YASKAWA MOTOMAN DX100 User manual

MANUAL NO.
0
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Part Number: 164276-1CD
Revision: 0
DX100 OPTIONS
INSTRUCTIONS
FOR LASER-TRACKING FUNCTION: MOTOEYE-LT
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
MOTOMAN INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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MANDATORY
•This instruction manual is intended to explain mainly on the
laser-tracking function part of the DX100 MOTOEYE-LT for the
application to the actual operation and for proper maintenance and
inspection. It describes on safety and handling, details on
specifications, necessary items on maintenance and inspection, to
explain operating instructions and maintenance procedures. Be
sure to read and understand this instruction manual thoroughly
before installing and operating the manipulator.
•General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation,
carefully read the DX100 Instructions 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 the 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 the product’s warranty.
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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.”
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.
Even items described as “CAUTION” may result in a serious accident in some situations.
At any rate, be sure to follow these important items.
To ensure safe and efficient operation at all times, be sure to follow all instructions,
even if not designated as “CAUTION” and “WARNING.”
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WARNING
•Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming 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 Emergency Stop
回す
•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.
- Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward the operator.
- Ensure to secure 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 the operator 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 res ult if anyone enters the P-point maximum envelope of the manipulator
during operation. Always press an emergency stop button immediately if there is a
problem.
The emergency stop buttons are located on the right of front door of the DX100 and
the programming pendant.
TURN
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WARNING
•Do not directly look at the laser beam emitted from the laser sensor.
•When the laser beam is emitted from the laser sensor onto a
mirror-like surface with a high reflection ratio, such as a stainless
surface or other shiny surfaces, be careful that the reflected laser
beam does not make direct contact with the eyes.
•
DX100 MOTOEYE-LT function uses the laser sensor manufactured by Servo-Robot, Inc.
whose power is classified into Class 3B. The laser beam emitted from the laser has a high
power density, and could harm the human body even in small amounts. In Japan, in order
to prevent injuries to operators of the laser products, guidelines based on the standard of
International Electrotechnical Commission (IEC), “Safety of laser products” JIS C 6802 is
specified. In JIS C 6802, the laser products are classified according to its risk evaluation
and the safety actions required are specified for each class.
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The outline of the classification is as follows.
Class Outline of risk evaluation
Class 1 Essentially safe in design
Class 1M Low output (wavelength: 302.5 to 4000 nm)
Safe under certain conditions, including visual contact with the inside of the
beam.
Observation of the inside of the beam with optical manners may pose a risk.
Class 2 Visible laser and low output (wavelength: 400 to 700 nm)
Eyes are protected by blink reflex, including direct visual contact with the
inside of the beam.
Class 2M Visible laser and low output (wavelength: 400 to 700 nm)
Eyes are protected by blink reflex. Visual contact with inside of the beam
with optical manners may pose a risk.
Class 3R In the visible laser, output is five times or less than that of Class 2
(wavelength: 400 to 700 nm). In the laser except for the visual laser, output
is five times or less than that of Class 1 (wavelength: 302.5 nm or longer).
The direct visual contact with the inside of the beam may pose a risk.
Class 3B 0.5 W or smaller output. Direct visual contact with the inside of the beam
poses a risk. However, observation of pulse laser which does not connect
focused points with scattered reflection is safe and it can be safely observed
under certain conditions.
Class 4 High output. Danger, scattered reflections may result. These can cause
skin injuries and may cause fires.
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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 the Warning Labels in the
DX100 Instructions before operating the manipulator.
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 manipulator cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
DX100 Controller DX100
DX100 Programming Pendant Programming Pendant (PP)
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Descriptions of the programming pendant keys, buttons, and displays are shown as follows:
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}
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.
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TABLE OF CONTENTS
1 Laser-tracking Function .............................................................................................1-1
1.1 Functions............................................................................................................1-3
2 Hardware Setup.........................................................................................................2-1
2.2 Connection of Laser Vision System.....................................................................2-1
2.3 Settings for Cooling Air........................................................................................2-2
2.4 Emergency Stop Button on Power-BOX..............................................................2-2
3 Start-up......................................................................................................................3-1
3.1 Start-up of the Power-BOX..................................................................................3-1
3.2 Start-up of the DX100 .........................................................................................3-1
3.3 Start-up of the WELDCOM..................................................................................3-2
4 Settings for Sensor Parameters and Job Files...........................................................4-1
4.1 Sensor Parameters.............................................................................................4-1
4.2 Required Application Job Files............................................................................4-3
5 Laser Sensor Calibration ...........................................................................................5-1
5.1 Workpiece for Calibration....................................................................................5-1
5.2 Tool Calibration for Reference Tool.....................................................................5-2
5.3 Sensor Camera’s Mounting Position ...................................................................5-3
5.4 Sensor Adjustment..............................................................................................5-5
5.5 Teaching of Calibration Job [LT-CALIB]..............................................................5-6
5.6 Execution of Calibration ....................................................................................5-17
6 Settings for Tracking Job...........................................................................................6-1
6.1 Tracking without a Welding-start-point Search....................................................6-1
6.2 Tracking with a Welding-start-point Search.........................................................6-6
7 Settings for the Laser-tracking Function File..............................................................7-1
7.1 Conditions for the Laser Sensor..........................................................................7-2
7.2 Conditions for Welding-start-point Search...........................................................7-3
7.3 Conditions for Welding-end-point Search............................................................7-5
7.4 Conditions for Laser Tracking..............................................................................7-6
7.5 Conditions for NON-detection and Error Detection..............................................7-7
7.6 Conditions to Pass Over......................................................................................7-8
8 Settings for Inspection Job Before Starting Operations..............................................8-1
8.1 Teaching an Inspection Job Before Starting........................................................8-2
8.2 Acquisition of Reference Data.............................................................................8-4
9 Tool Offset Setting.....................................................................................................9-1
9.1 How to Obtain the Tool Offset Amount................................................................9-1
9.2 How to Set the Tool Offset Amount.....................................................................9-3
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10 Settings for the Gap Adaptation Function................................................................10-1
10.1 Settings for the Gap Condition File.................................................................10-2
10.2 Conditions for Welding....................................................................................10-3
10.3 Conditions for Position....................................................................................10-4
10.4 Conditions for Speed......................................................................................10-5
11 Inspection Before Starting Operations.....................................................................11-1
11.1 Automatic Inspection Before Starting Operations............................................11-1
11.2 Manual Inspection Before Starting Operations................................................11-2
11.3 Camera Deviation Check at Welding-point Deviation Check...........................11-3
11.4 Verification of Tool Constants.........................................................................11-4
11.5 Verification of Detected Data..........................................................................11-5
12 Troubleshooting.......................................................................................................12-2
12.1 Corrective Actions after Torch Collision..........................................................12-2
12.2 Corrective Actions for Target Deviation...........................................................12-3
12.3 Corrective Actions for Tool Deviation..............................................................12-4
12.4 Corrective Actions for Camera Deviation........................................................12-5
13 Alarm List ................................................................................................................13-2
13.1 Alarm List .......................................................................................................13-2
14 Sensor Parameters..................................................................................................14-2
14.1 S5E Parameters.............................................................................................14-2
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164276-1CD Laser-tracking Function
1 Laser-tracking Function
The laser-tracking function uses a laser sensor manufactured by ServoRobot, Inc. and is the
DX100 option. This function can be used to correct the target position during welding
according to the information of the target position on the welding line detected by the laser
sensor.
Laser tracking includes the following control functions:
• Start point search
• Real-time tracking
• Target position offset
Fig. 1-1 Laser Sensor Camera Appearance
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Laser-tracking Function 164276-1CD
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Table 1-1 Parts List
No. Name Remarks
 Power-CAM (laser sensor camera) Purchased from ServoRobot Inc.
 Power-BOX (image processing system) Included in 
 Camera cable (5 m) Included in 
 Cooling air unit (with a 5 m control signal cable) Purchased from ServoRobot Inc. (option)
 Fume purge air Purchased from ServoRobot Inc. (option)
 Cooling air (in-flow and out-flow air) Included in 
 Air filter unit (oil, dry, regulator) Purchased from ServoRobot Inc. (option)
 LAN cable between personal computer for monitor
and the Power-BOX (5 m) Included in 
 LAN cable between the DX100 and the Power-BOX
(5 m) Included in 
 Sensor monitor application WELDCOM Included in (the customer prepares a
personal computer)
 Insulation support Purchased from ServoRobot Inc.
 Sensor clamp Needed to be designed and manufactured
System software dedicated for DX100 MOTOEYE-LT Arranged by Yaskawa (DX100 is set up)
Macro job for DX100 MOTOEYE-LT Arranged by Yaskawa (DX100 is set up)
Fig. 1-2 System Structure
Welding
torch
②
DX100
③
⑨
⑥
①
User LAN port
CN104
Manipulator
⑩
⑤
⑧
Factory air
⑪
④
⑦
Cooling air unit control signal
⑫
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164276-1CD Laser-tracking Function
Functions
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1.1 Functions
■
Start Point Search
• The laser sensor detects the start point of the welding line by an LTSRCH command.
• The difference between the detected point and the start point that is registered is
calculated.
If the difference is within the allowable value, the taught welding line is shifted by an LTSFT
command to compensate for this difference.
Registered start point of the welding
Shift amount
Detected point
Fig. 1-3 Welding Line Shift by the Start Point Search Function
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Laser-tracking Function 164276-1CD
Functions
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Fig. 1-5 Shifted Tracking Path by the Target Position Offset
■
Real-time Tracking
Using the target position data from the laser sensor, the welding line data is prepared in the
base coordinate system. Based on the welding line data and the taught direction of
movement, the path of the center point of the manipulator’s tool is corrected. This function
is carried out by an LTRCKON command and an LTRCKOF command.
■
狙いのオフセット機能
■
Target Position Offset
The target position offset function shifts the target position in the tool coordinate system
when the target position has deviated from the desired welding position.
Step1
Step2
Step3
Taught manipulator's path
Taught direction of movement
Current tool center point
Tool center point
after correction Amount of
correction
Fig. 1-4 Correction by the Real Time Tracking Function
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164276-1CD Hardware Setup
Connection of Laser Vision System
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2 Hardware Setup
2.2 Connection of Laser Vision System
Connect the laser vision system as shown in the following diagram.
Before installing the laser vision system of ServoRobot Inc., thoroughly read the
following manuals provided by ServoRobot Inc. and fully observe the precautions:
• Power-BOX Installation and Operation Manual {ZPBXV21106E02}
• Power-CAM Installation and Operation Manual {ZPWRCAM1003E00}
Sensor controller
Power-BOX
Laser sensor camera：
Power-CAM
Controller: DX100
Personal computer
for sensor monitor
(Monitor software:
WinUser)
Main board：YCP01
Ethernet cable
Camera cable
Cooling OUT
Dry air
supply
system
User LAN port
CN104
CN9
CN8
Ethernet cable
Front
window
Protection
Air IN
Cooling IN
CN7
CN6
Cooling unit control cable
Cooling unit
24VDC/1A
Constant voltage power supply
Power supply cable
Fig. 2-1 Laser Vision System Connection Diagram
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Hardware Setup 164276-1CD
Settings for Cooling Air
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2.3 Settings for Cooling Air
For cooling air, use clean and oil-free air or carbonic acid gas for the shielding gas. An air
flow of 10 liter/min. (pressure: 4 bars) is required for sufficient cooling and for protection of
the laser head and the work surfaces.
• Oil and dust in the cooling air may cause the sensor to malfunction.
• When using carbonic acid gas for the cooling air, be sure to use a heater to avoid
condensation.
2.4 Emergency Stop Button on Power-BOX
Connect the Power-BOX emergency stop button to robot controller emergency stop loop
and safety interlock circuit for work place with automatic device.
<The wiring of the emergency stop on the DX100>
Refer to "13.9 Robot system input terminal block (MXT)" in the "DX100
INSTRUCTIONS" {162536-1CD}.
<The wiring of the emergency stop on the Power-BOX>
Refer to "4.4.2 Emergency Stop Alarm I/O (CN2)" in the manual "Power-BOX
Installation and Operation Manual {ZPBXV21106E02}" provided with the laser vision
system of ServoRobot Inc.
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164276-1CD Start-up
Start-up of the Power-BOX
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Fig. 3-1 Power-BOX Front
3 Start-up
3.1 Start-up of the Power-BOX
The following procedure describes how to start up the Power-BOX.
1: Turn ON the power switch in the following diagram.
=> The power lamp illuminates and the system status lamp starts flashing.
=> After approximately one minute, the system status lamp changes from
flashing to illumination.
2: Turn ON the laser enable key switch .
=> The laser ON lamp illuminates.
=> After two or three seconds, a laser beam is emitted from the laser sensor
camera Power-CAM.
3.2 Start-up of the DX100
To start up DX100, turn ON the main power supply of the DX100.
=> When the DX100 properly starts up, the laser beam automatically goes out.
(The laser ON lamp  does not go out.)

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Start-up 164276-1CD
Start-up of the WELDCOM
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3.3 Start-up of the WELDCOM
WELDCOM is application software for the personal computer. WELDCOM is used for
Ethernet communication with the Power-BOX, the settings for image processing, and the
monitoring of the detected status.
Though WELDCOM does not start up, the manipulator tracking operates properly.
The following procedure describes how to start up WinUser:
Start up the personal computer where WinUser is installed.
Click the “Start” button, point to “Programs,” and then click “WinUser” to start up WinUser.
Fig. 3-2 Laser Vision System Connection Diagram
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164276-1CD Settings for Sensor Parameters and Job Files
Sensor Parameters
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4 Settings for Sensor Parameters and
Job Files
4.1 Sensor Parameters
• Minimum interval for sampling
The minimum interval for sampling must be set using the sensor parameters.
The minimum interval is the minimum value of the distance between the points detected by
the sensor. Because the buffer has limited memory, set the minimum interval to limit the
distance between samples so that the buffer will not overflow with an excessive amount of
information.
1. The distance between the point of light emitted by the laser and the
manipulator’s tool center point is called a “lookahead”.
The minimum interval for sampling can be calculated from this “lookahead” by the
following formula.
Fig. 4-1 Sensor Camera Mounting and Lookahead
Laser beam
Lookahead
Manipulator's tool center point
(the wire end)
Torch
Laser
sensor
camera
When "Lookahead" is L [mm] and the minimum interval for sampling is I [μm]:
I = (12 x L) [μm] (Example: When L is 40 [mm], I = 12 x 40 = 480 [μm])
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Settings for Sensor Parameters and Job Files 164276-1CD
Sensor Parameters
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2. Determine the value to be entered as a sensor parameter from the obtained
minimum interval for sampling, and enter the value.
Table 4-1 Sensor Parameter S5E32 “the Minimum Interval for Sampling”
Calculated Minimum Interval
[μm] 0 to 1000 1001 to 2000 2001 to 4000 4001 or more
S5E32 1000 2000 3000 5000
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