YASKAWA MOTOMAN DX100 User manual

MANUAL NO.
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YASKAWA ELECTRIC CORPORATION
DX100 OPTIONS
INSTRUCTIONS
FOR MULTISTEP PRESSURE FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-- INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 Operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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Part Number: 159046-1CD
Revision: 0

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MANDATORY
• This manual explains the multistep pressure function of the DX100
system. Read this manual carefully and be sure to understand its
contents before handling the DX100.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• 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.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items
WARNING Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
MANDATORY Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED Must never be performed.
NOTE To ensure safe and efficient operation at all times, be sure to
follow all instructions, even if not designated as "CAUTION"
and "WARNING".
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WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem. The emergency stop buttons are
located on the right of the front door of the DX100 and the programming
pendant.
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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:
CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the DX100
cabinet after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and DX100 Manipulator Cable
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Descriptions of the programming pendant, 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 the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Equipment Manual Designation
Programming
Pendant Character Keys The keys which have characters printed on them are denoted with [ ].
ex. [ENTER]
Symbol
Keys The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small
picture.
ex. page key
The cursor key is an exception, and a picture is
not shown.
Axis Keys
Number Keys “Axis Keys” and “Number Keys” 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}
PAGE
GO BACK
PAGE
GO BACK
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DX100 Contents
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1 Multistep pressure function .............................................................................................................1-1
1.1 Features.............................................................................................................................1-1
1.2 Restrictions ........................................................................................................................1-3
2 How to Use the Multistep Pressure Function..................................................................................2-1
2.1 Setting the Functions of the Multistep Pressure Function..................................................2-1
2.1.1 Pressure File Window...........................................................................................2-1
2.1.2 DETAIL EDIT Window ..........................................................................................2-2
2.1.3 Details of the SVSPOT Instruction........................................................................2-4
2.1.4 Details of the SVSPOTMOV Instruction ...............................................................2-5
2.2 Corrective Action in the Event that a WELD COMPLETE SIGNAL ERROR Alarm Occurs
...........................................................................................................................................2-6
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1 Multistep pressure function
DX100 1.1 Features
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1 Multistep pressure function
The conventional DX100 spot welding instruction (SVSPOT/
SVSPOTMOV) was ended, and the motor gun was opened, when one
welding completion signal was received. The multistep pressure function
is an extension of the conventional welding command. It starts the power
source multiple times (maximum of four times) during the first opening and
closing operation of the motor gun, enabling high quality spot welding to
be realized.
1.1 Features
The multistep pressure function has the functions and features indicated
in the table below.
The operation of the motor gun during multistep pressurization, and the
relationship between the gun pressure and the signal are as shown in the
figure below.
Motor gun operation (SVSPOTMOV, 2-Step pressure)
No. Functions and Features Advantages
1 It extends the SVSPOT/
SVSPOTMOV instruction, and
permits multistage pressurization in
up to four steps.
Higher quality spot welding can be
realized.
2 The number of pressurization steps
can be specified in the DETAIL EDIT
window for the SVSPOT/
SVSPOTMOV instruction.
The number of pressurization steps
can be varied between one and four
times.
3 Multiple “END WAIT” settings can
be made in the pressure file window. The pressure value at each step of multistep pressurization can be set in
detail.
Movable
electrode
(Close operation) (First pressurization) (Second pressurization) (Open motion)
1 SVSPOTMOV 2 SVSPOTMOV 3 SVSPOTMOV 4 SVSPOTMOV
Fixed
electrode
clearance file.
The gun stroke is set in the
teaching.
points is done by pressurization
Teaching of the pressurization A welding command is output twice,
and welding takes place twice.
Welding is completed at the second
welding completion signal.
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1 Multistep pressure function
DX100 1.1 Features
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Relationship between the gun pressure and the signal
When the pressure reaches the first pressure value after the motor gun
touched the workpiece, the welding start signal is output to the timer.
As soon as the first welding completion signal is input from the timer, the
motor gun proceeds to the second pressure value.
After the second pressure value is reached, the second welding start
signal is output.
As soon as the second welding completion signal is input from the timer,
the motor gun stops pressurization, and then opens.
value
pressure
First value
pressure
Second
Gun stroke
start signal
Welding
(Robot →Timer)
signal
completion
Welding
(Timer →Robot)
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1 Multistep pressure function
DX100 1.2 Restrictions
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1.2 Restrictions
cThe maximum number of multistep pressurizations in this function is the
upper limit (four) of the number of pressurization settings in “Pressure
file.”
dThe “welding conditions group output: WGO=” is common for one
multistep pressurization welding operation.
(The welding conditions group output value in each welding condition
output cannot be changed during multistep pressurization welding.)
eWhen multistep pressurization welding is taking place, I/O output
control of the power source start signal according to "WELD INST
OUTPUT TYPE" and "OUTPUT TIMING (WST)" in the Power Source
condition file is applied only to the first start signal output. The second
and subsequent start signal outputs are assumed to level-output
"WELDING COND (WTM)" and "WELDING COMMAND" at the same
timing.
fThe execution timing for bending correction is the same as that of the
current DX100.
(Bending correction does not take place during the second and
subsequent pressurization welding phases.)
gWhen the power source is restarted after being interrupted during
multistep pressurization welding, the welding sequence from the first
pressurization is reattempted.
hThe actual pressure values in the case where the pressure rises from
the first pressure value to the Nth pressure value may differ from the
corresponding values in the case where the pressure falls, due friction
torque, for example, even when the set pressure values on the gun
pressure window are the same.
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