YASKAWA Motoman DX200 User manual

MANUAL NO.
HW1485706
DX200/YRC1000 OPTIONS
INSTRUCTIONS
FOR HAND GUIDING 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/YRC1000 OPTIONS INSTRUCTIONS FOR HAND GUIDING FUNCTION DX200
INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
DX200 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY BOARD OPERATION
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY FUNCTION
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
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DANGER
• This manual explains the hand guiding function of the DX200/
YRC1000 system. Read this manual carefully and be sure to
understand its contents before handling the DX200/YRC1000. Any
matter not described in this manual must be regarded as
"prohibited" or "improper".
• General information related to safety are described in "Chapter 1.
Safety" of the DX200/YRC1000 INSTRUCTIONS. To ensure
correct and safe operation, carefully read "Chapter 1. Safety" of the
DX200/YRC1000 INSTRUCTIONS.
CAUTION
• In some drawings in this manual, protective covers or shields are
removed to show details. Make sure that all the covers or shields
are installed in place 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 the
product warranty.
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NOTES FOR SAFE OPERATION
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200/YRC1000.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.
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 imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.
CAUTION
Indicates a hazardous situation,
which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.
NOTICE
NOTICE is the preferred signal word
to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION".
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DANGER
• Before operating the manipulator, make sure the servo power is
turned off by pressing the emergency stop button on the front door
of the DX200/YRC1000, on the programming pendant, and on the
hand guiding device respectively. When the servo power is turned
OFF, the SERVO ON LED on the programming pendant is turned
OFF.
If operation of the manipulator cannot be stopped in an emergency,
personal injury and/or equipment damage may result.
Fig. : Emergency Stop Button
• Before releasing the emergency stop, make sure to remove the
obstacle or error caused the emergency stop, if any, and then turn
the servo power ON.
Failure to observe this instruction may cause unintended movement of
the manipulator, which may result in personal injury.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing a teaching
operation within the manipulator's operating range:
– Be sure to perform lockout by putting a lockout device on the
safety fence when going into the area enclosed by the safety
fence. In addition, the operator of the teaching operation must
display the sign that the operation is being performed so that no
other person closes the safety fence.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind emergency response measures against the
manipulator’s unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may cause improper or unintended
movement of the manipulator, which may result in personal injury.
• Confirm that no person is present in the manipulator's operating
range and that the operator is in a safe location before:
– Turning ON the DX200/YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
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Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the DX200/YRC1000
controller, the DX200 programming pendant or the YRC1000
programming pendant, and the power cables.
In this manual, the equipment is designated as follows:
WARNING
• Perform the following inspection procedures prior to conducting
manipulator teaching. If there is any problem, immediately take
necessary steps to solve it, such as maintenance and repair.
– Check for a problem in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the
YRC1000/YRC1000micro cabinet after use.
If the programming pendant is left unattended on the manipulator, on a
fixture, or on the floor, etc., in case the operation of the manipulator
starts, the manipulator or the tool may hit the programming pendant,
which may result in personal injury and/or equipment damage.
• Read and understand the Explanation of the Warning Labels of the
DX200/YRC1000 INSTRUCTIONS before operating the
manipulator.
Equipment Manual Designation
DX200 controller or
YRC1000 controller
Controller
DX200 programming pendant or
YRC1000 programming pendant
Programming pendant
Cable between the manipulator and the
controller
Power cable
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Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Equipment Manual Designation
Programming
Pendant
Character Keys
/Symbol Keys
The keys which have characters or symbols
printed on them are denoted with [ ].
e.g. [ENTER]
Axis Keys
/Numeric Keys
[Axis Key] and [Numeric Key] 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]+[COORD].
Mode Switch Mode Switch can select three kinds of modes
that are denoted as follows: REMOTE, PLAY or
TEACH.
(For YRC1000, the switch names are denoted
as symbols)
Button The three buttons on the upper side of the
programming pendant are denoted as follows:
START, HOLD, or EMERGENCY STOP.
(For YRC1000, the button names are denoted
as symbols)
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
<DX200> <YRC1000>
TEACH
PLAY
REMOTE
START HOLD
REMOTE
PLAY
TEACH
Numeric keys
Axis keys
Enter key
Mode switch Start button Hold button
Emergency stop button
Shift key
Page key
Coordinate key
E
M
E
R
G
E
N
C
Y
S
T
O
P
Numeric keys
Axis keys
Enter key
Mode switch*
Start button* Hold button*
Emergency stop button
Shift key
Page key
Coordinate key
PLAY
REMOTE
TEACH
START
*The button/switch names
are denoted as symbols.
HOLD
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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, 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 brand names for each company or
corporation. The indications of (R) and
TM
are omitted.
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Contents
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1 Introduction ..................................................................................................................................... 1-1
2 Hand Guiding Function ................................................................................................................... 2-1
2.1 Usage Conditions of Hand Guiding Function..................................................................... 2-1
2.2 Overview of Hand Guiding Function .................................................................................. 2-1
2.3 System Configuration of Hand Guiding Function............................................................... 2-2
2.3.1 System Configuration for Using Hand Guiding Device of Handle Type................ 2-4
2.3.2 System Configuration for Using Hand Guiding Device of Grip Type .................... 2-5
2.4 Connection for Hand Guiding Device................................................................................. 2-6
2.5 Connection for Presence Detection Sensor....................................................................... 2-7
2.6 Speed Limiting Function .................................................................................................... 2-8
2.6.1 Setting of Speed Limiting Function ....................................................................... 2-8
2.6.2 Setting Details Upon Shipment............................................................................. 2-8
3 Setup of Hand Guiding Function..................................................................................................... 3-1
3.1 Filter Setting....................................................................................................................... 3-2
3.2 Setting of Speed Upper Limit ............................................................................................. 3-2
3.3 Setting of Speed Coefficient ..............................................................................................3-3
3.4 Setting of Operation Angle Limit ........................................................................................ 3-4
3.5 Setting of Area Limit........................................................................................................... 3-5
3.6 Tool Setting........................................................................................................................ 3-6
3.7 Setting of Sensor Mounting Angle ..................................................................................... 3-6
3.7.1 Tool Coordinate System and Sensor Coordinate System .................................... 3-7
3.7.2 Calculating Setting Value of Sensor Mounting Angle ........................................... 3-8
3.7.3 Setting Example of Sensor Mounting Angle ......................................................... 3-9
3.7.4 Setting Confirmation of Sensor Mounting Angle................................................. 3-14
4 Hand Guiding Function Execution Procedures ............................................................................... 4-1
4.1 Execution Conditions of Hand Guiding Function ............................................................... 4-1
4.2 Hand Guiding Function Execution Procedures .................................................................. 4-1
4.3 Job Creation for Hand Guiding Function Execution........................................................... 4-2
4.4 Mode.................................................................................................................................. 4-3
4.4.1 Jog/Inching ........................................................................................................... 4-3
4.4.1.1 Jog Mode................................................................................................. 4-3
4.4.1.2 Inching Mode ........................................................................................... 4-4
4.4.2 Translation/Rotation.............................................................................................. 4-5
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4.4.2.1 Translation Mode .................................................................................... 4-5
4.4.2.2 Rotation Mode ......................................................................................... 4-5
4.4.3 Force Sensor/ I/O Input ........................................................................................ 4-6
4.4.3.1 Force Sensor Input Mode........................................................................ 4-6
4.4.3.2 I/O Input Mode ........................................................................................ 4-6
4.5 Calibration of Force Sensor ...............................................................................................4-7
4.6 Register Output Function................................................................................................... 4-8
5 Risk Assessment ............................................................................................................................ 5-1
5.1 Assumed Risk.................................................................................................................... 5-1
5.2 Risk Reduction Measures.................................................................................................. 5-2
6 User Variables and General I/O Signals to be Used with Hand Guiding Function ......................... 6-1
6.1 User Variable List .............................................................................................................. 6-1
6.2 General I/O Signal List....................................................................................................... 6-3
6.3 Ladder Program................................................................................................................. 6-4
7 Troubleshooting .............................................................................................................................. 7-1
7.1 Robot Operating Method when Force Sensor Disconnected ............................................ 7-1
7.1.1 Disabling Force Sensor ........................................................................................ 7-1
7.1.2 Enabling Force Sensor......................................................................................... 7-4
7.2 Robot Operating Method When Hand Guiding Device Disconnected ............................... 7-7
7.3 Troubleshooting ................................................................................................................. 7-8
8 Alarm List ........................................................................................................................................ 8-1
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1 Introduction
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1Introduction
The hand guiding function enables to realize the collaboration work
between people and robots. Therefore, make sure to perform the risk
assessment for the whole robot system before using this function since
the safety for the collaborative operation depends on the robot system.
For the risk assessment, refer to chapter 5 “Risk Assessment” .
DANGER
In order to enable the collaborative work between people and robots,
perform the risk assessment for the whole robot systems for
considering to worker’s safety to reduce the risk level of the workers to
the acceptable risk level, or to perform measures for the standards of
the industrial robot (ISO 10218-1:2011 and ISO 10218-2:2011) by the
ISO (International Organization for Standardization).
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2 Hand Guiding Function
2.1 Usage Conditions of Hand Guiding Function
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2 Hand Guiding Function
This chapter describes the overview and the system configuration of the
hand guiding function.
2.1 Usage Conditions of Hand Guiding Function
The usage conditions of the hand guiding function are as follows.
• Install the hand guiding device near the end effector.
• The hand guiding device and cables are installed by the customer.
Confirm that cables are not caught in or excessive tension at the
robot operation at this time.
• Do not apply the pressure of 100 [N] or more on the hand guiding
device.
The sensor may be damaged.
• This function cannot be used with other Motoplus applications.
• This function cannot be used with the conveyor synchronized
function.
2.2 Overview of Hand Guiding Function
The hand guiding function is a function that operates the robot,
approaching the robot by operating the hand guiding device equipped with
a force sensor.
The function can switch between an operation mode, a movement mode,
and an input mode.
Mode Overview
Operation
mode
Jog (Initial state) A robot moves continuously.
Inching A robot moves only a set
moving amount.
Movement
mode
Translation (Initial state) A control point of the robot is
translated.
Rotation Change the posture with fixing
the position of the control point.
Input
mode
Force sensor input (Initial state) Move a robot by a force sensor
input.
I/O input Move a robot by an I/O input.
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2 Hand Guiding Function
2.3 System Configuration of Hand Guiding Function
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2.3 System Configuration of Hand Guiding Function
The hand guiding function consists of two patterns depending on the hand
guiding device to use.
1. Hand guiding device of the handle type with both hands operation
2. Hand guiding device of the grip type with one-hand operation
The location of the screw holes on the hand guiding device and the force
sensor is as shown in the figure below.
The handle type of the hand guiding device can be installed at an angle of
45°, 135°, 225°, and 315° to the force sensor.
The grip type of the hand guiding device can be installed at an angle of 0°,
90°, 180°, and 270° to the force sensor.
Force sensor
Emergency stop
switch
Enable switch
Illuminated switch
Handle type Grip type
Locations of the screw holes on the hand guiding device
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2 Hand Guiding Function
2.3 System Configuration of Hand Guiding Function
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Locations of the screw holes on the force sensor
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2 Hand Guiding Function
2.3 System Configuration of Hand Guiding Function
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2.3.1 System Configuration for Using Hand Guiding Device of Handle Type
The jig , the presence detection sensor , and the robot stand in the
figure are prepared by the customer.
Presence detection sensor
Hand guiding cable
(robot side)
Force sensor cable
(robot side)
Controller
Prepared by customer
7
1
11
9
Hand guiding device
(handle type)
6
Force sensor
5
Jig
4
Robot
2
Hand guiding cable
(controller side)
10
Force sensor cable
(controller side)
8
Power cable
3
Prepared by customer
No. Device name Note
Controller DX200/YRC1000
Robot Robot for handling
Power cable
Jig This jig connects the robot with the force
sensor and the hand guiding device.
*Prepared by the customer.
Force sensor Force sensor designated by YASKAWA
Hand guiding device Hand guiding device of the handle type
Presence detection sensor A safety laser scanner and a light curtain,
etc.
*Prepared by the customer depending on
the purpose and then connected with the
controller.
Force sensor cable
(controller side)
*Wired by the customer.
Force sensor cable
(robot side)
*Wired by the customer.
Hand guiding cable
(controller side)
*Wired by the customer.
Hand guiding cable
(robot side)
*Wired by the customer.
4
7
1
2
3
4
5
6
7
8
9
10
11
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2 Hand Guiding Function
2.3 System Configuration of Hand Guiding Function
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2.3.2 System Configuration for Using Hand Guiding Device of Grip Type
The jig , the presence detection sensor , and the robot stand in the
figure are prepared by the customer.
Presence detection sensor
Hand guiding cable
(robot side)
Force sensor cable
(robot side)
Controller
Prepared by customer
7
1
11
9
Hand guiding device
(grip type)
6
Force sensor
5
Jig
4
Robot
2
Hand guiding cable
(controller side)
10
Force sensor cable
(controller side)
8
Power cable
3
Prepared by customer
No. Device name Note
Controller DX200/YRC1000
Robot Robot for handling
Power cable
Jig This jig connects the robot with the force
sensor and the hand guiding device.
*Prepared by the customer.
Force sensor Force sensor designated by YASKAWA
Hand guiding device Hand guiding device of the grip type
Presence detection sensor A safety laser scanner and a light curtain,
etc.
*Prepared by the customer depending on
the purpose and then connected with the
controller.
Force sensor cable
(controller side)
*Wired by the customer.
Force sensor cable
(robot side)
*Wired by the customer.
Hand guiding cable
(controller side)
*Wired by the customer.
Hand guiding cable
(robot side)
*Wired by the customer.
5
8
1
2
3
4
5
6
7
8
9
10
11
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2 Hand Guiding Function
2.4 Connection for Hand Guiding Device
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2.4 Connection for Hand Guiding Device
Each switch of the hand guiding device in the controller is connected as
follows.
The signals of the following table cannot be used for other purposes.
*The reserve inputs and reserve outputs are not connected to hand
guiding device switches, but are connected to cables inside the controller.
Switch Connection terminal block Terminal
No.
Signal name Contents
DX200 YRC1000
Emergency stop
switch
Machine safety
terminal block
board (YFC22)
Safety terminal
block board
5 EXESP1+ External emergency
stop
6 EXESP1-
7 EXESP2+
8 EXESP2-
Enable switch Functional safety
terminal block
board (YFC24)
Expansion safety
terminal block
board
1 XIN1_1+ Functional safety
general I/O signal 1
(corresponds to
FSBIN01)
2 XIN1_1-
3 XIN1_2+
4 XIN1_2-
Illuminated switch
Input
I/O terminal block
(CN309)
I/O terminal block
(CN309)
B3 IN 01 General input
Illuminated switch
Input
A3 IN 02 General input
Illuminated switch
LED
B10 OUT 01 General output
Illuminated switch
LED
A10 OUT 02 General output
Reserve input
* B4 IN 03 General input
Reserve input
* A4 IN 04 General input
Reserve output
* B11 OUT 03 General output
Reserve output
* A11 OUT 04 General output
1
2
1
2
1
2
1
2
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2 Hand Guiding Function
2.5 Connection for Presence Detection Sensor
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2.5 Connection for Presence Detection Sensor
The hand guiding function is recommended to use in the status with
monitoring the area with the safety laser scanner as a presence detection
sensor for the robot controller.
When a worker or an object is in the monitoring area, perform the stop
monitoring by the functional safety function and the operation of the robot
is limited.
Follow the procedures below to set the setting of the presence detection
sensor.
Connecting the output signal of the presence detection sensor
Connect the output signal of the presence detection sensor to the
functional safety general input signal 2 of the functional safety terminal
block.
Connect them by using the safety relay, etc. depending on the output
signal specifications of the presence detection sensor.
Setting the monitoring area of the presence detection sensor
Perform the monitoring setting of the operating range of the robot in
accordance with the manual of the presence detection sensor.
If using the other presence detection sensor except for the safety laser
scanner, perform sufficient risk assessment, and then use the hand
guiding function while ensuring safety.
1
Device Connection terminal block Terminal
No.
Signal name Contents
DX200 YRC1000
Presence detection
sensor
Functional safety
terminal block
board (YFC24)
Expansion safety
terminal block
board
5 XIN2_1+ Functional safety
general I/O signal 2
(corresponds to
FSBIN02)
6 XIN2_1-
7 XIN2_2+
8 XIN2_2-
2
Monitoring area
Setting Example of the Monitoring Area
by the Presence Detection Sensor (Safety Laser Scanner)
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2 Hand Guiding Function
2.6 Speed Limiting Function
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2.6 Speed Limiting Function
The hand guiding function limits the manipulator’s operation speed (TCP
speed) by “speed limiting function” which is a part of the functional safety
function.
2.6.1 Setting of Speed Limiting Function
For details of setting procedures for the functional safety, refer to the
following instruction manuals.
DX200: DX200 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY
BOARD OPERATION (HW1481991)
YRC1000: YRC1000 OPTIONS INSTRUCTIONS FOR FUNCTIONAL
SAFETY FUNCTION (HW1483576)
2.6.2 Setting Details Upon Shipment
Upon shipment, the speed limit is set to switch depending on the status of
safety general input signals FSBIN01 to connect with the enable signal of
the hand guiding device and FSBIN02 to connect with the output signal of
the presence detection sensor.
NOTE
The speed limit for the hand guiding function is set before-
hand upon shipment.
NOTE
Only the safety manager can change the setting of the
speed limiting function.
WARNING
If the condition file of the functional safety function is changed from the
setting upon shipment, the hand guiding function may not be able to
use safely or may not operate normally.
Table 2-1: Setting of Speed Limit Upon Shipment
Status of Safety General Input
Signal
Status of
Machine Safety
Output Signal
Available
Operation
Enabled
Speed
Limit File
Number
Details of Speed Limit
FSBIN01 FSBIN02 MS-OUT01
ON (No intruding
object in the
area)
Automatic
operation
Jog
None No speed limit
OFF (During
TEACH mode)
ON (Enable OFF) OFF (With
intruding object
in the area)
ON (During
PLAY mode)
Not available 2 Stop monitoring
(0 [mm/s] speed limit)
OFF (Enable ON) OFF (With
intruding object
in the area)
ON (During
PLAY mode)
Hand guiding 1 Speed limit for the
collaborative operation
(250 [mm/s] speed limit)
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3 Setup of Hand Guiding Function
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3 Setup of Hand Guiding Function
This chapter describes the setup procedures of the hand guiding function.
The following items to setup are required to be prepared by the
customers.
Item Details
1 Filter setting Setting of the smoothing filter
coefficient to the force sensor value
2 Setting of speed upper limit Setting of the moving speed limit of the
hand guiding function
3 Setting of speed coefficient Setting of the moving speed coefficient
of the hand guiding function
4 Setting of operation angle limit Setting of the operation angle limit of
the rotation at the hand guiding
5 Setting of area limiting function Setting of the translation area at the
hand guiding
* Setting is arbitrary.
6 Tool setting Setting of the tool file for using at the
hand guiding function
7 Setting of sensor mounting angle Setting of the force sensor angle to the
tool coordinate system
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3 Setup of Hand Guiding Function
3.1 Filter Setting
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3.1 Filter Setting
When using the hand guiding function, the robot may repeat unintentional
acceleration or deceleration caused by unstable input value of the force
sensor because of the time differences which occur in starting a robot
operation after applying force by the user or the influence of the force
sensor interlocking with the hand operation.
To avoid this phenomenon, the value which is input by using the filter
function is smoothed.
A filter coefficient can be set by variables.
[Filter Coefficient: Large]
Effect of smoothing: Large, Delay in changing the robot moving speed by
changing force: Large
[Filter Coefficient: Small]
Effect of smoothing: Small, Delay in changing the robot moving speed by
changing force: Small
If the value except for the possible values is input, when the general
output 4081 (#15110) of the hand guiding function enable signal is turned
ON, the following alarm is displayed.
8001: Parameter Setting error, Sub-code: Variable number
3.2 Setting of Speed Upper Limit
An upper limit of the robot moving speed of the hand guiding function can
be set by variables.
If the value except for the possible values is input, when the general
output 4081 (#15110) of the hand guiding function enable signal is turned
ON, the following alarm is displayed.
8001: Parameter Setting error, Sub-code: Variable number
User variable Variable name Possible value Initial value
I073 Filter coefficient setting 1 - 50 50
User variable Variable name Possible value Initial value
I087 X limit speed 0 - 250 [mm/s] 100
I088 Y limit speed 0 - 250 [mm/s] 100
I089 Z limit speed 0 - 250 [mm/s] 100
I090 Rx limit speed 0 - 200 [0.1 deg/s] 200
I091 Ry limit speed 0 - 200 [0.1 deg/s] 200
I092 Rz limit speed 0 - 200 [0.1 deg/s] 200
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