YASKAWA Motoman DX200 User manual

MANUAL NO.
0
HW1482281
Part Number: 165472-1CD
Revision: 0
DX200 OPTIONS
INSTRUCTIONS
FOR SENSOR FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions below thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN--  INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL ( for each purpose)
DX200 MAINTENANCE MANUAL
The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
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Sensor Function
MANDATORY
• This manual explains the sensor function of the DX200 system.
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.
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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".
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Sensor Function
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.
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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 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
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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 brand names for each company or
corporation. The indications of (R) and TM are omitted.
Equipment Manual Designation
Programming
Pendant Character Keys /Symbol Keys The keys which have characters or its symbol printed on them are denoted with [ ].
ex. [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,
ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
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Sensor Function Table of Contents
Table of Contents
1 Sensor Function..............................................................................................................................1-1
1.1 Real-time Path Correction Function...................................................................................1-1
1.2 Real-time Speed Correction Function................................................................................1-1
1.3 Shift Amount Creation Function.........................................................................................1-1
1.4 Search Function.................................................................................................................1-2
2 Wiring..............................................................................................................................................2-1
2.1 Analog Input Signal Connection ........................................................................................2-1
2.2 Direct-in Signal Connection...............................................................................................2-3
3 Real-time Path Correction Function................................................................................................3-1
3.1 Correction Amount.............................................................................................................3-2
3.2 Correction Direction...........................................................................................................3-3
3.2.1 Tool Coordinate....................................................................................................3-3
3.2.2 Forward Direction.................................................................................................3-4
3.2.3 Optional Direction.................................................................................................3-4
3.3 Monitoring of Sensor Input Voltage ...................................................................................3-5
3.3.1 Sensor Monitor Condition File..............................................................................3-5
3.3.2 Display of Sensor Monitor Condition File .............................................................3-7
3.3.3 Editing of Sensor Monitor Condition File..............................................................3-7
3.4 Instructions for the Real-time Path Correction Function....................................................3-8
3.4.1 ACORON and SACORON Instructions................................................................3-8
3.4.1.1 Registration of the ACORON Instruction.................................................3-9
3.4.2 ACOROF and SACOROF Instructions...............................................................3-11
3.4.2.1 Registration of the ACOROF Instruction...............................................3-11
3.4.3 ACORCH and SACORCH Instructions...............................................................3-12
3.4.3.1 Registration of the ACORCH Instruction...............................................3-13
4 Real-time Speed Correction Function.............................................................................................4-1
4.1 Override Ratio....................................................................................................................4-2
4.2 Instructions for the Real-time Speed Correction Function.................................................4-3
4.2.1 AOVRON Instruction ............................................................................................ 4-3
4.2.1.1 Registration of the AOVRON Instruction.................................................4-4
4.2.2 AOVROF Instruction.............................................................................................4-6
4.2.2.1 Registration of the AOVROF Instruction .................................................4-6
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Table of Contents
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5 Shift Amount Creation Function......................................................................................................5-1
5.1 Shift Amount ......................................................................................................................5-1
5.2 Coordinate System and Sensor Input Channel for Shift Amount Creation........................5-1
5.3 GETSFT Instruction...........................................................................................................5-2
5.3.1 Registration of the GETSFT Instruction................................................................5-3
6 Search Function..............................................................................................................................6-1
6.1 Detection Results...............................................................................................................6-2
6.2 Search Operation with Multiple Channels..........................................................................6-2
6.3 ASRCH Instruction.............................................................................................................6-3
6.3.1 Registration of the ASRCH Instruction .................................................................6-4
7 Calibration.......................................................................................................................................7-1
7.1 SCALIB Instruction.............................................................................................................7-1
7.1.1 Registration of the SCALIB Instruction.................................................................7-2
7.2 Entering an Offset Value....................................................................................................7-3
7.3 All Channels Calibration.....................................................................................................7-3
8 Sensor Output Status Display.........................................................................................................8-1
8.1 Calling Sensor Output Status Display................................................................................8-1
8.2 Editing in Sensor Output Status Display............................................................................8-1
8.3 Calibration of All Sensor Input Channels...........................................................................8-2
9 Sensor Parameters (SxE)...............................................................................................................9-1
10 Alarm List...................................................................................................................................10-1
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Sensor Function 1 Sensor Function
1.1 Real-time Path Correction Function
1 Sensor Function
The sensor function corrects the manipulator path and speed, measures
distance, and detects position using a sensor such as the distance sensor
or the torque sensor.
The analog input signals from a sensor are connected to the DX200, and
various controls are performed according to the input voltage. The signals
from a sensor directly connect to the DX200, and therefore an external
sequencer is not required. This allows easy and simple system
construction, and minimizes the delay of response to the signals.
The sensor function has the following various control functions to be used
depending on the application.
• Real-time path correction function
• Real-time speed correction function
• Shift amount creation function
• Search function
1.1 Real-time Path Correction Function
The real-time path correction function corrects the motion path of the
manipulator according to the input signals from a sensor.
Normally, a manipulator moves along the taught path. However, when the
manipulator cannot move along the taught path due to distortion or
displacement of the workpiece, the sensor function detects the distortion
or displacement in real-time and corrects the manipulator path accordingly
to do the job.
1.2 Real-time Speed Correction Function
The real-time speed correction function corrects the motion speed of the
manipulator according to the input signals from a sensor.
Normally, a manipulator moves at the set speed in a job. However, when
the work time for each workpiece differs, the sensor function detects the
progress of work and moves the manipulator at its optimum speed.
1.3 Shift Amount Creation Function
The shift amount creation function computes the distance to a selected
workpiece according to the input signals from a displacement sensor. The
measurement of more than one position enables a three-dimensional shift
when using the relative job conversion function.
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1 Sensor Function
1.4 Search Function
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Sensor Function
1.4 Search Function
The search function moves a manipulator according to the input signal
from a sensor, and stops the manipulator when the input signal reaches a
designated level.
The sensor monitors the manipulator operation, and stops the manipulator
at the moment of completing the operation.
<Application Example>
A manipulator performs a handling operation of panels.
1. The manipulator moves to the search starting position.
2. The manipulator moves to the goal position in the search operation at
low-speed. When the manipulator comes to the position to take the
panel, an input signal (Direct-IN signal) from the sensor turns ON, then
the manipulator stops. At this moment, the difference between the
search starting position and the detected position is calculated.
Panel
Search
starting
position
Stocker
Displacement
sensor
Direct IN signal
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Sensor Function 1 Sensor Function
1.4 Search Function
3. According to the calculated difference, the program is modified to
proceed the operation.
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2 Wiring
2.1 Analog Input Signal Connection
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2 Wiring
2.1 Analog Input Signal Connection
Connect analog input signals from each sensor to the analog input
terminals on the optional base board. Connect the signals from the
sensors in the following manner.
1. Provide an analog input cable between the sensor and the DX200.
For the connection specification, see Fig. 2-1 Analog Input Signal
Connection Diagram on page 2-2 to be described.
2. Turn OFF the main power supply by turning the DX200 to the OFF
position.
3. Connect the sensor with an analog input cable to the analog input
terminal: CN120 on the option base board: JANCD-YCP02.
4. Set the connected channel No. to the parameter: SxE020 to SxE027
(sensor input channel specification, see Chapter 9 "Sensor
Parameters (SxE)" on page 9-1.
Analog Input Signal Specification
Connector Specification for Input Cable
Channel number : 8 channel
Voltage range : ±10 V
Name Maker Type
MDR connectors, solder plug connector 3 M 10150-3000PE
MDR connector, plastic solder plug junction shell,
non-shielded 3 M 10350-52F0-008
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Sensor Function 2 Wiring
2.1 Analog Input Signal Connection
Fig. 2-1: Analog Input Signal Connection Diagram
Analog voltage output AIN 0
GND
CN120
Sensor 1
Analog output GND
AIN 1
Sensor 2
GND
AIN 2
Sensor 3
GND
AIN 3
Sensor 4
GND
AIN 4
Sensor 5
GND
AIN 5
Sensor 6
GND
AIN 6
GND
AIN 7
GND
10
35
9
34
8
33
7
32
6
31
5
30
4
29
3
28
JANCD-YCP02
Analog voltage output
Analog output GND
Analog voltage output
Analog output GND
Analog voltage output
Analog output GND
Analog voltage output
Analog output GND
Analog voltage output
Analog output GND
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2 Wiring
2.2 Direct-in Signal Connection
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Sensor Function
2.2 Direct-in Signal Connection
For the search function, the direct-in signal needs to be connected
between the optional base board and the terminal for transmission
between the sensor section and the servo section.
When the search function is not used, this wiring is not necessary.
Wire according to the instructions described in the section " ■Direct-in
(Servo)1 to 6 of 14.6.14 Connection for Direct-in" in the DX200
INSTRUCTIONS (Part No. 165292-1CD).
Then, set the channel No. to which the direct-in signal and the general
output signal of the YCP02 board are connected, to the parameters as
follows.
SxE057 General output signal No. of YCP02
board for the search function. (The set value is "2" for the following connection diagram.)
SxE058 Direct-in signal No. for the search
function. (The set value is "2" for the following connection diagram.)
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Sensor Function 2 Wiring
2.2 Direct-in Signal Connection
Fig. 2-2:
Direct IN Signal DIN1 Connection
The part of wiring is that if there is a slave for the coordinated control side
major axes control circuit board (SRDA-EAXA21A).
86
87
88
89
90
91
85
81,82
83,84 CN219
CN120
024V2
+24V2
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
AXDIN6
AXDIN_COM
86
87
88
89
90
91
85
81,82
83,84 CN219
024V2
+24V2
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
AXDIN6
AXDIN_COM
21 POUT1
46 POUTCM1
20 POUT2
45 POUTCM2
19 POUT3
44 POUTCM3
43 POUTCM4
18 POUT4
Connect the jumper cable.
Connect the jumper cable.
Major Axes Control
Circuit Board
(SRDA-EAXA21A)
Machine safety terminal
block circuit board
(JANCD-YFC22-E)
Machine safety terminal
block circuit board
(JANCD-YFC22-E)
Machine safety I/O
logic circuit board
(JANCD-YSF22-E)
Machine safety I/O
logic circuit board
(JANCD-YSF22-E)
Optional base circuit board
(JANCD-YCP02)
Major Axes Control
Circuit Board
(SRDA-EAXA21A)
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3 Real-time Path Correction Function
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3 Real-time Path Correction Function
The real-time path correction function corrects the motion path of the
manipulator according to the input signal from a sensor.
To start path correction, execute a real-time path correction start
instruction (ACORON). To end it, execute a real-rime path correction end
instruction (ACOROF).
During path correction, the manipulator moves in the motion instructed by
a move instruction with the correction amount output from the sensor
section.
<Job Example>
001 NOP
002 MOVJ VJ=25.00
003 MOVL V=100
004 ACORON TF TCH#(3) TV=0.000
005 MOVL V=100
006 ACORCH TCH#(3) TV=1.000
007 MOVL V=100
008 ACOROF
009 MOVL V=100
010 MOVJ VJ=25.00
011 END
Travel amount by Move
instruction
Composite travel
amount
Travel amount with correction
amount from sensor
STEP1 STEP2
Path correction
starts
STEP3
(Taught) STEP4 (Taught) STEP5
STEP3
Path correction
condition
changes STEP4
Path correction
ends
Tool Coordinate
X
Z
Changing Steps
The step is switched at
the same distance as the
taught travel distance.
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Sensor Function 3 Real-time Path Correction Function
3.1 Correction Amount
3.1 Correction Amount
For the deviation of the analog input, the correction amount is calculated
in the following formula.
i) V
in
> V
thresh
+ V
offset
+ V
nosens
C
out
= R ( V
in
- ( V
thresh
+ V
offset
+ V
nosens
))
ii) V
thresh
+ V
offset
- V
nosens
< V
in
< V
thresh
+ V
offset
+
V
nosens
C
out
= 0
iii) V
in
< V
thresh
+ V
offset
- V
nosens
C
out
= R ( V - ( V
thresh
+ V
offset
- V
nosens
))
C
out
:Correction amount
R:Resolution
V
in
:Input voltage
V
thresh
:Threshold
V
offset
:Offset value
V
nosens
:Dead zone
Offset
value
Threshold
Dead
zone Input voltage deviation
Correction amount
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3 Real-time Path Correction Function
3.2 Correction Direction
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3.2 Correction Direction
The direction in which the path is to be corrected can be determined in the
following three ways.
• Tool coordinate
• Forward direction
• Optional direction
The correction from the sensor is executed on the coordinates specified
by ACORON and SACORON instructions (real-time path correction start
instructions).
3.2.1 Tool Coordinate
The correction is performed using a tool mounted on the wrist flange of the
manipulator as a reference point. Select one of the following three
directions; the X-axis direction, the Y-axis direction, or the Z-axis direction.
Correction Direction Sensor Input Channel
(specify at registration of instruction)
X-axis direction CH1
Y-axis direction CH2
Z-axis direction CH3
X-axis
(CH1) Z-axis
(CH3)
Y-axis
(CH2)
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Sensor Function 3 Real-time Path Correction Function
3.2 Correction Direction
3.2.2 Forward Direction
The correction is executed toward the forward direction of move
instruction in execution.
3.2.3 Optional Direction
The motion path is corrected in the direction determined by two reference
points. (Not limited to the orthogonal coordinate system.)
Correction Direction Sensor Input Channel
(specify at registration of instruction)
Forward direction CH1
STEP N+1STEP N
Forward direction
(CH1)
Correction Direction Sensor Input Channel
(specify at registration of instruction)
Direction from REFP1 to REFP2
(Direction from SREFP1 to SREFP2) CH1
Direction from REFP1 to REFP3
(Direction from SREFP1 to SREFP3) CH2
Direction from REFP1 TO REFP4
(Direction from SREFP1 to SREFP4) CH3
REFP4
(CH3)
REFP1 REFP2
(CH1)
REFP3
(CH2)
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3 Real-time Path Correction Function
3.3 Monitoring of Sensor Input Voltage
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3.3 Monitoring of Sensor Input Voltage
To prevent the manipulator from deviating excessively from its path, the
analog signals are monitored during the path correction.
When the path correction starts, the signals are monitored according to a
specified sensor monitor condition file. When an error occurs, the
manipulator moves according to the motion condition of the
aforementioned file.
In the sensor monitor condition file, the maximum voltage value and the
minimum voltage value of each channel can be set. When the input
voltage of an analog signal exceeds these values, an error occurs.
3.3.1 Sensor Monitor Condition File
COND NO. (1 to 16)
Displays the file number.
MAX. VOL, MIN.VOL (-10.000 to 10.000 [V])
The monitor conditions of analog input signal. Set for each sensor input
channel.
No monitoring for the channels whose maximum and minimum voltages
are set to 0.
1
2
3
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