YASKAWA YRC1000micro User manual

HW1484764
4
MANUAL NO.
YRC1000/YRC1000micro
Collaborative Operation Instructions
Upon receipt of the product and prior to initial operation, read these instructions
thoroughly, and retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-HC10 INSTRUCTIONS
MOTOMAN-HC10DT INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
YRC1000micro INSTRUCTIONS
YRC1000micro OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000micro MAINTENANCE MANUAL
YRC1000micro ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
YRC1000/YRC1000micro INSTRUCTIONS FOR SmartPendant
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ii HW1484764
DANGER
•This manual explains the collaborative operation function of the
YRC1000/YRC1000micro system. Read this manual carefully and be sure to
understand its contents before handling the YRC1000/YRC1000micro. 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/YRC1000micro INSTRUCTIONS. To ensure correct and safe
operation, carefully read "Chapter 1. Safety" of the YRC1000/YRC1000micro
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/YRC1000micro.
In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”,
“CAUTION”, or “NOTICE”.
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.
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.
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 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.
Even items described as “CAUTION” may result in a serious accident in some
situations. At any rate, be sure to follow these important items.
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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DANGER
•Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or serious injury from
unexpected turning of the manipulator's arm.
WARNING
•Maintenance and inspection must be performed by specified personnel.
Failure to observe this caution may result in electric shock or injury.
•For disassembly or repair, contact your YASKAWA representative.
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<YRC1000>
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
•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. 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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<YRC1000micro>
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 button on the programming pendant or 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
•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 YRC1000micro 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 button is located on the upper right of the programming
pendant.
•Read and understand the Explanation of the Warning Labels before operating the
manipulator.
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<YRC1000micro only>
DANGER
•In the case of not using the programming pendant, be sure to supply the
emergency stop button on the equipment. Then before operating the manipulator,
check to be sure that the servo power is turned OFF by pressing the emergency
stop button.
Connect the external emergency stop button to the 4-14 pin and 5-15 pin of the
Safety connector (Safety).
•Upon shipment of the YRC1000micro, this signal is connected by a jumper cable
in the dummy connector. To use the signal, make sure to supply a new
connector, and then input it.
If the signal is input with the jumper cable connected, it does not function, which may
result in personal injury or equipment damage.
<YRC1000/YRC1000micro>
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.
•Return the programming pendant to a safe place 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.
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 the manipulator cables.
In this manual, the equipment is designated as follows:
Equipment
Manual Designation
YRC1000/YRC1000micro controller
YRC1000/YRC1000micro
YRC1000/YRC1000micro programming pendant
Programming pendant
Cable between the manipulator and the controller
Manipulator cable
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<YRC1000/YRC1000micro>
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}
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Description of the Operation Procedure
<YRC1000/YRC1000micro>
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
<YRC1000/YRC1000micro>
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.
Explanation of Warning Labels
<YRC1000/YRC1000micro>
The following warning labels are attached to the manipulator and
YRC1000/YRC1000micro.
Fully comply with the precautions on the warning labels.
DANGER
•The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
Failure to observe this caution may result in injury or damage to equipment.
Refer to the manipulator manual for the warning label location.
Fall down hazard label
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•The following warning labels are attached to YRC1000.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to equipment.
•The following warning labels are attached to YRC1000micro.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to equipment.
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List of contents
1. Introduction .........................................................................................................1-1
2. Functional Overview ...........................................................................................2-1
2.1. PFL Function ...................................................................................................2-3
2.2. Speed Monitor Function..................................................................................2-4
2.3. Avoidance Function.........................................................................................2-4
2.4. Force Detection Hold Function (Supported Only by YRC1000 System
Version YAS2.41 or Later and YRC1000micro System Version YBS2.10
or Later)...........................................................................................................2-5
2.5. Escape from Clamping Function.....................................................................2-6
2.6. Relationships among Various Stop Functions.................................................2-8
2.7. Direct Teach Function......................................................................................2-9
2.8. External Force Monitor Output......................................................................2-10
3. Configuring Each Function..................................................................................3-1
3.1. Changing the Security Mode...........................................................................3-1
3.2. Basic Settings for Collaborative Operation .....................................................3-2
3.2.1. Changing the External Force Limits........................................................3-2
3.2.2. Configuring the Speed Limit....................................................................3-6
3.3. Enabling or Disabling Collaborative Operation ...............................................3-7
3.3.1. Disabling Collaborative Operation by Changing the Safety
Logic Circuit............................................................................................3-8
3.3.2. Enabling or Disabling Collaborative Operation by Using
External Sensor Input...........................................................................3-10
3.4. Enabling or Disabling the PFL function .........................................................3-12
3.4.1. Steps for Disabling the PFL Function ...................................................3-12
3.4.2. Steps for Enabling the PFL Function ....................................................3-16
3.5. Configuring the Avoidance Function .............................................................3-20
3.5.1. Adding Instructions to a Job..................................................................3-20
3.5.2. Enabling the Avoidance Function..........................................................3-21
3.5.3. Setting the Start and End Thresholds...................................................3-23
3.5.4. Setting the Avoidance Speed................................................................3-23
3.5.5. Checking the Interrupt Job Settings......................................................3-24
3.6. Configuring the Force Detection Hold Function
(Supported Only by YRC1000 System Version YAS2.41 or Later and
YRC1000micro System Version YBS2.10 or Later)......................................3-25
3.7. Teaching the Manipulator with the Direct Teach Function.............................3-26
3.7.1. Moving the Robot Using the Hand Guiding ..........................................3-26
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3.7.2. Adding Operation Instructions to a Job by Using the Direct
Teach Button (for Only the MOTOMAN-HCxxDT (Equipped
with the Direct Teach Button)) ..............................................................3-29
4. Safety Precautions..............................................................................................4-1
4.1. How to Restart the Controller..........................................................................4-1
4.2. Check Items before Operating the Manipulator ..............................................4-1
4.3. About the Behavior near Singularity................................................................4-2
4.4. Settings Related to the Tool ............................................................................4-3
4.4.1. How to Configure the Tool File................................................................4-4
4.4.2. How to Configure the Tool Change Settings...........................................4-5
5. Daily Inspection Items.........................................................................................5-1
5.1. Checking the Torque Sensor Status................................................................5-1
5.1.1. Checking the Torque Sensor Status Using the Self-check Function
(Supported Only by YRC1000 System Version YAS2.52 or Later and
YRC1000micro System Version YBS2.10 or Later)...............................5-1
5.1.2. Checking the Torque Sensor Status Using the External Force
Monitor....................................................................................................5-3
5.2. How to Reconfigure the Torque Sensor Home Position..................................5-4
6. Troubleshooting ..................................................................................................6-1
7. Alarm List ............................................................................................................7-1
7.1. Major Alarms....................................................................................................7-1
7.2. Minor Alarms....................................................................................................7-9
8. Variable List.........................................................................................................8-1
9. I/O List.................................................................................................................9-1
9.1. Interface Panel Output ....................................................................................9-1
9.2. Auxiliary Relay.................................................................................................9-2
9.3. General Output................................................................................................9-3
9.4. General Input...................................................................................................9-4
9.5. External Outputs (used by the MOTOMAN-HC10xxDT
(equipped with the direct teach button))..........................................................9-5
9.5.1. YRC1000.................................................................................................9-5
9.5.2. YRC1000micro........................................................................................9-5
9.6. External Inputs (used by the MOTOMAN-HCxxDT
(equipped with the direct teach button))..........................................................9-5
9.6.1. YRC1000.................................................................................................9-5
9.6.2. YRC1000micro........................................................................................9-5
9.7. Control Status Signal.......................................................................................9-6
10. Register List ......................................................................................................10-1
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11. Default Settings of Function Safety General-Purpose I/O Signals ...................11-1
12. Default Settings of the Functional Safety Condition Files.................................12-1
13. Functions That Cannot be Used with Collaborative Operation
Simultaneously..................................................................................................13-1
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Introduction
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1. Introduction
The robot controller YRC1000/YRC1000micro provides functions to ensure that robots do not harm
workers working close to them for the enablement of human-robot collaborative operation.
This instruction manual explains how to use those functions.
When using the Smart Pendant, refer also to "HW1485509 YRC1000/YRC1000micro
INSTRUCTIONS FOR SmartPendant".
DANGER
Enabling human-robot collaborative operation requires you to conduct risk assessment on the entire
robot system taking into account the safety for humans and then reduce the danger of harm to
humans to a permissible level or implement the ISO (International Organization for Standardization)
standards for industrial robots (i.e., ISO 10218-1: 2011 and ISO 10218-2: 2011).
2. Functional Overview
Collaborative operation is supported mainly by the following functions:
Function name
Description
PFL (Power and
Force Limiting)
function
This function monitors the external force acting on the manipulator and
performs a protective stop of the manipulator if the external force exceeds the
preset limit.
Protective stop belongs to Stop Category 2.
After protective stop, "stop position monitoring" is performed using the "speed
limit function", one of the YRC1000/YRC1000micro functional safety
functions.
Speed monitor
function
This function limits the manipulator operating speed (TCP speed) to thereby
limit the force applied by the manipulator to its surroundings, using the
"speed limit function", one of the YRC1000/YRC1000micro functional safety
functions.
Avoidance
function
This function moves the manipulator in the direction where no force is acting
before the PFL function performs a protective stop of the manipulator.
Escape from
clamping
function
This function lets the manipulator automatically escape from a protective stop
condition due to something clamped (stuck) between the manipulator and
surrounding environment or between the joints of the manipulator.
Force detection
hold function
(supported only
by YRC1000)
This function stops the manipulator before the PFL function performs a
protective stop of the manipulator.
Direct teach
function
This function allows you to directly apply a force to the manipulator to move it
to the teaching position when you create a job (or teach the manipulator).
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Functional Overview
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■Collaborative operation and functional safety functions
The functions that support collaborative operation use some of the
YRC1000/YRC1000micro functional safety functions. Even if you disable collaborative
operation, you can still use the functional safety functions.
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Functional Overview
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2.1. PFL Function
The PFL (Power and Force Limiting) function stops the manipulator depending on the external force
acting on the manipulator with collaborative operation enabled.
With collaborative operation enabled, the PFL function monitors the external forces acting on the TCP
and each axis of the manipulator. If the external forces exceed the preset limit, it performs a protective
stop and puts the manipulator into the stop position monitoring state, i.e., the condition under which
the manipulator is subject to stop position monitoring by the functional safety functions. The job
execution is interrupted at this time. For information on how to configure the external force limit value,
refer to "3.2 Basic Settings for Collaborative Operation".
For YRC1000, the manipulator moves back a little along the path to reduce the impact
of collision when stopped by the PFL function. At this moment, a significant acceleration
occurs on the TCP, possibly resulting in vibration or noise.
If an external force remains acting in the stop position monitoring state, the manipulator may be
moved by the escape from clamping function described in Section 2.5.
With collaborative operation enabled, the collaborative operation lamp (shown below), located on the
cover between the T- and B-axes of the manipulator, lights up.
In addition, when in the stop position monitoring state, the resume switch (shown below) located below
the collaborative operation lamp lights up.
Pressing the resume switch while it is lit cancels the stop position monitoring and allows you to resume
the operation from the protective stop position.
Resume switch
Collaborative
operation lamp
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Functional Overview
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2.2. Speed Monitor Function
With collaborative operation enabled, the "speed limit function", one of the YRC1000/YRC1000micro
functional safety functions, limits the manipulator operating speed within the safe speed range. You
can change the speed limit but only to a speed lower than the factory default. For information on how
to configure the speed limit, refer to "3.2 Basic Settings for Collaborative Operation".
2.3. Avoidance Function
The avoidance function ensures the safe use of the manipulator by temporarily stopping or moving the
manipulator in the direction where no force is acting before the PFL function performs a protective stop
of the manipulator.
The avoidance function provides two avoidance modes that differ in how the manipulator moves.
Avoidance mode
Description
Joint mode
The avoidance operation is performed depending on the external
torque acting on each axis.
Translation mode
The avoidance operation is performed in the cartesian coordinate
system depending on the external force acting on the TCP.
When the avoidance function is enabled and the estimated external torque value for each axis
exceeds the start threshold for the avoidance function for the current mode, the mode-specific
interrupt job is executed.
The avoidance operation started when the estimated torque value for each axis exceeds the threshold
continues until the estimated external torque value for each axis drops below the end threshold for the
avoidance function (for each axis). The avoidance operation started when the estimated TCP external
force value exceeds the threshold continues until the estimated TCP external force value drops below
the end threshold for the avoidance function (for translation).
After the avoidance function ends, the suspended job is automatically resumed.
NOTICE
By factory default, the TCP speed is limited to 250 mm/s.
NOTICE
The avoidance function is not functions compliant with safety related standards.
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Functional Overview
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2.4. Force Detection Hold Function
(Supported Only by YRC1000 System Version YAS2.41 or Later and
YRC1000micro System Version YBS2.10 or Later)
The force detection hold function temporarily stops the job when the external force acting on the
manipulator exceeds the preset threshold with collaborative operation enabled. You can use this easily
configurable function to stop the manipulator more slowly than the PFL function.
When the manipulator is stopped by the force detection hold function, the [START] button lamp at the
top of the programming pendant goes off, the [HOLD] button lamp lights up, and the resume switch
located below the collaborative operation lamp lights up.
Pressing the resume switch while it is lit cancels the stop position monitoring and allows you to resume
the operation from the protective stop position.
NOTICE
The force detection hold function is not functions compliant with safety related standards.
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Functional Overview
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2.5. Escape from Clamping Function
With collaborative operation enabled, the PFL function described above puts the manipulator into a
stop position monitoring state in which it is not operable if something is clamped (stuck) between the
manipulator and surrounding environment or between the joints of the manipulator. The escape from
clamping function lets the manipulator escape from such a state.
If the PFL function performs a protective stop during collaborative operation and further the
manipulator is detected to be in a clamping state, the escape from clamping function determines which
axis of the manipulator was subjected to the highest torque and operates that axis in such a direction
that the manipulator can escape from the clamping state. During this process, the angular speed of
the axis is limited to 5 [deg/s].
When the manipulator escapes from the clamping state or the TCP's travel distance by the escape
operation reaches 50 [mm], the escape operation finishes and the manipulator goes into the stop
position monitoring state.
You can neither disable the escape from clamping function nor change the escape operation.
During the escape operation, the external force limit of the PFL function is temporarily set to the value
larger than the current external force. After the escape from clamping, the external force limit is reset
to the original setting and the job goes into the suspended state. You can resume the job from the
suspended position by pressing the resume switch to cancel the stop position monitoring state and
then pressing the [START] button.
After the escape, the
manipulator goes into
the stop position
monitoring state
Escape operation
on a single axis
Clamping occurs
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Functional Overview
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CAUTION
・Correctly configure the tool information by specifying the information on the hand and
workpiece. If it is not correctly configured, clamping state detection may fail, possibly causing
an unexpected operation of the manipulator.
・During the escape from clamping operation, the manipulator moves not in accordance with the
taught path.
・Do not input an external start instruction during the escape from clamping operation.
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