YASKAWA Motoman DX200 User manual

MANUAL NO.
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DX200/FS100 OPTIONS
INSTRUCTIONS
For MotoFit Function Engineering Support Tool
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 (for each purpose)
DX200 MAINTENANCE MANUAL
FS100 INSTRUCTIONS
FS100 OPERATOR’S MANUAL
FS100 MAINTENANCE MANUAL
The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
The FS100 OPERATOR’S MANUAL above is applicable to both FS100 and FS100L controllers.
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164254-1CD
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MANDATORY
• This manual explains MotoFit function engineering support tool.
Read this manual carefully and be sure to understand its contents
before handling the DX200/FS100.
• General items related to safety are listed in the Chapter 1: Safety of
the DX200/FS100 Instructions. To ensure correct and safe
operation, carefully read the DX200/FS100 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.
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NOTES FOR SAFE OPERATION
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200/FS100.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“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.
DANGER
Indicates an imminent hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
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 “DANGER”,
“WARNING” and “CAUTION” .
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<DX200>
WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on the programming pendant
is pressed.
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
• In the case of not using the programming pendant, be sure to
supply the emergency stop button on the equipment. Then before
operating the manipulator, check to be sure that the servo power is
turned OFF by pressing the emergency stop button.
Connect the external emergency stop button to the 5-6 pin and 16-
17 pin of the robot system signal connector (CN2).
• Upon shipment of the DX200, this signal is connected by a jumper
cable in the dummy connector. To use the signal, make sure to
supply a new connector, and then input it.
If the signal is input with the jumper cable connected, it does not
function, which may result in personal injury or equipment damage.
• 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:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– 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.
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<FS100>
WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on the programming pendant
is pressed.
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.
Fig. : Emergency Stop Button
• In the case of not using the programming pendant, be sure to
supply the emergency stop button on the equipment. Then before
operating the manipulator, check to be sure that the servo power is
turned OFF by pressing the emergency stop button.
Connect the external emergency stop button to the 5-6 pin and 16-
17 pin of the robot system signal connector (CN2).
• Upon shipment of the FS100, this signal is connected by a jumper
cable in the dummy connector. To use the signal, make sure to
supply a new connector, and then input it.
If the signal is input with the jumper cable connected, it does not
function, which may result in personal injury or equipment damage.
• 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
• Observe the following precautions when performing teaching
operations within the manipulator’s operating range:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– 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 manipulator’s operating
range and that you are in a safe location before:
– Turning ON the FS100 power.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the manipulator’s operating range
during operation. Always press the emergency stop button
immediately if there is a problem.
The emergency stop button is located on the right of the programming
pendant.
Turn
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WARNING
• Confirm that no person is present in the manipulator’s operating
range and that you are in a safe location before:
– Turning ON the power for the controller
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the manipulator’s operating range
during operation. Always press an emergency stop button immediately
if there are problems.
The emergency stop button is located on the right side of the DX200/
FS100 programming pendant.
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 DX200/
FS100 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 the Warning Labels in the
DX200/FS100 Instructions before operating the manipulator.
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Definition of Terms Used Often in This Manual (DX200)
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and the manipulator cables.
In this manual, the equipment is designated as follows:
Definition of Terms Used Often in This Manual (FS100)
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the FS100 controller,
manipulator cables, the FS100 programming pendant (optional), and the
FS100 programming pendant dummy connector (optional).
In this manual, the equipment is designated as follows:
Equipment Manual Designation
DX200 controller DX200
DX200 programming pendant Programming pendant
Cable between the manipulator and the
DX200 controller
Manipulator cable
Equipment Manual Designation
FS100 controller FS100
FS100 programming pendant Programming pendant
Cable between the manipulator
and the controller
Manipulator Cable
Robot Manipulator
FS100 programming pendant
dummy connector
Programming pendant
dummy connector
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Descriptions of the programming pendant keys, buttons, displays and
keyboard of the PC 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 [SELECT] is
pressed.
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 [ ].
e.g. [ENTER]
Symbol Keys The keys which have a symbol printed on them
are not denoted with [ ] but depicted with a
small picture.
e.g. 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.
e.g. SHIFT key + COORD key
Mode Key Three kinds of modes that can be selected by
the mode key are denoted as follows:
REMOTE, PLAY, or TEACH
Button Three buttons on the upper side of the
programming pendant are denoted as follows:
HOLD button
START button
EMERGENCY STOP button
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
PC Keyboard The name of the key is denoted.
e.g. Ctrl key on the keyboard
GO BACK
PAGE
SHIFT
TOOL SEL
COORD
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Contents
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1 Outline of Function.......................................................................................................................... 1-1
1.1 MotoFit Function Engineering Support Tool ...................................................................... 1-1
1.2 Automatic Adjustment Function of Force Control Parameter ............................................ 1-2
1.2.1 Force control ........................................................................................................ 1-2
1.2.2 Adjustment Method .............................................................................................. 1-3
1.3 MotoFit Teach Guidance Function..................................................................................... 1-5
1.4 Function for Calculation of Force Detection Threshold...................................................... 1-6
2 System Configuration...................................................................................................................... 2-1
2.1 System Configuration ........................................................................................................ 2-1
3 Operation Procedure....................................................................................................................... 3-1
3.1 Installing / Uninstalling FSE-Tool....................................................................................... 3-1
3.1.1 Installing FSE-Tool ............................................................................................... 3-1
3.1.2 Uninstalling FSE-Tool........................................................................................... 3-1
3.2 Setting the IP address ....................................................................................................... 3-2
3.3 Operation for Creating Fitting JOB .................................................................................... 3-5
3.3.1 Outline of Operation Step..................................................................................... 3-5
3.3.2 Detailed Operation Step ....................................................................................... 3-6
3.3.2.1 Startup of FSE-Tool ................................................................................ 3-6
3.3.2.2 Setting Force Condition File.................................................................... 3-8
3.3.2.3 Automatic Adjustment of Force Control Parameter............................... 3-13
3.3.2.4 TOUCH Command Teach ..................................................................... 3-25
3.3.2.5 FIT Command Teach ............................................................................ 3-33
3.3.2.6 INSERT Command Teach..................................................................... 3-39
3.3.2.7 Creating MotoFit JOB............................................................................ 3-47
3.3.2.8 Chage of Unit Scale (only for the FS100).............................................. 3-53
3.4 Teach of Force Sense Basic Command .......................................................................... 3-54
3.4.1 Outline of Teach Operation of Force Sense Basic Command............................ 3-54
3.4.2 Details of Teach Operation of Force Sense Basic Command ............................ 3-54
3.4.2.1 Creating JOB......................................................................................... 3-54
3.4.2.2 Threshold Setting by Data Logging ....................................................... 3-56
3.4.2.3 Operation Check ................................................................................... 3-61
4 Interface Panel................................................................................................................................ 4-1
5 Monitor Information ......................................................................................................................... 5-1
6 Operation Condition Data ............................................................................................................... 6-1
6.1 Force Condition File Data .................................................................................................. 6-1
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6.2 Adjustment Condition Data ................................................................................................6-2
6.3 MotoFit Command Argument Data .................................................................................... 6-3
6.4 Backup of Teach Data ....................................................................................................... 6-6
6.5 Data for Setting Detection Threshold................................................................................. 6-8
7 Error of Automatic Adjustment Function of Force Control Parameter............................................. 7-1
8 Alarm List of FSE-Tools .................................................................................................................. 8-1
9 How to Check the Version............................................................................................................... 9-1
10 Precautions ................................................................................................................................. 10-1
10.1 Operation during Force Control ..................................................................................... 10-1
10.2 Cancel Operation during Execution of Adjustment Operation or MotoFit Function ....... 10-1
10.3 Communication Error .....................................................................................................10-1
10.4 Limitation due to Using Environment .............................................................................10-1
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