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YK-XG series U/M English

1. Y axis origin sensor stay Y axis origin sensor Fig 4 6 4 18 CHAPTER 4 Adjustment 2 2 Changing the Y axis origin position The Y axis origin position can be changed to any position in the range from the front position of the Y axis arm and X axis arm to a maximum of 120 clockwise and counterclockwise at 30 intervals by changing the positions of the dog and the mounting bolt for the Y axis speed reduction unit as shown in Fig 4 7 CAUTION f the origin position has been changed then the absolute reset must be performed the machine reference must be adjusted and the standard coor dinate and point data must be reset The dog and bolt might come off and cause the joint to lock up unless you apply Screw Lock to them and tighten to the specified torque The following describes the method for changing the Y axis origin position for example to a position 90 counterclockwise 1 Prepare the necessary tools Hex wrench set Torque wrench Phillips screwdriver Screw Lock thread sealant Phillips screwdriver bit Hex bit 2 Check that no one is inside the safeguard enclosure and then turn on the controller 3 Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method 4 Place a sign indicating that
2. 3 11 CHAPTER 3 Installation 5 User Wiring and User Tubing Always turn off the controller and shut off air supply before attempting wiring and piping work If air or power is supplied during this work the manipulator may move erroneously causing a hazardous situation 1 The YK XG series robots are equipped with user wires and air tubes in the machine harness The table below shows the number of wires and air tubes available for each robot model YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 20 wires 6 3 tubes Robot models for custom specifications may have different wiring or tub ing The specifications of the user wires and air tubes are shown below Always observe the specifications User Wiring Rated voltage Allowable current Nominal cross section area of conductor Shield User Tubing Maximum pressure 0 58MPa 6Kgf cm Outer diameter x inner diameter o6mmxd4mm Fluid Dry clean air not containing deteriorated compressor oil filtration 40um or less 2 D sub connector for user wiring and a bulkhead union for user tubing are provided one each on the arm side and pedestal side For the locations refer to 1 2 External view and dimensions in Chapter 7 3 12 CHAPTER 3 Installation ee ee eee 3 Signal wiring connections in the ma
3. YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 5 12 5 26 CHAPTER 5 Periodic Inspection eee 3 R axis 1 Prepare the following tools and items Harmonic grease 4B No 2 Waste cloth rag Phillips screwdriver Hex wrench set Screw Lock thread sealant Torque wrench Hook wrench Replacement parts See table below YK500XG YK600XG Replacement parts Parts name Type No YAMAHA Parts No Note Harmonic drive SHF 17 30 KBF M1821 000 CD Rubber wire diameter 1 78mm x Ring inner diameter 63 22mm KN4 M1896 000 Lower part of harmonic drive 2 Rubber wire diameter 0 80mm x Ring inner diameter 45 40mm KN3 M257L 000 Supplied with harmonic drive O ring 3 Rubber wire diameter 1 00mm x Ring inner diameter 35 3mm 90990 17J031 Spline nut 4 Rubber wire diameter 1 00mm x Ring inner diameter 46 00mm 90990 17J032 Y axis arm 5 Rubber wire diameter 0 60mm x Ring inner diameter 22 00mm 90990 17J033 Wave generator Edge seal V 25A N C KBF M1886 000 FORSHEDA YK600XGH YK700XG YK800XG YK900XG YK1000XG Replacement parts Parts name Type No YAMAHA Parts No Note Harmonic drive SHF 20 50 KBP M1821 000 CD 71015 KN3 M2159 000 Lower part of harmonic drive 2 Rubber wire diameter 0 99mm x Ring inner diameter 53 28mm KN3 M2144 000 Supplied with harmonic drive O ring 3 Rubber wire diameter 1 00mm x Rin
4. 3 12 6 Attaching the End 3 16 6 1 R axis tolerable moment of inertia and acceleration coefficient 3 16 6 1 1 Acceleration coefficient vs moment of inertia 500 3 17 6 1 2 Acceleration coefficient vs moment of inertia YK600XQG 3 17 6 1 3 Acceleration coefficient vs moment of inertia YK600XQGH 3 18 6 1 4 Acceleration coefficient vs moment of inertia YK700XG YK800XG 3 18 6 1 5 Acceleration coefficient vs moment of inertia YK900XG YK1000XG 3 19 6 2 Equation for moment of inertia 3 20 63 Example of moment of inertia 3 23 6 4 Attaching the end 3 25 6 5 Gripping force of end 3 29 7 Limiting the Movement Range with X Axis Mechanical Stoppers 3 30 7 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 3 31 8 Working Envelope and Mechanical Stopper Positions for Maximum Working TRE 3 33 CHAPTER 4 Adjustment 4 1 2 Safety Precautions D tenax 4 1 g Adjusti
5. Azmax m sec 2 YK500XG 98 48 57 280 YK600XG 104 41 57 280 YK600XGH 78 60 38 176 YK700XG 96 60 38 176 YK800XG 101 51 38 176 YK900XG 95 51 38 176 YK1000XG 95 51 38 176 7 Tangential acceleration centrifugal Fig 3 28 Maximum acceleration on end effector attachment The gripping force of the end effector must have a sufficient extra margin of strength to prevent the workpiece from coming loose and flying off during robot operation If the gripping force is too weak the workpiece may come loose and fly off causing accidents or injuries CHAPTER 3 Installation 7 Limiting the Movement Range with Mechanical Stoppers In the YK XG Series the movement range can be limited by changing the X axis mechanical stopper positions See Fig 3 29 The Y axis mechanical stopper positions are fixed and cannot be changed When the robot is shipped from the factory the movement range is set to the maximum If the maximum movement range is too large compared to the actual work range or the manipulator might interfere with peripheral units then the movement range can be limited as out lined below The X axis mechanical stopper positions may slightly differ depending on machining precision Always turn off the controller before changing the mo
6. Resolver HLIM GND24 HLIM GND24 Connection Origin Sensor 24V ORG GND Origin Sensor 24V ORG N Connector Orange 1 Red Orange 1 Black 0 15sq Twisted pair Gray 1 Red Gray 1 Black 0 15sq Twisted pair Sky blue 2 Red Sky blue 2 Black 0 15sq Twisted pair Green 0 3sq Pink 1 Red Pink 1 Black 0 15sq Twisted pair Sky blue 1 Red Sky blue 1 Black 0 15sq Twisted pair Orange 2 Red Orange 2 Black 0 15sq Twisted pair Bright green 2 Red Bright green 2 Black 0 15sq Twisted pair Pink 2 Red Pink 2 Black 0 15sq Twisted pair Green 0 3sq Gray 2 Red 0 15sq Gray 2 Black 0 15sq Green 0 3sq Green 0 3sq Sky blue 3 Red Sky blue 3 Black 0 15sq Twisted pair Pink 3 Red Pink 3 Black 0 15sq Twisted pair Bright green 1 Red Bright green 1 Black 0 15sq Twisted pair e w e w w e Round terminal RM 7 18 Black Red 0 75sq White Yellow Green Yellow Brown Blue CHAPTER 7 Specifications
7. za n Blue User signal line E 5 Brown Red Orange En P a En o Blue u Purple Gray White Black Brown Red Orange o pra ER Blue Green Shield Frame ground Green Shield Origin Sensor 24V Brown ORG Red 0 2mm GND Orange Origin Sensor 24V Brown ORG RORG RORG Blue GND Orange Round terminal Round terminal Yellow Green Frame ground a Round terminal Round terminal Black 7 19 CHAPTER 7 Specifications Motor wiring table Color Connection Connector 2 Blue 1 1 54 Blue Black S1 Brown Resolver S3 Dck R1 Red R2 Black SHIELD Black 1 3 XP YP ZP RP U Red V White Black XM YM ZM RM PE Round terminal BK Yellow BK Blue Origin sensor wiring table Connection ZBK Z axis motor only Connector XORG YORG RORG 7 20 MEMO User s Manual YAMAHA YK XG series SCARA Robot Jun 2009 Ver 1 09 This manual is based on Ver 1 09 of Japanese manual
8. Robot cable 3 5m option 5m 10m Weight 48kg 50 50kg 52kg 52kg 54kg 54kg 56 56kg 58kg 1 At constant ambient temperature XY 2 There are limits to acceleration coefficient settings Noise level Maximum sound pressure level of the robot when there is 10dB Position where the maximum sound or larger difference from the back ground sound pressure level pressure is measured 1 meter apart from the back of the robot 1 6m height from the floor surface 78 408 Note The noise level can be higher when the robot is set nearby the objects that cause sound reflection 7 1 CHAPTER 7 Specifications 1 2 External view and dimensions 7 300 200 194 a gt 5 o e b le A ee ee _ 4 co 2 2 mr XI User tubing 1 06 black D sub connector for user wiring User tubing 2 96 red No 1 to 20 usable 40 120 4411 User tubing 3 06 blue 60 140 M10 bolt for installation 4bolts used 200 Base size 54 113 775 ooo Z300mm stroke 675 m Z200mm stroke Maximum 660 during arm rotation 89 L 373 351 i 283 A 253 5 259
9. eU UR 1 13 9 Adjustment and Inspeclgri ss 5 000 Leite Mabe steeds 1 13 10 Repair and 1 13 1 14 eee 1 16 MEMO CHAPTER 1 Using the Robot Safely Ee ne 1 Safety Information Industrial robots are highly programmable mechanical devices that provide a large degree of freedom when performing various manipulative tasks To ensure correct and safe use of YAMAHA industrial robots carefully read this manual and make yourself well acquainted with the contents FOLLOW THE WARN INGS CAUTIONS AND INSTRUCTIONS INCLUDED IN THIS MANUAL Failure to take necessary safety measures or mishandling due to not following the instructions in this manual may result in trouble or damage to the robot and in jury to personnel robot operator or service personnel including fatal accidents Warning information in this manual is shown classified into the following items Failure to follow DANGER instructions will result in severe injury or death to the robot operator a bystander or a person inspecting or repairing the robot Failure to follow WARNING instructions could result in severe injury or death to the robot operator a bystander or a person inspecting or repairing the robot ACAUTION Failure to
10. Tapped hole and screw for user Fig 2 2 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 2 2 CHAPTER 2 Functions Robot Controller The YK XG series robot comes supplied with a robot controller RCX240 For more details refer to the separate YAMAHA Robot Controller User s Manual YAMAHA RCX240 Fig 2 3 Robot controller 2 3 CHAPTER 2 Functions NIaGAEN ILRM 3 Robot Initialization Number List The YK XG series robots are initialized for optimum setting default setting according to the robot model prior to shipping The robot controllers do not have to be reinitialized during normal operation However if for some reason the con troller must be reinitialized proceed while referring to the list below CAUTION Absolute reset must be performed after reinitializing the controller Before reinitializing the controller read the descriptions in 3 Adjusting the origin in Chapter 4 and make sure you thoroughly understand the proce dure When the controller is initialized the ARM LENGTH and OFFSET PULSE settings in the axis parameters will be erased making the standard coordi nate settings i
11. D sub connector for user wiring No 1 to 20 usable 4 014 M12 bolt for installation 4bolts used 245 Base size 63 128 990 Z400mm stroke 790 Z200mm stroke 711 Maximum 770 during arm rotation 86 98 440 3 368 i 99 J 333 5 N i 339 5 396 cmd y 254 5 2737 an Sh Usertool 219 208 742 5 j installation range 2 2 1 25h7 0 021 5 55 229 5 Flat surface has no phase relation to R axis origin 0 2 b 9 5 lt 5 Hollow diameter 18 8 8 Z axis lower end A mechanical stopper position 5 g z i Cross section CM 4 M4x0 7 through hole for tool attachment Four M4x10L binding screws are supplied Do not screw the screws in deeper than 10mm from bottom surface of arm Fig 7 3 YK600XGH 7 6 CHAPTER 7 Specifications E M 9 User tubing 1 6 black User tubing 2 06 red User tubing 3 06 b
12. H D 242 gt 1 EE 213 3 204 User tool Lu E qn 187 installation range THIT E n 158 5 137 642 7 1 0 20h7 0 021 g 50 2 Flat surface has no phase relation to R axis origin 0 o 8 0 lt N Tm T 2 N o ie Hollow diameter 14 Z axis lower end Ili mechanical stopper position E 3 Ti Cross section A A 4 M4x0 7 through hole for tool attachment Four M4x10L binding screws are supplied Do not screw the screws in deeper than 10mm from bottom surface of arm Fig 7 1 YK500XG 7 2 CHAPTER 7 Specifications A 91 P lt a 4 N P e 144 114 Working envelope of left handed system User tubing 2 06 red User tubing 3 6 blue 67 47 27 15 0 Working envelope of right handed system X axis mechanical stopper position 132 46 Y axis mechanical stopper position 147 D sub connector for user wiring M4 ground terminal No 1 to 20 usable 7 3 CHAPTER 7 Specifications 178 M10 bolt for installation 4bolts used T 300 300
13. S 1 Robot Installation Conditions 1 1 Installation environments Be sure to install the robot in the following environments Setting environments Specifications Allowable ambient temperature 0 to 40 C Allowable ambient humidity 35 to 85 RH non condensation Altitude to 1000 meters above sea level Ambient environments Avoid installing near water cutting water oil dust metallic chips and organic solvent Avoid installation near corrosive gas and corrosive materials Avoid installation in atmosphere containing inflammable gas dust or liquid Avoid installation near objects causing electromagnetic interference electrostatic discharge or radio frequency interference Vibration Do not subject to impacts or vibrations Air supply pressure etc Below 0 58MPa 6 0kgf cm clean dry air not containing deteriorated compressor oil filtration 40um or less Working space Allow sufficient space margin to perform jobs teaching inspection repair etc For detailed information on how to install the robot controller refer to the sepa rate YAMAHA Robot Controller User s Manual Avoid installing the robot in locations where the ambient conditions may ex ceed the allowable temperature or humidity or in environments where water corrosive gases metallic powder or dust are generated Malfunction failure or short circuits may otherwise result This robot was not de
14. Symbol 417 IEC 5019 When the end effector uses an electrical device which if it malfunctions might make contact with the power supply the user must provide proper grounding on his own responsibility The YK XG series robots do not have a ground terminal for this purpose For details on protective bonding on the robot body to comply with CE Mark ing follow the instructions on protective bonding explained in the YAMAHA Robot Controller User s Manual or CE Marking manual Use a ground cable with a conductor wire cross section of at least 2 0mm and a length within 1 meter 3 9 CHAPTER 3 Installation e e a Ground symbol M4 Ground terminal Fig 3 6 Ground terminal 3 10 CHAPTER 3 Installation Robot Cable Connection The robot cable is pre connected to the YK XG series robot For details on con nections to the robot controller refer to Fig 3 7 and the YAMAHA Robot Con troller User s Manual After making connections check the operation while re ferring to 6 Trial operation in Chapter 1 Before connecting the cables check that there are no bends or breaks in the connector pins of the robot cable and that the cables are not damaged Bent or broken pins or cable damage may cause malfunction of the robot Ensure that the controller is off before connecting the robot cable to the con troller In the RCX240 contr
15. 6 1 5 Acceleration coefficient vs moment of inertia YK900XG YK1000XG Ax Av AR 96 0 07 0 7 100 bif 80 60 40 20 0 0 2 0 4 0 6 0 8 1 0 Ir kgm 0 2 0 4 0 6 0 8 0 10 0 Jr kgfcmsec Fig 3 13 mz1 to 20kg 3 19 CHAPTER 3 Installation 6 2 Equation for moment of inertia calculation Usually the R axis load is not a simple form and the calculation of the moment of inertia is not easy As a method the load is replaced with several factors that resemble a simple form for which the moment of inertia can be calculated The total of the moment of inertia for these factors is then obtained The objects and equations often used for the calculation of the moment of inertia are shown below Incidentally there is the following relation J kgfcmsec I x 10 2 1 Moment of inertia for material particle The equation for the moment of inertia for a material particle that has a rota tion center such as shown in Fig 3 14 is as follows This is used as an approximate equation when x is larger than the object size I mx kgm 2 J TE kgfcmsec Eq 3 1 g Gravitational acceleration cm sec m Mass of material particle kg W Weight of material particle kgf Fig 3 14 2 Moment of inertia for cylinder part 1 The equation for the moment of inertia for a cylinder that has a rotation center such as shown in Fig 3 15 is given below D h mD E 10 32 3 kgm 4
16. For items 1 to 3 follow the precautions and procedure for each section To perform item 4 refer to the description in 2 below Teaching When performing teaching within the safeguard enclosure comply with the instructions listed below 1 Check or perform the following points from outside the safeguard enclo sure 1 Make sure that no hazards are present within the safeguard enclosure by a visual check 2 Check that the programming unit MPB operates correctly 3 Check that no failures are found in the robot 4 Check that emergency stop works correctly 5 Select teaching mode and prohibit automatic operation 2 Never enter the movement range of the manipulator while within the safe guard enclosure CHAPTER 1 Using the Robot Safely M 8 Automatic Operation Automatic operation described here includes all operations in AUTO mode 1 Check the following before starting automatic operation 1 No one is within the safeguard enclosure 2 The programming unit and tools are in their specified locations 3 The alarm or error lamps on the robot and peripheral equipment do not flash 4 The safeguard enclosure is securely installed with safety interlocks ac tuated 2 Observe the following during automatic operation or in cases where an error occurs 1 After automatic operation has started check the operation status and warn ing lamp to ensure that the robot is in automatic operation 2 Never enter the safeg
17. The YK XG series robots only require the absolute reset to be performed once when the robot is introduced Once the absolute reset is performed you do not need to reperform it when the power is turned on next time Set the origin position while referring to absolute reset methods in 3 Adjusting the origin in Chapter 4 of this manual and in Absolute Reset of the YAMAHA Robot Controller User s Manual Setting of standard coordinates is not required in the above case To set the standard coordinates with high accuracy refer to 5 Setting the Standard Coordinates in Chapter 4 of this manual and Setting the Standard Coordinates in the YAMAHA Robot Controller User s Manual If the standard coordinate settings are incorrect robot malfunctions vibration excessive noise may occur Never enter the robot movement range once the robot servo is turned on as this is extremely hazardous 2 To set a position OTHER than the robot arm extended position the origin position adjusted at the factory prior to shipment as the origin position 1 Absolute reset The YK XG series robots only require the absolute reset to be performed once when the robot is introduced Once the absolute reset is performed you do not need to reperform it when the power is turned on next time Set the origin position while referring to absolute reset methods in 3 Adjusting the origin in Chapter 4 of this manual and in Absolute Reset of the YAMAHA Robot Contr
18. When installing the robot be sure to use the specified size and quantity of bolts that match the depth of tapped holes in the installation base and securely tighten the bolts to the correct torque If the bolts are not tightened correctly the robot might fall over during operation causing a serious accident Tightening torque Robot Model Bolts Used Tightening torque YK500XG YK600XG MIO 71Nm 720kgfcm YK600XGH YK700XG YK800XG YK900XG YK1000XG M12 128Nm 1310kgfcm Depth of tapped holes in installation base Tron installation base Bolt diameter x 1 5 or more Aluminum installation base Bolt diameter x 3 or more Recommended bolt JIS B 1176 hex socket head bolt or equivalent Strength class JIS B 1051 12 9 or equivalent eg t je nj dt ja Hex socket head bolt Installation base Fig 3 5 Installing the robot 3 8 CHAPTER 3 Installation 3 Protective Bonding Be sure to ground the robot and controller to prevent electrical shock Turn off the controller before grounding the robot The robot must be grounded as follows 1 2 3 4 Provide a terminal marked PE for the protective conductor of the entire system and connect it to an external protective conductor In addition se curely connect the ground terminal on the robot pedestal to the same protec tive conductor See Fig 3 6 for example of the YK500XG
19. set screw C supplied with harmonic drive Tightening torque YK500XG YK600XG 7kgfcm 0 7Nm YK600XGH to YK1000XG 17kgfcm 1 7Nm 5 37 CHAPTER 5 Periodic Inspection ICA ANIMAM AG cc cX Apply grease only to ball parts Wave generator ball Apply grease to fill the space around the ball Do not apply grease thicker than 0 5mm to the area above the end face seal lip End face seal lip Apply slight amount of grease to the lip only Remove all grease that remain inside the lip Harmonic grease Apply grease every around Be cautious about the amount of grease amounts of the grease applying to the area above and below the end face seal lip are different lt oe gt Below the end face seal lip apply grease as thick as the diameter of the wave generator ball Fig 5 21 5 38 CHAPTER Increasing the robot operating speed 1 Increasing the Robot Operating Speed MEMO CHAPTER 6 Increasing the robot operating speed Le ee a en ee mamme cci 1 Increasing the Robot Operating Speed The robot operating speed can be increased by the following methods Use these methods as needed when programming 1 Increasing speed by arch motion Also refer to Robot controller user s manual Axis parameters Arch position
20. to the inner side of the new wave generator Insert the wave generator into the inner end of the R axis motor shaft and secure it with the two setscrews See Fig 5 20 15 Apply harmonic grease to the circular spline See Fig 5 21 for applying grease properly 16 Fit a new O ring 1 coated with harmonic grease into the groove of the shaft Apply small amounts of Screw Lock to the bolts you removed earlier and tighten them to secure the new harmonic drive Also return the panhead bolt and nut to the original position and secure them Apply small amounts of Screw Lock to the panhead bolt The panhead bolt tightening torque should be 90cNm 9kgfcm On the YK600XGH and YK700XG to YK1000XG also apply Screw Lock to the dog mounting bolt and tighten it to a torque of 2 0Nm 20kgfcm See Fig 5 19 b CAUTION Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of groove 17 Fit the O ring coated with harmonic grease into the O ring groove of the new harmonic drive See Fig 5 18 Apply small amounts of Screw Lock to the bolts you removed earlier and tighten them to secure the new harmonic drive to the Y axis arm from the top of the Y axis arm See Fig 5 18 Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of gr
21. After absolute reset is complete check that the adjustment machine reference value is within the tolerance range 33 and 67 If the adjustment machine reference value is outside the tolerance range 33 to 67 then repeat the procedure from 4 to readjust it 4 28 CHAPTER 4 Adjustment 15 When the machine reference value is within the tolerance range lower the Z axis lower end damper until it makes tight contact with the holder and then reattach the cover Rear cover MAD 4 29 CHAPTER 4 Adjustment Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 Ball screw Z axis lower end damper Flat surface Z axis motor shaft located under the flange Flange Mark Fig 4 11 a 52 Is A SS n di A Ec Fig 4 11 b 4 30 CHAPTER 4 Adjustment ER 4 Setting the Soft Limits In the YK XG Series the working envelope during manual and automatic opera tion can be limited by setting the plus soft limit pulse and minus soft limit pulse on each axis The origin point O pulse is used as the reference to set the soft limits The working envelope can be limited by specifying the number of pulses from the 0 pulse position For the working envelope of each robot refer to 1 2 External view and dimensions in Chapter 7
22. Also refer to the external view and dimensions in the catalog or website www yamaha motor co jp global industrial robot for the working envelope area When performing actual checks of the soft limit settings operate the robot manu ally from outside the safeguard enclosure 1 Setting the X axis and Y axis soft limits The soft limits must be set within the movement range limited by the me chanical stoppers as explained in Section 7 in Chapter 3 or within the range where the manipulator does not interfere with the peripheral equipment but within maximum working envelope Set the soft limits with the following procedure Also use this procedure when the origin position has been changed Likewise in models where the mechanical stopper position cannot be changed reduce the soft limits to narrow the working envelope when the actual work ing range of the robot is small or the manipulator interferes with the periph eral equipment 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Press the emergency stop button on the MPB to set emergency stop Refer to the YAMAHA Robot Controller User s Manual for further details on emergency stop and canceling emergency stop 3 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 4 Enter the safeguard enclosure while holding the MPB 5 Move the X axis and Y axis arms by hand to the mechan
23. Machine harness wiring table YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Y axis arm side Base side Signal Connector Connection Connector Color Wire Y axis Resolver S2 Brown 0 2mm S4 White Twisted pair 1 Red 0 2mm S3 White Twisted pair R1 R2 DG Z axis Resolver S2 S4 1 3 R1 R2 DG R axis Resolver S2 S4 1 S3 1 NI OO Orange 0 2mm White Twisted pair Green Shield Brown 0 2mm Black Twisted pair ti Red 0 2mm Black Twisted pair s Orange 0 2mm Black Twisted pair Green Shield Brown 0 2mm Gray Twisted pair 1 Red 0 2mm Gray Twisted pair Orange 0 2mm Gray Twisted pair 3 Green Shield Brown Red 0 75mm Orange Y axis motor Z axis motor Blue Purple Gray Black White Brown White Black R axis motor lt lt lt lt Z axis brake Z axis brake Brown Red Orange I Blue Gray White Black Brown Red Orange D D o o o E
24. YAMAHA YAMAHA MOTOR CO LTD YAMAHA SCARA ROBOT YK X series User s Manual TETE E35 Ver 1 09 Before using the robot Be sure to read the following notes At this time our thanks for your purchase of this YAMAHA YK XG series SCARA robot 1 Please be sure to perform the following tasks before using the robot Failing to perform the tasks below will require re teaching of the robot since the origin position cannot be set to the same previous position Robot malfunctions vibration noise may also occur The origin position of the YK XG series robots is adjusted to the robot arm ex tended position at the factory prior to shipment so the reference or standard coor dinates are temporarily set The customer should set the origin position before any other job There are 2 types of origin position settings as shown below 1 Setting the robot arm extended position the origin position adjusted at the factory prior to shipment as the origin position When setting the origin position with the robot arm extended you must check that there will not be any interference from any periph eral equipment during the next absolute reset 2 Setting a position OTHER than the robot arm extended position the origin position adjusted at the factory prior to shipment as the origin position 1 To set the robot arm extended position the origin position adjusted at the factory prior to shipment as the origin position Absolute Reset
25. YAMAHA MOTOR CO LTD IM Operations All rights reserved No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO LTD Information furnished by YAMAHA in this manual is believed to be reliable However no responsibility is assumed for possible inaccuracies or omissions If you find any part unclear in this manual please contact YAMAHA or YAMAHA sales representatives
26. crushed by the moving parts of the robot during transportation or teaching Moving parts can pinch or crush hands Keep hands away from robot arms 1 2 CHAPTER 1 Using the Robot Safely WARNING Moving parts can pinch or crush Keep hands away from robot arms Fig 1 2 Warning label 2 3 Follow the instructions on warning labels and in this manual Warning label 3 Fig 1 3 is affixed to the robot See Fig 2 2 for the loca tions of warning labels Be sure to read the warning label and this manual carefully and make you thoroughly understand the contents before attempting installation and op eration of the robot Before starting the robot operation even after you have read through this manual read again the corresponding procedures and cautions in this manual as well as descriptions in this chapter Chapter 1 Using the Robot Safely Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual Improper installation or operation can result in serious injury or death Read user s manual and all warning labels before installation or operation WARNING Improper Installation or operation can result in serious injury or death Read user s owner s manual and all warning labels before operation Fig 1 3 Warning label 4 Do not remove the Z axis upper end mechanical stopper Removing or moving the upper end mechanical stopp
27. dep DM MD MD 5 3 4 NGDSCI ON ioo e rea Re o ER ix ee E EE 5 5 5 Replacing the Harmonic cita n e en een 5 9 5 1 Replacement period nennen nnns 5 9 5 2 Basic replacement procedure for harmonic drive and precautions 5 10 5 2 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 5 12 CHAPTER 6 Increasing the robot operating speed 1 Increasing the Robot Operating 6 1 CHAPTER 7 Specifications 1 cists Po nnn ut Ua apiid ui dits deme alate 7 1 T 7 1 1 2 External view and 7 2 1 3 Robot inner wiring diagram 7 16 14 Wiminngtablo trate rte eee x sre E aed ene tien sete delete 7 17 MEMO CHAPTER Using the Robot Safely UNE CAII UNS 1 1 2 Essential Caution Items cca foot aot eo tad LAT 1 2 Special Training for Industrial Robot Operation 1 8 4 Robot Safety Functions 1 9 5 Safety Measures for the 1 10 6 Total Operat Om co iie dal er bal da tute ers 1 11 7 Work Within the Safeguard Enclosure 1 12 Automatic
28. eene nnne nnns 1 13 Adjustment and 1 13 Repair and ModifiCatioth ater iet rate 1 13 lC MM t dd A E 1 14 d E 1 16 CHAPTER 2 Functions 1 2 3 Robot ManipUlatOf seti pedet etse ife et eed ete eus 2 1 Robot 2 3 Robot Initialization Number List 2 4 CHAPTER 3 Installation 1 Robot Installation Conditions cccccccecccceeeeceeceeeeessseeseeeceeeeeeeeeeseeeeeaas 3 1 1 1 Installation environments ennemis 3 1 1 2 Installation E ode di hos 3 2 PN UND Sp Ahn aerate eae 3 4 21 cei eer tere eene e ehe estt eit 3 4 2 2 Checking the 3 5 2 3 Moving ihe rob t eenia crine rect ve den e dee e ce Ye pee e Edere cus 3 6 2 3 1 Moving the YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YKT000XQx Ee ni BM RM is 3 6 2 4 Installing the robot cece cece 3 8 Protective Rabie 3 9 Robot Cable Connection cccccccccecceccececceccecccecaeececcuecauececeeeecaeeseeeseeeas 3 11 5 User Wiring and User
29. 19 20 21 22 23 24 25 D sub connector on arm side D sub connector on base side As viewed from solder side As viewed from solder side YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 3 8 WARNING The user cable wires should have a shield wire Connect it to the same No pin in the D sub connector on the robot side which also connects to the shield wire If this task is omitted noise may cause malfunction of the robot Securely attach the D sub connector supplied with the robot into the D sub connector on the robot side by tightening the screws on the connector hood If this connector comes loose or comes off malfunction may result Avoid fastening the user cable or tube with the machine harness as this may lead to harness breakage and malfunction Make sure that the user cable attached to the D sub connector for user wir ing and the tube attached to the bulkhead union for user tubing will not inter fere with the robot movement entangle around the robot or flap around dur ing operation Wiring and tubing might then be damaged causing malfunc tion of the robot Lay out the user cable attached to the D sub connector for user wiring and the tube attached to the bulkhead union for user tubing so that they do not obstruct the movement of the operator or any other persons Bodily injury may result if anyone trips on the cable or air tube 3 14 CHAPTER 3 Installation ACAUTION The D sub connector
30. 2 prbh WD kgfcmsec 32g 8g was Eq 3 2 h Density kg m kg cm Gravitational acceleration cm sec Mass of cylinder kg Weight of cylinder kgf zmB5gmm o Fig 3 15 3 20 CHAPTER 3 Installation 3 Moment of inertia for cylinder part 2 The equation for the moment of inertia for a cylinder that has a rotation center such as shown in Fig 3 16 is given below j 230 0 pt Dh D m 4 pr w 4 Density kg m kg cm Gravitational acceleration cm sec Mass of cylinder kg Weight of cylinder kgf h D k Poa a uy a MM 2 oa ene 3 3 4 Moment of inertia for prism The equation for the moment of inertia for a prism that has a rotation center as shown in Fig 3 17 is given as follows i j a5 0 abc a b _ m a xb 5 _ W a 62 2 12 12 keer kgf 2 12g 12g kgfcmsec CTS Eq 3 4 Density kg m kg cm Gravitational acceleration cm sec Mass of prism kg Weight of prism Fig 3 17 3 21 CHAPTER 3 Installation 5 When the object s center line is offset from the rotation center The equation for the moment of inertia when the center of the cylinder is offset by the distance x from the rotation center as shown in Fig 3 18 is given as follows _ _pmD h pnD
31. Adjustment a c HM 15 Temporarily fasten the X axis origin sensor stay using the bolts At this point check that the sensor does not interfere with other parts while turning the X axis arm by hand 16 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 17 Perform the absolute reset from outside the safeguard enclosure 18 After the absolute reset is completed read the machine reference value dis played on the MPB 19 If the machine reference value is in the range between 40 and 60 recom mended range then the origin position has been correctly changed Fully tighten the bolts to secure the X axis origin sensor stay If it is outside the recommended value then adjust the machine reference by referring to 1 1 Adjusting the X axis machine reference 20 Reattach the cover after the adjustment is complete Mounting bolt for X axis speed reduction unit X axis origin position adjustable range Factory preset X axis origin position Fig 4 4 4 13 Fig 4 5 b CHAPTER 4 Adjustment Hex nut Robot model Dog Tightening torque kgfcm Tightening torque cNm 16 160 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Recommended Screw Lock LOCTITE 262 made by Henkel Corporation Fig 4 5 c Bolt Robot
32. User tubing 6x3 Y axis 200W 200W Travel limit 1 Soft limit 2 Mechanical stopper XYZ axes Z axis 200W 200W Robot cable 3 5m option 5m 10m R axis 200W 200W Weight XY resultant 7 6m s 8 4m s 2 3m s 200mm stroke Z axis 1 7m s 300mm stroke Z axis R axis 1700 s 1700 s X axis ifi Y axis Z axis 1 At constant ambient temperature XY 2 There are limits to acceleration coefficient settings Robot model YK600XGH YK700XG YK800XG YK900XG YK1000XG Arm length 200mm 300mm 600mm Rotation angle 130 130 130 Arm length 400mm 400mm 400mm Rotation angle 150 150 150 200 400mm 200 400mm 200 400mm 200 400mm 200 400mm Rotation angle 360 360 360 X axis 750W 750W 750W Y axis 400W 400W 400W Z axis 400W 400W 400W R axis 200W 200W 200W XY resultant 7 7m s 8 4m s 10 6m s X axis Y axis 2 3m s 200mm stroke Z axis 1 7m s 400mm stroke Z axis R axis 920 s 920 5 9209 5 920 s 920 s XY axes 0 02mm 0 02mm 0 02mm 0 02mm 0 02mm Repeatability 1 Z axis 0 01mm 0 01mm 0 01mm 0 01mm 0 01mm R axis 0 004 0 004 0 004 0 0042 0 0042 Payload 20kg R axis tolerable moment of inertia 2 1 0kgm 10 0kgfcms User wiring 20 cables User tubing 6x3 Travel limit 1 Soft limit 2 Mechanical stopper XYZ axes Maximum speed Z axis
33. a physician for treatment Disposing of grease and the container Proper disposal is compulsory under federal state and local regulations Take appropriate measures in compliance with legal regulations Do not pressurize the empty container Pressurizing may cause the con tainer to rupture Do not attempt to weld heat up drill holes or cut this container This might cause the container to explode and the remaining materials inside it to ignite Unless grease specified by YAMAHA is used the service life of the ball screw and ball spline will shorten 1 Inspection to be performed with the controller turned off 1 Turn off the controller 2 Place a sign showing that the robot is being inspected to keep others from operating the controller switch 5 5 CHAPTER 5 Periodic Inspection SS a fuco mE a 3 Enter the safeguard enclosure and check the following points Checkpoint Procedure Manipulator bolts and screws Only for major bolts and screws exposed Check for looseness and tighten if necessary 1 externally Detection areas of the origin sensors of the X axis Y axis and R axis Clean if it is dirty Check for looseness at each terminal and connector on the Controller panel See 4 in Chapter 3 Lubricate the Z axis spline shaft and ball screw nut after removing the old grease The specified grease is Alvania S2 SHOWA SHELL SEKIYU KK See Fig 5 1 Grease lubrication of Z axis ball sc
34. and insert the sleeve into the hole Then tighten the bolt just enough to hold the sleeve See Fig 4 14 Turn the X and Y axis arms so that they are nearly straight See Fig 4 15 Remove the cover and plate Position the Y axis arm so that you can easily insert the pin into the sleeve through the elongated hole in the Y axis arm See Fig 4 16 Secure the pin with the bolt Tighten the bolt just enough to hold the pin Enter MANUAL gt POINT mode Lightly apply a clockwise torque to the Y axis to unload it while holding the X axis arm and make a note of the Y axis position pulse value displayed on POS 10 Lightly apply a counterclockwise torque to the Y axis to unload it while holding the X axis arm and make a note of the Y axis position pulse value displayed on POS 11 Move the X axis arm in the direction that you want to set as the direction of the X axis as shown in Fig 4 12 At this point make a note of the X axis position pulse value displayed on POS 4 35 CHAPTER 4 Adjustment Eee ee eee eee NA 12 Enter the following values in M1 and M2 for 11 Arm length mm of axis parameters M1 X axis arm length YK500XG M2 Y axis arm length YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 13 Enter the following values in 12 Offset pulse of axis parameters M1 X axis position pulse value you made a note of in step 11 M2 Y axis position p
35. b c and d are the respective interference positions with the base front panel base side panel base rear panel and base corners Be careful not to allow the robot load to interfere with any part of the robot The Z axis spline may touch the base or the Y axis arm may touch the wire harness before the robot strikes the X axis or Y axis mechanical stop pers so use caution 3 Interference positions where a load might touch the robot within the maxi mum movement range and their radii are shown in the figure Here a b c and d are the respective interference positions with the base front panel base side panel base rear panel and the base corners The Z axis spline may touch the base or the Y axis arm may touch the wire har ness before the robot strikes the X axis or Y axis mechanical stoppers so use caution 2 Z axis Do not attempt work outside the working envelope In particular do not at tempt work in the area between the working envelope and mechanical stop per position Mechanical stoppers are installed at both the upper and lower ends of the movement range The robot cable user wiring or tubing may be damaged if the robot load inter feres with them resulting in hazardous robot malfunctions Do not operate at points where the load may interfere with the robot cable user wiring or tubing 3 R axis The R axis has no mechanical stoppers ACAUTION Since the R axis has no mechanical stoppers make certain that
36. follow CAUTION instructions may result in injury to the robot opera tor a bystander or a person inspecting or repairing the robot or damage to the robot and or robot controller NOTE Explains the key point in the operation in a simple and clear manner Refer to the instruction manual by any of the following methods to operate or adjust the robot safely and correctly 1 Operate or adjust the robot while referring to the printed version of the in struction manual available for an additional fee 2 Operate or adjust the robot while viewing the CD ROM version of the in struction manual on your computer screen 3 Operate or adjust the robot while referring to a printout of the necessary pages from the CD ROM version of the instruction manual It is not possible to detail all safety items within the limited space of this manual So it is essential that the user have a full knowledge of basic safety rules and also that the operator makes correct judgments on safety procedures during operation This manual and warning labels supplied with or affixed to the robot are written in English If the robot operator or service personnel does not understand Eng lish do not permit him to handle the robot 1 1 CHAPTER 1 Using the Robot Safely EE 2 Essential Caution Items Particularly important cautions for handling or operating the robot are described below In addition safety information about installation ope
37. is the minimum distance between the positions where absolute reset can be performed and interval B is the distance between the position where the origin signal is detected and the position where absolute reset can be performed soon after the origin signal detection The machine reference value unit is displayed on the optional MPB screen Machine reference value B A x 100 CAUTION The machine reference must be adjusted within a specified range to keep the repeatability precision of the absolute reset position The machine reference is factory adjusted prior to shipping If the origin position is changed the ma chine reference must be readjusted For information on how to adjust the ma chine reference refer to 3 4 Changing the origin position and adjusting the machine reference in Chapter 4 When the temperature of the robot joint sec tions is high immediately after the robot has been operated the machine refer ence value might be outside the specified range 40 to 60 When checking or adjusting the machine reference value always make sure that the temperature of the robot joint sections has returned to room temperature Recommended machine reference value 40 to 60 Machine reference Origin signal detection ON Origin signal OFF Resolver B One motor revolution Positions where absolute reset gt can be performed Machine reference display on MPB screen MP
38. model Bolt Tightening torque Tightening torque Nm YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Recommended Screw Lock LOCTITE 262 made by Henkel Corporation Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 Fig 4 5 d 4 15 CHAPTER 4 Adjustment 2 1 Adjusting the Y axis machine reference CAUTION The origin position may change due to machine reference adjustment If it oc curs you must set point data again The adjustment method for the Y axis machine reference is as follows 1 Prepare a hex wrench set 2 Check that no one is inside the safeguard enclosure and then turn on the controller 3 Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method 4 If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure 5 Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel 6 Turn off the controller and enter the safeguard enclosure 7 Mark off the reference mark at the current origin position on the Y axis joint area of
39. move the target axis to the plus side Since the message Reset ABS encoder OK is displayed check that there are not any obstacles in the robot movement range and press the F4 key YES CHAPTER 4 Adjustment SE 8 After the absolute reset is completed check that the machine reference value displayed on the MPB is between 40 and 60 recommended range If the machine reference value is outside the recommended range then the next absolute reset may not be properly performed In this case refer to 3 4 Chang ing the origin position and adjusting the machine reference and make the necessary adjustments Origin position at shipment Return to origin is impossible from this area side I 2 Y Return to origin direction d PA Fig 4 2 CHAPTER 4 Adjustment 3 3 2 Stroke end method Z axis Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset The operation procedure using the MPB is described next Press the ESC key on the MPB if you want to return to the preceding step See the YAMAHA Robot Controller User s Manual for information on operat ing the robot controller 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Place a sign indicating the robot is being ad
40. origin and reperform the origin return operation If the return to origin operation is not interrupted the robot will continue the operation and may collide with the me chanical stopper or a peripheral device Since a mechanical stopper is not pro vided in the R axis the wiring and piping installed on the end effecter may be wound up by the operation 3 1 2 Stroke end method Z axis In the stroke end method absolute reset is performed at a position slightly backed off from the stroke end after the Z axis contacts the mechanical stopper and stroke end is detected Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset CHAPTER 4 Adjustment SSS SSE 3 2 Machine reference The YK XG series position detectors are resolvers that have four positions where absolute reset can be performed per motor revolution If the sensor method is used for the absolute reset the origin position will be set at the positions where absolute reset can be performed soon after the origin sensor reacts to the dog the origin signal is detected The machine reference means the position relationship of the position where the robot detects the origin signal to the position where the absolute reset can be performed soon after detection see Fig 4 1 The machine reference is expressed with the ratio of interval A to interval B shown in Fig 4 1 Interval A
41. supplied with the robot should be connected to the arm side by pin contact and to the pedestal side by socket contact Use caution at these points when soldering Be sure to use the D sub connector and hood which are supplied with the robot Using other types may result in contact failure D sub connectors supplied with robot Robot model D sub connector on arm side D sub connector on base side Hood YK500XG YK600XG YK600XGH R gt 29 S aur YK700XG YK800XG YK900XG YK1000XG DE DBA2SS NR DB C2 J9R Manufacturer Japan Aviation Electronics Industry Limited 5 To check the operation and signal transmission between the end effector and the controller or peripheral equipment after making connections refer to 6 Trial operation in Chapter 1 3 15 CHAPTER 3 Installation Attaching the End Effector 6 6 1 R axis tolerable moment of inertia and acceleration coeffi cient 1 The moment of inertia of a load end effector and workpiece that can be attached to the R axis is limited by the strength of the robot drive unit and residual vibration during positioning It is therefore necessary to reduce the acceleration coefficient in accordance with the moment of inertia The R axis tolerable moment of inertia and the acceleration coefficient ver sus R axis moment of inertia for each robot model are shown in Fig 3 9 to Fig 3 13 on the subsequent pages The symbols Ax Av and Ar in each figur
42. surface of the harmonic drive so be careful not to let it drop into the peripheral unit See Fig 5 11 11 Remove the bolts securing the Y axis harmonic drive and also remove the panhead bolt along with the nut See Fig 5 11 12 Remove the Y axis harmonic drive from the top of the X axis arm CAUTION An O ring is fitted to the upper surface of the X axis arm Replace this O ring with a new one 13 Fit a new O ring 1 coated with harmonic grease into the O ring groove of the X axis arm See Fig 5 11 14 Place the new harmonic drive on the X axis arm and secure it with the bolts you removed earlier At this point apply small amounts of Screw Lock to those bolts and uniformly tighten them Also return the panhead bolt and nut to the original position and secure them Apply small amounts of Screw Lock to the panhead bolt See 2 2 in 3 4 1 1 for the panhead bolt tightening and tighten the bolt to the specified torque Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of the groove 15 Fit a new O ring 3 coated with harmonic grease into the O ring groove of the harmonic drive Fig 5 11 5 21 CHAPTER 5 Periodic Inspection B 16 Secure the Y axis arm to the harmonic drive with the bolts you removed earlier At this time ke
43. the X axis arm and place it where it will not obstruct the work 12 Remove the bolts securing the X axis harmonic drive and also remove the panhead bolt along with the nut See Fig 5 5 13 Remove the X axis harmonic drive from the X axis arm A CAUTION An O ring is fitted to the X axis arm Replace this O ring with a new one 14 Fit a new O ring D coated with harmonic grease into the O ring groove of the X axis arm See Fig 5 5 Grease to the O ring is to prevent the O ring from coming off so a small amount is enough Apply small amounts of Screw Lock to the bolts you removed earlier and tighten them to secure the new harmonic drive to the X axis arm Also return the panhead bolt and nut to the original position and secure them See Fig 5 5 Apply small amounts of Screw Lock to the panhead bolt See 1 2 in 3 4 1 1 for the panhead bolt tightening and tighten the bolt to the specified torque ACAUTION Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of the groove 15 Apply harmonic grease to the new wave generator and flexible spline See Fig 5 7 for applying grease properly 16 Fit a new O ring 3 coated with harmonic grease into the O ring groove of the harmonic drive Apply small amount of Screw Lock to the positioning bolts then fix the harmonic drive to the base with 16 pieces
44. the end effec tor wiring and tubing do not become entangled during operation 3 33 CHAPTER 3 Installation 4 Robot overrun during impacts with mechanical stopper A urethane damper is installed to absorb the shock when an impact occurs with the mechanical stopper so a certain amount of overrun occurs when the robot strikes the mechanical stopper Use caution and take overrun into ac count since the end effector may interfere with the robot body and peripheral equipment or the robot body may interfere with the peripheral equipment Maximum overrun amounts are listed below for normal operation maxi mum payload maximum speed Robot model X axis Y axis Z axis YK500XG YK600XG 12 oH TON TRS e Note Here deg is the overrun angle at the X axis and Y axis joints 1 If the X axis Y axis or Z axis mechanical stopper is deformed or dam aged by impacts please contact our sales office or dealer Using the de formed or damaged mechanical stopper is dangerous so it must be re placed 2 When the robot strikes the X axis or Y axis mechanical stopper or an other object or when the R axis collides with an object speed reduction gears are locked while being meshed if the collision impact is large If this happens please contact our sales office or dealer 3 34 CHAPTER Adjustment COVBEUIBW ened eaters tenn al en LL EI 4 1 Safety Preoautlolls ooh Aan to ice be Sea bet
45. the end effector gripper workpiece and reaction force while the robot is operating The maximum reaction force see Fig 3 1 applied to the X axis and Z axis of each robot during operation is shown in the table below These values are an instantaneous force applied to the robot during operation and do not indicate the maximum load capacity The maximum reaction force Fxmax Robot Model N kgf YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 3 2 CHAPTER 3 Installation Mxmax Fig 3 1 Maximum reaction force applied during operation 2 The parallelism of the installation base surface must be machined within a precision of 0 05mm 500mm The robot base mount must be installed fac ing down and in a level position except ceiling mount models which should be installed with the base mount facing up 3 Tap holes into the surface of the installation base For machining dimensions and positions refer to 1 2 External view and dimensions in Chapter 7 4 Securely fix the installation base on the floor with anchor bolts 3 3 CHAPTER 3 Installation 2 Installation 2 1 Unpacking The robot and controller are heavy Take sufficient care not to drop them during moving or unpacking as this may damage the equipment or cause bodily injury CAUTION When moving the robot or controller by equipment such as a folklift that r
46. the robot At this time be careful to prevent the origin position from deviating since the Y axis arm is touched 8 Remove the cover 9 Scribe a mark on the position of the Y axis origin sensor stay 10 Using the hex wrench loosen the two bolts securing the Y axis origin sensor stay See Fig 4 6 The bolts only need to be loosened and do not need to be completely re moved 4 16 CHAPTER 4 Adjustment aA Se n m ee eS ee 11 Move the Y axis origin sensor stay in the following manner and then secure it with the bolts NOTE When the machine reference is less than 40 move the stay in direction See Fig 4 6 When the machine reference is more than 40 move the stay in direction 2 See Fig 4 6 As an approximate guide a 0 8mm movement equals to 100 12 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 13 Perform the absolute reset from outside the safeguard enclosure 14 After the absolute reset is completed read the machine reference value dis played on the MPB 15 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it 16 Reattach the cover after the adjustment is complete CHAPTER 4 Adjustment
47. unit are pressed standard setting at the factory Fig 2 2 on the subsequent pages show part names and functions of each robot model X axis arm Sete E Y axis Y axis arm 9 A Ji Z axis D x o Z D X o Fig 2 1 Manipulator movement 2 1 CHAPTER 2 Functions a i User tubing 1 06 black Eyebolt installation position User tubing 2 6 red User tubing 06 blue D sub connector for user wiring No 1 to 20 Machine harness P i DN Ball screw P4 Y axis motor R axis motor 4 Y axis arm Y axis mechanical stopper X axis speed reduction gear X axis arm n 0 X axis movable mechanical stopper s R axis speed Warning label 1 Warning label 2 on opposite side Z axis motor User tubing 1 86 black Y axis speed reduction gear User tubing 2 6 red Warning label 3 User tubing 3 6 blue Z axis spline reduction gear Serial label Warning label 4 D sub connector for user wiring No 1 to 20 X axis motor End effector attachment M4 ground terminal Robot cable
48. workpiece more quickly The default value of the OUT effective position is 2000 pulses Reference Relation between X Y R axis rotating angle Z axis movement distance and pulse values The arch position tolerance and OUT effective position parameters are set in pulses For the relation between X Y R axis rotating angle Z axis movement distance and pulse values refer to the tables listed under item 4 in 4 Setting the soft limits Chapter 4 in this manual 6 5 MEMO 6 6 CHAPTER Specifications t ndr Y o Ae 7 1 1 1 Basic specificatiOri eie ee o bed ien iet ies 7 1 1 2 External view and 7 2 1 3 Robotinner wiring 7 16 1547 Wiring table REI 7 17 MEMO CHAPTER 7 Specifications a 1 Manipulator 1 1 Basic specification Robot model YK500XG YK600XG Robot model YK500XG YK600XG Arm length 200mm 300mm Repeatability 1 XY axes 0 01 0 01mm Rotation angle 130 130 Z axis 0 01mm 0 01mm Arm length 300mm 300mm R axis 0 004 0 004 Rotation angle 145 145 Payload 10kg Z axis Stroke 200 300mm 200 300mm R axis tolerable moment of inertia 2 0 30kgm 3 R axis Rotation angle 360 360 User wiring 20 cables X axis 400W 400W
49. 0 User tubing 1 06 black User tubing 2 6 red User tubing 3 6 blue 4 014 M12 bolt for installation 4bolts used 990 Z400mm stroke rt 790 Z200mm stroke 711 Maximum 770 during arm rotation 476 440 4 368 99 333 5 319 5 339 5 SE I x D 254 5 273 A E 1219 208 742 i User tool installation range 2517 0 021 ge 055 e 2 ee 0 g E Flat surface has no phase relation to R axis origin 5 N 8 Hollow diameter 018 9 Z axis lower end mechanical stopper position Li _ Cross section a 4 M4x0 7 through hole for tool attachment Four M4x10L binding screws are supplied Do not screw the screws in deeper than 10mm from bottom surface of arm Fig 7 7 YK1000XG 7 14 CHAPTER 7 Specifications A 91 n j e a Working envelope of left handed system LL User tubing 1 06 black User tubing 2 66 red User tubing 3 6 blue gt Working envelope of right handed system 74 D sub connector for user wiring ur X axis mechani
50. 0XG For M5 installation diameter 9 53 YK500XG YK600XG Replacement parts Parts name Type No YAMAHA Parts No Note Harmonic drive SHG 25 80 KBF M2110 000 CD S90QIS KN4 M2143 000 Top of harmonic drive O ring 2 Rubber wire diameter 1 78mm x Ring inner diameter 66 4mm 90990 17J030 Base robot pedestal 3 Rubber wire diameter 1 30mm x Ring inner diameter 66 50mm KN5 M257L 000__ Supplied with harmonic drive YK600XGH YK700XG YK800XG YK900XG YK1000XG Replacement parts Parts name Type No YAMAHA Parts No Note Harmonic drive SHG 32 80 KBF M2110 000 1 S511QIS KN5 M2159 000 Top of harmonic drive O ring 2 Rubber wire diameter 1 50mm x Ring inner diameter 82 00mm 90990 17J035 Base robot pedestal 3 Rubber wire diameter 1 50mm x Ring inner diameter 87 50mm KN5 M2199 000 Supplied with harmonic drive 5 12 CHAPTER 5 Periodic Inspection A 2 Turn off the controller 3 Place a sign indicating that the robot is being inspected to keep others from operating the controller switch 4 Enter the safeguard enclosure 5 Remove the base front and rear covers See Fig 5 2 6 Unplug the connectors on the X axis motor power wire XM and resolver wire XP in the base Also disconnect the X axis motor ring tongue terminal CAUTION Carefully remove the motor not to pinch fingers between the motor and the base An O ring is placed between the motor mating end fa
51. 0XG Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 3 31 CHAPTER 3 Installation sii Y axis mechanical stopper BS X X axis movable mechanical stopper Ay Fig 3 29 X axis movable mechanical stopper position Screw plug X axis stopper bolt Washer YK500XG YK600XG 1 washer YK600XGH YK700XG YK800XG YK900XG YK1000XG 2 washers Fig 3 30 Changing the X axis mechanical stopper position 3 32 CHAPTER 3 Installation G4 nee 8 Working Envelope and Mechanical Stopper Positions for Maximum Working Envelope Working envelope of each robot and mechanical stopper positions for the maxi mum working envelope are shown in 1 2 External view and dimensions in Chap ter 7 Here those are described using the 500 as an example Other robot mod els are the same 1 X aandY axes 1 Do not attempt operation outside the working envelope On the YK XG series the origin can be set at a discrete position The working envelope described in this manual is an area with the robot frontal reference when no load is applied 2 Interference positions where a load may touch the robot within the work ing envelope and their radii are shown in the figure Here a
52. 194 S a t g LU User tubing 1 06 black D sub connector for user wiring User tubing 2 6 red No 1 to 20 usable User tubing 3 6 blue 60 140 54 113 200 Base size 775 Z300mm stroke rt 675 Z200mm stroke 89 351 Ct 283 A 81 253 4 242 f es 204 0 User tool m 8 installation range EN 71 137 62 D 0 20h7 0 021 he 2 2 Flat surface has no phase relation to R axis origin 2 N 2 E 3 S 8 o a Z axis lower end Hollow diameter 14 mechanical stopper position 3 i Cross section 652 Maximum 660 during arm rotation 373 259 187 158 5 4 M4x0 7 through hole for tool attachment Four M4x10L binding screws are supplied Do not screw the screws in deeper than 10mm from bottom surface of arm Fig 7 2 YK600XG 7 4 CHAPTER 7 Specifications User tubing 1 6 black User tubing 2 User tubing 3 Working envelope of right handed system X axis mechanical stopper position 132 0 39 40 D sub connector for user wiring Y axis mechanical stopper position 147 M4 ground terminal No 1 to 20 usable 7 5 CHAPTER 7 Specifications 80 400 200 220
53. 3 22 the weight of the stay Ws is given as follows Ws 0 0078 x 12x 2x2 0 37 kgf Center line Fig 3 22 The moment of inertia of the stay Js is then calculated from Eq 3 7 _ 0 37 x 12425 0 37 x 5 Js 0 014 kgfcmsec 12 x 980 980 CHAPTER 3 Installation 2 3 4 5 Moment of inertia of the chuck C2 When the chuck form resem 2cm Mem bles that shown in Fig 3 23 the weight of the chuck We a is 4cm Wc 0 0078 x 2x4x6 0 37 kgf eom The moment of inertia of the chuck Jc is then calculated from Eq 3 7 Jo 037 2 4 Fig 3 23 12 x 980 0 37 x 10 980 0 038 kgfcmsec Moment of inertia of workpiece When workpiece form E s resembles that shown in Fig 3 24 the weight of the workpiece Ww 15 zm Ww _pmD h 0 0078 x 2x4 4 4 4cm 0 098 kgf The moment of inertia of the p workpiece Jw is then calcu lated from Eq 3 5 jo 0 097 x 2 0 097 x 10 Fig 3 24 8 x 980 980 0 010 kgfcmsec Total weight The total weight W is calculated as follows W Ws Wc Ww 0 84 kgf Total moment of inertia The total moment of inertia J is then obtained as follows J Js Jc Jw 0 062 kgfcmsec 3 24 CHAPTER 3 Installation 6 4 Attaching the end effector Before attaching the end effector be sure to turn off the controller When the end effector is attached by slot clamping always
54. 9 333 5 319 5 1339 5 2 l 254 5 273 9 208 7 2 User tool 219 installation range 28 0 2 5 2517 0 021 ge 55 22 2 E 3 Flat surface has no phase relation to R axis origin 0 o N 0 8 il on p E E S p Hollow diameter 18 S Z axis lower end S mechanical stopper position 5 ig Hn Cross section A A e 48 48 4 M4x0 7 through hole for tool attachment Four M4x10L binding screws are supplied Do not screw the screws in deeper than 10mm from bottom surface of arm N DERESE 32 4 15 36 25 2 5 Depth 20 Bottom of spline Fig 7 5 YK800XG 7 10 CHAPTER 7 Specifications a 1 D sub connector for user wiring No 1 to 20 usable Working envelope of right handed system X axis mechanical stopper position 132 Y axis mechanical stopper position 152 E 7 11 CHAPTER 7 Specifications EI 990 Z400mm stroke 790 Z200mm stroke 440 368 333 5 80 400 500 220 D sub connector for user wiring No 1 to 20 usable 161 220 Base size M12 bolt for installation 4bolts
55. B RST ABS 50 MG Machine reference 1 50 M2 R axis X axis Y axis Z axis Fig 4 1 4 4 CHAPTER 4 Adjustment 3 3 Absolute reset procedures 3 3 1 Sensor method X axis Y axis and R axis Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset The operation procedure using the MPB is described next Press the ESC key on the MPB if you want to return to the preceding step See the YAMAHA Robot Controller User s Manual for information on operating the robot controller 1 Check that no one is inside the safeguard enclosure and then turn on the controller Place a sign indicating the robot is being adjusted to keep others from touch ing the controller switch or operation panel Set the controller to MANUAL mode if not in MANUAL mode Press the F13 LOWER F3 key to select RST ABS Select the axis for absolute reset X axis M1 Y axis M2 R axis M4 To perform absolute reset on all axes select ALL with the F11 LOWER F1 key The Z axis of the stroke end method first rises during the absolute reset of all axes default setting Be careful that your fingers do not get pinched or crushed by any sudden movement 6 Check that the absolute reset axis must be positioned at the plus side of the origin See Fig 4 2 If it is not at the plus side then press the jog key to
56. Prepare the necessary tools Hex wrench set Torque wrench Phillips screwdriver Screw Lock thread sealant Phillips screwdriver bit Hex bit 2 Check that no one is inside the safeguard enclosure and then turn on the controller 3 Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method 4 Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel 5 Turn off the controller and enter the safeguard enclosure 6 Remove the cover See Fig 4 5 a 7 Using the hex wrench loosen the two bolts securing X axis origin sensor stay 8 Remove the X axis origin sensor stay 9 Remove the dog and hex nut through the elongated hole We recommend using the Phillips screwdriver bit and wrench to remove the dog since it is secured with Screw Lock 10 Rotate the X axis arm 90 counterclockwise See Fig 4 5 b 11 Remove the bolt located opposite the elongated hole 12 Apply Screw Lock to the dog and nut insert them into the tapped hole where the bolt was attached and tighten to the specified torque See Fig 4 5 c 13 Return the X axis arm to the current origin position See Fig 4 5 d 14 Apply Screw Lock to the bolt insert it into the tapped hole where the dog was attached and tighten to the specified torque 4 12 CHAPTER 4
57. RCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR WARRANTIES ARISING FROM A COURSE OF DEALING OR USAGE OF TRADE YAMAHA MOTOR CO LTD SOLE LIABILITY SHALL BE FOR THE DE LIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO LTD SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES WHETHER ARISING FROM CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY YAMAHA MOTOR CO LTD MAKES NO WARRANTY WHAT SOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED BY YAMAHA MOTOR CO LTD CHAPTER 1 Using the Robot Safely E 12 CE Marking When the YAMAHA robots are exported to or used in EU European Union countries refer to the separate YAMAHA Robot Controller User s Manual or CE marking manual for related information about CE marking CHAPTER Functions 1 Manipulator a ea adiu tede Rd 2 1 2 Robot Controller 3 Robot Initialization Number List 2 4 MEMO CHAPTER 2 Functions LS 1 Robot Manipulator The YK XG series robots are available in 4 axis models having an X Y axis arm equivalent to human arm and a Z R axis equivalent to human wrist With these 4 axes the YK XG series robots can move as shown in Fig 2 1 By attaching different types of end effector gripper to the end of the arm a wide range of tasks can be performed with high precision at high speeds The and signs show the direction of axis movement when the jog keys on the programming
58. Uniformly tighten the four bolts temporarily fastened in the previous step while turning the Y axis joint If any jamming or catching is felt at this time then reassemble from the beginning 21 Reattach the connectors on the Y axis motor power wire YM and resolver wire YP See Fig 5 8 Also reattach the Y axis motor ring tongue terminal 22 Reattach the cover 23 Go outside the safeguard enclosure 24 Check that no one is inside the safeguard enclosure and then turn on the controller After the Harmonic drive is replaced an absolute reset must be performed and the standard coordinate and point data must be reset Refer to Chapter 4 Ad justment to adjust it 5 22 CHAPTER 5 Periodic Inspection Y axis arm Disconnect this Y axis motor ring tongue terminal located inside the cover Fig 5 8 M5x12 M6x16 Y axis motor Fig 5 9 5 23 CHAPTER 5 Periodic Inspection M3x16 M4x18 E 2 x 9 Fig 5 10 5 24 CHAPTER 5 Periodic Inspection M3x30L M4x30L panhead bolt During reassembly reattach this bolt to the same position on the X axis arm as before Harmonic drive M4 nut M5 nut O ring D M3 setscrew y Wave generator supplied with harmonic ae Harmonic drive YK500XG YK600XG Fig 5 12 CHAPTER 5 Periodic Inspection M4 setscrew supplied with harmonic drive O ring 2 Wave generator Harmonic drive
59. XG YK800XG YK900XG YK1000XG Fig 5 6 5 18 CHAPTER 5 Periodic Inspection Apply grease to sufficiently fill in the ball space Wave generator Apply grease to entire oldham coupling Apply grease to entire inner surface to the thickness equal to ball diameter Fit O ring supplied into this groove Never remove these temporarily tightened bolts The axis will otherwise deviate from center Fig 5 7 5 19 CHAPTER 5 Periodic Inspection pa SSS SSS ny 2 Y axis 1 Prepare the following tools and items Harmonic grease 4B No 2 Waste cloth rag Phillips screwdriver Hex wrench set Screw Lock thread sealant Torque wrench Replacement parts See table below YK500XG YK600XG Replacement parts Parts name Type No YAMAHA Parts No Note Harmonic drive SHG 20 80 KBF M2510 000 CD Rubber wire diameter 1 78mm x Ring inner diameter 72 75mm KN4 M257K 000 Lower part of harmonic drive O ring 2 Rubber wire diameter 1 50mm x Ring inner diameter 49 00mm KN3 M2143 000 For motor 3 Rubber wire diameter 0 99mm x Ring inner diameter 53 28mm KN3 M2144 000 Supplied with harmonic drive YK600XGH YK700XG YK800XG YK900XG YK1000XG Replacement parts Parts name Type No YAMAHA Parts No Note Harmonic drive SHG 25 80 KBP M2510 000 CD 590 8 KN4 M2143 000 Lower part of harmonic drive O ring 2 Rubber wire diameter 1 78mm x Ring inne
60. YAMAHA robots have been completely adjusted at the factory or by the sales representative before shipment including the origin position adjustment If the operating conditions are changed and the robot must be adjusted then follow the procedures described in this chapter Safety Precautions 1 Read and understand the contents of this chapter completely before attempt ing to adjust the robot 2 Place a conspicuous sign indicating the robot is being adjusted to prevent others from touching the controller switch programming unit or operation panel 3 If a safeguard enclosure has not yet been provided right after installation of the robot rope off or chain off the movement area around the manipulator in place of a safeguard enclosure and observe the following points Use stable posts which will not fall over easily 2 The rope or chain should be easily visible by everyone around the robot 3 Place a conspicuous sign prohibiting the operator or other personnel from entering the movement area of the manipulator 4 To check operation after adjustment refer to 6 Trial Operation in Chapter 1 4 1 CHAPTER 4 Adjustment E 3 Adjusting the Origin All models of the YK XG series robots use an absolute type position detector The origin position zero pulse point can be determined by absolute reset Once absolute reset is performed you do not have to repeat absolute reset when turning the power on next time However a
61. a adus 4 1 PROJUSTING the OBITU e orans dona rette Mat er a a 4 2 3 1 Absolute reset eene nnn nennen nenne 4 3 3 1 1 Sensor method X axis Y axis and 4 3 3 1 2 Stroke end method Z axis cnet cete reed 4 3 3 2 Machine 4 4 3 3 Absolute reset procedures i edre eiei anaa REE E EEEE REA AERES 4 5 3 3 1 Sensor method X axis Y axis 4 5 3 3 2 Stroke end method 2 4 6 4 7 3 4 Changing the origin position and adjusting the machine reference 4 8 341 sSensor metodi teoria RU 4 9 3 4 1 1 gt YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG 1000 4 9 3 4 2 Stroke end method cde idee tecta rcd feeder iiec 4 27 3 4 2 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 4 27 Setting the Sort Limits ausu cuisse id edet Le bg 4 31 Setting the Standard Coordinates sss 4 34 5 1 Standard coordinate setting using a standard coordinate setup jig option 4 35 Affixing the Stickers for Movement Directions and Axis Names 4 38 MEMO CHAPTER 4 Adjustment 2 Overview
62. ace a sign indicating the robot is being inspected to keep others from operating the controller programming unit or operation panel 3 Check the following points from outside the safeguard enclosure Checkpoint Procedure Safeguard enclosure Emergency stop device Check if the safeguard enclosure is in place Check if emergency stop is triggered when the door is opened Check if warning labels are affixed at the entrance and clearly visible Press the emergency stop button to check if it works Robot movement Check for abnormal movement and excessive vibration and noise If any abnormal symptom is found contact YAMAHA dealer Z axis brake operation 1 Check if the brake works to stop the Z axis from dropping more than 3mm from the stationary point If any abnormal operation is found contact YAMAHA dealer 1 Visually check the Z axis movement when you press the emergency stop button from outside the safeguard enclosure and also when you turn off the controller 5 3 CHAPTER 5 Periodic Inspection a e 3 Adjustment and parts replacement 1 After inspection if you notice any adjustment or parts replacement is needed first turn off the controller and then enter the safeguard enclosure to perform the necessary work After adjustment or replacement is fin ished again review the checkpoints outlined in 1 and 2 above 2 If repair or parts replacement is required for the ro
63. ameter left set at 10kg this method shortens the cycle time since the acceleration is increased Chuck is gripping workpiece No workpiece Chuck 5kg Pl Chuck opens Workpiece 5kg P2 P3 Chuck closes 6 3 CHAPTER 6 Increasing the robot operating speed 3 Increasing the speed by the tolerance parameter Robot controller user s manual Also refer to Example Axis parameters Programming manual TOLE statement in 11 Command statements T From P1 to P3 via P2 TOLE 1 2048 TOLE 2 2048 TOLE 3 2048 TOLE 4 2048 MOVE P P2 TOLE 1 80 TOLE 2 80 TOLE 3 80 TOLE 4 80 MOVE P P3 Tolerance in Chapter 4 P3 Pl X axis tolerance pulses Increases the tolerance Y axis tolerance pulses Z axis tolerance pulses R axis tolerance pulses Returns the tolerance to the default value Tolerance can be set for each axis If the same tolerance is used for all axes you can write as TOLE 2048 If the same tolerance is used for all axes you can write as TOLE 80 When P2 is an escape point and does not need to be accurately positioned setting the tolerance parameter to a larger value allows the robot arm to pass through P2 quickly The larger the tolerance value for the positioning time the shorter the cycle time will be The maximum value of the tolerance parameter is 2048 pulses and the default is 80 puls
64. ase to the pallet supplied or installation base if robot is to be moved to another installation base 8 Using caution to keep the balance of the robot and avoid subjecting it to any strong vibrations and shocks operate the hoist carefully to move to the installation base The angle between each rope and the arm surface should be kept at 45 degrees or more 9 Slightly lower the robot on the installation base and temporarily secure it by tightening the bolts For tightening torque to secure the robot firmly see the next section 2 4 Installing the robot 10 Remove the rope eyebolts and arm clamp stay Screw the bolts into the upper surface of the X axis Always attach these bolts to protect the eyebolt hole threads Be sure to keep the eyebolts arm clamp stay bolts and pallet since they may be used to move the robot again Washers under stay Bolt Sa af L 22 N MNS H f Bolt M16x25 Hoist hook A LIS supplied with YK500XG YK600XG C Bolt M20x25 aD supplied with YK600XGH or longer arm robots 4 pieces supplied Rope Tightening torque 71Nm 720kgfcm Arm clamp stay supplied Bolts M4x8 2 pieces supplied Tightening torque 4 5Nm 46kgfcm Pallet supplied with the robot 3 7 CHAPTER 3 Installation 2 4 Installing the robot Install the robot securely with the four hex socket head bolts as shown in Fig 3 5
65. bot at the slowest possible speed The standard coordinate and point data must be reset when the origin posi tion is changed Make point data setting after changing the origin position After changing the origin position do not use the previous point data There are three absolute reset methods for the YK XG series the sensor method mark method and stroke end method The X axis Y axis and R axis use the sensor method as the initial setting while the Z axis uses the stroke end method 4 2 CHAPTER 4 Adjustment EA 3 1 Absolute reset method 3 1 1 Sensor method X axis Y axis and R axis In the sensor method the target axis is automatically operated for the absolute reset and the absolute reset is performed at the position where the proximity sensor provided on the target axis detects the detection area dog The absolute reset in the sensor method can be executed with the teaching pendant MPB RS 232C communication and dedicated input Serious injury might occur from physical contact with the robot during opera tion Never enter within the robot movement range during absolute reset CAUTION The origin cannot be detected in any axis which is not positioned on the plus side from the origin see Fig 4 2 before starting the return to origin operation Factory setting at shipment In this case press the STOP key to interrupt the return to origin operation move the target axis to the plus side of the
66. bot or controller please contact your YAMAHA dealer This work requires specialized technical knowledge and skill so do not attempt it by yourself 5 4 CHAPTER 5 Periodic Inspection Six Month Inspection Take the following precautions when performing 6 month inspection The Z axis will slide down when the Z axis brake is released causing a hazard ous situation Do not release the brake when lubricating the Z axis parts When lubricating the ball screw and spline shaft observe the following precautions Precautions when handling grease Inflammation may occur if this gets in the eyes Before handling the grease wear your safety goggles to ensure the grease will not come in contact with the eyes Inflammation may occur if the grease comes into contact with skin Be sure to wear protective gloves to prevent contact with skin Do not take orally or eat Eating will cause diarrhea and vomiting Hands and fingers might be cut when opening the container so use protec tive gloves Keep out of the reach of children Do not heat the grease or place near an open flame since this could lead to sparks and fires Emergency Treatment f this grease gets in the eyes wash liberally with pure water for about 15 minutes and consult a physician for treatment f this grease comes in contact with the skin wash away completely with soap and water f taken internally do not induce vomiting but promptly consult
67. bsolute reset is required if any of the follow ing cases occur The robot is shipped from the factory in condition c below so please perform absolute reset after installing the robot For more details on abso lute reset refer to Absolute Reset in Chapter 4 of the YAMAHA Robot Con troller User s Manual a Absolute related error occurred on the axis b Power drop was detected in the absolute battery for the driver installed inside the robot controller c Cable connecting the robot unit to the controller was disconnected This is the status when shipped from the factory d Robot generation was changed e Parameters were initialized f Axis parameters Origin shift Origin method Origin direction or Motor direction were changed g Motor was replaced Motor wiring connector was removed h Data in the ALL data file extension ALL or parameter file extension PRM was written into the controller by way of the RS 232C The following sections explain how to perform absolute reset CAUTION f any of the above cases occur after installing the robot absolute reset must be performed again To perform absolute reset move the robot arms back to their origin positions where the robot does not interfere with peripheral equip ment after the setup is complete After performing absolute reset move the robot to a known point to check whether the origin position is correctly set When doing this check move the ro
68. by Henkel Corporation Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 5 9 CHAPTER 5 Periodic Inspection 5 2 Basic replacement procedure for harmonic drive and precautions Basic procedures and precautions for replacing the harmonic drive are described below Before beginning the replacement work always be sure to read these re placement procedures and caution The motor and speed reduction gear casing are extremely hot after auto matic operation so burns may occur if these are touched Before touching these parts turn off the controller wait for a while and check that the tem perature has cooled When removing the wave generator from the motor shaft or reinstalling it back onto the motor shaft use caution to avoid as much as possible apply ing a thrust load to the motor shaft If a load is applied the resolver may be damaged resulting in a hazardous situation of the robot trouble Precautions when handling harmonic grease cleaning oil Inflammation may occur if they get in the eyes Before handling them wear your safety goggles to ensure they will not come in contact with the eyes Inflammation may occur if they come into contact with skin Be sure to wear protective gloves to prevent contact with skin Do not take orally or eat Eating will cause diarrhea and vomiting Hands and fingers might be cut when opening the container so use protec tive gl
69. cal connections to the robot correct 3 Are items such as air pressure correctly supplied 4 Is the robot correctly connected to peripheral equipment 5 Have safety measures safeguard enclosure etc been taken 6 Does the installation environment meet the specified standards 3 After the controller is turned on check the following points from outside the safeguard enclosure 1 Does the robot start and stop as intended Can the operation mode be selected correctly 2 Does each axis move as intended within the soft limits 3 Does the end effector move as intended Are the signal transmissions to the end effector and peripheral equipment correct Does emergency stop work Are the teaching and playback functions normal Are the safeguard enclosure and interlock working as intended Does the robot move correctly during automatic operation 2 wa CHAPTER 1 Using the Robot Safely E Work Within the Safeguard Enclosure 7 1 When work is required inside the safeguard enclosure always turn off the 2 wa controller and place a sign indicating that the robot is being adjusted or serv iced in order to keep any other person from touching the controller switch or operation panel except for the following cases 1 Origin position setting See Section 3 in Chapter 4 2 Soft limit settings See Section 4 in Chapter 4 3 Standard coordinate settings See Section 5 in Chapter 4 4 Teaching
70. cal stopper position 132 54 No 1 to 20 usable Y axis mechanical stopper position 152 47 x 34 mle g 19 T 0 21 25 46 M4 ground terminal 7 15 CHAPTER 7 Specifications SSS SSE ney 1 3 Robot inner wiring diagram User tubing Machine harness User IO connector Reavis resolver RP 1 Y axis resolver R axis motor RM I LI YM Y axis motor Round terminal 586 X axis arm Y axis origin sensor mamme Z axis motor Y axis arm Z axis brake Reaxis origin sensor Z axis resolver g X axis motor 2 Xaxis resolver XP I 4 HH Hh Sym I H m Tm mu User tubing I Y H ZP ZP N User IO connector RP HIH Yora N HO zone HO Ron rora H H H 7M 1 HO ZR Robot cable M4 ground terminal YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 7 8 7 16 CHAPTER 7 Spec
71. ce and the base Replace this O ring with a new one See Fig 5 4 and Fig 5 6 On the YK600XGH and YK700XG to YK1000XG an O ring is placed between the motor flange end face and the base 7 Remove the bolts securing the motor by using a hexagon long bit and ratchet handle while holding the motor not to let it drop see Fig 5 3 Items in parentheses apply to the YK600XGH and YK700XG to YK1000XG 8 Pull the motor out of the base while turning the X axis arm 9 Remove the wave generator from the motor shaft The wave generator is secured with a set screw 1 piece and keyway see Fig 5 6 A spacer and bolts need to be removed for YK600XGH and YK700XG to YK1000XG ACAUTION A spacer is inserted between the wave generator and the motor so be careful not to lose it No spacer is used there for the YK600XGH and YK700XG to YK1000XG When you remove the X axis arm installation bolts in the next step the X axis arm may come off causing a hazardous situation Be especially careful to keep the arm from falling when a heavy tool is attached to the arm tip See Fig 5 4 Removing the X axis arm is dangerous for just one person Always use two or more people or remove the Y axis arm in advance Refer to 2 Y axis of 5 2 1 for removing the Y axis arm 10 Remove the X axis arm installation bolts by using a hexagon bit and ratchet handle See Fig 5 4 5 13 CHAPTER 5 Periodic Inspection Se 11 Remove
72. chine harness 1 YK500XG YK600XG Connector pins 1 to 20 can be used Pin 25 is connected to a shield wire and cannot be used as a signal wire Connector Connection Connector o o 10 Base side User signal line 10 Arm side a RET cut EET gt E E o 2 u A o o Shield Flame Ground Robots models with non standard specifications may have different wiring colors 3 13 CHAPTER 3 Installation 4 As shown in Fig 3 8 solder the user cable wires to the D sub connector supplied with the robot Reattach the hood to the D sub connector after soldering then plug it into the user wiring connector The connector pinouts as viewed from the solder side are shown below Hood Soldering Cable to be prepared by user D sub connector 13 12 11 10 9 8 7 6 5 4 3 2 1 123245060 7 8 9 10 11 12 13 o 00000000000 0 m Q 0 oO O O O O O O O O O 5 24 23 1 20 19 18 17 16 15 14 14 15 16 17 18
73. d or difficult to see necessary cautions may not be taken resulting in an accident Do not remove alter or stain the warning labels on the robot Do not allow the warning labels to be hidden by the device installed to the robot by the user Provide proper lighting so that the symbols and instructions on the warning labels can be clearly seen even from the outside of safeguard enclosure 18 Protective bonding Be sure to ground the robot and controller to prevent electrical shock 19 Be sure to make correct parameter settings CAUTION The robot must be operated with correct tolerable moment of inertia and accel eration coefficients according to the manipulator tip mass and moment of iner tia If this is not observed premature end to the life of the drive units damage to the robot parts or residual vibration during positioning may result 20 Do not use the robot for tasks requiring motor thrust CAUTION Avoid using the YK XG series robots for tasks which make use of motor thrust press fitting burr removal etc These tasks may cause malfunctions of the robot 21 1f the X Y R axis rotation angle is small CAUTION If the X Y or R axis rotation angle is smaller than 5 so that it always moves in the same position an oil film is difficult to be formed on the joint support bear ing possibly leading to damage to the bearing In this type of operation add a movement so that the joint mo
74. del ots used mm YK500XG YK600XG M6 or lager 2 or more 15 3 20 021 YK600XGH YK700XG YK800XG YK900XG YK1000XG 8 lager 2 or more 37 0 380 25 et Table 3 3 Tron material base Bolt diameter X 1 5 or more Depth of t hol Aluminum material base Bolt diameter 3 0 or more JIS B 1176 hex socket head bolt or equivalent Strength class JIS B 1051 12 9 or equivalent Recommended bolt 3 27 CHAPTER 3 Installation End effector or stay Hole diameter Fig 3 27 3 28 Bolt Slot Spline shaft CHAPTER 3 Installation Gripping force of end effector The gripping force of the end effector must have a sufficient extra margin of strength versus the workpiece weight and reaction force applied to the workpiece during robot operation The reaction force applied to the workpiece during opera tion can be calculated from the acceleration applied to the end effector attach ment The maximum acceleration on the end effector attachment of each robot model is listed in the table below When the workpiece position is offset to the end effector attachment the accelerations Amax and Axvmax become larger by an amount equal to the offset versus the arm length When the R axis rotates during operation this acceleration must be taken into account Table 3 4 Maximum acceleration during robot operation Amax m sec2
75. e respectively indicate the acceleration coefficients of the X axis Y axis and R axis The symbol Ir Jr is the moment of inertia of the load around the R axis and m is the tip mass Example YK500XG Assume that the mass of the load installed to the R axis is 1 5kg and the moment of inertia around R axis is 0 1kgm 1 0kgfcmsec When the tip mass parameter is set to 2kg the robot can be operated by reducing the X Y and R axis acceleration coefficients to 62 as can be seen from Fig 3 9 Be sure to select an optimum tip mass and acceleration coefficient param eters that meet the mass of the load and moment of inertia before using the robot To make settings for the tip mass and acceleration coefficient refer to the separate YAMAHA Robot Controller User s Manual Methods for calculating the moment of inertia of the load are shown in Sec tion 6 2 however it is not easy to precisely figure out these values If a calcu lated value smaller than the actual moment of inertia is set residual vibra tions may occur If this happens reduce the acceleration coefficient param eter even further The robot must be operated with correct tolerable moment of inertia and acceleration coefficients according to the manipulator tip mass and moment of inertia If this is not observed premature end to the life of the drive units damage to the robot parts or residual vibration during positioning may result Depending on the Z axis posi
76. e Fig 5 16 CAUTION An O ring 3 is fitted to the shaft Replace this O ring with a new one Also replace the V ring with a new one Do not remove the sleeve See Fig 5 16 9 Remove the bolts securing the R axis motor and pull out the R axis motor while turning the R axis See Fig 5 17 CAUTION An O ring is placed between the R axis motor flange and the Y axis arm Replace this O ring with a new one See Fig 5 17 10 Loosen the two setscrews for the wave generator Pull the wave generator out of the R axis motor shaft See Fig 5 20 CAUTION An O ring 5 is placed between the R axis motor shaft and the wave generator Replace this O ring with a new one See Fig 5 20 11 Remove the bolts securing the harmonic drive and remove the harmonic drive See Fig 5 18 An O ring 2 is fitted to the harmonic drive Replace this O ring with a new one See Fig 5 18 12 Remove the shaft mounting bolts from the harmonic drive and also remove the panhead bolt along with the nut Then remove the shaft On the YK600XGH and YK700XG to YK1000XG remove the dog and bolt See Fig 5 19 b An O ring is placed between the harmonic drive and shaft Replace this O ring with a new one See Fig 5 19 a b 5 28 CHAPTER 5 Periodic Inspection A 13 Apply the harmonic grease to the new wave generator See Fig 5 21 for applying the grease 14 Fit the O ring
77. e brake Use caution not to let your body get caught between the Z axis and installa tion base when releasing the brake to perform direct teach 1 9 CHAPTER 1 Using the Robot Safely EE 5 Safety Measures for the System Since the robot is commonly used in conjunction with an automated system dan gerous situations are more likely to occur from the automated system than from the robot itself Accordingly appropriate safety measures must be taken on the part of the system manufacturer according to the individual system The system manufacturer should provide a proper instruction manual for safe correct opera tion and servicing of the system CHAPTER 1 Using the Robot Safely G 6 Trial Operation After making installations adjustments inspections maintenance or repairs to the robot make a trial run using the following procedures 1 If a safeguard enclosure has not yet been provided right after installation of the robot rope off or chain off around the movement area of the manipulator in place of the safeguard enclosure and observe the following points 1 Use sturdy stable posts which will not fall over easily 2 The rope or chain should be easily visible by everyone around the robot 3 Place a sign to keep the operator or other personnel from entering the movement range of the manipulator Check the following points before turning on the controller 1 Is the robot securely and correctly installed 2 Are the electri
78. e date of shipment 2 After one year has elapsed from the date of installation 3 After 2 400 hours of operation This warranty will not apply in the following cases 1 Fatigue arising due to the passage of time natural wear and tear occurring during op eration natural fading of painted or plated surfaces deterioration of parts subject to wear etc 2 Minor natural phenomena that do not affect the capabilities of the robot and or related product noise from computers motors etc 3 Programs point data and other internal data that were changed or created by the user Failures resulting from the following causes are not covered by warranty repair 1 Damage due to earthquakes storms floods thunderbolt fire or any other natural or man made disasters 2 Troubles caused by procedures prohibited in this manual 3 Modifications to the robot and or related product not approved by YAMAHA or YAMAHA sales representatives 4 Use of any other than genuine parts and specified grease and lubricants 5 Incorrect or inadequate maintenance and inspection 6 Repairs by other than authorized dealers CHAPTER 1 Using the Robot Safely N YAMAHA MOTOR CO LTD MAKES NO OTHER EXPRESS OR IMPLIED WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS IN LIEU OF ALL EXPRESSED OR IMPLIED WARRANTIES INCLUDING WARRAN TIES OF ME
79. e end effec tor attachment should be used only for preventing the end effector from com ing loose Do not fasten the end effector just by using this tapped hole If the end effec tor is fastened only with this tapped hole it may come loose from the attach ment during robot operation and fly off resulting in accidents or injuries 3 26 CHAPTER 3 Installation Table 3 1 Fxymax Fzmax Frmax Mrmax Mmax N kgf N kgf N kgf Nm kgfm Nm kgfm YK500XG 173 18 134 14 506 52 24 2 6 15 1 5 YK600XG 173 18 134 14 506 52 24 2 6 15 1 5 YK600XGH 489 49 214 22 696 71 56 57 26 2 7 YK700XG 489 49 214 22 696 71 56 5 7 26 2 7 YK800XG 489 49 191 19 696 71 56 57 24 24 YK900XG 443 46 191 19 696 71 56 5 7 24 2 4 YK1000XG 443 46 191 19 696 71 56 5 7 24 2 4 The end effector attachment must have adequate strength to withstand the loads listed in Table 3 1 If too weak the attachment may break during robot operation and fragments fly off causing accidents or injuries The end effector attachment must have sufficient rigidity versus the loads listed in Table 3 1 If this rigidity is inadequate the end effector may vibrate during robot operation causing bad effects on the manipulator operation End effector Stay FRmax Fig 3 26 Maximum load applied to end effector attachment Table 3 2 torque Hole diameter Bolts Used Number of bolts Robot Mo
80. e reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it 16 Reattach the cover after the adjustment is complete X axis origin dog Fig 4 3 a 4 10 CHAPTER 4 Adjustment X axis origin sensor stay X axis origin sensor Cover Fig 4 3 b 4 11 CHAPTER 4 Adjustment M 1 2 Changing the X axis origin position The X axis origin position can be changed to any position in the range from the front position of the X axis arm base to a maximum of 120 clockwise and counterclockwise at 30 intervals by changing the positions of the dog and the mounting bolt for the X axis speed reduction unit as shown in Fig 4 4 CAUTION f the origin position has been changed then the absolute reset must be performed the machine reference must be adjusted and the standard coor dinate and point data must be reset The dog and bolt might come off and cause the joint to lock up unless you apply Screw Lock to them and tighten to the specified torque The following describes the method for changing the X axis origin position for example to a position 90 counterclockwise 1
81. eattach the cover 24 Go outside the safeguard enclosure 25 Check that no one is inside the safeguard enclosure and then turn on the controller After the Harmonic drive is replaced the absolute reset must be performed and the point data must be reset Refer to Chapter 4 Adjustment to adjust it 5 30 CHAPTER 5 Periodic Inspection Cover Disconnect this R axis motor ring tongue terminal located inside the cover e Fig 5 13 Holder Bearing mount plate 5 5 14 Spline Fig 5 14 5 31 CHAPTER 5 Periodic Inspection Flat surface Bearing moun YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 5 15 V ring Degrease and make it tight contact with sleeve Sleeve Do not remove this sleeve from spline nut Spline nut CHAPTER 5 Periodic Inspection Fig 5 17 5 33 CHAPTER 5 Periodic Inspection M3x14 M3x16 O ring 2 5 34 CHAPTER 5 Periodic Inspection O ring YK500XG YK600XG Fig 5 19 a 5 35 CHAPTER 5 Periodic Inspection YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 5 19 b 5 36 CHAPTER 5 Periodic Inspection e O ring Wave generator Harmonic drive M4 setscrew gt lt
82. ection 1 See Fig 4 9 When the machine reference is more than 40 move the stay in direction See Fig 4 9 As an approximate guide a 1 9mm movement equals to 100 4 24 CHAPTER 4 Adjustment 2 12 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 13 Perform the absolute reset from outside the safeguard enclosure 14 After the absolute reset is completed read the machine reference value dis played on the MPB 15 If the machine reference value is in the range between 40 and 60 recom mended range then the machine reference has been completely adjusted If it is outside the recommended range then repeat the procedure that starts in 5 to readjust it 16 Reattach the cover after the adjustment is complete 4 25 CHAPTER 4 Adjustment SSS lt lt 1 R axis origin dog R axis origin sensor stay CHAPTER 4 Adjustment 3 4 2 Stroke end method The stroke end method is employed on the YK XG series robots for the absolute reset of the Z axis The origin position of the Z axis is fixed at the upper end of the Z axis stroke and it cannot be changed The machine reference is factory adjusted at shipment and readjustment is not necessary for normal use The read justment in the following procedure is required ho
83. ee E eaa 3 9 Robot Cable Connection oio EDD cba n 3 11 User Wiring and User Tubing 3 12 Attaching the End Effector a 3 16 6 1 R axis tolerable moment of inertia and acceleration coefficient 3 16 6 1 1 Acceleration coefficient vs moment of inertia 5 0 3 17 6 1 2 Acceleration coefficient vs moment of inertia 3 17 6 1 3 Acceleration coefficient vs moment of inertia YK600XGH 3 18 6 1 4 Acceleration coefficient vs moment of inertia YK700XG 8 3 18 6 1 5 Acceleration coefficient vs moment of inertia YK900XG YK1000XG 3 19 6 2 Equation for moment of inertia calculation sese 3 20 63 Example of moment of inertia 3 23 6 4 Attaching the end effector sse eene nennen nnne nen 3 25 6 5 Gripping force of end 3 29 Limiting the Movement Range with X Axis Mechanical Stoppers 3 30 7 1 gt YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 3 31 Working Envelope and Mechanical Stopper Positions for Maximum Working ENIVCIODG arcc 3 33 MEMO CHAPTER 3 Installation See
84. ely follow the procedure below See Fig 3 4 Use the same procedure to move other robots 1 Lower the Z axis to a point approximately 24mm 35mm for YK600XGH or longer arm robots lower than the origin position Then turn off the controller and unplug the robot cable from the controller The Z axis is fixed to the base with an arm clamp stay at the factory prior to shipment 2 Remove the bolts on the X axis arm 3 Fold the X and Y axis arms as shown in the drawing and clamp the Y axis arm to the robot base by using the stay bolts and washers 2 washers for YK500XG and YK600XG 1 washer for YK600XGH or longer arm robots that come with the robot If the arms cannot be folded in the carrying position due to the X axis mechanical stoppers then remove them When the robot is shipped the mechanical stoppers are installed to provide the maximum movement range 3 6 CHAPTER 3 Installation Se eS SS SSS SSS SS 4 Screw the two eyebolts through washers into the upper surface of the X axis arm 5 Wind the robot cable around the upper part of the robot base so that it does not hang up on the base mount then fasten the cable end with adhesive tape 6 Prepare two looped ropes with the same length to allow a good lifting balance then pass each rope through each eyebolt and catch it on the hoist hook 7 Slightly lift the hoist so that each rope has light tension to hold the robot In this state remove the bolts securing the robot b
85. ence The adjustment method for the R axis machine reference is as follows 1 Prepare a hex wrench set 2 Check that no one is inside the safeguard enclosure and then turn on the controller 3 Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method 4 If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adjustment procedure 5 Placea sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel 6 Turn off the controller and enter the safeguard enclosure 7 Mark off the reference mark at the current origin position on the R axis area of the robot At this time be careful not to touch the tool at the tip of the robot arm so that the origin position does not shift 8 Remove the cover 9 Scribe a mark on the position of the R axis origin sensor stay 10 Using the hex wrench loosen the two bolts securing the R axis origin sensor stay See Fig 4 9 CAUTION The bolts only need to be loosened and do not need to be completely re moved 11 Move the R axis origin sensor stay in the following manner and then secure it with the bolts NOTE When the machine reference is less than 40 move the stay in dir
86. ep the Y axis arm level by two people so as not to apply a moment to the Y axis One person supports the tip of the Y axis arm The other person secures the Y axis arm Apply small amounts of Screw Lock to the 16 bolts and tighten them uni formly to secure the Y axis arm See Fig 5 10 Tighten the bolts to the specified torque CAUTION Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of the groove 17 Apply harmonic grease to the new wave generator and flexible spline See Fig 5 7 for applying grease properly 18 Fit the wave generator onto the motor shaft and fully insert it against the motor Then apply small amounts of Screw Lock to the set screw 1 piece you removed earlier and tighten it to secure the wave generator See Fig 5 12 On the YK600XGH and YK700XG to YK1000XG do not forget to insert a spacer 19 Fit a new O ring 2 to the motor and place the motor in the Y axis arm while turning the Y axis joint Then tighten the bolts you removed earlier to temporarily secure the motor to the Y axis arm See Fig 5 9 On the YK600XGH and YK700XG to YK1000XG fit the new O ring 2 into the groove in the Y axis arm See Fig 5 12 Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of groove 20
87. equire a license only properly qualified personnel may operate it The equipment and tools used for moving the robot should be serviced daily The YK XG series robot comes packed with a robot controller and accessories according to the order specifications Using a carrying cart dolly or forklift move the package to near the installation base Take sufficient care not to apply shocks to the equipment when unpacking it Robot manipulator m ua n lt d Robot controller and accessories Arm clamping stay Used only for transportation Remove after installation YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 3 2 Packed state 3 4 CHAPTER 3 Installation 1 2 2 Checking the product After unpacking check the product configuration and conditions The following configurations are typical examples so please check that the prod uct is as specified in your order CAUTION If there is any damage due to transportation or insufficient parts please notify your YAMAHA sales office or dealer immediately Controller RCX240 Robot YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Standard Warning label x 1 CD ROM User s Manual or User s Manual Sas Standard coordinate setting jig 2 TU option Robot manipulator YK XG series Eyebolts x2 RCX240controller RPB pr
88. er attached to the Z axis spline can damage the Z axis ball screw Never remove or move it CAUTION Do not remove this part Damage to the ball screw will result not remove this D to ball FEIERN Fig 1 4 Warning label 4 1 3 CHAPTER 1 Using the Robot Safely 5 Do not use the robot in environments containing inflammable gas etc This robot was not designed for operation in environments where inflamma ble or explosive substances are present Do not use the robot in environments containing inflammable gas dust or liquids Explosions or fire could otherwise result 6 Do not use the robot in locations possibly subject to electro magnetic interference etc Avoid using the robot in locations subject to electromagnetic interference elec trostatic discharge or radio frequency interference Malfunction may otherwise occur 7 Use caution when releasing the Z axis vertical axis brake The Z axis will slide down when the Z axis brake is released causing a hazard ous situation Press the emergency stop button and prop up the Z axis with a support stand before releasing the brake Use caution not to let your body get caught between the Z axis and installa tion base when releasing the brake to perform direct teach 8 Provide safety measures for end effector gripper etc End effectors must be designed and manufactured so that they cause no ha
89. es 6 4 CHAPTER 6 Increasing the robot operating speed EE ee ee ee 4 Increasing the speed by the OUT effective position parameter Also refer to Robot controller user s manual Axis parameters Out effective Position in Chapter 4 Programming manual OUTPOS statement in 11 Command statements Example From P1 when chuck is open OUTPOS 1 10000 X axis OUT effective position OUTPOS 2 10000 Y axis OUT effective position OUTPOS 3 10000 Z axis OUT effective position pulses pulses pulses Increases the OUT effective position C The OUT effective position can be set for each axis If the same OUT effective ma OUTPOS 4 10000 R axis OUT effective position pulses MD position is used for all axes you MOVE P P2 Z 0 can write as OUTPOS 10000 DO3 0 1 Chuck closes OUTPOS 1 2000 Returns the OUT effective position to the default value If the same OUT effective OUTPOS 2 2000 position is used for all s it OUTPOS 3 2000 OUTPOS 4 2000 Chuck starts closing OUT effective position P1 P2 Chuck closed When all of the X Y Z and R axes enter the OUT effective position 10000 pulses prior to P2 the chuck starts closing By setting the OUT effective posi tion larger the chuck starts closing while the robot arm is still moving at an earlier point so that the chuck can grip the
90. g inner diameter 43 00mm 90990 17J036 Spline nut 4 Rubber wire diameter 1 30mm x Ring inner diameter 53 00mm 90990 17J038 Y axis arm 5 Rubber wire diameter 0 5mm x Ring inner diameter 28 00mm 90990 17J037 Wave generator Edge seal V 28A N C KBP M1886 000 FORSHEDA 2 Turn off the controller 3 Place a sign indicating that the robot is being inspected to keep others from operating the controller switch 4 Enter the safeguard enclosure 5 Remove the cover See Fig 5 13 Unplug the connectors on the R axis motor power wire RM and resolver wire RP in the Y axis arm Also disconnect the R axis motor ring tongue terminal The Z axis will slide down when the bearing mounting bolts are removed in the next step causing a hazardous situation Prop the Z axis with a support stand before loosening these bolts See Fig 5 14 5 27 CHAPTER 5 Periodic Inspection SSS EAT 6 Remove the bolts securing the bearing to the upper end of the spline and remove the spline and bearing from the holder See Fig 5 14 7 Fitthe spanner or wrench to the flat surfaces at the bottom of the spline to grip it and loosen and remove the U nut on top of the spline with the hook spanner Then remove the bearing and bearing mount plate See Figs 5 15 and 5 16 At this point be careful to keep the spline shaft from coming off the spline nut 8 Remove the bolts securing the spline nut and remove the spline nut Se
91. hx I kgm 32 4 8 Ten gn Center line as 4 21 2 J B DA Rotation center gt _ WD wx kgfcmsec 8g g h sc Eq 3 5 Density kg m kg cm g Gravitational acceleration cm sec Pf m Mass of cylinder kg W Weight of cylinder kgf Fig 3 18 In the same manner the moment of inertia of a cylinder as shown in Fig 3 19 is given by np puD hx m D nm j MR MEM j Pr D h 2 PR D hx 16g D h 3 4g Cneterline gt E m kgfcmsec Eq 3 6 Fig 3 19 In the same manner the moment of inertia of a prism as shown in Fig 3 20 is given by pabc a b gt m a b pabex mx 2 2 4 Center line C gt J b pabex 12g g 2 b INS kgfcmsec 12g g Eq 3 7 m Mass of prism kg W Weight of prism kgf 3 22 CHAPTER 3 Installation a ee ee ee eee 6 3 Example of moment of inertia calculation Let s discuss an example in which the chuck and workpiece are at a position offset by 10cm from the R axis by a stay as shown in Fig 3 21 The moment of inertia is calculated with the following three factors assuming that the load mate rial is steel and its density is 0 0078kg cm 6cm Workpiece Fig 3 21 1 Moment of inertia of the stay From Fig
92. ical stopper posi tions or to the point where interference with the peripheral equipment oc curs and note the X axis and Y axis plus and minus direction pulses displayed on the MPB 6 Check that no one is inside the safeguard enclosure then cancel emergency stop from outside the safeguard enclosure 7 Setthe soft limits to within the figure for the X axis and Y axis encoder pulses that you noted above in step 5 This software limit setting must be made from outside the safeguard enclo sure Refer to the YAMAHA Robot Controller User s Manual for further details on soft limit settings 4 31 CHAPTER 4 Adjustment CAUTION The origin position factory adjusted at shipment is not completely aligned with the front face position of the robot When introducing the robot be sure to set the soft limits with the number of pulses from the origin position 0 pulse posi tion 2 3 Setting the Z axis soft limits Make this setting from outside the safeguard enclosure The Z axis has me chanical stoppers fixed at the upper and lower ends of the Z axis movement range When the actual working range of the robot is smaller than the maxi mum working envelope or the manipulator interferes with the peripheral equip ment reduce the Z axis plus soft limit pulses to narrow the working envelope Setting the R axis soft limit To make this setting set emergency stop just as for the X axis and Y axis or be s
93. ifications 1 4 Wiring table Robot cable wiring table Resolver Resolver HLIM GND24 HLIM GND24 Origin Sensor GND ORG 24V Origin Sensor 24V ORG k c AB Orange 1 Red Orange 1 Black 0 15sq Twisted pair Gray 1 Red Gray 1 Black 0 15sq Twisted pair Sky blue 2 Red Sky blue 2 Black 0 15sq Twisted pair Green 0 3sq Orange 2 Red Orange 2 Black 0 15sq Twisted pair Bright green 2 Red Bright green 2 Black 0 15sq Twisted pair Pink 2 Red Pink 2 Black 0 15sq Twisted pair Green 0 3sq Gray 2 Red 0 15sq Gray 2 Black 0 15sq Green 0 359 Green 0 3sq Sky blue 3 Red Sky blue 3 Black 0 15sq Twisted pair Pink 3 Red Pink 3 Black 0 15sq Twisted pair Bright green 1 Red Bright green 1 Black 0 15sq Twisted pair Round terminal YM Black Red 0 75sq 0 75sq White Yellow Green 0 75sq 0 75sq AR e v gt exo Yellow Brown 0 75sq 0 75sq Blue 0 75sq CHAPTER 7 Specifications Resolver Connector
94. in Chapter 4 Programming manual ARCH statement in 11 Command statements D Gate motion From point P1 to P4 via P2 and P3 Z 0 P2 P3 MOVE P P2 MOVE P P3 MOVE P P 4 Pl P4 2 Arch motion Using default arch position 2000 pulses From point P1 to P2 MOVE P P2 Z 0 MI M2 M4 A Axis parameters Arch position MI X axis arch position 2000 pulses M3 M2 Y axis arch position 2000 pulses P1 o P2 M3 Z axis arch position 2000 pulses MA R axis arch position 2000 pulses When the Z axis moves upward from P1 and enters the M3 arch position range 2000 pulses prior to Z 0 the X Y and R axes begin to move When these 3 axes enter the M1 M2 and M4 arch position range 2000 pulses prior to P2 the Z axis moves downward to P2 Compared with the gate motion 1 this arch motion shortens the cycle time approximately 2096 by moving the robot arm along an arc 6 1 CHAPTER 6 Increasing the robot operating speed aS Se ee nnn erii 3 Arch motion Making the arch position value larger In the arch motion 2 making the arch position value larger can further shorten the cycle time Since the robot arm moves along a larger arc use caution to avoid obstacles if they are located near the arm movement path The arch position pa rameter can be set for each axis 4 Arch motion changing the arch positions in the program From point P1 to P2 and then to P3 ARCH 1 10000 X axis arch position
95. inate setting using a standard coordinate setup jig de scribes how to set the standard coordinates more accurately using an optional setup jig 6 Whenthe standard coordinate settings are complete check the following points from outside the safeguard enclosure 1 Check that the robot arm tip can move at right angles in MANUAL opera tion cartesian coordinates 2 Check that the values nearly equal to the X axis and Y axis arm lengths are entered in Arm length of the axis parameters If the above points are not satisfied the standard coordinate settings are in correct so make the standard coordinate settings again 4 34 CHAPTER 4 Adjustment E 5 1 Standard coordinate setting using a standard coordinate setup jig option 1 2 3 4 5 6 7 8 9 Y direction X direction Fig 4 12 Check that no one is inside the safeguard enclosure and then turn on the controller Press the emergency stop button on the MPB to set emergency stop Refer to the YAMAHA Robot Controller User s Manual for further details on emergency stop and canceling emergency stop Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel Enter the safeguard enclosure while holding the MPB Position the robot arms as shown in Fig 4 13 and remove the screw Position the robot arms so that you can easily insert the sleeve into the hole
96. justed to keep others from touch ing the controller switch or operation panel 3 Set the controller to MANUAL mode if not in MANUAL mode 4 Press the F13 LOWER F3 key to select RST ABS 5 Select M3 Z axis 6 Since the message Reset ABS encoder OK is displayed check that there are not any obstacles in the robot movement range and press the F4 key YES 7 After absolute reset is complete check that the adjustment machine refer ence value displayed on the MPB is within the absolute reset tolerance range 33 to 67 CAUTION Use the following procedure to display the adjustment machine reference value When adjusting the machine reference value always check the ad justment machine reference value with this procedure 1 Press the MODE key 2 Press the F3 key to enter MANUAL mode 3 Press the F13 key LOWER F3 to select ABS Reset 4 After the Z axis absolute reset is complete press the F10 UPPER F5 key to display the adjustment machine reference value 06 If the machine reference value is outside the absolute reset tolerance range then the next absolute reset may not be properly performed In this case make the necessary adjustments by referring to 3 4 Changing the origin position and adjusting the machine reference in Chapter 4 4 7 CHAPTER 4 Adjustment ER 3 4 Changing the origin position and adjusting the machine reference CAUTION e If the origin positi
97. lue cs D sub connector for user wiring 74 No 1 to 20 usable 54 47 f Working envelope of right handed system e di E X axis mechanical stopper position 132 13 21_ Y axis mechanical stopper position 152 25 46 M4 ground terminal 7 7 CHAPTER 7 Specifications 80 400 300 220 D sub connector for user wiring No 1 to 20 usable a aa T lt si User tubing 1 06 black we User tubing 2 66 red 50 4 014 User tubing 3 06 blue 75 M12 bolt for installation 4bolts used 245 Base size 63 128 990 2400 stroke en 790 Z200mm stroke 71 Maximum 770 during arm rotation 476 440 368 333 5 319 5 4 1939 5 278 208 7 2 User tool 219 installation range gt gt 0 2 2517 0 021 E 32 950 ge pee 3 8 surface has no phase relation to R axis origin 2 S E N 8 S Z axis lower end mechanical stopper position Cross section e 4 M4x0 7 through hole for tool attachment Four M4x10L binding screws are supplied Do not screw the screws in deeper than 10
98. mm from bottom surface of arm o 5 9 iem E e 15 136 N M20x2 5 Depth 20 Bottom of spline 2 Fig 7 4 YK700XG 7 8 CHAPTER 7 Specifications E M 9 J BED Rn S o 730 ove 124 Working envelope of left handed system User tubing 1 6 black User tubing 2 6 red User tubing 3 D sub connector for user wiring No 1 to 20 usable 74 54 A 34 He Working envelope of right handed system 19 alda X axis mechanical stopper position 132 0 25 46 _ Y axis mechanical stopper position 152 4 ground terminal 7 9 CHAPTER 7 Specifications 80 400 D sub connector for user wiring No 1 to 20 usable 120 189 99 User tubing 1 66 black User tubing 2 06 red User tubing 3 06 blue 99 220 4 014 M12 bolt for installation 4bolts used 245 Base size 63 128 990 Z400mm stroke eo 790 Z200mm stroke 711 Maximum 770 during arm rotation 86 _ 98 LJ 476 440 D 368 9
99. nates CAUTION If the standard coordinate settings are incorrect the acceleration cannot be optimized to match the arm position This results in too short a service life damage to the drive unit or residual vibration during positioning In addition the cartesian coordinate accuracy will be impaired Setting the standard coordinates enables the following operations and functions 1 Optimizes acceleration according to arm position during automatic op eration 2 Allows moving robot arm tip at right angles 3 Allows using shift coordinates 4 Enables commands such as linear interpolation and arm switching The procedure for setting standard coordinates and cautions are shown below 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Check that the soft limits are correctly set If not correctly set adjust the soft limits while referring to the description of 4 Setting the Soft Limits in Chapter 4 3 Place a sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 4 Enter the safeguard enclosure while holding the MPB Stay outside the robot movement range at this time 5 Make the standard coordinate settings while referring to methods for Setting the Standard Coordinates as explained in the YAMAHA Robot Controller User s Manual Never enter within the robot movement range The next section 5 1 Stand ard coord
100. ng th Orgio ura at ese ema 4 2 3 1 Absolute reset 4 3 3 1 1 Sensor method X axis Y axis and R axis sss 4 3 3 1 2 Stroke end method Z axis r aa E e a aa nennen nnne 4 3 3 2 Machine reference ee ge eee dpa et ca en aa de Fa e eed 4 4 3 3 Absolute reset 4 5 3 3 1 Sensor method X axis Y axis and R axis sss 4 5 3 3 2 Stroke end method Z axis essent 4 7 3 4 Changing the origin position and adjusting the machine reference 4 8 3 4 1 Sensormethod ee eee vae ee ed eee es 4 9 3 4 1 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 4 9 3 4 2 Stroke end method eene enne nennen 4 27 3 4 2 1 gt YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 4 27 4 Setting the Soft Limits asc Un utro nato reco sa aen dedecus 4 31 5 Setting the Standard 4 34 5 1 Standard coordinate setting using a standard coordinate setup jig option 4 35 6 Affixing the Stickers for Movement Directions and Axis Names 4 38 CHAPTER 5 Periodic Inspecition 1 COVEFVIGW Loa coo pen oto RM 5 1 2 oe manco Dr ae odit Bota mes 5 2 Daily Aspect
101. nt Use a cloth moistened with alcohol to re move grease from the surface where you will affix the stickers After the surface is dry affix the stickers securely See Fig 4 18 Affix the origin position stickers precisely on the origin positions Align the direc tion of movement stickers with the jog direction and affix them correctly Affix each axis name sticker on the correct axis Affixing the sticker at a wrong loca tion may cause faulty operation and hazardous situations a Origin position stickers b Direction of movement and axis name stickers Fig 4 17 4 38 CHAPTER 4 Adjustment a GIN End effector Fig 4 18 4 39 MEMO 4 40 a A C CHAPTER Periodic Inspecition QI m Ic 5 1 Precautions atin tins 5 2 DENNA olei nieee E ec 5 3 Six Month Inspection oleae allan d Pa al ene tes 5 5 Replacing the Harmonic 5 9 5 1 Replacement 5 9 5 2 Basic replacement procedure for harmonic drive and precautions 5 10 5 2 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 5 12 MEMO CHAPTER 5 Periodic Inspection A 1 Overvie
102. nvalid For details on standard coordinates see 5 Setting the Standard Coordinates in Chapter 4 If you do not want to change the origin position by initializing make a note of the ARM LENGTH and OFF SET PULSE settings before initializing and re enter their settings after ini tialization is complete Robot initialization number Model name 2117 YK500XG 7200 2118 YK500XG 7300 2119 YK600XG 7200 2120 YK600XG 7300 2121 YK600XGH 7200 2122 YK600XGH 7400 2123 YK700XG 7200 2124 YK700XG 7400 2125 YK800XG 7200 2126 YK800XG 7400 2127 YK900XG 7200 2128 YK900XG 7400 2129 YK1000XG 7200 2130 YK1000XG 7400 2 4 a amp O CHAPTER Installation Robot Installation Conditions 3 1 1 1 Installation 3 1 1 2 Installatiori base iie ne etd ERE ron etes Doni npa cei dee insta abes Den ed Ferne 3 2 MERE I TITTEN 3 4 2 1 eerte e ee Hee Pl eee bee eee et bu ee e EH e eek sd 3 4 2 2 Checking the 3 5 2 3 Moving the robot uinci tee Le Ue tnb e Ld unc 3 6 2 3 1 Moving the YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG VK OOO X Gitte 2s ELT I E 3 6 2 4 Installing the ertet denm Peas irren eter Erro ER ds 3 8 Protective Bonding Luise cues ve sors es
103. observe the con ditions listed in Table 3 2 If these are ignored the end effector may come loose and fly off during robot operation resulting in an accident or injury In cases where other attachment methods are used be sure that the end effector will not come off when the loads listed in Table 3 1 are applied The user s end effector that attaches to the robot must have adequate strength and rigidity as well as gripping force to prevent positioning errors Table 3 1 shows the maximum load that can be applied to the end effector attachment of each robot model Recommended methods for attaching end effectors are shown in Table 3 2 and Fig 3 27 Refer to Fig 3 25 for details on the end effector attach ment of each robot model Refer to Fig 3 3 for the depth of tapped hole and recommended type of tap bolt When checking end effector operation refer to 6 Trial Operation in Chapter 1 3 25 CHAPTER 3 Installation Never loosen this bolt End effector attachment area Spline shaft hollow diameter 14 20 h7 8021 Q M16x2 depth 20 YK500XG YK600XG 40 Never loosen this bolt Spline shaft hollow diameter 18 End effector attachment area 25 h7 8021 M20x2 5 depth 20 YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 3 25 The tapped hole see Figs 3 25 provided on the lower part of th
104. of bolt by using hexagon bit and torque wrench see Fig 5 5 and Fig 5 7 Tighten the bolts to the specified torque Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of the groove 17 Fit the spacer and wave generator onto the motor shaft and fully insert them against the motor Then apply small amounts of Screw Lock to the set screw 1 piece you removed earlier and tighten it to secure the wave genera tor onto the motor shaft see Fig 5 6 For 600XGH and YK700XG to YK1000XG the wave generator need to be fixed with M5 bolts and spacers prior to this step 5 14 CHAPTER 5 Periodic Inspection 18 Place a new O ring 2 in the cylindrical section of the base and push the O ring to the top end face See Fig 5 4 CAUTION Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of the groove 19 Push the X axis motor into the base while moving the X axis arm by hand Push the X axis motor into the base while moving the X axis arm by hand Uniformly tighten the four bolts by using the hexagon long bit and torque wrench while moving the X axis arm by hand slowly left and right through 45 If any jamming or catching is felt while moving the axis at this time then reassemble from the beginning See Fig 5 3 20 Rea
105. of the controller during inspection always first turn off the controller power switch and also the power source in order to prevent possible electrical shock Never touch any internal parts of the controller For precautions on handling the controller refer to the YAMAHA Robot Con troller User s Manual 15 Consult us for corrective action when the robot is damaged or malfunction occurs If any part of the robot is damaged or any malfunction occurs continuous op eration may be very dangerous Please consult YAMAHA dealer for corrective action If the following damages or troubles exist These dangers can happen Damage to machine harness or robot cable Electrical shock malfunction of robot Flying outwards of damaged parts during robot Damage to exterior of robot operation Abnormal operation of robot Tu MT Malfunction of robot positioning error excessive vibration etc Z axis brake trouble Dropping of load 16 Use caution not to touch the high temperature motor or speed reduction gear casing The motor and speed reduction gear casing are extremely hot after automatic operation so burns may occur if these are touched Before touching these parts during inspections or servicing turn off the controller wait for a while and check that the temperature has cooled 1 6 CHAPTER 1 Using the Robot Safely 17 Do not remove alter or stain the warning labels If warning labels are remove
106. ogramming box etc Fig 3 3 Product configurations 3 5 CHAPTER 3 Installation 2 3 Moving the robot WARNING Serious injury may occur if the robot falls and pins someone under it Do not allow any part of your body to enter the area beneath the robot during work Always wear a helmet safety shoes and gloves during work To check the mass of each robot refer to 1 1 Basic specifications in Chapter 7 2 3 1 Moving the YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Serious injury may occur if the robot falls and pins someone under it Check that there are no cracks and corrosion on the eyebolt installation If found do not use eyebolts to move the robot Screw the eyebolts securely into the tapped holes until the bearing surface of eyebolt makes tight contact with the bearing surface on the arm Use a hoist and rope with carrying capacity strong enough to support the robot weight Make sure the rope stays securely on the hoist hook Remove all loads attached to the robot manipulator end If any load is still attached the robot may lose balance while being carried and topple over causing accidents CAUTION When moving the robot by equipment such as cranes that require a license only properly qualified personnel may operate it The equipment and tools used for moving the robot should be serviced daily To move a robot for example the YK500XQG correctly and saf
107. oller the MOTOR connectors XM and ZM and YM and RM each have identical shapes In addition the connectors XY and ZR have identical shapes Do not confuse these connectors when making con nections Wrong connections may result in malfunction and hazardous situa tions If the connector installation is inadequate or if there are contact failures in the pins the robot may malfunction causing a hazardous situation Reconfirm that each connector is securely installed before turning on the controller To attach the PI connector securely tighten the screws supplied with the robot Take caution not to apply an excessive load to the connectors due to stress or tension on the cables Lay out the cables so that they do not obstruct the movement of the manipu lator Determine the robot work area in which the robot cables will not inter fere with the load or workpiece picked up by the manipulator If the robot cables interfere with the movable parts of the robot the cables may be dam aged causing malfunction and hazardous situations Refer to 1 2 External view and dimensions in Chapter 7 Lay out the robot cables so as to keep the operator or any other person from tripping on them Bodily injury may result if someone trips on the cables Controller side connector Robot side connector RCX240 XM S ZM Robot cable XY POBIO XY SS ROB I O ZR ZR Fig 3 7 Robot cable connections
108. oller User s Manual Set the origin position with the absolute reset CAUTION Never enter the robot movement range once the robot servo is turned on as this is extremely hazardous 2 Affixing the origin position sticker Set in emergency stop when absolute reset is complete and immediately affix the origin point sticker according to instructions in 6 Affixing Stickers for Origin Positions Movement Directions and Axis Names in Chapter 4 of this manual 3 Setting the reference coordinates Set the reference coordinates while referring to instructions in 5 Setting the Reference Coordinates in Chapter 4 of this manual and also to Setting the Reference Coordinates in the YAMAHA Robot Controller User s Manual Robot malfunctions vibration noise may occur if the reference coordinates are not set correctly Even though there is no problem with the robot the following error messages are issued when the robot and controller are connected and power first turned on Actual error messages may differ according to how the robot and controller are connected Error messages issued when robot amp controller are connected RCX240 17 81 D ABS battery wire breakage 17 83 D Backup position data error 1 17 85 D Backup position data error 2 17 92 D Resolver disconnected during power off 17 93 D Position backup counter overflow etc 2 If the X Y or R axis rotation angle is small If the X Y or R axis rota
109. on has been changed then the absolute reset must be performed the machine reference must be adjusted and the standard coor dinate and point data must be reset If any machine reference is adjusted the origin position may change Before the adjustment mark off the reference mark at the current origin position on the main body of the robot After the machine reference is adjusted be sure to check that the origin position has not deviated If the origin position changes after the machine reference has been adjusted then the standard coordi nate and point data must be reset 4 8 3 4 1 3 4 1 1 CHAPTER 4 Adjustment Sensor method YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 1 1 Adjusting the X axis machine reference CAUTION The origin position may change due to machine reference adjustment If it oc curs you must set point data again The adjustment method for the X axis machine reference is as follows 1 2 8 9 Prepare a hex wrench set Check that no one is inside the safeguard enclosure and then turn on the controller Perform the absolute reset from outside the safeguard enclosure Refer to 3 3 Absolute reset procedures for information about the absolute reset method If any machine reference value displayed on the MPB is not in the range between 40 and 60 recommended range after the absolute reset has been completed then proceed with the following adj
110. oove 18 Fit the new O ring 4 coated with harmonic grease into the O ring groove of the Y axis arm Insert the R axis motor into the Y axis arm while turning the R axis Then tighten the bolts to secure the R axis motor while turning the R axis See Fig 5 17 CAUTION Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of groove 5 29 CHAPTER 5 Periodic Inspection E 19 Fit the new O ring 3 coated with harmonic grease into the groove at the bottom of the shaft Attach a new V ring to the top of the sleeve and secure the spline nut to the shaft with the bolts you removed earlier See Fig 5 16 CAUTION Do not allow the O ring to get caught out of the groove during reassembly A problem will occur if the robot is operated with the O ring left caught out of groove 20 Insert the bearing mount plate and bearing onto the spline from the top and tighten the U nut to secure the bearing Utilize the flat surfaces when tightening the U nut like you did to loosen it On the YK600XGH and YK700XG to YK1000XG do not forget to insert a spacer See Fig 5 15 21 Insert the spline and bearing through the holder and secure them with the bolts you removed earlier See Fig 5 14 22 Reconnect the R axis motor power wire RM and resolver wire RP Also reconnect the R axis motor ring tongue terminal 23 R
111. orking envelope in manual operation after return to origin and during automatic operation Note The working envelope is the area limited by soft limits 4 Mechanical stoppers If the servo power is suddenly shut off during high speed operation by emer gency stop or safety functions these mechanical stoppers prevent the axis from exceeding the movement range The movement range is the area lim ited by mechanical stoppers The movement ranges of the X axis arm can be limited as needed by use of mechanical stoppers On the Y axis arm mechanical stoppers are fixed at both ends of the maxi mum movement range The Z axis has a mechanical stopper at the upper end and lower end No mechanical stopper is provided on the R axis Axis movement will not stop immediately after the servo power supply is shut off by emergency stop or other safety functions 5 Z axis vertical axis brake An electromagnetic brake is installed on the Z axis to prevent the Z axis from sliding down when servo power is turned off This brake is working when the controller is off or the Z axis servo power is off even when the controller is on The Z axis brake can be released by means of the program ming unit or by a command in the program when the controller is on The Z axis will slide down when the Z axis brake is released creating a haz ardous situation Press the emergency stop button and prop the Z axis with a support stand before releasing th
112. ormance cannot be maintained if any part of the harmonic drive is used in a damaged state This damage or wear may also lead to trouble with the harmonic drive Since a positional shift occurs after replacing the harmonic drive it is neces sary to make absolute reset standard coordinate setting and point data set ting again 5 11 CHAPTER 5 Periodic Inspection SE ee en ne 2 a CEN eS ne MU eme 5 2 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG The following steps describe procedures and precautions when replacing the har monic drives of the YK500XG and YK600XG The illustrations show the 500 For the bolt tightening torques in this work refer to Table 5 2 Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 1 X axis 1 Prepare the following tools and items Harmonic grease 4B No 2 Waste cloth rag Phillips screwdriver Hex wrench set Screw Lock thread sealant e Ratchet handle Hexagonal socket set Torque wrench with ratchet Replacement parts See table below Hexagon long bit YK500XG YK600XG For M6 installation diameter 9 53 outer diameter 17 or lessl 83 mm approx at full length lt YK600XGH to YK1000XG gt For M5 installation diameter 9 53 outer diameter 17 less 128mm approx at full length Hexagon bit lt YK500XG YK600XG gt For M4 installation diameter 6 35 YK600 to YK100
113. oves Keep out of the reach of children Do not heat them or place near an open flame since this could lead to sparks and fires Emergency Treatment f they get in the eyes wash liberally with pure water for about 15 minutes and consult a physician for treatment f they come in contact with the skin wash away completely with soap and water f taken internally do not induce vomiting but promptly consult a physician for treatment Disposing of harmonic grease cleaning oil and the container Proper disposal is compulsory under federal state and local regulations Take appropriate measures in compliance with legal regulations Do not pressurize the empty container Pressurizing may cause the con tainer to rupture Do not attempt to weld heat up drill holes or cut this container This might cause the container to explode and the remaining materials inside it to ignite CAUTION The harmonic drive service life may shorten if the grease recommended by YAMAHA is not used 5 10 CHAPTER 5 Periodic Inspection E MG Recommended grease Use the following harmonic drive grease 4B No 2 made by Harmonic Drive Systems Inc CAUTION Harmonic drive Do not apply strong shocks or impacts to these parts such as with a hammer Also do not scratch scar or dent these parts by dropping etc Such actions will damage the harmonic drive The specified perf
114. period The harmonic drive replacement period is determined by the total number of turns of the wave generator used in the harmonic drive It is recommended to replace the harmonic drive when the total number of turns has reached 8 4x10 at ambient operating temperatures of 0 C to 40 C This means that re placement period will differ depending on the following operating conditions If the robot operation duty ratio is high or the robot is operated in environments at higher temperatures the harmonic drive should be replaced earlier Replacement peed 8 4x108 nx60xhxDxNx6 years where n Number of axis movements per minute 0 Average turn per axis movement Speed reduction ratio h Operation time per day D Operation days per year For example when the robot is used under the following conditions the replacement period for the X axis harmonic drive of the YK500XG can be calculated as follows n 10 0 0 25 N 80 h 24 hours per day D 240 days per year Replacement perdes 8 4x10 nx60xhxDXxNx90 8 4 10 10 60 24 240 80 0 25 12 2 Table 5 1 Harmonic drive speed reduction ratio YK500XG YK600XG 80 80 30 YK600XGH YK700XG YK800XG YK900XG YK1000XG 80 80 50 Table 5 2 Bolt tightening torque Bolt size Tightening torque kgfcm Tightening torque Nm M3 button head bolt set screw M3 M4 5 M6 M8 Recommended Screw Lock LOCTITE 262 made
115. pulses Arch position can be set for each axis ARCH 2 20000 Y axis arch position pulses ARCH 3 20000 Z axis arch position pulses ARCH 4 20000 R axis arch position pulses MOVE P P2 Z 0 ARCH 1 2000 If the same arch position value ARCH 2 2000 pulses is used for all axes you can write as ARCH 2000 ARCH 3 2000 ARCH 4 2000 MOVE P P3 Z 100 Since the arch positions can be changed in the program optimizing the arch po sitions can further shorten the cycle time Arch position large Arch position small X Z 100 P1 P2 Z 0 6 2 CHAPTER 6 Increasing the robot operating speed l 2 Increasing the speed with the WEIGHT statement Also refer to Robot controller user s manual Robot parameters Axis tip weight in Chapter 4 Programming manual WEIGHT statement in 11 Command statements Example From P1 when chuck is open WEIGHT 5 Changes the axis tip weight parameter to 5kg no workpiece MOVE P P2 Z 0 DO3 0 1 Chuck closes WEIGHT 10 Changes the axis tip weight parameter to 10kg with workpiece MOVE P P3 Z 0 In the above program the acceleration can be set to a higher level by reducing the axis tip weight parameter to 5kg while the chuck does not grip any workpiece and then set to a lower level by changing the axis tip weight parameter to 10kg Compared to programs using an axis tip weight par
116. r diameter 66 40mm 90990 17J030 For motor 3 Rubber wire diameter 1 3mm x Ring inner diameter 66 50mm 5 2571 000 with harmonic drive 2 Turn off the controller 3 Place a sign indicating that the robot is being inspected to keep others from operating the controller switch 4 Enter the safeguard enclosure 5 Remove the cover See Fig 5 8 6 Unplug the connectors on the Y axis motor power wire YM and resolver wire YP in the Y axis arm Also disconnect the Y axis motor ring tongue terminal 7 Remove the bolts securing the Y axis motor and slowly pull out the Y axis motor while turning the Y axis joint See Fig 5 9 Items in parentheses apply to the YK600XGH and YK700XG to YK1000XG An O ring 2 is fitted to the motor Replace this O ring with a new one See Fig 5 12 5 20 CHAPTER 5 Periodic Inspection 8 Remove the wave generator from the motor shaft The wave generator is secured with a set screw 1 piece and keyway See Fig 5 12 When you remove the Y axis arm installation bolts in the next step the Y axis arm may come off causing a hazardous situation Be especially careful to keep the arm from falling when a heavy tool is attached to the arm tip See Fig 5 10 9 Remove the Y axis arm installation bolts See Fig 5 10 10 Remove the Y axis arm and place it where it will not obstruct the work CAUTION An O ring 3 is fitted to the upper
117. ration inspection and maintenance is provided in each chapter Be sure to comply with these in structions to ensure safe use of the robot 1 Observe the following cautions during automatic operation Warning labels 1 Fig 1 1 are affixed to the robot See Fig 2 2 for the loca tions of warning labels Install a safeguard enclosure protective enclosure to keep any person from entering within the movement range of the robot and suffering injury due to being struck by moving parts nstall a safety interlock that triggers emergency stop when the door or panel is opened nstall safeguards so that no one can enter inside except from doors or panels equipped with safety interlocks The warning labels shown in Fig 1 1 are supplied with the robot and should be affixed to a conspicuous spot on doors or panels equipped with safety interlocks Serious injury or death will result from impact with moving robot Keep outside of guard during operation Lock out power before approaching robot DANGER Serious injury or death will result from impact with moving robot Keep outside of guard during operation Lock out power before approaching robot Fig 1 1 Warning label 1 2 Use caution to prevent hands or fingers from being pinched or crushed Warning labels 2 Fig 1 2 are affixed to the robot See Fig 2 2 for the loca tions of warning labels Be careful not to let hands or fingers be pinched or
118. rew and spline Check for backlash If any abnormality is found contact Z axis ball spline ball screw YAMAHA dealer 1 Bolt tightening torque Bolt size Tightening torque kgfcm Tightening torque Nm M3 button head bolt set screw M3 M4 5 M6 M8 Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 5 6 CHAPTER 5 Periodic Inspection Supply grease through the grease nipple Apply grease to the groove Lower the spline and apply grease to the groove Fig 5 1 5 7 CHAPTER 5 Periodic Inspection 2 Inspection to be performed with the controller turned on The robot controller must be installed outside the safeguard enclosure to prevent a hazardous situation in which you or anyone enter the safeguard enclosure to inspect the controller while it is turned on Bodily injury may occur from coming into contact with the fan while it is rotat ing When removing the fan cover for inspection first turn off the controller and make sure the fan has stopped 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller programming unit or operation panel 3 Check the following points from outside the safeguard enclosure Checkpoint P
119. rocedure Check if the fan rotates normally Check if objects blocking the fan are located and remove if any are found Check for abnormal noise from the rotating fan If abnormal noise is heard visually check and remove the cause If no cause is found contact YAMAHA dealer Check for dust on the fan cover Remove and clean if necessary Cooling fan at rear of controller 3 Adjustment and parts replacement 1 After inspection if you notice any adjustment or parts replacement is needed first turn off the controller and then enter the safeguard enclosure to perform the necessary work After adjustment or replacement is fin ished again review the checkpoints outlined in 1 and 2 above 2 If repair or parts replacement is required for the robot or controller please contact your YAMAHA dealer This work requires specialized technical knowledge and skill so do not attempt it by yourself 5 8 CHAPTER 5 Periodic Inspection Replacing the Harmonic Drive The YK XG series robots listed in Table 5 1 use a harmonic drive as the speed reduction gear for the X Y and R axes Harmonic drives need to be replaced after a specified operation time Use the guideline explained below to determine the replacement period and replace the harmonic drive periodically Since the YK XG series robots listed in Table 5 1 use long life harmonic grease it is not neces sary to replace the harmonic grease 5 1 Replacement
120. signed for operation in environments where inflamma ble or explosive substances are present Do not use the robot in environ ments containing inflammable gas dust or liquids Explosions or fire could otherwise result Avoid using the robot in locations subject to electromagnetic interference electrostatic discharge or radio frequency interference Malfunction may oth erwise occur Do notuse the robot in locations subject to excessive vibration Robot instal lation bolts may otherwise become loose causing the manipulator to fall over 3 1 CHAPTER 3 Installation 1 2 Installation base Install the robot on a horizontal surface with the base mount section facing down If installed by other methods with the base mount section not facing down grease might leak from the reduction gear unit Do not place the robot on a moving installation base Excessive loads will be applied to the robot arm by movement of the installation base resulting in damage to the robot CAUTION The manipulator positioning might decrease if the installation surface preci sion is insufficient f the installation base is not sufficiently rigid and stable or a thin metallic plate is attached to the installation base vibration resonance may occur during operation causing detrimental effects on the manipulator work 1 Prepare a sufficiently rigid and stable installation base taking account of the robot weight including
121. te reset is completed read the machine reference value dis played on the MPB 19 If the machine reference value is in the range between 40 and 60 recom mended range then the origin position has been correctly changed Fully tighten the bolts to secure the Y axis origin sensor stay If it is outside the recommended value then adjust the machine reference by referring to 2 1 Adjusting the Y axis machine reference 20 Reattach the cover after the adjustment is complete Y axis origin position adjustable range Factory preset Y axis origin position Dog Mounting bolt for Y axis speed reduction unit Fig 4 7 4 20 CHAPTER 4 Adjustment Fig 4 8 a CHAPTER 4 Adjustment Fig 4 8 c CHAPTER 4 Adjustment Robot model EAT kgfcm Tightening a cNm YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Recommended Screw Lock LOCTITE 262 made by Henkel Corporation Hex nut Robot model Bolt Tightening kgfcm em YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Recommended Screw Lock LOCTITE 262 made by Henkel Corporation Use only YAMAHA genuine bolts or JIS B 1176 hex socket head bolts strength class JIS B 1051 12 9 Fig 4 8 e 4 23 CHAPTER 4 Adjustment SSS SSS 3 Adjusting R axis machine refer
122. ter 1 When you need to touch the terminals or connectors on the outside of the controller during inspection always first turn off the controller power switch and also the power source in order to prevent possible electrical shock Never touch any internal parts of the controller For precautions on handling the controller refer to the YAMAHA Robot Con troller User s Manual 5 2 CHAPTER 5 Periodic Inspection Daily Inspection The following is an inspection list that must be performed every day before and after operating the robot 1 Inspection to be performed with the controller turned off 1 Turn off the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller switch 3 Enter the safeguard enclosure and check the following points Checkpoint Procedure Machine harness Robot cable User cable and wiring Check for scratches dents and excessive bend and kinks If the machine harness or robot cable is damaged contact YAMAHA dealer Regulator joints air tube solenoid valve air cylinder Check air pressure Check for air leaks Check drain Check air filter for clogging or damage Robot exterior Check for damage If a damage is found contact YAMAHA dealer 2 Inspection to be performed with the controller turned on 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Pl
123. the robot is being adjusted in order to keep others from operating the controller or operation panel 5 Turn off the controller and enter the safeguard enclosure 6 Remove the cover See Fig 4 8 a 7 Using the hex wrench loosen the two bolts securing the Y axis origin sensor stay 8 Remove the Y axis origin sensor stay 9 Remove the dog and hex nut through the elongated hole See Fig 4 8 b We recommend using the Phillips screwdriver bit and wrench to remove the dog since it is secured with Screw Lock 10 Rotate the Y axis arm 90 counterclockwise See Fig 4 8 c 11 Remove the bolt located opposite the elongated hole 12 Apply Screw Lock to the dog and nut insert them into the tapped hole where the bolt was attached and tighten to the specified torque See Fig 4 8 d 13 Return the Y axis arm to the current origin position See Fig 4 8 e 14 Apply Screw Lock to the bolt insert it into the tapped hole where the dog was attached and tighten to the specified torque 4 19 CHAPTER 4 Adjustment EE 15 Temporarily fasten the Y axis origin sensor stay using the bolts At this point check that the sensor does not interfere with any parts while turning the Y axis arm by hand 16 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 17 Perform the absolute reset from outside the safeguard enclosure 18 After the absolu
124. tion vibration may occur when the X Y or R axis moves If this happens reduce the X Y or R axis acceleration to an appropriate level If the moment of inertia is too large vibration may occur on the Z axis de pending on its operation position If this happens reduce the Z axis accel eration to an appropriate level CHAPTER 3 Installation 6 1 1 Acceleration coefficient vs moment of inertia YK500XG Ax AY AR 0 04 0 4 100 L RB 0 05 0 1 0 15 0 2 0 25 0 3 Ir kgm 4 1 5 2 0 2 5 3 0 Jr kgfcmsec Fig 3 9 mz1 to 10kg o o a zi o 6 1 2 Acceleration coefficient vs moment of inertia YK600XG Ax Av AR 96 306 J 0 03 0 3 80 60 40 20 0 0 05 0 1 0 15 0 2 0 25 0 3 Ir kgm 0 0 5 1 0 1 5 2 0 2 5 3 0 Jr kgfcmsec Fig 3 10 m 1 to 10kg 3 17 CHAPTER 3 Installation aE 6 1 3 Acceleration coefficient vs moment of inertia YK600XGH Ax Av AR 96 0 03 0 3 24 55 03 0 2 0 4 0 6 0 8 10 Ir kgm2 2 0 4 0 6 0 8 0 10 0 Jr kgfcmsec Fig 3 11 mz1 to 20kg 6 1 4 Acceleration coefficient vs moment of inertia YK700XG YK800XG Ax AY AR 0 02 0 2 100 X 80 60 20 0 0 2 0 4 0 6 0 8 1 0 1 kgm 0 2 0 4 0 6 0 8 0 10 0 Jr kgfcmsec Fig 3 12 1 to 20kg 3 18 CHAPTER 3 Installation a a ek
125. tion angle is smaller than 5 so that it always moves in the same position an oil film is difficult to be formed on the joint support bear ing possibly leading to damage to the bearing In this type of operation add a movement so that the joint moves through 90 or more about 5 times a day 3 Do not remove the Z axis upper end mechanical stopper Removing or moving the upper end mechanical stopper attached to the Z axis spline can damage the Z axis ball screw Never remove or move it ee Introduction The YAMAHA YK XG series robots are SCARA type industrial robots devel oped based on years of YAMAHA experience and achievements in the automa tion field as well as efforts to streamline our in house manufacturing systems The YK XG series robots have a two joint manipulator consisting of an X axis arm and a Y axis arm and are further equipped with a vertical axis Z axis and a rotating axis R axis at the tip of the manipulator The YK XG series robots can be used for a wide range of assembly applications such as installation and inser tion of various parts application of sealant and packing operations This instruction manual describes the safety measures handling adjustment and maintenance of YK XG series robots for correct safe and effective use Be sure to read this manual carefully before installing the robot Even after you have read this manual keep it in a safe and convenient place for future reference This ins
126. truction manual should be used with the robot and considered an integral part of it When the robot is moved transferred or sold send this manual to the new user along with the robot Be sure to explain to the new user the need to read through this manual This manual describes the YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG and YK1000XG For details on specific operation and programming of the robot refer to the separate YAMAHA Robot Controller User s Manual NOTES The contents of this manual are subject to change without prior notice Information furnished by YAMAHA in this manual is believed to be reliable However if you find any part unclear or inaccurate in this manual please contact YAMAHA sales office or dealer YAMAHA MOTOR CO LTD IM Operations MEMO CONTENTS CHAPTER 1 Using the Robot Safely 1 N O oa A CO PD _ 8 _tb 12 Safety Informallofpeas os 1 1 Essential Caution Items cas 1 2 Special Training for Industrial Robot Operation 1 8 Robot Safety 1 9 Safety Measures for the 1 10 Operation Eoo iets rS PR GU d EO p DE rM Id 1 11 Work Within the Safeguard Enclosure 1 12 Automatic Operation
127. ttach the connectors on the X axis motor power wire XM and resolver wire XP See Fig 5 2 Also reattach the X axis motor ring tongue terminal 21 Reattach the base robot pedestal front and rear covers 22 Go outside the safeguard enclosure 23 Check that no one is inside the safeguard enclosure and then turn on the controller CAUTION After the Harmonic drive is replaced an absolute reset must be performed and the standard coordinate and point data must be reset Refer to Chapter 4 Ad justment to adjust it Cover The ring terminal for the X axis motor is located behind the cover Disconnect the terminal 5 15 CHAPTER 5 Periodic Inspection CHAPTER 5 Periodic Inspection M4x18 M5x40 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG Fig 5 4 5 17 CHAPTER 5 Periodic Inspection M5 nut M6 nut Harmonic drive M4x30L M5x40L panhead bolt Es During reassembly reattach amp O ring 3 supplied with harmonic drive this bolt to the same position on the X axis arm as before gt setscrew lt e J Wave generator supplied with harmonic drive Harmonic drive M4 setscrew supplied with harmonic drive 429 0 ES Motor mating end face lt gt Motor flange end face Motor flange end face Do not remove this spacer YK500XG YK600XG YK600XGH YK700
128. uard enclosure during automatic operation 3 If an error occurs in the robot or peripheral equipment observe the fol lowing procedure before entering the safeguard enclosure 1 Press the emergency stop button to set the robot to emergency stop 2 Place a sign on the start switch indicating that the robot is being in spected in order to keep any other person from touching the start switch and restarting the robot 9 Adjustment and Inspection Do not attempt any installation adjustment inspection or maintenance unless it is described in this manual 10 Repair and Modification Do not attempt any repair parts replacement and modification unless described in this manual These works require technical knowledge and skill and may also involve work hazards 1 13 CHAPTER 1 Using the Robot Safely SSS a 11 Warranty The YAMAHA robot and or related product you have purchased are warranted against the defects or malfunctions as described below Warranty description Warranty Period Exceptions to the Warranty Ifa failure or breakdown occurs due to defects in materials or workmanship in the genuine parts constituting this YAMAHA robot and or related product within the warranty period then YAMAHA will repair or replace those parts free of charge hereafter called warranty repair The warranty period ends when any of the fol lowing applies 1 After 18 months one and a half year have elapsed from th
129. ulse value you made note of in step 9 Y axis position pulse value you made a note of in step 10 2 Round off the decimal part of the M2 value 14 After entering the parameters remove the pin bolt and sleeve Reattach the cover plate and screw 4 36 CHAPTER 4 Adjustment Fig 4 14 Fig 4 15 Sleeve Fig 4 16 4 37 CHAPTER 4 Adjustment 6 Affixing the Stickers for Movement Directions and Axis Names The robot comes packed with stickers showing origin positions movement direc tions and axis names as shown in Fig 4 17 Using the following procedure at tach these stickers in conspicuous points on the robot after changing the origin position and installing peripheral equipment 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Move the robot to the 0 pulse position To move the axes to their 0 pulse positions see Chapter 4 Point trace function in the YAMAHA Robot Controller User s Manual 3 Turn off the controller 4 Placea sign indicating the robot is being adjusted to keep others from oper ating the controller switch 5 Enter the safeguard enclosure 6 Being careful not to move the origin positions attach stickers at conspicuous points on matching sides of components such as the robot arm of each axis base robot pedestal and end effector Affix stickers nearby showing the axis name and direction of moveme
130. upport stand under the Z axis because it will drop under its own weight 11 Use caution on Z axis movement when air supply is stopped 2 axis robots with air driven Z axis The Z axis may suddenly drop when the air pressure to the Z axis air cylinder solenoid valve is reduced creating a hazardous situation Turn off the controller and place a prop or support under the Z axis before cutting off the air supply 12 Use the following caution items when disassembling or replac ing the pneumatic equipment Air or parts may fly outwards if pneumatic equipment is disassembled or parts replaced while air is still supplied Do service work after first turning off the controller and reducing the air pres sure Before reducing the air pressure place a support stand under the Z axis 2 axis robots with air driven Z axis since it will drop under its own weight 1 5 CHAPTER 1 Using the Robot Safely 13 Use the following caution items when removing the Z axis mo tor The Z axis will drop when the Z axis motor is removed possibly resulting in injury Turn off the controller and set a support stand under the Z axis before re moving the motor Use caution not to allow hands or body to be squeezed or crushed by moving parts on the Z axis or between the Z axis and the installation base 14 Use the following caution during inspection of controller When you need to touch the terminals or connectors on the outside
131. ure to do this from outside the safeguard enclosure The R axis has no mechanical stoppers When the actual working range of the R axis is small or it interferes with the peripheral equipment reduce the R axis plus soft limit pulse and minus soft limit pulses to narrow the working enve lope CAUTION Overloads may occur if the soft limit is almost near the encoder pulse at the mechanical stopper and the operating point is used at the edge of the move ment range Set the soft limit to the inner side of the mechanical stopper with an ample safety margin 4 32 CHAPTER 4 Adjustment a ee RY 4 Relation between the X Y and R axis movement angle the Z axis movement distance and the number of pulses The tables below are for calculating resolver pulses with respect to the X Y and R axis movement angles and to the Z axis movement distance for each robot Use these figures as a guide to set the soft limits X Y and R axis speed reduction ratio and Z axis ball screw lead for each robot nis Yes rais YK500XG YK600XG 80 20mm 30 YK600XGH YK700XG YK800XG YK900XG YK1000XG 80 80 20mm 50 Operation angle distance vs number of resolver pulses X Y and R axis speed reduction ratio 491520 819200 1310720 1638400 1720320 1982464 Z axis Lead Number of resolver pulses per lead movement 4 33 CHAPTER 4 Adjustment E 5 Setting the Standard Coordi
132. us situation Always prop up the Z axis with a support stand or the like 7 Prop the spline or end effector with a support stand to prevent the Z axis from dropping 8 Lift up the Z axis lower end damper If this is difficult insert a screwdriver between the damper and the holder and pry up the damper See Fig 4 11 a 9 Put a mark to indicate the current flange position with respect to the motor shaft Fit the spanner wrench to the flat surfaces of the flange and loosen the bolts This allows the ball screw to rotate freely independent of the Z axis motor 10 Rotate the flange with respect to the motor shaft See Fig 4 11 b Rotating the flange 30 degrees changes the machine reference value by 33 The machine reference value decreases by rotating the flange clockwise as viewed from top while it increases by rotating the flange counterclockwise Determine the flange position based on the Z axis machine reference value you made a note of so that the machine reference value is within 33 to 67 11 Tighten the bolts a little at a time in a diagonal pattern The tightening torque should be 2 0Nm 20kgfcm The bolts can be inserted into 10 holes among 12 through holes 12 Go outside the safeguard enclosure 13 Check that no one is inside the safeguard enclosure and then turn on the controller 14 Perform the Z axis absolute reset To perform the Z axis absolute reset see 3 3 Absolute reset procedures in Chapter 4
133. used 319 5 278 273 i HE 208 742 A o User tool gt installation range 5 0 22 2517 0 021 L 5 28 055 gE 8 surface has no phase relation to R axis origin N o F4 5 id a P 2 Z axis lower end mechanical stopper position at EZ T Cross section A A 4 M4x0 7 through hole for tool attachment Four M4x10L binding screws are supplied Do not screw the screws in deeper than 10mm from bottom surface of arm Fig 7 6 YK900XG 7 12 711 Maximum 770 during arm rotation 476 339 5 254 5 219 CHAPTER 7 Specifications Working envelope of left handed system HI User tubing 1 6 black User tubing 2 06 red User tubing 3 06 blue Working envelope of right handed system D sub connector for user wiring 74 No 1 to 20 usable X axis mechanical stopper position 132 st Y axis mechanical stopper position 152 47 TN amp 34 e 8 19 21 0 E E 25 46 M4 ground terminal 7 13 CHAPTER 7 Specifications 80 400 600 220 D sub connector for user wiring No 1 to 20 usable 161 22
134. ustment procedure Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel Turn off the controller and enter the safeguard enclosure Mark off the reference mark at the current origin position on the X axis joint area of the robot At this time be careful to prevent the origin position from deviating since the X axis arm is touched Remove the cover Scribe a mark on the position of the X axis origin sensor stay 10 Using the hex wrench loosen the two bolts securing the X axis origin sensor stay See Fig 4 3 CAUTION The bolts only need to be loosened and do not need to be completely re moved CHAPTER 4 Adjustment Se 11 Move the X axis origin sensor stay in the following manner and then secure it with the bolts NOTE When the machine reference is less than 40 move the stay in direction O See Fig 4 3 b When the machine reference is more than 40 move the stay in direction See Fig 4 3 b As an approximate guide a Imm movement equals to 100 12 Go out of the safeguard enclosure and check that no one is inside the safe guard enclosure Then turn on the controller 13 Perform the absolute reset from outside the safeguard enclosure 14 After the absolute reset is completed read the machine reference value dis played on the MPB 15 If the machin
135. vement range with me chanical stoppers CAUTION When the mechanical stoppers are installed the soft limits must be set to a point inside the mechanical stopper positions Refer to 4 Setting the Soft Lim its in Chapter 4 3 30 CHAPTER 3 Installation aa a a Ha e 7 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG To change the X axis mechanical stopper positions for example from the maxi mum movement range 132 to 87 use the following procedure 1 Prepare a hex wrench set 2 Turn off the robot controller 3 Placea sign indicating the robot is being adjusted to keep others from touch ing the controller switch 4 Enter the safeguard enclosure 5 Remove the screw plug X axis mechanical stopper bolt and washer as shown in Fig 3 30 Then reinstall the mechanical stopper bolt and washer at the position that determines the desired movement range by tightening the bolt to the torque specified in Table 3 5 Reinstall the screw plug you removed into the position where the X axis stopper bolt was installed 6 Check that the movement range is limited by the mechanical stoppers as desired 7 Go outside the safeguard enclosure 8 Check that no one is inside the safeguard enclosure when turning on the controller Table 3 5 Robot Model Tightening torque kgfcm Tightening torque Nm YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK100
136. ves through 90 or more about 5 times a day 1 7 CHAPTER 1 Using the Robot Safely E M 3 Special Training for Industrial Robot Opera tion Companies or factories using industrial robots must make sure that every person who handles the robot such as for teaching programming movement check in spection adjustment and repair has received appropriate training and also has the skills needed to perform the job correctly and safely Since the YK XG series robots fall under the industrial robot category the user must observe local regulations and safety standards for industrial robots and provide special training for every person involved in robot related tasks teach ing programming movement check inspection adjustment repair etc 1 8 CHAPTER 1 Using the Robot Safely G 4 Robot Safety Functions 1 Overload detection This function detects an overload applied to the motor and shuts off the servo power If an overload error occurs take the following measures 1 Insert a timer in the program 2 Reduce the acceleration coefficient 2 Overheat detection This function detects an abnormal temperature rise in the driver inside the controller and shuts off the servo power If an overheat error occurs take the following measures 1 Insert a timer in the program 2 Reduce the acceleration coefficient 3 Soft limits Soft limits can be set on each axis to limit the w
137. w Daily and periodic inspection of the YAMAHA robot is essential in order to en sure safe and efficient operation This chapter describes the periodic inspection items and procedures for the YAMAHA YK XG series robots Periodic inspection includes Daily inspection 6 month inspection Replacement of speed reduction gear harmonic drive Make sure that you thoroughly understand details of the inspection and follow the procedures and precautions explained in this chapter 5 1 CHAPTER 5 Periodic Inspection e EEE Ea al 2 Precautions 1 Periodic inspection must be performed by or in the presence of personnel who have received the Robot Training given by YAMAHA or YAMAHA dealers 2 Do not attempt any inspection adjustment repair and parts replacement not described in this manual This work requires specialized technical knowl edge and skill and may also involve work hazards 3 When inspection is required inside the safeguard enclosure always turn off the controller and also the external switch board 4 If the inspection or maintenance procedure calls for operation of the robot stay outside the safeguard enclosure 5 Place a sign indicating the robot is being inspected to keep others from oper ating the controller switch programming unit or operation panel 6 Use only the lubricants specified by YAMAHA or YAMAHA dealers 7 To check the operation after inspection refer to 6 Trial operation in Chap
138. wever if the machine refer ence exceeds the tolerance range 33 to 67 of the absolute reset for any reason CAUTION The origin position may change due to machine reference adjustment If it occurs you must set point data again 3 4 2 1 YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG 1 Check that no one is inside the safeguard enclosure and then turn on the controller 2 Placea sign indicating the robot is being adjusted to keep others from oper ating the controller or operation panel 3 Perform the Z axis absolute reset To perform the Z axis absolute reset see 3 3 Absolute reset procedures in Chapter 4 Make a note of the Z axis machine reference value Use the following procedure to display the adjustment machine reference value When adjusting the machine reference value always check the adjustment machine reference value with this procedure 1 Press the MODE key 2 Press the F3 key to enter MANUAL mode 3 Press the F13 key LOWER F3 to select ABS Reset 4 After the Z axis absolute reset is complete press the F10 UPPER F5 key to display the adjustment machine reference value 4 Turn off the controller The Z axis motor brake is now working at the origin position 5 Enter the safeguard enclosure 4 27 CHAPTER 4 Adjustment 6 Remove the cover See Fig 4 10 If the ball screw comes off the Z axis motor the Z axis drops causing a hazard o
139. zards for example loosening of workpiece even if power electricity air pressure etc is shut off or power fluctuations occur f there is a possible danger that the object gripped by the end effector may fly off or drop then provide appropriate safety protection taking into account the object size weight temperature and chemical properties 1 4 CHAPTER 1 Using the Robot Safely 9 Be cautious of possible Z axis movement when the controller is turned off or emergency stop is triggered 2 axis robots with air driven Z axis The Z axis moves up when the power to the controller or PLC is turned off the program is reset emergency stop is triggered or air is supplied to the solenoid valve for the Z axis air cylinder Do not let hands or fingers get caught and squeezed by moving parts of the Z axis Keep the usual robot position in mind so that the Z axis will not interfere with obstacles during raising of the Z axis except in case of emergency stop 10 Use the following caution items when the Z axis is interfering with peripheral equipment 2 axis robots with air driven Z axis When the Z axis comes to a stop due to obstructions from peripheral equip ment the Z axis may move suddenly when the obstruction is removed causing injury such as pinched or crushed hands Turn off the controller and reduce the air pressure before attempting to re move the obstruction Before reducing the air pressure place a s

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