YASKAWA Motoman DX200 User manual

MANUAL NO.
HW1481731 7
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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1 Outline of Function
1.1 MotoFit Function Engineering Support Tool
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1 Outline of Function
1.1 MotoFit Function Engineering Support Tool
The MotoFit function is an application using force control, attaching with
the 6-axis force sensor. It realizes the optimum fit operation by the
combination of commands as “TOUCH (Push of workpiece)”, “FIT
(Search)”, and “INSERT (Insertion)” (refer to DX200/FS100 OPTIONS
INSTRUCTIONS for MotoFit (HW1481732)).
During the force control, the robot moves based on the force condition file
in DX200/FS100. On the other hand, during the operation of each
command, the robot moves based on the command argument.
The MotoFit Function Engineering Support Tool (abbreviated as FSE-
Tool) is a tool to support teaching the MotoFit function. It operates on the
PC connected with the robot controller.
Fig. 1-1: Operation of MotoFit Function
In FSE-Tool, operation according to the teach guidance on the PC screen
will create the force condition file and a JOB added MotoFit command.
The guidance is mainly on the automatic adjustment of force control
parameters in the force condition file, and argument setting of the MotoFit
command. The former function is called as the automatic adjustment
function of force control parameter, and the latter function is called as the
MotoFit teach guidance function. They adjust to the optimum parameters
suitable for the robot configuration or workpiece form and materials in
operation, realizing a precise fit operation. Note that, however,
adjustment may be hard to apply to such a workpiece of unstable shape
due to its insufficient hardness.
Fig. 1-2: System Configuration
Realizing fit work by the operation command optimum to the insertion status
TOUCH
(Successful) INSERT
(Successful)
TOUCH
(Failed)
FIT(Successful)
FIT(Failed)
INSERT
(Failed)
6-axis force sensor
PC Robot Controller
Programming
Pendant (PP)
Robot 6-axis
force sensor
MotoFit Function
The MotoFit
Function
Engineering
Support Tool
(FSE-Tool)
force condition
file
JOB
Automatic Adjustment of
Force Control Parameter
Argument setting of MotoFit command
(MotoFit teach guidance function)
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1 Outline of Function
1.2 Automatic Adjustment Function of Force Control Parameter
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1.2 Automatic Adjustment Function of Force Control
Parameter
1.2.1 Force control
In the MotoFit function, the impedance control is used as a model of force
control. The impedance control parameter has M (Mass
parameter)[kg,kgm2], D (Damping parameter) [Ns/m,Nms] and K (Spring
parameter) [N/m,Nm] as shown in the following figure. The behavior of the
robot is different depending on these values. In the MotoFit function, the
damping parameter, D, is automatically adjusted. The values of M and K
are fixed as M = 1 [kg, kgm2] and K = 0 [N/m, Nm]. For the units described
in the parentheses, the former indicates the translational direction and the
latter indicates the rotational direction.
Fig. 1-3: Impedance Control Model
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1 Outline of Function
1.2 Automatic Adjustment Function of Force Control Parameter
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1.2.2 Adjustment Method
The operation of the automatic adjustment function of force control
parameter consists of the following two steps.
1. Tuning Step 1
Obtains a limit value of damping parameter to maintain the stable
contact condition of the workpiece with a small force, without
divergent.
Fig. 1-4: Operation of Tuning Step 1
2. Tuning Step 2
In this step, the force command is given to allow repetitive contact of
workpiece, enabling to automatically adjust to the damping
parameter so that the response of force FB, the force toward the
force command at that time, becomes excellent. As for the
operation, the pressing with constant force is repeated.
Fig. 1-5: Operation of Tuning Step 2
Force
Small
Force
Time
Force
Small
Force
Time
OK (Stable contact) NG (Unstable contact)
Divergent (applying force increases)
Rattling
Adjust to a
convergent value
Damping changed
by amplitude
Force
Repeats
contacts
Force sensor
Workpieces Time
Adjust to damping
property of early follow
Force
command Force response
Condition B
(Optimum value)
Condition C
(Response delay)
Condition A
(Vibrational)
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1 Outline of Function
1.2 Automatic Adjustment Function of Force Control Parameter
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By executing the Tuning Steps 1 and 2, adjust three translational
axes (X, Y, Z) and three rotational axes (Rx, Ry, Rz). Both
adjustment operations, translational and rotational, are shown in the
figure below. In the rotational adjustment, the side of the workpiece
contacts to another.
Fig. 1-6: Translational and Rotational Adjustment Operation
When there is no workpiece and accordingly no contact occurs, the
robot stops its operation.
Fig. 1-7: Operation of Stop
(a) Adjustment in
translational direction (b)Adjustment in rotational direction
Workpiece Control
points
(a) Adjustment in
translational direction
(b) Adjustment in
rotational direction
Stops if it exceeds
the maximum value
Stops if it exceeds
the maximum value
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1 Outline of Function
1.3 MotoFit Teach Guidance Function
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1.3 MotoFit Teach Guidance Function
In the parameters of MotoFit function commands, the following values
should be set (for details, refer to DX200/FS100 OPTIONS
INSTRUCTIONS for MotoFit (HW1481732). Among them, the
parameters with the asterisk mark* need to be the values suitable for the
shape of workpiece. Follow the guidance, and determine the set value by
executing the MotoFit command and performing the measurement.
(1) TOUCH
Arg1: Force condition file No.
Arg2: Touch force threshold
Arg3: Approach speed
Arg4: Force command value
Arg5: Insertion length threshold
Arg6: Touch length* (See the right figure)
Arg7: After - TOUCH, time - out time
Fig. 1-8: TOUCH
(2) FIT
Arg1: Force condition file No.
Arg2: Force command value
Arg3: Insertion length threshold
Arg4: Search operation pattern
Arg5: Search force command value
Arg6: Search vibration cycle*
(See the right figure)
Arg7: Search operation start direction
designation
Arg8: Search operation time
Fig. 1-9: FIT
(3) INSERT
Arg1: Force condition file No.
Arg2: Force command value
Arg3: Insertion length threshold 1*
(See the right figure)
Arg4: Insertion length threshold 2*
(See the right figure)
Arg5: Unchoke operation designation
Arg6: Unchoke operation force command
Arg7: Unchoke operation force
command cycle
Arg8: Unchoke operation start direction
designation
Arg9: Unchoke operation time
Fig. 1-10: INSERT
Touch
length
Search vibration
cycle (Seach width)
Insertion
length
threshold 1
Insertion
length
threshold 2
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1 Outline of Function
1.4 Function for Calculation of Force Detection Threshold
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1.4 Function for Calculation of Force Detection Threshold
Force sense basic command is a command which targets relatively simple
tasks such as pressing with constant force or stopping the operation when
detecting the force which exceeds the specified force. This can be used
for the error detection such as the case that the different force from the
normal state is applied as described below. For details, refer to DX200/
FS100 OPTIONS INSTRUCTIONS for MotoFit (HW1481732).
By using the Engineering Support Tool, the threshold of the force
detection is calculated from the log data and it's shown as the
recommended value.
Fig. 1-11: Error Detection
OK
NG
X
Z
Tape
Plate
Pressing with
constant force
Movement
Protrusion
Robot arm head
Force sensor
Tool
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2 System Configuration
2.1 System Configuration
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2 System Configuration
2.1 System Configuration
The MotoFit function consists of the robot, the robot controller, the 6-axis
force sensor, the Interface panel on the programming pendant and PC for
teaching which is prepared by user.
Fig. 2-1: System Configuration of MotoFit Function
Table 2-1: Components
Device Note
Robot (Manipulator) -
Robot controller The setting of MotoFit
function is completed
Power supply cable -
Programming pendant Interface panel for MotoFit
The setting is completed
6-axis force sensor Rated 200N,Rated 1000N
Sensor cable Manipulator side
Robot Controller side
PC for teaching1)
1 PC, LAN cable and Tool are prepared by user.
OS: Windows7,Windows8,
Windows10
LAN cable for PC connection1) -
Tool for the manipulator’s tip1) -
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3 Operation Procedure
3.1 Installing / Uninstalling FSE-Tool
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3 Operation Procedure
3.1 Installing / Uninstalling FSE-Tool
3.1.1 Installing FSE-Tool
1. Copy the FSE-Tool folder in the CD-ROM to the PC.
2. Execute setup.exe in the FSE-Tool folder and install FSE-Tool
according to the guidance.
3. When starting FSE-Tool,Connect the DX200/FS100 (CPU
board:ANCD-YCP21-E(CN104(LAN))) and the PC by LAN cable and
double-click the FSE-Tool icon created on the desktop.
3.1.2 Uninstalling FSE-Tool
*Below is the procedure for Windows 7.For other OSs, please refer to the
general uninstallation method from external document.
1. Select in the following order:{Start},{Control Panel},"Add or Remove
Programs"
2. Uninstall NI LabVIEW Run-Time Engine 6.1.
3. Delete the FSE-Tool folder copied from the CD to the PC.
NOTE
If the DX200/FS100 and the PC is not connected by LAN
cable or the setting of IP address is inappropriate, the mes-
sage “Communication error” is shown when using the FSE-
Tool.
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3 Operation Procedure
3.2 Setting the IP address
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3.2 Setting the IP address
1. Make sure the IP address of PC is in the same network of the IP
address of the DX200/FS100.
• Select [SYSTEM INFO] - [NETWORK SERVICE] on the main menu.
• IP address can be confirmed.
NOTE
The network service screen is displayed only when the
security mode is management mode.
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3 Operation Procedure
3.2 Setting the IP address
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*Below is the procedure for Windows 7.For other OSs, please refer to the
general setting method of the IP address from external document.
2. Change the PC's IP address so that the robot controller and the PC
are in the same network.
Select [Start] - [Control Panel] - [Network and Sharing Center] -
[Change adapter settings].
In case items to be selected are difficult to find, select "Small Icon" to
change the icon display.
3. From the adapter setting change item, find a port to which Ethernet
cable is connected and right-click it. The property window opens.
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