YASKAWA Motoman DX200 User manual

MANUAL NO.
0
HW1481939
Part Number: 165634-1CD
Revision: 0
DX200 OPTIONS
INSTRUCTIONS
FOR TWIN GUN FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL
DX200 MAINTENANCE MANUAL
The DX200 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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Twin Gun Function
MANDATORY
• This manual explains the twin gun 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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Twin Gun Function
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200.
In this manual,the Notes for Safe Operationare 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
personnelanddamagetoequipment.
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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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 ON the servo power.
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 of 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 the front door of the DX200 and the programming
pendant.
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Twin Gun Function
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 DX200
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 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 bland 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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Table of Contents
1 Twin Gun Function..........................................................................................................................1-1
1.1 Twin Gun Function.............................................................................................................1-1
1.2 Outline of Twin Gun Function............................................................................................1-2
2 Twin Gun Setup..............................................................................................................................2-1
2.1 Home Position Calibration for Twin Gun............................................................................2-1
2.2 Settings of Gun Condition File...........................................................................................2-2
2.3 Settings of Tool File of when a Twin Gun is Mounted on the Manipulator.........................2-3
2.4 Settings of Tool File of when Twin Gun is Fixed................................................................2-4
3 Preparing of Twin Gun Job.............................................................................................................3-1
3.1 Registration of MOVE Instructions.....................................................................................3-1
3.2 Operation Flow Chart of Hit Points Teaching ....................................................................3-1
3.3 Job Example for a Twin Gun Mounted on the Manipulator................................................3-2
3.4 Job Example for Fixed Twin Gun.......................................................................................3-2
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1 Twin Gun Function
1.1 Twin Gun Function
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1 Twin Gun Function
1.1 Twin Gun Function
As illustrated in the figure below, a twin gun has one operating axis and
two pairs of electrodes which apply pressure.
Twin gun function is the function that maximizes and controls
twin gun performance.
Movable
Operating axis
Fixed
Movable
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1 Twin Gun Function
1.2 Outline of Twin Gun Function
1.2 Outline of Twin Gun Function
In the DX200, a twin gun is treated as a station with one axis, and the
station is configured with two guns.
Use an S-axis key to perform JOG operation, etc. since the twin gun is a
station with one axis.
For MOVE instructions, register the instructions in the same manner as a
station with one axis.
When applying pressure, select either gun of the twin gun, that applies
pressure.
The following show an example of use of the twin gun function in the
system with one manipulator and one twin gun.
S1
GUN 1
GUN 2
S-
X- S+ X+
L-
Y- L+ Y+
U-
Z- U+ Z+
7- 7+
R-
X- R+ X+
B-
Y- B+ Y+
T-
Z- T+ Z+
9
6
3
-
.
2
5
8
7
4
1
0
Programming Pendant
NOP
MOVJ
MOVJ
MOVJ
SVSPOTMOV GUN# (1)
SVSPOTMOV GUN# (2)
Configuration of Control Group
R1 : ES200N-A0*
S1 : TWIN-GUN
Operates S1 with MOVE instruction.
Selects a gun No. to apply pressure.
Twin gun
Selects S1 to perform JOG operation with S-axis key.
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2 Twin Gun Setup
2.1 Home Position Calibration for Twin Gun
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2 Twin Gun Setup
2.1 Home Position Calibration for Twin Gun
For setting of home position of a twin gun, move the twin gun in the
direction of "S -(minus)" as shown in the figure below by JOG operation,
and set the position, where one tip is aligned with another tip, as home
position.
SUPPLE-
MENT
Home position can also be set to a desired position.
If there are means such as an alignment mark, etc. to
specify the position of a gun, use the mean and set home
position at this position.
SUPPLE-
MENT
For home position settings, refer to Section 8.1 “Home
Position Calibration" of the "DX200 INSTRUCTIONS”
(Part No.165557-1CD).
Home position
+
-
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2 Twin Gun Setup
2.2 Settings of Gun Condition File
2.2 Settings of Gun Condition File
Twin gun has a gun condition file for each gun; specify gun conditions in
the files of both guns.
Gun conditions for each gun of the twin gun can be set in either gun
condition file. Conditions of the gun which applies pressure in the forward
direction are usually set in the gun condition file of the smaller file number.
Pressure direction
Backward direction
Pressure direction
Forward direction
GUN (X)
Smaller gun file No.
GUN (Y)
Bigger gun file No.
NOTE
Pressure directions of two guns of the twin gun are different.
(Forward/Backward direction)
When setting the gun condition files of both guns, perform
the settings with attention to the pressure direction.
SUPPLE-
MENT
For details on settings of gun condition files, see Section
9.4.1 “Gun Condition Files" of "DX200 OPERATOR’S
MANUAL FOR SPOT WELDING USING MOTOR GUN"
(Part No. 165557-1CD).
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2 Twin Gun Setup
2.3 Settings of Tool File of when a Twin Gun is Mounted on the
Manipulator
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2.3 Settings of Tool File of when a Twin Gun is Mounted on
the Manipulator
Taking each fixed tip of a twin gun as TCP (tool tip position), set positional
data in any two tool files so that the Z-axis direction of the tool coordinates
faces the movable side electrode.
NOTE
In case of using a twin gun mounted on the manipulator,
also change a tool file to the tool file corresponding to the
twin gun when applying pressure.
SUPPLE-
MENT
For details on the tool file, see Section 8.3 “Tool Data
Setting" in the "DX200 INSTRUCTIONS"
(Part No. 165557-1CD).
SUPPLE-
MENT
For details on settings of the gun condition file, see Section
9.4.3 “Gun Condition File" in the “DX200 OPERATOR’S
MANUAL FOR SPOT WELDING USING MOTOR GUN”
(Part No. 165297-1CD).
Tool
file No. (X)
Tool
file No. (Y)
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2 Twin Gun Setup
2.4 Settings of Tool File of when Twin Gun is Fixed
2.4 Settings of Tool File of when Twin Gun is Fixed
Taking each fixed tip of a twin gun as a home position of the user
coordinates, set positional data in any two user coordinate files so that the
Z-axis direction of the user coordinates faces the movable side electrode.
NOTE
After selecting {FIXED}to the setting figure of the gun
condition files, assign numbers of the set user coordinates
files.
For details, see Section 9.12.5 “Electrode Wear
Compensation for Fixed Gun" in the DX200 OPERATOR’S
MANUAL FOR SPOT WELDING USING MOTOR GUN
(Part No. 165297-1CD).
SUPPLE-
MENT
For details on the user coordinates, see Section 8.8 “User
Coordinates Setting" in the "DX200 INSTRUCTIONS"
(Part No. 165557-1CD).
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3 Preparing of Twin Gun Job
3.1 Registration of MOVE Instructions
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3 Preparing of Twin Gun Job
3.1 Registration of MOVE Instructions
Perform teaching of MOVE instructions: MOVJ, MOVL, MOVC, etc. for a
twin gun in the same manner as the usual station with one axis.
3.2 Operation Flow Chart of Hit Points Teaching
When applying pressure with a twin gun, specify a gun number to be the
subject to PRESSURE instructions: SVSPOTMOV, SVGUNCL, etc., then
apply pressure.
The following show the operation flow chart to perform pressure teaching
of SVSPOTMOV with a twin gun mounted on the manipulator.
SUPPLE-
MENT
To register a PRESSURE instruction with a twin gun
mounted on the manipulator, also change a file to the tool
file corresponding to the subject twin gun.
Set the gun number which is subject for
teaching in MANUAL SPOT window.
Move the manipulator to the hit point.
Apply pressure.
Stop applying the pressure.
End
Change a file to the tool file corresponding to the gun
which is subject for teaching.
(For the gun mounted on the manipulator)
Register SVSPOTMOV.
(Specify the gun number which is the subject for teaching.)
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3 Preparing of Twin Gun Job
3.3 Job Example for a Twin Gun Mounted on the Manipulator
3.3 Job Example for a Twin Gun Mounted on the Manipulator
The following show a job example which is created with the gun mounted
on the manipulator.
3.4 Job Example for Fixed Twin Gun
The following show a job example which is created with the fixed gun.
NOP
MOVJ (TOOL#(1))
MOVJ (TOOL#(1))
SVSPOTMOV GUN#(1) (TOOL#(1)) Specifies the gun for teaching.
MOVJ (TOOL#(2)) Changes the tool.
MOVJ (TOOL#(2))
SVSPOTMOV GUN#(2) (TOOL#(2)) Specifies the gun for teaching.
MOVJ (TOOL#(1)) Changes the tool.
MOVJ (TOOL#(1))
MOVJ (TOOL#(1))
SVGUNCL GUN#(1) Specifies the gun for teaching.
MOVJ (TOOL#(2)) Changes the tool.
SVGUNCL GUN#(2) Specifies the gun for teaching.
END
NOP
MOVJ
MOVJ
SVSPOTMOV GUN#(1) Specifies the gun for teaching.
MOVJ
MOVJ
SVSPOTMOV GUN#(2) Specifies the gun for teaching.
MOVJ
MOVJ
MOVJ
SVGUNCL GUN#(1) Specifies the gun for teaching.
MOVJ
SVGUNCL GUN#(2) Specifies the gun for teaching.
END
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MANUAL NO.
Specifications are subject to change without notice
for ongoing product modifications and improvements.
DX200 OPTIONS
INSTRUCTIONS
FOR TWIN GUN FUNCTION
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