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Disk Handling Robot (3, 4-axis specifications) USER`S MANUAL

1. Cross section B B Scale 1 1 Scale 2 1 180 180 A User wiring connector pho EN A 10 pins ok a Red User wiring 1 D a j amp amp White User wiring 2 A z Green User wiring 3 P White User wiring 4 o Ee KR c gt T x un o e m re e LIT lL a Iz E s Ki 1 N To atachman Z axis A o _ sha axis Q UN ELI Y axis a KP te eS EM X axis eo LI sisi 5 72 oo B 147 199 SES Ko es IB s is e cH e bs iz lA N O 5 Note 4 550 R axis stroke stote 2 50 767 35 10 09 thru hole thickness 27 75 4X200 800 915 2 External view and dimensions E Fig 7 1 4 axis specifications without hand holder 3 Backward mechanical Forward mechanical stopper uou D 7 Stopper position position EF a EN Contact with stopper occurs Contact with stopper occurs after origin position is after arm extended position is exceeded exceeded Y axis forward mechanical stopper position Mechanical stopper position may vary somewhat depending on parts machining accuracy X and Y axis origin positions 532 Y axis forward strok Origin position may differ slightly from those shown above due to origin posi
2. R axis side Signal Color Connection Remarks Wiring box side Yellow Blue Un O Green h SHIELD Black Heat shrinkable tube s Wii LI i e Black N Yellow green Ring terminal LI LI O Grounded to R axis frame Grounded in wiring box and R axis motor 7 20 5 Wiring tables 4 axis specifications S013 M31H6 012 X and Y axis curl cable Z axis stroke 200mm Connection No Connector Base side Red 0 2mm White Twisted pair Yellow 0 2mm Blue Twisted pair Gray 0 2mm Black Twisted pair Green Shield Red 0 2mm White Twisted pair Yellow 0 2mm Blue Twisted pair Gray 0 2mm Black Twisted pair Green Shield Red White Yellow 0 2mm Blue Twisted pair YORG Gray Black Ring terminal Green Shield Red XM White 0 2mm Yellow o Z axis side Connector X resolver Po a mh Ni OO or o mi oO f V l E Y resolver oa R2 DG Origin sensor GND ORG 24V Origin sensor 24V ORG GND f WIN NIVI NIO wN NI VINIO V E wo w AO m Ring terminal Yellow green Blue YM Gray Black
3. B Fig 4 17 Part 1 Part 2 Part 3 2 M4x0 7 depth 10 S01 2 M4x0 7 depth 15 SoA 2 M4x0 7 depth 15 1301 x 5 thru hole Z 5 thru hole g 5 thru hole Sho bap Sho ra Pio 650 5 01 ff 5 ITO 5 TO 10 A Ta io P 30 10 02 Al 710 02 Al a 0 02 A 63 o o 6 3 a nN bs d 63 o A ks TA i 6 3 A p 6 3 A 25 A 25 25 SS400 t10 7 SS400 t10 lt 7 SS400 t10 7 Note Note Note 1 Corner chamfer is C0 5 1 Corner chamfer is C0 5 1 Corner chamfer is C0 5 unless otherwise indicated unless otherwise indicated unless otherwise indicated 4 28 7 X axis and Y axis arm alignment B Fig 4 18 Part 4 319 15 134 155 Lo S 6 6445 thru hole 0 1 A o F8 3 05 thru hole 3 l 0 1 JAI pee b E 70 05 6 3 i I 6 3 ri 2710 05 SS400 t10 amp Note v 1 Corner chamfer is C0 5 unless otherwise indicated B Fig 4 19 Part 5 6 M3x0 5 depth 10 6 3 5 thru hole 9 44 O wo e ll 3 M4x0 7 depth 7 036H7 co A5052 7 50 Note Cross section A A 1 Corner chamfer is C0 5 unless otherwise indicated This jig is not required if equipped with a hand holder 10 Set the X and Y axis arms and tool attachment shaft in roughly a
4. wn 2 f e e z N 7 23 5 Wiring tables 4 axis specifications S013 M31K0 011 Y axis motor Signal Connection Remarks X axis side Yellow Blue black Brown Brown black Red Black Black Heat shrinkable tube Red White Black Yellow g Ring terminal Ring terminal is grounded to X axis wn Q e D 5 un 7 24 5 Wiring tables 2 3 axis specifications Cables different from 4 axis specifications are shown below 3 axis specifications 1 Base side S00K M8714 X02 Robot cable X21 Length 3 5m X 2 5 0m X23 10m Signal Resolver z o Connector MIIN oJ Aa AJOJ N Resolver N wo oj o o 2 HLIM GND24 HLIM GND24 Origin sensor 24V ORG GND Connection Connector Color No Blue Orange Wire 0 15sq Twisted pair Green Brown 0 15sq Twisted pair Gray Red 0 15sq Twisted pair Green 0 3sq Black Yellow 0 15sq Twisted pair Pink Violet 0 15sq Twisted pair White Blue red 0 15sq Twisted pair Orange white Green white 0 15sq Twisted pair Brown white Gray
5. Edge face seal for speed X11 KN5 M1886 000 SEAL reduction gear input section X12 KN3 M2159 000 O RING 1 O ring for speed reduction gear output section X13 S013 M31H4 001 HARNESS JO WIR In am See 5 Wiring table 15 X15 S013 M3146 003 HARNESS MACHINE 2 Curl cable See 5 Wiring table 12 Y1 S013 M31K0 011 AC SERVO MOTOR wn 2 f e D o z un Motor See 5 Wiring table 18 Y2 KN4 M1892 000 BRG 2 Upper bearing for supporting speed reduction gear input section Y3 KN4 M1891 000 BRG Lower bearing for supporting speed reduction gear input section Y4 KN4 M181H 000 O RING 4 Upper bearing outer O ring for supporting speed reduction gear input section Vade Y5 KN4 M1821 007 HARMONIC DRIVE ASSY Speed reduction gear Y6 KN4 M181G 000 O RING 3 O ring for speed reduction gear input section Y7 S013 M3155 000 BELT 1 Belt Y8 KN3 M4850 501 PROXIMITY SW ASSY Origin sensor See 5 Wiring table 12 O ring for speed reduction gear Y9 KN4 M1896 000 O RING 2 output section Y10 S013 M31L1 000 SEAL Edge ale BRA for speed reduction gear input section Y11 S013 M3125 000 BEARING Y axis upper support bearing 7 31 6 Maintenance parts 013 M3102 000 Part name BRG Remarks Y axis support bearing 90933 02J62
6. 90K80 020L00 LM BROCK HSR20 L Guide bearing 90K80 020R00 LM BROCK HSR20 L Guide bearing 90933 01J005 BEARING Non motor side bearing KX8 M2271 501 BALL SCREW 1 Ball screw 90990 04J002 KEY Motor section key KX8 M2231 000 BRG 6302V DB C5 Ball screw support bearing 90K72 840240 AC SERVO MOTOR Motor See 5 Wiring table KX9 M2231 000 BRG Resolver bearing KT1 M4891 000 PART CONNECTOR 1 1 2 2 2 1 1 2 1 1 1 User wiring connector and pin 2 3 axis specifications Part No Part name 6 Maintenance parts Remarks X1 KN5 M1892 000 BRG 2 Lower bearing for supporting speed reduction gear input section X2 KN5 M1891 000 BRG 1 Upper bearing for supporting speed reduction gear input section X3 90990 17J016 O RING Lower bearing outer O ring for supporting speed reduction gear input section X4 KN5 M1821 004 HARMONIC DRIVE ASSY Speed reduction gear X5 KN5 M181H 000 O RING 4 O ring for X axis speed reduction gear input section X6 90K90 62012X AC SERVO MOTOR Motor See 5 Wiring table 2 X axis X7 013 M3156 000 BELT 1 Belt X8 S013 M3138 201 STOPPER Mechanical stopper X9 S013 M3139 000 DAMPER 1 Mechanical stopper damper X10 KN3 M4850 301 PROXIMITY SW ASSY Origin sensor See 5 Wiring table 13
7. 2 4 3 Parameter factory settings 3 Parameter factory settings This robot is a custom order item and therefore has customized parameters Be sure to make a backup copy of the parameter factory settings The parameter settings will be lost if the parameters are initialized In that event use the backup data to download the parameter settings again The parameters are indicated on the custom parameter sheet attached to each robot Custom parameter sheet To purchasers of this custom made robot Thank you for purchase of this YAMAHA robot This robot is a custom order item and therefore shipped with parameters customized by changing the standard robot settings If this robot is used with parameter settings that differ from the customized parameter settings this may cause problems such as malfunctions Do not change the customized parameter settings indicated on the custom parameter sheet The parameter settings will be lost if the robot parameters are initialized In that event set the parameters again Make a backup of the parameter settings before using the robot Please keep the custom parameter sheet carefully along with the user s manual as it will be needed in cases where the parameters have to be set again suonoun4 N Setting models Date of manufacture month year Mechanical unit Disk handling 3 axis robot F17 Controller RCX142 Customized parameter settings
8. Customized parameter settings are shown below Boxes left blank indicate standard parameter settings Robot configuration Configuration Robot No MULTI Axis configuration Configuration Axis name Axis No Custom setting F14H 20 F14 20 F17 20V F17 10 Robot settings Name Changed value Name Changed value Tip mass 0 Return to origin sequence 231456 On the 3 axis model X Y and Z axes using an RCX142 controller only M1 to M3 settings are needed 2 5 3 Parameter factory settings e E o N 2 6 Changed value soft limit 386844 M2 269654 M3 163840 soft limit 386844 4552 Return to origin method Sensor Sensor Axis polarity Acceleration Kvp Kvi Motor model Overload reference Overload time Id max Id limit Maximum torque command Maximum motor revolution Kip Kii Origin position return pulse Stroke end origin position torque Axis settings Blank boxes indicate default settings Do not change them Never increase acceleration more than this level Never change maximum motor revolution On the 3 axis model X Y and Z axes using an RCX142 controller only M1 to M3 settings are needed Installation 1 Robot installation conditions 1 1 Installation environments Be sure to insta
9. E E pee D D D S E E S hrs rej o LO z 2 7 g 2 g eo E oO eo co E c oO c T T e x o z st o E E co o o D D e T o 79 a O T oe T o E o o N N z S E s S S e o z D 53 eo p m Ww a X Q a N L N z c 2 o o E tc co eo o i Y 0 Z axis moves up P1 204800 0 Units pulses P4 204800 B Fig 5 3 e Ee e A p ite i s E ab 22 le N a o Operating the Robot 3 Creating point data direct teaching and external forces to arms 3 Creating point data direct teaching and external forces to arms Direct X and Y axis teaching is difficult when the servo is OFF because any attempt to rotate the X axis by hand will result in Y axis motion Y axis performs a straight forward motion Since the Z axis is heavy it is hazardous to perform direct teaching X Y and Z axis point data should therefore be created by a manual data in or teaching playback operation For details refer to the YAMAHA Robot Controller RCX142 Series User s Manual Torque should never be applied to the Y axis and tool attachment shaft by hand as this could cause belt slippage in the X axis and Y axis arms or could result in damage oqoy ay SunejadQ C 5 5 MEMO 5 6 Periodic Inspection 1 Overview 1 Overview Daily and periodic inspection of the YAMAHA robot is essential in order t
10. Because the robot construction is such that the X axis rotates as the Y axis reduction gear rotates the axis rotation must be obtained from the point data Both in case of the X axis and Y axis one rotation consists of 819200 pulses Ex If the robot moves 10 times per minute averaging 1 4 of a turn per motion the harmonic drive grease replacement period would be calculated as shown below operation time 24 hours day operation days 240 days year n 10 0 0 25 N 50 h 24 hours per day D 240 days per year Replacement interval 1 5x10 nx60xhxDxNx6 1 5x10 10x60x24x240x50x0 25 3 5 years E Table 6 2 Harmonic speed reduction ratio 6 7 5 Replacing the harmonic drive grease uonoadsu iporiag Jg 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 turn off the controller wait for a while and check that the temperature has cooled Precautions when handling harmonic grease and cleaning oil Inflammation may occur if they get in the eyes Before handling them wear 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 conta
11. User wiring Without hand holder Suction hole End effector prepared by user suction tool etc Internal air flow path is required for suction Cover When taking user wires out of hand holder drill an additional hole in this cover and provide sealing etc Hand support supplied M3 bolt 6 pcs supplied Spare tubing user tubing 2 Suction tubing g user tubing 1 3 29 6 Attaching the end effector Table 3 2 Tightening torque Bolt size Number of bolts Nm kgf ecm uore ejsu Gg 3 30 ws e 0 20 Recommended bolt JIS B 1176 or equivalent Hex socket head bolt Strength class JIS B 1051 12 9 or equivalent In cases where the end effector cannot withstand the tightening torque for M3 bolts reduce the tightening torque as needed Use care however to avoid reducing the tightening torque to the point where the end effector may shift or fall off 2 Refer to Fig 3 28 for details on the end effector attachment section of the robot Fig 3 28 Without hand holder 6 M3x0 5 depth 10 O ring S7 2 pcs supplied 33 33 User tubing 1 9 3 User wiring 0 1mm Red User wiring 1 White User wiring 2 Yellow User wiring 3 Blue User wiring 4 OS Cross section A A 6 Attaching the end effector E Fig 3 28 With hand holder User wiring
12. YAMAHA ROBOT Disk Handling Robot 3 4 axis specifications User s Manual E41 Ver 1 01 Before using the robot Be sure to read the following notes Thanks for your purchase of this YAMAHA disk handling 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 positions of this robot are adjusted at the factory before shipment to the positions indicated in 3 3 Absolute reset in Chapter 4 The customer should perform the following absolute reset before any other job Absolute reset This robot only requires the absolute reset to be performed once when the robot is introduced Once the absolute reset is performed it does not need to be reperformed when the power is turned on next time Perform the absolute reset while referring to 3 Adjusting the origin in Chapter 4 of this manual and Absolute Reset of the YAMAHA Robot Controller RCX142 User s Manual CAUTION Never enter the robot movement range once the robot servo is turned on as this is extremely hazardous Affixing the origin position sticker 9330u Suiwo 0J au pea4 0 ans ag 310qo1 y Suisn 310J9g Set in emergency stop when absolute reset is complete and immediately affix the origin posit
13. Companies or factories using industrial robots must make sure that every person who handles the robot such as for teaching programming movement check inspection adjustment and repair has received appropriate training and also has the skills needed to perform the job correctly and safely Since the YAMAHA disk handling 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 teaching programming movement check inspection adjustment repair elc Ajayes oqoy ay Suis 1 8 4 Robot safety functions 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 working envelope in manual operation after return to origin and during automatic operation The working envelope is the area limited by soft limits Ajayes
14. See 3 5 in Chapter 4 Check for looseness at each terminal and connector on the controller panel See 4 in Chapter 3 and also YAMAHA Robot Controller RCX142 Series User s Manual After removing old grease with wiping cloth apply LG2 NSK grease to the Z axis ball screw shaft surface and guide rail See Fig 6 1 To remove the cover see 3 4 Removing the robot covers in Chapter 4 Check for play or backlash Z axis ball screw and guide If an abnormal condition is found contact YAMAHA dealer Controller Grease on Z axis ball screw and guide 6 5 4 Six month inspection E Table 6 1 1 Bolt tightening torque Bolt size Tightening torque kgf cm Tightening torque N m M3 button head bolt M4 set screw M3 M4 M5 M6 M8 For 6 month inspection of the R axis travel axis refer to the F17 single axis robot described in the FLIP X Series User s Manual B Fig 6 1 uonoadsu iporiag 2 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 safety enclosure to perform the necessary work After adjustment or replacement is finished again review the checkpoints outlined in 1 above 2 If repair or parts replacement is required for the robot or controller please contact your YAMAHA dealer This work
15. from touching the controller switch programming unit or operation panel 3 If a safety 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 safety enclosure and observe the following points D 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 see 6 Trial operation in Chapter 1 4 1 3 Adjusting the origin juesunsn py ty 3 Adjusting the origin The disk handling robot uses absolute position sensors The origin position zero pulse position is set by performing an absolute reset return to origin Once an absolute reset has been performed it need not be performed again at the next power ON An absolute reset is required however under the conditions shown below Note that the robot is in condition c when shipped from the factory and an absolute reset is therefore required after installation For details regarding absolute resets refer to 11 8 Absolute reset in Chapter 4 of the YAMAHA Robot Controller RCX142 Series User s Manual a After an absolute related error occurs at an axis b After a low voltage condition is detected in the absolute battery installed out
16. 0 1mm 6 03 5 thru hole Red User wiring 1 User tubing 1 White User wiring 2 g Yellow User wiring 3 A Blue User wiring 4 Set screw 3 pcs for hand m 4 AM o 3 holder tilt adjustment ercb 2 t Set screw lock nut User tubing 2 4 11 3 11 3 Hand holder mounting bolt 3 pcs 49 Details of A 7 Scale 1 1 S 5 Inside of hand holder with cover removed E B B f S E 6 M3 bolt length 8 so LO Hand holder cover HE E 3 Hand O ring S5 supplied E E L T Ww gt Hand support 97 3 Cross section D D Details of C Scale 1 1 Scale 4 1 o 39 8 eg e o Eq 293 d 55 5 69 Cross section B B Scale 1 1 6 M3x0 5 thru hole T 40 4 ej gd 3 ap an tet 113 11 3 Hand support When the end effector is mounted using the M3 bolts shown in Fig 3 28 be sure that the bolts are adequately tightened If loose the end effector could fly off during robot operation causing a hazardous situation Do not mount by any method other than that described above 3 31 6 Attaching the end effector 3 If the end effector is attached in a way that it is not aligned with the stra
17. 5Nm 46kgf cm ACAUTION Belt slippage will occur if the tensioner end face shifts to a position in front of the scribe mark and a shift beyond the scribe mark will reduce the durability of the Y axis drive system Therefore be sure that the tensioner end face is aligned with the scribe mark 10 Reattach the covers 6 2 2 Adjusting the Y axis arm belt 1 Soh Prepare the necessary tools Hex wrench set Phillips screwdrivers 7mm wrench yuawysnipy A Turn off the controller N 3 Place a sign indicating the robot is being adjusted to keep others from operating the controller switch 4 Enter the safety enclosure 5 Remove the Y axis arm cover See 3 4 Removing the robot covers for this procedure 6 No adjustment is necessary if the tensioner end face is aligned with the scribe mark Fig 4 15 If not aligned adjust using the procedure described below B Fig 4 15 Pulley behind cover M4 mounting bolt 2 pcs A Li Cover Y axis arm Tensioner Tensioner end face Scribe mark also on opposite side M4 tension bolt 2 pcs 4 25 6 Adjusting the timing belt tension 7 Slightly loosen the two tensioner mounting M4 bolts Do not loosen to the degree that play occurs at the tensioner and the Y axis arm 8 Verify that the belt is securely in place on the pulley 9 Loosen the tension bolt nut turn the tension bolt until the tensioner end fac
18. D Press the MODE key 2 Press the F3 key to enter MANUAL mode 3 Press the F13 LOWER F3 key to select RST ABS 4 After the Z axis absolute reset is completed press the F10 UPPER F5 The machine reference value for adjustment is then displayed in percent 96 If the machine reference value is outside the allowable absolute reset range then the next absolute reset may not be properly performed In this case adjust the machine reference by referring to 3 5 Adjusting the machine reference 4 8 3 Adjusting the origin 3 4 Removing the robot covers Before removing the robot covers be sure to turn off the controller power Refer to the figures below when removing the covers to adjust soft limits or belt tension For the R axis travel axis details refer to the F17 single axis robot described in the FLIP X Series User s Manual E Fig 4 4 Removing the robot covers M3x6 flat head screw 4 pcs then turn it around tool attachment shaft M3x6 flat head screw 4 pcs X axis arm cover Remove cover while raising Z axis juaunsn py A M3x6 flat head screw 12 pcs 1 Base side cover be Slider side cover 4 9 3 Adjusting the origin jusunsn py O 3 5 Adjusting the machine reference CAUTION If any machine reference is adjusted the origin position may change Before the adjustment mark off the reference mark at
19. Harmonic Drive Systems Inc Do not use 4B No 2 grease as it may leak out AA 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 performance 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 CAUTION A positional shift occurs when the harmonic drive grease is replaced Therefore an absolute reset and point data resetting are required after replacing the grease uonoadsu iporiag o 6 9 MEMO 6 10 Specifications l Basic specifications 1 4 axis specifications Payload 1 Basic specifications 0 2kg R axis rotational moment of inertia 0 04kgfcms Working envelope Y axis forward stroke 532mm X axis rotation angle 340 Z axis up down stroke 200mm R axis travel stroke 550mm X axis 200w Y axis 100w Z axis 400w R axis 400w Maximum speed Y axis forward direction 300mm s X axis rotation 290 s Z axis up down direction 1000mm s R axis travel direction 1000mm s Resolution Y axis forward direction 50um X axis rotation direction 0 0010 Z axis up down directio
20. O RING 3 q Oing forspeed reduction gear input section Y7 S013 M3155 000 BELT 1 1 Belt Y8 KN3 M4850 501 PROXIMITY SW ASSY Origin sensor See 5 Wiring table 12 O ring for speed reduction gear Y9 KN4 M1896 000 O RING 2 1 output section Y10 S013 M31L1 000 SEAL q Edge face seal for speed reduction gear input section Y11 S013 M3125 000 BEARING 1 Y axis upper support bearing 7 28 Part No Part name 6 Maintenance parts Remarks A1 S013 M3102 000 BRG 1 Y axis support bearing Me A2 90933 02J626 BEARING 4 Tensioner bearing A3 S013 M3103 000 BELT 2 1 Belt B1 S013 M3102 000 BRG 1 Tool attachment shaft support bearing B2 90933 02J626 BEARING 4 Tensioner bearing bead B3 S013 M3104 000 BELT 1 1 Belt B4 S013 M3145 101 STOPPER 2 Mechanical stopper B5 S013 M3144 000 DAMPER 2 Mechanical stopper damper B6 S013 M3154 000 O RING 2 2 Tool attachment shaft O ring S7 Z1 90K72 0L0400 LM RAIL 20 1 Guide Z2 90K72 0U0400 LM RAIL 20 1 Guide Z3 90K80 020R00 LM BROCK HSR20 R 2 Guide bearing Z4 90K80 020L00 LM BROCK HSR20 L 2 Guide bearing Z5 KN4 M2281 001 STOPPER 1 Upper end stopper Z6 kN3 M2596 002 DAMPER 1 Upper end damper Z7 S013 M31K9 002 MOTOR ASSY 1 1 Motor See 5 Wiring table Z8 KX7 M2231 000 BRG 1 Ball sc
21. Robot Controller User s Manual for how to operate 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 adjusted to keep others from touching 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 the axis for absolute reset X axis M1 Y axis M2 To perform absolute reset on all axes select ALL with the F11 LOWER F1 key ACAUTION When performing absolute reset on all axes the Z axis of the stroke end method lowers following the Y axis absolute reset and then the R axis of the stroke end method detects the origin following the X axis absolute reset default setting Be careful that your fingers do not get pinched or crushed by axis movement 6 Check that the X and Y axes for absolute reset are positioned at the plus side of the origin See Fig 4 3 a to d If it is not at the plus side then press the jog key to move the target axis to the plus side 7 Since the message Reset ABS encoder OK appears check that there are not any obstacles in the robot movement range and press the F4 YES key 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 recomm
22. axis arm Tool attachment n 4 for suction at Y axis joint 4 for suction in X axis arm X axis arm x Base 4x2 for user tubing i i 4x2 for user tubing 4x3 for suction Coupler 4x3 Coupler 8 Meca Coupler S013 M31H5 01 1 j T 4x6 curl tubes Four I O Jj WA D ote ind enn DES wires are passed through OC one of these 04 tubes en 912 m suction in base 4x2 R axis Coupler Wiring box A pus Suction coupler 12x2 12x2 for suction User tubing 4x2 4x2 for user tubing suomi adg N 2 3 axis specifications The 3 axis model has no R axis User tubing and suction couplers directly come out of the base 7 16 5 Wiring tables 1 4 axis specifications 4 axis specifications 1 SOOR M3643 X02 Robot cable X 1 Length 1 0m X 2 2 0m X 3 3 5m X 4 4 0m X 5 5 0m X 6 6 0m X 7 7 0m X 8 8 0m X 9 9 0m X A 10 0m Signal Wiring box side Resolver S2 S4 S1 3 R1 R2 DG Connector XP Ez Brake MB MB XBK Resolver S2 S4 S1 3 R1 R2 DG YP Brake MB MB HLIM GND24 HLIM GND24 YBK MIINA RR oO ms Mm es NI oO ay AJOJN Sensor 24V ORG GND24 ORG Sensor 24V ORG GND24 ORG Connection No Connector Color No Blue Ora
23. axis origin positions Origin position may differ slightly from those shown above due to origin position adjustments Suction tube 12 in base Suction tube 12 in X and Y axis arms User tubing 1 4 i User wiring User tubing 2 4 t6 30 connector 4 pins 8 sig M4 ground terminal 7 N Robot cable 35 30 30 7 14 3 Robot s internal wiring diagram 3 Robot s internal wiring diagram 1 4 axis specifications See 5 Wiring tables for items numbered to 8 E Fig 7 5 User wiring Tool attachment shaft P xu DE axis arm PA d I i Y axis motor 2Y axis sensor Z 4X axis motor Z axis motor Y axis arm 3X axis sensor ms Wiring box _ Robot cable x To controller OOOO R axis motor Connector suone2iiadg e User wiring connector 2 3 axis specifications The 3 axis model has no R axis Robot cable and user wiring connector directly come out of the base 7 15 4 Robot s internal tubing 4 Robot s internal tubing 1 4 axis specifications B Fig 7 6 Y axis arm User tubing 2 tubes for suction in Y
24. it E Fig 3 2 Packed state Owl Travel axis Robot controller and accessories 4 axis model 3 axis model does not have travel axis 3 4 2 Installation 2 2 Checking the product After unpacking check the product configuration and conditions CAUTION If there is any damage due to transportation or insufficient parts please notify your YAMAHA sales office or dealer immediately E Fig 3 3 Product configuration 4 axis model robot 3 axis model does not have travel axis uore ejsu A Movement direction and axis name label CD ROM User s Manual or User s Manual Robot cable mil jue b User wiring connector i For 4 axis model J For 3 axis model O ring for sealing of end effector attachment Model without hand holder S7 2 pcs Model with hand holder S51pc Options il OP DIO connector Expansion I O connector 3 5 2 Installation 2 3 Moving the robot Serious injury may occur if the robot falls and pins someone underneath it Do not allow any part of your body within the area beneath the robot during work Always wear a helmet safety shoes and gloves during work AA CAUTION Allow only properly qualified personnel to operate equipment such as cranes that require a license to use Equipment and tools used for moving the robot should be ser
25. occur from physical contact with the robot during operation Never enter within the robot movement range during absolute reset The operation procedure using the MPB is described below Press the ESC key on the MPB if you want to return to the preceding step Refer to the YAMAHA Robot Controller User s Manual for how to the robot controller For the R axis travel axis details refer to the F17 single axis robot described in the FLIP X Series User s Manual 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 adjusted to keep others from touching 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 the axis for absolute reset Z axis M3 R axis M4 6 Since the message Reset ABS encoder OK appears check that there are not any obstacles in the robot movement range and press the F4 YES key 7 After the absolute reset is completed check that the machine reference value for stroke end method adjustment displayed on the MPB is within the allowable absolute reset range 40 to 60 CAUTION Use the following procedure to display the machine reference value for stroke end method adjustment When adjusting the machine reference always use this procedure to check the machine reference value for adjustment
26. requires specialized technical knowledge and skill so do not attempt it by yourself 6 6 5 Replacing the harmonic drive grease 5 Replacing the harmonic drive grease The disk handling robot uses harmonic drives as the X axis and Y axis reduction gears The harmonic drive grease HC 1A or SK 1A must be replaced periodically The grease replacement interval should be determined according to the guidelines given below As the robot base must be completely disassembled in order to replace the harmonic drive grease please contact a YAMAHA sales office or dealer for assistance 5 1 Replacement interval The harmonic drive grease replacement interval is determined according to the total number of wave generator turns It is recommended to replace the harmonic drive grease when the total number of turns has reached 1 5x10 at ambient operating temperatures of 0 C to 40 C This means that the replacement interval 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 interval 1 5x10 nx60xhxDxNx0 years where n Number of robot motions per minute Average rotation of axis per motion Speed reduction ratio Operation time per day Operation days per year U zc uonoadsu iporiag o 0 is 1 4 of a turn relative to an axis rotation of 90
27. the belt the belt is too tight Use this as a reference for belt tension 4 19 6 Adjusting the timing belt tension E Fig 4 9 Belt tension adjustment Push pull scale Belt Pulley 4 B Fig 4 10 Stay example 5 Belt S i gt x I 7 Push pull Lo v pull scale e zi Oo Lo Nut O Hole Nut KY Y 15 Metal plate 3 2mm thickness B Fig 4 11 X axis l Y axis motor belt 4 Front base 2 Er X axis motor g 2 Plate Be Z axis motor Pulley Pulley X axis motor belt M5 bolt D 4 pcs 4 20 6 Adjusting the timing belt tension B Fig 4 12 Y axis Inspection window Pulley M3 bolt 2 4 pcs Part 1 Plate Part 2 eo eed AS sa c Y axis motor belt Reduce tension Pulley Bi Fig 4 13 Z axis y N Z axis motor kK S p d T li QO OG D C s b amp S Q Q la amp j d P FUE re d Plate 9 Lu z M5 bolt 3 NS QU 5 bolt 3 pcs BTS v Increase tension Y axis motor Pulley Z axis motor belt Pulley 4 21 6 Adjusting the timing belt tension 7 Belt te
28. with the controller turned on e mis o 2 6 3 N e e Ss o 5 1 Check that no one is inside the safety 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 safety enclosure Checkpoint Procedure Check if the safety enclosure is in place Check if emergency stop is triggered when the door is Safety enclosure opened Check if warning labels are affixed at the entrance and clearly visible Emergency stop device Press the emergency stop button to check if it works Check for abnormal movement and excessive vibration Robot movement and noise If an abnormal condition is found contact YAMAHA dealer Check if the brake works to stop the Z axis from Z axis brake operation 1 dropping more than 3mm from the stationary point If an abnormal condition is found contact YAMAHA dealer 1 Visually check the Z axis movement when you press the emergency stop button from outside the safety enclosure and also when you turn off the controller 6 3 3 Daily inspection 3 Adjustment and parts replacement uonoadsu iporiag Jg 6 4 1 After inspection if you notice any adjustment or parts replacement is needed first turn off the controller and then enter the safety enclosure to perform the necessary work A
29. 10 Z axis up down direction 20um Repeatability X and Y axes R axis position at arm end x0 1mm Z axis R axis position at arm end 0 05mm Cleanliness degree Class 1000 0 3um base during suction R axis position at arm end in Z axis up down stroke range Suction rate 60NI min User tubing 4 2 tubes User wiring 0 1mm 4 wires wn O e D z o z un Weight Robot body 40kg RCX142 controller W180xD235xH250mm 6 5kg Travel limit 1 Soft limit X Y and Z axes 2 Mechanical limit X Y and Z axes Robot cable 3 5m option 5m 10m Arm and base Almite coated aluminum Arm and base covers Almite coated aluminum Outer bolts and screws Stainless At constant ambient temperature Sound level Maximum sound pressure level of robot at 10dB or more difference from background sound pressure level Position of maximum sound pressure level In direction of 45 to right as viewed from front of robot 1 0m away from arm s movable section AM CAUTION 1 4m height Sound level may increase when sound reflecting objects are located near the robot 7 2 2 External view and dimensions 2 External view and dimensions E Fig 7 1 4 axis specifications without hand holder 1 Tool attachment shaft X axis mechanical m stopper position 340 W
30. 4 y Suisn 340J2g Introduction The disk handling robot arm is a two joint manipulator comprising X and Y axes with a tool attachment shaft at the manipulator tip The robot also has a Z axis that moves the arm up and down and an R axis that serves as a travel axis This configuration is ideal for handling DVD disks etc Please note that this robot is not completely designed for clean room use because the travel axis does not conform to clean room specifications uononpoau This user s manual describes the safety measures handling adjustment inspection and maintenance of the disk handling robots for correct safe and effective use Be sure to read this manual carefully before installing the robot Even after reading this manual keep it in a safe and convenient place for future reference This user s manual should be used with the robot and considered an integral part of it When the robot is moved transferred or sold be sure to send this manual to the new user along with the robot and explain to the new user the need to read through this manual For robot operation and programming details refer to the YAMAHA Robot Controller RCX142 Series 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 YAMAH
31. 4 X02 CABLE ROBOT Robot cable 90K41 000110 LABEL ALERT Warning label Japanese h1 AOOARY hikita 90K41 000140 LABEL ALERT Warning label English Serious injury or death 6 Maintenance parts E Fig 7 7 4 axis specifications se x 5 pu part 3 iib a 7 2 S g ae Ze I I Le d a s e p aH spat i E o DT zi 7 33 6 Maintenance parts Bi Fig 7 8 3 axis specifications maa L 89 oer part 2r eli suomi adg N PES _ D 7 34 MEMO Revision record Manual version Issue date Description Ver 1 00 Feb 2008 English manual Ver 1 00 is based on Japanese manual Ver 1 00 Ver 1 01 Mar 2008 English manual Ver 1 01 is based on Japanese manual Ver 1 01 User s Manual YAMAHA Disk Handling Robot Mar 2008 3 4 axis specifications Ver 1 01 This manual is based on Ver 1 01 of Japanese manual 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 I
32. 6 BEARING Tensioner bearing 013 M3103 000 BELT 2 Belt 013 M3102 000 BRG Tool attachment shaft support bearing 90933 02626 BEARING Tensioner bearing 013 M3104 000 BELT 1 Belt S013 M3145 101 STOPPER Mechanical stopper S 013 M3144 000 DAMPER Mechanical stopper damper S013 M3154 100 O RING 2 Tool attachment shaft O ring S5 wn O e D o 2 un 7 32 90K72 0L0400 LM RAIL 20 Guide 90K72 0U0400 LM RAIL 20 Guide 90K80 020R00 LM BROCK HSR20 R Guide bearing 90K80 020L00 LM BROCK HSR20 L Guide bearing KN4 M2281 001 STOPPER Upper end stopper kN3 M2596 002 DAMPER Upper end damper 90K93 64214Z MOTOR ASSY 1 Motor See 5 Wiring table 9 KX7 M2231 000 BRG Ball screw support bearing S013 M31G3 000 BELT Belt 013 M31G2 100 BOLT Lower end stopper 013 M31H6 012 HARNESS X and Y axis curl cable Z axis stroke 200mm See 5 Wiring table S013 M31H5 01 1 HARNESS I O curl cable See 5 Wiring table 40 X 0 length 3 5m X 1 5 0m X 2 10 0m S013 M31E0 001 HARNESS EARTH FG curl cable See 5 Wiring table S013 M31K4 001 CONNECTOR E L 1 User wiring connector 013 M31K5 000 CONNECTOR E L 2 User wiring connector soldering side by user SOOK M871
33. A MOTOR CO LTD IM Operations MEMO General Contents C l Safety information 1 1 D 2 Essential caution items 1 2 3 Special training for industrial robot operation 1 8 4 Robot safety functions 1 9 5 Safety measures for the system 1 10 6 Trial operation 1 10 7 Work within the safety enclosure 1 11 8 Automatic operation 1 12 9 Adjustment and inspection 1 12 10 Repair and modification 1 12 11 Warranty 1 13 12 CE Marking 1 14 1 Robot manipulator 2 1 2 Robot controller 2 4 3 Parameter factory settings 2 5 Custom parameter sheet 2 5 Chapter 3 Installation 1 Robot installation conditions 3 1 1 1 Installation environments 3 1 1 2 Installation base 3 2 2 Installation 3 4 2 Unpacking 3 4 2 2 Checking the product 3 5 2 3 Moving the robot 3 6 2 3 1 4 axis model 3 6 2 3 2 3 axis model 3 8 2 4 Installing the robot 3 10 2 4 1 4 axis model 3 10 2 4 2 3 axis model 3 11 2 5 Adjusting the robot base tilt 3 12 3 Protective bonding 3 13 4 Robot cable connection 3 15 O 5 User wiring connector and user tubing 3 16 e 5 User wiring 3 17 e 5 2 User tubing 3 20 6 Attaching the end effector 3 21 Q 6 Acceleration 3 21 6 2 Equation for moment of inertia calculation 3 22 g 6 3 Example of moment of inertia calculation 3 25 T 6 4 End effector attachment strength and rigidity 3 27 6 5 Attaching the end effector 3 29 6 6 Adjusting the end effector tilt when equipped with hand holder 3 33 6 7 Grippin
34. AJOJN Ring terminal Yellow green 0 75mm wn 2 f e e z N 7 21 Ring terminal is grounded to Z axis Ring terminal is grounded to base Only Unit 1a insulator coating is 0 3mm thick Others are 0 15mm thick 4 axis specifications 9 S013 M31K9 002 Z axis motor Signal Connection Remarks Base side S2 Yellow S4 Blue S1 Red S3 Black R1 White R2 Green SHIELD Black Heat shrinkable tube Red 1 V White 2 WwW Black 3 4 L Ring terminal Yellow green Ring terminal Yellow 1 Yellow 2 Ring terminal is grounded to base 5 Wiring tables 4 axis specifications S 013 M31H5 011 I O curl cable 5X04 air tube Z axis stroke 200mm Z axis side Connector No Connection No Connector Base side User signal wire i Red White Yellow Blue 4 axis specifications 1 013 M31E0 001 FG curl cable Z axis stroke 200mm Signal Connectorfe Connection Jo Connector Color Wire Base side Ping terminal Ring terminal Yelowreen 0 7omm Ring terminal is grounded to Z axis Ring terminal is grounded to base Z axis side 4 axis specifications 2 S013 M3146 003 X axis curl cable X axis side Signal Connector No Connection No Connector Z
35. Basic specifications 7 1 2 External view and dimensions 7 3 3 Robot s internal wiring diagram 7 15 4 Robot s internal tubing 7 16 5 Wiring tables 7 17 6 Maintenance parts 7 28 MEMO Using the Robot Safely 1 Safety information l 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 WARNINGS 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 injury to personnel robot operator or service personnel including fatal accidents Warning information in this manual is classified by the following signal words 7 DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury Ajayes oqoy ay Suis a CAUTION CAUTION indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or damage to the equipment or software Refer to the user s manual by any of th
36. Brown 0 75sq i 7 Blue 0 75sq wn O e e z o 2 un 7 26 U Ww V e v e w w e Ring terminal is grounded to base 5 Wiring tables 3 axis specifications 2 90K93 64214Z Z axis motor No Signal 1 Color Connection CN Remarks Base side Yellow Blue Red Black White Green Black Heat shrinkable tube Red White Black Yellow green F Ring terminal Yellow Yellow Ring terminal is grounded to base 3 axis specifications 3 S013 M31K4 001 User wiring connector Base side Connector No Connection No Connector User wiring side Red White Yellow Blue wn 2 za e D z o 5 N 2 6 Maintenance parts 6 Maintenance parts Part No beginning with S is a custom item and requires about 1 month for delivery 1 4 axis specifications Part No Part name Remarks X1 KN5 M1892 000 BRG 2 Lower bearing for supporting speed reduction gear input section X2 KN5 M1891 000 BRG 1 Upper bearing for supporting speed reduction gear input section X3 90990 17J016 O RING Lowe
37. M CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY YAMAHA MOTOR CO LTD MAKES NO WARRANTY WHATSOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED BY YAMAHA MOTOR CO LTD 1 13 12 CE Marking 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 Supporting Supplement Manual for related information about CE marking Ajayes JOqOY y SUISA 1 14 1 Robot manipulator 1 Robot manipulator The disk handling robot can move as illustrated in Fig 2 1 below The and signs show the direction in which the robot moves when the jog keys on the programming unit are pressed standard setting at the factory E Fig 2 1 Robot motions Tool end effector attachment shaft C Y axis suonoun4 N X Y Z and R axis origin positions Tool attachment S shaft direction is R axis 4 4 r held during Y axis Y axis forward motion Direct forward motion of tool attachment shaft Z axis up down motion R axis linear motion 2 1 1 Robot manipulator Fig 2 2 to Fig 2 5 below show part names and functions of each robot model E Fig 2 2 4 axis model without hand holder Tool end effector X axis arm 7 attachment shaft Y axis arm i Warning label 1 Warning label 2 Warning label 3 Y axis motor and speed reduction gear
38. On the 4 axis model the user wiring connecter is located inside the wiring box On the 3 axis model the user wiring connector is located on the rear of the robot base E Fig 3 12 Screw Tool attachment shaft e Cover eee uore ejsu A User wiring User wiring Without hand holder With hand holder Arm side Base User wiring connector EAA LI O jo Q 2 4 axis model 3 axis model Controller side 3 17 5 User wiring connector and user tubing 3 Signal wire connections in machine harness Pins 1 to 4 in the user wiring connector can be used 4 axis model Connection Connector Red White Yellow Blue I O Controller side User signal wire Arm side Cannot be used uore ejsu o o 100 fF C k o 3 axis model Connection i Connector Red Red White White 1 0 Controller side User signal wire Arm side Yellow Yellow Blue Blue Cannot be used 3 18 5 User wiring connector and user tubing 4 On the 4 axis model as shown in Fig 3 13 crimp the wires prepared by user to the pins supplied using a crimping tool and insert the pins into the connector supplied Then plug that connector into the user wiring connector Take out the user wires through the cutout in the wiring box so that they will not interfere with the movabl
39. Twisted pair DG Green Shield Brake MB Brown white 0 3sq MB RBK Gray white Twisted pair HLIM E 10 Green GND24 11 HLIM 1 28 Green GND24 29 Sensor 24V 1 9 Red white 0 3sq Twisted ORG ong 2 12 Yellow black 0 3sq GND24 3 13 Pink black Twisted pair Sensor 24V 27 White blue 0 3sq Twisted ORG ORG t 30 Blue red 0 3sq GND24 31 Twisted pair U EM 0 75sq V ZM m 0 75sq Ww l M 0 75sq FG Ring terminal 0 75sq U 0 75sq V RM 0 75sq RM WwW 0 75sq FG Ring terminal O Grounded in wiring box gt M4 ground terminal on the rear of wiring box po i a a a olo mjw olo s5 o m i j NINII N oa w AJN H wn O e D z o 2 N 7 18 AJo N AJOJN sfolr fafe r o m 5 Wiring tables 4 axis specifications 2 KT8 M4814 N12 Cable carrier X and Y axis power wires R axis stroke 550mm Base side Connector Connection Connector Remarks 0 75sq Green yellow 0 75sq 0 75sq Green yellow 0 75sq 4 axis specifications 3 Wiring box side KT8 M4813 N12 Cable carrier Z axis power wire R axis stroke 550mm Base side Connector B
40. X axis motor and speed reduction gear Z axis ball screw guide and motor Robot cable suonoun4 N Base tilt adjustment screw Travel axis R axis Warning label 2 X NS User tubing 2 User tubing 1 User wiring Serial number label Wiring box User wiring connector pins 1 to 4 usable User tubing 2 04 User tubing 1 04 Suction coupler 612 x 2 2 2 1 Robot manipulator E Fig 2 3 4 axis model with hand holder User tubing 1 at lower part Hand holder User tubing 2 and user wiring inside End effector attachment suonoun4 N Suction coupler 612 x 2 User wiring connector pins 1 to 4 usable J p g p e Robot cable A Ground terminal Base tilt adjustment screw E Fig 2 5 3 axis model with hand holder User tubing 1 4 User tubing 2 04 Hand holder 2 3 2 Robot controller 2 Robot controller An RCX142 controller is used with the disk handling robot For detailed information on the controller refer to the separate YAMAHA Robot Controller RCX142 Series User s Manual E Fig 2 6 RCX142 suonoun4 N 200 230V 50 60Hz MAX 2500VA
41. Y oO Pp Connection No Connector AJN Red Remarks White Black Yellow green 4 axis specifications 4 KT8 M4811 N13 Cable carrier Z axis resolver and brake wires R axis stroke 550mm Base side D G Connector Brake 24V 4 axis specifications 5 Connection No Connector Remarks 0 3sq Twisted pair Drain wire 0 3sq Twisted pair KT8 M4815 N04 Cable carrier I O wire R axis stroke 550mm Base side General purpose 1 0 Connector Red Remarks White Green White Yellow 0 3sq White Twisted pair Blue White Violet White Wiring box side Wiring box side wn 2 f e e z N Wiring box side Only No 1 to No 4 are usable 7 19 5 Wiring tables 4 axis specifications 6 KT8 M4816 N04 2 pieces Cable carrier X and Y axis resolver and sensor wires R axis stroke 550mm Base side Wiring box side 0 3sq Twisted pair gt w NIOJ Drain wire 0 3sq Twisted pair Origin sensor 24V 0 3sq Twisted 0 3sq 24VGND Twisted pair 4 axis specifications 7 90K92 840240 R axis motor
42. alled Refer to 2 External view and dimensions in Chapter 7 for machining positions uore ejsu Gg 2 Remove the screws holding the upper cover of the robot and remove the upper cover Move the slider to a position where the mounting holes in the bottom of the robot are seen 3 Fix the robot to the installation base with the specified bolts Tightening torque Number of bolts M8 SNm 80Kgfum 10 Depth of tapped holes in installation base Iron installation base 15mm or more bolt length 40mm or more Aluminum installation base 25mm or more bolt length 50mm or more Recommended bolt JIS B 1176 hex socket head bolt or equivalent Strength class JIS B 1051 12 9 or equivalent E Fig 3 6 Installing the robot 10 M8 bolts for robot installation Screw into holes just outside guide Remove upper cover mounting screws 2 pcs J Va Remove upper cover mounting screws 4 pcs Upper cover 4 Reattach the upper cover 3 10 2 Installation 2 4 2 3 axis model Fix the robot securely with 4 hex socket head bolts as shown in Fig 3 7 Tightening torque Tightening torque Number of bolts ma S7Nm SB0Kgfom Depth of tapped holes in installation base Iron installation base 17mm or more bolt length 30mm or more Aluminum installation base 27mm or more bolt length 40mm or more Recommended bolt JIS B 1176 hex socket head bolt or equivalent Strength class JIS B 1051 12 9 or higher or equivale
43. ameter settings ACAUTION The robot must be operated with an acceleration rate that is appropriate for the manipulator tip s weight 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 Ajayes oqoy ay Suis a 19 Do not use the robot for tasks requiring motor thrust Avoid using the disk handling robot for tasks which make use of motor thrust press fitting burr removal etc These tasks may cause malfunctions of the robot 20 If the X axis or Y axis rotation angle is small AA CAUTION If the X axis or Y 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 bearing 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 21 If the Z axis or R axis travel distance is short If the Z axis or R axis travel distance is shorter than 5mm so that it always moves in the same position an oil film is difficult to be formed on the linear motion bearing possibly leading to damage to the bearing In this type of operation add a movement so that the axis moves more than 5mm about 5 times a day 1 7 3 Special training for industrial robot operation 3 Special training for industrial robot operation
44. ammable or explosive substances are present Do not use the robot in environments 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 otherwise occur Do not use the robot in locations subject to excessive vibration Robot installation bolts may otherwise become loose causing the robot to fall over 3 1 1 Robot installation conditions 1 2 Installation base Always install the robot on a level surface with the robot base mount facing downward Grease may leak out from the speed reduction gear if the robot is installed in such a way that the base mount does not face downward CAUTION The manipulator positioning may decrease if the installation surface precision is insufficient If 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 uore ejsu 9 1 Prepare a sufficiently rigid and stable installation base taking account of the robot weight including the end effector gripper workpiece and reaction force while the robot is operating The maximum reaction force see Fig 3 1 applied to the robot is as shown below These values are an instantan
45. and holder 3 Backward mechanical stopper position Contact with stopper occurs after origin position is exceeded Forward mechanical stopper lt position Contact with stopper occurs after arm extended position is exceeded Y axis forward mechanical stopper position Mechanical stopper position may vary somewhat depending on parts machining accuracy X and Y axis origin positions 17226 532 Y axis forward stroke Origin position may differ slightly from those shown above due to origin position adjustments wn Q e D o z un 7 8 M4 ground terminal Slo d e ele e D N Fe fees et nm 168 User tubing 2 04 User tubing 1 4 Suction coupler 612X2 2 External view and dimensions E Fig 7 3 3 axis specifications without hand holder 1 Tool attachment shaft LA X axis mechanical ARAZ 189 N stopper position 340 an o N o oj oe Working envelope Working envelope tool attachment shaft position and X axis mechanical stopper position Mechanical stopper position may vary somewhat depending on parts machining accuracy X and Y axis arms and tool attachment shaft may not extend fully depe
46. ass of cylinder kg W Weight of cylinder kgf 2 ff x 3 23 6 Attaching the end effector In the same manner the moment of inertia of a cylinder as shown in Fig 3 20 is given as follows B Fig 3 20 Cneter line lt gt _pmD h D bh punD hx m D hb uore ejsu Gg I 2 TA E EL EE 2 4 Cg 7342 mx kgm 2 2 2 2 2 je pr Dh ade NN pm D hx 16g 4 3 4g Ww D h wx 2c rad g kgfcmsec zs Eg 36 In the same manner the moment of inertia of a prism as shown in Fig 3 21 is given as follows E Fig 3 21 2 2 2 2 Center line y Pee ev pabex MA mx kgm pabc a b pabcx js ee ea 12g g W a b Wx C 2 b Med KC sme kgfcmsec Eq 3 7 m Mass of prism kg W Weight of prism kgf 3 24 6 Attaching the end effector 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 tool attachment shaft by a stay as shown in Fig 3 22 The moment of inertia is calculated with the following three factors assuming that the load material is steel and its density p is 0 0078kg cm B Fig 3 22 Tool attachment shaft I uorne ejsu A 6cm Workpiece 4cm 1 Moment of inertia of the stay B Fig 3 23 Center line lt gt Tool attachment shaft From Fig 3 23 the weight of the stay Ws is g
47. ation base and then position the lifter against the edge of the installation base At this point hold the robot to ensure it will not fall over See Fig 3 4 c Shift the robot onto the installation base with two people Make sure the robot is stably placed on the installation base See Fig 3 4 d Bolt the robot promptly by referring to the description in 2 4 Installing the robot uorne ejsu A 3 7 2 Installation 2 3 2 3 axis model The robot weighs more than 40kg so take suitable precautions when carrying the robot Use 3 or more people for the following work 1 uore ejsu Gg 3 8 Move each axis to its origin position and then turn off the controller and disconnect the robot cable from the controller The robot is bolted to a pallet at the time of shipment Fig 3 5 Installation base or pallet This figure shows a pallet Push here same on opposite side by hand to move robot Push here ls on opposite side by n hand to move robot a Lifter s fork b Wind the robot cable around the robot base and fasten the robot cable with adhesive tape See Fig 3 5 a In the following work hold the robot being careful to keep it balanced so it will not fall over Remove the robot base mounting bolts See 2 4 Installing the robot Move the robot to one edge of the installation base or pallet by pushing the robot toward the edge with two people one at eac
48. avitational acceleration cm sec Mass of cylinder kg Weight of cylinder kgf oO zB 3 22 6 Attaching the end effector 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 17 is given below B Fig 3 17 2 h EE kgm C m D 4 4 n Dh D m D h dz cx Rc eg M _ Eq 3 3 Density kg m kg cm Gravitational acceleration cm sec Mass of cylinder kg Weight of cylinder kgf uore ejsu 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 18 is given as follows B Fig 3 18 2 2 2 2 cT P e b me kgm 2 2 2 2 ee ae jo Rage EE b ee kgfcmsec LT Eq 3 4 Density kg m kg cm Gravitational acceleration cm sec Mass of prism kg Weight of prism kgf BnD 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 19 is given as follows B Fig 3 19 Rotation 4 hx 2 paD h punD hx _ mD 2 2 Center line center I 32 4 g mar TREE _ pnD h pmD hx 32g 4g 2 2 oD Q NE kgfcmsec 8g g Eq 3 5 p Density kg m kg cm g Gravitational acceleration cm sec m M
49. axis arms are aligned in a line at the front base position when they are extended Be careful not to enter within the robot movement range at this time 6 Make a visual check and if the arms are not aligned then perform the following steps However please note that even when the arms are fully extended the X and Y axis arms and tool attachment shaft are not completely aligned in a line due to parts machining accuracy and assembly condition 7 Turn off the controller power 8 Refer to 6 2 Adjusting the X and Y axis timing belt tension Loosen the tensioner nut and tension bolt and re adjust the belt tension so the relative positions of the bolts and the valleys of the pulley teeth are approximately as shown in Fig 4 16 Then retighten the tensioner nut and tension bolt 4 27 7 X axis and Y axis arm alignment E Fig 4 16 X axis arm bottom view M3 bolt 4 pcs Valley of pulley teeth Y axis arm Valley of pulley teeth juesunsn py M4 bolt 4 pcs inner side of elongate holes 9 Prepare the jigs as shown in Fig 4 17 Fig 4 18 and Fig 4 19
50. axis side Y resolver Red 0 2mm White Twisted pair Yellow 0 2mn Blue Twisted pair Gray 0 2mm Black Twisted pair Green Shield Red White 0 2mm Yellow Coating t0 3 I M Blue YORG H YORG Gray 0 2mm a Black Coating t0 15 Ring terminal _ _ Ring terminal Yellow green 0 2mm Coating t0 3 wn O e e z o z un Ring terminal is grounded to X axis Ring terminal is grounded to Z axis 4 axis specifications 3 KN3 M4850 301 X axis sensor Connection Z axis side 7 22 5 Wiring tables 4 axis specifications 90K90 62012X X axis motor Signal Connection Remarks Z axis side S2 Yellow S4 Blue S1 Red S3 Black R1 White R2 Green SHIELD Black Heat shrinkable tube Red White Black Yellow green Ring terminal Ring terminal is grounded to Z axis 4 axis specifications 5 S013 M31H4 001 Arm I O wire Tool Signal Connector No Connection No Connector attachment ser signal wire c Red ati White Yellow Blue 4 axis specifications 7 KN3 M4850 501 Y axis sensor No Signal Color Connection CN
51. bolt is hidden so shift air tubes screws on arm side N 4 surface and attach NS gt this bolt XK FM M4 bolt B 4 pcs inner side of elongate holes 12 Gradually tighten the bolts A and B If equipped with a hand holder then tighten the bolt C The jigs are heavy so be careful not to drop them and cause injuries Suddenly tightening the bolts may prevent the arms from extending straight after removing the jigs so use caution 4 30 7 X axis and Y axis arm alignment 13 Remove the jigs 14 Turn on the controller power and make the tool attachment shaft move straight forward When the arms are fully extended check that the X and Y axis arms and tool attachment shaft are aligned in a straight line Be careful not to enter within the robot movement range at this time 15 Even if no jigs are available you can make a visual check to see that the X and Y axis arms and tool attachment shaft approximately form a straight line and then tighten the bolts A B and C yuawysnipy A 4 31 MEMO 4 32 Operating the Robot 1 Robot motion 1 Robot motion Before operating the disk handling robot be aware that its motion differs from that of the SCARA robots Unlike the SCARA robots the reference coordinates cannot be set for this robot Point displays based on an orthogonal coordinate system have no meaning and such a coordinate system should not be used As shown in Fig 5 1 t
52. d residual vibration during positioning uore ejsu A 3 21 6 Attaching the end effector 6 2 Equation for moment of inertia calculation Usually the load on the tool attachment shaft 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 There is the following relation J kgf cm sec I kgm x 10 2 z 1 Moment of inertia for material particle e The equation for the moment of inertia for a material particle that has a rotation D center such as shown in Fig 3 15 is as follows This is used as an approximate equation when x is sufficiently larger than the object size B Fig 3 15 2 2 es I mx kgm Wx J kgfcmsec Eq 3 1 g Gravitational acceleration cm sec m Mass of material particle kg W Weight of material particle kgf 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 16 is given below E Fig 3 16 pr Dh mp g p E e DE 3o em pr Dh wD F J kgfcemsec 32g 8g Eq 3 2 Density kg m kg cm Gr
53. ds away from robot arms 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 locations of warning labels e Be sure to read the warning labels and this manual carefully and make sure you thoroughly understand their contents before attempting installation and operation of the robot Ajayes 310q03 ay SuIsN A e Before starting robot operation even after you have read through this manual read again the procedures and cautions relating to your work as well as the description in this chapter Chapter 1 Using the Robot Safely e 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 and operation E Fig 1 3 Warning label 3 A WARNING Improper Installation or operation can result in serious injury or death Read user s owner s manual and all warning labels before operation 4 Do not use the robot in environments containing inflammable gas etc This robot was not designed for operation in environments where inflammable or explosive substances are present Do not use the robot in environments containing inflammable gas dust or liquids Explosions or fire may otherwise result 1 3 2 Essential cautio
54. e move it in the direction reducing the tension Then retighten the bolts Recheck the belt tension using the same procedure in step 6 When the load applied to produce the specified slack is within the specified load range of Table 4 1 the adjustment is okay If not repeat the above procedure from steps 1 to 3 3 Z axis belt adjustment 1 23 4 22 Loosen the bolts 3 shown in Fig 4 13 Never remove them If the load producing the slack specified in Table 4 1 step 6 above is smaller than the specified range move the Z axis motor plate in the direction increasing the tension If the load is greater than that range move it in the direction reducing the tension Then retighten the bolts Recheck the belt tension using the same procedure in step 6 When the load applied to produce the specified slack is within the specified load range of Table 4 1 the adjustment is okay If not repeat the above procedure from steps 1 to 3 6 Adjusting the timing belt tension 8 After adjustment is complete tighten the bolts D or to the torque specified in Table 4 2 9 Attach the base cover 10 Go outside the safety enclosure 11 Check that no one is inside the safety enclosure and then turn on the controller yuawysnipy A 4 23 6 Adjusting the timing belt tension juesunsn py O 6 2 Adjusting the timing belt tension for the X axis and Y axis arms The timing belts used in the X and Y axis a
55. e 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 user s manual available for an additional fee 2 Operate or adjust the robot while viewing the CD ROM version of the user s 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 user s 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 do not understand English do not permit him her to handle the robot 1 1 2 Essential caution items 2 Essential caution items Particularly important cautions for handling or operating the robot are described below In addition safety information about installation operation inspection and maintenance is provided in each chapter Be sure to comply with these instructions 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 locations of warning labels e Install a safety enclosure to keep any
56. e is aligned with the scribe mark then tighten the tensioner mounting bolt The tightening torque for the tensioner mounting bolt is 4 5Nm 46kgf cm Finally secure the tension bolt nut ACAUTION Belt slippage will occur if the tensioner end face shifts to a position in front of the scribe mark and a shift beyond the scribe mark will reduce the durability of the R axis drive system Therefore be sure that the tensioner end face is aligned with the scribe mark 10 Reattach the covers jusunsn py O 4 26 7 X axis and Y axis arm alignment 7 X axis and Y axis arm alignment If the X or Y axis arm strikes the peripheral hardware with a harsh impact the belt inside the arm will jump from the gear teeth so that the X and Y axis arms might no longer fully extend during Y axis forward movement If that happens realign the X and Y axis arms using the jigs like those shown below The alignment jigs must be made by the customer The arms can be approximately aligned even without the jigs The arm alignment procedure is described below 1 Prepare the following tools Hex wrench set Phillips screwdrivers 2 Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel 3 Check that no one is inside the safety enclosure and then turn on the controller 4 Enter the safety enclosure while holding the MPB 5 Check whether the X and Y
57. e mass Kg x The maximum acceleration applied to a workpiece during operation is shown in the table below E Table 3 3 Maximum acceleration during robot operation Amax m sec Axmax m sec Avmax m sec Azmax m sec Wo 0 20 9 E Fig 3 31 Maximum acceleration on end effector attachment uore ejsu 9 Gripping or suction point Avmax Y axis forward acceleration or R axis forward acceleration Amax centrifugal acceleration Axmax connecting direction acceleration or R axis forward acceleration Since simultaneous X Y and R axis operations are prohibited see 2 Operating the robot in Chapter 5 Amax Axmax and Avmax are not applied at the same time Allow an adequate gripping force margin to ensure that the workpiece gripped by the end effector is held in a secure manner An insufficient gripping force could cause the workpiece to fly off causing a hazardous situation 3 34 7 Working envelope and mechanical stopper positions for maximum working envelope 7 Working envelope and mechanical stopper positions for maximum working envelope For details concerning the robot s working envelope and the operation limit mechanical stopper positions see 2 External View and Dimensions in Chapter 7 1 X axis and Y axis Do not attempt operation outside the working envelope Due to origin adjustments the origin positions may differ slightly from those shown in the external vi
58. e parts On the 3 axis model solder the user wires to the connector pins B Fig 3 13 User wiring connector robot side uore ejsu A oS Wiring prepared by user For 4 axis model Wiring prepared by user User wiring connector Rubber packing robot side Contact 7 V Guide key position Insulator For 3 axis model Contact layout Securely attach the supplied connector into the user wiring connector on the robot side If this connector comes loose or comes off malfunction may result The connector for the 4 axis model has lock tabs CAUTION Always use the pins and connector supplied with the robot Using other types may result in contact failure For 4 axis model Supplied connector for user wiring SMR 10 V B Supplied pins for user wiring SYM 001T 0 6 Manufacturer JST Mfg Co Ltd For 3 axis model Supplied connector for user wiring NJW 16 5 PF 9 Manufacturer MISUMI Corporation 3 19 5 User wiring connector and user tubing 5 2 User tubing 1 Air tubes are installed in the arm side and an O ring groove formed at the port of each air tube to allow direct attachment of a suction hand or gripper Fit the supplied O ring in this O ring groove when using the air tube When taking the user tubing 2 out of the hand holder if provided drill an additional hole in the cover of the hand holder and provide sealing etc 2 There are bulkhead unions for user tubing on the co
59. ended range then the next absolute reset may not be properly performed In this case adjust the machine reference by referring to 3 5 Adjusting the machine reference 4 5 3 Adjusting the origin Bi Fig 4 3 a X axis plus direction X axis return to origin direction X axis origin is the position where up hand s plus direction straight forward direction matches R axis R axiS travel axis plus direction 2 e o c un 3 one n X axis arm direction does not correspond X axis position is on hand s plus direction to X axis direction because X axis arm straight forward direction l also produces Y axis motion This is the position where X axis moves 90 in plus direction Bi Fig 4 3 b Y axis plus direction X axis and Y axis origin positions Y axis return to origin direction 3 Adjusting the origin Bi Fig 4 3 c Z axis origin position Z axis return to origin direction yuawysnipy A Lo o Xo Ko Ko Ke 1 SS ey o e e e o Ko Xo Ko Ko Xo Xo R axis origin position R axis plus direction R axis return to origin direction 4 7 3 Adjusting the origin yuawjsnipy O 3 3 2 Strike end method Z axis and R axis Serious injury might
60. eous force applied to the robot during operation and do not indicate the maximum load capacity Maximum reaction force during robot operation 3 2 1 Robot installation conditions E Fig 3 1 Maximum reaction force applied during operation n 3 5 u euin m S A 3 Mxmax 3 axis model 2 The installation base surface must be machined within a flatness of 0 05mm 500mm The robot base mount must be installed facing down and in a level position 3 Tap holes into the surface of the installation base Refer to 2 External view and dimensions in Chapter 7 for machining dimensions and positions 4 Securely fix the installation base on the floor with anchor bolts 3 3 2 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 ACAUTION Allow only properly qualified personnel to operate equipment such as forklifts that require a license to use Equipment and tools used for moving the robot should be serviced daily uore ejsu 9 The disk handling 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
61. et and point data setting again yuawysnipy A 6 1 Adjusting the X axis Y axis and Z axis motor belt tension 1 Prepare the necessary tools e Push pull scale e Stay See Fig 4 10 This stay should be prepared by the user e Hex wrench set e Phillips screwdrivers e Scale 2 When adjusting the X axis or Y axis belt tension position the X axis at the front base and the Z axis at a stroke position of 130mm 106496 pulses When adjusting the Z axis belt tension move the Z axis to its origin position If adjustment is made with the Z axis not at the origin position the Z axis may slides down causing a hazardous situation Then turn off the controller 3 Place a sign indicating the robot is being adjusted to keep others from operating the controller switch 4 Enter the safety enclosure 5 Remove the base cover See 3 4 Removing the robot covers for this procedure 6 Adjust the belt tension by two people as follows Using the push pull scale one person applies a load perpendicular to the middle of the belt The other person checks the slack of the belt See Fig 4 9 Fig 4 10 Fig 4 11 Fig 4 12 and Fig 4 13 At the Y axis belt the Fig 4 12 part 1 must be removed from part 2 in order to use the push pull scale to measure the tension An easy way to check the belt tension is to press a finger against the belt through the inspection window There should be some give in the belt when pressed If there is no give in
62. ew The mechanical stopper positions may vary somewhat depending on the parts machining accuracy etc 2 Tool attachment shaft The tool attachment shaft movement is indirectly restricted by the Y axis mechanical stoppers uore ejsu A 3 Z axis The Z axis has mechanical stoppers at the upper and lower ends The manipulator lowers approximately 3mm from near the origin position during return to origin by stroke end detection 4 R axis The R axis has a mechanical stopper at its stroke end The manipulator moves approximately 5mm to the mechanical stopper from near the origin position during return to origin by stroke end detection 5 Others Depending on the parts machining accuracy and assembly condition the X and Y axis arms and tool attachment shaft may not be completely aligned in a straight line even when the arms are fully extended 6 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 account 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 normal operation at maximum speed When the robot strikes the X axis or Y axis mechanical stopper or another object or when the end effector collides with an object the X axis or Y axis s
63. f pulses from the 0 pulse position Refer to the YAMAHA Robot Controller RCX142 Series User s Manual for further details Also refer to 2 External view and dimensions in Chapter 7 for the robot s working envelope When performing actual checks of the soft limit settings operate the robot manually from outside the safety enclosure jusunsn py Soft limit settings on each axis 1 The factory set soft limits are for the maximum working envelope Follow the procedure below to set soft limits that prevent interference with peripheral equipment but are within the maximum working envelope When the servo power is off it is difficult to move the X and Y axes because of their structures and the Z axis because of its weight Manually move each axis with the following procedure See 3 Creating point data direct teaching and external forces to arms in Chapter 5 for more details Place a sign indicating that the robot is being adjusted in order to keep others from operating the controller or operation panel Check that no one is inside the safety enclosure and then turn on the controller Enter the safety enclosure while holding the MPB Keep clear of the robot s working envelope Manually move each axis to positions just prior to interference with peripheral equipment then make a note of the plus direction and minus direction pulses for each axis displayed on the MPB screen Set the soft limits using the pulses for each axis that
64. f the screw holes Doing so may cause the hand holder to come off the tool attachment shaft After the adjustment is finished tighten the M4 bolts to a torque of 4 5Nm 46Kgfcm and lock the set screws with the nuts Making this adjustment affects the hand holder s horizontal alignment that was made at the factory prior to shipment so do not attempt this adjustment unless necessary E Fig 3 30 External view User wiring 0 1mm Red User wiring 1 White User wiring 2 Yellow User wiring 3 Blue User wiring 4 6 3 5 thru hole User tubing 1 uorne ejsu A 9MA set screw 3 pcs for hand E holder tilt adjustment epe TR 2 Set screw lock nut User tubing 2 4 id 113 413 Hand holder mounting M4 bolt 3 pcs 49 Details of A Inside of hand holder with cover removed 3 33 6 Attaching the end effector 6 7 Gripping force of end effector The gripping force of the end effector must have a sufficient extra margin of strength versus the workpiece mass and reaction force applied to the workpiece during robot operation The reaction force applied to the workpiece during operation can be calculated from the maximum acceleration applied to the workpiece Maximum acceleration 9 8 Reaction force N Workpiece mass Kg x Maximum acceleration Reaction force Kgf Workpiec
65. fter adjustment or replacement is finished again review the checkpoints outlined in 1 and 2 above 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 4 Six month inspection 4 Six month inspection The following inspections must be performed every 6 months The Z axis will slide down when the Z axis brake is released causing a hazardous situation Do not release the brake when lubricating the Z axis parts Injury can occur if hands or fingers are squeezed between the drive pulley and belt Always turn off the controller and use caution when handling these parts AM CAUTION The ball screw and guide life may shorten if the grease recommended by YAMAHA is not used 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 3 Enter the safety enclosure and check the following points Checkpoint Procedure Major bolts and screws on robot only for bolts and screws Check for looseness and tighten if necessary exposed externally uonoadsu iporiag o X Y Zand R axis timing belts Check belt tension See 6 in Chapter 4 Detection areas of X and Y axis origin sensors Clean if it is dirty
66. g accuracy X and Y axis arms and tool attachment shaft may not extend fully depending on parts machining accuracy or assembly condition 40 3 6 M3x0 5 thru hole suomi adg N uo I Ww Stm Go ae e IS s 9 990 A uw og W 611 3 11 3 55 5 e 69 Hand support Cross section B B Scale 1 1 7 12 2 External view and dimensions E Fig 7 4 3 axis specifications with hand holder 2 E BE E 2 User wiring 0 1mm 6 03 5 thru hole Egg 6 M3 bolts length 8 Red User wiring 1 User tubing 1 Soo Hand hold White User wiring 2 amp d Hand and holder Cover Yellow User wiring 3 995 Blue User wiring 4 Set screw 3 pcs for c Lo hand holder tilt Tim X es j o 2 adjustment C Hand support oE Cross section D D 10 m s Set screw lock nut Scale 1 1 7 O ring S5 supplied User tubing 2 4 Bhgres GUpplEd 11 3 11 3 Hand holder mounting bolt 3 pcs 49 Details of A Scale 1 1 Inside of hand holder wi
67. g force of end effector 3 34 7 Working envelope and mechanical stopper positions for maximum working envelope 3 35 8 Base suction tube 3 36 Chapter 4 Adjustment l Overview 4 1 Safety precautions 4 1 Adjusting the origin 4 2 3 1 Absolute reset method 4 3 3 1 1 Sensor method X axis and Y axis 4 3 3 1 2 Stroke end method Z axis and R axis 4 3 3 2 Machine reference 4 4 3 3 Absolute reset procedures 4 5 3 3 1 Sensor method X axis and Y axis 4 5 3 3 2 Strike end method Z axis and R axis 4 8 3 4 Removing the robot covers 4 9 3 5 Adjusting the machine reference 4 10 3 5 1 Adjusting the X axis machine reference 4 10 3 5 2 Adjusting the Y axis machine reference 4 12 3 5 3 Adjusting the Z axis machine reference 4 14 Setting the soft limits 4 16 Affixing stickers for movement directions and axis names 4 17 Adjusting the timing belt tension 4 19 6 1 Adjusting the X axis Y axis and Z axis motor belt tension 4 19 6 2 Adjusting the timing belt tension for the X axis and Y axis arms 4 24 6 2 1 Adjusting the X axis arm belt 4 24 6 2 2 Adjusting the Y axis arm belt 4 25 7 X axis and Y axis arm alignment 4 27 Chapter 5 Operating the Robot 1 Robot motion 5 2 Operating the robot 5 2 3 Creating point data direct teaching and external forces to arms 5 5 S C l Overview 6 1 2 Precautions 6 2 3 Daily inspection 6 3 4 Six month inspection 6 5 5 Replacing the harmonic drive grease 6 7 5 1 Replacement interval 6 7 l
68. gency 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 1 4 2 Essential caution items 9 Use caution 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 equipment 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 remove the obstruction Before reducing the air pressure place a support stand under the Z axis because it will drop under its own weight 10 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 Ajayes oqoy ay Suis a 11 Use caution when disassembling or replacing the pneumatic equipment Air or parts may fly outwards if pneumatic equipment is disassembled or parts replaced whi
69. h end of the robot base Have another person use a lifter to position it against the edge of the installation base or pallet Use a lifter with a maximum payload capacity sufficient to support the robot weight Shift the robot onto the forks of the lifter with two people See Fig 3 5 b Hold the robot while the lifter is moving up or down to ensure the robot will not fall over 2 Installation 7 Move the robot on the lifter to the new installation base and then position the lifter against the edge of the installation base At this point hold the robot to ensure it will not fall over See Fig 3 5 c 8 Shift the robot onto the installation base with two people Make sure the robot is stably placed on the installation base See Fig 3 5 d 9 Bolt the robot promptly by referring to the description in 2 4 Installing the robot uore ejsu A 3 9 2 Installation 2 4 Installing the robot When installing the robot use the specified size and number of bolts that match the depth of tapped holes in the installation base and securely tighten the bolts to the correct torque If this is not observed the robot might fall over during operation causing a serious accident Make sure that the bolts do not reach the bottom of the tapped holes 2 4 1 4 axis model The method for installing the robot is described below 1 Tap holes into the surface of the installation base where the robot is to be inst
70. he Y axis performs a straight forward motion while the X axis rotates the straight forward direction of the Y axis The Z axis moves the X and Y axes up and down together The R axis moves the X Y and Z axes together Since the RCX142 controller is used the coordinates are displayed in pulses The table below shows axis travel distances and corresponding pulse counts Travel distance Pulse count 819200 pulses Approx 269654 pulses 163840 pulses 450560 pulses The Y axis travel distance is not proportional to the pulse count For motion programming details refer to the YAMAHA Robot Controller RCX142 Series User s Manual E Fig 5 1 Robot motions 204800 0 0 0 172 yOqoy ay SunejadQ X Y Z and R axis origin positions 0 0 0 0 4 zay X Y Z and R axis origin positions X Y Z R a X axis motion 0 0 0 0 Units pulses 0 269653 163840 0 0 134258 0 0 e EE o Lp N LL i X Z and R axis origin positions 0 269654 0 0 0 269653 0 0 b Y axis motion c Z axis motion X Y Z and R axis 0 0 0 450560 550 origin positions 0 0 0 0 d n je T aes T d R axis motion 2 Operating the robot yOqoy ay SunejadQ CG 2 Operating the robot The robot s X axis and Y axis acceleration is determined by the X axis motion only
71. he controller during inspection always first turn off the controller power and also the power source in order to prevent possible electrical shock Never touch any internal parts of the controller The controller must be installed outside the safety enclosure When inspecting the controller it is dangerous to enter the safety enclosure while the controller power is ON For precautions on handling the controller refer to the YAMAHA Robot Controller RCX142 Series User s Manual 6 2 3 Daily inspection 3 Daily inspection The following inspections 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 safety enclosure and check the following points Checkpoint Procedure Wire harness in cable carrier Check for scratches dents and excessive bend and Robot cable kinks If the wire harness in the cable carrier or robot User cable and wiring cable is damaged contact YAMAHA dealer Check air pressure Air regulator air coupler air Check for air leaks tube solenoid valve air cylinder Check drain Check air filter for clogging or damage Check for damage If damage is found contact YAMAHA dealer Robot exterior 2 Inspection to be performed
72. ical unit contacts the mechanical stopper and stroke end is detected Serious injury might occur from physical contact with the robot during operation Never enter within the robot movement range during absolute reset 4 3 3 Adjusting the origin juesunsn py O 3 2 Machine reference The disk handling robot uses a resolver as the position sensor The resolver provides 4 absolute reset positions per motor turn When performing an absolute reset by the sensor method the origin position is set at one of those absolute reset positions located just after the point where the origin sensor reacts to the dog origin signal 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 in the ratio of interval A to interval B shown in Fig 4 1 Interval A 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 is displayed on the optional MPB screen unit 96 Machine reference value B A x 100 CAUTION The machine reference must be adjusted within a specified range to keep the repeatabilit
73. ide the safety enclosure 13 After the absolute reset is completed read the machine reference value displayed on the MPB 14 The machine reference adjustment is complete when the machine reference is within the 40 to 60 range recommended range Turn off the controller and then reattach the base cover If the machine reference is still outside the recommended range readjust it by repeating the procedure from step 9 yuawysnipy A 4 13 3 Adjusting the origin juesunsn py O 3 5 3 Adjusting the Z axis machine reference The Z axis origin position is fixed at the lower end of the Z axis stroke and cannot be changed The Z axis machine reference value is preadjusted before shipment and does not need to be adjusted in normal operation However if for some reason the machine reference value goes outside the allowable absolute reset range 40 to 60 adjust with the procedure below To check the machine reference value refer to step 13 Fingers may get caught between the drive pulley and belt causing injury Before touching those parts always turn off the controller and perform the work carefully CAUTION Adjusting the machine reference will usually change the origin position The point data must be set again after the machine reference adjustment 1 Check that no one is inside the safety enclosure and then turn on the controller 2 Place a sign indicating that the robot is being adju
74. ight forward direction of the tool attachment shaft it moves along a path deviating from the straight forward direction With the X axis and Y axis arms positioned as shown in Fig 3 29 attach the end effector so its side surface is perpendicular to the arm side surface E Fig 3 29 Without hand holder Align end effector by adjusting clearance gap between bolt and through hole XO holder prepared by user uore ejsu 9 Fasten end effector so its side Position X axis and Y axis arms surface is perpendicular to arm side so their side surfaces are parallel surface with each other E Fig 3 29 With hand holder Hand holder Hand holder is positioned in advance so it is perpendicular to arm side surface Fasten end effector so its side surface is perpendicular to arm side surface Position X axis and Y axis arms so their side surfaces are parallel with each other 4 Refer to 6 Trial operation in Chapter 1 to check the end effector motion 3 32 6 Attaching the end effector 6 6 Adjusting the end effector tilt when equipped with hand holder Fig 3 30 shows details of the hand holder section The hand holder is fastened to the tool attachment shaft with three M4 bolts To adjust the tilt of the hand attached to the hand holder loosen those M4 bolts and then adjust the tightening of the M4 bolts and three M4 set screws Do not tighten the set screws more than 1 2 turn after they reach the bottom o
75. in position For the R axis details refer to the F17 single axis robot described in the FLIP X Series User s Manual 4 2 3 Adjusting the origin 3 1 Absolute reset method 3 1 1 Sensor method X axis and Y axis In the sensor method the target axis is automatically operated for absolute reset and the absolute reset is performed at the position where the proximity sensor provided on the target axis detects the detection point 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 operation Never enter within the robot movement range during absolute reset The origin cannot be detected in any axis which is not positioned on the plus side from the origin See Fig 4 3 a to d 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 origin and reperform the return to origin operation If the return to origin operation is not interrupted the robot will continue the operation and may collide with the mechanical stopper or a peripheral device yuawysnipy A 3 1 2 Stroke end method Z axis and R axis In the stroke end method absolute reset is performed at a position slightly backed off from the stroke end after the mechan
76. iner so use protective gloves 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 If they get in the eyes wash liberally with pure water for about 15 minutes and consult a physician for treatment If they come in contact with the skin wash away completely with soap and water If 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 container 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 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 applying 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 The harmonic drive may be damaged if the grease recommended by YAMAHA is not used 6 8 5 Replacing the harmonic drive grease Recommended grease Use the following harmonic drive grease HC 1A or SK 1A made by
77. ion stickers according to instructions in 5 Affixing stickers for movement directions and axis names in Chapter 4 of this manual 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 and controller are connected RCX142 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 axis or Y axis rotation angle is small If the X axis or Y 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 bearing 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 If the Z axis or R axis travel distance is short If the Z axis or R axis travel distance is shorter than 5mm so that it always moves in the same position an oil film is difficult to be formed on the linear motion bearing possibly leading to damage to the bearing In this type of operation add a movement so that the axis moves more than 5mm about 5 times a day 930u SuiwoJ oj JY pea1 0j ans 2g 10q0
78. is commonly used in conjunction with an automated system dangerous 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 operation and servicing of the system Trial operation making installations adjustments inspections maintenance or repairs to the robot make a trial run using the following procedures 1 If a safety 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 safety enclosure and observe the following points 1 23 3 Use sturdy stable posts which will not fall over easily The rope or chain should be easily visible by everyone around the robot Place a sign to keep the operator or other personnel from entering the movement range of the manipulator 2 Check the following points before turning on the controller Oo Ui RA c Ncl Is the robot securely and correctly installed Are the electrical connections to the robot correct Are items such as air pressure correctly supplied Is the robot correctly connected to peripheral equipment Have safety measures safety enclosure etc been taken Does the installation environment meet the specified standa
79. iven as follows Ws pabc 0 0078 x 12x 2x 2 0 37 kgf The moment of inertia of the stay Js is then calculated from Eq 3 7 2 037 x 127427 0 37 x 5 12 x 980 980 0 014 kgfcmsec 3 25 6 Attaching the end effector 2 Moment of inertia of the chuck When the chuck form resembles that shown in Fig 3 24 the weight of the chuck Wc is B Fig 3 24 Tool attachment shaft Wc 20 0078 x 2x 4x6 0 37 kgf The moment of inertia of the chuck Jc is then calculated from Eq 3 7 10cm lez 0 37 x 27 47 12 x 980 0 37 x 10 te 980 0 038 kgfcmsec 6cm uore ejsu 9 3 Moment of inertia of workpiece When the workpiece form resembles that shown in Fig 3 25 the weight of the workpiece Ww is B Fig 3 25 Tool attachment shaft Ww prD h 0 00780 x 2x4 cy 4 4 10cm 0 098 kgf The moment of inertia of the T workpiece Jw is then calcu lated from Eq 3 5 4cm iwe 0 097 x M 0 097 x 10 8 x 980 980 0 010 kgfcmsec 2cm 4 Total weight The total weight W is calculated as follows W Ws Wc Ww 0 84 kgf 5 Total moment of inertia The total moment of inertia J is then obtained as follows J Js Jc Jw 0 062 kgfcmsec 3 26 6 Attaching the end effector 6 4 End effector attachment strength and rigidity The end effector attachment must have adequate strength and rigidity as well as gripping force to prevent positioning erro
80. k or perform the following points from outside the safety enclosure 1 Make sure that no hazards are present within the safety enclosure by a visual check Check that the programming unit MPB operates correctly Check that no failures are found in the robot Check that emergency stop works correctly om A W N Select teaching mode and prohibit automatic operation 2 Never enter the movement range of the robot while within the safety enclosure 1 11 8 Automatic operation 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 safety 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 safety enclosure is securely installed with safety interlocks actuated 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 warning lamp to ensure that the robot is in automatic operation c wv ga ma gt oO A o a o e un E 2 Ne 2 Never enter the safety enclosure during automatic operation 3 If an error occurs in the robot or peripheral equipment observe the following procedure before entering the safety enclosure 1 Press the emergency stop button to set the r
81. le air is still supplied Do service work after first turning off the controller and reducing the air pressure Before reducing the air pressure place a support stand under the Z axis 2 axis robots with air driven Z axis because it will drop under its own weight 12 Use caution when removing the Z axis motor The Z axis will drop when the Z axis motor is removed causing a hazardous situation Turn off the controller and set a support stand under the Z axis before removing 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 1 5 2 Essential caution items Ajayes oqoy ay Suis 13 Use caution during inspection of controller e 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 e Never touch any internal parts of the controller For precautions on handling the controller refer to the YAMAHA Robot Controller User s Manual 14 Consult us for corrective action when the robot is damaged or malfunction occurs A WARN NG 0 00 00 If any part of the robot is damaged or any malfunction occurs continuous operation may be very dangerous Please consult YAMAHA sales office or dealer for corrective action Da
82. ll the robot in the following environments Items Specifications Allowable ambient temperature 0 to 40 C Allowable ambient humidity 35 to 8596 RH non condensation Altitude 0 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 1 Robot installation conditions uorne ejsu For detailed information on how to install the robot controller refer to the separate YAMAHA Robot Controller User s Manual Avoid installing the robot in locations where the ambient conditions may exceed 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 designed for operation in environments where infl
83. lus direction is the plus direction Example 1 Please note that the X axis also rotates while the tool attachment shaft moves straight forward When the end effector is long as shown in example 2 you may affix stickers to it along the straight forward direction of the tool attachment shaft Align the direction 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 location may cause faulty operation and hazardous situations 4 17 5 Affixing stickers for movement directions and axis names E Fig 4 8 Example 1 o lo Io Ko IKo Ko Ike e e S juesunsn py O C O E Fig 4 8 Example 2 4 18 6 Adjusting the timing belt tension 6 Adjusting the timing belt tension If the timing belt becomes slack use the following procedure to give proper tension to the belt 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 turn off the controller wait for a while and check that the temperature has cooled Injury can occur if hands or fingers are squeezed between the drive pulley and belt Always turn off the controller and use caution when handling these parts AM CAUTION Since a positional shift occurs after adjusting the belt tension it is necessary to make absolute res
84. mage or Trouble Possible Danger Damage to machine harness or robot cable Electrical shock malfunction of robot Flying outwards of damaged parts during Damage to exterior of robot robot operation Abnormal operation of robot Me f Malfunction of robot positioning error excessive vibration etc Z axis brake trouble Dropping of load 15 Use caution not to touch the high temperature motor or speed reduction gear casing A WARNNG 0 0 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 16 Do not remove alter or stain the warning labels SAN 00 0 0 0 0 0 0 00 00 0 0 If warning labels are removed 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 safety enclosure 1 6 2 Essential caution items 17 Protective bonding Be sure to ground the robot and controller to prevent electrical shock 18 Be sure to make correct par
85. mm and a length within 1 meter On the 4 axis model take out the ground cable through the cutout in the wiring box so that it will not interfere with the movable parts 3 14 4 Robot cable connection 4 Robot cable connection For details on connecting the robot cable to the controller refer to Fig 3 11 and the YAMAHA Robot Controller User s Manual After making connections check the operation while referring 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 controller In the RCX142 controller the MOTOR connectors XM and ZM and YM and RM each have identical shapes In addition the PI connectors XY and ZR have identical shapes Do not confuse these connectors when making connections Wrong connections may result in malfunction and hazardous situations 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 stres
86. n 20um R axis travel direction 20um Repeatability X and Y axes tool attachment shaft position 0 1mm Z and R axes tool attachment shaft position wn 2 f e D o 5 un 0 05mm Cleanliness degree Class 1000 0 3um base during suction Tool attachment shaft Z axis up down stroke range and R axis travel area do not conform to clean room specs Suction rate 60NI min User tubing 04 2 tubes User wiring 0 1mm 4 wires Weight Robot body 70kg RCX142 controller W180xD235xH250mm 6 5kg Travel limit 1 Soft limit X Y Z and R axes 2 Mechanical limit X Y Z and R axes Robot cable 3 5m option 1m 2m and 4m to 10m in 1m steps Arm and base Almite coated aluminum Arm and base covers Almite coated aluminum Outer bolts and screws Stainless At constant ambient temperature 1 Basic specifications 2 3 axis specifications Payload 0 2kg R axis rotational moment of inertia 0 04kgfcms Working envelope Y axis forward stroke 532mm X axis rotation angle 340 Z axis up down stroke 200mm X axis 200w Y axis 100w Z axis 400w Maximum speed Y axis forward direction 300mm s X axis rotation 290 s Z axis up down direction 1000mm s Resolution Y axis forward direction 50um X axis rotation direction 0 00
87. n items 5 Do not use the robot in locations possibly subject to electromagnetic interference etc Avoid using the robot in locations subject to electromagnetic interference electrostatic discharge or radio frequency interference Malfunction may otherwise occur 6 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 hazardous 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 installation base when releasing the brake to perform direct teach Ajayes oqoy ay Suis 7 Provide safety measures for end effector gripper etc End effectors must be designed and manufactured so that they cause no hazards for example loosening of workpiece even if power electricity air pressure etc is shut off or power fluctuations occur If 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 8 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 emer
88. nding on parts machining accuracy or assembly condition suone2iiadg e 7 9 2 External view and dimensions E Fig 7 3 3 axis specifications without hand holder 2 3 3 3 3 User tubing 1 O ring S7 2 pcs supplied 9 3 Te k 9 o T co i 4 o eOe ee d c en User wiring 0 1mm User tubing 2 Red User wiring 1 11 8 11 3 SO White User wiring 2 Yellow User wiring 3 Details of A Blue User wiring 4 Scale 1 1 Cross section B B Scale 2 1 389 50 le N eno Ps D T A Sy 9 is L 4 M8x0 75 a Leveling bolt e D 4 010 for a M8 mounting bolt D i o Z axis lower end mechanical E Z axis origin position vom EE l stopper position ie Tool o ttachment axis Z axis lowers to this position 310 snam gu 2 axis o during absolute reset return Q gt _ _Y axis oe oe to origin Xais i co c N 7 E Sy Dub o gt L1 2 Fe e e P 147 199 172 217 389 7 10 2 External view and dimensions E Fig 7 3 3 axis specifications without hand holder 3 Backward mechanical op C sto
89. nformation 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
90. nge Green Brown 5 Wiring tables Wire 0 3sq Twisted pair 0 3sq Twisted pair Gray Red 0 3sq Twisted pair Drain wire Black Yellow 0 3sq Twisted pair Pink Violet 0 3sq Twisted pair White Blue red 0 3sq Twisted pair Orange white Green white 0 3sq Twisted pair Shield Brown white Gray white 0 3sq Twisted pair Red white 0 3sq Twisted Yellow black Pink black 0 3sq Twisted pair XM Ring terminal YM FG Ring terminal AJOIN AJOJN N White blue 0 3sq Twisted Blue red Orange white 0 3sq Twisted pair 1 0 75sq 2 0 75sq 3 0 75sq Yellow green 0 75sq 0 75sq 0 75sq 0 75sq Controller side wn 2 f e e z o N Grounded in wiring box M4 ground terminal on the rear of wiring box 7 17 5 Wiring tables 4 axis specifications 2 Signal Connector No Connection No Connector Color No Wie Resolver S2 0 3sq S4 Orange Twisted pair 1 Green 0 3sq S3 ZP Twisted pair R2 l l Red Twisted pair DG f T Drain wire Brake MB 0 3sq MB ZBK Yellow Twisted pair Resolver S2 Pink 0 3sq S4 Violet Twisted pair ZR 81 White 0 3sq S3 RP 22 Blue red Twisted pair R1 l 23 Orange white 0 3sq l R2 24 Green white
91. not interfere with robot motion and do not become entangled with the robot or swing about freely as such conditions can damage the wiring or tubing and possibly cause malfunctions User wiring and tubing installed utilizing the user wiring connector and tubing bulkhead unions should be positioned so that they will not be in the way of the operator and other workers Tripping over the wiring or tubing could result in falls and The disk handling robots are equipped with user signal wires and air tubes in the robot s machine harness The table below shows the number of signal wires and air tubes available to users The specifications of user signal wires and air tubes are shown below Always observe these 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 o4mm x 2 5mm Fluid 3 16 Dry clean air not containing deteriorated compressor oil air filter filtration 40um or less 5 User wiring connector and user tubing 5 1 User wiring 1 User wiring is provided on the arm side See Fig 3 12 Make wiring to the end effector When taking the user wires out of the hand holder if provided drill an additional hole in the cover of the hand holder 2 A user wiring connector is provided on the controller side of the robot See Fig 3 12
92. nsion 11 Go out of the safety enclosure 12 Check that no one is inside the safety enclosure Then turn on the controller 13 Perform an absolute reset on the Z axis After the absolute reset is completed check that the machine reference value for stroke end method adjustment is within the allowable absolute reset range 40 to 60 CAUTION Use the following procedure to display the machine reference value for stroke end method adjustment When adjusting the machine reference always use this procedure to check the machine reference value for adjustment D Press the MODE key 2 Press the F3 key to enter MANUAL mode 3 Press the F13 LOWER F3 key to select RST ABS 4 After the Z axis absolute reset is completed press the F10 UPPER F5 The machine reference value for adjustment is then displayed in percent 96 If the machine reference value for adjustment is still outside the allowable absolute reset range 40 to 60 repeat from step 7 onward so it is within the allowable range 14 Reattach the cover 4 15 4 Setting the soft limits 4 Setting the soft limits In the disk handling robot the working envelope during manual and automatic operation can be limited by setting the plus soft limit pulses and minus soft limit pulses on each axis The origin point O pulses is used as the reference to set the soft limits The working envelope can be limited by specifying the number o
93. nsion adjustment is not required if the load producing the Table 4 1 Slack is within the Load range in Table 4 1 If outside the load range adjust using the procedure described below E Table 4 1 Location Load N Load kgf Slack mm X axis Belt 6 1 to 7 4 0 62 to 0 75 Y axis Belt 2 7 to 4 1 0 28 to 0 42 Z axis Belt 5 7 to 6 3 0 58 to 0 64 E Table 4 2 Tightening torque Bolt size Tightening torque kgf cm Tightening torque N m 1 2 jusunsn py O 1 X axis belt adjustment Loosen the bolt D shown in Fig 4 11 Never remove it If the load producing the slack specified in Table 4 1 step 6 above is smaller than the specified range move the X axis motor plate in the direction increasing the tension If the load is greater than that range move it in the direction reducing the tension Then retighten the bolt Recheck the belt tension using the same procedure in step 6 When the load applied to produce the specified slack is within the specified load range of Table 4 1 the adjustment is okay If not repeat the above procedure from steps 1 to 3 2 Y axis belt adjustment Ta 2 Loosen the bolts 2 shown in Fig 4 11 and Fig 4 12 Never remove them If the load producing the slack specified in Table 4 1 step 6 above is smaller than the specified range move the Y axis motor plate in the direction increasing the tension If the load is greater than that rang
94. nt E Fig 3 7 Installing the robot uorne ejsu A Installation base Hex socket head bolt 3 11 2 Installation 2 5 Adjusting the robot base tilt Use the following method to adjust the robot base tilt versus the slider 4 axis model or installation base 3 axis model See Fig 3 8 Making this adjustment also affects the robot base alignment that was made at the factory prior to shipment so do not attempt this adjustment unless necessary E Fig 3 8 4 axis model 4 base tilt adjustment screws width across flats 6mm 4 screw lock nuts width across flats 13mm uore ejsu Gg Slider lWlFig 3 8 3 axis model Installation base 4 base tilt adjustment screws width across flats 6mm 4 screw lock nuts width across flats 18mm 4 M8 bolts for base installation 1 Loosen the M8 bolts securing the robot base 2 Loosen the nuts securing the robot base tilt adjustment screws 3 Tighten the robot base tilt adjustment screws to adjust the tilt as needed 4 When finished retighten the M8 bolts to a torque of 37Nm 380Kgfcm to secure the robot base 5 Retighten the nuts to secure the robot base tilt adjustment screws 3 12 3 Protective bonding 3 Protective bonding Be sure to ground the robot and controller to prevent electrical shock Turn off the controller before grounding the robot The
95. ntroller side of the robot E Fig 3 14 User tubing O ring S7 O ring edge User tubing 1 S Pa User tubing 1 ES Es O ring groove Q S V4 Tool attachment shaft uore ejsu Gg O ring S5 5 Screw e c Cover Coupler DN User tubing 2 64 spare Without hand holder Arm side With hand holder User tubing 1 04 User tubing 2 04 2 User tubing 2 04 Q User tubing 1 4 4 axis model 3 axis model Controller side 3 To check the signal exchange and operation between the end effector and the controller or peripheral equipment after making user wiring and tubing connections refer to 6 Trial Operation in Chapter 1 3 20 6 Attaching the end effector 6 Attaching the end effector 6 1 Acceleration The disk handling robot has a maximum load mass capacity of 200g tool attachment shaft rotation s moment of inertia 0 040kgf cm sec Therefore a mass and moment of inertia exceeding this level should never be applied to the tool attachment shaft An excessive end effector moment of inertia can cause vibration and overload during operation of the X or Y axis or tool attachment shaft This may also produce residual vibration during positioning CAUTION An excessive end effector moment of inertia can cause vibration and overload Failure to comply with the maximum load mass capacity and moment of inertia will shorten the drive system life and may result in damage an
96. o ensure safe and efficient operation This chapter describes the periodic inspection items and procedures for the disk handling robots Periodic inspection includes Daily inspection 6 month inspection Replacing the grease for 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 uonoadsu iporiag o 6 1 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 knowledge and skill and may also involve work hazards 3 When inspection is required inside the safety 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 safety enclosure D 5 Place a sign indicating the robot is being inspected to keep others from operating the uonoadsu iporiag 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 see 6 Trial operation in Chapter 1 When you need to touch the terminals or connectors on the outside of t
97. obot to emergency stop 2 Place a sign on the start switch indicating that the robot is being inspected 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 12 11 Warranty 11 Warranty The YAMAHA robot and or related product you have purchased are warranted against the defects or malfunctions as described below Warranty description If a 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 Warranty Period The warranty period ends when any of the following applies 1 After 18 months one and a half year have elapsed from the date of shipment 2 After one year has elapsed from the date of installation 3 After 2 400 hours of operation Ajayes oqoy ay SuIsN a Exceptions to the Warranty This warranty will not apply in the following cases 1 Fatigue arising due to the passage of time natural wear and tea
98. oqoy ay Suis a 4 Mechanical stoppers If the servo power is suddenly shut off during high speed operation by emergency stop or safety functions these mechanical stoppers prevent the axis from exceeding the movement range The movement range is the area limited by mechanical stoppers The X Y Z and R axes have fixed mechanical stoppers at their movement range limits in plus and minus directions Axis movement will not stop immediately after the servo power supply is shut off by emergency stop or other safety functions so use caution 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 power is off or the Z axis servo power is off even when the controller power is on The Z axis brake can be released by means of the programming unit or by a command in the program when the controller power is on The Z axis will slide down when the Z axis brake is released creating a hazardous situation Press the emergency stop button and prop 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 installation base when releasing the brake to perform direct teach 1 9 5 Safety measures for the system 5 6 After Ajayes 10q03 y SuIsN Safety measures for the system Since the robot
99. or Y axis motion only operations shown in Fig 5 2 below Therefore when the X axis and Y axis are operated simultaneously or the X axis rotates while the Y axis is far from its origin position this will shorten the drive system life and could result in mechanical damage overload conditions and residual vibration during positioning The Y axis should always be near its origin position when the X axis rotates and the X and Y axes should not be operated simultaneously The R axis travel axis is located beneath the disk handling robot Do not attempt to move the X Y and Z axes while the travel axis is moving If attempted an inertia force will be applied to the X and Y axes by the travel axis motion This will shorten the drive system life and could result in mechanical damage overload conditions and residual vibration during positioning If the Z axis is moved while the travel axis is moving the Z axis harness may interfere with the Z axis drive section causing the harness wires to break A sample robot motion program is shown below See also Fig 5 3 LO FOR I 1 TO 10 MOVE P P I DELAY 1000 NEXT I GOTO LO 5 2 2 Operating the robot E Fig 5 2 Robot motions a X axis motion only b Y axis motion only yOqoy ay SunejadQ C c X Y and X axis operation prohibited during R axis travel axis motion Se o 1o Io o Xo Ko Ko e AS Ss o 5 3 o e
100. orking envelope Working envelope tool attachment shaft position and X axis mechanical stopper position Mechanical stopper position may vary somewhat depending on parts machining accuracy X and Y axis arms and tool attachment shaft may not extend fully depending on parts machining accuracy or assembly condition En aaa suone2iiadg e 170 7 3 2 External view and dimensions E Fig 7 1 4 axis specifications without hand holder 2 6 M3x0 5 depth 10 O ring S7 3 3 3 3 User tubing 1 2 pcs supplied 9 L Es B l B Lo moet Te User wiring 0 1mm i e ANS Red User wiring 1 User tubing 2 Lp White User wiring 2 1 11 3 11 8 s Yellow User wiring 3 Details of A Q Blue User wiring 4
101. peed reduction gears might be locked while being meshed if the collision impact is large Belt slippage could also occur inside the robot arms If this occurs please contact a YAMAHA sales office or dealer E Table 3 4 Cka Ya O mis Ras Forward end Backward end Upper end Lower end Forward end Backward end 2 5 2mm 2mm 2mm 2mm 2mm 2mm Note Here deg is the overrun angle at the X axis joint 3 35 8 Base suction tube 8 Base suction tube Couplers for suction in the robot base and arms are located on the rear of the robot base A suction rate of 60 Nl min is required Refer to 1 Basic specifications in Chapter 7 for information about the cleanliness degree during suction E Fig 3 32 4 axis model i dd uore ejsu 9 WFig 3 32 3 axis model 7 d GP D W Q Y 3 36 Suction coupler 12x2 1 Overview 1 Overview 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 2 Safety precautions 1 Read and understand the contents of this chapter completely before attempting to adjust the robot 2 Place a conspicuous sign indicating the robot is being adjusted to prevent others
102. person from entering within the movement range of the robot and suffering injury due to being struck by moving parts e Install a safety interlock that triggers emergency stop when the door or panel is opened Ajayes oqoy ay Suis e Install safeguards so that no one can enter inside except from doors or panels equipped with safety interlocks e 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 DANGER Serious injury or death will result from impact with moving robot e Keep outside of guard safety enclosure during operation e Lock out power or press emergency stop button before approaching robot E Fig 1 1 Warning label 1 DANGER Serious injury or death will result from impact with moving robot Keep outside of guard during operation Lock out power before approaching robot 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 locations of warning labels Be careful not to let hands or fingers be pinched or 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 2 Essential caution items E Fig 1 2 Warning label 2 A WARNING Moving parts can z pinch or crush Keep han
103. pper position Contact with stopper occurs after origin position is A ey exceeded Forward mechanical stopper position IA Contact with stopper occurs after arm extended position is exceeded Y axis forward mechanical stopper position Mechanical stopper position may vary somewhat depending on parts machining accuracy ED 172 6 532 Y axis forward stroke X and Y axis origin positions Origin position may differ slightly from those shown above due to origin position adjustments a suone2iiadg e Suction tube 12 in base Suction tube 12 in X and Y axis arms User tubing 1 4 User wiring connector User tubing 2 04 4 pins Lo liad Lo 35130 30 a eg jg NS M4 ground terminal N Robot cable 7 11 2 External view and dimensions E Fig 7 4 3 axis specifications with hand holder 1 Tool attachment shaft 340 A AP A X axis mechanical 7 gt wae R 180 X stopper position N lo 9 amp Working envelope Working envelope tool attachment shaft position and X axis mechanical stopper position Mechanical stopper position may vary somewhat depending on parts machinin
104. r bearing outer O ring for supporting speed reduction gear input section X4 KN5 M1821 004 HARMONIC DRIVE ASSY Speed reduction gear X5 KN5 M181H 000 O RING 4 O ring for X axis speed reduction gear input section X6 90K90 62012X AC SERVO MOTOR Motor See 5 Wiring table X axis X7 1 S013 M3156 000 BELT 1 1 Belt X8 S013 M3138 201 STOPPER 1 Mechanical stopper X9 S013 M3139 000 DAMPER 1 2 Mechanical stopper damper X10 KN3 M4850 301 PROXIMITY SW ASSY Origin sensor See 5 Wiring table 13 Edge face seal for speed X11 KN5 M1886 000 SEAL 1 reduction gear input section X12 KN3 M2159 000 O RING 1 4 O ring for speed reduction gear output section X13 S013 M31H4 001 HARNESS E MIB dam See 5 Wiring table 15 A O e D o 2 un X15 S013 M3146 003 HARNESS MACHINE 2 Curl cable See 5 Wiring table 12 Y1 S013 M31K0 011 AC SERVO MOTOR Motor See 5 Wiring table 8 Y2 KN4 M1892 000 BRG 2 Upper bearing for supporting speed reduction gear input section Y3 KN4 M1891 000 BRG Lower bearing for supporting speed reduction gear input section Y4 KN4 M181H 000 O RING 4 Upper bearing outer O ring for supporting speed reduction gear input section Y axis Y5 KN4 M1821 007 HARMONIC DRIVE ASSY 1 Speed reduction gear Y6 KN4 M181G 000
105. r occurring during operation 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 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 WARRANTIES OF MERCHANTABILITY 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 DELIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO LTD SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES WHETHER ARISING FRO
106. rds 3 After the controller is turned on check the following points from outside the safety enclosure IP ON DU BW h2 1 10 Does the robot start and stop as intended Can the operation mode be selected correctly Does each axis move as intended within the soft limits 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 safety enclosure and interlock working as intended Does the robot move correctly during automatic operation 7 Work within the safety enclosure 7 Work within the safety enclosure 1 When work is required inside the safety enclosure always turn off the controller and place a sign indicating that the robot is being adjusted or serviced 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 setting See section 4 in Chapter 4 3 X axis and Y axis arm alignment See section 7 in Chapter 4 4 Teaching For items 1 2 and 3 follow the precautions and procedure described in each section To perform item 4 refer to the description in 2 below Ajayes oqoy ay Suis a 2 Teaching When performing teaching within the safety enclosure comply with the instructions listed below 1 Chec
107. rew support bearing Z9 S013 M31G3 000 BELT 1 Belt Z10 S013 M31G2 100 BOLT 1 Lower end stopper X and Y axis curl cable Z11 S013 M31H6 012 HARNESS 1 Z axis stroke 200mm un See 5 Wiring table I O curl cable A Z12 S013 M31H5 011 HARNESS gee 5 Wiring table Q9 FG curl cable Z13 S013 M31E0 001 HARNESS EARTH 1 See 5 Wiring table Cable carrier X and Y axis S Z axis 714 KT8 M4814 N12 CABLE TERMINAL4 MEE iion an R axis stroke 550mm See 5 Wiring table Cable carrier Z axis power wire Z15 KT8 M4813 N12 CABLE TERMINAL4 1 R axis stroke 550mm See 5 Wiring table Cable carrier I O wire Z16 KT8 M4815 NO4 CABLE TERMINAL4 1 R axis stroke 550mm See 5 Wiring table Cable carrier Z axis resolver and Z17 KT8 M4811 N13 CABLE TERMINAL4 1 oo hae See 5 Wiring table Cable carrier X and Y axis Z18 KT8 M4816 NO4 CABLE TERMINAL4 2 se tee a See 5 Wiring table Warning label Japanese SF Z19 90K41 000110 LABEL ALERT 1 HU Eie ee 2 Z20 90K41 000140 LABEL ALERT q4 Warning label English Serious injury or death 7 29 6 Maintenance parts suomi adg 7 30 Part No SOOR M3643 X02 Part name CABLE ROBOT Remarks Robot cable See 5 Wiring table X N length N m Note that X23 is 3 5m and X A is 10 0m 90K72 0U0730 LM RAIL 20 Guide 90K72 0L0730 LM RAIL 20 Guide
108. rms have almost no stretch Therefore the belt tension will be appropriate as long as the tensioners See Fig 4 14 and Fig 4 15 are not moved If for some reason their positions have moved adjust the belt tension with the following procedure 6 2 1 Adjusting the X axis arm belt 1 Prepare the necessary tools e Hex wrench set e Phillips screwdrivers e 7mm wrench Turn off the controller N 99 Place a sign indicating the robot is being adjusted to keep others from operating the controller switch Enter the safety enclosure Remove the X axis arm cover See 3 4 Removing the robot covers for this procedure C1 6 No adjustment is necessary if the tensioner end face is aligned with the scribe mark Fig 4 14 If not aligned adjust using the procedure described below E Fig 4 14 Bottom view of X axis arm Tensioner Pulley Tensioner end face Scribe mark Nut 2 pcs M4 tension bolt 2 pcs 7 Slightly loosen the two tensioner mounting M4 bolts Do not loosen to the degree that play occurs at the tensioner and the X axis arm 8 Verify that the belt is securely in place on the pulley 4 24 6 Adjusting the timing belt tension 9 Loosen the tension bolt nut turn the tension bolt until the tensioner end face is aligned with the scribe mark then tighten the tensioner mounting bolt and secure the tension bolt nut The tightening torque for the tensioner mounting bolt is 4
109. robot must be grounded as follows 1 Provide a terminal marked PE for the protective conductor of the entire system and connect it to an external protective conductor In addition securely connect the ground terminal on the robot to the same protective conductor See Fig 3 9 uore ejsu A Symbol 417 IEC 5019 E Fig 3 9 4 axis model Ground terminal Ground symbol 3 13 3 Protective bonding Bi Fig 3 9 3 axis model gt Ke 5 0 m 0 o gt Ground symbol M4 ground terminal 2 An M4 machine screw with a spring washer and a tooth lock washer is attached to the ground terminal Tighten the M4 machine screw by inserting it through the tooth lock washer ring terminal and spring washer See Fig 3 10 E Fig 3 10 Machine screw with spring washer Ring terminal MEER Tooth lock washer ZRRRRK 3 When the tool end effector uses an electrical device which if it malfunctions might make contact with the power supply ground the end effector properly on your responsibility since no ground terminal is provided for such a device on the robot body 4 For protective bonding on the robot body to comply with CE marking follow the instructions on controller protective bonding explained in the YAMAMA Robot Controller User s Manual or CE Marking Supporting Supplement Manual 5 Use a ground cable with a conductor wire cross section of at least 2 0
110. rom outside the safety enclosure See 3 3 1 Sensor method X axis and Y axis about the absolute reset method 4 The following adjustment is required if a machine reference outside the 40 to 60 range recommended range is displayed on the MPB after absolute reset For machine reference details see 3 2 Machine reference 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 safety enclosure 7 Mark off the reference mark at the current origin position on the Y axis joint area of the robot See Fig 4 5 At this time avoid touching the Y axis arm to prevent the origin position from deviating B Fig 4 5 Sensor plate M4 bolt 2 pcs Mark 7 Y axis drive unit TM xas JL 8 Remove the base cover See 3 4 Removing the robot covers for this procedure 9 Make a reference mark at the sensor plate position 4 12 3 Adjusting the origin 10 Loosen the M4 bolts and move the sensor plate as described below then tighten the bolts When machine reference lt 40 Move sensor plate in direction A When machine reference gt 60 Move sensor plate in direction B As an approximate guide a 1 7mm movement equals 100 11 Go out of the safety enclosure and check that no one is inside the safety enclosure Then turn on the controller 12 Perform an absolute reset from outs
111. rs Table 3 1 and Fig 3 26 show the maximum load that can be applied to the end effector attachment during operation E Fig 3 26 End effector attachment prepared by user End effector uorne ejsu A End effector attachment prepared by user With hand holder 3 27 6 Attaching the end effector E Table 3 1 kgf kgf kgf Nm kgfm Nm kgfm 24 5 2 5 9 8 1 24 5 2 5 12 7 1 3 0 14 Be sure that the end effector mounting area has an adequate strength versus the loads in Table 3 1 If the strength is inadequate the attachment may break during robot operation and the end effector may fly off causing a hazardous situation Be sure that the end effector mounting area has an adequate rigidity versus the loads in Table 3 1 If this rigidity is inadequate the end effector may vibrate during robot operation causing bad effects on the manipulation tasks uore ejsu Gg 3 28 6 5 Attaching the end effector Before attaching the end effector be sure to turn off the controller 1 Recommended methods for attaching the end effector are shown in Fig 3 27 and Table 3 2 below B Fig 3 27 Suction hole End effector prepared by user suction tool etc c ee Internal air flow path p Fastening bolt prepared by user is required for suction p uore ejsu A End effector hand holder prepared by user i M3 bolt 6 pcs s O ring supplied prepared by user Ta
112. s or tension on the cables Lay out the cables so that they do not obstruct robot motion Determine the robot work area in which the robot cables will not interfere with the load or workpiece picked up by the manipulator tip If the robot cables interfere with the movable parts of the robot the cables may be damaged causing malfunction and hazardous situations 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 uore ejsu A Connect the robot cable to the controller as shown below Bi Fig 3 11 Robot cable connections Connector on controller Connector on robot side RCX142 e XM YM S ZM RM Robot cable C XY ROB I O XY ROB I O ZR ZR On the 3 axis X Y and Z axes model it is not necessary to connect the RM connector but always connect the ZR connector 3 15 5 User wiring connector and user tubing 5 User wiring connector and user tubing Always turn off the controller and shut off air supply before attempting wiring or tubing work If air or power is supplied during this work the robot may move erroneously causing a hazardous situation uore ejsu Gg possible injury Be sure that user wiring and tubing installed utilizing the user wiring connectors and user tubing bulkhead unions do
113. side the controller c After the cable that connects the controller to the robot is disconnected Shipping status d After robot generation is changed e After parameters are initialized f After Origin shift Origin method Origin direction or Motor Direction of the axis parameter data is changed g After motor replacement after disconnecting the motor cable h After writing all data files data with ALL extension name or parameter files data with PRM extension name to the controller via the RS 232C interface This chapter explains the absolute reset procedures If any of the above cases a to h occur after installing the robot absolute reset must be performed again The robot must be moved to its origin position in order to perform an absolute reset Install the robot in a location where there is no interference with peripheral equipment etc after the origin position fixed setup is completed After performing an absolute reset move the robot to a known point to check whether the origin position is correctly set When doing this check move the robot at the slowest possible speed The X axis and Y axis use a search method sensor method to detect the origin positions while the Z axis uses a stroke end method that allows the mechanical unit to strike the lower end mechanical stopper to detect the origin position The R axis travel axis also uses the same stroke end method to detect the orig
114. sted in order to keep others from operating the controller or operation panel 3 Before beginning the following steps always perform a Z axis absolute reset The Z axis may otherwise slide down Perform an absolute reset on the Z axis See 3 3 2 Stroke end method Z axis and R axis about the Z axis absolute reset method 4 Turn off the controller 5 Enter the safety enclosure 6 Remove the base cover See 3 4 Removing the robot covers for this procedure 7 Hold the X axis arm by hand as it moves down about 3mm after the Z axis motor is removed Be careful that your fingers do not get pinched See Fig 4 6 4 14 3 Adjusting the origin B Fig 4 6 Z axis lower end damper avi Plate Z axis motor plate Z axis motor Hold X axis arm by hand as it moves down about 3mm after Z axis motor is removed Be careful that your fingers do not get pinched M5 bolt 3 pcs 8 Remove the M5 bolts securing the Z axis motor plate and then remove the Z axis motor yuawysnipy A 9 While holding the arms install the Z axis motor plate so the distance from the Z axis lower end damper to the bottom of the plate is 2 5mm At this point make sure that the belt is properly engaged with the motor pulley and ball screw pulley 10 After reassembling the Z axis motor adjust the timing belt tension To adjust the timing belt tension see 6 1 Adjusting the X axis Y axis and Z axis motor belt te
115. straight line 11 Loosen the bolts A and B remove the flat head screws on the arm side surface and set the jigs as shown in Fig 4 20 If equipped with a hand holder then loosen the bolt C 4 29 7 X axis and Y axis arm alignment E Fig 4 20 No hand holder Bolt M3x10 6 pcs Tool attachment shaft M3 bolt A 4 pcs Y axis arm Part 5 E CORRER Secure i sues X axis arm Part 1 center of z through holes ta sae Remove flat head screws on arm side surface and attach Md part Ba Tm Pana Bolt M4x40 1 pc Mak 1 pc Bolt M4x16 6 pcs o Bolt Part 2 M4x55 1 pc Remove flat head screws on arm side surface and attach this part One bolt is hidden so shift air tubes juesunsn py M4 bolt B 4 pcs inner side of elongate holes E Fig 4 20 Equipped with hand holder M3 bolt C 3 pes M3 bolt A 4 pcs Y axis arm Tool attachment shaft Hand holder lae 07 7 9 Le X axis arm Part 1 Remove flat head screws on arm side f surface and attach ius this part Bolt Back side Part 4 Bolt M4x40 1 pc Bolt M4x16 6 pcs Part 2 M4x25 1 pc Remove flat head Screws on arm side Bolt M4x55 1 pc surface and attach this part ON TUR Remove flat head One
116. th cover removed Details of C 389 50 Scale 4 1 164 209 180 180 M B a e je le 4 p e e e d N D en ceo Jw Do the CS 5 Be e e ie E m 9 s o ceo Hi e iS 4 M8X0 75 un Z axis upper end mechanical stopper position Leveling bolt p e 4 910 for M8 eS a 4 mounting bolt 0 o S D H P 7 i ix re snp CE ay Z axis lower end mechanical Z axis origin position S stopper position NL Tool attachment Z axis 73 Z axis lowers to this position E sis shaft Y axis during absolute reset return 74 mis J A X axis to origin E B m 3 ES e e LJ 2 2 2 B i 2 18 oE B 3 LO Q is d e 2 S 2 e o imi gt T m co L1 8 2 THe e e 147 199 389 7 13 2 External view and dimensions suomi adg N E Fig 7 4 3 axis specifications with hand holder 3 6 Backward mechanical Forward mechanical stopper lt P 7 ET stopper position position i Contact with stopper occurs Contact with stopper occurs e e B EK after origin position is after arm extended position is f oo X SI ed exceeded exceeded j T Tr 359 209 Y axis forward mechanical stopper position Mechanical stopper position may vary somewhat depending on parts machining accuracy O ny QU 172 6 532 Y axis forward stroke X and Y
117. the origin position from deviating B Fig 4 4 2 M4 bolts Dog Mark Origin position mark yuawysnipy A Sensor Sensor plate 9 Make a reference mark at the sensor plate position 10 Loosen the M4 bolts and move the sensor plate as described below then tighten the bolts When machine reference lt 40 Move sensor plate in direction A When machine reference gt 60 Move sensor plate in direction B As an approximate guide a 2 4mm movement equals 100 11 Go out of the safety enclosure and check that no one is inside the safety enclosure Then turn on the controller 12 Perform an absolute reset from outside the safety enclosure 13 After the absolute reset is completed read the machine reference value displayed on the MPB 14 The machine reference adjustment is complete when the machine reference is within the 40 to 60 range recommended range Turn off the controller and then reattach the base cover If the machine reference is still outside the recommended range readjust it by repeating the procedure from step 9 4 11 3 Adjusting the origin yuawjsnipy O 3 5 2 Adjusting the Y axis machine reference The adjustment method for the Y axis machine reference is as follows 1 Prepare the necessary tools e Hex wrench set e Phillips screwdrivers 2 Check that no one is inside the safety enclosure and then turn on the controller 3 Perform an absolute reset f
118. the current origin position on the robot body After the machine reference is adjusted be sure to check that the origin position has not deviated The point data must be set again if the origin position is changed after machine reference adjustment 3 5 1 Adjusting the X axis machine reference The adjustment method for the X axis machine reference is as follows 1 Prepare the necessary tools Hex wrench set Phillips screwdrivers Check that no one is inside the safety enclosure and then turn on the controller Perform an absolute reset from outside the safety enclosure See 3 3 1 Sensor method X axis and Y axis about the absolute reset method The following adjustment is required if a machine reference outside the 40 to 60 range recommended range is displayed on the MPB after absolute reset For details on machine reference see 3 2 Machine reference 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 safety enclosure Remove the base cover See 3 4 Removing the robot covers for this procedure At this time avoid touching the X axis arm to prevent the origin position from deviating 4 10 3 Adjusting the origin 8 Mark off the reference mark at the current origin position on the X axis joint area of the robot See Fig 4 4 At this time avoid touching the X axis arm to prevent
119. tion adjustments A oe wn 2 za e D z o 5 un 7 5 M4 ground terminal 207 125 79 Ire e e jm j 168 Im tubing 2 64 User tubing 1 4 Suction coupler 12X2 2 External view and dimensions E Fig 7 2 4 axis specifications with hand holder 1 Tool attachment shaft X axis mechanical N stopper position 340 Working envelope Working envelope tool attachment shaft position and X axis mechanical stopper position Mechanical stopper position may vary somewhat depending on parts machining accuracy X and Y axis arms and tool attachment shaft may not extend fully depending on parts machining accuracy or assembly condition suomi adg N 6 M3x0 5 thru hole 0 1 Or af Is iC OESTE ce o o Y lt H es SLU NR SEE 295 BEB 611 3 11 3 69 N E Cross section D D Hand support Scale 1 1 7 6 2 External view and dimensions E Fig 7 2 4 axis specifications with hand holder 2 User wiring 0 1mm Hand 6 M3 bolts length 8 Red User wiring 1 6 03 5 thru hole Hand holder cover White User wiring 2 User tubing 1 3 Yellow User wiring 3 Blue User wiring 4 Set screw 3 pcs User hand thickness must not e
120. viced daily uorne ejsu Gg 2 3 1 4 axis model The robot weighs more than 70kg so take suitable precautions when carrying the robot Use 3 or more people for the following work 1 Move each axis to its origin position and then turn off the controller and disconnect the robot cable from the controller The robot is bolted to a pallet at the time of shipment E Fig 3 4 Installation base or pallet This figure shows a pallet Push here by hand to move robot Push here by hand to move robot a b 2 Wind the robot cable around the robot base and fasten the robot cable with adhesive tape See Fig 3 4 a 3 6 2 Installation 3 In the following work hold the robot being careful to keep it balanced so it will not fall over Remove the R axis travel axis mounting bolts See 2 4 Installing the robot Move the robot to one edge of the installation base or pallet by pushing the robot toward the edge with two people one each at the ends of the R axis travel axis Have another person use a lifter to position it against the edge of the installation base or pallet Use a lifter with a maximum payload capacity sufficient to support the robot mass Shift the robot onto the forks of the lifter with two people See Fig 3 4 b Hold the robot while the lifter is moving up or down to ensure the robot will not fall over Move the robot on the lifter to the new install
121. were noted in step 3 above This software limit setting must be made from outside the safety enclosure Refer to the YAMAHA Robot Controller RCX142 Series User s Manual for further details on soft limit settings Unlike the SCARA robots the soft limits cannot be set on an orthogonal coordinate system Point displays based on an orthogonal coordinate have no meaning and such a coordinate system should not be used 4 16 5 Affixing stickers for movement directions and axis names 5 Affixing stickers for movement directions and axis names The robot comes packed with stickers self adhesive labels showing movement directions and axis names as shown in Fig 4 7 Using the following procedure attach these stickers in conspicuous points on the robot after installing peripheral equipment E Fig 4 7 yuawysnipy A Movement direction and axis name stickers 1 Turn off the controller 2 Place a sign indicating the robot is being adjusted to keep others from operating the controller switch 3 Enter the safety enclosure 4 Affix the axis name stickers and movement direction stickers in prominent positions on each of the robot arms Use a cloth moistened with alcohol to remove grease from the surface where you will affix the stickers After the surface is completely dry affix the stickers securely See Fig 4 8 The direction in which the Y axis joint rotates to move the tool attachment shaft straight forward p
122. white 0 15sq Twisted pair Green 0 3sq Red white 0 15sq Black white 0 15sq Green 0 3sq Green 0 3sq U Ww V Ring terminal U Ww V RM White blue 0 15sq Blue red2 Orange white2 0 15sq Twisted pair 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq Controller side wn 2 za e D z o 5 N 245 5 Wiring tables 3 axis specifications 2 o N OD oO AJ ow pl Connection No Connector Color No Wire Blue 0 15sq Orange Twisted pair Signal Connector Resolver Green 0 15sq Brown Twisted pair Gray 0 15sq Red Twisted pair Green 0 3sq Black 0 15sq Yellow Twisted pair Pink 0 15sq Violet Twisted pair White 0 15sq Blue red Twisted pair Resolver e s e Green 0 3sq X o Orange White 0 15sq Green white 0 15sq HLIM Green 0 3sq GND24 HLIM Green 0 3sq GND24 Origin sensor GND ORG 24V Origin sensor 24V ORG GND Yellow black 0 15sq Pink black Twisted pair Violet white 0 15sq White blue Twisted pair Blue red2 0 15sq Orangelwhite2 Twisted pair 1 Black 0 75sq 2 White 0 75sq 3 Red 0 75sq Ring terminal 4Green 0 75sq Y YM 1 5 Yellow 0 75sq w 6
123. xceed 3mm in T for hand holder e 3 9 G tilt adjustment Cross section B B n T i e Set screw l Scale 1 1 Tg a O ring S5 supplied PE NO User tubing 2 4 0 413 113 Hand holder mounting bolt 3 pcs 7 3 49 Details of A ae of C Scale 1 1 cale 4 1 Inside of hand holder with cover removed 180 180 User wiring connector 10 pins Red User wiring 1 White User wiring 2 Green User wiring 3 White User wiring 4 3 Note 4 200 Z axis stroke un 5 E 8 Tool attachment Z axis shaft Y axis zh st i Tb TD X axis 5 1 w m T T p Se D I gs Es BS 147 199 m SS BS eu UO or k IN Jeo LB i im o j B 5S S i es LOS o Ko Ko 1G Ko f e t N o i 5 Note4 550 R axis stroke 5 Note4 50 24042 60 767 35 132 10 99 thru hole thickness 27 4X200 800 915 75 7 7 2 External view and dimensions E Fig 7 2 4 axis specifications with h
124. y precision of the absolute reset position The machine reference is factory adjusted and does not normally require further adjustment If the origin position is changed the machine reference must be readjusted For information on how to adjust the machine reference see 3 4 Adjusting the machine reference in Chapter 4 When the temperature of the robot joint sections is high immediately after the robot has been operated the machine reference 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 6096 E Fig 4 1 Machine reference Origin signal detection ON Origin signal OFF Resolver Z Positions where ___ LB absolute reset One motor revolution can be performed E Fig 4 2 Machine reference value display on MPB screen MPB ns Ass 50 MG S0HOJ Machine reference 96 Mi 52 4 4 3 Adjusting the origin 3 3 Absolute reset procedures 3 3 1 Sensor method X axis and Y axis Serious injury might occur from physical contact with the robot during operation Never enter within the robot movement range during absolute reset The operation procedure using the MPB is described below Press the ESC key on the MPB if you want to return to the preceding step Refer to the YAMAHA

Disk Handling Robot (3, 4-axis specifications) USER`S MANUAL

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