User`s Manual - Yamaha Robotics
Contents
1. 12mm or less 3 To install the single axis robot 4 2 M4 x 0 7 use M4 x 0 7 hex socket head Depth 8 Effective stroke 50 100 150 200 250 300 bolts with a length under head L 248 298 348 398 448 498 of less than 12mm Section View C A 125 5 175 5 225 5 275 5 325 5 375 5 D 125 5 125 5 M 0 1 2 3 0 1 Note 1 Distance from both ends to the mechanical stopper N 4 6 8 10 6 8 Note 2 Minimum bend radius of motor cable is R50 50mm n Note 3 Weight of models with no brake The weight of brake attached models is 0 2 kg heavier than the models Weight kg 14 1 2 1 3 14 1 5 1 6 with no brake shown in the table 4 4 T5 T5H Basic specifications Chapter 4 Specifications Static loading moment Motor output AC W 30 TEC Repeated positioning accuracy 1 20 02 Deceleration mechanism Ball screw Class C10 Ball screw lead mm 20 12 6 ec Maximum speed mm sec 3 1200 800 400 Maximum payload Horizontal installation 3 5 9 kg Vertical installation 12 24 Unit Rated thrust N 19 32 64 MY 30 Stroke mm 50 to 800 50 pitch 2 MP 34 Cable length m Standard 3 5 OP 5 10 MR 40 Horizontal installation T5 ERCX ERCD Vert2. Improper installation or operation can result in serious injury or death Read the user s manual and all warning labels before operation 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 alter or stain the warning labels WARNING If warning labels are removed or difficult to see then essential precautions might not be taken resulting in accidents Do not remove alter or stain the warning labels on the robot Do not allow the warning labels to be hidden by devices installed onto the robot by the user Provide proper lighting so that the symbols and instructions on the warning labels can be clearly seen even from outside the safeguard enclosure b Do not use the robot in environments containing inflammable gas etc WARNING This robot was not designed for operation in environments where inflammable or explosive substances are present Do not use the robot in environments containing inflammable gas dust or liquids Explosions or fire might otherwise result 6 Do not use the robot in locations possibly subject to electromagnetic interference etc WARNING Avoid using the robot in locations subject to electromagnetic interference electro static discharge or radio frequency interference Malfunctions might
3. against noise Check or replace the motor cable and controller 5 3 Chapter 5 Troubleshooting 5 2 Feedback error Feedback error Turn power off and check for friction by moving manually No Are parameters for controller and robot OK No Is there electrical Are wiring and connector a connected Are connector pins securely inserted Securely insert pins or repair defective pins Yes Yes No Is external Yes Is controller noise large ardware OK Much mechanical Yes friction Replace motor with brake Any foreign matter No aught inside No Adjust mechanical alignment Is there electrical Y Recheck Repair No Is 24V Supplied to brake Replace power supply unit or repair defective parts Is brake installed Yes Is brake sound heard when turning power quum Initialize parameters Securely connect wiring and connector When feedback error is occurring perform continuity check 1 Check motor power supply lines U V and W 2 Check encoder signal lines for phases A and B Replace motor since motor has shorted or burnt out OK measures No Is motor encoder Replace motor OK 1 Check position shift by repetitive accuracy measurement 2 If replacement motor is available check by exchanging the motors 1 If replacement controller is available check by exchangi
4. these mechanical stoppers prevent the axis from exceeding the movement range No mechanical stopper is provided on the rotating axis Note The movement range is the area limited by mechanical stoppers WARNING Axis movement will not stop immediately after the servo power supply is shut off by emergency stop or other safety functions 5 Vertical axis brake An electromagnetic brake is installed on the vertical use robot to prevent the vertical axis from sliding down when servo power is turned off This brake is working when the control ler is off or the vertical axis servo power is off even when the controller is on The vertical axis brake can be released by means of the programming box or by a command in the program when the controller is on WARNING The vertical axis will slide down when the brake is released creating a hazardous situation Press the emergency stop button and prop the vertical axis with a support stand before releasing the brake Use caution not to let your body get caught between the vertical axis and installa tion base when releasing the brake to perform direct teach Chapter 1 About Safety Safety Measures for the System 1 5 1 6 Since the robot is commonly used in conjunction with an automated system dangerous situa tions are more likely to occur from the automated system than from the robot itself Accord ingly appropriate safety measures must be taken on
5. 5 Incorrect or inadequate maintenance and inspection 6 Repairs by other than authorized dealers YAMAHA MOTOR CO LTD MAKES NO OTHER EXPRESS OR IMPLIED WARRAN TIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE THE WARRANTY SET FORTH ABOVE IS EXCLU SIVE AND IS IN LIEU OF ALL EXPRESSED OR IMPLIED WARRANTIES INCLUDING WARRANTIES 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 DELIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO LTD SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES WHETHER ARISING FROM CONTRACT WAR RANTY NEGLIGENCE OR STRICT LIABILITY YAMAHA MOTOR CO LTD MAKES NO WARRANTY WHATSOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED BY YAMAHA MOTOR CO LTD Chapter Installation and Connections 2 1 Checking the product eese 2 3 2 2 2 2 3 2 3 Robot Installation Conditions 2 4 2 4 Installation 2 5 2 5 Installing the 2 6 2 6 2 8 2 6 1 Connecting the robot cables 2 8 2 6 2 System Configuration Exam
6. amp YAMAHA YAMAHA MOTOR CO LTD AMAHA SINGLE AXIS ROBOT FLIP X series 14 14H 15 I5H User s Manual ESTE YAMAHA MOTOR CO LTD IM Operations 882 Soude Naka ku Hamamatsu Shizuoka 435 0054 Japan URL http www yamaha motor jp robot index html E18 Ver 2 01 Introduction Contents Chapter 1 About Safety 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 3 3 1 3 2 3 3 3 4 3 5 Safety Information 1 3 Essential Caution 1 5 Industrial Robot Operating and Maintenance Personnel 1 10 Robot Safety Functions 401 07 12 1 2 1 11 Safety Measures for the System 1 12 Trial Operator ee 1 12 Work Within the Safeguard Enclosure 1 13 Automatic Operation 1 13 oiii ssi ns xis liue ede 1 14 Installation and Connections Checking the product eese 2 3 Robot part Names 2 3 Robot Installation Conditions 2 4 Installation base 2 5 Installing the robot eseesss 2 6 ie ioo sec 2 8 2 6 1 Connecting the robot
7. in distance occurs between the position where the origin signal is detected and the point at which the next 0 pulse is re ceived This is called the machine reference and is usually expressed as a percent with 100 being equal to 1 4th of one turn of the motor The machine reference value must be within the allowable range 25 to 7596 to maintain axis movement repeatability To check the machine reference value an optional programming box HPB is needed The machine reference value is displayed on the LCD screen of the programming box when return to origin is complete See the figure below NOTE The FLIP X series uses an absolute type position detector You do not have to perform return to origin each time the robot controller is turned on and readjust the machine reference value If for some reason the machine reference adjustment becomes necessary please contact YAMAHA sales office or dealer Machine reference Origin signal Origin detection J L signal Machine reference Machine reference Stroke end detection N p di Origin dog detection Zero signal Pulse 1 4th of one turn of motor Machine reference value display examples OPRT ORG SEARCH origin complete machine ref 5096 SR1 ERCX ERCD Duty To achieve maximum service life for the YAMAHA single axis robots the robot must be operated within the allowable duty 50 The duty is calculated as follows Operation time Operation t
8. injury or death will result from impact with moving robot Keep outside of guard during operation Lock out power before approaching robot DANGER Serious injury or death will result from impact with moving robot Keep outside of guard during operation Lock out power before approaching robot Fig 1 1 Warning label 1 2 Use caution to prevent hands or fingers from being pinched or crushed Warning labels 2 Fig 1 2 are affixed to the robot WARNING Moving parts can pinch or crush Keep hands away from robot arms WARNING Moving parts can 2 pinch or crush Keep hands away from robot arms Fig 1 2 Warning label 2 Chapter 1 About Safety lt 3 Follow the instructions on listed on warning labels and in this manual Be sure to read the warning labels and this manual carefully and make sure you thor oughly understand their contents before attempting installation and operation of the robot Before starting robot operation be sure to reread the procedures and cautions relating to your work as well as descriptions in this chapter Chapter 1 About Safety Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual The warning labels shown in Fig 1 3 are supplied with the robot and should be affixed to the robot or conspicuous spots near the robot WARNING
9. otherwise occur 1 6 Chapter 1 About Safety p o ss _ 7 Use caution when releasing the brake of a vertical use robot WARNING The vertical axis will slide down when the brake is released causing a hazardous situation Press the emergency stop button and prop up the vertical axis with a support stand before releasing the brake Be careful not to let your body get caught between the vertical axis and installation base when releasing the brake to perform direct teach 8 Provide safety measures for end effector gripper etc WARNING End effectors must be designed and manufactured so that they create no hazards for example a workpiece that comes loose even if power electricity air pressure etc is shut off or power fluctuations occur 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 Use caution when removing the motor Vertical use robots WARNING The vertical axis will slide down when the motor is released causing a hazardous situation Turn off the robot controller and prop up the vertical axis with a support stand before removing the motor Be careful not to let your body get caught between th
10. work instructions for the following items in cases where personnel must work within the robot movement range to perform teaching maintenance or inspection Make sure the workers know these work instructions well 1 Robot operating procedures needed for tasks such as startup procedures and handling switches 2 Robot speeds used during tasks such as teaching 3 Methods for workers to signal each other when two or more workers perform tasks 4 Steps that the worker should take when a problem or emergency occurs 5 Steps to take after the robot has come to a stop when the emergency stop device was triggered including checks for cancelling the problem or error state and safety checks in order to restart the robot 6 In cases other than above the following actions should be taken as needed to prevent hazardous situations due to sudden or unexpected robot operation or faulty robot opera tion as listed below 1 Show a display on the operator panel 2 Ensure the safety of workers performing tasks within the robot movement range 3 Clearly specify position and posture during work Position and posture where worker can constantly check robot movements and imme diately move to avoid trouble if an error problem occurs 4 Install noise prevention measures 5 Use methods for signaling operators of related equipment 6 Use methods to decide that an error has occurred and identify the type of error Implement the work instructions accor
11. 4 543 E v Note 1 Distance from both ends to the mechanical stopper Note 2 Minimum bend radius of motor cable is R50 50mm Note 3 Weight of models with no brake The weight of brake attached models is 0 2 kg heavier than the models with no brake shown in the table To install the single axis robot use M4 x 0 7 hex socket head bolts with a length under head 15mm or less Installation hole 4 5 inner surface counter bore dedit ig Note 4 Effective strokes of 650to 800 mm are only available with high lead specifications Lead 20 of less than 15mm e Effective stroke 50 100 150 200 250 350 400 450 500 550 600 650 Nt4 700 Note 4 750 Note 4 800 Note 4 Section View L 251 5 301 5 351 5 401 5 451 5 501 5 551 5 601 5 651 5 701 5 751 5 801 5 851 5 901 5 951 5 1001 5 A 130 180 230 280 330 380 430 480 530 580 630 680 730 780 830 880 D 230 230 230 230 230 230 230 230 230 230 M 0 1 2 3 4 5 0 1 2 3 4 5 6 7 8 9 N 4 6 8 10 12 14 6 8 10 12 14 16 18 20 22 24 Weight kg Note 3 2 0 2 2 2 2 3 2 4 2 5 2 6 2 4 2 8 2 9 3 0 3 1 3 2 3 3 3 4 3 5 Chapter 4 Specifications a 4 2 AC servo motor specifications 4 2 1 AC servo motor termination Connector specifications Servo motor Receptacle housing SMR 09V B C
12. About Safety 1 1 Safety Information een 1 3 1 2 Essential Caution Items eene 1 5 1 3 Industrial Robot Operating and Maintenance Personnel 1 10 1 4 Robot Safety Functions eese 1 11 1 5 Safety Measures for the System 1 12 1 6 Trial Operatlon cierre recente nee 1 12 1 7 Work Within the Safeguard Enclosure 1 13 1 8 Automatic 1 13 1 0 ann 1 14 MEMO Chapter 1 About Safety 1 1 Safety Information Industrial robots are highly programmable mechanical devices 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 WARNINGS 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 injury to personnel robot operator or service personnel including fatal accidents Warning information in this manual is shown classified into the following items DANGER Failure to follow DANGER instructions will result in severe injury or death to the robot operator bystanders or persons inspecting o
13. N1 Pin contact BYM 001T P0 6 CN1 Receptacle housing 5557 04R CN 4 polarities Receptacle 5556T CN2 Connector wiring Connector Wire Color S2 Blue black S4 Blue 51 Yellow black S3 Yellow R1 White R2 White black JP1 Red JP2 Red Shield Black Black White Red green yellow EF o JOJN AOIN Heat shrinkable tube E3 Chapter 4 Specifications u 4 2 2 Brake cable specifications vertical use Connector specifications Brake parts Receptacle housing SMR 02V B Pin contact BYM 001T P0 6 Connector Wire Color Yellow black Yellow black CN1 4 8 Chapter 4 Specifications p H P 4 3 Robot cable Signal cable To controller To robot Connection Controller CN1 Resolver 0 3sq Blue SPMCU 14K Orange Green Brown Grey Red Clear Shield Black Yellow Pink White Blue Red Power cable To controller To robot Connecti
14. allation near objects causing electromagnetic interference electrostatic discharge and radio frequency interference Vibration Do not subject to impacts or vibrations 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 separate YAMAHA Robot Controller User s Manual WARNING Avoid installing the robot in locations where the ambient conditions may exceed the allowable temperature or humidity or in environments where excessive moisture corrosive gases metallic powder or dust are generated Malfunctions failures or short circuits may otherwise result WARNING This robot was not designed for operation in environments where inflammable or explosive substances are present Do not use the robot in environments containing inflammable gas dust or liquids Explosions or fire could otherwise result WARNING Avoid using the robot in locations subject to electromagnetic interference electro static discharge or radio frequency interference Malfunctions may otherwise occur WARNING Do not use the robot in locations subject to excessive vibration Robot installation bolts may otherwise become loose causing the manipulator to fall over Chapter 2 Installation and Connections 2 4 Installation base To mount the r
15. ator can press the emergency stop button if any danger occurs WARNING When the robot does not need to be operated during adjustment or maintenance always turn off the controller and the external switch board Do not touch internal parts of the controller for 10 minutes after the controller has been turned off Use only lubricant and greases specified by YAMAHA sales office or dealer Use only parts specified by YAMAHA sales office or dealer Take sufficient care not to allow any foreign matter to contaminate them during adjustment parts replace ment or reassembly Do not modify any parts on the robot or controller Modification may result in unsat isfactory specifications or threaten operator safety When adjustment or maintenance is complete retighten the bolts and screws Securely During robot adjustment or maintenance place a sign indicating that the robot is being adjusted or serviced to prevent others from touching the control keys or Switches Provide a lock on the switch keys or ask someone to keep watch as needed 3 3 Chapter 3 Periodic Inspection amc A When applying grease to the ball screws and linear guide take the following precautions WARNING Precautions when handling grease Inflammation may occur if this gets in the eyes Before handling the grease wear
16. cables 2 8 2 6 2 System Configuration Example eee 2 9 About machine reference 2 10 PLE 2 10 Periodic Inspection Before beginning work sse 3 3 Periodic inspection iiis 3 5 3 2 T Dailyinspection eo ee Ren ABE 3 5 3 2 2 Three month inspection 3 5 37223 Six month inspection I Herten epe purs 3 6 3 2 4 Three year Inspection te een nina 3 6 Applying grease 3 7 Replacing the shutter 3 8 Adjusting shutter looseness sss 3 10 Chapter 4 Specifications 4 1 Robot specifications eese 4 3 4 Iz1 S Ae i etr RO Eee ome eee 4 3 441220 IS 4 5 4 2 servo motor specifications 4 7 4 2 1 servo motor termination 4 7 4 2 2 Brake cable specifications vertical use 4 8 4 3 Robot cable iioc tiet er pee eoi ni oaa pice Rr uns 4 9 Chapter 5 Troubleshooting 5 1 Positioning error 2 2 een aan 5 3 5 2 Feedback error 1 ek 5 4 Introduction The YAMAHA FLIP X series is a family of single axis industrial robots that use the absolute positi
17. contents before attempting the robot operation Tasks related to industrial robots teaching programming movement check inspection adjustment repair etc must be performed by qualified persons who meet requirements established by local regulations and safety standards for industrial robots Chapter 1 About Safety ee 1 4 Robot Safety Functions 1 Overload detection This function detects an overload applied to the motor and shuts off the servo power 2 Overheat detection This detects an abnormal temperature rise in the controller driver and shuts off the servo power If an overload or overheat error occurs take the following measures 1 a timer in the program 2 Reduce the acceleration coefficient 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 WARNING Soft limits must be set within the movement range mechanical stopper If the soft limit is set outside the movement range the robot axis may collide with the mechani cal stopper at high speed causing the object gripped by the end effector to fly or drop and the robot to malfunction 4 Mechanical stoppers If the servo power is suddenly shut off during high speed operation by emergency stop or safety functions
18. ding to the type of robot installation location and type of work task When drawing up the work instructions make an effort to include opinions from the work ers involved equipment manufacture s technicians and workplace safety consultants etc 25 Display a sign on operation panel during work Display an easy to understand sign or message on the programming box Handy Terminal and operation panel during the job task to prevent anyone other than the operators for that job task from mistakenly operating a start or selector switch If needed take other measures such as locking the cover on the operation panel 1 9 Chapter 1 About Safety P M Ot 26 Make daily and periodic inspections 1 Always make sure that daily and periodic inspections are performed and make a pre work check to ensure there are no problems with the robot or related equipment If a problem or abnormality is found then promptly repair it or take other measures as neces sary 2 When you make periodic inspections or repairs make a record and store it for at least 3 years 1 3 Industrial Robot Operating and Maintenance Personnel Operators or persons who handle the robot such as for teaching programming movement check inspection adjustment and repair must receive appropriate training and also have the skills needed to perform the job correctly and safely They must read the user s manual care fully to understand its
19. e and skill and may also involve work hazards Chapter 1 About Safety un 2 18 Location for installing the controller and the programming box or Handy Terminal The robot controller programming box and Handy Terminal should be installed at a loca tion that is outside the robot movement range yet where it is easy to operate and view the robot performing tasks 19 Protect electrical wiring and hydraulic pneumatic hoses as needed Install a cover or similar item to protect the electrical wring and hydraulic pneumatic hoses from possible damage 20 Install an operation status light Install an operation status light signal light tower etc at an easy to see position so the operator will know whether the robot is merely stopped or is in emergency error stop 21 Clean work tools etc Work tools such as welding guns and paint nozzles which are mounted in the robot arm will preferably be cleaned automatically 22 Provide adequate lighting Make sure to provide enough lighting to ensure safety during work 23 Prevent the gripped object from flying outwards If the object or workpiece gripped by the robot might fly outward or drop and create a hazard to the operator then protective equipment should be installed by taking the size weight temperature and chemical properties of the object into account 24 Draw up work instructions and makes sure the operator learns them well Decide on
20. e vertical axis parts and installation base 10 Be careful not to touch the motor or speed reduction gear casing when hot WARNING The motor and speed reduction gear casing are extremely hot after automatic opera tion so burns may occur if these are touched Before handling these parts during inspection or servicing turn off the controller wait for a while and check that the part has cooled 11 Take the following safety precautions during inspection of controller WARNING When you need to touch the terminals or connectors on the outside of the control ler 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 Refer to the YAMAHA Robot Controller User s Manual for precautions on handling the controller Chapter 1 About Safety 12 Use caution not to touch the controller cooling fan WARNING Bodily injury may occur from coming into contact with the cooling fan while it is rotating When removing the fan cover for inspection first turn off the controller and make sure the fan has stopped 13 Consult us for corrective action when the robot is damaged or malfunctions occur WARNING If any part of the robot is damaged or any malfunction occurs continuing the opera tion may be very dan
21. eakdown occurs due to defects in materials or workmanship in the genuine parts constituting this YAMAHA robot and or related product within the warranty 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 following ap plies 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 operation natural fading of painted or plated surfaces deterioration of parts subject to wear etc 2 Minor natural phenomena that do not affect the capa bilities 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 Damage 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
22. ended within the soft limits 3 Does the end effector move as intended 4 Are the signal transmissions to the end effector and peripheral equipment correct 5 Does emergency stop work 6 Are the teaching and playback functions normal 7 Are the safeguard enclosure and interlock working as intended 8 Does the robot move correctly during automatic operation Chapter 1 About Safety Work Within the Safeguard Enclosure 1 7 1 8 1 Work within the safeguard enclosure When work is required inside the safeguard enclosure always turn off the controller and place a sign indicating that the robot is being adjusted or serviced in order to keep any other person from touching the controller switch or operation panel except for the following cases 1 Soft limit settings See Section 4 in Chapter 4 2 Teaching For item 1 follow the precautions and procedure for each section To perform item 2 refer to the description in 2 below Teaching When performing teaching within the safeguard enclosure comply with the instructions listed below I Check or perform the following points from outside the safeguard enclosure 1 Make sure that no hazards are present within the safeguard enclosure by a visual check 2 Check that the programming box Handy Terminal operate 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 N
23. er 4 2 Remove the screws securing the side covers of the robot and remove the side covers on both sides NOTE If necessary move the slider to a location where it does not block the installation holes on the bottom of the robot frame 2 6 Chapter 2 Installation and Connections p X X A ee 3 Secure the robot to the base with the specified bolts 4 bolts and torque The bolts and tightening torque are shown below Robot Type Bolt Tightening torque T4 T4H Hex socket head bolt length longer than 12mm is recommended 5 5 Hex socket head M4 bolt length longer than 15mm is recommended 30kg cm to 45kg cm ACAUTION Be careful not to damage the shutter when tightening the bolts Be sure to tighten the bolt to the correct torque The wrong torque may not only cause robot position errors but also lead to serious accidents 4 Reattach the side covers after installing the robot 2 7 Chapter 2 Installation and Connections p Arcs CAM AEG 2 6 Connections 2 6 1 Connecting the robot cables Connect the robot cables to the mating connectors on the controller as shown Refer to SR1 robot controller user s manual for the controller connectors Robot cable power cable FLIP X s
24. eries T4 T4H T5 T5H WARNING Before connecting the cables check that there are no bends or breaks in the robot cable connector pins and that the cables are not damaged Bent or broken pins or cable damage may cause robot malfunctions Chapter 2 Installation and Connections 2 6 2 System Configuration Example System Configuration Example Programming box HPB option lt gt 2 lt Robot controller SR1 SD memory card SRI X guum RS 232C option ew PO communication control RS 232C or communication control communication cable Resolver signal Motor power POPCOM communication software option Input 16 general purpose pins 7 custom purpose pins c 2 Output 16 general purpose pins 3 custom purpose pins control 24V power supply built in Power supply AC100 115 200 230V 10 External control The controller is supplied with the robot as a standard unit The programming box HPB POPCOM and SD memory card are optional FLIP X series T4 T4H T5 T5H 2 9 Chapter 2 Installation and Connections 2 7 About machine reference The position detector built into the motor issues a 0 pulse each time the motor rotates 1 4th of one turn When return to origin is performed a difference
25. ever enter the movement range of the manipulator while within the safeguard enclosure 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 box Handy Terminal 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 actuated Observe the following during automatic operation or in cases where an error occurs 1 After automatic operation has started check the operation status and warning 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 following 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 inspected in order to keep any other person from touching the start switch and restarting the robot Chapter 1 About Safety mre aC s 1 9 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 br
26. gerous Please consult your YAMAHA sales office or dealer for corrective action Damage or Trouble Possible Danger Damage to machine harness or robot cable Electrical shock malfunction of robot 7 Flying outwards of damaged parts during robot Damage to exterior of robot operation Abnormal operation of robot AR ME Malfunction of robot positioning error excessive vibration etc Z axis brake trouble Dropping of load 14 Protective bonding WARNING Be sure to ground the robot and controller to prevent electrical shock 15 Be sure to make correct parameter settings ACAUTION The robot must be operated with correct acceleration coefficients according to the tolerable moment of inertia and manipulator tip mass or moment of inertia If these are not correct drive unit service life may end prematurely and damage to robot parts or residual vibration during positioning may result 16 Follow the specified procedures when installing adjusting or inspecting the robot WARNING Always follow the specified procedures when installing adjusting or inspecting the robot Never attempt any procedure not described in this manual 17 Do not attempt any repair parts replacement and modification WARNING Do not attempt any repair parts replacement and modification unless described in this manual These works require technical knowledg
27. h the side covers 3 7 Chapter 3 Periodic Inspection 5 lt lt lt 77 NP 3 4 Replacing the shutter Use the following procedure when the shutter must be replaced Make sure that the controller power switch is off before beginning work If the motor has a trouble and must be replaced please contact YAMAHA sales office or dealer 1 Remove the 4 screws securing the slider cover and take off the slider cover 2 Remove the screws securing the shutter Remove the 2 screws on the endplate side and the 2 screws on the motor side 3 Remove the shutter and shutter guide from the robot Shutter guide 3 8 Chapter 3 Periodic Inspection ecel uruluotvwNen uuikiktt it u ttit tL o asm mmc 4 Remove the shutter from the shutter guide and pass the new shutter through it 5 Reinstall the shutter and the slider cover using the reverse of the above procedure NOTE Do not fully tighten the screws to secure the shutter on the endplate side at this time Fully tighten these screws after adjusting for shutter looseness in step 6 6 Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shutter ACAUTION Do not press down on the shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp 3 9 Chapter 3 Periodic Inspect
28. ical installation Controller Horizontal installation T5H SR1 X 05 Vertical installation 1 Positioning repeatability in one direction 2 650mm or longer strokes are only available with high lead specifications Lead 20 3 When the stroke is longer than 650mm resonance of the ball screw may occur depending on the operation conditions hazardous speed In this case reduce the speed setting on the program by referring to the maximum speeds shown in the table below Stroke mm 650 700 750 800 Maximum speed mm sec 960 840 720 660 SPEED setting 80 70 60 55 E Allowable overhang A B B Horizontal installation Unit mm Wall installation Unit mm Vertical installation Unit mm T5 T5H A B T5 T5H A B T5 T5H AC 1kg 600 323 683 ikg 600 291 600 Lead 20 Lead 20 Lead 12 1 2kg 242 240 675 103 247 215 73 589 2kg 1170 159 406 2kg 368 127 1082 Lead 12 Lead 12 Lead 6 2 4kg 113 113 5kg 555 59 155 5kg 127 30 449 3kg 1498 104 294 3kg 263 73 970 Lead 6 Lead 6 9kg 628 31 89 9kg 54 0 400 Distance from center of the top face of the slider carriage to the gravity center of the item being carried This is calculated assuming that the service life of the guide is 10 000km 4 5 Chapter 4 Specifications Dimensions Approx 250 motor cable length 12743 Effective stroke 1
29. ime Non operation time Duty 96 x100 If the robot duty is high an error such as overload or overheat occurs In this case increase the stop time to reduce the duty 2 10 Chapter Periodic Inspection 3 1 Before beginning work eere 3 3 3 2 Periodic inspection ee 3 5 3 2 1 D ily inspecti n 3 5 3 2 2 Three month inspection eerte ere trees 3 5 3 2 3 Sixsmonth Inspection hee RR ee ee REED 3 6 3 2 4 Three year inspection 3 6 3 3 Applying grease 3 7 3 4 Replacing the shutter esee 3 8 3 5 Adjusting shutter 5 3 10 MEMO 3 2 3 1 Chapter 3 Periodic Inspection Before beginning work Periodic inspection and maintenance are essential to ensure safe and efficient operation of YAMAHA robots This chapter describes periodic inspection items and procedures for the FLIP X series Before beginning work read the precautions below and also in Chapter 1 About Safety and follow the instructions If the inspection or maintenance procedure calls for operation of the robot stay out of the working area of the robot during operation Do not touch any parts inside the controller Keep watching the robot movement and surrounding area so that the oper
30. ion lamcc AE MANC UN NN n 3 5 Adjusting shutter looseness The shutter may elongate with continued use In such cases adjust as follows 1 Slightly loosen the two screws securing the endplate side of the shutter Do not remove 2 While pulling on the shutter with your fingers tighten the screws so that there is no looseness See step 6 of 3 4 Replacing the shutter 3 10 Chapter Specifications 4 1 Robot Specifications as rant ra cec rb 4 3 4 1 eterne ter Ro incen 4 3 4 1 2 siete the mire eo p e Ev CH eere 4 5 4 2 servo motor specifications 4 7 4 2 1 servo motor termination 4 7 4 2 2 Brake cable specifications vertical use 4 8 4 3 Robot cable aiii ceo iren cei iti ees tei cena ccr edax 4 9 MEMO 4 2 Chapter 4 Specifications 4 1 Robot specifications Basic specifications Static loading moment Motor output AC W 30 er 1 Repeated positioning accuracy mm 1 20 02 Deceleration mechanism Ball screw Class C10 Ball screw lead mm 12 6 2 Maximum speed mm sec 720 360 120 enm Maximum payload Horizontal installa
31. n Check the following points every 3 months and apply grease if needed Checkpoints Check items Notes Check for dirt or grime If dirt or grime is found clean See 3 3 in the part Apply grease after cleaning this chapter Apply grease if the items checked are dry or do not Ball screw linear guide and ball have enough grease bushing Recommended grease is as follows Standard model Use No Showa Shell Daphne Eponex No 2 Idemitsu Clean room model Use LG 2 NSK See 3 5 in Shutter Check for slack Adjust if necessary this chapter ACAUTION Using a grease other than recommended by YAMAHA may shorten the service life of the ball screw linear guide and linear bushing shaft 3 5 Chapter 3 Periodic Inspection 3 2 3 Six month inspection Check the following points every six months and make adjustments or apply grease if neces sary Checkpoints Main bolts and screws on robot Check items Check for looseness If loose tighten Notes Ball screw and linear guide Check for looseness in the ball screw and linear guide Tighten if necessary Check for vibration during operation Tighten drive section and X and Y axis installation bolts if necessary If problem is not solved or wear and backlash are found please Lubrication of ball screw nut and linear guides Apply Alvania No 2 Showa Shell Daphne Epo
32. nex No 2 Idemitsu Sekiyu to the ball Screw nut and linear guides Check for wear and backlash If any abnormality is found contact us contact YAMAHA sales office or dealer Check for loose terminals Controller Check for loose connectors See 3 3 in this chapter CAUTION Using a grease other than recommended by YAMAHA may shorten the service life of the ball screw linear guide and linear bushing shaft 3 2 4 Three year inspection Inspect the following points once every three years and contact us if any problem is found Set an earlier inspection interval if parts are subject to long term or frequent usage Checkpoints Check items Notes Ball screw nut sections and linear guides Check for wear and looseness in the ball screw nut and linear guide Contact us if trouble is found 3 6 Chapter 3 Periodic Inspection warm 3 3 Applying grease Follow these instructions when applying grease to the 4 5 robot ball screws and linear guides during periodic maintenance Make sure that the controller power switch is off before beginning work 1 Remove the screw securing the robot side covers and remove the side covers 2 Coatthe ball screw and linear guides with grease by hand and move the slider back and forth to spread the grease Ball screw Applying grease to the ball screw Linear guide Applying grease to the linear guide 3 Reattac
33. ng the controllers MEMO User s Manual FLIP X series YAMAHA 5 5 Ver 2 01 This manual is based on Ver 2 01 of Japanese manual YAMAHA MOTOR CO LTD IM Operations 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
34. obot use an installation base that satisfies the following conditions 1 The installation base is subjected to a great deal of stress while the robot is in operation Prepare a sufficiently rigid and stable installation base taking into account the robot weight including the end effector gripper and workpiece ACAUTION If the installation base is not sufficiently rigid and stable vibration resonance may occur during operation causing adverse effects on the robot work 2 The installation base surface must be machined within a flatness of 0 05mm 500mm The robot positioning accuracy might decrease if the installation surface precision is insufficient 3 Use an installation base of sufficient size to match the robot body so that the robot can be installed with the specified number of bolts Avoid installing the robot with less than the specified number of bolts 4 bolts or installing the robot closer to one end as shown at the lower right Installation base Installation base Good example Bad example ACAUTION Using less than the specified number of bolts to install the robot may cause vibration and poor positioning accuracy 2 5 Chapter 2 Installation and Connections 2 5 Installing the robot 1 Tap holes into the installation base where the robot is to be secured For hole diameter and pitch see the external view and dimensions in 4 1 Robot specifica tions of Chapt
35. on Yellow Green 0 75sq Red Motor wire SS 0 75sq 0 7550 White 0 75sq Black MEMO 4 10 Chapter Troubleshooting 5 1 Positioning error rares itn teg een 5 3 5 2 5 4 MEMO 5 2 Chapter 5 Troubleshooting Da Hl 5 1 Positioning error Position deviates The position deviates after moving the robot or set up of workpiece tool Robot bumped into something or there are traces of bumping Operation was correct but position deviates into rubbing against something Is cable broken Are cables correctly wired Are connectors correctly fitted Replace the cable 1 Check tool and workpiece for warping 2 Check robot alignment Check wiring and connectors Are the robot tools and workpiece correctly installed Does the position return after return to origin operation Mechanical cause Check installation method 1 Check for looseness of mechanical parts Retighten if necessary 2 Replace mechanical parts Electrical cause Check for looseness of robot mechanical parts Is there a large source of noise nearby Take measures
36. oning method as a standard feature to improve ease of use resistance to environmental conditions and maintenance work A wide varaiety of product lineup allows you to select the desired robot model that best matches your application This user s manual describes the safety measures handling adjustment and mainte nance of FLIP X 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 e 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 e Specifications of robot models other than standard models may be omitted in this manual if they are common to those of standard models In this case refer to the specifications of standard models For details on specific operation of the robot refer to the separate user s manual for the robot controller being used NOTES The contents of this manual are subject to change without prior notice While every effort has been made to ensure the contents of this manual are correct please contact us if you find any part of this manual to be unclear confusing or inaccurate YAMAHA MOTOR CO LTD IM Operations MEMO Chapter
37. ple serene 2 9 2 7 About machine reference esc 2 10 MEMO 2 2 Chapter 2 Installation and Connections mcm eU nc mem 2 1 Checking the product After unpacking make sure that all components and accessories are included as specified in your order Also check the product for any damage on the exterior which might have occurred during transportation If there are any missing parts or damage due to transportation please notify your YAMAHA sales office or dealer immediately 2 2 Robot part names Shutter mounting screw Motor case lt Slider Slider cover Side cover B 2 Shutter mounting screw Side cover Shutter mounting screw gt Side cover mounting screw Endplate 2 3 Chapter 2 Installation and Connections pr n E 2 3 Robot Installation Conditions Be sure to install the robot in the following environments Specifications Allowable ambient temperature 0 to 459 Allowable ambient humidity 35 to 8596 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 and liquid Avoid inst
38. r repairing the robot WARNING Failure to follow WARNING instructions could result in severe injury or death to the robot operator bystanders or persons inspecting or repairing the robot CAUTION Failure to follow CAUTION instructions may result in injury to the robot operator bystanders or persons inspecting or repairing the robot or damage to the robot and or robot controller NOTE Explains the key point in the operation in a simple and clear manner Chapter 1 About Safety 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 avail able for an additional fee 2 Operate or adjust the robot while viewing the CD ROM version of the 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 list all safety items in detail 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 For specific safety information and standards refer to the applicable local regulations and comply with the instructions This manual and warning labels supplied with or attached
39. the part of the system manufacturer according to the individual system The system manufacturer should provide a proper instruc tion manual for safe correct operation and servicing of the system Trial Operation After making installations adjustments inspections or 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 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 15 the robot correctly connected to peripheral equipment 5 Have safety measures safeguard enclosure etc been taken 6 Does the installation environment meet the specified standards 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 int
40. tion 4 5 6 6 kg Vertical installation 12 24 7 2 Unit Nem Rated thrust N 32 64 153 MY 15 Stroke mm 50 to 300 50 pitch MP 19 Cable length m Standard 3 5 OP 5 10 MR 18 Horizontal installation T4 ERCX ERCD Vertical installation Controller Horizontal installation T4H SR1 X 05 Vertical installation 1 Positioning repeatability in one direction E Allowable overhang A B B Horizontal installation Unit mm Wall installation Unit mm Vertical installation Unit mm T4 T4H A B T4 T4H A B T4 T4H 2kg 433 87 2kg 149 54 376 Lead 12 Lead 12 Lead 12 1 2kg 125 125 4 5kg 223 33 4 5kg 50 1 148 3kg 515 58 3kg 107 24 380 Lead 6 Lead 6 Lead 6 2 4kg 56 57 6kg 340 26 6kg 31 0 195 3kg 1585 58 142 3kg 113 24 1180 3kg 41 42 Lead2 Lead 2 Lead 2 6kg 755 27 66 6kg 32 O 440 72kg 010 Distance from center of the top face of the slider carriage to the gravity center of the item being carried This is calculated assuming that the service life of the guide is 10 000km 4 3 Chapter 4 Specifications Dimensions Approx 250 motor cable length Effective stroke _ He aeg H 1 0t J 4 M4 x 0 7 Depth 9 11 cover thickness M used when Bde is attached 0 50 Installation hole 4 5 inner surface 8 counter bore depth 4 5 13 Q
41. to the robot are written in English Unless the robot operators or service personnel understand Eng lish do not permit them to handle the robot Cautions regarding the official language of EU countries For equipment that will be installed in EU countries the language used for the user s manu als CE declarations and operation screen characters is English only Warning labels only have pictograms or else include warning messages in English In the latter case Japanese messages might be added 1 4 Chapter 1 About Safety 1 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 instructions to ensure safe use of the robot 1 Observe the following cautions during automatic operation Install a safeguard 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 Install a safety interlock that triggers emergency stop when the door or panel is opened Install safeguards so that 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 conspicuous spots on doors or panels equipped with safety interlocks Serious
42. 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 Hands and fingers might be cut when opening the container so use protective 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 If grease gets in the eyes wash liberally with pure water for about 15 minutes and consult a physician for treatment If grease comes in contact with the skin wash away completely with soap and water If taken internally do not induce vomiting but promptly consult a physician for proper treatment 3 4 Chapter 3 Periodic Inspection p M r P u 3 2 Periodic inspection 3 2 1 Daily inspection Check the following points on a daily basis before and after robot operation Checkpoints Check items Notes Cables and shutter Check for scratches dents and excessively tight bends Replace if Ball screws and bearings Check for unusual vibration and noise necessary See 3 4 in this Check for unusual vibration and noise and for abnormal Motor chapter temperature rise 3 2 2 Three month inspectio
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