YASKAWA Motoman DX200 User manual

MANUAL NO.
0
HW1481987
Part Number: 165468-1CD
Revision: 0
DX200 OPTIONS
INSTRUCTIONS
FORM CUTTING FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL
DX200 MAINTENANCE MANUAL
The DX200 Operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
1/49

ii
165468-1CD
HW1481987
Form Cutting
MANDATORY
• This manual explains the form cutting function of the DX200. Read
this manual carefully and be sure to understand its contents before
handling the DX200.
• General items related to safety are listed in Chapter 1: Safety of the
DX200 Instructions. To ensure correct and safe operation, carefully
read the DX200 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 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.
2/49

iii
165468-1CD
HW1481987
Form Cutting
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200.
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
"CAUTION" and "WARNING".
3/49

iv
165468-1CD
HW1481987
Form Cutting
WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX200 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.
Figure 1: 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.
Figure 2: 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.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– 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 DX200.
– 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 DX200 and the programming pendant.
4/49

v
165468-1CD
HW1481987
Form Cutting
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 DX200 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
DX200 Instructions before operating the manipulator.
Equipment Manual Designation
DX200 controller DX200
DX200 programming pendant Programming pendant
Cable between the manipulator and the
controller Manipulator cable
5/49

vi
165468-1CD
HW1481987
Form Cutting
Descriptions of the programming pendant, 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 bland 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 asmall
picture.
ex. page key
The cursor key is an exception, and a picture is
not shown.
Axis Keys
Number Keys “Axis Keys” and “Number 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
6/49

vii
165468-1CD
HW1481987
Form Cutting
Table of Contents
1 Form Cutting Motion .......................................................................................................................1-1
2 Patterns for Cutting.........................................................................................................................2-1
3 Teaching.........................................................................................................................................3-1
3.1 How to Teach a Pattern.....................................................................................................3-1
3.2 Tool Position and Cutting Pattern......................................................................................3-5
3.3 Cutting Width Correction Function.....................................................................................3-6
3.4 Example of Form Cutting Function....................................................................................3-7
3.4.2 Example of a Motion Path ....................................................................................3-8
3.4.2.1 Motion Example 1 ...................................................................................3-9
3.4.2.2 Motion Example 2 .................................................................................3-10
4 Form Cutting Start Motion Instruction.............................................................................................4-1
4.1 FORMAPR Instruction (Form Cutting Start Motion Instruction).........................................4-1
4.2 Registering Instructions.....................................................................................................4-3
4.2.1 Registering by Teaching.......................................................................................4-3
4.2.2 Registering in Variables........................................................................................4-7
5 Form Cutting Instruction..................................................................................................................5-1
5.1 FORMCUT (Form Cutting Motion Instruction)...................................................................5-1
5.2 Registering Instructions.....................................................................................................5-3
6 Form Cut Setting File......................................................................................................................6-1
6.1 Settings..............................................................................................................................6-2
6.2 Details of File Settings.......................................................................................................6-5
6.2.1 Specifying the ROUNDNESS ERR ......................................................................6-5
6.2.2 Specifying the CUT IN LENGTH and the CUT IN ANGLE...................................6-5
6.2.3 Specifying the ROTATION DIRECTION...............................................................6-6
6.2.4 Specifying the ROTATION ANGLE......................................................................6-6
6.3 Examples of File Setting for Each Pattern.........................................................................6-7
6.3.1 Circle ....................................................................................................................6-7
6.3.2 Rectangle Including Squares................................................................................6-8
6.3.3 Ellipse...................................................................................................................6-9
6.3.4 Pentagon............................................................................................................6-10
6.3.5 Hexagon.............................................................................................................6-11
6.4 Displaying and Editing File ..............................................................................................6-12
7 Alarm Message List ........................................................................................................................7-1
7/49

1 Form Cutting Motion
1-1
165468-1CD
HW1481987
Form Cutting
1 Form Cutting Motion
The form cutting motion cuts workpieces according to a pattern with a tool
such as a laser cutting machine handled by a manipulator.
NOTE
In the form cutting function, there may be some differences
between the set design and the actual cutting motion path,
depending on the calibration, ambient temperature, and
load applied to the manipulator.
Please understand this point, and then use this function.
In order to minimize the above explained differences, be
sure to calibrate your tools before using this function.
8/49

2-1
165468-1CD
HW1481987
Form Cutting
2 Patterns for Cutting
2 Patterns for Cutting
Five patterns, circle, rectangle (including square), ellipse, pentagon, and
hexagon are available.
The minimum and maximum set values of a pattern can be set at the
following parameters.
The minimum and maximum values of data required for a pattern are set
as follows.
Parameter Contents Initial Value
S1C G63 Minimum set value 1,000 m
S1C G64 Maximum set value 1,000,000 m
Pattern Item Minimum Value Maximum Value
Circle Radius S1CG63 / 2 S1CG64 / 2
Rectangle Width 1 (S1CG64 )
2
- (Height)
2
Height S1CG63 / 2 (S1CG64 )
2
- (Width)
2
Ellipse Radius S1CG63 / 2 (S1CG64 / 2) - (Width / 2)
Width 0 S1CG64 - (2* Radius)
Pentagon Radius S1CG63 / 2 S1CG64 / 2
Hexagon Radius S1CG63 / 2 S1CG64 / 2
Circle Rectangle Ellipse
Pentagon Hexagon
Radius
Height
Width Width
Radius
Radius Radius
9/49

3 Teaching
3.1 How to Teach a Pattern
3-1
165468-1CD
HW1481987
Form Cutting
3 Teaching
Follow the example of teaching shown below to teach a motion instruction
for cutting a form
* The items to be set in the form cut setting file are shown in " ".
3.1 How to Teach a Pattern
With the form cutting function, teaching can be done by registering the
FORMAPR and FORMCUT instructions.
The FORMAPR instruction is a move instruction to move to the cutting
motion’s starting point, and the FORMCUT instruction is a cutting motion
instruction.
Move the manipulator axis in the step where the manipulator moves to the
cutting motion’s starting point and use the FORMAPR instruction to
register the position which is the center of the form’s pattern to be set.
Register the FORMCUT instruction in the step where the cutting motion
starts (the next step after the FORMAPR instruction).
Teaching Position of the FORMAPR Instruction
10/49

3-2
165468-1CD
HW1481987
Form Cutting
3 Teaching
3.1 How to Teach a Pattern
By setting the "START POINT" of the form cut setting file to the center or
the specified point, the FORMCUT instruction can start a cutting motion
from the center of the pattern or any point near the pattern.
By pressing PLAYBACK, TEST RUN, or INTERLOCK and NEXT at the
same time, the FORMAPR instruction is carried out and the manipulator
moves to the center of the pattern when the center is set as the "START
POINT"; or it moves to the specified point near the pattern when a specific
point is set as the "START POINT".
By pressing the NEXT or BACK, the FORMAPR instruction is carried out
and the manipulator disregards the "START POINT" setting and moves to
the center of the pattern.
NOTE
Do not register any move instruction (MOVJ, MOVL, etc.)
between the FORMAPR and FORMCUT instructions.
If any move instruction is registered, normal operation is
disabled or an alarm occurs.
NOTE
Set the same value for both the FORMAPR and FORMCUT
instruction tag values (form cut setting file No., etc.) except
for "SPEED".
If the values are different, the FORMAPR instruction tag
value is validated.
The speed in the FORMAPR instruction is for the speed
when moving to the starting point, and the FORMCUT
instruction is for the speed when cutting.
Move to the shelter point
Move to the starting point of the pattern
Cutting
Move to the shelter point
11/49

3 Teaching
3.1 How to Teach a Pattern
3-3
165468-1CD
HW1481987
Form Cutting
When the center is set as the "START POINT"
When a specified point is set to as the "START POINT"
SUPPLE-
MENT
When a specified point is set as the "START POINT", the
position is set with "CUT IN LENGTH" and "CUT IN ANGLE"
of the form cut setting file for the starting point (a point near
the pattern). Refer to Section 6.2.2 “Specifying the CUT IN
LENGTH and the CUT IN ANGLE” on page 6-5.
12/49

3-4
165468-1CD
HW1481987
Form Cutting
3 Teaching
3.1 How to Teach a Pattern
Only when the center is set as the "START POINT", the starting point
position (the center of the pattern) can be set by a move instruction
(MOVL, MOVJ, etc.) other than FORMAPR instruction. If so, the
FORMCUT instruction can be carried out with the registered position as
the center.
* A job including a conventional FORMCUT instruction can be used by
setting the center as the "START POINT". The following shows an
example of a job.
NOTE
To carry out a FORMCUT instruction, in which
PLACEMENT is set as the "START POINT", by pressing
PLAYBACK, TEST RUN, or INTERLOCK and NEXT at the
same time after a NEXT or BACK operation, be sure to
carry out the NEXT or BACK operation several steps before
the FORMCUT instruction. All the instructions between the
instruction carried out by pressing the NEXT or BACK and
the FORMCUT instruction must be carried out by pressing
PLAYBACK, TEST RUN, or INTERLOCK and NEXT at the
same time.
Move to the shelter point
Move to the starting point (center) of the pattern
Cutting
Move to the shelter point
13/49

3 Teaching
3.2 Tool Position and Cutting Pattern
3-5
165468-1CD
HW1481987
Form Cutting
3.2 Tool Position and Cutting Pattern
The following figures show the relation between the tool position each the
cutting pattern.
Circle
: Tool coordinate system
X-axis direction : Tool coordinate system Y-axis direction
Overlap
Overlap Overlap
Overlap Overlap
Radius
Radius Radius
Height
Width
Corner radius
Rectangle Ellipse
Width
Radius
X
Y
X
Y
X
Y
X Y
X X
YY
Pentagon Hexagon
14/49

3-6
165468-1CD
HW1481987
Form Cutting
3 Teaching
3.3 Cutting Width Correction Function
3.3 Cutting Width Correction Function
The cutting width correction function shifts the scale of the cutting width of
the laser for the cutting path when cutting the form according to the
pattern. The following parameter is used for the setting.
Set the cutting width of the laser to 1/2 of its value. When cutting, the path
is corrected by the parameter set values.
The following illustration is an example of the path correction when cutting
the ellipse pattern. The correction for the motion path is similar when
using the other patterns.
The center of the circle does not change before and after the cutting width
correction.
Parameter Contents Initial Value
S3C1191 Cutting width correction
(in units of 0.001 mm) 0 mm
When the cutting width correction value is (+)
When no cutting width correction
When the cutting width correction value is (-)
The set value at S3C1191
15/49

3 Teaching
3.4 Example of Form Cutting Function
3-7
165468-1CD
HW1481987
Form Cutting
3.4 Example of Form Cutting Function
3.4.1 Example of a Job
An example of a job for cutting the following pattern is shown.
0000 NOP
0001 MOVJ VJ=100.00
0002 MOVJ VJ=100.00
0003 FORMAPR FCF#(1)Move to the starting point (center)
0004 CALL LASERONInstruction to a laser, etc. to start motion
0005 FORMCUT FCF#(1)Cutting motion (circle)
0006 CALL LASEROFFInstruction to a laser, etc. to end motion
0007 MOVL V=50
0008 MOVJ VJ=100.00
0009 FORMAPR FCF#(2) R=10.000Move to the starting point
(specified point)
0010 CALL LASERONInstruction to a laser, etc. to start motion
0011 FORMCUT FCF#(2) R=10.000Cutting motion (circle)
0012 CALL LASEROFFInstruction to a laser, etc. to end motion
0013 MOVL V=50
0014 MOVJ VJ=100.00
0015 MOVL V=50Move to the starting point (center)
0016 CALL LASERONInstruction to a laser, etc. to start motion
0017 FORMCUT FCF#(3)Cutting motion (rectangle)
0018 CALL LASEROFFInstruction to a laser, etc. to end motion
0019 MOVL V=50
0020 MOVJ VJ=100.00
0021 MOVL V=50Move to the starting point (center)
0022 CALL LASERONInstruction to a laser, etc. to start motion
0023 FORMCUT FCF#(4)Cutting motion (ellipse)
0024 CALL LASEROFFInstruction to a laser, etc. to end motion
1
2
3
78
9
13 14
15
19 20
21
25
26
*
*
16/49

3-8
165468-1CD
HW1481987
Form Cutting
3 Teaching
3.4 Example of Form Cutting Function
0025 MOVL V=50
0026 MOVJ VJ=100.00
0027 END
* Set the same file No.
3.4.2 Example of a Motion Path
By setting the "END POINT" to PATH or to PLACEMENT in the form cut
setting file, the FORMCUT instruction can be used to cut in on the pattern
path or inwards from the path to complete a cutting motion.
Also, the "ROTATION DIRECTION", and the "ROTATION ANGLE", etc. of
the pattern can be set in the form cut setting file. (Refer to Chapter 6 Form
Cut Setting File on page 6-1.)
Cutting pattern:
Rectangle
Manipulator
17/49

3 Teaching
3.4 Example of Form Cutting Function
3-9
165468-1CD
HW1481987
Form Cutting
3.4.2.1 Motion Example 1
Conditions
FIGURE
START POINT
END POINT
ROTATION
DIRECTION
: RECTANGLE
: CENTER
: PATH
: CW
1. The starting point is the center of pattern.
in the positive direction.
of the Xaxis on the tool coordinate system
2. The manipulator moves in the direction
by 90 to start drawing the rectangle.
the manipulator changes the cutting direction
3. After proceeding the half of the width,
specified in "AMOUNT OF OVERLAP".
4. Performs overlapping for the length
Half of
the width
Amount of overlap
Center
of pattern
18/49

3-10
165468-1CD
HW1481987
Form Cutting
3 Teaching
3.4 Example of Form Cutting Function
3.4.2.2 Motion Example 2
Conditions
FIGURE
START POINT
END POINT
ROTATION
DIRECTION
: RECTANGLE
: PLACEMENT
: PLACEMENT
: CW
pattern.
1. The starting point is the point near the form cutting
coordinate system in the positive direction.
cutting pattern and the X-axis direction on the tool
2. The manipulator moves to the intersection of the
rectangle.
pattern, the manipulator starts drawing the specified
3. After proceeding up to the edge of the form cutting
"AMOUNT OF OVERLAP".
4. Performs overlapping for the length specified in
LENGTH" and "CUT INANGLE".
moves to the end point specified by "CUT IN
5. When overlapping is completed, the manipulator
Amount of overlap
Center of pattern
Starting point
Starting point
Starting point
Center of pattern
Center of pattern
Starting point
Center of pattern
Amount of overlap
Starting point
Center of pattern
X
Y
X
X
End point
19/49

4 Form Cutting Start Motion Instruction
4.1 FORMAPR Instruction (Form Cutting Start Motion Instruction)
4-1
165468-1CD
HW1481987
Form Cutting
4 Form Cutting Start Motion Instruction
4.1 FORMAPR Instruction (Form Cutting Start Motion
Instruction)
The FORMAPR instruction is to move the manipulator to the position
where the form cutting motion starts according to the conditions set in the
form cut setting file.
The additional items to the FORMAPR instruction are as follows. The
additional items can be omitted except for "FORM CUT SETTING".
FORMAPR P000 FCF#(10) R=10 W=50 H=100 V=100 ROT=90
      
POSITION VARIABLES IN CENTER OF PATTERN
Set when the center of the form cutting pattern is registered as position
variables.
The variable number is omitted when the center of the form cutting
pattern is taught to be registered.

FORM CUT SETTING
The manipulator moves to the starting point of the cutting motion
according to the conditions of the file No. specified by the FORMAPR
instruction.
RADIUS (mm)
Specifies the radius when the radius in the file conditions specified in 
should be changed.
The radius specified in has a priority.
WIDTH (mm)
Specifies the width when the width in the file conditions specified in 
should be changed.
The width specified in has a priority.
HEIGHT (mm)
Specifies the height when the height in the file conditions specified in 
should be changed.
The height specified in has a priority.
APPROACH SPEED (cm/min) (mm/min) (inch/min)
Specifies the approach speed when the approach speed in the file
conditions specified in should be changed.
The approach speed in has a priority.
ROTATION ANGLE (degrees)
Specifies the rotational angle when the rotational angle in the file
conditions specified in should be changed.
The rotational angle in has a priority.
20/49