YASKAWA MOTOMAN DX100 User manual

YASKAWA
YASKAWA MANUAL NO. RE-CSO-A040
DX100
OPERATOR’S MANUAL
FOR SPOT WELDING USING MOTOR GUN
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL DX100
MAINTENANCE MANUAL
The DX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
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DX100
ii
MANDATORY
• This manual explains the various components of the DX100 system
and general operations. Read this manual carefully and be sure to
understand its contents before handling the DX100.
• General items related to safety are listed in Section 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instruction before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized
modification voids your product’s warranty.
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DX100
iii
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.”
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
MANDATORY
Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED
Must never be performed.
NOTE To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “CAU-
TION” and “WARNING.”
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DX100
iv
WARNING
• Before operating the manipulator, check that servo power is turned
off when the emergency stop buttons on the front door of the DX
100 and programing pendant are pressed.
When the servo power is turned off, the SERVO ON LED on the
programing pendant is turned off.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of EM
TURN
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning on the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the working envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there are problems.
The emergency stop button is located on the right of the front door of
the DX 100 and programing pendant.
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DX100
v
Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows.
CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator.
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the
controller
Manipulator cable
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DX100
vi
Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Description of the Operation Procedure
In the explanation of the operation procedure, the expression "Select • • • "
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
Equipment Manual Designation
Programming
Pendant
Character Keys The keys which have characters printed on
them are denoted with [ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on
them are not denoted with [ ] but depicted
with a small picture.
ex. page key
The cursor key is an exception, and a picture
is not shown.
Axis Keys
Numeric Keys
“Axis Keys” and “Numeric Keys” are generic
names for the keys for axis operation and
number input.
Keys pressed
simultaneously
When two keys are to be pressed
simultaneously, the keys are shown with a
“+” sign between them,
ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
PAGE
GO BACK
PAGE
GO BACK
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DX100 Contents
vii
1 Introduction .
1-1
1.1 DX100 Overview.
1-1
1.2 Programming Pendant. 1-2
1.2.1 Programming Pendant Overview.
1-2
1.2.2 Key Description .
1-3
1.2.2.1 Character Keys .
1-3
1.2.2.2 Symbol Keys .
1-3
1.2.2.3 Axis Keys and Numeric Keys .
1-3
1.2.2.4 Keys Pressed Simultaneously.
1-3
1.2.3 Programming Pendant Keys. 1-4
1.2.4 Programming Pendant Display.
1-11
1.2.4.1 Five Display Areas .
1-11
1.2.4.2 General-purpose Display Area .
1-12
1.2.4.3 Main Menu Area.
1-13
1.2.4.4 Status Display Area. 1-13
1.2.4.5 Human Interface Display Area .
1-16
1.2.4.6 Menu Area.
1-16
1.2.5 Screen Descriptions .
1-17
1.2.6 Character Input Operation .
1-18
1.2.6.1 Character Input .
1-18
1.2.6.2 Operation .
1-18
1.2.6.3 Alphanumeric Input . 1-19
1.2.6.4 Symbol Input .
1-20
1.3 Mode.
1-21
1.3.1 Teach Mode .
1-21
1.3.2 Play Mode .
1-21
1.3.3 Remote Mode.
1-21
1.3.4 Teach Mode Priority .
1-21
1.4 Security Mode.
1-22
1.4.1 Types of Security Modes.
1-22
1.4.2 Changing Security Modes .
1-26
2 Manipulator Coordinate Systems and Operations .
2-1
2.1 Control Groups and Coordinate Systems .
2-1
2.1.1 Control Group.
2-1
2.1.2 Types of Coordinate Systems .
2-2
2.2 General Operations . 2-3
2.2.0.1 Check Safety .
2-3
2.2.0.2 Select Teach Mode . 2-3
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DX100 Contents
viii
2.2.0.3 Select Control Group . 2-3
2.2.0.4 Select Coordinate System . 2-3
2.2.0.5 Select Manual Speed . 2-4
2.2.0.6 Servo ON. 2-4
2.2.0.7 Axis Operation. 2-4
2.2.0.8 HIGH SPEED . 2-4
2.3 Coordinate Systems and Axis Operation. 2-5
2.3.1 Joint Coordinates. 2-5
2.3.2 Cartesian Coordinates . 2-6
2.3.3 Cylindrical Coordinates. 2-7
2.3.4 Tool Coordinates . 2-9
2.3.4.1 Selecting Tool. 2-11
2.3.5 User Coordinates. 2-12
2.3.5.1 Selecting User Coordinates. 2-13
2.3.5.2 Examples of User Coordinate Utilization. 2-14
2.3.6 External Axis. 2-14
2.3.7 Control Point Operation . 2-15
2.3.7.1 Control Point Change . 2-18
3 Teaching . 3-1
3.1 Preparation for Teaching . 3-1
3.1.1 Checking Emergency Stop Buttons . 3-1
3.1.2 Setting the Teach Lock . 3-1
3.1.3 Registering a Job. 3-2
3.1.3.1 Registering Job Names . 3-2
3.1.3.2 Registering Jobs. 3-2
3.1.3.3 Registering Comments . 3-3
3.1.3.4 Registering Control Groups . 3-3
3.1.3.5 Switching to the Teaching Window. 3-4
3.2 Teaching Operation .3-5
3.2.1 Teaching Window . 3-5
3.2.2 Interpolation Type and Play Speed. 3-6
3.2.2.1 Joint Interpolation . 3-6
3.2.2.2 Linear Interpolation. 3-7
3.2.2.3 Circular Interpolation . 3-8
3.2.2.4 Spline Interpolation. 3-9
3.2.3 Teaching Steps. 3-11
3.2.3.1 Registering Move Instructions . 3-11
3.2.3.2 Registering Reference Point Instructions . 3-17
3.2.3.3 Registering Timer Instructions. 3-18
3.2.4 Overlapping the First and Last Steps . 3-21
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DX100 Contents
ix
3.3 Checking Steps.
3-22
3.3.1 FWD/BWD Key Operations .
3-22
3.3.1.1 Precautions When Using FWD / BWD Operations.
3-23
3.3.1.2 Selecting Manual Speed .
3-25
3.3.1.3 Moving to Reference Point .
3-26
3.3.1.4 Test Operations.
3-26
3.3.1.5 Machine Lock Operation .
3-27
3.4 Modifying Steps .
3-28
3.4.1 Displaying the JOB CONTENT Window for Editing.
3-32
3.4.1.1 Currently Called Up Job .
3-32
3.4.1.2 Calling Up Other Jobs .
3-32
3.4.2 Inserting Move Instructions.
3-33
3.4.3 Deleting Move Instructions .
3-35
3.4.4 Modifying Move Instructions .
3-36
3.4.4.1 Modifying Position Data.
3-36
3.4.4.2 Modifying Interpolation Type .
3-36
3.4.5 Undo Operation .
3-37
3.4.6 Modifying Reference Point Instructions .
3-38
3.4.6.1 Deleting Reference Point Instructions.
3-38
3.4.6.2 Modifying Reference Point Instructions.
3-38
3.4.7 Modifying Timer Instructions.
3-39
3.4.7.1 Deleting Timer Instructions.
3-39
3.4.7.2 Modifying Timer Instructions .
3-39
3.5 Modifying Jobs.
3-40
3.5.1 Calling Up a Job .
3-40
3.5.2 Windows Related to Job.
3-40
3.5.3 JOB HEADER Window.
3-41
3.5.4 JOB CONTENT Window .
3-42
3.5.4.1 COMMAND POSITION Window .
3-43
3.5.5 JOB CAPACITY Window.
3-44
3.6 Editing Instructions .
3-45
3.6.1 Instruction Group.
3-46
3.6.2 Inserting Instructions .
3-47
3.6.3 Deleting Instructions .
3-50
3.6.4 Modifying Instructions.
3-50
3.6.5 Modifying Additional Numeric Data .
3-54
3.6.6 Modifying Additional Items.
3-55
3.6.7 Inserting Additional Items .
3-56
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DX100 Contents
x
3.6.8 Deleting Additional Items . 3-57
3.7 Editing Jobs . 3-58
3.7.1 Selecting the Range . 3-60
3.7.2 Copying . 3-61
3.7.3 Cutting . 3-61
3.7.4 Pasting. 3-62
3.7.5 Reverse Pasting . 3-63
3.8 Test Operations . 3-64
3.8.1 Test Operation Procedures. 3-64
3.9 Other Job-editing Functions. 3-65
3.9.1 Editing Play Speed . 3-65
3.9.1.1 Modification of Speed Type . 3-65
3.9.1.2 Relative Modification . 3-65
3.9.1.3 Modification by TRT (Traverse Time) . 3-67
3.9.2 Editing Interpolation Type . 3-69
3.9.3 Editing Condition Files . 3-70
3.9.4 User Variables . 3-71
3.9.4.1 Setting Byte, Integer, Double Precision Integer, and Real Type Variables .
3-72
3.9.4.2 Setting Character Type Variables. 3-74
3.9.4.3 Registering Variable Name. 3-75
3.9.4.4 Displaying Position Variables . 3-76
3.9.4.5 Setting Position Variables. 3-77
3.9.4.6 Setting Position Variables Using the Numeric Keys. 3-78
3.9.4.7 Setting Position Variables Using the Axis Keys. 3-80
3.9.4.8 Deleting Data Set of Position Variables. 3-81
3.9.4.9 Checking Positions by Position Variables . 3-81
3.9.4.10 Manipulator Types. 3-82
3.9.5 Flip/No Flip. 3-83
3.9.6 R-axis Angle . 3-83
3.9.7 T-axis Angle. 3-84
3.9.8 Front/Back . 3-84
3.9.9 Upper Arm/Lower Arm . 3-86
3.9.10 S-axis Angle. 3-86
3.9.11 Editing Local Variables . 3-87
3.9.11.1 Setting the Number of Local Variables. 3-89
3.9.12 Search . 3-90
3.9.12.1 Line Search . 3-91
3.9.12.2 Step Search. 3-92
3.9.12.3 Label Search . 3-93
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DX100 Contents
xi
3.9.12.4 Instruction Search . 3-95
3.9.12.5 Tag Search.
3-97
4 Playback .
4-1
4.1 Preparation for Playback .
4-1
4.1.1 Selecting a Job.
4-1
4.1.1.1 Calling a Job .
4-1
4.1.1.2 Registering the Master Job .
4-2
4.1.1.3 Calling the Master Job.
4-4
4.1.2 The PLAYBACK Window.
4-6
4.1.2.1 Display of Cycle Time.
4-6
4.1.2.2 Operation Cycle .
4-7
4.2 Playback .
4-10
4.2.1 Playback Operation .
4-10
4.2.1.1 Selecting the Start Device.
4-10
4.2.1.2 Servo On .
4-10
4.2.1.3 Start Operation.
4-10
4.2.2 Special Playback Operations.
4-11
4.2.2.1 Low Speed Operation .
4-11
4.2.2.2 Limited Speed Operations.
4-12
4.2.2.3 Dry-run Speed Operations .
4-12
4.2.2.4 Machine Lock Operation .
4-13
4.2.2.5 Check Mode Operation .
4-13
4.2.2.6 Weaving Prohibit Setting during Check Mode Operation.
4-13
4.2.2.7 Cancel All Special Operations.
4-14
4.3 Stop and Restart.
4-15
4.3.1 Hold . 4-15
4.3.1.1 Using the Programming Pendant .
4-15
4.3.1.2 Using an External Input Signal (System Input).
4-15
4.3.2 Emergency Stop .
4-16
4.3.2.1 Restart After Emergency Stop.
4-17
4.3.3 Stop by Alarm .
4-18
4.3.4 Others.
4-19
4.3.4.1 Temporary Stop by Mode Change .
4-19
4.3.4.2 Temporary Stop by the PAUSE Instruction.
4-19
4.4 Modifying Play Speed. 4-20
4.4.1 Speed Override .
4-20
4.4.1.1 Setting Speed Overrides .
4-21
4.4.1.2 Modifying Play Speed .
4-22
4.4.1.3 Cancelling Speed Override Settings . 4-22
4.5 Playback with Reserved Start.
4-23
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DX100 Contents
xii
4.5.1 Preparation for Reserved Start. 4-23
4.5.1.1 Enabling Reserved Start. 4-24
4.5.1.2 Registering Reserved Start I/O Signal. 4-26
4.5.1.3 Registering Jobs to Stations. 4-28
4.5.1.4 Deleting Registered Jobs from Stations . 4-30
4.5.2 Playback from Reserved Start . 4-31
4.5.2.1 Start Operation . 4-31
4.5.2.2 Checking Job Reservation Status . 4-32
4.5.2.3 Resetting Job Reservation . 4-33
4.5.3 Hold Operation. 4-34
4.5.3.1 [HOLD] on the Programming Pendant. 4-34
4.5.3.2 Hold by External Input Signal (System Input). 4-34
4.5.3.3 Hold at the Station. 4-35
4.6 Displaying Job Stack. 4-36
5 Editing Jobs.5-1
5.1 Copying Jobs . 5-2
5.1.0.1 Copying Jobs on the JOB CONTENT Window. 5-2
5.1.0.2 Copying Jobs on the JOB LIST Window . 5-4
5.2 Deleting Jobs . 5-6
5.2.0.1 Deleting Jobs on the JOB CONTENT Window. 5-6
5.2.0.2 Deleting Jobs on the JOB LIST Window . 5-7
5.3 Modifying Job Names . 5-8
5.3.0.1 Modifying Job Names on the JOB CONTENT Window. 5-8
5.3.0.2 Modifying Job Names on the JOB LIST Window. 5-10
5.4 Editing Comments. 5-12
5.5 Setting Edit Lock on Individual Job Units. 5-14
5.6 Enabling the Modification of Position Data Only. 5-15
6 Convenient Functions . 6-1
6.1 One-touch Operation “Direct Open”. 6-1
6.2 Parallel Shift Function . 6-3
6.2.1 Function Overview . 6-3
6.2.1.1 Parallel Shift of Step . 6-4
6.2.1.2 Parallel Shift of Job .6-4
6.2.2 Setting the Shift Value . 6-5
6.2.2.1 Coordinate Systems . 6-5
6.2.2.2 Setting the Shift Value. 6-5
6.2.3 Registering Shift Instructions . 6-7
6.2.3.1 SFTON Instruction. 6-8
6.2.3.2 SFTOF Instruction . 6-10
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DX100 Contents
xiii
6.2.3.3 MSHIFT Instruction .
6-11
6.2.4 Continuation of the Parallel Shift Function .
6-13
6.2.5 Examples of Use .
6-14
6.2.5.1 Example of Use of Shift Addition/Subtraction.
6-14
6.2.5.2 Example of Use of MSHIFT Instruction.
6-15
6.3 Parallel Shift Job Conversion Function.
6-16
6.3.1 Function Overview.
6-16
6.3.2 Coordinate Systems for Conversion.
6-17
6.3.3 Executing the Parallel Shift Job Conversion.
6-21
6.3.3.1 Window Display.
6-21
6.3.3.2 Parallel Shift Job Conversion Operation .
6-23
6.3.4 Specifying the Shift Value by Position Variables.
6-29
6.3.4.1 Window Display.
6-29
6.3.4.2 Jobs Targeted for Conversion .
6-31
6.3.4.3 Conversion of Coordinated Jobs .
6-32
6.3.4.4 Operation Procedure.
6-35
6.4 PAM Function .
6-37
6.4.1 Function Overview.
6-37
6.4.1.1 Input Ranges for Adjustment Data .
6-37
6.4.2 Operating Methods .
6-39
6.4.2.1 Setting Adjustment Data .
6-39
6.4.2.2 Executing the Adjustment . 6-41
6.5 Mirror Shift Function .
6-45
6.5.1 Function Overview.
6-45
6.5.2 Pulse Mirror-shift Function.
6-46
6.5.2.1 Parameter Setting .
6-46
6.5.2.2 Object Job .
6-46
6.5.2.3 Group Axes Specification .
6-46
6.5.2.4 Position Variables .
6-46
6.5.3 Robot-coordinates Mirror-shift Function .
6-47
6.5.3.1 Object Job .
6-47
6.5.3.2 Group Axes Specification .
6-47
6.5.3.3 Position Variables .
6-47
6.5.4 User-coordinates Mirror-shift Function .
6-48
6.5.4.1 Object Job .
6-48
6.5.4.2 Group Axes Specification .
6-48
6.5.4.3 Position Variables .
6-48
6.5.5 Notes on the Mirror Shift Function.
6-49
6.5.6 Operation Procedures .
6-50
6.5.6.1 Calling Up the JOB CONTENT Window.
6-50
6.5.6.2 Mirror Shift Conversion.
6-50
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DX100 Contents
xiv
6.5.6.3 Explanation of the Mirror Shift Window . 6-51
6.6 Multi Window Function. 6-53
6.6.1 Function Overview . 6-53
6.6.2 Setting the Dividing Pattern of the General-Purpose Display Area .
6-53 6.6.2.1 Calling Up and Operating Methods of the Display
Dividing Pattern
Setting Window. 6-54
6.6.3 Displaying the Multi Window.6-58 6.6.3.1 Multi Window Mode and Single Window
Mode .
6-58 6.6.3.2 Displaying the Status of Plural (more than two) Window
Dividing
Pattern Setting. 6-58
6.6.3.3 Displaying of Active Window and Non-Active Window . 6-59
6.6.3.4 Limited Matters in Multi Window Mode. 6-59
6.6.4 Operation of Multi Window. 6-60
6.6.4.1 Switching of Multi Window Mode and Single Window Mode. 6-60
6.6.4.2 Switching of Active Window. 6-62
6.6.5 Switching the Axis Operation Control Group .
6-64 6.6.5.1 S2C540 “Choosing Method of Notifying the Change of
Axis
Operation Control Group when Switching the Active Window” . 6-64
7 External Memory Devices . 7-1
7.1 Memory Devices . 7-1
7.1.1 Compact Flash (CF Cards). 7-2
7.1.1.1 Recommended Compact Flash Cards . 7-2
7.1.1.2 Notes on handling Compact Flash . 7-2
7.1.1.3 Inserting a Compact Flash. 7-3
7.1.2 USB Memory Stick. 7-4
7.1.2.1 Recommended USB Memory Stick. 7-4
7.1.2.2 Notes on handling USB Memory Stick . 7-4
7.1.2.3 Inserting a USB Memory Stick. 7-5
7.2 Handling Data . 7-6
7.2.1 Data Classification . 7-6
7.2.2 File Existence . 7-9
7.2.2.1 Saving by Overwriting. 7-10
7.3 Operation Flow. 7-11
7.3.0.1 Operating a Folder . 7-12
7.3.0.2 Saving Data. 7-16
7.3.0.3 Loading Data . 7-28
7.3.0.4 Verifying Data. 7-38
7.3.0.5 Deleting Data. 7-41
7.3.0.6 Job Selection Mode .7-43
8 Parameter . 8-1
8.1 Parameter Configuration. 8-1
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8.2 Motion Speed Setting Parameters.
8-2
8.2.0.1 S1CxG000: IN-GUARD SAFE OPERATION MAX. SPEED . 8-2
8.2.0.2 S1CxG001: DRY-RUN SPEED .
8-2
8.2.0.3 S1CxG002 to S1CxG009: JOINT SPEED FOR REGISTRATION.
8-2
8.2.0.4 S1CxG010 to S1CxG017: LINEAR SPEED FOR REGISTRATION .
8-3
8.2.0.5 S1CxG018 to S1CxG025: POSITION ANGLE SPEED.
8-3
8.2.0.6 S1CxG026 to S1CxG029: JOG OPERATION ABSOLUTE VALUE SPEED .
8-3
8.2.0.7 S1CxG030 to S1CxG032: INCHING MOVE AMOUNT.
8-4
8.2.0.8 S1CxG033 to S1CxG040: POSITIONING ZONE.
8-4
8.2.0.9 S1CxG044: LOW-SPEED START .
8-6
8.2.0.10 S1CxG045 to S1CxG048: JOG OPERATION LINK SPEED .
8-6
8.2.0.11 S1CxG056: WORK HOME POSITION RETURN SPEED .
8-6
8.2.0.12 S1CxG057: SEARCH MAX. SPEED.
8-6 8.2.0.13 S2C201: POSTURE CONTROL AT CARTESIAN OPERATION OF JOG .
8-6 8.2.0.14 S2C202: OPERATION IN USER COORDINATE SYSTEM
(WHEN EXTERNAL REFERENCE POINT CONTROL FUNCTION USED).
8-6
8.2.0.15 S2C320: CONTROLLED GROUP JOB TEACHING POSITION CHANGE .
8-7
8.2.0.16 S2C422: OPERATION AFTER RESET FROM PATH DEVIATION.
8-7
8.2.0.17 S2C423: OPERATION AFTER JOB .
8-7
8.2.0.18 S2C424: DEVIATED POSITION .
8-8 8.2.0.19 S2C425: CIRCULAR INTERPOLATION TOOL POSITION CONTROL .
8-9 8.2.0.20 S2C653: EMERGENCY STOP CURSOR ADVANCE
CONTROL
FUNCTION.
8-9 8.2.0.21 S2C654: EMERGENCY STOP CURSOR ADVANCE CONTROL
FUNCTION CONT PROCESS COMPLETION POSITION .
8-10
8.2.0.22 S2C655: EMERGENCY STOP ADVANCE CONTROL FUNCTION
WORK START INSTRUCTION STEP MOTION COMPLETION
DELAY TIME .
8-10 8.2.0.23 S2C698: BASE AXIS OPERATION KEY ALLOCATION SETTING .
8-10 8.2.0.24 S3C1098 to S3C1102: POSITION CORRECTING
FUNCTION
DURING PLAYBACK .
8-11
8.3 Mode Operation Setting Parameters .
8-12 8.3.0.1 S2C195: SECURITY MODE WHEN CONTROL POWER
SUPPLY IS TURNED ON.
8-12
8.3.0.2 S2C196: SELECTION OF CARTESIAN/CYLINDRICAL.
8-12
8.3.0.3 S2C197: COORDINATE SWITCHING PROHIBITED.
8-12
8.3.0.4 S2C198: EXECUTION UNITS AT “FORWARD” OPERATION.
8-12 8.3.0.5 S2C199: INSTRUCTION (EXCEPT FOR MOVE) EXECUTION
AT
“FORWARD” OPERATION .
8-13
8.3.0.6 S2C203: CHANGING STEP ONLY.
8-13
8.3.0.7 S2C204: MANUAL SPEED STORING FOR EACH COORDINATE .
8-13
8.3.0.8 S2C206: ADDITIONAL STEP POSITION .
8-13 8.3.0.9 S2C207: MASTER JOB CHANGING OPERATION.
8-14 8.3.0.10 S2C208: CHECK AND MACHINE-LOCK KEY
OPERATION IN
PLAY MODE .
8-14 8.3.0.11 S2C209: RESERVED WORK JOB CHANGING OPERATION.
8-14 8.3.0.12 S2C210: MASTER OR SUBMASTER CALL OPERATION
IN
PLAY MODE .
8-14
8.3.0.13 S2C211: LANGUAGE LEVEL .
8-15
8.3.0.14 S2C214: INSTRUCTION INPUT LEARNING FUNCTION .
8-15
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xvi
8.3.0.15 S2C215: ADDRESS SETTING WHEN CONTROL POWER IS TURNED
ON . 8-15
8.3.0.16 S2C216: JOB LIST DISPLAY METHOD AT JOB SELECTION .
8-15
8.3.0.17 S2C217: INITIAL OPERATION OF MANIPULATOR . 8-16
8.3.0.18 S2C218: PLAYBACK EXECUTION AT CYCLE MODE “1- STEP” .
8-16
8.3.0.19 S2C219: EXTERNAL START. 8-16
8.3.0.20 S2C220: PROGRAMMING PENDANT START. 8-16
8.3.0.21 S2C221: SPEED DATA INPUT FORM . 8-17
8.3.0.22 S2C222: RESERVED START . 8-17
8.3.0.23 S2C224: JOB SELECTION AT REMOTE FUNCTION (PLAY MODE) .
8-17
8.3.0.24 S2C225: EXTERNAL MODE SWITCH. 8-17
8.3.0.25 S2C227: EXTERNAL CYCLE SWITCHING . 8-17
8.3.0.26 S2C228: PROGRAMMING PENDANT CYCLE SWITCHING.
8-18
8.3.0.27 S2C229: SERVO ON FROM EXTERNAL PP PROHIBITION.
8-18 8.3.0.28 S2C230: PROGRAMMING PENDANT OPERATION WHEN “IO”
IS SELECTED FOR REMOTE MODE . 8-18
8.3.0.29 S2C234: STEP REGISTRATION AT TOOL NO. CHANGE .
8-19
8.3.0.30 S2C293: REMOTE FIRST CYCLE MODE. 8-19
8.3.0.31 S2C294: LOCAL FIRST CYCLE MODE. 8-19
8.3.0.32 S2C312: POWER ON FIRST CYCLE MODE . 8-19
8.3.0.33 S2C313: TEACH MODE FIRST CYCLE MODE . 8-20 8.3.0.34
S2C314: PLAY MODE FIRST CYCLE MODE .
8-21 8.3.0.35 S2C316: START CONDITION AFTER ALARM-4107 (“OUT OF
RANGE (ABSO DATA)”) . 8-21
8.3.0.36 S2C395: SIGNAL NAME ALIAS FUNCTION . 8-22
8.3.0.37 S2C396: VARIABLE NAME ALIAS FUNCTION. 8-23
8.3.0.38 S2C397: I/O VARIABLE CUSTOMIZE FUNCTION . 8-24
8.3.0.39 S2C415 to S2C419: TIME RESET. 8-25
8.3.0.40 S2C431: TOOL NO. SWITCHING. 8-25 8.3.0.41 S2C433:
POSITION TEACHING BUZZER .
8-25 8.3.0.42
S2C434: JOB LINKING DESIGNATION (When Twin Synchronous
Function Used) . 8-25
8.3.0.43 S2C437: PLAYBACK OPERATION CONTINUATION FUNCTION .
8-27
8.4 Parameters according to Interference Area.8-28
8.4.0.1 S1CxG400 to S1CxG415: PULSE SOFT LIMIT. 8-28
8.4.0.2 S2C001: CUBE SOFT LIMIT CHECK . 8-28
8.4.0.3 S2C002: S-AXIS INTERFERENCE CHECK . 8-29
8.4.0.4 S2C003 to S2C066: CUBE/AXIS INTERFERENCE CHECK.
8-30
8.4.0.5 S2C067 to S2C194: CUBE USING METHOD. 8-32
8.4.0.6 S3C000 to S3C047: CUBE SOFT LIMIT. 8-34
8.4.0.7 S3C048 to S3C063: S-AXIS INTERFERENCE AREA . 8-34
8.4.0.8 S3C064 to S3C1087: CUBIC INTERFERENCE AREA. 8-34
8.4.0.9 S3C1089 to S3C1096: ROBOT INTERFERENCE AREA . 8-34
8.4.0.10 S3C1097: A SIDE LENGTH OF WORK-HOME-POSITION CUBE .
8-34
8.5 Parameters according to Status I/O. 8-35
8.5.0.1 S2C235: USER OUTPUT RELAY WHEN CONTROL POWER IS ON .
8-35
8.5.0.2 S4C000 to S4C015: PARITY OF USER INPUT GROUPS . 8-35
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8.5.0.3 S4C016 to S4C031: PARITY OF USER OUTPUT GROUPS .
8-36
8.5.0.4 S4C032 to S4C047: DATA OF USER INPUT GROUPS .
8-37
8.5.0.5 S4C048 to S4C063: DATA OF USER OUTPUT GROUPS .
8-38 8.5.0.6 S4C064 to S4C079: USER OUTPUT GROUP TO BE
INITIALIZED
AT SWITCHING MODE .
8-39 8.5.0.7 S4C240: USER OUTPUT NO. WHEN MANIPULATOR DROP
ALLOWABLE RANGE ERROR OCCURS .
8-39
8.6 Parameters according to Coordinated or Synchronized Operation .
8-40
8.6.0.1 S2C212: +MOV or +SMOV INSTRUCTION SPEED INPUT. 8-40
8.6.0.2 S2C213: +MOV INSTRUCTION INTERPOLATION INPUT.
8-40 8.6.0.3 S2C231: OPERATION METHOD AT FWD/BWD OPERATION
OR
TEST RUN BY INDEPENDENT CONTROL .
8-40 8.6.0.4 S2C232: JOB AT CALLING MASTER OF SUBTASK 1, 2, 3, 4, 5,
6, 7 BY INDEPENDENT CONTROL .
8-41
8.6.0.5 S2C264: STATION AXIS CURRENT VALUE DISPLAY FUNCTION .
8-41 8.6.0.6 S2C265 to S2C288: STATION AXIS DISPLAYED UNIT .
8-41 8.6.0.7 S2C420: POSTURE CONTROL OF SYNCHRONIZED
MANIPULATOR
(When Twin Synchronous Function Used).
8-42 8.6.0.8 S2C421: POSTURE CONTROL OF MANIPULATOR IN MULTI-JOB
(When Twin Synchronous Function Used).
8-42 8.6.0.9 S2C687: OPERATION OF JOB WITHOUT CONTROL
GROUP
SPECIFICATION.
8-43 8.6.0.10 S2C688: EXECUTION OF “BWD” OPERATION .
8-43 8.6.0.11 S3C1101: MAXIMUM DEVIATION ANGLE OF
CURRENT
STATION POSITION (When Twin Synchronous Function Used) .
8-43
8.7 Parameters for Other Functions or Applications.
8-44 8.7.0.1 S1CxG049 to S1CxG051: SMALL CIRCLE CUTTING .
8-44 8.7.0.2 S1CxG052 to S1CxG053: SMALL CIRCLE CUTTING
DIRECTION LIMIT VALUE .
8-44
8.7.0.3 S1CxG054 to S1CxG055: SMALL CIRCLE CUTTING OVERLAP VALUE .
8-44
8.7.0.4 S1CxG063, S1CxG064: PATTERN CUTTING DIMENSION.
8-44
8.7.0.5 S1CxG065: MIRROR SHIFT SIGN INVERSION .
8-44 8.7.0.6 S2C430: RELATIVE JOB OPERATION METHOD .
8-44 8.7.0.7 S3C1111 to S3C1190: ANALOG OUTPUT FILTER
CONSTANT
(When analog output corresponding to speed function is used) .
8-45 8.7.0.8 S3C1191: CUT WIDTH CORRECTION VALUE (When
form cutting
function is used) .
8-45
8.8 Hardware Control Parameters.
8-46
8.8.0.1 S2C646: ANTICIPATOR FUNCTION.
8-46
8.8.0.2 S2C786 to S2C788: COOLING FAN ALARM DETECTION . 8-47
8.8.0.3 S4C327 to S4C390: SETTING OF OPERATING RELAY NO. .
8-47
8.8.0.4 S4C391 to S4C454: OPERATING METHOD OF RELAYS .
8-47
8.8.0.5 S2C789 to S2C792: COOLING FAN ALARM 1 OPERATION .
8-48
8.8.0.6 S2C793 to S2C796: COOLING FAN ALARM 2 OPERATION .
8-48
8.8.0.7 S2C797 to S2C800: COOLING FAN ALARM 3 OPERATION .
8-48
8.8.0.8 S2C801 to S2C804: FAN ALARM 1 POWER SOURCE STATUS.
8-48
8.8.0.9 S2C805 to S2C808: FAN ALARM 2 POWER SOURCE STATUS.
8-48
8.8.0.10 S2C809 to S2C812: FAN ALARM 3 POWER SOURCE STATUS .
8-48
8.9 TRANSMISSION PARAMETERS.
8-49
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8.10 Application Parameters. 8-49
8.10.1 Arc Welding . 8-49
8.10.1.1 AxP000: APPLICATION .
8-49 8.10.1.2 AxP003: WELDING ASSIGNMENT OF WELDING
START
CONDITION FILE. 8-49 8.10.1.3 AxP004: WELDING ASSIGNMENT
OF WELDING END
CONDITION FILES .8-49
8.10.1.4 AxP005: WELDING SPEED PRIORITY. 8-49
8.10.1.5 AxP009: WORK CONTINUING . 8-49
8.10.1.6 AxP010: WELDING INSTRUCTION OUTPUT. 8-50
8.10.1.7 AxP011, AxP012: MANUAL WIRE OPERATION SPEED. 8-50
8.10.1.8 AxP013, AxP014: WELDING CONTROL TIME . 8-50 8.10.1.9
AxP015 to AxP017: NUMBER OF WELDING CONTROL .
8-50 8.10.1.10 AxP026 to AxP029: TOOL ON/OFF USER OUTPUT
NO.
(Jigless system). 8-50
8.10.2 Handling Application . 8-50
8.10.2.1 AxP002, AxP004: f1 KEY FUNCTION. 8-50
8.10.2.2 AxP003, AxP005: f2 KEY FUNCTION. 8-50
8.10.3 Spot Welding . 8-50
8.10.3.1 AxP003: MAXIMUM NUMBER OF CONNECTED POWER SOURCES . 8-50
8.10.3.2 AxP004: GUN FULL OPEN STROKE ON/OFF SIGNAL . 8-51
8.10.3.3 AxP005: STROKE CHANGE ANSWER TIME LIMIT . 8-51
8.10.3.4 AxP006: PARITY SPECIFICATION FOR WELDING CONDITIONS . 8-51
8.10.3.5 AxP007: ANTICIPATE TIME . 8-51
8.10.3.6 AxP015: WELDING ERROR RESET OUTPUT TIME. 8-51
8.10.3.7 AxP016, AxP017: ELECTRODE WEAR AMOUNT ALARM VALUE . 8-51
8.10.4 General-purpose Application . 8-52
8.10.4.1 AxP009: WORK CONTINUE PROHIBIT . 8-52
9 Spot Welding Application Using a Motor Gun .9-1
9.1 System Overview . 9-1
9.2 Function Keys . 9-3
9.3 Before Teaching. 9-5
9.3.1 Manual Welding . 9-5
9.3.2 Manual Dry Spotting . 9-5
9.3.3 Open/Close of a Motor Gun. 9-6
9.3.4 Mounting Electrodes. 9-7
9.3.5 Registering the Operation Tool. 9-7
9.3.5.1 When Using a Single Gun . 9-7
9.3.5.2 When Using a Double Gun. 9-8
9.3.6 Teaching. 9-9
9.3.6.1 Preparing a Pressure Instruction Job . 9-9
9.3.6.2 Registering Steps . 9-10
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9.3.6.3 Registering the SVSPOT Instruction .
9-11
9.4 Setting Welding Conditions.
9-12
9.4.1 Setting of MANUAL SPOT Window.
9-12
9.4.2 Pressure Setting .
9-14
9.4.3 Welding Current and Welding Time Settings.
9-17
9.5 Playback (Motor Gun). 9-18
9.5.1 Check Run.
9-18
9.5.2 Actual Welding .
9-18
9.6 Dry Spotting (Motor Gun).
9-19
9.6.1 SVGUNCL (Dry Spotting Motion) Instruction.
9-19
9.6.2 Dry Spotting Pressure Setting .
9-19
9.7 Electrode Wear Detection and Wear Compensation .
9-23
9.7.1 Wear Detection and Wear Compensation Operation Flow Chart.
9-23
9.7.2 Wear Detection.
9-24
9.7.2.1 Dry Spotting Touch Motion.
9-24
9.7.2.2 Sensor Detection.
9-24
9.7.2.3 Example of Wear Detection .
9-25
9.7.3 SPOT WELD DIAGNOSIS .
9-26
9.7.4 Wear Compensation.
9-29
9.7.5 Teaching Positions with a Worn Electrode.
9-30
9.7.5.1 Teaching Example .
9-30
9.7.5.2 Parameters.
9-30
9.7.6 Wear Amount Loading.
9-31
9.8 Other Functions Using a Motor Gun .
9-32
9.8.1 Motor Gun Stroke . 9-32
9.8.1.1 Registering the Full-open/Short-open Position.
9-32
9.8.1.2 Registering the current position.
9-33
9.8.1.3 Registering by entering a numerical value .
9-33 9.8.1.4 Moving to Full-open/Short-open Position .
9-34 9.8.1.5 Moving to Full-open/Short-open Position While Other
Window is
Displayed. 9-34
9.8.2 Gun Change .
9-35
9.8.2.1 Gun Change Instruction .
9-35
9.8.2.2 Signal Status to Execute a GUNCHG Instruction.
9-35
9.8.2.3 Gun Change Job .
9-37
9.8.2.4 Gun Changing Timing .
9-39
9.8.3 Electrode Touch Position Teaching Function .
9-40
9.8.3.1 Setting the Workpiece Thickness .
9-40
9.8.3.2 Registering and Confirming Positions by Touch Motion Teaching.
9-43
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xx
9.8.4 Forced Gun-pressurizing Function . 9-44
9.8.4.1 Setting an Input Signal Number. 9-44
9.8.5 Electrode Wear Compensation for Fixed Gun . 9-46
9.8.5.1 Setting the User Coordinates . 9-46
9.8.5.2 Parameters. 9-47
9.8.5.3 Example of Wear Compensation. 9-48
9.8.6 Clearance Teaching Function. 9-49
9.8.6.1 Operation Flow Chart . 9-49
9.8.6.2 Setting the Teaching Type . 9-50
9.8.6.3 Setting the Clearance Files . 9-52
9.8.6.4 Operations for Teaching Welding Points. 9-54
9.8.6.5 Move Instruction for Clearance. 9-55
9.8.6.6 Moving for Clearance . 9-56
9.8.7 Teaching with Gun Pressure . 9-58
9.8.7.1 Operation Flow Chart . 9-58
9.8.7.2 Procedure for Registering the Position. 9-59
9.8.7.3 Setting the Pressure Conditions . 9-59
9.8.8 Gun Pressure Compensation Function. 9-60
9.8.8.1 Operation Flow Chart . 9-60
9.8.8.2 Overview . 9-61
9.8.8.3 Setting the Pressure Compensation Value. 9-64
9.8.9 Workpiece Transfer Function Using a Motor Gun . 9-66
9.8.9.1 Operation Flow Chart . 9-66
9.8.9.2 Setting the Conditions for Grasping/Releasing Workpieces. 9-67
9.8.9.3 Instruction for Grasping/Releasing Workpieces . 9-69
9.8.9.4 Manual Operation for Grasping/Releasing Workpieces . 9-72
9.8.10 Individual Reset Function for Wear Amount . 9-73
9.8.10.1 Operation Flow Chart . 9-73
9.8.10.2 Procedure for Signal Assignment. 9-73
9.8.11 Welding Conditions Group Output Function . 9-75
9.8.11.1 Operation Flow Chart . 9-75
9.8.11.2 Procedure for Assigning the Group Output Relay . 9-75
9.8.11.3 Setting the Group Output Tag . 9-77
9.8.11.4 Group Output. 9-79
9.8.12 Compensation of Gun Arm Bend for C-Gun and X-Gun (SINGLE ARM
MOTION) . 9-80
9.8.12.1 Setting the Gun Bend Compensation Coefficient. 9-80
9.8.12.2 Compensation Example . 9-81
9.8.13 Gun Stroke Setting for Welding Start. 9-82
9.8.13.1 Setting the Gun Stroke Position . 9-82
9.8.13.2 Setting the Gun Stroke Motion Speed . 9-83
9.8.13.3 Motion Example. 9-84
9.8.14 Setting the Gun Pushing Coefficient. 9-84
9.8.14.1 Setting of gun pushing coefficient . 9-85
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