movement of the installation base resulting in dam age to the robot CAUTION The manipulator positioning might decrease if the installation surface precision is insufficient If the installation base is not sufficiently rigid and stable or a thin metallic plate is attached to the installation base vibration resonance may occur during operation causing detrimental effects on the manipulator work 3 4 CHAPTER 3 Installation 2 Installation 2 1 Unpacking The robot and controller are heavy Take sufficient care not to drop them during moving or unpacking as this may damage the equipment or cause bodily injury CAUTION When moving the robot or controller by equipment such as a forklift that require a license only properly qualified personnel may operate it The equipment and tools used for moving the robot should be serviced daily The package comes with a robot manipulator YK120X series or YK180X series a robot controller and accessories according to the order specifications Transport the p
12. 24 hours day No of operation days 240 days year n 10 0 gt 0 25 N 50 h 24 hours per day D 240 days per year Replacement period 1 5x10 Mmx60xhxDxNx0 1 5x10 10x60x24x240x50x0 25 3 5 years Table 5 1 Harmonic drive speed reduction ratio X axis Y axis R axis 50 50 30 5 8 CHAPTER 5 Periodic Inspection The motor and speed reduction gear casing are extremely hot after automatic operation so burns may occur ifthese are touched Before touching these parts turn off the controller wait for a while and check that the temperature has cooled Precautions when handling harmonic grease cleaning oil Inflammation may occur if they get in the eyes Before handling them wear your safety goggles to ensure they will not come in contact with the eyes Inflammation may occur if they come into contact with skin Be sure to wear protective gloves to prevent contact with skin Do not take orally or eat Eating will cause diarrhea and vomiting e Hands and fingers might be cut when opening the container so use protec tive gloves Keep out of the reach of children Do not heat them or place near an open flame since this could lead to sparks and fires Emergency Treatment e If they get in the eyes wash liberally with pure water for about 15 minutes and consult a physician for treatment If they come in contact with the skin wash away completely with soap and water e If taken intern
13. 33 7kgfcm 2 2Nm 22 4kgfcm 26 Check the machine reference value when the arm struck against the mechanical stopper CAUTION When the arm moves at high speed and strikes against a mechanical stopper violently the machine reference value may change If this has happened check the machine reference value Also check the mechanical stopper for any dam age and the origin position for shift If the machine reference value is outside the recommended range adjust the machine reference In this case re teach ing may be required if the origin position has shifted 1 8 CHAPTER 1 Using the Robot Safely G 27 Use caution not to apply excessive force to the machine har ness user signal cables and air tubes CAUTION A positioning error may occur if excessive force is applied to the machine har ness user signal cables or air tubes A positioning error may also occur if the machine harness user signal cables or air tubes have deteriorated due to im proper installation environment 28 Caution when turning off the robot controller CAUTION The XY arm positions might move slightly due to the harness reaction force when the power to the robot controller is turned off making it difficult to back up the correct position data To avoid this before turning off the power to the robot controller press the emergency stop button and check that the robot arms have completely stopped 29 Take th
14. 48 a A W N CHAPTER Periodic Inspecition O 5 1 AAA NA O O 5 2 Dally Inspeccion o cole 5 3 Six Month Inspection Css as 5 5 Replacing the Harmonic Drive Grease oooocccnoccccconoccccnonooancnnnonnnnnanannnnnnns 5 8 5 1 Replacement Period A E Airai Aa AAAA EATA 5 8 MEMO CHAPTER 5 Periodic Inspection AA AAA AAA A 1 Overview Daily and periodic inspection of the YAMAHA robot is essential in order to ensure safe and efficient operation This chapter describes the periodic inspection items and procedures for the YAMAHA YK120X series and YK180 series robots Periodic inspection includes e Daily inspection 6 month inspection e Replacing the speed reduction gear harmonic drive grease Make sure that you thoroughly understand details of the inspection and follow the procedures and precautions explained in this chapter 5 1 CHAPTER 5 Periodic Inspection EA K A AAA 2 Precautions 1 Periodic inspection must be performed by or in the presence of personnel who have received the Robot Training given by YAMAHA or YAMAHA dealers 2 Do not attempt any inspection adjustment repair and parts replacement not described in this manual This work requires specialized technical knowl edge and skill and may also involve work hazards 3 When inspection is required inside the safeguard enclosure always turn off the controller and also the external switch board 4 If the inspection or maintenance procedur
15. 7 _ 0 37 1274 27 0 37 x 5 Js 0 014 kgfemsec 12 x 980 980 3 27 CHAPTER 3 Installation 2 3 4 5 Moment of inertia of the chuck gt When the chuck form resem 20m i oer bles that shown in Fig 3 21 the weight of the chuck Wc SS E 4cm We 0 0078 X2x4x6 0 37 kgf oem The moment of inertia of the chuck Jc is then calculated from Eq 3 7 0 37 x 2744 aro O Fig 3 21 A 0 37 x 10 980 0 038 kgfemsec Moment of inertia of workpiece Era When the workpiece form pan as resembles that shown in Fig 3 22 the weight of the workpiece Ww is a prD h 0 00787 x 2 x 4 w 4 4 4cm 0 098 kgf Map The moment of inertia of the pr workpiece Jw is then calcu lated from Eq 3 5 Jw 0 097 x 2 0 097 x 10 Fig 3 22 8 x 980 980 0 010 kgfcmsec Total weight The total weight W is calculated as follows W Ws Wc Ww 0 84 kgf Total moment of inertia The total moment of inertia J is then obtained as follows J Js Jc Jw 0 062 kgfcmsec 3 28 User tool installation range Attaching the end effector CHAPTER 3 Installation Before attaching the end effector be sure to turn off the controller The manipulator part to which an end effector is attached must have adequate strength and rigidity as well as gripping force to prevent positioning errors Table 3 1 shows the maximum load that can be applied to the end effector attachme
16. AAA AAA 5 Replacing the Harmonic Drive Grease The YK120X series and YK180X series robots use a harmonic drive as the speed reduction gear for the X axis Y axis and R axis The harmonic drive grease SK 2 must be replaced periodically Determine the harmonic grease replacement period with the following procedures Each axis must be disassembled when replacing the harmonic drive grease so contact YAMAHA for servicing 5 1 Replacement period The harmonic drive replacement period is determined by the total number of turns of the wave generator used in the harmonic drive A calculation example is shown below It is recommended to replace the harmonic drive when the total number of turns has reached 1 5x10 at ambient operating temperatures of 0 C to 40 C This means that the replacement period will differ depending on the following operating conditions If the robot operation duty ratio is high or the robot is operated in environments at higher temperatures the harmonic drive should be replaced earlier Replacement peo 1 5x10 nx60xhxDxNx0 years where Number of axis movements per minute Average turn per axis movement Speed reduction ratio Operation time per day Operation days per year ESF ZOB For 6 a 90 axis rotation is a one quarter rotation Example Harmonic drive replacement period when axis rotates an average of one quarter with each movement and moves 10 times in one minute Operation time
17. Explosions or fire could otherwise result Avoid using the robot in locations subject to electromagnetic interference elec trostatic discharge or radio frequency interference Malfunction may otherwise occur 3 1 CHAPTER 3 Installation Do not operate the robot in locations subject to strong vibrations The robot installation bolts might work loose and the robot topple over The bolts on the robot body itself might also loosen causing parts to fall off etc A positioning error may occur if the machine harness user signal cables or air tubes have deteriorated due to improper installation environment 3 2 CHAPTER 3 Installation A A IA IA 1 2 Installation base 1 Prepare a sufficiently rigid and stable installation base taking account of the robot weight including the end effector gripper workpiece and reaction force while the robot is operating The maximum reaction force see Fig 3 1 applied to the X axis and Z axis of each robot during operation is shown in the table below These values are an instantaneous force applied to the robot during operation and do not indicate the maximum load capacity The maximum reaction force Fxmax Robot Mode N Fzmax Y Mxmax Fig 3 1 Maximum reaction force applied during operation 2 The parallelism of the installation base surface must be machined within a precision of 0 05mm 500mm The robot base mount must be installed fac
18. HoH RP ZR X axis resolver ZBK HTH ZBK RORG H RORG YP HoH YP XY FG 2H FG XP HETH XM HoH MM XM YM HoH YM 2 KO Mwa Brake is incorporated in Z axis motor MHH M B E a g for YK180X and YK220X MHH a iB 2 Robot cable Round terminal M3 ground terminal 7 14 CHAPTER 7 Specifications 1 4 Wiring table Robot cable wiring table Robot side Controller side Connector No Connection No Connector Color No Orange Red 1 0 14sq Orange Black 1 Twisted pair Gray Red 1 0 14sq Gray Black 1 Twisted pair White Red 1_ 0 14sq White Black 1 Twisted pair Green 0 15sq Yellow Red 1 0 14sq Yellow Black 1 Twisted pair Pink Red 1 0 14sq Pink Black 1 Twisted pair Orange Red 2 0 14sq Orange Black 2 Twisted pair Green 0 15sq Gray Red 2 0 14sq Gray Black 2 Twisted pair Resolver S2 Resolver No JAA VIN INIo anA V N Signal Connector No Connection Connector Color No Resolver S2 Orange Red 1 0 14sq Orange Black 1 Twisted pair Gray Red 1_ 0 14sq Gray Black 1 Twisted pair White Red 1_ 0 14sq White Black 1 Twisted pair Green 0 15sq Yellow Red 1 0 14sq Yellow Black 1 Twisted pair Pink Red 1 0 14sq Pink Black 1 Twisted pair Orange Red 2 0 14sq Orange Black 2 Twisted pair Green 0 15sq Gray Red 2 0 14
19. Initializing the parameters deletes previous parameter settings If necessary load the backup parameters Parameter changes The following parameter has been changed Blank portions indicate standard speci fications are used Axis settings Parameter No Name Changes M2 M3 PRM37 Max motor rotation 1500 2 7 CHAPTER 2 Functions 5 Tip weight parameter setting and WEIGHT statement in programs The tip weight parameter setting and WEIGHT statement in programs for the YK120X and YK180X series differ from those for other robots Set the tip weight parameter and WEIGHT statement to match the actual load as shown in the table below If this is not observed drive units will be damaged or the service life will shorten Actual load kg Tip weight parameter x0 1kg WEIGHT po WEIGHT O WEIGHT 1 WEIGHT 2 WEIGHT 3 WEIGHT 4 WEIGHT 5 WEIGHT 6 WEIGHT 7 WEIGHT 8 WEIGHT 9 WEIGHT 10 OlOINI DI NIHR Wl wo e na o 2 8 N O 0 A O CHAPTER Installation Robot Installation Onda 3 1 1 1 Installation environments ooooocccnccncccccnncnnononnonnncnnnnncnnnnnnnnn nn o nn nn cnn rca nn nnannan nn nnnnccnnn 3 1 1 2 Installation base oooonnnninnccncccnccnnnncccnnnnnnnonnnncnnncnnnnncnnnnnnnnnn nn nn nn cnn nn nn rra nnnnnnnnnncnnnnn 3 3 Installation assi 3 5 2 UNPACKING nia da dedos 3 5 2 2 Checking the Product cccoinncnnnnccccnnonnnnnonccononcnnnncnnnnn cnn nn cnn
20. SS oa 4 64 User tap 4 M3x0 5 Depth 6 99 Q Do not screw the screw in deeper than this M3x length 6 pin supplied Use M3 bolt for installation Fig 7 2 YK150X 7 4 CHAPTER 7 Specifications a a O lon Working envelope t L User tubing 2 3 8 User tubing 1 3 Viewed from direction A User tubing 2 3 User tubing 1 43 H X Y axis origin position When carrying out X Y axis absolute reset stopper origin setting move the X axis to a position counterclockwise from this position and the Y axis to a position clockwise M3 ground terminal M It NY A Nw O g3 thi QJ 4 Ir 4 5 4 5 au X Y axis maximum movement position during X Y axis absolute reset stopper origin setting Take care to prevent interference between the end tool robot and peripheral devices etc CHAPTER 7 Specifications 44 Connector for user wiring No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector SMR 6V B pin BYM 001T 0 6 or SYM 001T P0 6 supplied Use the YC12 crimping machine
21. Sensor method R axis Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset The operation procedure using the MPB is described next Press the ESC key on the MPB if you want to return to the preceding step See the YAMAHA Robot Controller User s Manual for information on operat ing the robot controller 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Place a sign indicating the robot is being adjusted to keep others from touch ing the controller switch or operation panel 3 Set the controller to MANUAL mode if not in MANUAL mode 4 Press the F13 LOWER F3 key to select RST ABS 5 Select the R axis for absolute reset R axis M4 To perform absolute reset on all axes select ALL with the F11 LOWER F1 key AACAUTION The Z axis of the stroke end method first rises during the absolute reset of all axes default setting Be careful that your fingers do not get pinched or crushed by any sudden movement 6 Confirm that the R axis to perform absolute reset is at a position on the plus side of the origin See Fig 4 1 Fig 4 4 If it is not at the plus side then press the jog key to move the target axis to the plus side When performing absolute reset for the other axes at the same time confirm that the other axes are also at an appropriate position Refer to
22. a sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 4 Perform the Z axis absolute reset To perform the Z axis absolute reset see 3 3 3 Stroke end method Z axis in Chapter 4 5 After completing absolute reset check to see if the machine reference value is within the tolerance range for absolute reset When within the tolerance range 26 to 74 the distance between the upper end urethane damper and the lower end of the spline nut is approximately 5mm 6 Ifthe machine reference value is not within the tolerance range perform the following steps 7 Turn off the controller 8 Enter the safeguard enclosure 4 36 CHAPTER 4 Adjustment 9 Remove the Y axis upper cover To remove the covers see 7 Removing the Robot Covers in Chapter 4 Place the upper cover on the robot base pedestal side with the machine harness still connected The Z axis will slide down during the following work causing a hazardous situation Prop up the Z axis with a support stand before beginning the work 10 Lift up the lower end urethane damper and loosen the bolts 6 pieces securing the ball screw shown in Fig 4 15 Then rotate the ball screw with respect to the Z axis motor so that the distance between the upper end urethane damper and the lower end of the spline is 5mm When the lower end position of the ball screw is determined push the ball screw in so that it makes conta
23. arm reduction gear p pe A i 2 F VL Connector for user wiring ha pu No 1 to 6 7 at sil Y axis speed User tubing 2 k reduction gear 63 ip Bellows Z axis brake type suction coupler Bellows HE i X axis arm b d L A End effector attachment Warning label 3 X axis motor Suction coupler for base interior 6 type suction coupler 3 User tubing 1 63 Serial label Robot cable Suction coupler for X Y and R axis joints Fig 2 3 YK120XC YK150XC 2 3 CHAPTER 2 Functions AAA AAA _ Connector for user wiring No 1 to 6 User tubing 2 3 Ball screw g User tubing 1 3 Y axis motor Viewed from direction A Warning label 2 Machine harness User signal cable Warning label 1 Y axis R axis motor NA mechanical stopper X axis d mechanical stopper Y axis arm N E X axis speed A reduction gear R axis speed M3 ground terminal Y axis speed reduction gear ducti T reduction gear Z axis spline a Warning label 4 End effector attachment Z axis motor Z axis brake X axis arm X axis motor Warning label 3 Serial label Connector for us
24. cable Doing so may reduce positioning accuracy Bellows type suction coupler 3 Es 7 User tubing 1 3 User tubing 2 3 Viewed from direction A l 4247 Connector for user wiring No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector SMR 6V B pin BYM 001T 0 6 or SYM 001T P0 6 supplied Use the YC12 crimping machine y 151 A OT 4143 ing et i NY 125 pad 113 l 88 Pp 16 20 h i 8 4 L 0 E Suction coupler 6 Z axis 4 i 0 e origin pea y lt MEN 66 J L 5 7 for X Y and R axis joints Maximum 10 mm rise k26 k 73 L 50 J 4 during Z axis stopper origin setting Fig 7 4 YK150XC 7 8 CHAPTER 7 Specifications L7 J 3 93 99 08 NOTE 4 1 Suction amount for suction coupler 1 25 Nl min t t Suction amount lower than this level cannot maintain the degree of cleanliness and higher than this level may damage the
25. completing absolute reset check the machine reference value 14 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it Fig 4 14 Adjustment of Y axis machine reference 4 35 CHAPTER 4 Adjustment EE AAA 3 4 2 4 Adjusting the Z axis machine reference The stroke end method is employed on the YK180X series robots for the absolute reset of the Z axis The origin position of the Z axis is fixed at the upper end of the Z axis stroke and 1t cannot be changed The machine reference is factory adjusted at shipment and readjustment is not necessary for normal use The readjustment in the following procedure is required however if the machine reference exceeds the tolerance range 26 to 74 of the absolute reset for any reason CAUTION The origin position may change when the machine reference amount is ad justed The point data must be reset after adjusting the machine reference 1 Check that the Z axis upper end mechanical stopper is at the position shown in Fig 4 15 If not loosen the bolt and adjust the mechanical stopper to the specified position Retighten the bolt to a torque of 20kgfcm 2 0Nm 2 Check that no one is inside the safeguard enclosure and then turn on the controller 3 Place
26. described in this manual These works require technical knowledge and skill and may also involve work hazards CHAPTER 1 Using the Robot Safely 11 Warranty The YAMAHA robot and or related product you have purchased are warranted against the defects or malfunctions as described below Warranty description If a failure or breakdown occurs due to de fects in materials or workmanship in the genuine parts constituting this YAMAHA robot and or related product within the war ranty period then YAMAHA will repair or replace those parts free of charge hereafter called warranty repair Warranty Period The warranty period ends when any of the fol lowing applies 1 After 18 months one and a half year have elapsed from the date of shipment 2 After one year has elapsed from the date of installation 3 After 2 400 hours of operation Exceptions to the Warranty This warranty will not apply in the following cases 1 Fatigue arising due to the passage of time natural wear and tear occurring during op eration natural fading of painted or plated surfaces deterioration of parts subject to wear etc 2 Minor natural phenomena that do not affect the capabilities of the robot and or related product noise from computers motors etc 3 Programs point data and other internal data that were changed or created by the user Failures resulting from the following causes are not covered by warranty repair 1 Dam
27. detects the origin signal and the position where the absolute reset can be performed soon after the origin signal detection See Fig 4 6 The machine reference is expressed in the ratio of interval A to interval B shown in Fig 4 6 Interval A is the minimum distance between the positions where absolute reset can be performed and interval B is the distance between the position where the origin signal is detected and the position where absolute reset can be performed soon after the origin signal detection The machine reference value is displayed on the optional MPB screen Unit Machine reference value B A x 100 AACAUTION It is necessary for the machine reference to be adjusted in a specified range in order to keep the repeatability precision of the absolute reset position Factory adjusted at shipment Refer to Chapter 4 3 4 Adjusting the machine reference for the machine ref erence adjustment method Recommended machine reference value 40 to 60 26 to 74 only for Z axis Machine reference Origin signal detection ON Origin signal OFF Resolver j sa One motor revolution Positions where absolute reset de can be performed Machine reference display on MPB screen MPB MANNA gt asT ABS 50 MG SOHOJ Machine reference M1 50 M2 M4 R axis X axis Y axis Z axis Fig 4 6 4 10 CHAPTER 4 Adjustment 3 3 Absolute reset procedures 3 3 1
28. for information about the absolute reset method If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel Turn off the controller and enter the safeguard enclosure Mark off the reference mark at the current origin position on the Y axis joint area of the robot At this time be careful to prevent the origin position from deviating since the Y axis arm is touched Using a hex wrench loosen the bolts 2 pieces securing the Y axis dog See Fig 4 14 AACAUTION The bolt only needs to be loosened and does not need to be completely re moved 9 Move the movable mechanical stopper in the following manner When machine reference lt 40 Move mechanical stopper in A direction When machine reference gt 60 Move mechanical stopper in B direction The movement guide is 1 1mm 100 10 Tighten the bolt and fix the movable mechanical stopper The tightening torque is 20kgfcm 2 0Nm 4 34 CHAPTER 4 Adjustment AAA AN E 11 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 12 Perform the absolute reset from outside the safeguard enclosure 13 After
29. kg cm g Gravitational acceleration cm sec m Mass of cylinder kg g W Weight of cylinder kgf Fig 3 16 In the same manner the moment of inertia of a cylinder as shown in Fig 3 17 is given by 2 2 2 2h 2 2 2 pt Dh D h pr D hx m D h 2 P J A AU ca ge ge eg NS 2 2 2 2 2 aca gt pep Pra 8 D h 8 Cneter line gt W 4 Wx SA li Pb E kof 2 Fe tz tee Kgfomsec Eq 3 6 b Fig 3 17 In the same manner the moment of inertia of a prism as shown in Fig 3 18 is given by 2 2 2 2 zee pabex mla b mx kgm 2 4 2 12 Center line lt TD J pabc a b pabcx 12g g 2 2 2 Wa b ei kgfcmsec 12g Eq 3 7 m Mass of prism kg W Weight of prism kgf 3 26 CHAPTER 3 Installation 7 3 Example of moment of inertia calculation Let s discuss an example in which the chuck and workpiece are at a position offset by 10cm from the R axis by a stay as shown in Fig 3 19 The moment of inertia is calculated with the following three factors assuming that the load material is steel and its density p is 0 0078kg cm R axis I 6cm Workpiece Fig 3 19 1 Moment of inertia of the stay From Fig 3 20 the weight of the stay Ws is given as follows Ws pabc 0 0078 x 12x2 x 2 0 37 kgf Center line C gt Fig 3 20 The moment of inertia of the stay Js is then calculated from Eq 3
30. limit to the inner side of the mechanical stopper with an ample safety margin 4 Relation between the X Y and R axis movement angle the Z axis movement distance and the number of pulses The resolver pulse for X Y and R axes movement angle and the for the Z axis movement length are shown below Use these figures as a guide to set the soft limits YK120X YK150X Number of resolver pulses per turn 360 degrees XY 204800 R 122880 Number of resolver pulses per 12 mm movement of one lead Z 4096 YK180X YK220X Number of resolver pulses per turn 360 degrees X Y 819200 R 491520 Number of resolver pulses per 12 mm movement of one lead 16384 CHAPTER 4 Adjustment ee AN 5 Setting the Standard Coordinates CAUTION If the standard coordinate settings are incorrect the acceleration cannot be optimized to match the arm position This results in too short a service life damage to the drive unit or residual vibration during positioning In addition the cartesian coordinate accuracy will be impaired Setting the standard coordinates enables the following operations and functions 1 Optimizes acceleration according to arm position during automatic op eration 2 Allows moving robot arm tip at right angles 3 Allows using shift coordinates 4 Enables commands such as linear interpolation and arm switching The procedure for setting standard coordinates and cautions a
31. machine reference 3 4 2 YK180X series YK180X YK220X 00oooocccocooccccccccconncccoconananccnncnnnnnncnnnnnannccnnnninnnns 3 4 2 1 Adjusting the R axis machine reference YK180X YK220X eseese 4 30 3 4 2 2 Adjusting the X axis machine reference 3 4 2 3 Adjusting the Y axis machine reference 3 4 2 4 Adjusting the Z axis machine reference Setting the SOM MMS a A A e Setting the Standard Coordinates cccccnnnninininocononononnnnnnnnnnnnnnnnnnnnnnnnnn Affixing Stickers for Movement Directions and Axis Names 4 43 Removing the Robot Covers susarrinca ratita 4 45 MEMO CHAPTER 4 Adjustment 1 Overview YAMAHA robots have been completely adjusted at the factory or by the sales representative before shipment including the origin position adjustment If the operating conditions are changed and the robot must be adjusted then follow the procedures described in this chapter 2 Safety Precautions 1 Read and understand the contents of this chapter completely before attempt ing to adjust the robot 2 Place a conspicuous sign indicating the robot is being adjusted to prevent others from touching the controller switch programming unit or operation panel 3 If a safeguard enclosure has not yet been provided right after installation of the robot rope off or chain off the movement area around the manipulator in place of a safeguard enclosure and observe the following points Use stable posts which wi
32. of the robot cable to the robot controller For details on connections to the robot controller refer to Fig 3 7 and the YAMAHA RCX 142 Robot Controller User s Manual After making connections check the operation while referring to 6 Trial operation in Chapter 1 Before connecting the cables check that there are no bends or breaks in the connector pins of the robot cable and that the cables are not damaged Bent or broken pins or cable damage may cause malfunction of the robot Ensure that the controller is off before connecting the robot cable to the controller The MOTOR connectors XM and ZM and YM and RM each have identical shapes In addition the Pl connectors XY and ZR have identical shapes Do not confuse these connectors when making connections Wrong connections may result in malfunction and hazardous situations e If the connector installation is inadequate or if there are contact failures in the pins the robot may malfunction causing a hazardous situation Recon firm that each connector is securely installed before turning on the control ler e To attach the Pl connector securely tighten the screws supplied with the robot e Take caution not to apply an excessive load to the connectors due to stress or tension on the cables Lay out the cables so that they do not obstruct the movement of the manipula tor Determine the robot work area in which the robot cables will not interfere with the load or workpiece picked
33. procedures for absolute reset of other axes CHAPTER 4 Adjustment 7 8 Since the message Reset ABS encoder OK is displayed check that there are not any obstacles in the robot movement range and press the F4 key YES After the absolute reset is completed check that the R axis machine refer ence value displayed on the MPB is between 40 and 60 recommended range If the machine reference value is outside the recommended range then the next absolute reset may not be properly performed In this case refer to 3 4 Adjusting the machine reference and make the necessary adjustments 4 12 CHAPTER 4 Adjustment 3 3 2 Stroke end method X and Y axes of YK120X YK150X Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset The operation procedure using the MPB is described next Press the ESC key on the MPB if you want to return to the preceding step See the YAMAHA Robot Controller User s Manual for information on operat ing the robot controller 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Place a sign indicating the robot is being adjusted to keep others from touch ing the controller switch or operation panel 3 Set the controller to MANUAL mode if not in MANUAL mode 4 Press the F13 LOWER F3 key to select RST ABS 5 Select the X axis or Y axis for absol
34. pulses position is used for all axes you MOVE P P2 Z 0 can write as OUTPOS 10000 DO3 0 1 wee Chuck closes OUTPOS 1 2000 Returns the OUT effective position to the default value If the same OUT effective position is used for all OUTPOS 2 2000 axes you can write as OUTPOS 3 2000 OUTPOS 2000 OUTPOS 4 2000 Chuck starts closing OUT effective position P1 P2 Chuck closed When all of the X Y Z and R axes enter the OUT effective position 10000 pulses prior to P2 the chuck starts closing By setting the OUT effective position larger the chuck starts closing while the robot arm is still moving at an earlier point so that the chuck can grip the workpiece more quickly The default value of the OUT effective position is 2000 pulses Reference Relation between X Y R axis rotating angle Z axis movement distance and pulse values The arch position tolerance and OUT effective position parameters are set in pulses For the relation between X Y R axis rotating angle Z axis movement distance and pulse values refer to the tables listed under item 4 in 4 Setting the soft limits Chapter 4 in this manual 6 5 MEMO 6 6 CHAPTER amp Specifications ManipUla Or iii veleaditndu au EA S i eNe iae 7 1 Tel BasiciSpeciticationiwnd nec eaie idad id 7 1 1 2 External view and dimensions ocoonoocccccnnnoncccconnonncncnnnnnncncnnnnnnn cnc nnnnn nn ncnnnnnnnncncn
35. shown in 1 2 External view and dimensions in Chapter 7 An example using the YK120X is described below Refer to Fig 7 1 Other robot models are the same 1 X and Y axes Do not attempt operation outside the working envelope The working enve lope described in this manual is an area with the robot frontal reference 2 Z axis Do not attempt work outside the working envelope In particular do not at tempt work in the area between the working envelope and mechanical stop per position Mechanical stoppers are installed at both the upper and lower ends of the movement range The robot cable user wiring or tubing may be damaged if the robot load inter feres with them resulting in hazardous robot malfunctions Do not operate at points where the load may interfere with the robot cable user wiring or tubing 3 R axis The R axis has no mechanical stoppers Since the R axis has no mechanical stoppers make certain that the end effec tor wiring and tubing do not become entangled during operation 3 33 MEMO 3 34 N O Oo A CHAPTER Adjustment OVER aa ater ai TENERA E 4 1 Safety Precautions ra AA lA 4 1 Adjusting the OI a e oia 3 1 Absolute reset Method oocccccccnnncccccnnnnnoccncnnnononnncnnnnnnnn cnn nn nnnn cnn nr nn nn rra nnnn rra 3 1 1 YK120X series YK120X YK150X 0oooocccccoooocccoccccononccoccnonanncnnnconnnnnnonncnnnnnnccnncnannnns 3 1 1 1 Sensor method R aXis cocina iD 3 1 1 2 Stroke end metho
36. the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it R axis Sensor 4 31 CHAPTER 4 Adjustment A Adjusting the X axis machine reference 3 4 2 2 The adjustment method for the X axis machine reference is as follows 1 2 3 4 5 6 7 8 Prepare the necessary tools e Hex wrench set Check that no one is inside the safeguard enclosure and then turn on the controller Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel Turn off the controller and enter the safeguard enclosure Mark off the reference mark at the current origin position on the X axis joint area of the robot At this time be careful to prevent the origin position from deviating since the X axis arm is touched Using a hex wrench loosen the bolts 2 pieces securing the X axis dog See Fig 4 13 AACAUTION The bolt only needs to be loosened and does not need to be completely r
37. the mechanical stopper again After completing absolute reset check to see if the machine reference value is within the tolerance range for absolute reset When within the tolerance range turn off the controller power switch and reinstall the Y axis upper cover to complete the work 4 27 CHAPTER 4 Adjustment 8 If the machine reference value is not within the tolerance range 26 to 74 perform the following steps The Z axis will slide down when the Z axis brake is released causing a hazard ous situation e Press the emergency stop button and prop up the Z axis with a support stand before releasing the brake 9 With the robot controller s power ON apply emergency stop on the control ler and release the Z axis brakes Refer to the YAMAHA Robot Controller User s Manual for details on emergency stop releasing emergency stop re leasing the Z axis brakes and turning the brakes ON 10 Loosen the set screw two screws on upper side fixing the ball screw in Fig 4 11 b and change the phase of the ball screw in respect to the sleeve as shown below When machine reference lt 5 Turn ball screw 180 clockwise looking from above When 5 lt machine reference lt 26 Turn ball screw 90 clockwise looking from above When 74 lt machine reference lt 90 Turn ball screw 90 counterclockwise looking from above When 90 lt machine reference Turn ball screw 180 counterclockwise looking from above 11 Tighten t
38. 25 30 Maximum 120 during arm rotation 315 User tubing 2 3 No phase relation User tubing 1 3 between flat spot and R axis origin 203 Cross section A A 163 5 173 962 147 B i ane 126 100 2 Viewed from direction C 109 5 Z axis origin position Rises 5mm during return to origin Connector for user wiring o F Slr axis stroke ONZ axis No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector SMR 6V B 0 0 pin SYM 001T P0 6 supplied Use the YC12 crimping machine o BE J o bs User tool installation range For user tool installation 4 M4x0 7 Depth 6 10 h7 29 Details of B Viewed from direction C Fig 7 5 YK180X 7 10 User tubing 2 3 M3 ground terminal CHAPTER 7 Specifications Working envelope X axis origin is at 0 5 with respect to front of robot base i X Y axis origin position When performing return to origin move the axes counterclockwise in advance from the position shown above User tubing 1 43 7 11 CHAPTER 7 Specifications Connector for user wiring No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector SMR 6V B pin SYM 001T P0 6 supplied Use the YC12 crimping machi
39. 3 3 4 1 4 Adjusting the Y axis machine reference ee eee cece e cesses eeseeeeaeetsaeeeaeenaees 4 25 3 4 1 5 Adjusting the Z axis machine reference ccecceeeceneeeeeeeeeeeeeeeeeeeaeeeeeeeeeteaaes 4 27 4 5 6 7 CHAPTER 1 2 3 4 5 CHAPTER 1 CHAPTER 1 3 4 2 YK180X series YK180X YK220X coooooconcocccononnccnonnnonannnnnnennnnnnn ono nnnn nan nan nnnnnnanennns 4 30 3 4 2 1 Adjusting the R axis machine reference YK180X YK220X ou eee 4 30 3 4 2 2 Adjusting the X axis machine reference oonoiincnnononocnnnonccnnncnanananc cnn oran cnn canino 4 32 3 4 2 3 Adjusting the Y axis machine reference oconncnnnnnnnnnocnnncnanonccnnnanancnnoncnanccnn nano 4 34 3 4 2 4 Adjusting the Z axis Machine reference nnnnoiincnnononocnnnoncnanncnna nana nan c rar cnna canino 4 36 Setting the Soft Limits pila 4 39 Setting the Standard Coordinates oooonoocccccccnoncccnoccccconnnanancconnncnnnnnnnnnns 4 42 Affixing Stickers for Movement Directions and Axis Names occccccno 4 43 Removing the Robot Covers coccococcccccccnooooccccncnncnnnnnnncnnnnncnnnnnnnncnnnnnannns 4 45 5 Periodic Inspecition OMC aaa ene einer ent Or mmm me Crone Omer OO ern eran Neen 5 1 A A na aED EN eia 5 2 Dally IMSS CUON ts a e 5 3 Six Month Inspection es A A 5 5 Replacing the Harmonic Drive Grease ooocccnnccccconococcconooancnnnnrn cnn cnn nnnnno 5 8 5 1 Replacement Period cccconoccccccnnnoccccccnncnncnnnnnnononononn
40. 4 88 492 473 User tool installation range Connector for user wiring No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector SMR 6V B Zaxis 25 2 pin BYM 001T 0 6 or SYM 001T P0 6 supplied origin position 7 Use the YC12 crimping machine Maximum 10 mm rise lad during Z axis stopper g H LO origin setting User tap 4 M3x0 5 Depth 6 Do not screw the screw in deeper than this M3x length 6 pin supplied 99 Fig 7 1 YK120X 7 2 4 04 Use M3 bolt for installation CHAPTER 7 Specifications e Working envelope User tubing 2 43 A User tubing 1 43 Viewed from direction A Y f User tubing 2 3 LJ User tubing 1 63 H X Y axis origin position Ja When carrying out X Y axis absolute reset stopper origin setting move the X axis to a position counterclockwise from this position and the Y axis to a position clockwise l og M3 ground terminal l VA Y LO O O o O si y 4 tt 45 J 4 5 4 X Y axis maximum movement position during X Y axis absolute reset stopper origin setting Take care to prevent interference between the end tool robot and peri
41. 5 0 01 Ir kgm2 0 0 05 0 1 Jr kgfcmsec W 0 9 1 0kg Fig 3 11 CHAPTER 3 Installation AAA AAA AAA AO AAA AAA 7 2 Equation for moment of inertia calculation Usually the R axis load is not a simple form and the calculation of the moment of inertia is not easy As a method the load is replaced with several factors that resemble a simple form for which the moment of inertia can be calculated The total of the moment of inertia for these factors is then obtained The objects and equations often used for the calculation of the moment of inertia are shown below Incidentally there is the following relation J kefcmsec I kgm x 10 2 1 2 Moment of inertia for material particle The equation for the moment of inertia for a material particle that has a rota tion center such as shown in Fig 3 12 is as follows This is used as an approximate equation when x is larger than the object size I mx kgm as 2 J Wx g kgfcmsec Eg 3 1 g Gravitational acceleration cm sec m Mass of material particle kg W Weight of material particle kgf Fig 3 12 Moment of inertia for cylinder part 1 The equation for the moment of inertia for a cylinder that has a rotation center such as shown in Fig 3 13 is given below 4 2 fr mD kgm 8 Tm 4 2 J pnt Dh WD kefemsec ae 32g 8g Eq 3 2 h Density kg m kg cm Gravitational acceleration cm sec Mass of cy
42. E marking manual for related information about CE marking 1 18 a A W N CHAPTER Functions Robot Manipulator srini add lleida 2 1 Robot Controller saaa o Aa 2 5 Robot initialization number Stunt ad 2 6 Parameters for Clean Room Models YK120XC YK150XC eee 2 7 Tip weight parameter setting and WEIGHT statement in programs 2 8 MEMO CHAPTER 2 Functions AAA AA A A 1 Robot Manipulator The YK X series robots are available in 4 axis models having an X Y axis arm equivalent to human arm and a Z R axis equivalent to human wrist With these 4 axes the YK X series robots can move as shown in Fig 2 1 By attaching different types of end effector gripper to the end of the arm a wide range of tasks can be performed with high precision at high speeds The and signs show the direction of axis movement when the jog keys on the programming unit are pressed standard setting at the factory Fig 2 2 to Fig 2 4 on the subsequent pages show part names and functions of each robot model Y axis arm Fig 2 1 Manipulator movement 2 1 CHAPTER 2 Functions Connector for user wiring No 1 to 6 Linear busing shaft Ball screw AAN Warning label 2 Warning label 1 gt SS Machine harness User tubing MN Z A j l y
43. R 4 Adjustment 3 3 3 Stroke end method Z axis Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset The operation procedure using the MPB is described next Press the ESC key on the MPB if you want to return to the preceding step See the YAMAHA Robot Controller User s Manual for information on operat ing the robot controller 1 2 3 4 5 6 7 Check that no one is inside the safeguard enclosure and then turn on the controller Place a sign indicating the robot is being adjusted to keep others from touch ing the controller switch or operation panel Set the controller to MANUAL mode if not in MANUAL mode Press the F13 LOWER F3 key to select RST ABS Select M3 Z axis Z axis M3 To perform absolute reset on all axes select ALL with the Fl 1 LOWER F1 key Since the message Reset ABS encoder OK is displayed check that there are not any obstacles in the robot movement range and press the F4 key YES After the absolute reset is completed check that the machine reference value displayed on the MPB is within the absolute reset tolerance range 26 to 74 If the machine reference value is outside the absolute reset tolerance range then the next absolute reset may not be properly performed In this case refer to Chapter 4 3 4 Adjusting the machine reference and make the necess
44. YAMAHA YAMAHA MOTOR CO LTD YAMAHA SCARA ROBOT YK X series YK120X YKI50X YK180X YK220X User s Manual Before using the robot Be sure to read the following notes At this time our thanks for your purchase of this YAMAHA YK X series SCARA robot 1 Please be sure to perform the following tasks before using the robot Note that the robot may operate abnormally abnormal vibration or noise if the following work is not carried out Before the YK X series is shipped the position shown in Chapter 7 1 2 Exter nal view and dimensions is adjusted as the origin position and the standard coordinates are provisionally set 1 Absolute Reset Absolute reset must be carried out just once before the YK X series robot can be used Once absolute reset is completed it does not need to be carried out again when the power is turned ON the next time Refer to Chapter 4 3 Adjusting the origin in this manual and Absolute Reset in the YAMAHA Robot Controller User s Manual for details on ab solute reset 2 Setting the standard coordinates Set the standard coordinates while referring to instructions in 5 Setting the Standard coordinates in Chapter 4 of this manual and also to Setting the Standard coordinates in the YAMAHA Robot Controller User s Manual Robot malfunctions vibration noise may occur if the standard coordinates are not set correctly Even though there is no problem with the robot the followin
45. Z axis bellows 2 Suction amount for suction couplers 2 25 NI min Simultaneous suction through two 46 couplers is possible Suction amount lower than this level cannot maintain the degree of cleanliness 3 Always set the maximum Z axis rotating speed axis parameter No 37 to 1500 If higher than this value the degree of cleanliness cannot be maintained and the bellows might be damaged 170 x R axis bellows type suction coupler 3 M3 ground terminal E User tubing 1 844 03 User tubing 2 Rs wW 57 5 48 45 a 38 5 a y X Y axis origin position Suction coupler for X Y axis maximum movement position during EGER base interior 96 X Y axis absolute reset stopper origin setting When carrying out X Y axis absolute reset 2 22 Take care to prevent interference between the stopper origin setting move the X axis to a end tool robot and peripheral devices etc position counterclockwise from this position 0 0 and the Y axis to a position clockwise 7 9 CHAPTER 7 Specifications HA Connector for user wiring No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector SMR 6V B pin SYM 001T P0 6 supplied Use the YC12 crimping machine So 34 S 4 7 Use M6 bolt for installation A 109 ti Do not attach any wire and tube to these cables 44 Doing so may reduce positioning accuracy 463 5 TT 420 During arm rotation 4
46. able for clean room is used for the Z axis ball screw ball spline and linear bushing shaft Use the LG2 clean room grease for periodic maintenance 5 Specifications and external appearance are somewhat changed See sections 1 1 and 1 2 in chapter 7 The X and Y axis repeated positioning accuracy and Z axis maximum speed are different from standard specifications The external appearance and dimensions are different in that the Z axis bellows flexible tube and suction couplers are added CHAPTER 1 o oOo N O 0d A W PD b kh gt O 12 CHAPTER 1 2 3 4 5 CHAPTER 1 CONTENTS 1 Using the Robot Safely Safety JMOL Mal ao cl 1 1 Essential Caution MMS AN 1 2 Special Training for Industrial Robot Operation ooooccccccnnccccccnnnccccccnnnos 1 10 Robot Safety Functions ccccconnnnnnnnnooooonononncnnnnnononnnnnnnnnnncnnnnnoninnananannnnns 1 11 Safety Measures for the System oooccccnnncccccncccccononcccnnnnnnnnanannnnncnnnnnnnnnns 1 12 Trial Operatio saint dd 1 13 Work Within the Safeguard Enclosure oooooooccccnonininnncccccnnccnnnccnncccnnnannnns 1 14 Automatic Operation oooooooooccccnncconnoncccnnnnnnnnnncnnccnnnnnnnnnnnnnnnncnnnnnnncnnnnnnnnnns 1 15 Adjustment and Inspection sscoreorenntomngia nido deta 1 15 Repair and Modifica Tears 1 15 A A A E IO 1 16 CE Mad es eee A PIERS oe et Pr coa A Ae AP tear ene 1 18 2 Functions Robot Manipulator cu scsctenketideciegidsasheeetahivinde ies tpeibleedath
47. ackage by dolly to near the installation base before unpacking Take sufficient care not to apply shocks to the equipment when unpacking it Robot controller and accessories Fig 3 2 Packed state 3 5 CHAPTER 3 Installation AAA AA ee 2 2 Checking the product After unpacking check the product configuration and conditions The following configurations are typical examples so please check that the prod uct is as specified in your order CAUTION If there is any damage due to transportation or insufficient parts please notify your YAMAHA sales office or dealer immediately Controller RCX142 T RCX142 Robot YK120X YK150X YK180X YK220X Standard L Warning label x 1 CD ROM User s Manual or User s Manual SP User wiring connector x 2 Er User wiring pin x 20 Robot manipulator YK 120X series YK120X YK150X YK 180X series YK180X YK220X RCX142 T controller and accessories YK120X YK150X RCX142 controller and accessories YK180X YK220X Refer to the YAMAHA Robot Controller User s Manual for details on the con troller accessories and options Fig 3 3 Product configurations 3 6 CHAPTER 3 Installation 2 3 Moving the robot 1 Fold in the arm and wind the robot cable as shown in Fig 3 4 2 The robot must be carried by two workers One worker must hold the support sections shown in the drawing with both hands and the other worker must carry the ro
48. age due to earthquakes storms floods thunderbolt fire or any other natural or man made disasters 2 Troubles caused by procedures prohibited in this manual 3 Modifications to the robot and or related product not approved by YAMAHA or YAMAHA sales representatives 4 Use of any other than genuine parts and specified grease and lubricants 5 Incorrect or inadequate maintenance and inspection 6 Repairs by other than authorized dealers 1 16 CHAPTER 1 Using the Robot Safely A YAMAHA MOTOR CO LTD MAKES NO OTHER EXPRESS OR IMPLIED WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS IN LIEU OF ALL EXPRESSED OR IMPLIED WARRANTIES INCLUDING WARRAN TIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR WARRANTIES ARISING FROM A COURSE OF DEALING OR USAGE OF TRADE YAMAHA MOTOR CO LTD SOLE LIABILITY SHALL BE FOR THE DE LIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO LTD SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES WHETHER ARISING FROM CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY YAMAHA MOTOR CO LTD MAKES NO WARRANTY WHAT SOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED BY YAMAHA MOTOR CO LTD CHAPTER 1 Using the Robot Safely E 12 CE Marking When the YAMAHA robots are exported to or used in EU European Union countries refer to the separate YAMAHA Robot Controller User s Manual or C
49. ally do not induce vomiting but promptly consult a physician for treatment Disposing of harmonic grease cleaning oil and the container e Proper disposal is compulsory under federal state and local regulations Take appropriate measures in compliance with legal regulations Do not pressurize the empty container Pressurizing may cause the con tainer to rupture Do not attempt to weld heat up drill holes or cut this container This might cause the container to explode and the remaining materials inside it to ig nite When removing the wave generator from the motor shaft or reinstalling it back onto the motor shaft use caution to avoid as much as possible applying a thrust load to the motor shaft If a load is applied the resolver may be damaged resulting in a hazardous situation of the robot trouble 5 9 CHAPTER 5 Periodic Inspection EA A AA AAA AA CAUTION The harmonic drive service life may shorten if the grease recommended by YAMAHA is not used Recommended grease Use the following harmonic drive grease SK 2 made by Harmonic Drive Systems Inc Harmonic drive Do not apply strong shocks or impacts to these parts such as with a ham mer Also do not scratch scar or dent these parts by dropping etc Such actions will damage the harmonic drive e The specified performance cannot be maintained if any part of the harmonic drive is used in a damaged state This damage or w
50. andards for industrial robots and provide special training for every person involved in robot related tasks teaching programming movement check inspection adjustment repair etc CHAPTER 1 Using the Robot Safely EA A A A 4 Robot Safety Functions 1 Overload detection This function detects an overload applied to the motor and shuts off the servo power If an overload error occurs take the following measures 1 Insert a timer in the program 2 Reduce the acceleration coefficient 2 Overheat detection This function detects an abnormal temperature rise in the driver inside the controller and shuts off the servo power If an overheat error occurs take the following measures 1 Insert a timer in the program 2 Reduce the acceleration coefficient 3 Soft limits Soft limits can be set on each axis to limit the working envelope in manual operation after return to origin and during automatic operation Note The working envelope is the area limited by soft limits 4 Mechanical stoppers If the servo power is suddenly shut off during high speed operation by emer gency stop or safety functions these mechanical stoppers prevent the axis from exceeding the movement range On the X axis Y axis arm mechanical stoppers are fixed at both ends of the maximum movement range The Z axis has a mechanical stopper at the upper end and lower end No mechanical stopper is provided on the R axis Note The movement ran
51. ary adjustments 4 15 CHAPTER 4 Adjustment 3 3 4 Sensor method X and Y axes of YK180X YK220X Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset The operation procedure using the MPB is described next Press the ESC key on the MPB if you want to return to the preceding step See the YAMAHA Robot Controller User s Manual for information on operat ing the robot controller 1 2 3 4 5 Check that no one is inside the safeguard enclosure and then turn on the controller Place a sign indicating the robot is being adjusted to keep others from touch ing the controller switch or operation panel Set the controller to MANUAL mode if not in MANUAL mode Press the F13 LOWER F3 key to select RST ABS Select the X axis or Y axis for absolute reset X axis M1 Y axis M2 To perform absolute reset on all axes select ALL with the F11 LOWER F1 key ACAUTION The Z axis of the stroke end method first rises during the absolute reset of all axes default setting Be careful that your fingers do not get pinched or crushed by any sudden movement 6 7 Move the X and Y axes to a position on the plus side of their origins See Fig 4 5 so that the robot is positioned in a left handed system as shown in Fig 4 5 If the axes are not at these positions press the jog keys etc and mov
52. as removed h Data in the ALL data file extension ALL or parameter file extension PRM was written into the controller by way of the RS 232C The following sections explain how to perform absolute reset If any of the above cases occur after installing the robot absolute reset must be performed again The robot must be moved to the origin position to perform absolute reset Select a robot position where the origin position will not interfere with peripheral devices after setup is completed CAUTION After performing absolute reset move the robot to a known point to check whether the origin position is correctly set When doing this check move the robot at the slowest possible speed The YK120X series and YK180X series absolute methods include the sensor method and stroke end method The YK120X series uses the stroke end method for the X axis Y axis and Z axis and the sensor method for the R axis The YK180X series uses the stroke end method for the Z axis and the sensor method for the X axis Y axis and R axis 4 2 CHAPTER 4 Adjustment 3 1 Absolute reset method 3 1 1 YK120X series YK120X YK150X 3 1 1 1 Sensor method R axis In the sensor method the target axis is automatically operated for the absolute reset and the absolute reset is performed at the position where the proximity sensor provided on the target axis detects the detection area dog The absolute reset in the sensor method can b
53. ations Allowable ambient temperature 0 to 40 C Allowable ambient humidity 35 to 85 RH non condensation Altitude 0 to 1000 meters above sea level Ambient environments Avoid installing near water cutting water oil dust metallic chips and organic solvent Avoid installation near corrosive gas and corrosive materials Avoid installation in atmosphere containing inflammable gas dust or liquid Avoid installation near objects causing electromagnetic interference electrostatic discharge or radio frequency interference Vibration Do not subject to impacts or vibrations Air supply pressure etc Below 0 58MPa 6 0kgf cm clean dry air not containing deteriorated compressor oil filtration 40um or less Working space Allow sufficient space margin to perform jobs teaching inspection repair etc For detailed information on how to install the robot controller refer to the sepa rate YAMAHA Robot Controller User s Manual Avoid installing the robot in locations where the ambient conditions may ex ceed the allowable temperature or humidity or in environments where water corrosive gases metallic powder or dust are generated Malfunction failure or short circuits may otherwise result e This robot was not designed for operation in environments where inflamma ble or explosive substances are present Do not use the robot in environments containing inflammable gas dust or liquids
54. bels can be clearly seen even from the outside of safeguards 19 Protective bonding Be sure to ground the robot and controller to prevent electrical shock 20 Always connect the robot to the specified controller The controller for the YK120X series robots YK120X YK150X is designed to provide 24V output and the model name RCX142 T is shown on the serial number label see Fig 2 5 Do not connect other controllers to the YK120X series robot If operated from a controller other than the RCX142 T the robot s motors may be damaged 21 Avoid fastening any cable or tube prepared by the user with the machine harness user signal wires or air tubes of the robot Do not utilize the machine harness user signal wires or air tubes of the robot to fasten any cable or tube prepared by the user as this may break the robot harness wires or user signal wires causing malfunction of the robot This will also result in poor positioning accuracy 22 Do not use the robot in locations subject to strong vibrations Do not operate the robot in locations subject to strong vibrations The robot installation bolts might work loose and the robot topple over The bolts on the robot body itself might also loosen causing parts to fall off etc 1 7 CHAPTER 1 Using the Robot Safely A 23 Be sure to make correct parameter settings CAUTION The robot must be operated with correct tolerable moment of inertia and accel eration c
55. ble Danger Damage to machine harness or robot cable Electrical shock malfunction of robot Flying outwards of damaged parts during robot Damage to exterior of robot operation Abnormal operation of robot Buin ae Ronen Malfunction of robot positioning error excessive vibration etc Z axis brake trouble Dropping of load 16 Use caution not to touch the controller rear panel cooling fan Bodily injury may occur from coming into contact with the cooling fan while it is rotating e When removing the fan cover for inspection first turn off the controller and make sure the fan has stopped 17 Use caution not to touch the high temperature motor or speed reduction gear casing The motor and speed reduction gear casing are extremely hot after automatic operation so burns may occur if these are touched Before touching these parts during inspections or servicing turn off the control ler wait for a while and check that the temperature has cooled 1 6 CHAPTER 1 Using the Robot Safely 18 Do not remove alter or stain the warning labels If warning labels are removed or difficult to see necessary cautions may not be taken resulting in an accident Do not remove alter or stain the warning labels on the robot Do not allow the warning labels to be hidden by the device installed to the robot by the user e Provide proper lighting so that the symbols and instructions on the warning la
56. bot cable Place the robot on the installation base and temporar ily tighten with the bolts Refer to section 2 4 Installing the robot for the bolt tightening torque values Robot cable Support part Bolt installation hole Fig 3 4 CAUTION If the robot is transported long distances by truck while mounted on an installation base or packed in a case other than the dedicated carton box in which the robot was shipped the bolts installing the robot or the bolts on the robot body itself might come loose due to vibration The robot might then topple over or the parts fall off When transporting the robot long distances use the dedicated case in which the robot was shipped from our factory 3 7 CHAPTER 3 Installation 2 4 Installing the robot Install the robot securely with the four hex socket head bolts as shown in Fig 3 5 Be sure to use the specified type and number of bolts and securely tighten them to the correct torque If the bolts are not tightened correctly the robot may cause positioning errors or fall over during operation causing a serious acci dent Tightening torque Robot Mode Bolts Used Tightening torque 3 YK120X YK150X M 2 0Nm 20kgfcm YK180X YK220X M6 15 3Nm 156kgfcm Installation base Y Hex socket head bolt Fig 3 5 Installing the robot 3 8 CHAPTER 3 Installation 3 Protective Bonding Be sure to ground the robot and controller to pr
57. can be used for a wide range of assembly applications such as installation and insertion of various parts application of sealant and packing operations This user s manual describes the safety measures handling adjustment and main tenance of YK120X series robots for correct safe and effective use Be sure to read this manual carefully before installing the robot Even after you have read this manual keep it in a safe and convenient place for future reference This user s manual should be used with the robot and considered an integral part of it When the robot is moved transferred or sold send this manual to the new user along with the robot Be sure to explain to the new user the need to read through this manual This user s manual explains the YAMAHA industrial robots YK120X series stand ard models YK120X YK150X clean room models YK120XC YK150XC and YK180X series YK180X YK220X Some descriptions of YK120XC and YK150XC are not listed in this manual when they are the same as standard models Refer to the descriptions of standard models For information on difference between the clean room model and standard model refer to the description on the next page For details on specific operation and programming of the robot refer to the separate YAMAHA Robot Controller User s Manual NOTES e The contents of this manual are subject to change without prior notice Information furnished by YAMAHA in this manual is believed t
58. ce value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel Turn off the controller and enter the safeguard enclosure Mark off the reference mark at the current origin position on the R axis joint area of the robot At this time be careful to prevent the origin position from deviating since the R axis is touched Using a hex wrench loosen the bolts 2 pieces securing the dog on the R axis joint See Fig 4 12 CAUTION The bolt only needs to be loosened and does not need to be completely removed 9 Move the dog in the following manner When machine reference lt 40 Move dog in A direction When machine reference gt 60 Move dog in B direction The movement guide is 0 8mm 100 10 Tighten the screw and fix the dog 4 30 CHAPTER 4 Adjustment ANN AN E 11 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 12 Perform the absolute reset from outside the safeguard enclosure 13 After the absolute reset is completed read the machine reference value dis played on the MPB 14 If the machine reference value is in the range between 40 and 60 recom mended range then
59. ces that provide a large degree of freedom when performing various manipulative tasks To ensure correct and safe use of YAMAHA industrial robots carefully read this manual and make yourself well acquainted with the contents FOLLOW THE WARN INGS CAUTIONS AND INSTRUCTIONS INCLUDED IN THIS MANUAL Failure to take necessary safety measures or mishandling due to not following the instructions in this manual may result in trouble or damage to the robot and in jury to personnel robot operator or service personnel including fatal accidents Warning information in this manual is shown classified into the following items Failure to follow DANGER instructions will result in severe injury or death to the robot operator a bystander or a person inspecting or repairing the robot Failure to follow WARNING instructions could result in severe injury or death to the robot operator a bystander or a person inspecting or repairing the robot CAUTION Failure to follow CAUTION instructions may result in injury to the robot opera tor a bystander or a person inspecting or repairing the robot or damage to the robot and or robot controller Refer to the user s manual by any of the following methods to operate or adjust the robot safely and correctly 1 Operate or adjust the robot while referring to the printed version of the user s manual available for an additional fee 2 Operate or adjust the robot while viewing the CD ROM version of t
60. ct with the bottom of the Z axis motor installation hole 11 Tighten the bolts to secure the ball screw The tightening torque should be 20kgfcm 2 0Nm Tighten the bolts a little at a time in a diagonal pattern Otherwise the ball screw might be off center After tightening the bolts securely lower the lower end urethane damper 12 Exit the safeguard enclosure 13 Check that no one is inside the safeguard enclosure and then turn on the controller 14 After completing absolute reset for the Z axis check to see if the machine reference value is within the tolerance range for absolute reset 15 Turn the controller power OFF 16 Install the Y axis arm upper cover 4 37 CHAPTER 4 Adjustment Lower end urethane damper Ball screw Upper end urethane damper Fig 4 15 4 38 CHAPTER 4 Adjustment ER 4 Setting the Soft Limits In the YK120X and YK180 series the working envelope during manual and auto matic operation can be limited by setting the plus soft limit pulses and minus soft limit pulses on each axis The origin point O pulses is used as the reference to set the soft limits The working envelope can be limited by specifying the number of pulses from the 0 pulse position Refer to the YAMAHA Robot Controller User s Manual for further details Also refer to 1 2 External view and dimensions in Chapter 7 for the working envelope area When performing actual checks of th
61. d X axis Y axis 3 1 1 3 Stroke end method Z axis 3 1 2 YK180X series YK180X YK220X cocoocconocccononnccnnonconannnncnoncncnnn nn nano nnn nano nr nana nnrnnnnos 3 1 2 1 Sensor method R axis iii dd 3 1 2 2 Sensor method X axis Y axis 3 1 2 3 Stroke end Method Z axis c ooonociconncccnonococnnononccncnonccnnnnrncnnnorncnn cnn crncc anna nena 3 2 Machine reference ooonncccinncnnnnnccnnccnnnnncnnnnnrccn anna 3 3 Absolute reset Procedures ccccoonocccccnnonoccccnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnn nn EEEE EEEN CEE RR 3 3 1 Sensor method R AXiS piesi eisein iadaan nade a aai isiende iie 3 3 2 Stroke end method X and Y axes of YK120X YK150X 0oooooococccoocconccconconanccanccnns 4 13 3 3 3 Stroke end Method Z axis oooonoconncnnccnnncnnnccnonncnnnccancnnnnnnonc nono nc acc rra crac cnn ncnnnncns 4 15 3 3 4 Sensor method X and Y axes of YK180X YK220X 0oooocooccccocicoocococcconconancnannanns 4 16 3 4 Adjusting the machine reference oococcconnocccccconocnccccnnnoncnnnnnnnnncnn canon nnccnnnnnnncncnnnns 4 18 3 4 1 YK120X series YK120X YK150X 0ooooocccoooocccccccoconoconocononnccnncnnnnnncnnnnnannnccnnnninnnns 4 19 3 4 1 1 Adjusting the R axis machine reference YK120X YK150X nosses 4 19 3 4 1 2 Adjusting the R axis machine reference YK120XC YK150XC eeeeeeeeereee 4 21 3 4 1 3 Adjusting the X axis machine reference 3 4 1 4 Adjusting the Y axis machine reference 3 4 1 5 Adjusting the Z axis
62. dabbiesdecatdtextadce 2 1 Robot Controle tata dl 2 5 Robot initialization number liSt oooccccnoninicicicononanancccconananananannccncnnnnnn nor 2 6 Parameters for Clean Room Models YK120XC YK150XC eseese 2 7 Tip weight parameter setting and WEIGHT statement in programs 2 8 3 Installation Robot Installation Conditions oooooooccccccnnoccccccccncnonananaccnononnnnananncnnnnnnnnnns 3 1 1 1 Installation environments oooonoccccnnnnoccccccnnnoncnnnnnnnnnnnccnnno nn eee nn nnn nn cnn nnnnnnn cc naar ncccnins 3 1 1 2 Installation BaSe oo ee cece ce eeeeeeeeeeeeeeeeeeeeeeeeaeaeeeeeaaaeaeeeessaeaaeeeeeaaeeeeeeeseeaeeenes 3 3 nal MM a A are Snore mere E aai 3 5 22h UNPAID ii vd eed ae a eee eee 3 5 2 2 Checking the Product cceccecceeeeeeeece eect eeeeaaeeeeeeeeeeaaeeseeeeesaaeesseneeessaeeeteneeeseas 3 6 2 37 MOVING METODO e erre TaN a rantcevbeaneedeePeshuveghs rane EEE REEN EER 3 7 2 4 Anstaling the robot oooonioccccnnnnccccnnnnaccccnnnnnnncncnnnnnne TATAEE EN TAA 3 8 Protective Bonds 3 9 N O 0 A 8 CHAPTER Robot Cable Connection oooooooooocccccccccccnncccnccnnnnnnnnnnncnnnn non nnnnnnnnnnnnnnnnnnos 3 11 User Wiring and User Tubing ccooocccccnnncconcccccccncnnnananancnoncnnnannnnccnnnnannns 3 13 Connecting a suction hose YK120XC YK150XC cococcccoocccccccccconacannnons 3 16 Attaching The End Effector cccceeeeescceceeeeeeeeeeeeeeeeeeeeeenaeeeeeeeeeeaaees 3 17 7 1 R axis tolerable
63. e moved 9 Move the movable mechanical stopper in the following manner When machine reference lt 40 Move mechanical stopper in A direction When machine reference gt 60 Move mechanical stopper in B direction The movement guide is 1mm 100 10 Tighten the bolt and fix the movable mechanical stopper The tightening torque is 20kgfcm 2 0Nm 4 32 CHAPTER 4 Adjustment ANN AN E 11 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 12 Perform the absolute reset from outside the safeguard enclosure 13 After completing absolute reset check the machine reference value 14 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it X axis dog X axis Sensor Fig 4 13 Adjustment of X axis machine reference 4 33 CHAPTER 4 Adjustment Adjusting the Y axis machine reference 3 4 2 3 The adjustment method for the Y axis machine reference is as follows 1 2 3 4 5 6 7 8 Prepare the necessary tools e Hex wrench set Check that no one is inside the safeguard enclosure and then turn on the controller Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures
64. e shown below 93 2 tubes Robot models for custom specifications may have different wiring or tub ing The specifications of the user wires and air tubes are shown below Always observe the specifications User signal cable Rated voltage Allowable current Nominal cross section area of conductor Shield User Tubing Maximum pressure 0 58MPa 6Kgf cm Outer diameter x inner diameter 03x01 5 Fluid Dry clean air not containing deteriorated compressor oil filtration 40um or less 2 User wiring connectors and user piping joints are provided on the arm side and base side Refer to Chapter 7 1 2 External view and dimensions for the positions 3 13 CHAPTER 3 Installation AAA 3 Signal wiring connections in the machine harness Connector pins 1 to 6 can be used User signal line 10 10 Arm side 4 4 Base side Robots models with non standard specifications may have different wiring colors 4 Crimp the user wiring to the connector supplied using a crimping tool J S T Mfg Co Ltd YC12 or solder as shown in Fig 3 8 Lock mechanism Cable to be o prepared by user Connector supplied LE S a Robot side connector pin Fig 3 8 Securely fix the connector supplied to the robot s connector using the lock mechanism attached with the housing See Fig 3 8 The operation could mal function if t
65. e X axis arm first returns to the origin the tool on the end might interfere with the robot base pedestal if the Y axis arm is near its origin X axis origin is at 0 5 with respect to front of robot base Plus side uan gt Minus side Plus side lt gt Minus side tolerable load radius 1 Maximum tolerable load radius 1 YK180X YK220X 1 When load is cylindrical object Fig 4 5 Default origin position 4 8 3 1 2 3 CHAPTER 4 Adjustment Stroke end method Z axis With this method the Z axis is pushed against the mechanical stopper and after the axis end is detected absolute reset is performed from a position slightly back from the axis end Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset 4 9 CHAPTER 4 Adjustment E 3 2 Machine reference The YK X series position detector uses a resolver having one position that can perform absolute reset in respect to one motor rotation When absolute reset is performed with the sensor method or stroke end method the origin position will be set to a position where it can be reset immediately after the origin sensor reacts to the dog where the origin signal is detected or the stroke end mechanical stopper is detected The machine reference means the position relationship between the position where the robot
66. e calls for operation of the robot stay outside the safeguard enclosure 5 Place a sign indicating the robot is being inspected to keep others from oper ating the controller switch programming unit or operation panel 6 Use only the lubricants specified by YAMAHA or YAMAHA dealers 7 To check the operation after inspection refer to 6 Trial operation in Chapter 1 e When you need to touch the terminals or connectors on the outside of the controller during inspection always first turn off the controller power switch and also the power source in order to prevent possible electrical shock Never touch any internal parts of the controller For precautions on handling the controller refer to the YAMAHA Robot Con troller User s Manual 5 2 CHAPTER 5 Periodic Inspection A 3 Daily Inspection The following is an inspection list that must be performed every day before and after operating the robot 1 Inspection to be performed with the controller turned off 1 Turn off the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller switch 3 Enter the safeguard enclosure and check the following points Checkpoint Procedure Machine harness Check for scratches dents and excessive bend and kinks Robot cable If the machine harness or robot cable is damaged contact YAMAHA User cable and wiring dealer Check air pressure Regulator joints air tube
67. e executed with the teaching pen dant MPB RS 232C communication and dedicated input Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset AACAUTION The origin cannot be detected in any axis which is not positioned on the plus side from the origin See Fig 4 1 before starting the return to origin opera tion Factory setting at shipment In this case press the STOP key to interrupt the return to origin operation move the target axis to the plus side of the origin and reperform the origin return operation If the return to origin operation is not stopped the robot will continue moving and could collide with the peripheral devices The R axis does not have a me chanical stopper so the wiring and piping installed on the end effector could become entangled R axis dog Plus side Nw Plus A R axis Sensor R axi axis R axis Sensor R axis Minus side Minus side YK120X YK150X YK120XC YK150XC Fig 4 1 View of R axis from below 4 3 CHAPTER 4 Adjustment 3 1 1 2 Stroke end method X axis Y axis With the stroke end method the X and Y axes are pushed against the mechanical stopper and after the axis end is detected absolute reset is performed from a position slightly back from the axis end Serious injury might occur from physical contact with the robot during opera tio
68. e following precautions when transporting the robot CAUTION If the robot is transported long distances by truck while mounted on an installa tion base or packed in a case other than the dedicated carton box in which the robot was shipped the bolts installing the robot or the bolts on the robot body itself might come loose due to vibration The robot might then topple over or the parts fall off When transporting the robot long distances use the dedicated case in which the robot was shipped from our factory 30 If the X Y or R axis rotation angle is small If the X Y or R axis rotation angle is smaller than 5 so that it always moves in the same position an oil film is difficult to be formed on the joint support bear ing possibly leading to damage to the bearing In this type of operation add a movement so that the joint moves through 90 or more about 5 times a day 1 9 CHAPTER 1 Using the Robot Safely E AAA AAA AAA AA 22 3 Special Training for Industrial Robot Opera tion Companies or factories using industrial robots must make sure that every person who operates or handles the robot such as for teaching programming movement check inspection adjustment and repair has received appropriate training and also has the skills needed to perform the job correctly and safely Since the YK120X and YK180X series robots fall under the industrial robot cat egory the user must observe local regulations and safety st
69. e soft limit settings operate the robot manually from outside the safeguard enclosure 1 Setting the X axis and Y axis soft limits Set the soft limit on the inner side of the movement range limited by the mechanical stopper or on the inner side of the position that interferes with the peripheral devices note that this must within the maximum working enve lope Set the soft limit with the following procedures 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Press the emergency stop button on the MPB to set emergency stop Refer to the YAMAHA Robot Controller User s Manual for further details on emergency stop and canceling emergency stop 3 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 4 Enter the safeguard enclosure while holding the MPB 5 Move the X axis and Y axis arms by hand to the mechanical stopper posi tions or to the point where interference with the peripheral equipment oc curs and note the X axis and Y axis plus and minus direction pulses displayed on the MPB 6 Check that no one is inside the safeguard enclosure then cancel emergency stop from outside the safeguard enclosure 4 39 CHAPTER 4 Adjustment E 7 Set the soft limits to within the figure for the X axis and Y axis encoder pulses that you noted above in step 5 This software limit setting must be made from outside the sa
70. e the target axes When performing absolute reset for the other axes at the same time check that the other axes are also at an appropriate position Refer to procedures for absolute reset of other axes Since the message Reset ABS encoder OK is displayed check that there are not any obstacles in the robot movement range and press the F4 key YES 4 16 CHAPTER 4 Adjustment _ a 8 After the absolute reset is completed check that the X axis and Y axis ma chine reference value displayed on the MPB is within the absolute reset tol erance range 40 to 60 If the machine reference value is outside the absolute reset tolerance range then the next absolute reset may not be properly performed In this case refer to Chapter 4 3 4 Adjusting the machine reference and make the necessary adjustments CHAPTER 4 Adjustment ER 3 4 Adjusting the machine reference CAUTION If any machine reference is adjusted the origin position may change Before the adjustment mark off the reference mark at the current origin posi tion on the main body of the robot After the machine reference is adjusted be sure to check that the origin posi tion has not deviated If the origin position changes after the machine reference has been adjusted then the standard coordinate and point data must be reset AACAUTION When the arm moves at high speed and strikes against a mechanical stopper violently the machine re
71. ear may also lead to trouble with the harmonic drive ACAUTION Since a positional shift occurs after replacing the harmonic drive it is neces sary to make absolute reset standard coordinate setting and point data setting again CHAPTER Increasing the robot operating speed 1 Increasing the robot operating Speed oocccccccccnnnininnnnccnonanannnnnnnncnoncnnnnnos MEMO CHAPTER 6 Increasing the robot operating speed AAA AAA IIA E AA 1 Increasing the robot operating speed The robot operating speed can be increased by the following methods Use these methods as needed when programming 1 Increasing speed by arch motion Also refer to Robot controller user s manual Axis parameters Arch position in Chapter 4 Programming manual ARCH statement in 11 Command statements Gate motion From point P1 to P4 via P2 and P3 Z 0 P2 P3 MOVE P P2 MOVE P P3 MOVE P P 4 j ss 2 Arch motion Using default arch position 2000 pulses From point P1 to P2 MOVE P P2 Z 0 M1 M2 M4 7 7 Axis parameters Arch position i M1 X axis arch position 2000 pulses M2 Y axis arch position 2000 pulses Pl p2 M3 Z axis arch position 2000 pulses M4 R axis arch position 2000 pulses When the Z axis moves upward from P1 and enters the M3 arch position range 2000 pulses prior to Z 0 the X Y and R axes begin to move When these 3 axes enter the M1 M2 and M4 arch p
72. eeeeeaees 4 6 3 1 2 YK180X series YK180X YK220X 0oooococccocococccococonaonconcconnnnnconccnnnnnncnnncnnnnnncnnnninnnns 4 7 3 1 2 1 Sensor Method R AXiS oonocccnonnconnonccnnccncnnncnncnrncc rra nnnc rra cnr nn 4 7 3 1 2 2 Sensor method X axis Y axis coooonccnonnnnicnonnocincncnccnnnnnccnnnnrc cnn nnrccnrnnrcrnncnncnnan 4 8 3 1 2 3 Stroke end Method Z AXIS c oococonnnicnicnnccnnonecncnncnncnnrnrncnnrnr crac 4 9 3 2 Machine reference moscatel td 4 10 3 3 Absolute reset procedures onocccccconooccccconconccncnnnanncncnnnnoncnnnnnnnnn cnn nnnnn o nn nnnnnnrnnnnnnnnns 4 11 3 3 1 Sensor method R axiS sinnene aei ee nan 4 11 3 3 2 Stroke end method X and Y axes of YK120X YK150X coooocooocococccoccccocnconcnnannnono 4 13 3 3 3 Stroke end Method Z axis oooonooccnnccnnciconccnnccconcnnncnnnncnnnnnnnncnrann nana nnnn cc nnnn nn ncnnnnnns 4 15 3 3 4 Sensor method X and Y axes of YK180X YK220X 0cooooococcooccccoocconcccanncnnncnannnnno 4 16 3 4 Adjusting the Machine reference omcinicccinonicinnccccconnnonnncncnnn can ann cnn cnn cn ran nnnnnncccnns 4 18 3 4 1 YK120X series YK120X YK150X 0oooococccoooccccccconononccnncnnnnnncnncnnannncnnnnnannnnnnnncannnns 4 19 3 4 1 1 Adjusting the R axis machine reference YK120X YK150X essnee 4 19 3 4 1 2 Adjusting the R axis machine reference YK120XC YK150XC se eeceeseeeeeee 4 21 3 4 1 3 Adjusting the X axis machine reference e ee cece cee eeee eee eceeeeeeeeseeseeeeeaeenees 4 2
73. els at an easy to see position on the robot 1 Turn off the controller 2 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller switch 3 Enter the safeguard enclosure 4 Attach the movement direction and axis name labels at an easy to see posi tion on the robot arm base and end effector etc of each axis which moves relatively Wipe the surface with alcohol etc and allow to dry completely before attaching the labels See Fig 4 17 Attach the movement direction label according to the jog movement direction and the axis name label according to the axis Incorrect label positions could result in incorrect operations Direction of movement and axis name stickers Fig 4 16 4 43 CHAPTER 4 Adjustment Fig 4 17 Positions for affixing the stickers CHAPTER 4 Adjustment AAA A A A A 7 Removing the Robot Covers To remove the robot cover follow the procedure below 1 Prepare the necessary tools e Phillips head screwdriv
74. er 2 Turn off the controller 3 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller switch 4 Enter the safeguard enclosure 5 Remove the covers while referring to Fig 4 18 Fig 4 19 CAUTION The Z axis might be locked depending on how the Y axis upper cover is reattached So after reattaching the cover release the Z axis brake while prop ping the Z axis with a proper support or stand to check that the Z axis is not locked 4 45 CHAPTER 4 Adjustment OM2x5 x4 A gt Y Y axis arm upper cover I K 2M2x5 x4 same on opposite side Base robot pedestal side cover YK120X YK150X Y axis arm upper cover DM2x4 x4 M2x6 x2 this side M2x4 x2 opposite side Y axis arm side cover M2x4 x2 same on opposite side 2M2x4 x4 same on opposite side Base robot pedestal side cover YK120XC YK150XC Fig 4 18 4 46 CHAPTER 4 Adjustment Y axis arm upper cover So DM3x6 x4 _ LE Ia al O pe Y e L HP TH DM3x6 x4 a h M3x6 x4 ma rear cover Base front cover YK180X YK220X Fig 4 19 4 47 MEMO 4
75. er inspection 1f you notice any adjustment or parts replacement is needed first turn off the controller and then enter the safeguard enclosure to perform the necessary work After adjustment or replacement is fin ished again review the checkpoints outlined in 1 and 2 above 2 If repair or parts replacement is required for the robot or controller please contact your YAMAHA dealer This work requires specialized technical knowledge and skill so do not attempt it by yourself 5 4 CHAPTER 5 Periodic Inspection Six Month Inspection Take the following precautions when performing 6 month inspection Injury can occur if hands or fingers are squeezed between the drive pulley and belt Always turn off the controller and use caution when handling these parts The Z axis will slide down when the Z axis brake is released causing a hazard ous situation Do not release the brake when lubricating the Z axis parts When lubricating the ball screw spline shaft and linear busing shaft observe the following precautions Precautions when handling grease Inflammation may occur if this gets in the eyes Before handling the grease wear your safety goggles to ensure the grease will not come in contact with the eyes Inflammation may occur if the grease comes into contact with skin Be sure to wear protective gloves to prevent contact with skin Do not take orally or eat Eating will cause diarrhea and vomiting e Hands and
76. er wiring No 1 to 6 Fig 2 4 YK180X YK220X 2 4 CHAPTER 2 Functions Robot Controller The YK120X series robots YK120X YK150X come with a robot controller RCX142 T The YK180X series robots YK180X YK220X come with a robot controller RCX142 Refer to the separate YAMAHA Robot Controller User s Manual for details on the robot controller For the YK120X series robots YK120X YK150X always use the RCX142 T controller that is designed to provide 24V output The model name RCX142 T is shown on the serial number label See Fig 2 5 Do not connect other robot controllers to the YK120X series robots If operated from a controller other than the RCX142 T the robot s motors may be damaged 2 l Serial number label RCX14 SVANANA E 60Hz MAX 300VA RCX142 T Fig 2 5 Robot controller for YK120X series YK120X YK150X 2 5 CHAPTER 2 Functions ee AAA AAA A 3 Robot initialization number list The YK X series robots are initialized for optimum setting default setting ac cording to the robot model prior to shipping The robot controllers do not have to be reinitialized during normal operation However 1f for some reason the con troller must be reinitialized proceed while referring to the list below CAUTION Absolute reset must be performed after reinitializing the controller Before reinitializing the controller read the d
77. eration of the robot e Before starting the robot operation even after you have read through this manual read again the corresponding procedures and cautions in this manual as well as descriptions in this chapter Chapter 1 Using the Robot Safely e Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual Improper installation or operation can result in serious injury or death Read user s manual and all warning labels before installation or operation A WARNING Improper Installation or operation can result in serious injury or death Read user s owner s manual and all warning labels before operation Fig 1 3 Warning label 3 4 Do not remove the Z axis upper end mechanical stopper Removing or moving the upper end mechanical stopper attached to the Z axis spline shaft of the YK180X and YK220X series can damage the Z axis ball screw Never remove or move it AACAUTION Do not remove this part Damage to the ball screw will result Es Do not remove this part ye CAUTION Damage to ball screw will result Fig 1 4 Warning label 4 5 Do not use the robot in environments containing inflammable gas etc e This robot was not designed for operation in environments where inflamma ble or explosive substances are present Do not use the robot in environments containing inflammable gas dust or liquids Explosions or fire c
78. escriptions in 3 Adjusting the ori gin in Chapter 4 and make sure you thoroughly understand the procedure CAUTION When the controller is initialized the ARM LENGTH and OFFSET PULSE settings in the axis parameters will be erased making the standard coordinate settings invalid Refer to Chapter 4 Setting the Standard Coordinates for details on the stand ard coordinates Write down the arm length and offset pulse values before hand and input each value again after completing the initialization process Robot initialization number Robot initialization number Robot model name Applicable models YK120X YK120X YK120XC YK150X YK150X YK150XC YK180X YK180X YK220X YK220X 2 6 CHAPTER 2 Functions A AAA 4 Parameters for Clean Room Models YK120XC YK150XC Part of robot parameters on clean room models has been changed to maintain the degree of cleanliness and the Z axis bellows durability Along with this robot parameter change shown below you must take the follow ing precautions To purchasers of this robot At this time our sincere thanks for your purchase of our robot Since this robot is custom designed and manufactured a robot parameter has been changed from the standard specifications Please keep this sheet carefully along with the user s manual Check the following points before using the robot Precautions during use Always make a backup of robot parameters
79. event electrical shock Turn off the controller before grounding the robot The robot must be grounded as follows 1 2 3 4 Provide a terminal marked PE for the protective conductor of the entire system and connect it to an external protective conductor In addition se curely connect the ground terminal on the robot pedestal to the same protec tive conductor See Fig 3 6 Symbol 417 IEC 5019 When the end effector uses an electrical device which if it malfunctions might make contact with the power supply the user must provide proper grounding on his own responsibility The YK X series robots do not have a ground terminal for this purpose For details on protective bonding on the robot body to comply with CE mark ing follow the instructions on protective bonding explained in the YAMAHA Robot Controller User s Manual or CE marking manual Use a ground cable with a conductor wire cross section of at least 2 0mm and a length within 1 meter 3 9 CHAPTER 3 Installation Ground symbol Ground symbol M3 Ground terminal si H M3 Ground terminal YK120X YK150X YK180X YK220X Fig 3 6 Ground terminal 3 10 CHAPTER 3 Installation Robot Cable Connection The robot cable is pre connected to each robot Correctly install the other end
80. feguard enclosure Refer to the YAMAHA Robot Controller User s Manual for further details on soft limit settings CAUTION The origin position adjusted before shipment may vary as shown in Chapter 7 1 2 External view and dimensions When introducing the robot be sure to set the soft limits with the number of pulses from the origin position 0 pulse position 4 40 CHAPTER 4 Adjustment SSE Se A 2 Setting the Z axis soft limits Make this setting from outside the safeguard enclosure The Z axis has mechanical stoppers fixed at the upper and lower ends of the Z axis movement range When the actual working range of the robot is smaller than the maximum working envelope or the manipulator interferes with the peripheral equipment reduce the Z axis plus soft limit pulses to narrow the working envelope 3 Setting the R axis soft limit To make this setting set emergency stop just as for the X axis and Y axis or be sure to do this from outside the safeguard enclosure The R axis has no mechanical stoppers When the actual working range of the R axis is small or it interferes with the peripheral equipment reduce the R axis plus soft limit pulse and minus soft limit pulses to narrow the working enve lope CAUTION Overloads may occur if the soft limit is almost near the encoder pulse at the mechanical stopper and the operating point is used at the edge of the move ment range Set the soft
81. ference value may change If this has happened check the machine reference value Also check the mechanical stopper for any dam age and the origin position for shift If the machine reference value is outside the recommended range adjust the machine reference In this case re teach ing may be required if the origin position has shifted 4 18 CHAPTER 4 Adjustment R 3 4 1 YK120X series YK120X YK150X 3 4 1 1 Adjusting the R axis machine reference YK120X YK150X The adjustment method for the R axis machine reference is as follows 1 8 Prepare the necessary tools e Phillips head screwdriver Check that no one is inside the safeguard enclosure and then turn on the controller Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel Turn off the controller and enter the safeguard enclosure Mark off the reference mark at the current origin position on the R axis joint area of the robot At this time be careful to prevent the origin position from deviating since the R axi
82. ffector may vibrate during robot operation causing bad effects on the manipulator operation When the end effector is attached by slot clamping always observe the con ditions listed in Table 3 2 If these are ignored the end effector may come loose and fly off during robot operation resulting in an accident or injury e In cases where other attachment methods are used be sure that the end effector will not come off when the loads listed in Table 3 1 are applied CAUTION The YK120X series YK120X YK150X and YK180X series YK180X YK220X is designed to be compact so the joints could be damaged if excessive force is applied for example during installation of an end effector Make sure that excessive force is not applied to the joints YK120X YK150X Tolerable radial load Tolerable thrust load Tolerable moment load Tolerable torque 100N 10 2kgf 100N 10 2kgf 1 5Nm 15 3kgfem 1 7Nm 17 3kgfcm 45N 4 6kgf 45N 4 6kgf 0 45Nm 4 6kgfcm 0 5Nm 5 1kgfem 45N 4 6kgf 45N 4 6kgf 0 45Nm 4 6kgfcm 0 3Nm 3 1kgfem YK180X YK220X Tolerable radial load Tolerable thrust load Tolerable moment load Tolerable torque 275N 28 1kgf 900N 91 8kgf 6 0Nm 61 2kgfcm 9 0Nm 91 8kgfcm 150N 15 3kgf 600N 61 2kgf 3 3Nm 33 7kgfcm 4 0Nm 40 8kgfcm 150N 15 3kgf 600N 61 2kgf 3 3Nm 33 7kgfcm 2 2Nm 22 4kgfcm 3 31 CHAPTER 3 Installation A A SSS 7 5 Gripping fo
83. fingers might be cut when opening the container so use protec tive gloves Keep out of the reach of children Do not heat the grease or place near an open flame since this could lead to sparks and fires Emergency Treatment e If this grease gets in the eyes wash liberally with pure water for about 15 minutes and consult a physician for treatment e If this grease comes in contact with the skin wash away completely with soap and water e If taken internally do not induce vomiting but promptly consult a physician for treatment Disposing of grease and the container e Proper disposal is compulsory under federal state and local regulations Take appropriate measures in compliance with legal regulations e Do not pressurize the empty container Pressurizing may cause the con tainer to rupture Do not attempt to weld heat up drill holes or cut this container This might cause the container to explode and the remaining materials inside it to ig nite CAUTION Unless grease specified by YAMAHA is used the service life of the ball screw ball spline and linear bushing shaft will shorten 5 5 CHAPTER 5 Periodic Inspection ANN 1 Inspection to be performed with the controller turned off 1 Turn off the controller 2 Place a sign showing that the robot is being inspected to keep others from operating the controller switch 3 Enter the safeguard enclosure and check the following points Check
84. g error messages are issued when the robot and controller are connected and power first turned on Actual error messages may differ according to how the robot and controller are connected Error messages issued when robot amp controller are connected RCX142 17 27 D ABS backup failed CPU 17 80 D ABS backup failed DRIVER 17 81 D ABS battery wire breakage 17 92 D Resolver disconnected during power off 17 93 D Position backup counter overflow 17 94 D ABS battery low voltage etc 2 3 4 5 wa 6 Caution when turning off the robot controller On the YK120X and YK180X series robots the harness exerts a large reaction force on the X and Y axis arms When the power to the robot controller is turned off the arm positions might move slightly due to the harness reaction force depending on where the arms are positioned If the arms moved a large distance in this case the correct position data may not be backed up To avoid this before turning off the power to the robot controller press the emergency stop button and check that the robot arms have completely stopped Connection to the controller The controller for the YK120X series robots YK120X YK150X is designed to provide 24V output and the model name RCX142 T is shown on the serial number label see Fig 2 5 Do not connect other controllers to the YK120X series robot If operated from a controller other than the RCX142 T the robot s mot
85. ge is the area limited by mechanical stoppers Axis movement will not stop immediately after the servo power supply is shut off by emergency stop or other safety functions 5 Z axis vertical axis brake An electromagnetic brake is installed on the Z axis to prevent the Z axis from sliding down when servo power is turned off This brake is working when the controller is off or the Z axis servo power is off even when the controller is on The Z axis brake can be released by means of the pro gramming unit or by a command in the program when the controller is on The Z axis will slide down when the Z axis brake is released creating a haz ardous situation e Press the emergency stop button and prop the Z axis with a support stand before releasing the brake Use caution not to let your body get caught between the Z axis and installa tion base when releasing the brake to perform direct teach CHAPTER 1 Using the Robot Safely 5 Safety Measures for the System Since the robot is commonly used in conjunction with an automated system dan gerous situations are more likely to occur from the automated system than from the robot itself Accordingly appropriate safety measures must be taken on the part of the system manufacturer according to the individual system The system manufacturer should provide a proper user s manual for safe correct operation and servicing of the system CHAPTER 1 Using the Robot Safely AAA AAA AA AAA gt
86. he connector dislocates Do not utilize the machine harness user signal wires or air tubes of the robot to fasten any cable or tube prepared by the user as this may break the robot harness wires or user signal wires causing malfunction of the robot This will also result in poor positioning accuracy Make sure that user wiring and piping connected with the user wiring connector and user wiring joint do not interfere with the robot get wound around the robot or led around when the robot moves The wiring and piping could be damaged and result in malfunctioning 3 14 CHAPTER 3 Installation Arrange the user wiring and piping installed with the user wiring connector and user piping joint not to pose hazards for the operators The operators could trip on these parts and be injured CAUTION Always use the supplied connectors and pins Contact faults could occur if other types are used Arm side and base side connector supplied Pin Manufacture BYM 001T 0 6 or sym 001T Po 6 9 S T Mfg Co Ltd SM Connector SMR 6V B 5 To check the operation and signal transmission between the end effector and the controller or peripheral equipment after making connections refer to 6 Trial operation in Chapter 1 3 15 CHAPTER 3 Installation 6 Connecting a suction hose YK120XC YK150XC Always turn off the robot controller and shut off air supply before connecting a suction hose Clean room models ha
87. he set screw and fix the ball screw The tightening torque is 17kgfcm 1 7Nm 12 Exit the safeguard enclosure 13 Confirm that there no workers in the safeguard enclosure and then release the controller emergency stop state 14 After completing absolute reset for the Z axis check to see if the machine reference value is within the tolerance range for absolute reset 15 Turn the controller power OFF 16 Install the Y axis arm upper cover 4 28 CHAPTER 4 Adjustment Z axis upper end mechanical stopper position Bolt Upper end mechanical stopper Linear shaft Ha I 11 1 Ball screw Set screw A Ball screw Sleeve A Set screw Ball screw Section A A c Fig 4 11 4 29 CHAPTER 4 Adjustment EE YK180X series YK180X YK220X 3 4 2 3 4 2 1 Adjusting the R axis machine reference YK180X YK220X The adjustment method for the R axis machine reference is as follows 1 8 Prepare the necessary tools e Phillips head screwdriver Check that no one is inside the safeguard enclosure and then turn on the controller Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method If any machine referen
88. he user s manual on your computer screen 3 Operate or adjust the robot while referring to a printout of the necessary pages from the CD ROM version of the user s manual It is not possible to detail all safety items within the limited space of this manual So it is essential that the user have a full knowledge of basic safety rules and also that the operator makes correct judgments on safety procedures during operation This manual and warning labels supplied with or affixed to the robot are written in English If the robot operator or service personnel does not understand Eng lish do not permit him to handle the robot 1 1 CHAPTER 1 Using the Robot Safely E 2 Essential Caution Items Particularly important cautions for handling or operating the robot are described below In addition safety information about installation operation inspection and maintenance is provided in each chapter Be sure to comply with these in structions to ensure safe use of the robot 1 Observe the following cautions during automatic operation Warning labels 1 Fig 1 1 are affixed to the robot Refer to Fig 2 2 to Fig 2 4 in Chapter 2 for the position e Install a safeguard enclosure protective enclosure to keep any person from entering within the movement range of the robot and suffering injury due to being struck by moving parts e Install a safety interlock that triggers emergency stop when the door or panel is opened e Install safeguards
89. ide the safeguard enclosure and then turn on the controller Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel Turn off the controller and enter the safeguard enclosure Mark off the reference mark at the current origin position on the R axis joint area of the robot At this time be careful to prevent the origin position from deviating since the R axis is touched Using a hex wrench loosen the set screws 4 pieces securing the dog ring to the R axis joint See Fig 4 8 CAUTION The set screws only need to be loosened and do not need to be completely removed 9 Move the dog ring in the following manner When machine reference lt 40 Move dog ring in A direction When machine reference gt 60 Move dog ring in B direction The movement guide is 2 9mm 100 10 Tighten the set screws to secure the dog ring Rotate the R axis by hand to check that the dog and sensor do not come in contact with each other See Fig 4 8 4 21 CHAPTER 4 Adjustment A NN ANN
90. in advance from the position shown above 7 13 CHAPTER 7 Specifications 1 3 Robot inner wiring diagram Machine harness A AS j m AA gt y A DS Y SS User air tube 1 ON User signal cable N as 1 q H User wiring connector 1 i RORGRORGI dh PEL ZBK HTH ZBK RM HH AM HH RP HoH RP Y ZP HI ZP ZM CCH YP oH YP y User tubing YM HH YM Y iy R axis resolver Y axis resolver A H Z axis motor Y axis motor R axis motor T HN Z axis resolver Round terminal Z axig brake Wa User wiring connector User tubing R axis sensor Ms AS SH I Round terminal ZP HH 7 axis motor RP
91. is moveable mechanical stopper on back side of arm looking from above X axis arm X axis fixed mechanical stopper Bolt Fig 4 9 Adjustment of X axis machine reference 4 24 CHAPTER 4 Adjustment AAA AA SSS SS A 3 4 1 4 Adjusting the Y axis machine reference The adjustment method for the Y axis machine reference is as follows 1 2 3 4 5 6 7 8 Prepare the necessary tools e Hex wrench set Check that no one is inside the safeguard enclosure and then turn on the controller Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel Turn off the controller and enter the safeguard enclosure Mark off the reference mark at the current origin position on the Y axis joint area of the robot At this time be careful to prevent the origin position from deviating since the Y axis arm is touched Using a hexagon wrench loosen the two bolts fixing the Y axis movable mechanical sto
92. linder kg Weight of cylinder kgf lt 30m Fig 3 13 3 24 CHAPTER 3 Installation AAA AAA Se AAA DIA 3 Moment of inertia for cylinder part 2 The equation for the moment of inertia for a cylinder that has a rotation center such as shown in Fig 3 14 is given below pr Dh D i D h i ie ao a a Eat gm 2 2 2 2 2 J gt CA ae f kefemsec Eq 3 3 Cy gt p Density kg m kg cm g Gravitational acceleration cm sec m Mass of cylinder kg D W Weight of cylinder kgf h E Fig 3 14 4 Moment of inertia for prism The equation for the moment of inertia for a prism that has a rotation center as shown in Fig 3 15 is given as follows i p abc a b F m a b 2 12 p kem _P abc a b _W 2 b am 5 J ie o kgfcmsec eT Eq 3 4 a ae Density kg m3 kg cm Gravitational acceleration cm sec Mass of prism kg Weight of prism kgf 23070 Fig 3 15 3 25 CHAPTER 3 Installation 5 When the object s center line is offset from the rotation center The equation for the moment of inertia when the center of the cylinder is offset by the distance x from the rotation center as shown in Fig 3 16 is given as follows pmD h prD hx _ mp J Sn i no 2 k 2 32 i 4 8 iij a Center line ery prD h prD hx J ET ME DA Rotation center WD Wx a kgfcmsec 8g g h a Egas p Density kg m
93. ll not fall over easily 2 The rope or chain should be easily visible by everyone around the robot 3 Place a conspicuous sign prohibiting the operator or other personnel from entering the movement area of the manipulator 4 To check operation after adjustment refer to 6 Trial Operation in Chapter 1 4 1 CHAPTER 4 Adjustment E 3 Adjusting the origin All models of the YK120X series and YK180X series robots use an absolute type position detector The origin position zero pulse point can be determined by absolute reset Once absolute reset is performed you do not have to repeat absolute reset when turning the power on next time However absolute reset is required if any of the following cases occur The robot is shipped from the factory in condition c below so please perform absolute reset after installing the robot For more details on absolute reset refer to Absolute Reset in Chapter 4 of the YAMAHA Robot Controller User s Manual a Absolute related error occurred on the axis b Power drop was detected in the absolute battery for the driver installed inside the robot controller c Cable connecting the robot unit to the controller was disconnected This is the status when shipped from the factory d Robot generation was changed e Parameters were initialized f Axis parameters Origin shift Origin method Origin direction or Motor direction were changed g Motor was replaced Motor wiring connector w
94. moment of inertia and acceleration coefficient 3 17 7 1 1 Acceleration coefficient vs moment of inertia YK120X eeeeeeeeeseeeeeteneeeeeeeee 3 19 7 1 2 Acceleration coefficient vs moment of inertia YK150X oe eeeeeeeeeeeteteeeeeeeee 3 21 7 1 3 Acceleration coefficient vs moment of inertia YK180X YK220X n 3 23 7 2 Equation for moment of inertia calculation cccccceeeseeeeeeeeeeeeeeeeeteeeesaeeeeaes 3 24 7 3 Example of moment of inertia calculation cccccccceeeeeseeeeeeeeeeeeeeeeeteeessaeeeeees 3 27 7 4 Attaching the end effector 2 cececcccceeceeececeeeeeeeeeeeeeceaeeeeeaeeeceaeesseaaeeseeeeesaaeenaes 3 29 7 5 Gripping force Of end effector ee ceceeecececeeeeeeeeeceaaeeeeeeeeeeaaeeeeaaeesesaeeesaaeeeeas 3 32 Working Envelope and Mechanical Stopper Positions for Maximum Working Envelope 3 33 4 Adjustment OV GIVIGW chests oh Rotate Edd 4 1 malety PreCaullOns tc it 4 1 Adjusting th Origin ti is 4 2 3 1 Absolute reset Method cooonooccccnnnicocccononacncnnnnnnoncnnnnnnnnnncnnnnnn nn cnn naar nn nn n naar cnn nana 4 3 3 1 1 YK120X series YK120X YK150X o0oooococccocococccccoconannconcccnnnnnconncnnnnnncnnccnnnanncannninnnns 4 3 3 1 1 1 Sensor method R axis 3 1 1 2 Stroke end method X axis Y AXIS oo ee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeaeseeeeeeeeeeeeaees 4 4 3 1 1 3 Stroke end Method Z AXIS oe eee eee eee eeeeeeeeeeesetaeeeeeeaeeeeeeaeeeeesaeeeeesaeen
95. n Never enter within the robot movement range during absolute reset ACAUTION Before starting return to origin operation move the X axis to a position on the plus side from the origin position See Fig 4 2 and the Y axis to a position on the minus side so that the robot is positioned in a right handed system as shown in Fig 4 2 When the return to origin operation starts the X axis will move to the minus side and the Y axis will move to the plus side After pushing against the me chanical stopper the axes will return slightly and the return to origin will be completed The X and Y axes will move to the positions shown in Fig 4 3 during return to origin so make sure that the tool on the end the robot and the peripheral devices do not interfere The maximum tolerable load radius when load is cy lindrical object is shown in Fig 4 3 If return to origin is performed with a load larger than this radius installed on the R axis the base and load could interfere 4 4 CHAPTER 4 Adjustment Plus side Minus side l Maximum tolerable Maximum tolerable load radius 1 YK150X YK150XC YK120X YK120XC 1 When load is cylindrical object Fig 4 3 X and Y axis maximum movement position during X and Y axis stopper origin position setting 4 5 CHAPTER 4 Adjustmen
96. nan rre narnia cnn 3 6 2 3 NS A 3 7 2 4 SA 3 8 Protective BONdINO eee asic dais 3 9 Robot Cable Connection oooocooooooooocncncnncnnnnnncnnnnnonnnannnnnnnnn nono nn nnnnnnnnnnnnos 3 11 User Wiring and User Tubing picos iio ia 3 13 Connecting a suction hose YK120XC YK150XC coccccccoocccccccccccnccnnnnoos 3 16 Attaching The End Efecto to 3 17 7 1 R axis tolerable moment of inertia and acceleration coefficient 3 17 7 1 1 Acceleration coefficient vs moment of inertia YK120X eessen 3 19 7 1 2 Acceleration coefficient vs moment of inertia YK150X esseere 3 21 7 1 3 Acceleration coefficient vs moment of inertia YK180X YK220X e 3 23 7 2 Equation for moment of inertia calculation ceceeeeeeseeeeeeeeeeeeeeteeteeeeeeaeeeeaes 3 24 7 3 Example of moment of inertia calculation ccccceceeeeseeeeeeeeeeeeeeeseteeeeenaeeeeaes 3 27 7 4 Attaching the end effector cceccceceeseeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeesaeeeseaeeessaeeeseeeesaas 3 29 7 5 Gripping force of end effector ee eeeeeeeeeeceeeeeeeeeeeeeeeaeeeeeeeeeeaaeeeeeneeeesaeeeseeeeeaas 3 32 Working Envelope and Mechanical Stopper Positions for Maximum Working Envelope ccccceeeeeeeeeneeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeaeeeeeeeeeee 3 33 MEMO CHAPTER 3 Installation ee AA ee 1 Robot Installation Conditions 1 1 Installation environments Be sure to install the robot in the following environments Items Specific
97. ne Ro a Q 3 4 7 Use M6 bolt for installation 41 109 E 111 44 Do not attach any wire and tube to these cables Doing so may reduce positioning accuracy 463 57 420 During arm rotation 425 ko 30 Maximum 120 during arm rotation 315 User tubing 2 3 No phase relation between flat spot User tubing 1 3 and R axis origin 4 4 T A A d 203 TE Cross section A A E e 0 163 5 Ty T o 962 EX 147 B Viewed from direction C 126 100 2 109 5 Rises 5mm during return to origin o on Z axis 2 Z axis stroke Z axis origin position Connector for user wiring No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector SMR 6V B 0 o pin SYM 001T P0 6 supplied 103 Use the YC12 crimping machine R12 10 24 5 15 User tool installation range 10 h7 28 Details of B For user tool installation 4 M4x0 7 Depth 6 24 5 Viewed from direction C Fig 7 6 YK220X 7 12 User tubing 2 43 M3 ground terminal CHAPTER 7 Specifications Working envelope X axis origin is at 0 5 with respect to front of robot base X Y axis origin position i When performing return to origin move the axes counterclockwise
98. nnnnnrcrnnn nn cnn rn nn aE rra 5 8 6 Increasing the robot operating speed Increasing the robot operating speed cocooococccccncccconoccccncccnnnnnnnnncnccnnnnnnns 6 1 7 Specifications Mamipulatot ipod 7 1 Tt Basic specificalON esterilidad deter 7 1 1 2 External view and dimensions ocoonoccccccnnocccccconannccnnnnnnonnnnnnnnnnnncnnnnnn nc cnn nana ncnnnnnns 7 2 1 3 Robot inner wiring diagram ooocccccnnnnnnccnnnnnoccccnnnnaorccn nana n cnn naar rc cnn rca 7 14 TA Winngtable os ai la si ied as 7 15 MEMO oO 0 N O a A QQ N gt o 11 12 CHAPTER Using the Robot Safely A A e ea a aa a aaa aad ea 1 1 Essential Caution tems cui a A nennen nnne 1 2 Special Training for Industrial Robot Operation ooooonnnnccccnnnnnnnnccccccno 1 10 Robot Safety Functions caia ta noes 1 11 Safety Measures for the System ooccocnnnccccccncccnocaoocncncnonananancnnnnncnnnnnnnnons 1 12 Thal Operat Om Ake elias 1 13 Work Within the Safeguard Enclosure oooocccccnnnccccccccccccnnnncncnnnnncnnnannnnnns 1 14 AUTOMATIC OPS Muscari 1 15 Adjustment and InSpectiOn ccsicolinnsri atadas 1 15 Repair and Modification ooooonnncccccnnnnnonccccccccccnnnnnnancnnnnncnnnnnnnnncnnnnnnnnns 1 15 Wamani y erori aiie niad aeaa E EE a a aeaa a aeaa arae aate 1 16 CGE Marking ich e e e a EE E AE AE A AN te 1 18 MEMO CHAPTER 1 Using the Robot Safely A 1 Safety Information Industrial robots are highly programmable mechanical devi
99. nnns 7 2 1 3 Robot inner wiring diagram ooooccccninnoncccnnnncccccnnonnoncccnnnnnrnccnna narrar 7 14 1 47 Wir table iii 7 15 MEMO CHAPTER 7 Specifications EA AAA AAA A 1 Manipulator 1 1 Basic specification Robot model YK120X YK150X YK120XC YK150XC YK180X YK220X Arm length 69 5mm 99 5mm 69 5mm 99 5mm 71mm 111mm X axis 7 Rotation angle 113 113 113 113 120 120 Arm length 50 5mm 50 5mm 50 5mm 50 5mm 109mm 109mm Y axis Rotation angle 139 139 139 139 140 140 Z axis Stroke 30mm 30mm 30mm 30mm 100mm 100mm R axis Rotation angle 360 360 360 360 360 360 X axis 15W 15W 15W 15W 50W 50W Y axis 13W 13W 13W 13W 30W 30W Z axis 13W 13W 13W 13W 30W 30W R axis 13W 13W 13W 13W 30W 30W XY resultant 1 8m s 2 1m s 1 8m s 2 1m s 3 3m s 3 4m s Maximum speed Z axis 0 7m s 0 7m s 0 5m s 0 5m s 0 7m s 0 7m s R axis 1700 s 1700 s 1700 s 1700 s 1700 s 1700 s XY axes 0 005mm 0 005mm 0 01mm 0 01mm 0 01mm 0 01mm Repeatability 1 Z axis 0 01mm 0 01mm 0 01mm 0 01mm 0 01mm 0 01mm R axis 0 006 0 006 0 006 0 006 0 01 0 01 Payload 0 5kg 1 0kg R axis tolerable moment of inertia 2 0 002kgm 0 02kgfcms 0 0098kgm 0 1 kgfcms User wiring 6 cables User tubing 3x2 Travel limit 1 Soft limit 2 Mechanical limit XYZ axes
100. nt of each robot model Recommended methods for attaching end effectors are shown in Table 3 2 and Fig 3 25 Refer to Fig 3 23 for details on the end effector attachment of each robot model When checking end effector operation refer to 6 Trial Operation in Chapter 1 dle gt lt 6 8 012 YK120X YK150X Retaining ring to set the user tool O Never loosen this bolt User tool installation range Fig 3 23 Z axis tip shape p p 10 h7 Bots YK180X YK220X Fxymax Robot Mode N kgf CHAPTER 3 Installation End effector Fxymax Fzmax Fig 3 24 Maximum load applied to end effector attachment Table 3 2 Tightening torque Robot Mode Bolts Used Number of bolts gt diameter mm a YK120X YK150X M3 or lager 2 or more le YK180X YK220X M4 or lager 2 or more 4 5 2005 Hole diameter Slot Spline shaft End effector or stay os 3 30 CHAPTER 3 Installation The end effector attachment must have adequate strength to withstand the loads listed in Table 3 1 If too weak the attachment may break during robot operation and fragments fly off causing accidents or injuries The end effector attachment must have sufficient rigidity versus the loads listed in Table 3 1 If this rigidity is inadequate the end e
101. o be reliable However if you find any part unclear or inaccurate in this manual please contact YAMAHA sales office or dealer YAMAHA MOTOR CO LTD IM Company Clean Room Models YK120XC YK150XC Compared to standard YX120X and YK150X clean room models differ in the following points 1 Robot parameter has been changed See section 4 in chapter 2 The Z axis speed is lowered to maintain the degree of cleanliness and the bellows durability This is preset prior to shipment 2 Suction couplers have been added See section 6 in chapter 3 For the suction amount versus degree of cleanliness see 1 1 Basic specifications in chapter 7 For the location of the suction couplers see 1 2 External view and dimensions in chapter 7 The suction amount for each suction coupler is very important to maintain the degree of cleanliness and the bellows durability so always comply with the instruction 3 R axis machine reference adjustment is different See section 3 4 1 2 in chapter 4 The structure around the R axis origin sensor differs from standard specifications so the method for adjusting the machine reference is different Since the Z axis bellows type suction tube is attached to the R axis care must be taken when performing return to origin so that the suction tube will not entangle around the R axis 4 Different grease is used for the Z axis drive mechanism See section 4 in chapter 5 LG2 grease NSK suit
102. oefficients according to the manipulator tip mass and moment of iner tia If this is not observed premature end to the life of the drive units damage to the robot parts or residual vibration during positioning may result 24 Do not use the robot for tasks requiring motor thrust CAUTION Avoid using the YK X series robots for tasks which make use of motor thrust press fitting burr removal etc These tasks may cause malfunctions of the robot 25 Do not apply excessive force to each section CAUTION The YK120X series YK120X YK150X and YK180X series YK180X YK220X are designed to be compact so the joints could be damaged if excessive force is applied for example during installation of an end effector Make sure that excessive force is not applied to the joints YK120X YK150X Tolerable radial load Tolerable thrust load Tolerable moment load Tolerable torque 100N 10 2kgf 100N 10 2kgf 1 5Nm 15 3kgfcem 1 7Nm 17 3kgfcm YK180X YK220X Tolerable radial load 275N 28 1kgf 45N 4 6kgf 45N 4 6kgf 45N 4 6kgf 45N 4 6kgf Tolerable thrust load 900N 91 8kgf 0 45Nm 4 6kgfcm 0 45Nm 4 6kgfcm Tolerable moment load 6 0Nm 61 2kgfcm 0 5Nm 5 1kgfcm 0 3Nm 3 1kgfcm Tolerable torque 9 0Nm 91 8kgfcm 150N 15 3kgf 600N 61 2kgf 3 3Nm 33 7kgfcm 4 0Nm 40 8kgfcm 150N 15 3kgf 600N 61 2kgf 3 3Nm
103. ors may be damaged If the X Y or R axis rotation angle is small If the X Y or R axis rotation angle is smaller than 5 so that it always moves in the same position an oil film is difficult to be formed on the joint support bearing possibly leading to damage to the bearing In this type of operation add a movement so that the joint moves through 90 or more about 5 times a day Tip weight parameter setting and WEIGHT statement in programs The tip weight parameter setting and WEIGHT statement in programs for the YK120X and YK180X series differ from those for other robots Refer to 5 Tip weight parameter setting and WEIGHT statement in pro grams in Chapter 2 for instructions on how to set these Do not remove the Z axis upper end mechanical stopper Removing or moving the upper end mechanical stopper attached to the Z axis spline shaft of the YK180X and YK220X series can damage the Z axis ball screw Never remove or move it AAA AAA AAA AAA Introduction The YAMAHA YK120X and YK180 series robots are SCARA type industrial robots developed based on years of YAMAHA experience and achievements in the automation field as well as efforts to streamline our in house manufacturing systems The SCARA robots have a two joint manipulator consisting of an X axis arm and a Y axis arm and are further equipped with a vertical axis Z axis and a rotating axis R axis at the tip of the manipulator The YK120X and YK180 series robots
104. osition range 2000 pulses prior to P2 the Z axis moves downward to P2 Compared with the gate motion this arch motion shortens the cycle time approximately 20 by moving the robot arm along an arc 6 1 CHAPTER 6 Increasing the robot operating speed A en enn 3 Arch motion Making the arch position value larger In the arch motion 2 making the arch position value larger can further shorten the cycle time Since the robot arm moves along a larger arc use caution to avoid obstacles if they are located near the arm movement path The arch position parameter can be set for each axis 4 Arch motion changing the arch positions in the program From point P1 to P2 and then to P3 ARCH 1 10000 X axis arch position pulses Arch position can be set for each axis ARCH 2 20000 Y axis arch position pulses ARCH 3 20000 Z axis arch position pulses ARCH 4 20000 R axis arch position pulses MOVE P P2 Z 0 ARCH 1 2000 If the same arch position value pulses is used for all axes you ARCH 2 2000 can write as ARCH 2000 ARCH 3 2000 ARCH 4 2000 MOVE P P3 Z 100 Since the arch positions can be changed in the program optimizing the arch po sitions can further shorten the cycle time Arch position large Arch position small ra Z 100 P1 P2 P3 Z 0 6 2 CHAPTER 6 Increasing the robot operating speed G 2 Increasing the speed with the WEIGHT sta
105. ossible i Suction amount lower than this level cannot maintain the degree of Working envelope cleanliness 3 Always set the maximum Z axis rotating speed axis parameter No 37 to 1500 If higher than this value the degree of cleanliness cannot be maintained and the bellows might be damaged 170 x F R axis bellows type suction coupler 43 M3 ground terminal k User tubing 1 847 03 User tubing 2 E es y 57 5 87 45 Suction coupler for dd base interior 06 9 422 y X Y axis maximum movement position during a 7 X Y axis absolute reset stopper origin setting X Y axis origin position BR 0 Take care to prevent interference between the When carrying out X Y axis absolute reset stopper origin setting ODON end tool robot and peripheral devices etc move the X axis to a position counterclockwise from this position and the Y axis to a position clockwise 7 7 CHAPTER 7 Specifications HA S 89 Connector for user wiring No 1 to 6 usable socket contact J S T Mfg Co Ltd SM connector SMR 6V B pin BYM 001T 0 6 or SYM 001T P0 6 supplied Use the YC12 crimping machine 05 Use M4 bolt for installation 7425 Do not attach any wire or tube to this
106. ot will continue moving and could collide with the peripheral devices The R axis does not have a me chanical stopper so the wiring and piping installed on the end effector could become entangled R axis Sensor R axis dog 4 7 CHAPTER 4 Adjustment 3 1 2 2 X axis origin is at 0 5 with respect to front of robot base Sensor method X axis Y axis Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset AACAUTION The origin cannot be detected in any axis which is not positioned on the plus side from the origin See Fig 4 5 before starting the return to origin opera tion Factory setting at shipment In this case press the STOP key to interrupt the return to origin operation move the target axis to the plus side of the origin and reperform the origin return operation If the return to origin operation is not stopped the robot will continue moving and could collide with the peripheral devices The X and Y axes will move to the positions shown in Fig 4 5 during return to origin so make sure that the tool on the end the robot and the peripheral devices do not interfere The maximum tolerable load radius when load is cy lindrical object is shown in Fig 4 5 If return to origin is performed with a load larger than this radius installed on the R axis the base and load could interfere Since th
107. ould otherwise result 1 3 CHAPTER 1 Using the Robot Safely 6 Do not use the robot in locations possibly subject to electro magnetic interference etc Avoid using the robot in locations subject to electromagnetic interference elec trostatic discharge or radio frequency interference Malfunction may otherwise occur 7 Use caution when releasing the Z axis vertical axis brake The Z axis will slide down when the Z axis brake is released causing a hazard ous situation Press the emergency stop button and prop up the Z axis with a support stand before releasing the brake Use caution not to let your body get caught between the Z axis and installa tion base when releasing the brake to perform direct teach 8 Provide safety measures for end effector gripper etc e End effectors must be designed and manufactured so that they cause no hazards for example loosening of workpiece even if power electricity air pressure etc is shut off or power fluctuations occur e If there is a possible danger that the object gripped by the end effector may fly off or drop then provide appropriate safety protection taking into account the object size weight temperature and chemical properties 9 Be cautious of possible Z axis movement when the controller is turned off or emergency stop is triggered 2 axis robots with air driven Z axis The Z axis moves up when the power to the controller or PLC is turned off
108. ovement range of the manipulator while within the safe guard enclosure CHAPTER 1 Using the Robot Safely 8 Automatic Operation Automatic operation described here includes all operations in AUTO mode 1 Check the following before starting automatic operation 1 No one is within the safeguard enclosure 2 The programming unit and tools are in their specified locations 3 The alarm or error lamps on the robot and peripheral equipment do not flash 4 The safeguard enclosure is securely installed with safety interlocks ac tuated 2 Observe the following during automatic operation or in cases where an error occurs 1 After automatic operation has started check the operation status and warn ing lamp to ensure that the robot is in automatic operation 2 Never enter the safeguard enclosure during automatic operation 3 If an error occurs in the robot or peripheral equipment observe the fol lowing procedure before entering the safeguard enclosure 1 Press the emergency stop button to set the robot to emergency stop 2 Place a sign on the start switch indicating that the robot is being in spected in order to keep any other person from touching the start switch and restarting the robot 9 Adjustment and Inspection Do not attempt any installation adjustment inspection or maintenance unless it 1s described in this manual 10 Repair and Modification Do not attempt any repair parts replacement and modification unless
109. pheral devices etc 7 3 CHAPTER 7 Specifications 55 gt Connector for user wiring No 1 to 6 usable socket contact z eor J S T Mfg Co Ltd SM connector SMR 6V B pin BYM 001T 0 6 or SYM 001T P0 6 supplied Zi Se Use the YC12 crimping machine G y amp g 505 346 Maximum 355 during arm rotation 316 307 Do not attach any wire or tube to these cables Doing so may reduce positioning accuracy 4245 R axis sensor JUL 1 R axis origin dog 4 A 140 tpt i 4 139 a 123 nil a 4125 111 R12 tH 7 YT i No 104 88 92 73 User tool nstallationirange 45 E 22 Connector for user wiring Cir cli No 1 to 6 usable socket contact Z axis 25 2 E J S T Mfg Co Ltd SM connector SMR 6V B origin position 7 ds je E pin BYM 001T 0 6 or SYM 001T PO 6 supplied Maximum 10 mm rise q pe Use the YC12 crimping machine during Z axis stopper 04 H I 0 origin setting 73 pe Hh a ag LO i AMN N piim
110. point Procedure Manipulator bolts and screws Only for major bolts and screws exposed Check for looseness and tighten if necessary 1 externally Detection areas of the origin sensors of re 5 Clean if it is dirty the R axis Check for looseness at each terminal and connector on the Controller panel See 4 in Chapter 3 Grease lubrication of Z axis ball screw After removing the old grease with a cloth or paper towel spline linear shaft apply new grease to the Z axis linear bushing shaft spline shaft ball screw shaft and ball screw nut Recommended grease YK120K YK150X YK180X YK220X Alvania No 2 Showa Shell Sekiyu K K YK120XC YK150XC LG2 NSK Always use the LG2 grease for the YK120XC and YX150XC clean room models Check for backlash If any abnormality is found contact YAMAHA dealer Z axis ball spline ball screw 1 Bolt tightening torque Bolt size Tightening torque kgfcm Tightening torque Nm M3 button head bolt M3 set screw M4 set screw M2 bolt installation hole M2 5 bolt installation hole M3 bolt installation hole M4 bolt installation hole MS bolt installation hole M6 bolt installation hole M8 bolt installation hole M10 bolt installation hole M12 bolt installation hole M14 bolt installation hole 5 6 CHAPTER 5 Periodic Inspection 2 Inspection to be performed with the controller turned on The robot cont
111. pper See Fig 4 10 AACAUTION The bolt only needs to be loosened and does not need to be completely re moved 9 Move the movable mechanical stopper in the following manner When machine reference lt 40 Move mechanical stopper in A direction When machine reference gt 60 Move mechanical stopper in B direction The movement guide is 3 5mm 100 10 Tighten the bolt and fix the movable mechanical stopper The tightening torque is 4 4kgfcm 0 43Nm 4 25 CHAPTER 4 Adjustment A NN ANN 11 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 12 Perform the absolute reset from outside the safeguard enclosure 13 After completing absolute reset check the machine reference value 14 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it Y axis moveable mechanical stopper a o QS aw DES X axis arm Bolt On back side of arm Fig 4 10 Adjustment of Y axis machine reference 4 26 CHAPTER 4 Adjustment 3 4 1 5 Adjusting the Z axis machine reference The stroke end method is employed on the YK 120X series robots for the absolute rese
112. rce of end effector The gripping force of the end effector must have a sufficient extra margin of strength versus the workpiece weight and reaction force applied to the workpiece during robot operation The reaction force applied to the workpiece during operation can be calculated from the acceleration applied to the end effector attachment The maximum ac celeration on the end effector attachment of each robot model is listed in the table below When the workpiece position is offset to the end effector attachment the accelerations Amax and Axymax become larger by an amount equal to the offset versus the arm length When the R axis rotates during operation this acceleration Armax must be taken into account Table 3 3 Maximum acceleration during robot operation Robot Model Amax m sec Axymax m sec2 Azmax m sec Armax rad sec Amax Axymax Azmax Fig 3 26 Maximum acceleration on end effector attachment The gripping force of the end effector must have a sufficient extra margin of strength to prevent the workpiece from coming loose and flying off during robot operation If the gripping force is too weak the workpiece may come loose and fly off causing accidents or injuries 3 32 CHAPTER 3 Installation SSS lt 8 Working Envelope and Mechanical Stopper Positions for Maximum Working Envelope Working envelope and mechanical stopper positions for the maximum working envelope of each robot are
113. re shown below 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Check that the soft limits are correctly set If not correctly set adjust the soft limits while referring to the description of 4 Setting the Soft Limits in Chapter 4 3 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 4 Enter the safeguard enclosure while holding the MPB Stay outside the robot movement range at this time 5 Make the standard coordinate settings while referring to methods for Set ting the Standard Coordinates as explained in the YAMAHA Robot Con troller User s Manual Never enter within the robot movement range 6 When the standard coordinate settings are complete check the following points from outside the safeguard enclosure 1 Check that the robot arm tip can move at right angles in MANUAL opera tion cartesian coordinates 2 Check that the values nearly equal to the X axis and Y axis arm lengths are entered in Arm length of the axis parameters If the above points are not satisfied the standard coordinate settings are in correct so make the standard coordinate settings again 4 42 CHAPTER 4 Adjustment 6 Affixing Stickers for Movement Directions and Axis Names The movement direction and axis name label shown in Fig 4 16 is supplied with the robot After installing the peripheral devices attach these lab
114. roller must be installed outside the safeguard enclosure to pre vent a hazardous situation in which you or anyone enter the safeguard enclo sure to inspect the controller while it is turned on e Bodily injury may occur from coming into contact with the fan while it is rotat ing e When removing the fan cover for inspection first turn off the controller and make sure the fan has stopped After turning on the controller check the following points Checkpoint Procedure e Check if the fan rotates normally e Check if objects blocking the fan are located and remove if any are found e Check for abnormal noise from the rotating fan If abnormal noise is heard visually check and remove the cause If no cause is found contact YAMAHA dealer e Check for dust on the fan cover Remove and clean if necessary e Cooling fan at rear of controller 3 Adjustment and parts replacement 1 After inspection if you notice any adjustment or parts replacement is needed first turn off the controller and then enter the safeguard enclosure to perform the necessary work After adjustment or replacement is fin ished again review the checkpoints outlined in 1 and 2 above 2 If repair or parts replacement is required for the robot or controller please contact your YAMAHA dealer This work requires specialized technical knowledge and skill so do not attempt it by yourself 5 7 CHAPTER 5 Periodic Inspection AAA AAA AA
115. s TOLE 4 2048 R axis tolerance pulses MOVE P P2 TOLE 1 80 Returns the tolerance to the default value TOLE 2 80 TOLE 3 80 TOLE 4 80 MOVE P P3 Tolerance can be set for each axis If the same tolerance is used for all axes you can write as TOLE 2048 If the same tolerance is used for all axes you can write as TOLE 80 When P2 is an escape point and does not need to be accurately positioned setting the tolerance parameter to a larger value allows the robot arm to pass through P2 quickly The larger the tolerance value for the positioning time the shorter the cycle time will be The maximum value of the tolerance parameter is 2048 pulses and the default is 80 pulses 6 4 CHAPTER 6 Increasing the robot operating speed AAA DIA 4 Increasing the speed by the OUT effective position parameter Also refer to Robot controller user s manual Axis parameters Out effective Position in Chapter 4 Programming manual OUTPOS statement in 11 Command statements Example From P1 when chuck is open OUTPOS 1 10000 X axis OUT effective position pulses Increases the OUT effective position Ss _ OUTPOS 2 10000 Y axis OUT effective position pulses The OUT effective position can we b f h a i OUTPOS 3 10000 Z axis OUT effective position pulses ed ee OUTPOS 4 10000 R axis OUT effective position
116. s from operating the controller or operation panel Turn off the controller and enter the safeguard enclosure Mark off the reference mark at the current origin position on the X axis joint area of the robot At this time be careful to prevent the origin position from deviating since the X axis arm is touched Using a hexagon wrench loosen the two bolts fixing the X axis movable mechanical stopper See Fig 4 9 AACAUTION The bolt only needs to be loosened and does not need to be completely re moved 9 Move the movable mechanical stopper in the following manner When machine reference lt 40 Move mechanical stopper in A direction When machine reference gt 60 Move mechanical stopper in B direction The movement guide is 2 2mm 100 10 Tighten the bolt and fix the movable mechanical stopper The tightening torque is 4 4kgfcm 0 43Nm 4 23 CHAPTER 4 Adjustment A NN ANN 11 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 12 Perform the absolute reset from outside the safeguard enclosure 13 After completing absolute reset check the machine reference value 14 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it X ax
117. s emergency stop work Are the teaching and playback functions normal Are the safeguard enclosure and interlock working as intended Does the robot move correctly during automatic operation o Qu 1 13 CHAPTER 1 Using the Robot Safely E Work Within the Safeguard Enclosure 7 1 When work is required inside the safeguard enclosure always turn off the 2 wa controller and place a sign indicating that the robot is being adjusted or serv iced in order to keep any other person from touching the controller switch or operation panel except for the following cases 1 Adjusting the Z axis machine reference See Section 3 4 1 5 in Chapter 4 2 Setting the Soft Limits See Section 4 in Chapter 4 3 Setting the Standard Coordinates See Section 5 in Chapter 4 4 Teaching For items 1 to 3 follow the precautions and procedure for each section To perform item 4 refer to the description in 2 below Teaching When performing teaching within the safeguard enclosure comply with the instructions listed below 1 Check or perform the following points from outside the safeguard enclo sure 1 Make sure that no hazards are present within the safeguard enclosure by a visual check 2 Check that the programming unit MPB operates correctly 3 Check that no failures are found in the robot 4 Check that emergency stop works correctly 5 Select teaching mode and prohibit automatic operation 2 Never enter the m
118. s is touched Using a Phillips screwdriver loosen the two screws fixing the dog at the R axis joint See Fig 4 7 CAUTION The screw only needs to be loosened and does not need to be removed com pletely 9 Move the dog in the following manner When machine reference lt 40 Move dog in A direction When machine reference gt 60 Move dog in B direction The movement guide is 2 3mm 100 10 Tighten the screw and fix the dog 4 19 CHAPTER 4 Adjustment A NN ANN 11 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 12 Perform the absolute reset from outside the safeguard enclosure 13 After the absolute reset is completed read the machine reference value dis played on the MPB 14 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it R axis dog ee R axis Sensor a R axis Fig 4 7 Adjustment of R axis machine reference View from below 4 20 CHAPTER 4 Adjustment N 3 4 1 2 Adjusting the R axis machine reference YK120XC YK150XC The adjustment method for the R axis machine reference is as follows 1 2 3 4 5 6 7 8 Prepare the necessary tools e Hex wrench set Check that no one is ins
119. so that no one can enter inside except from doors or panels equipped with safety interlocks The warning labels shown in Fig 1 1 are supplied with the robot and should be affixed to a conspicuous spot on doors or panels equipped with safety interlocks DANGER Serious injury or death will result from impact with moving robot e Keep outside of guard during operation e Lock out power before approaching robot 2 Use caution to prevent hands or fingers from being pinched or crushed Warning labels 2 Fig 1 2 are affixed to the robot Refer to Fig 2 2 in Chap ter 2 for the position Be careful not to let hands or fingers be pinched or crushed by the moving parts of the robot during transportation or teaching Moving parts can pinch or crush hands Keep hands away from robot arms A DANGER Serious injury or death will result from impact Moving parts can with moving robot e e Keep outside of guard Al pinch or crush Keep hands away during operation Lock bet ceca T from robot arms MFig 1 1 Warning label 1 Fig 1 2 Warning label 2 1 2 CHAPTER 1 Using the Robot Safely 3 Follow the instructions on warning labels and in this manual Warning label 3 Fig 1 3 is affixed to the robot Refer to Fig 2 2 to Fig 2 4 in Chapter 2 for the position e Be sure to read the warning label and this manual carefully and make you thoroughly understand the contents before attempting installation and op
120. sq Gray Black 2 Twisted pair 0 14sq White Red 2 Twisted pair Yellow Red 2 0 14sq Yellow Black 2 Twisted pair Green 0 3sq Resolver S2 1 2 3 4 5 6 7 1 2 3 4 5 6 D YJ MB i O Fl Connector No Connection No Connector Color No Black XM White Red Round terminal _ Yellow Green YM HH Green Blue Yellow Signal Connector No Connection No Connector Color No _ Brown Pink Sky blue Orange Purple Gray 7 15 CHAPTER 7 Specifications An Machine harness wiring table Y axis arm side Base side Signal Connector No Connection Connector Color Wire Y axis Resolver S2 Brown 0 10mm White Twisted pair Red 0 10mm White Twisted pair Orange 0 10mm White Twisted pair Green Shield Brown 0 10mm Black Twisted pair Red 0 10mm Black Twisted pair Orange 0 10mm Black Twisted pair Green Shield Brown 0 10mm Gra Twisted pair Red 0 10mm Gray Twisted pair Orange 0 10mm Gray Twisted pair Green Shield Brown 0 10mm Blue Twisted pair 0 10mm Origin position sensor 24V Blue Twisted pair ORG Orange 0 10mm GND 3 Blue Twisted pair i
121. ssembled or parts replaced while air is still supplied e Do service work after first turning off the controller and reducing the air pres sure e Before reducing the air pressure place a support stand under the Z axis 2 axis robots with air driven Z axis since it will drop under its own weight 13 Cautions for removing Z axis brake or Z axis motor The Z axis can drop and cause a hazard when the Z axis brake or Z axis motor is removed Turn off the controller and set a support stand under the Z axis before re moving the motor e Use caution not to allow hands or body to be squeezed or crushed by moving parts on the Z axis or between the Z axis and the installation base 1 5 CHAPTER 1 Using the Robot Safely 14 Use the following caution during inspection of controller e When you need to touch the terminals or connectors on the outside of the controller during inspection always first turn off the controller power switch and also the power source in order to prevent possible electrical shock Never touch any internal parts of the controller For precautions on handling the controller refer to the YAMAHA Robot Con troller User s Manual 15 Consult us for corrective action when the robot is damaged or malfunction occurs If any part of the robot is damaged or any malfunction occurs continuous op eration may be very dangerous Please consult YAMAHA dealer for corrective action Damage or Trouble Possi
122. t 3 1 1 3 Stroke end method Z axis With this method the Z axis is pushed against the mechanical stopper and after the axis end is detected absolute reset is performed from a position slightly back from the axis end Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset 4 6 CHAPTER 4 Adjustment A NN NN A 3 1 2 YK180X series YK180X YK220X 3 1 2 1 Sensor method R axis In the sensor method the target axis is automatically operated for the absolute reset and the absolute reset is performed at the position where the proximity sensor provided on the target axis detects the detection area dog The absolute reset in the sensor method can be executed with the teaching pen dant MPB RS 232C communication and dedicated input Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset AACAUTION The origin cannot be detected in any axis which is not positioned on the plus side from the origin See Fig 4 4 before starting the return to origin opera tion Factory setting at shipment In this case press the STOP key to interrupt the return to origin operation move the target axis to the plus side of the origin and reperform the origin return operation If the return to origin operation is not stopped the rob
123. t of the Z axis The origin position of the Z axis is fixed at the upper end of the Z axis stroke and it cannot be changed The machine reference is factory adjusted at shipment and readjustment is not necessary for normal use The readjustment in the following procedure is required however if the machine reference exceeds the tolerance range 26 to 74 of the absolute reset for any reason ACAUTION The origin position may change when the machine reference amount is ad justed The point data must be reset after adjusting the machine reference 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 3 Perform the Z axis absolute reset To perform the Z axis absolute reset see 3 3 3 Stroke end method Z axis in Chapter 4 4 Turn off the controller 5 Enter the safeguard enclosure 6 Remove the Y axis upper cover To remove the covers see 7 Removing the Robot Covers in Chapter 4 Place the upper cover on the robot base pedestal side with the machine harness still connected 7 Confirm that the Z axis rising end mechanical stopper is at the position shown in Fig 4 11 a If not at that position loosen the bolt and fix the stopper at the position shown in the drawing The tightening torque is 4 4kgfcm 0 43Nm Carry out steps 1 to 3 after fixing
124. tement Also refer to Robot controller user s manual Robot parameters Axis tip weight in Chapter 4 Programming manual WEIGHT statement in 11 Command statements Example From P1 when chuck is open WEIGHT 5 Changes the axis tip weight parameter to 5kg no workpiece MOVE P P2 Z 0 DO3 0 1 Chuck closes WEIGHT 10 Changes the axis tip weight parameter to 10kg with workpiece MOVE P P3 Z 0 In the above program the acceleration can be set to a higher level by reducing the axis tip weight parameter to 5kg while the chuck does not grip any workpiece and then set to a lower level by changing the axis tip weight parameter to 10kg Compared to programs using an axis tip weight parameter left set at 10kg this method shortens the cycle time since the acceleration is increased No workpiece Chuck is gripping workpiece Chuck 5kg Pl Chuck opens Workpiece 5kg P2 P3 Chuck closes 6 3 CHAPTER 6 Increasing the robot operating speed 3 Increasing the speed by the tolerance parameter Also refer to Robot controller user s manual Axis parameters Tolerance in Chapter 4 Programming manual TOLE statement in 11 Command statements D Example From P1 to P3 via P2 P3 P1 TOLE 1 2048 X axis tolerance pulses Increases the tolerance TOLE 2 2048 Y axis tolerance pulses TOLE 3 2048 Z axis tolerance pulse
125. the program is reset emergency stop is triggered or air is supplied to the solenoid valve for the Z axis air cylinder Do not let hands or fingers get caught and squeezed by moving parts of the Z axis Keep the usual robot position in mind so that the Z axis will not interfere with obstacles during raising of the Z axis except in case of emergency stop 1 4 CHAPTER 1 Using the Robot Safely 10 Use the following caution items when the Z axis is interfering with peripheral equipment 2 axis robots with air driven Z axis When the Z axis comes to a stop due to obstructions from peripheral equip ment the Z axis may move suddenly when the obstruction is removed causing injury such as pinched or crushed hands e Turn off the controller and reduce the air pressure before attempting to re move the obstruction e Before reducing the air pressure place a support stand under the Z axis because it will drop under its own weight 11 Use caution on Z axis movement when air supply is stopped 2 axis robots with air driven Z axis The Z axis may suddenly drop when the air pressure to the Z axis air cylinder solenoid valve is reduced creating a hazardous situation Turn off the controller and place a prop or support under the Z axis before cutting off the air supply 12 Use the following caution items when disassembling or replac ing the pneumatic equipment Air or parts may fly outwards if pneumatic equipment is disa
126. up by the manipulator See 1 2 External view and dimensions in Chapter 7 If the robot cables interfere with the mov able parts of the robot the cables may be damaged causing malfunction and hazardous situations Lay out the robot cables so as to keep the operator or any other person from tripping on them Bodily injury may result if someone trips on the cables 3 11 CHAPTER 3 Installation For the YK120X series robots YK120X YK150X always use the RCX142 T controller that is designed to provide 24V output The model name RCX142 T is shown on the serial number label see Fig 2 5 Do not connect other robot controllers to the YK120X series robots If operated from a controller other than the RCX142 T the robot s motors may be damaged Controller side connector Robot side connector RCX142 T XM A YM Go E ZM RM Robot cable XY gt ZR Fig 3 7 Robot cable connections 3 12 CHAPTER 3 Installation User Wiring and User Tubing Always turn off the controller and shut off air supply before attempting wiring and piping work If air or power is supplied during this work the manipulator may move erroneously causing a hazardous situation 1 The robot has a user signal wire and air tube laid in parallel with the robot body s machine harness The signal wires and air tubes that can be used ar
127. ute reset X axis M1 Y axis M2 To perform absolute reset on all axes select ALL with the F11 LOWER F1 key ACAUTION The Z axis of the stroke end method first rises during the absolute reset of all axes default setting Be careful that your fingers do not get pinched or crushed by any sudden movement 6 Confirm that the X axis is at a position on the plus side of the origin See Fig 4 2 and that the Y axis is at the minus side Make sure that the robot is positioned in a right handed system as shown in Fig 4 2 If the axes are not at these positions press the jog keys etc and move the target axes When performing absolute reset for the other axes at the same time confirm that the other axes are also at an appropriate position Refer to procedures for absolute reset of other axes 7 Since the message Reset ABS encoder OK is displayed check that there are not any obstacles in the robot movement range and press the F4 key YES 4 13 CHAPTER 4 Adjustment EE 8 After the absolute reset is completed check that the X axis and Y axis ma chine reference value displayed on the MPB is within the absolute reset tol erance range 40 to 60 If the machine reference value is outside the absolute reset tolerance range then the next absolute reset may not be properly performed In this case refer to Chapter 4 3 4 Adjusting the machine reference and make the necessary adjustments 4 14 CHAPTE
128. ve two suction couplers 6 on the rear of the manipulator base for air suction from the base interior and from the X Y R axis joints and also have one bellows type suction coupler 3 for the R axis The required degree of cleanliness can be maintained by sucking air through these suction couplers For the suction amount versus degree of cleanliness see 1 1 Basic specifications in chapter 7 For the location of the suction couplers see 1 2 External view and dimensions in chapter 7 Lay out the suction hoses so as to keep the operator or any other person from tripping on them Bodily injury may result if someone trips on the hoses ACAUTION Carefully connect the suction hoses to the suction couplers so that they do not obstruct the movement of the robot manipulator 3 16 CHAPTER 3 Installation 7 Attaching The End Effector 7 1 R axis tolerable moment of inertia and acceleration coeffi cient 1 The moment of inertia of a load end effector and workpiece that can be attached to the R axis is limited by the strength of the robot drive unit and residual vibration during positioning It is therefore necessary to reduce the acceleration coefficient in accordance with the moment of inertia The R axis tolerable moment of inertia and the acceleration coefficient ver sus R axis moment of inertia for each robot model are shown in Fig 3 9 Fig 3 10 and Fig 3 11 on the subsequent pages The symbols Ax Ay and Ar
129. y result CHAPTER 3 Installation CAUTION Depending on the Z axis position vibration may occur when the X Y or R axis moves If this happens reduce the X Y or R axis acceleration to an appropri ate level CAUTION If the moment of inertia is too large vibration may occur on the Z axis depend ing on its operation position If this happens reduce the Z axis acceleration to an approriate level 3 18 CHAPTER 3 Installation AAA AAA 7 1 1 Acceleration coefficient vs moment of inertia YK120X O Ax AY AR 0 00025 0 0025 100 80 60 40 20 y 0 0005 0 0010 0 0015 0 0020 Ir kgm 0 0 005 0 010 0 015 0 020 Jr kgfcmsec W 0 1kg Ax Ay AR 0 0008 0 00008 100 80 60 40 20 0 0005 0 0010 0 0015 0 0020 Ir kgm2 0 0 005 0 010 0 015 0 020 Jr kgfcmsec W 0 2kg O Ax Ay AR 0 0005 0 00005 100 80 60 40 20 A Ca 0 0011 0 0 0005 0 0010 0 0015 0 0020 Ir kgm2 0 0 005 0 010 0 015 0 020 Jr kgfcmsec W 0 3kg 3 19 CHAPTER 3 Installation AS yy IAS AX AY AR 000002 0 0002 100 80 60 40 20 0 0 0005 0 0010 0 0015 0 0020 Ir kgm2 0 005 0 010 0 015 0 020 Jr kgfcmsec W 0 4kg Ax AY AR 100 0 00002 0 0002 80 60 40 20 0 0005 0 0010 0 0015 0 0020 Ir kgm 0 0 005 0 010 0 015 0 020 Jr kgfcmsec W 0 5kg Fig 3 9

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