YASKAWA MOTOMAN DX100 User manual

MANUAL NO.
2
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YASKAWA ELECTRIC CORPORATION
DX100 OPTIONS
INSTRUCTIONS
FOR SERVOFLOAT FUNCTION
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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Part Number: 156437-1CD
Revision: 2

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MANDATORY
• This manual explains the servofloat function 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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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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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
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 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.
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Definition of Terms Used Often in This Manual
The MOTOMAN manipulator is the YASKAWA industrial robot product.
The MOTOMAN usually consists of 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 DX100
cabinet 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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Descriptions of the programming pendant keys, buttons, and dis-
plays 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.
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}
GO BACK
PAGE
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DX100 Contents
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1 Servofloat Function .........................................................................................................................1-1
1.1 Link Servofloat Function ....................................................................................................1-1
1.2 Linear Servofloat Function.................................................................................................1-2
1.3 Using the Link Servofloat Function and the Linear Servofloat Function ............................1-2
2 The Servofloat Function..................................................................................................................2-1
2.1 Moving with the Move Instruction.......................................................................................2-2
2.2 Moving with the TIMER and WAIT Instructions .................................................................2-3
2.3 Operation Check................................................................................................................2-3
2.4 When an Alarm Occurs......................................................................................................2-3
2.5 Display during Servofloat Operation ..................................................................................2-3
2.6 Turning Servo ON Again During Servofloat Operation ......................................................2-4
3 Servofloat Condition Files ...............................................................................................................3-1
3.1 Link Servofloat Condition File ............................................................................................3-1
3.1.1 Procedures ...........................................................................................................3-1
3.1.2 Link Servofloat Condition Setting..........................................................................3-2
3.2 Linear Servofloat Condition File.........................................................................................3-3
3.2.1 Procedures ...........................................................................................................3-3
3.2.2 Linear Servofloat Condition Setting ......................................................................3-4
4 Instructions for the Servofloat Function...........................................................................................4-1
4.1 FLOATON Instruction ........................................................................................................4-1
4.2 FLOATOF Instruction.........................................................................................................4-1
4.3 SPDL Tag ..........................................................................................................................4-1
5 Registration of Instruction ...............................................................................................................5-1
5.1 FLOATON Instruction ........................................................................................................5-1
5.2 FLOATOF Instruction.........................................................................................................5-3
5.3 Addition of SPDL Tag to a Move Instruction......................................................................5-4
6 Application Example of the Servofloat Function..............................................................................6-1
6.1 Movement Example ...........................................................................................................6-1
6.2 Job Example ......................................................................................................................6-4
6.3 A Setting Example in the Linear Servofloat Condition File ................................................6-5
6.4 A Setting Example for the Link Servofloat Condition File ..................................................6-6
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1 Servofloat Function
DX100 1.1 Link Servofloat Function
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1 Servofloat Function
The servofloat function of the DX100 consists of the link servofloat
function and the linear servofloat function. The link servofloat function
controls the torque independently for each axis; and the linear servofloat
function controls the torque on the Cartesian coordinates. Select these
two functions by setting the servofloat instructions accordingly.
1.1 Link Servofloat Function
The link servofloat function works in combination with the position control
and the torque control, whereas an ordinary control is a position control
that generates torque to keep the taught position regardless of the applied
external force. “Torque control” keeps the taught position only by using
the torque against the gravitational and frictional forces. Therefore, a
manipulator moved by an external force will not return to its original
position.
With the servofloat function, external force moves the manipulator since
the torque control has priority over the position control.
For example, when removing a workpiece from the die-casting machine, a
large external force is applied to the manipulator by the extruding cylinder
when a workpiece is grasped and pulled out. The servofloat function is
used to protect the manipulator from excessive external force, and the
manipulator moves according to the force applied from the die-casting
machine.
Note that the manipulator does not move exactly to the taught position or
along the taught path, because complete position control is not performed
during execution of the servofloat function.
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1 Servofloat Function
DX100 1.2 Linear Servofloat Function
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1.2 Linear Servofloat Function
When a manipulator pushes a workpiece or visa-versa, a movement to
one predetermined direction may be desirable. With the link servofloat
function, a servofloat motion in one direction is not possible since torque
control is performed independently for each axis.
This function can specify the control of force in one direction within a
space.*1
When unloading a die-casting machine, this function is useful for
considerably long ejection distances or when polishing or grinding.
*1 When external force is applied, the R, B, and T-axes move the
same as in the link servo-float function.
Only the end of the U-axis moves in a linear motion.
1.3 Using the Link Servofloat Function and the Linear
Servofloat Function
Use the link servofloat function when high-ferquency noise, motor
vibration, or unsteady manipulator motion occur depending on the
manipulator posture, speed, and movement direction.
NOTE
Tool load information setting
• The servofloat function compensates for gravity in real-
time in order to prevent the arms from dropping due to
gravity even when the generated torque is limited. For
this purpose, the tool load information used for gravity
compensation must be set correctly. Otherwise, the servo-
float function cannot be performed properly and the arms
may drop down or rise up.
• For the tool load information, refer to Section “9.11.3 Tool
Load Information Setting” in the DX100 INSTRUCTIONS
(manual number: RE-CTO-A215) to correctly set the tool
load information.
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2 The Servofloat Function
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2 The Servofloat Function
Enable the servofloat function with the servofloat function start instruction
FLOATON. It remains enabled until one of the following conditions is
established.
• Performing the a servofloat function end instruction FLOATOF
• Performing the FWD/BWD key operation, jogging, or a job startup
after the cursor is moved
• Performing the FWD/BWD key operation, jogging, or a job startup
after a job call, job selection, or job editing
• Turning the servo ON again after an emergency stop
When the function is enabled, the manipulator generates only the torque
that is less that the value set to the servofloat condition file. The
manipulator uses the torque to operate and keep the position. If a large
external force is applied, the manipulator moves according to this force.
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2 The Servofloat Function
DX100 2.1 Moving with the Move Instruction
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2.1 Moving with the Move Instruction
If an external force prevents manipulator operation, the manipulator does
not reach the taught position when the servofloat function is enabled.
Even though the manipulator does not actually reach the taught position,
the instruction that would be activated at that position are nonetheless
enabled, so the move instruction terminated.
Therefore, when the manipulator cannot reach the taught position
because of an external force, the manipulator performs the next
instruction.
The following figure shows an example where the operation time is 5
seconds from STEP 1 to STEP 2. If the manipulator hits an obstruction 3
seconds after STEP 1 and stops there, it remains stopped at the position
for the remaining 2 seconds, and then moves to STEP 3 without moving
to STEP 2 when moving with the torque control.
STEP 1 MOVL V=100.0
FLOATON FL#(1)
STEP 2 MOVL V=100.0
STEP 3 MOVL V=100.0
FLOATOF
STEP 1 STEP 2
STEP 3
Obstruction
3 seconds
5 seconds
obstruction and stops for is completed.
2 seconds until the MOVE instruction
to STEP 2. The manipulator hits an
After completion of discharging, it
moves to STEP 3 in torque controlled status.
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2 The Servofloat Function
DX100 2.2 Moving with the TIMER and WAIT Instructions
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2.2 Moving with the TIMER and WAIT Instructions
When the servofloat function is enabled, torque control can be performed
even during the TIMER and WAIT instructions. These instructions end
when time is up or when a condition described in page 2-1 is established.
For example, in the following figure, the manipulator reaches STEP 1, and
the FLOATON instruction enables the servofloat function. Then the
manipulator waits for the input of IN#1 by the WAIT instruction. In this
state, if an external force is applied to the manipulator, the manipulator
moves to the point P and stops. If the FLOATOF instruction is performed
at this point, the servofloat function is disabled and the manipulator moves
from point P to STEP 2.
2.3 Operation Check
When the servofloat function is enabled, the soft limit, cube interference,
and the S-axis interference are checked at the actual position of the
manipulator even though external force moved the manipulator.
2.4 When an Alarm Occurs
If an alarm occurs when the servofloat function is enabled, the servofloat
function may remain effective depending on the type of alarm.
To disable the servofloat during an alarm, enter “external emergency stop”
or “servo OFF signal” during the “alarm occurrence” signal output. This
turns OFF the servo power supply and applies the brakes.
2.5 Display during Servofloat Operation
When the servofloat function is enabled, the message “Servo float
activated” appears at the bottom of the programming pendant display, and
the specific output #50510 to #50517 “SERVOFLOAT ON R1 to R8” is
output.
STEP 1 MOVL V=100.0
FLOATON FL#(1)
WAIT IN#(1)=ON
FLOATOF
STEP 2 MOVL V=100.0
STEP 2
Point P
STEP 1
Movement by
external force
Actual path
Taught path
Application of
external force
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2 The Servofloat Function
DX100 2.6 Turning Servo ON Again During Servofloat Operation
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2.6 Turning Servo ON Again During Servofloat
Operation
When the servo power has been turned OFF due to an emergency stop
during servofloat operation and turns ON again, press the [SERVO ON
READY] on the playback panel until this servo recognizes that the power
supply is turned ON. If the button is not pressed for a long enough time,
the message “depress servo power ON” appears and the servo power
cannot be turned ON.
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3 Servofloat Condition Files
DX100 3.1 Link Servofloat Condition File
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3 Servofloat Condition Files
There are two kinds of servofloat condition files: the link servofloat
condition file specified for the link servofloat function, and the linear
servofloat condition file specified for the linear servofloat function.
3.1 Link Servofloat Condition File
3.1.1 Procedures
1. Select {ROBOT} from the main menu.
2. Select {LINK SERVOFLOAT}
– The link servofloat window appears.
3. Select an item to be set, and set the value.
(1) The display enters the number input status.
(2) Enter a value for “MAX. TORQUE” by pressing the numeric keys.
4. Press [ENTER].
CAUTION
• If the values for the maximum force and maximum torque are set
too low, gravity may cause an arm to drop.
The arm drop may cause an accident or damage to the devices.
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3 Servofloat Condition Files
DX100 3.1 Link Servofloat Condition File
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3.1.2 Link Servofloat Condition Setting
A. FUNC
Enables/Disables the linear servofloat function for each axis.
“z” indicates that the function is enabled; “{” indicates that the function is
disabled.
Pressing [SELECT] switches between “z” and “{”.
B. (+) MAX. TORQUE / (-) MAX. TORQUE
Limits the amount of torque generated for keeping control of the position
of each axis.
Set the value for each axis using the ratios (%) of the positive and
negative sides of the motor to the motor rated torque.
The smaller the value is set, the more easily an axis can be moved by an
external force.
AB
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3 Servofloat Condition Files
DX100 3.2 Linear Servofloat Condition File
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3.2 Linear Servofloat Condition File
3.2.1 Procedures
1. Select {ROBOT} from the main menu.
2. Select {LNR. SERVOFLOAT}
– The linear servofloat window appears.
3. Select an item to be set, and set the value.
(1) The display enters the number input status.
(2) Enter a value for “MAX. TORQUE” by pressing the numeric keys.
Then, press [ENTER].
4. Press [ENTER]
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3 Servofloat Condition Files
DX100 3.2 Linear Servofloat Condition File
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3.2.2 Linear Servofloat Condition Setting
A. COORDINATE
Sets a coordinate system for the linear servofloat function.
Select the ROBOT coordinates, BASE coordinates, USER coordinates or
TOOL coordinates.
The selection dialog box appears by pressing [SELECT]. Select a
coordinate system to be set.
B. FUNC
Enables/Disables the linear servofloat function for each axis.
“z” indicates that the function is enabled; “{” indicates that the function is
disabled.
Pressing [SELECT] switches between “z” and “{”.
C. (+) MAX. FORCE / (-) MAX. FORCE
Limits the amount of force generated for keeping control of the position of
each axis.
When the linear servofloat is enabled, a force bigger than this set value is
not generated.
The smaller the value is set, the more easily a set coordinate axis can be
moved by an external force.
However, if the set value is less than the manipulator friction, the
manipulator may not move.
A
B
C
D
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3 Servofloat Condition Files
DX100 3.2 Linear Servofloat Condition File
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D. (+) MAX. TORQUE / (-) MAX. TORQUE
Limits the amount of torque generated for keeping control of the position
of R-, B-, and T-axes.
Set the value for each axis using the ratios (%) of the positive and
negative sides of the motor to the motor rated torque.
The smaller the value is set, the more easily an axis can be moved by an
external force.
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4 Instructions for the Servofloat Function
DX100 4.1 FLOATON Instruction
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4 Instructions for the Servofloat Function
4.1 FLOATON Instruction
FLOATON is an instruction to enable and start the link servofloat function
or the linear servofloat function.
Additional items for the FLOATON instruction are as follows:
A. FL# ( ) (Setting range: 1 to 8)
Sets the link servofloat condition file number.
B. LFL# ( ) (Setting range: 1 to 8)
Sets the linear servofloat condition file number.
4.2 FLOATOF Instruction
FLOATOF is an instruction to disable and end the link servofloat function
or the linear servofloat function. The servofloat function can be also
disabled by performing servo OFF.
4.3 SPDL Tag
The SPDL tag is a stop confirmation tag with which a motion is completed
when the number of speed feedback pulses of all the axes becomes less
than a constant value.
Use an SPDL tag to confirm the end of a motion caused by an external
force. Add it to the move instruction immediately before the FLOATOF
instruction.
If the move instruction is completed with a SPDL tag added, the next
instruction will not be performed as long as the manipulator is being
moved by an external force.
Only “0” can be set for the SPDL tag.
An example of an SPDL tag added to a move instruction is shown as
follows:
MOVJ VJ=50.00 SPDL=0
FLOATON
FL#(1 to 8)
LFL#(1 to 8)
A
B
FLOATOF
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5 Registration of Instruction
DX100 5.1 FLOATON Instruction
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5 Registration of Instruction
When in the job content display in teach mode, register an instruction with
the cursor in the address area.
1. Select {JOB} from the main menu.
2. Select {JOB CONTENT}
– The job content window appears.
3. Move the cursor to the address area.
5.1 FLOATON Instruction
1. Move the cursor to the line where “FLOATON” is to be registered.
2. Press [INFORM LIST]
– The instruction dialog box appears.
3. Select “FLOATON”
– The “FLOATON” instruction appears in the input buffer line.
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