YASKAWA MOTOMAN Series User manual

MANUAL NO.
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YRC1000 OPTIONS
INSTRUCTIONS
FOR ARC WELDING DIAGNOSIS FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
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DANGER
• This manual explains the arc welding diagnosis function of the
YRC1000 system. Read this manual carefully and be sure to
understand its contents before handling the 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 YRC1000 INSTRUCTIONS. To ensure correct and
safe operation, carefully read "Chapter 1. Safety" of the 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.
• YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized
modification voids the product warranty.
NOTICE
• 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.
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NOTES FOR SAFE OPERATION
Read this manual carefully before installation, operation, maintenance, or
inspection of the 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 performing the following operations. When the servo
power is turned OFF, the SERVO ON LED on the programming
pendant is turned OFF.
– Press the emergency stop buttons on the front door of the
YRC1000, on the programming pendant, on the external control
device, etc.
– Disconnect the safety plug of the safety fence.
(when in the play mode or in the remote mode)
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 YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
Personal injury may result if a person enters the manipulator's
operating range during operation. Immediately press an emergency
stop button whenever there is a problem. The emergency stop buttons
are located on the front panel of the YRC1000 and on the right of the
programming pendant.
• Read and understand the Explanation of the Warning Labels before
operating the manipulator.
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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.
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 cabinet after use.
If the programming pendant is left unattended on the manipulator, on a
fixture, or on the floor, etc., the Enable Switch may be activated due to
surface irregularities of where it is left, and the servo power may be
turned ON. In addition, in case the operation of the manipulator starts,
the manipulator or the tool may hit the programming pendant left
unattended, which may result in personal injury and/or equipment
damage.
Equipment Manual Designation
YRC1000 controller YRC1000
YRC1000 programming pendant Programming pendant
Cable between the manipulator and the
controller
Manipulator 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.
(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.
(The button names are denoted as symbols)
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
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 Outline of Arc Welding Diagnosis Function.....................................................................................1-1
1.1 Function Outline.................................................................................................................1-1
2 Operation Outline............................................................................................................................ 2-1
2.1 Operation Process of Arc Welding Diagnosis Function .....................................................2-1
2.1.1 JOB Setting...........................................................................................................2-1
2.1.2 Data Setting for Arc Welding Diagnosis................................................................2-3
2.1.3 Displaying / Non-displaying Arc Weld Diagnosis Window ....................................2-5
2.2 Preparation for Arc Weld Diagnosis Window .....................................................................2-6
2.2.1 Diagnosis Mode Setting........................................................................................2-7
3 Operating Arc Weld Diagnosis Window ..........................................................................................3-1
3.1 Selection of JOB ................................................................................................................3-1
3.2 Selection of Bead Number.................................................................................................3-2
3.3 Setting of Threshold for Determining Error ........................................................................3-3
3.4 Setting of Error Output Mode and Signal Number .............................................................3-4
3.5 Setting of Standard Current and Standard Voltage ...........................................................3-5
3.6 Changing of Standard Current and Standard Voltage .......................................................3-7
3.7 Enable/Disable of Diagnosis.............................................................................................. 3-9
4 Saving of Arc Welding Diagnosis Data ...........................................................................................4-1
4.1 Saving of Arc Welding Diagnosis Data ..............................................................................4-1
4.2 Setting for Saving of Arc Welding Diagnosis Data (Automatic) .........................................4-1
4.3 Setting for Saving of Arc Welding Diagnosis Data (Manual)..............................................4-6
4.4 Retry Saving of Data..........................................................................................................4-7
5 Saving Format of Arc Welding Diagnosis Data ...............................................................................5-1
5.1 Saving Data .......................................................................................................................5-1
6 Concurrent I/O Ladder ....................................................................................................................6-1
6.1 Specific Input Signal ..........................................................................................................6-1
6.2 Specific Output Signal........................................................................................................6-1
7 Parameter .......................................................................................................................................7-1
7.1 SC Parameter ....................................................................................................................7-1
7.2 AP Parameter ....................................................................................................................7-2
8 Alarm / Error / Inform.......................................................................................................................8-1
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8.1 Alarm List........................................................................................................................... 8-1
8.2 Error Dialogue List ............................................................................................................. 8-1
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1 Outline of Arc Welding Diagnosis Function
1.1 Function Outline
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1 Outline of Arc Welding Diagnosis Function
1.1 Function Outline
This function diagnoses if the welding bead is normal or abnormal based
on the data such as welding current waveforms or welding voltage
waveforms. Notifying the error welding position can prevent a defective
product flowing to the post process, or can indicate the place to adjust at
the adjusting process.
Score mode
Score mode will comprehensively diagnose if the welding bead is normal
or abnormal based on the data from welding current waveforms or welding
voltage waveforms.
Current out-of-range mode
Current out-of range will diagnose if the welding bead is normal or
abnormal based on the differences between the welding current command
value and the effective value.
NOTE The arc welding diagnosis function is not a function to
ensure product quality.
NOTE
The arc welding diagnosis function will determine if the
welding bead is normal or abnormal based on the data such
as welding current waveforms. A normal or abnormal diag-
nosis may be unable to be determined depending on weld-
ing conditions or usage environment. In addition, if tack
welding or welding time is short (less than 2 seconds),
diagnosis will not be possible because the variation in
scores will increase. It can not be used together with
COMARC.
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1 Outline of Arc Welding Diagnosis Function
1.1 Function Outline
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NOTE
Arc welding diagnosis function can be used in the following
versions.
YRC1000: YAS2.71.00A-00 or later
DX200: DN.2.81.00A_00 or later
MOTOWELD-X350: 1.20-020-E or later
MOTOWELD-X500: 1.20-020-F or later
MOTOWELD-RL350: 1.00-070-A or later
(When using RL350, change to C Parameter C39 of weld-
ing power source to100. Also, if the weld diagnosis
function is enabled, the communication failure will
occur if the RL350 has the above version or earlier.
Please upgrade the RL350.)
The score mode cannot be used in welders other than the
above. Use the current out-of-range mode.
NOTE
Corresponding welding method
• DC short circuit welding
• DC pulse welding
* For short circuit welding, it is recommended to turn on the
automatic correction of output voltage.
(Refer to 6.3.3 short circuit of MOTOWELD-X350 / X500
instruction manual)
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2 Operation Outline
2.1 Operation Process of Arc Welding Diagnosis Function
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2 Operation Outline
2.1 Operation Process of Arc Welding Diagnosis Function
2.1.1 JOB Setting
Add the bead number to the ARCON instruction in the JOB. Move the
cursor to the ARCON, and press [ENTER]. The bead number is shown,
and then register an arbitrary number.
NOTE
To use the arc welding diagnosis function, set each item
after completing welding conditioning.
When the welding condition, the welding speed, or the
welding teaching point, etc. have been changed, make sure
to set items again.
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2 Operation Outline
2.1 Operation Process of Arc Welding Diagnosis Function
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NOTE
When the welding diagnosis function has been enabled
after upgrading, to show the bead number, perform “RESET
INSTRUCTION” or change “LANGUAGE LEVEL” in the
management mode.
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2 Operation Outline
2.1 Operation Process of Arc Welding Diagnosis Function
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2.1.2 Data Setting for Arc Welding Diagnosis
Set the register address of data to use the welding diagnosis on the
APPLICATION CONDITION SETTING window. To show the
APPLICATION CONDITION SETTING window, set the security to the
management mode. Under the Main Menu, select the sub menu, {ARC
WELDING} - {APPLI COND.}, and the following window appears.
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2 Operation Outline
2.1 Operation Process of Arc Welding Diagnosis Function
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Specify the register address of the following data on the APPLICATION
CONDITION SETTING window.
Name Initial
Value
Register address for sampling welding voltage value 152
Register address for sampling welding current value 153
Register address for sampling welding feed speed value output 158
Register address for sampling welding feed load value output 159
Bead number output register address 166
Register address for effective current value (average) output 167
Register address for effective voltage value (average) output 168
Score output register address 169
Register address for welding diagnosis data 1 310
Register address for welding diagnosis data 2 311
Register address for welding diagnosis data 3 312
Register address for welding diagnosis data 4 313
Register address for welding diagnosis data 5 314
Register address for welding diagnosis data 6 315
Register address for welding diagnosis data 7 316
Register address for welding diagnosis data 8 317
Register address for welding diagnosis data 9 318
Register address for welding diagnosis data 10 319
Register address for welding diagnosis data 11 320
Register address for welding diagnosis data 12 321
Register address for welding diagnosis data 13 322
Register address for welding diagnosis data 14 323
Register address for welding diagnosis data 15 324
Register address for welding diagnosis data 16 325
Register address for welding diagnosis data 17 326
Register address for welding diagnosis data 18 327
Register address for welding diagnosis data 19 328
Register address for welding diagnosis data 20 329
NOTE When setting the register address, confirm that the register
number is not duplicated.
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2 Operation Outline
2.1 Operation Process of Arc Welding Diagnosis Function
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2.1.3 Displaying / Non-displaying Arc Weld Diagnosis Window
Under the Main Menu, select the sub menu, {ARC WELDING} - {ARC
WELD DIAG.}, and the following window appears. To close the window,
press {CLOSE}.
NOTE When the Arc Weld diagnosis window is being activated,
the test operation and the next/back operation are invalid.
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2 Operation Outline
2.2 Preparation for Arc Weld Diagnosis Window
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2.2 Preparation for Arc Weld Diagnosis Window
Set the Arc Weld diagnosis window settings in accordance with the
following flow chart.
Start Arc weld diagnosis window
Select diagnosis mode
Check the checkbox of “Start diagnosis”
Complete of diagnosis preparation
Score mode Current out-of-range mode
Selection of JOB Selection of JOB
Selection of bead number Selection of bead number
Setting threshold for determining error Setting threshold for determining error
Setting error output mode Setting error output mode
Setting signal number Setting signal number
Welding
Confirmation of bead
NG
OK
Registration of basic data
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2 Operation Outline
2.2 Preparation for Arc Weld Diagnosis Window
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2.2.1 Diagnosis Mode Setting
Press {Setting} on the Arc Weld diagnosis window, the following window
appears.
Select either {Score mode} or {Current out-of-range mode} as the
Diagnosis mode.
NOTE If the Diagnosis mode is changed, the data of the Arc Weld
diagnosis window is initialized.
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3 Operating Arc Weld Diagnosis Window
3.1 Selection of JOB
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3 Operating Arc Weld Diagnosis Window
3.1 Selection of JOB
Move the cursor as shown below on the Arc Weld diagnosis window.
Press [ENTER] to select the JOB.
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3 Operating Arc Weld Diagnosis Window
3.2 Selection of Bead Number
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3.2 Selection of Bead Number
Move the cursor as shown below on the Arc Weld diagnosis window.
Press [ENTER] to select the bead number.
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