YASKAWA YRC1000 User manual

MANUAL NO.
HW1483590
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”.
1/49
178664-1CD
0

ii
HW1483590
HW1483590
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.
2/49

iii
HW1483590
HW1483590
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”.
3/49

iv
HW1483590
HW1483590
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.
4/49

v
HW1483590
HW1483590
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
5/49

vi
HW1483590
HW1483590
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}
6/49

Contents
vii
HW1483590
HW1483590
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
7/49

1 Form Cutting Motion
1-1
HW1483590
HW1483590
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.
8/49

2 Patterns for Cutting
2-1
HW1483590
HW1483590
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
9/49

3Teaching
3.1 How to Teach a Pattern
3-1
HW1483590
HW1483590
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
10/49