YASKAWA MH SIGMA-5 Series User manual

MANUAL NO.
0
162068-1CD
Part Number: 162068-1CD
Revision: 1
MH-SERIES
SIGMA-5 POSITIONER MANUAL
MH95, MH185, MH505, MH1605, and MH3105
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
DX100OPERATOR’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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MANDATORY
General items related to safety are listed in Section 2 of the DX100
Controller Manual. To ensure correct and safe operation, carefully read
the DX100 Controller Manual before reading this manual.
CAUTION
• 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 a 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 the
products warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the MH-SERIES POSITIONER.
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
personnelanddamageto 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 MH-SERIES POSITIONER, check that servo
power is turned OFF by pressing the EMERGENCY STOP buttons
on the operator station or Programming Pendant (refer to Figure 1).
When 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 positioner during an emergency. The positioner should
not be used if the EMERGENCY STOP buttons do not function.
Figure 1: EMERGENCY STOP Button
• Release the EMERGENCY STOP button (refer to Figure 2). Once
this button is released, clear the cell of all items which could
interfere with the operation of the positioner then, turn servo power
ON.
Injury may result from unintentional or unexpected positioner motion.
Figure 2 : Release of EMERGENCY STOP Button
TURN
• Observe the following precautions when performing teaching
operations within the working envelope of the positioner:
– View the positioner from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that there is a safe place to retreat to in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the working envelope of the
positioner and that you are in a safe location before:
– Turning on the power for the DX100 controller.
– Moving the positioner with the Programming Pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the working envelope of the
positioner during operation. Always press an EMERGENCY STOP
button immediately if there is a problem. The EMERGENCY STOP
buttons are located on the operator station and on the Programming
Pendant.
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Definition of Terms Used Often in This Manual
The positioner usually consists of 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
positioner teaching. If problems are found, repair them immediately
and be sure that all other necessary processing has been
performed.
– Check for problems in positioner movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the Programming Pendant to the hook on the cabinet
of the DX100 controller after use.
• The Programming Pendant can be damaged if it is left in the work
area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Controller Manual before operating the MH-SERIES
POSITIONER.
Equipment Manual Designation
DX100 controller DX100
DX100 Programming Pendant Programming Pendant
Cable between the positioner and the
controller Power cables
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POSITIONER Table of Contents
1 Introduction.....................................................................................................................................1-1
1.1 About this Document .........................................................................................................1-1
1.2 System Overview...............................................................................................................1-2
1.3 System Layout...................................................................................................................1-2
1.3.1 System Layout......................................................................................................1-4
1.4 Customer Support Information...........................................................................................1-7
2 Safety..............................................................................................................................................2-1
2.1 Introduction........................................................................................................................2-1
2.2 General Safeguarding Tips................................................................................................2-1
2.3 Mechanical Safety Devices................................................................................................2-2
2.4 Installation Safety ..............................................................................................................2-2
2.5 Programming, Operation, and Maintenance Safety...........................................................2-3
3 Equipment Description....................................................................................................................3-1
3.1 General Information...........................................................................................................3-1
3.2 MH-Series SIGMA-5 Positioner Assembly – Type I ..........................................................3-1
3.2.1 MH-Series SIGMA-5 Positioner Type I – Specifications.......................................3-2
3.3 MH-Series SIGMA-5 Positioner Assembly – Type II .........................................................3-3
3.3.1 MH3105-Series SIGMA-5 Positioner, Type II – Specifications.............................3-4
3.4 MotoMount™.....................................................................................................................3-5
4 Installation.......................................................................................................................................4-1
4.1 Materials Required.............................................................................................................4-1
4.1.1 Customer-Supplied Items.....................................................................................4-1
4.1.2 List of Tools..........................................................................................................4-1
4.2 Installing the MH-Series SIGMA-5 Positioner – Type I......................................................4-2
4.2.1 Site Preparation....................................................................................................4-2
4.2.2 Unpacking ............................................................................................................4-2
4.2.3 Headstock Assembly Mounting Hole Pattern – MH95/185/505/1605...................4-3
4.2.4 Column Assembly Mounting – Type I Assembly..................................................4-5
4.2.5 Connecting the Cables.........................................................................................4-7
4.2.6 Home Position......................................................................................................4-7
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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II.....................................................4-8
4.3.1 Site Preparation....................................................................................................4-8
4.3.2 Unpacking.............................................................................................................4-8
4.3.3 Unbolting the Drive Assembly Floor Mounting – Type II.......................................4-9
4.3.4 Connecting the Cables .......................................................................................4-11
4.3.5 Home Position ....................................................................................................4-11
4.4 Tailstock Column Installation...........................................................................................4-12
4.4.1 Type I Installation................................................................................................4-12
4.4.2 Type II Installation...............................................................................................4-13
4.4.3 Leveling the Tailstock.........................................................................................4-14
4.4.4 Tooling Fixture Installation (initial)......................................................................4-17
4.4.5 Tooling Fixture Installation (regular)...................................................................4-18
4.4.6 Final Alignment Check........................................................................................4-18
4.4.7 Tooling Fixture Removal.....................................................................................4-21
4.5 MotoMount Installation.....................................................................................................4-22
4.5.1 Preparation.........................................................................................................4-22
4.5.2 Unpack and Assemble........................................................................................4-22
4.5.3 Securing MotoMount Drive Components onto Faceplate...................................4-24
4.5.4 Retrofitting Tailstock Assembly...........................................................................4-24
4.6 MotoMount HD Adjustments............................................................................................4-25
4.6.1 Allowable Misalignment......................................................................................4-25
4.6.2 Tooling Fixture Installation – MotoMount HD......................................................4-26
4.6.3 Tooling Fixture Removal.....................................................................................4-26
4.6.4 Variable Tooling Size Accommodations.............................................................4-27
4.7 Conducting a Safety/Operation Check.............................................................................4-27
5 Tooling Recommendations .............................................................................................................5-1
5.1 Headstock Only – Tooling Recommendations...................................................................5-1
5.1.1 Customer-supplied Tooling Fixture.......................................................................5-2
5.2 Headstock/Tailstock with MotoMount ................................................................................5-5
5.2.1 Customer-supplied Tooling Fixtures.....................................................................5-5
5.2.2 Multiple Tooling Fixtures.......................................................................................5-5
5.2.3 Specifications........................................................................................................5-5
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6 Maintenance ...................................................................................................................................6-1
6.1 Spare Parts........................................................................................................................6-1
6.2 Servomotor........................................................................................................................6-1
6.3 Weld Ground Brush Replacement – Type I.......................................................................6-2
6.3.1 MH95/185/505/1605.............................................................................................6-2
6.4 Weld Ground Brush Replacement – Type II......................................................................6-5
6.4.1 MH3105................................................................................................................6-5
6.5 Reset Headstock To Home Position..................................................................................6-7
6.5.1 Homing.................................................................................................................6-7
6.6 Maintenance Schedule....................................................................................................6-11
6.6.1 MH-Series SIGMA-5 Positioner..........................................................................6-11
6.6.2 MotoMount .........................................................................................................6-11
6.7 Troubleshooting...............................................................................................................6-12
6.7.1 MH-Series SIGMA-5 Positioner..........................................................................6-12
6.7.2 MotoMount .........................................................................................................6-12
A Performance Charts .......................................................................................................................A-1
A.1 MH-Series Positioner Assemblies.....................................................................................A-1
A.1.1 MH95 ...................................................................................................................A-1
A.1.2 MH185 .................................................................................................................A-2
A.1.3 MH505 .................................................................................................................A-3
A.1.4 MH1605 ...............................................................................................................A-4
A.1.5 MH3105 ...............................................................................................................A-5
B Illustrated Parts list.........................................................................................................................B-1
B.1 Introduction .......................................................................................................................B-1
B.1.1 Contents...............................................................................................................B-1
B.1.2 Parts List..............................................................................................................B-1
B.1.3 Symbols and Abbreviations..................................................................................B-2
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1 Introduction
1.1 About this Document
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1 Introduction
1.1 About this Document
This manual provides the following information:
CHAPTER 1 – INTRODUCTION
Provides general information about the MH-SERIES POSITIONER
system and components and customer support contact information.
CHAPTER 2 – SAFETY
Provides general safety information regarding installation, maintenance,
and operation.
CHAPTER 3 – DESCRIPTION OF EQUIPMENT
Provides a description of the major components.
CHAPTER 4 – INSTALLATION
This chapter provides installation procedures.
CHAPTER 5 – TOOLING RECOMMENDATIONS
This chapter provides guidelines for customer-supplied tooling design.
CHAPTER 6 – MAINTENANCE
This chapter provides preventive maintenance requirements for certain
components MH-SERIES POSITIONER.
APPENDIX A – PERFORMANCE CHARTS
This appendix provides performance charts for each of the MH-SERIES
POSITIONER.
APPENDIX B – ILLUSTRATED PARTS LIST
This appendix contains the Illustrated Parts List (IPL). The IPL provides
detailed views (with part numbers).
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1.2 System Overview
1.2 System Overview
The MH-SERIES POSITIONER Assembly is available in four basic
mechanical configurations:
• The Drive Assembly
• The Drive Assembly with MotoMount
• The Headstock Positioner Assembly
• The Headstock and Tailstock Positioner Assembly
These assemblies are combined with the appropriate single or multiple
external axis control packages to provide a complete positioner kit.
1.3 System Layout
The two major components of a typical headstock and tailstock positioner
assembly (MHT) are;
• MHT System Layout Type I (Fig. 1-1)
• MHT System Layout Type II (Fig. 1-2)
WARNING
Do not use a MotoMount™ with stand-alone headstock (no tailstock)
applications. Use of a stand-along application will result in uncontrolled
tooling motion.
NOTE
The warranty is void if the Yaskawa drive or headstock
assembly is integrated with other than a Yaskawa tailstock
or MotoMount system.
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1 Introduction
1.3 System Layout
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Fig. 1-1: MHT System Layout - Type I
Fig. 1-2: MHT System Layout - Type II
DRIVE
ASSEMBLY
MotoMount™
ASSEMBLY (HS)
AC SERVO
MOTOR
MotoMount™
ASSEMBLY (TS)
TAILSTOCK
COLUMN
STANDARD
TOOL RADIUS
LEVELING
SCREW, TYP
HEADSTOCK
COLUMN
MotoMount™
HEADSTOCK
ASSEMBLY
S TANDARD
TOOL RADIUS
FORKLIFT
POCKETS
HOUSING
MotoMount™
TAILSTOCK
ASSEMBLY
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1.3 System Layout
1.3.1 System Layout
The modular drive assembly provides precision-controlled rotary motion
and can be mounted in any orientation that the welding, material handling,
or dispensing application might require. The standard configuration
utilizes an AC servo motor, a high ratio gear reducer with integral output
bearing, faceplate, and a cast iron housing. It also includes dual integral
position switches and weld ground brushes.
1.3.1.1 Drive Assembly with MotoMount
The Drive Assembly combined with the MotoMount compliant tool
mounting system provides headstock and tailstock components for
applications requiring custom headstock and tailstock supporting
structures. MotoMount is a modular accessory for MHT positioners that
provides improved repeatability as compared to hard-mounted tooling
systems.
Fig. 1-3: Drive Assembly and MotoMount Assembly
Drive Assembly
MotoMount
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1.3 System Layout
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1.3.1.2 Headstock Assembly
The Headstock Assembly integrates the drive assembly with a column
that is designed to be floor-mounted or mounted to a machine base, as
required for use in cantilevered (stand-alone) applications. The standard
configuration provides connectors in the column for motor control and
safety circuits. Leveling bolts are included. The user must provide suitable
anchor bolts.
Fig. 1-4: Headstock Assembly
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1.3 System Layout
1.3.1.3 Positioner Assembly (headstock and tailstock)
The positioner assembly integrates the headstock with a tailstock column
and the MotoMount compliant tool mounting system. This system is
designed to be floor-mounted or mounted to a machine base. Span
between the headstock and tailstock is determined by the application. The
standard configuration provides a 815-mm tooling sweep radius.
Fig. 1-5: Positioner Assembly (headstock and tailstock)
NOTE
If integrating the Yaskawa drive or headstock assembly with
other than Yaskawa tailstock or the MotoMount system voids
the warranty
TailStock
Assembly
HeadStock
Assembly
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1.4 Customer Support Information
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1.4 Customer Support Information
If you need assistance with any aspect of your MH-SERIES POSITIONER
system, please contact Yaskawa Motoman Customer Support at the
following 24-hour telephone number:
For routine technical inquiries, you can also contact Yaskawa Motoman
Customer Support at the following e-mail address:
When using e-mail to contact Yaskawa Motoman Customer Support,
please provide a detailed description of your issue, along with complete
contact information. Please allow approximately 24 to 36 hours for a
response to your inquiry.
Please have the following information ready before calling:
[e-mail]
NOTE
Please use e-mail for routine inquiries only. If an urgent or
emergency need for service, replacement parts, or
information, contact Yaskawa Motoman Customer Support
at the telephone number shown above.
• System MH-SERIES POSITIONER
• Robots
• Software Version Access this information on the
Programming Pendant’s LCD display
screen by selecting {MAIN MENU} -
{SYSTEM INFO} - {VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX100 controller data
plate
[phone]
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2.1 Introduction
2 Safety
2.1 Introduction
It is the purchaser’s responsibility to ensure that all local, county, state,
and national codes, regulations, rules, or laws relating to safety and safe
operating conditions for each installation are met and followed.
We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-1999). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: [phone]
FAX: [phone]
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the robot
system. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the robot cell. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE ROBOT SYSTEM!
We recommend approved Motoman training courses for all personnel
involved with the operation, programming, or repair of the robot system.
This training is designed to familiarize personnel with the safe and correct
operation of the robot system.
2.2 General Safeguarding Tips
All operators, programmers, plant and tooling engineers, maintenance
personnel, supervisors, and anyone working near the robot must become
familiar with the operation of this equipment. All personnel involved with
the operation of the equipment must understand potential dangers of
operation. General safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to
the equipment. Only trained personnel familiar with the operation of
this robot, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this robot
system.
• Do not enter the robot cell while it is in automatic operation.
Programmers must have the teach pendant when they enter the
robot cell.
• Improper connections can damage the robot. All connections must
be made within the standard voltage and current ratings of the robot
I/O (Inputs and Outputs).
• The robot must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
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2 Safety
2.3 Mechanical Safety Devices
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• In accordancewith ANSI/RIA R15.06-1999, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
2.3 Mechanical Safety Devices
The safe operation of the robot, positioner, auxiliary equipment, and
system is ultimately the user's responsibility. The conditions under which
the equipment will be operated safely should be reviewed by the user. The
user must be aware of the various national codes, ANSI/RIA R15.06-1999
safety standards, and other local codes that may pertain to the installation
and use of industrial equipment. Additional safety measures for personnel
and equipment may be required depending on system installation,
operation, and/or location. The following safety equipment is provided as
standard:
• Safety fences and barriers
• Light curtains and/or safety mats
• Door interlocks
• Emergency stop palm buttons located on operator station, robot
controller, and programming pendant
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
2.4 Installation Safety
Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace,
existing federal, local, and state laws and regulations. Additional safety
measures for personnel and equipment may be required depending on
system installation, operation, and/or location. Installation tips are as
follows:
• Be sure that only qualified personnel familiar with national codes,
local codes, and ANSI/RIA R15.06-1999 safety standards are
permitted to install the equipment.
• Identify the work envelope of each robot with floor markings, signs,
and barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against
unauthorized entry into the work envelope.
• Eliminate areas where personnel might get trapped between a
moving robot and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching
and maintenance procedures.
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2.5 Programming, Operation, and Maintenance Safety
2.5 Programming, Operation, and Maintenance Safety
All operators, programmers, plant and tooling engineers, maintenance
personnel, supervisors, and anyone working near the robot must become
familiar with the operation of this equipment. Improper operation can
result in personal injury and/or damage to the equipment. Only trained
personnel familiar with the operation, manuals, electrical design, and
equipment interconnections of this robot should be permitted to program,
operate, and maintain the system. All personnel involved with the
operation of the equipment must understand potential dangers of
operation.
• Inspect the robot and work envelope to be sure no potentially
hazardous conditions exist. Be sure the area is clean and free of
water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment
for proper operation. Repair or replace any non-functioning safety
equipment immediately.
• Do not enter the robot cell while it is in automatic operation. Be sure
that only the person holding the programming pendant enters the
workcell.
• Check the E-Stop button on the programming pendant for proper
operation before programming. The robot must be placed in
Emergency Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are
done and before any changes are made to options, accessories, or
equipment.
• Any modifications to PART 1, System Section, of the robot controller
concurrent I/O program can cause severe personal injury or death,
as well as damage to the robot! Do not make any modifications to
PART 1, System Section. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require
special passwords. Special passwords are for Motoman use only.
YOUR WARRANTY WILL BE VOID if you use these special
passwords.
• The robot controller allows modifications of PART 2, User Section, of
the concurrent I/O program and modifications to controller
parameters for maximum robot performance. Great care must be
taken when making these modifications. All modifications made to
the controller will change the way the robot operates and can cause
severe personal injury or death, as well as damage the robot and
other parts of the system. Double-check all modifications under
every mode of robot operation to ensure that you have not created
hazards or dangerous situations.
• Check and test any new or modified program at low speed for at
least one full cycle.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
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• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the robot. All connections must
be made within the standard voltage and current ratings of the robot
I/O (Inputs and Outputs).
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