YASKAWA YRC1000 User manual

MANUAL NO. RE-CSO-A055
YRC1000
OPERATOR’S MANUAL
FOR SPOT WELDING USING AIR GUN
Upon receipt of the product and prior to initial operation, read these instructions below
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”.
182902-1CD
0
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ii
DANGER
• This manual explains the various components of the YRC1000
system and general operations. Read this manual carefully and be
sure to understand its contents before handling the YRC1000.
• General items related to safety are listed in “Chapter 1.Safety” of
the YRC1000 INSTRUCTIONS. To ensure correct and safe
operation, carefully read the YRC1000 Instructions before reading
this manual.
CAUTION
• In some drawings in this manual, the protective covers or shields
are removed to show details. Make sure to install all the covers and
shields 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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iii
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
“DANGER”, “WARNING” and “CAUTION”.
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iv
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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v
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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vi
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
vii
1 Spot Welding Application Using an Air Gun.................................................................................... 1-1
1.1 System Overview of Spot Welding System Using an Air Gun ........................................... 1-1
1.2 Function Keys .................................................................................................................... 1-3
1.3 Teaching ............................................................................................................................ 1-5
1.3.1 Manual Spot Welding Function............................................................................. 1-5
1.3.1.1 Manual Dry Spotting................................................................................ 1-5
1.3.1.2 Stroke Switching ..................................................................................... 1-5
1.3.1.3 Welding On/Off........................................................................................ 1-6
1.3.1.4 Resetting Alarms ..................................................................................... 1-7
1.3.2 Registering Work Instructions............................................................................... 1-8
1.3.2.1 GUNCL Instruction .................................................................................. 1-9
1.3.2.2 SPOT Instruction ................................................................................... 1-11
1.3.2.3 STROKE Instruction .............................................................................. 1-14
1.3.2.4 STRWAIT Instruction............................................................................. 1-16
1.4 Setting Welding Conditions (for Air Gun)......................................................................... 1-17
1.4.1 Settings for Manual Spot Welding ...................................................................... 1-17
1.4.2 Spot Welder Condition Data Setting................................................................... 1-19
1.4.3 Spot Gun Condition Data File............................................................................. 1-22
1.5 Spot Welding Diagnosis................................................................................................... 1-25
1.5.1 Spot Welding Diagnosis Window........................................................................ 1-25
1.5.1.1 Setting Tolerance Value ........................................................................ 1-25
1.5.1.2 Tip Hit Count Clear................................................................................ 1-26
1.6 Spot Gun Motion Control ................................................................................................. 1-27
1.6.1 Gun Motion Control ............................................................................................ 1-27
1.6.1.1 X Type Gun ........................................................................................... 1-27
1.6.1.2 C Type Gun ........................................................................................... 1-28
1.6.2 Process Timing................................................................................................... 1-30
1.6.2.1 OPERATION MODE = 0
(SINGLE GUN, OPEN →WELDING →OPEN).................................... 1-30
1.6.3 OPERATION MODE = 1
(SHORT OPEN →WELDING →SHORT OPEN).............................................. 1-31
1.6.3.1 OPERATION MODE = 2
(SHORT OPEN →WELDING →FULL OPEN) .................................... 1-32
1.6.3.2 OPERATION MODE = 3
(FULL OPEN →WELDING →SHORT OPEN) .................................... 1-33
1.6.3.3 OPERATION MODE = 4
(FULL OPEN →WELDING →FULL OPEN) ........................................ 1-34
1.6.4 Stroke Change Control Method.......................................................................... 1-35
1.6.4.1 Single Gun, C Double Gun, X Double Cylinder Gun............................. 1-35
1.6.4.2 X Double Mechanical Stopper Type...................................................... 1-35
1.6.5 I/O Allocation ...................................................................................................... 1-37
1.6.5.1 Input Allocation Window ........................................................................ 1-37
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Contents
viii
1.6.5.2 Output Allocation Window ..................................................................... 1-38
1.6.5.3 Pseudo Input Signal Window.................................................................1-39
1.6.6 Allocation Signal Meanings................................................................................. 1-40
1.6.7 Monitor Function for Spot Welding Equipment ................................................... 1-42
1.6.8 Spot Welding Exclusive Signal Allocation List .................................................... 1-43
1.7 Instruction List.................................................................................................................. 1-47
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1 Spot Welding Application Using an Air Gun
1.1 System Overview of Spot Welding System Using an Air Gun
1-1
1 Spot Welding Application Using an Air Gun
1.1 System Overview of Spot Welding System Using an Air Gun
An I/O signal diagram of a typical spot welding system is shown below.
Fig. 1-1: I/O Signal Diagram for Spot Welding System
• WELD COND (level signal)
• Sets the welding conditions for the welder.
• The output format can be set as binary or discrete.
• Can handle up to 255 conditions (for binary).
• WELD REQUEST (level/pulse)
Outputs the start instruction to the welder.
• WELD ERROR RESET (level)
Resets the welding alarm status of the welder.
• GUN PRESSURE (level)
Outputs gun pressure instruction to the welding gun.
Robot
Controller
Welder
WELD COND
(8 bits max)
Welding Gun
WELD
REQUEST
WELD
COMPLETION
WELD ERROR
WELD ERROR
RESET
WELD ON/OFF
GUN PRESSURE
STROKE CHANGE
DOUBLE STROKE GUN
FULL-OPEN DETECTION
(Single Solenoid /
Double Solenoid)
DOUBLE STROKE GUN
SHORT-OPEN DETECTION
128 64 32 16 8 4 2 1
(8) (7) (6) (5) (4) (3) (2) (1)
8-bit
* Values in parentheses are for discrete.
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1 Spot Welding Application Using an Air Gun
1.1 System Overview of Spot Welding System Using an Air Gun
1-2
• STROKE CHANGE (level)
Select the stroke of the gun.
• In case of single solenoid: Change by 1 signal
• In case of double solenoid: Change by 2 signal
SUPPLE-
MENT
For details on signal contents, refer to chapter 1.6 Spot Gun
Motion Control.
For details on I/O allocation, refer to chapter 1.6.5 "I/O
Allocation".
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1 Spot Welding Application Using an Air Gun
1.2 Function Keys
1-3
1.2 Function Keys
Each function used for spot welding is allocated on [Numeric Key]s of the
programming pendant. These keys become available when the WORK
HOME POSITION is on the display.
Displays the MANUAL SPOT window.
Displays the WORK HOME POSITION window.
[FWD] + [TASK ORIGIN]
With the WORK HOME POSITION window in the teach
mode, press these keys to move the manipulator to the work
home position.
Displays the SPOT instruction in the input buffer to register
welding operations.
[INTERLOCK] + [SPOT]
With the MANUAL SPOT window displayed, press these
keys to perform manual welding.
Displays the GUNCL instruction in the input buffer to register
dry spot welding operations.
[INTERLOCK] + [GUN CLOSE]
With the MANUAL SPOT window displayed, press these
keys to perform manual dry spot welding.
[INTERLOCK] + [WELD ON/OFF]
Press these keys to turn on or off the welding ON/OFF signal.
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1 Spot Welding Application Using an Air Gun
1.2 Function Keys
1-4
However, the following two keys are for the function keys for spot welding
with motor gun and not for spot welding with air gun.
Instruction to change the stroke to the short open position
when using a double stroke gun:
Displays the STROKE SHORT instruction in the input buffer.
The SHORT OPEN POSITION SETTING window appears
the first time the key is pressed.
The selection No. for the short open position appears from
the second time the key is pressed.
[INTERLOCK] + [SHORT OPEN]
The movable side electrode moves to the selected short
open position.
Instruction to change the stroke to the full open position when
using a double stroke gun:
Displays the STROKE LONG instruction in the input buffer.
The FULL OPEN POSITION SETTING window appears the
first time the key is pressed.
The selection number for the full open position appears from
the second time the key is pressed.
[INTERLOCK] + [FULL OPEN]
The movable side electrode moves to the selected full open
position.
[INTERLOCK] + [WELD ALM RESET]
A Power Source alarm reset signal is output to the Power
Source only while these keys are held down.
The welding conditions, gun pressure and weld request are
reset with this function.
3
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1 Spot Welding Application Using an Air Gun
1.3 Teaching
1-5
1.3 Teaching
In order to use the air gun function, first perform teaching as described
below.
1.3.1 Manual Spot Welding Function
To perform manual spot welding, carry out the following operation.
1. Press [0/MANUAL SPOT] of [Numeric Key]s.
2. Press [INTERLOCK] + [SPOT] simultaneously.
To perform manual spot welding, press these keys simultaneously while
the MANUAL SPOT window is called up.
The conditions displayed in the MANUAL SPOT window are used for
manual spot welding.
Regarding the condition setting, refer to chapter 1.4.1 "Settings for
Manual Spot Welding".
When registering the welding instruction [SPOT], the values set in the
MANUAL SPOT window are used as the initial data.
1.3.1.1 Manual Dry Spotting
To perform manual dry spotting, carry out the following operation.
1. Press [0/MANUAL SPOT] of [Numeric Key]s
2. Press [INTERLOCK] + [GUN CLOSE] simultaneously.
To perform manual dry spotting, press these keys simultaneously while
the MANUAL SPOT window is called up.
The conditions displayed in the MANUAL SPOT window are used for
manual dry spotting.
Note that the numbers specified in the MANUAL SPOT window are used
as the initial values for the gun number of the gun to be operated and the
gun number used when registering the dry spot instruction GUNCL.
While the key is being pressed, the dry spotting motion is performed.
When the key is released, the operation stops.
1.3.1.2 Stroke Switching
• Press [INTERLOCK] and [FULL OPEN] simultaneously to switch to
the full open position.
• Press [INTERLOCK] and [SHORT OPEN] simultaneously to switch
to the short open position.
Note that the numbers specified in the MANUAL SPOT window are used
as the initial values for the gun number of the gun to be operated and the
gun number used when registering the stroke switching instruction
STROKE.
AP parameter specifies whether the stroke signal should be set ON or
OFF to make the stroke full open. (The initial setting is OFF.)
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1 Spot Welding Application Using an Air Gun
1.3 Teaching
1-6
1.3.1.3 Welding On/Off
Press [INTERLOCK] and [WELD ON/OFF] simultaneously in the teach
mode to turn on or off the welding ON/OFF signal to all connected
welders.
A user message appears when the welding ON/OFF signal is turned ON
in the teach mode.
During manual spot welding, the welding current flows only when this
message appears.
The output destination must be allocated in the spot input/output
allocation information window before this function is used.
SUPPLE-
MENT
For information on the signal allocation method, see
chapter 1.6.5 "I/O Allocation".
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1 Spot Welding Application Using an Air Gun
1.3 Teaching
1-7
1.3.1.4 Resetting Alarms
The alarm reset signal to all connected welders remains ON while
[INTERLOCK] and [WELD ALM RESET] are being pressed
simultaneously. The welding conditions, gun pressure and weld request
are reset with this function.
The output destination must be allocated in the spot input/output
allocation information window before this function is used.
SUPPLE-
MENT
For information on signal allocation method, see
chapter 1.6.5 "I/O Allocation".
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1 Spot Welding Application Using an Air Gun
1.3 Teaching
1-8
1.3.2 Registering Work Instructions
The function keys [GUNCL](GUNCL instruction), [SPOT](SPOT
instruction), [SHORT OPEN]/[FULL OPEN](STROKE instruction) can be
used for registering the work instructions.
The STRWAIT instruction is registered using [INSTRUCTION LIST].
Table 1-1: Registering Work Instructions
Instructions are registered during the teach mode when the cursor is in the
address area of the job content window.
1. Select {JOB} under the main menu.
2. Select {JOB CONTENT}.
– The JOB CONTENT window is displayed.
3. Move the cursor to the address area.
Specific Keys Instructions
[GUN CLOSE] GUNCL instruction
[SPOT] SPOT instruction
[SHORT OPEN]
[FULL OPEN]
STROKE instruction
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1 Spot Welding Application Using an Air Gun
1.3 Teaching
1-9
1.3.2.1 GUNCL Instruction
This is the dry spotting instruction. It performs dry spotting for the
specified time. The gun performs dry spotting then returns to the start
position after the time-up timer counts out. Use this instruction when
spotting is required, such as after automatic tip dressing or automatic tip
replacement.
Additional Items
(1) Gun# (X)
Specifies a gun to be pressed.
(2) T = X
Specifies the time when the gun is closed.
(3) ATT = X
Starts execution of GUNCL X second(s) before reaching the move
instruction located immediately before it. However, it is necessary
to specify “NWAIT” to the move instruction immediately before the
GUNCL instruction.
NOTE
Be sure to use this instruction in the short open status with
a double stroke gun other than X double stroke mechanical
stopper type gun.
The instruction controls only one gun at one time. Two
guns cannot perform dry spotting simultaneously. When
GUNCL instruction is executed, it takes a time for the stroke
action and dry spotting time is shortened.
GUNCL
GUN#(X)
GUN NO.
X: 1 to 8 X: 0.01 to 655.35 sec.
T=X
GUN PRESSURE TIME
ATT=X
ANTICIPATION CONDITION
X: 0 to 655.35 sec.
(1) (2) (3)
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1 Spot Welding Application Using an Air Gun
1.3 Teaching
1-10
Operation Procedure
1. Move the cursor to the line before the place where the GUNCL
instruction is to be registered.
2. Press [2/GUN CLOSE] or [INSTRUCTION LIST].
3. Select the {GUNCL} instruction.
– When [2/GUN CLOSE] is pressed, the “GUNCL” instruction appears
in the input buffer line.
– When [INSTRUCTION LIST] is pressed, the instruction list dialog
appears. Select “GUNCL” from the list.
4. Move the cursor to the address area.
5. Add items and modify the number data.
6. Press [ADD], then press [ENTER].
– The GUNCL instruction is registered.
Example
The gun pressure signal is turned ON 0.5 seconds before the manipulator
reaches the step 5 position and then turns OFF after 2 seconds (1.5
seconds after reaching there) and moves to the execution of step 6.
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1 Spot Welding Application Using an Air Gun
1.3 Teaching
1-11
1.3.2.2 SPOT Instruction
This instruction starts the spot welding sequence. It outputs the gun
pressure signal then executes the welding sequence appropriate for the
gun type. The function key [SPOT] can be used for its registration.
The condition number used for the registration of the spot instruction is a
value set on the manual spot condition window.
Two guns can be controlled simultaneously.
Additional Items
(1) GUN #(X)
Specifies the number of welding condition set to the welder.
(2) MODE = X
Specifies the gun move operation mode.
In the case of double stroke, specifies the open status before and
after the welding.
(3) WTM=X
Specifies the number of welding conditions set to the welder.
(4) GUN#(X)
Specifies the second gun at two-gun control.
Cannot be omitted at simultaneous two-gun control. Do not set
when only one gun is used.
(5) MODE=X
SUPPLE-
MENT
Under two-gun control, this instruction is completed when
the gun with the slower welding sequence completes weld-
ing. See chapter 1.6 Spot Gun Motion Control for informa-
tion on the welding sequence executed by this instruction.
SPOT
GUN#(X)
GUN1 NO.
X: 1 to 8 X: 0 to 4
MODE=X
GUN1 ACTION MODE
WTM=X
GUN1 WELD CONDITION
X: 1 to 255
ATT=X
ANTICIPATION CONDITION
X: 0 to 655.35 sec.
GUN#(X)
GUN2 NO.
X: 1 to 8 X: 0 to 4
GUN2 ACTION MODE
MODE=X WTM=X
GUN2 WELD CONDITION
X: 1 to 255
(1) (2) (3)
(4) (5) (6)
(7)
Setting Data Before Welding After Welding
0SingleGun
1 Short Open Short Open
2 Short Open Full Open
3 Full Open Short Open
4 Full Open Full Open





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1 Spot Welding Application Using an Air Gun
1.3 Teaching
1-12
Specifies the operation mode of the second gun at two-gun con-
trol. Specifies the open status before and after welding in the case
of double stroke.
Do not set when only one gun is used.
Setting data is the same as shown in the table in (2).
(6) WTM=X
Specifies the number of the welding conditions set to the second
welder at two-gun control.
Do not set when only one gun is used.
(7) ATT=X
Starts execution of SPOT X second(s) before reaching the move
instruction immediately before it. However, it is necessary to
specify “NWAIT” to the move instruction immediately before the
SPOT instruction. By omitting this item, the SPOT instruction is
executed as usual after reaching the move instruction.
Operation Procedure
1. Move the cursor to the line before the place where the SPOT
instruction is to be registered.
2. Press [./SPOT] or [INSTRUCTION LIST].
– When [./SPOT] is pressed, the “SPOT” instruction appears in the
input buffer line.
– When [INSTRUCTION LIST] is pressed, the instruction list dialog
appears. Select {SPOT} from the list.
3. Add items and modify the number data.
4. Press [ADD], then press [ENTER].
– The SPOT instruction is registered.
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