YASKAWA YRC1000 User manual

MANUAL NO.
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YRC1000 OPTIONS
INSTRUCTIONS
FOR FORM CUTTING 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)
The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”.
The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.
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DANGER
• This manual explains the form cutting function of the YRC1000
system. Read this manual carefully and be sure to understand its
contents before handling the YRC1000. Any matter, including
operation, usage, measures, and an item to use, 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 and 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:
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.
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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Contents
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1 Form Cutting Motion ....................................................................................................................... 1-1
2 Patterns for Cutting......................................................................................................................... 2-1
3 Teaching ......................................................................................................................................... 3-1
3.1 How to Teach a Pattern ..................................................................................................... 3-1
3.2 Tool Position and Cutting Pattern ...................................................................................... 3-5
3.3 Cutting Width Correction Function..................................................................................... 3-6
3.4 Example of Form Cutting Function .................................................................................... 3-7
3.4.2 Example of a Motion Path .................................................................................... 3-8
3.4.2.1 Motion Example 1 ................................................................................... 3-9
3.4.2.2 Motion Example 2 ................................................................................. 3-10
4 Form Cutting Start Motion Instruction ............................................................................................. 4-1
4.1 FORMAPR Instruction (Form Cutting Start Motion Instruction) ......................................... 4-1
4.2 Registering Instructions ..................................................................................................... 4-3
4.2.1 Registering by Teaching....................................................................................... 4-3
4.2.2 Registering in Variables........................................................................................ 4-7
5 Form Cutting Instruction.................................................................................................................. 5-1
5.1 FORMCUT (Form Cutting Motion Instruction) ................................................................... 5-1
5.2 Registering Instructions ..................................................................................................... 5-3
6 Form Cut Setting File ...................................................................................................................... 6-1
6.1 Settings.............................................................................................................................. 6-2
6.2 Details of File Settings ....................................................................................................... 6-5
6.2.1 Specifying the ROUNDNESS ERR ...................................................................... 6-5
6.2.2 Specifying the CUT IN LENGTH and the CUT IN ANGLE ................................... 6-5
6.2.3 Specifying the ROTATION DIRECTION............................................................... 6-6
6.2.4 Specifying the ROTATION ANGLE ...................................................................... 6-6
6.3 Examples of File Setting for Each Pattern......................................................................... 6-7
6.3.1 Circle .................................................................................................................... 6-7
6.3.2 Rectangle Including Squares................................................................................ 6-8
6.3.3 Ellipse ................................................................................................................... 6-9
6.3.4 Pentagon ............................................................................................................ 6-10
6.3.5 Hexagon ............................................................................................................. 6-11
6.4 Displaying and Editing File .............................................................................................. 6-12
7 Alarm Message List ........................................................................................................................ 7-1
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1 Form Cutting Motion
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1 Form Cutting Motion
The form cutting motion cuts workpieces according to a pattern with a tool
such as a laser cutting machine handled by a manipulator.
NOTE
In the form cutting function, there may be some differences
between the set design and the actual cutting motion path,
depending on the calibration, ambient temperature, and
load applied to the manipulator.
Please understand this point, and then use this function.
In order to minimize the above explained differences, be
sure to calibrate your tools before using this function.
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2 Patterns for Cutting
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2 Patterns for Cutting
Five patterns, circle, rectangle (including square), ellipse, pentagon, and
hexagon are available.
The minimum and maximum set values of a pattern can be set at the
following parameters.
The minimum and maximum values of data required for a pattern are set
as follows.
Parameter Contents Initial Value
S1C G63 Minimum set value 1,000 μm
S1C G64 Maximum set value 1,000,000 μm
Pattern Item Minimum Value Maximum Value
Circle Radius S1CG63 / 2 S1CG64 / 2
Rectangle Width 1 (S1CG64 )2- (Height)2
Height S1CG63 / 2 (S1CG64 )2- (Width)2
Ellipse Radius S1CG63 / 2 (S1CG64 / 2) - (Width / 2)
Width 0 S1CG64 - (2* Radius)
Pentagon Radius S1CG63 / 2 S1CG64 / 2
Hexagon Radius S1CG63 / 2 S1CG64 / 2
Circle Rectangle Ellipse
Pentagon Hexagon
Radius
Height
Width Width
Radius
Radius Radius
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3Teaching
3.1 How to Teach a Pattern
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3 Teaching
Follow the example of teaching shown below to teach a motion instruction
for cutting a form
* The items to be set in the form cut setting file are shown in “ ”.
3.1 How to Teach a Pattern
With the form cutting function, teaching can be done by registering the
FORMAPR and FORMCUT instructions.
The FORMAPR instruction is a move instruction to move to the cutting
motion’s starting point, and the FORMCUT instruction is a cutting motion
instruction.
Move the manipulator axis in the step where the manipulator moves to the
cutting motion’s starting point and use the FORMAPR instruction to
register the position which is the center of the form’s pattern to be set.
Register the FORMCUT instruction in the step where the cutting motion
starts (the next step after the FORMAPR instruction).
Teaching Position of the FORMAPR Instruction
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3 Teaching
3.1 How to Teach a Pattern
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By setting the “START POINT” of the form cut setting file to the center or
the specified point, the FORMCUT instruction can start a cutting motion
from the center of the pattern or any point near the pattern.
By pressing PLAYBACK, TEST RUN, or INTERLOCK and NEXT at the
same time, the FORMAPR instruction is carried out and the manipulator
moves to the center of the pattern when the center is set as the “START
POINT”; or it moves to the specified point near the pattern when a specific
point is set as the “START POINT”.
By pressing the NEXT or BACK, the FORMAPR instruction is carried out
and the manipulator disregards the “START POINT” setting and moves to
the center of the pattern.
NOTE
Do not register any move instruction (MOVJ, MOVL, etc.)
between the FORMAPR and FORMCUT instructions.
If any move instruction is registered, normal operation is
disabled or an alarm occurs.
NOTE
Set the same value for both the FORMAPR and FORMCUT
instruction tag values (form cut setting file No., etc.) except
for “SPEED”.
If the values are different, the FORMAPR instruction tag
value is validated.
The speed in the FORMAPR instruction is for the speed
when moving to the starting point, and the FORMCUT
instruction is for the speed when cutting.
Move to the shelter point
Move to the starting point of the pattern
Cutting
Move to the shelter point
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3Teaching
3.1 How to Teach a Pattern
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When the center is set as the “START POINT”
When a specified point is set to as the “START POINT”
SUPPLE
-MENT
When a specified point is set as the “START POINT”, the
position is set with “CUT IN LENGTH” and “CUT IN ANGLE”
of the form cut setting file for the starting point (a point near
the pattern). Refer to Section chapter 6.2.2 “Specifying
the CUT IN LENGTH and the CUT IN ANGLE” .
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3 Teaching
3.1 How to Teach a Pattern
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Only when the center is set as the “START POINT”, the starting point
position (the center of the pattern) can be set by a move instruction
(MOVL, MOVJ, etc.) other than FORMAPR instruction. If so, the
FORMCUT instruction can be carried out with the registered position as
the center.
* A job including a conventional FORMCUT instruction can be used by
setting the center as the “START POINT”. The following shows an
example of a job.
NOTE
To carry out a FORMCUT instruction, in which PLACE-
MENT is set as the “START POINT”, by pressing PLAY-
BACK, TEST RUN, or INTERLOCK and NEXT at the same
time after a NEXT or BACK operation, be sure to carry out
the NEXT or BACK operation several steps before the
FORMCUT instruction. All the instructions between the
instruction carried out by pressing the NEXT or BACK and
the FORMCUT instruction must be carried out by pressing
PLAYBACK, TEST RUN, or INTERLOCK and NEXT at the
same time.
Move to the shelter point
Move to the starting point (center) of the pattern
Cutting
Move to the shelter point
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3Teaching
3.2 Tool Position and Cutting Pattern
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3.2 Tool Position and Cutting Pattern
The following figures show the relation between the tool position each the
cutting pattern.
Circle
: Tool coordinate system
X-axis direction
: Tool coordinate system
Y-axis direction
Overlap
Overlap Overlap
Overlap Overlap
Radius
Radius Radius
Height
Width
Corner radius
Rectangle Ellipse
Width
Radius
X
Y
X
Y
X
Y
X Y
X X
YY
Pentagon Hexagon
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3 Teaching
3.3 Cutting Width Correction Function
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3.3 Cutting Width Correction Function
The cutting width correction function shifts the scale of the cutting width of
the laser for the cutting path when cutting the form according to the
pattern. The following parameter is used for the setting.
Set the cutting width of the laser to 1/2 of its value. When cutting, the path
is corrected by the parameter set values.
The following illustration is an example of the path correction when cutting
the ellipse pattern. The correction for the motion path is similar when
using the other patterns.
The center of the circle does not change before and after the cutting width
correction.
Parameter Contents Initial Value
S3C1191 Cutting width correction
(in units of 0.001 mm)
0 mm
When the cutting width correction value is (+)
When no cutting width correction
When the cutting width correction value is (-)
The set value at S3C1191
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3Teaching
3.4 Example of Form Cutting Function
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3.4 Example of Form Cutting Function
3.4.1 Example of a Job
An example of a job for cutting the following pattern is shown.
0000 NOP
0001 MOVJ VJ=100.00
0002 MOVJ VJ=100.00
0003 FORMAPR FCF#(1)Move to the starting point (center)
0004 CALL LASERONInstruction to a laser, etc. to start motion
0005 FORMCUT FCF#(1)Cutting motion (circle)
0006 CALL LASEROFFInstruction to a laser, etc. to end motion
0007 MOVL V=50
0008 MOVJ VJ=100.00
0009 FORMAPR FCF#(2) R=10.000Move to the starting point
(specified point)
0010 CALL LASERONInstruction to a laser, etc. to start motion
0011 FORMCUT FCF#(2) R=10.000Cutting motion (circle)
0012 CALL LASEROFFInstruction to a laser, etc. to end motion
0013 MOVL V=50
0014 MOVJ VJ=100.00
0015 MOVL V=50Move to the starting point (center)
0016 CALL LASERONInstruction to a laser, etc. to start motion
0017 FORMCUT FCF#(3)Cutting motion (rectangle)
0018 CALL LASEROFFInstruction to a laser, etc. to end motion
0019 MOVL V=50
0020 MOVJ VJ=100.00
0021 MOVL V=50Move to the starting point (center)
0022 CALL LASERONInstruction to a laser, etc. to start motion
0023 FORMCUT FCF#(4)Cutting motion (ellipse)
1
2
3
78
9
13 14
15
19 20
21
25
26
*
*
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3 Teaching
3.4 Example of Form Cutting Function
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0024 CALL LASEROFFInstruction to a laser, etc. to end motion
0025 MOVL V=50
0026 MOVJ VJ=100.00
0027 END
* Set the same file No.
3.4.2 Example of a Motion Path
By setting the “END POINT” to PATH or to PLACEMENT in the form cut
setting file, the FORMCUT instruction can be used to cut in on the pattern
path or inwards from the path to complete a cutting motion.
Also, the “ROTATION DIRECTION”, and the “ROTATION ANGLE”, etc. of
the pattern can be set in the form cut setting file. (Refer to Section
chapter 6 “Form Cut Setting File” .)
Cutting pattern:
Rectangle
Manipulator
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3Teaching
3.4 Example of Form Cutting Function
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3.4.2.1 Motion Example 1
Conditions
FIGURE
START POINT
END POINT
ROTATION
DIRECTION
: RECTANGLE
: CENTER
: PATH
: CW
1. The starting point is the center of pattern.
in the positive direction.
of the Xaxis on the tool coordinate system
2. The manipulator moves in the direction
by 90 to start drawing the rectangle.
the manipulator changes the cutting direction
3. After proceeding the half of the width,
specified in "AMOUNT OF OVERLAP".
4. Performs overlapping for the length
Half of
the width
Amount of overlap
Center
of pattern
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3 Teaching
3.4 Example of Form Cutting Function
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3.4.2.2 Motion Example 2
Conditions
FIGURE
START POINT
END POINT
ROTATION
DIRECTION
: RECTANGLE
: PLACEMENT
: PLACEMENT
: CW
pattern.
1. The starting point is the point near the form cutting
coordinate system in the positive direction.
cutting pattern and the X-axis direction on the tool
2. The manipulator moves to the intersection of the
rectangle.
pattern, the manipulator starts drawing the specified
3. After proceeding up to the edge of the form cutting
"AMOUNT OF OVERLAP".
4. Performs overlapping for the length specified in
LENGTH" and "CUT IN ANGLE".
moves to the end point specified by "CUT IN
5. When overlapping is completed, the manipulator
Amount of overlap
Center of pattern
Starting point
Starting point
Starting point
Center of pattern
Center of pattern
Starting point
Center of pattern
Amount of overlap
Starting point
Center of pattern
X
Y
X
X
End point
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4 Form Cutting Start Motion Instruction
4.1 FORMAPR Instruction (Form Cutting Start Motion Instruction)
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4 Form Cutting Start Motion Instruction
4.1 FORMAPR Instruction (Form Cutting Start Motion
Instruction)
The FORMAPR instruction is to move the manipulator to the position
where the form cutting motion starts according to the conditions set in the
form cut setting file.
The additional items to the FORMAPR instruction are as follows. The
additional items can be omitted except for “FORM CUT SETTING”.
FORMAPR P000 FCF#(10) R=10 W=50 H=100 V=100 ROT=90

POSITION VARIABLES IN CENTER OF PATTERN
Set when the center of the form cutting pattern is registered as position
variables.
The variable number is omitted when the center of the form cutting pat-
tern is taught to be registered.
FORM CUT SETTING
The manipulator moves to the starting point of the cutting motion
according to the conditions of the file No. specified by the FORMAPR
instruction.
RADIUS (mm)
Specifies the radius when the radius in the file conditions specified in 
should be changed.
The radius specified in has a priority.
WIDTH (mm)
Specifies the width when the width in the file conditions specified in 
should be changed.
The width specified in has a priority.
HEIGHT (mm)
Specifies the height when the height in the file conditions specified in 
should be changed.
The height specified in has a priority.
APPROACH SPEED (cm/min) (mm/min) (inch/min)
Specifies the approach speed when the approach speed in the file con-
ditions specified in should be changed.
The approach speed in has a priority.
ROTATION ANGLE (degrees)
Specifies the rotational angle when the rotational angle in the file condi-
tions specified in should be changed.
The rotational angle in has a priority.
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