Robotic Arc Welding Manual

488 Pages·2014·10.37 MB·English

DX100
Robotic Arc Welding Manual
FOR LINCOLN ARCLINK XT INTERFACE
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN ROBOTIC ARC WELDING INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
Part Number: 158051-1CD
Revision: 5
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MANDATORY
• This manual explains the various components of the DX100 system
and general operations. Read this manual carefully and be sure to
understand its contents before handling the DX100.
• General items related to safety are listed in Section 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instruction 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.”
Indicates a potentially hazardous
WARNING situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous
CAUTION 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.
Always be sure to follow explicitly the
MANDATORY items listed under this heading.
Must never be performed.
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.
To ensure safe and efficient operation at all times, be sure
NOTE
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 when the emergency stop buttons on the front door of the DX
100 and programing pendant are pressed.
When the servo power is turned off, the SERVO ON LED on the
programing 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.
Figure1: 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.
Figure2: Release of EM
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.
– 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 working envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there are problems.
The emergency stop button is located on the right of the front door of
the DX 100 and programing pendant.
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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 cabinet
of the DX100 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.
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.
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller
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Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters printed on
Pendant 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.
GGOO BBAACCKK
ex. page key
PPAAGGEE
The cursor key is an exception, and a picture
is not shown.
Axis Keys “Axis Keys” and “Numeric Keys” are generic
Numeric Keys names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously 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}
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.
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.
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Robotic Arc Welding Table of Contents
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Table of Contents
1 Introduction.....................................................................................................................................1-1
1.1 DX100 Overview................................................................................................................1-1
1.2 Programming Pendant.......................................................................................................1-2
1.2.1 Programming Pendant Overview..........................................................................1-2
1.2.2 Key Description....................................................................................................1-3
1.2.2.1 Character Keys.......................................................................................1-3
1.2.2.2 Symbol Keys...........................................................................................1-3
1.2.2.3 Axis Keys and Numeric Keys..................................................................1-3
1.2.2.4 Keys Pressed Simultaneously.................................................................1-3
1.2.3 Programming Pendant Keys.................................................................................1-4
1.2.4 Programming Pendant Display...........................................................................1-11
1.2.4.1 Five Display Areas................................................................................1-11
1.2.4.2 General-purpose Display Area..............................................................1-11
1.2.4.3 Main Menu Area....................................................................................1-13
1.2.4.4 Status Display Area...............................................................................1-13
1.2.4.5 Human Interface Display Area..............................................................1-15
1.2.4.6 Menu Area.............................................................................................1-16
1.2.5 Screen Descriptions...........................................................................................1-17
1.2.6 Character Input Operation..................................................................................1-18
1.2.6.1 Character Input.....................................................................................1-18
1.2.6.2 Operation..............................................................................................1-18
1.2.6.3 Alphanumeric Input...............................................................................1-19
1.2.6.4 Symbol Input.........................................................................................1-19
1.3 Mode................................................................................................................................1-21
1.3.1 Teach Mode.......................................................................................................1-21
1.3.2 Play Mode..........................................................................................................1-21
1.3.3 Remote Mode.....................................................................................................1-21
1.3.4 Teach Mode Priority...........................................................................................1-21
1.4 Security Mode..................................................................................................................1-22
1.4.1 Types of Security Modes....................................................................................1-22
1.4.2 Changing Security Modes..................................................................................1-26
2 Manipulator Coordinate Systems and Operations..........................................................................2-1
2.1 Control Groups and Coordinate Systems..........................................................................2-1
2.1.1 Control Group.......................................................................................................2-1
2.1.2 Types of Coordinate Systems..............................................................................2-2
2.2 General Operations...........................................................................................................2-3
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2.2.0.1 Check Safety...........................................................................................2-3
2.2.0.2 Select Teach Mode.................................................................................2-3
2.2.0.3 Select Control Group...............................................................................2-3
2.2.0.4 Select Coordinate System.......................................................................2-3
2.2.0.5 Select Manual Speed..............................................................................2-3
2.2.0.6 Servo ON.................................................................................................2-4
2.2.0.7 Axis Operation.........................................................................................2-4
2.2.0.8 HIGH SPEED..........................................................................................2-4
2.3 Coordinate Systems and Axis Operation...........................................................................2-5
2.3.1 Joint Coordinates..................................................................................................2-5
2.3.2 Cartesian Coordinates..........................................................................................2-6
2.3.3 Cylindrical Coordinates.........................................................................................2-7
2.3.4 Tool Coordinates..................................................................................................2-9
2.3.4.1 Selecting Tool........................................................................................2-10
2.3.5 User Coordinates................................................................................................2-11
2.3.5.1 Selecting User Coordinates...................................................................2-12
2.3.5.2 Examples of User Coordinate Utilization...............................................2-13
2.3.6 External Axis.......................................................................................................2-14
2.3.7 Control Point Operation......................................................................................2-14
2.3.7.1 Control Point Change............................................................................2-17
3 Teaching.........................................................................................................................................3-1
3.1 Preparation for Teaching...................................................................................................3-1
3.1.1 Checking Emergency Stop Buttons......................................................................3-1
3.1.2 Setting the Teach Lock.........................................................................................3-1
3.1.3 Registering a Job..................................................................................................3-2
3.1.3.1 Registering Job Names...........................................................................3-2
3.1.3.2 Registering Jobs......................................................................................3-2
3.1.3.3 Registering Comments............................................................................3-3
3.1.3.4 Registering Control Groups.....................................................................3-3
3.1.3.5 Switching to the Teaching Window..........................................................3-3
3.2 Teaching Operation...........................................................................................................3-4
3.2.1 Teaching Window.................................................................................................3-4
3.2.2 Interpolation Type and Play Speed.......................................................................3-5
3.2.2.1 Joint Interpolation....................................................................................3-5
3.2.2.2 Linear Interpolation..................................................................................3-6
3.2.2.3 Circular Interpolation...............................................................................3-7
3.2.2.4 Spline Interpolation..................................................................................3-8
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3.2.3 Teaching Steps..................................................................................................3-10
3.2.3.1 Registering Move Instructions...............................................................3-10
3.2.3.2 Registering Reference Point Instructions..............................................3-16
3.2.3.3 Registering Timer Instructions...............................................................3-17
3.2.4 Overlapping the First and Last Steps.................................................................3-20
3.3 Checking Steps................................................................................................................3-21
3.3.1 FWD/BWD Key Operations................................................................................3-21
3.3.1.1 Precautions When Using FWD / BWD Operations................................3-21
3.3.1.2 Selecting Manual Speed.......................................................................3-23
3.3.1.3 Moving to Reference Point....................................................................3-24
3.3.1.4 Test Operations.....................................................................................3-24
3.3.1.5 Machine Lock Operation.......................................................................3-25
3.4 Modifying Steps...............................................................................................................3-26
3.4.1 Displaying the JOB CONTENT Window for Editing............................................3-30
3.4.1.1 Currently Called Up Job........................................................................3-30
3.4.1.2 Calling Up Other Jobs...........................................................................3-30
3.4.2 Inserting Move Instructions.................................................................................3-31
3.4.3 Deleting Move Instructions.................................................................................3-32
3.4.4 Modifying Move Instructions...............................................................................3-33
3.4.4.1 Modifying Position Data.........................................................................3-33
3.4.4.2 Modifying Interpolation Type.................................................................3-33
3.4.5 Undo Operation..................................................................................................3-34
3.4.6 Modifying Reference Point Instructions..............................................................3-35
3.4.6.1 Deleting Reference Point Instructions...................................................3-35
3.4.6.2 Modifying Reference Point Instructions.................................................3-35
3.4.7 Modifying Timer Instructions...............................................................................3-36
3.4.7.1 Deleting Timer Instructions....................................................................3-36
3.4.7.2 Modifying Timer Instructions.................................................................3-36
3.5 Modifying Jobs.................................................................................................................3-37
3.5.1 Calling Up a Job.................................................................................................3-37
3.5.2 Windows Related to Job.....................................................................................3-37
3.5.3 JOB HEADER Window.......................................................................................3-38
3.5.4 JOB CONTENT Window....................................................................................3-39
3.5.4.1 COMMAND POSITION Window...........................................................3-40
3.5.5 JOB CAPACITY Window....................................................................................3-41
3.6 Editing Instructions..........................................................................................................3-42
3.6.1 Instruction Group................................................................................................3-43
3.6.2 Inserting Instructions..........................................................................................3-44
3.6.3 Deleting Instructions...........................................................................................3-47
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3.6.4 Modifying Instructions.........................................................................................3-47
3.6.5 Modifying Additional Numeric Data.....................................................................3-51
3.6.6 Modifying Additional Items..................................................................................3-52
3.6.7 Inserting Additional Items...................................................................................3-53
3.6.8 Deleting Additional Items....................................................................................3-54
3.7 Editing Jobs.....................................................................................................................3-55
3.7.1 Selecting the Range...........................................................................................3-57
3.7.2 Copying..............................................................................................................3-58
3.7.3 Cutting................................................................................................................3-58
3.7.4 Pasting................................................................................................................3-59
3.7.5 Reverse Pasting.................................................................................................3-60
3.8 Test Operations...............................................................................................................3-61
3.8.1 Test Operation Procedures.................................................................................3-61
3.9 Other Job-editing Functions.............................................................................................3-62
3.9.1 Editing Play Speed.............................................................................................3-62
3.9.1.1 Modification of Speed Type...................................................................3-62
3.9.1.2 Relative Modification.............................................................................3-62
3.9.1.3 Modification by TRT (Traverse Time)....................................................3-64
3.9.2 Editing Interpolation Type...................................................................................3-66
3.9.3 Editing Condition Files........................................................................................3-67
3.9.4 User Variables....................................................................................................3-68
3.9.4.1 Setting Byte, Integer, Double Precision Integer, and
Real Type Variables..............................................................................3-69
3.9.4.2 Setting Character Type Variables..........................................................3-71
3.9.4.3 Registering Variable Name....................................................................3-72
3.9.4.4 Displaying Position Variables................................................................3-73
3.9.4.5 Setting Position Variables......................................................................3-74
3.9.4.6 Setting Position Variables Using the Numeric Keys..............................3-75
3.9.4.7 Setting Position Variables Using the Axis Keys.....................................3-77
3.9.4.8 Deleting Data Set of Position Variables.................................................3-78
3.9.4.9 Checking Positions by Position Variables.............................................3-78
3.9.4.10 Manipulator Types...............................................................................3-79
3.9.5 Flip/No Flip..........................................................................................................3-80
3.9.6 R-axis Angle.......................................................................................................3-80
3.9.7 T-axis Angle........................................................................................................3-81
3.9.8 Front/Back..........................................................................................................3-81
3.9.9 Upper Arm/Lower Arm........................................................................................3-83
3.9.10 S-axis Angle......................................................................................................3-83
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