Yamaha YK180X, YK120X User Manual
YAMAHA MOTOR CO., LTD.
OWNER'S MANUAL
Before using the robot (Be sure to read the following notes.)
At this time, our thanks for your purchase of this YAMAHA YK-X series SCARA
robot.
(1) Please be sure to perform the following tasks before using the robot.
Note that the robot may operate abnormally (abnormal vibration or noise) if
the following work is not carried out.
Before the YK-X Series is shipped, the position shown in "Chapter 7, 1-2 External view and dimensions" is adjusted as the origin position, and the standard
coordinates are provisionally set.
1. Absolute Reset
Absolute reset must be carried out just once before the YK-X Series robot can
be used.
Once absolute reset is completed, it does not need to be carried out again when
the power is turned ON the next time.
Refer to "Chapter 4, 3. Adjusting the origin" in this manual and "Absolute
Reset" in the "YAMAHA Robot Controller owner's manual" for details on
absolute reset.
2. Setting the standard coordinates
Set the standard coordinates while referring to instructions in "5. Setting the
Standard coordinates" in Chapter 4 of this manual and also to "Setting the
Standard coordinates" in the "YAMAHA robot controller owner's manual".
Robot malfunctions (vibration, noise) may occur if the standard coordinates
are not set correctly.
Even though there is no problem with the robot, the following error messages are
issued when the robot and controller are connected and power first turned on.
(Actual error messages may differ according to how the robot and controller are
connected.)
Error messages issued when robot & controller are connected (RCX142)
17.27 : D?.ABS. backup failed (CPU)
17.80 : D?.ABS. backup failed (DRIVER)
17.81 : D?.ABS.battery wire breakage
17.92 : D?.Resolver disconnected during power off
17.93 : D?.Position backup counter overflow
17.94 : D?.ABS.battery low voltage
etc
(2) Caution when turning off the robot controller
On the YK120X and YK180X series robots, the harness exerts a large reaction
force on the X and Y axis arms. When the power to the robot controller is
turned off, the arm positions might move slightly due to the harness reaction
force, depending on where the arms are positioned. If the arms moved a large
distance in this case, the correct position data may not be backed up. To avoid
this, before turning off the power to the robot controller, press the emergency
stop button and check that the robot arms have completely stopped.
(3) Connection to the controller
The controller for the YK120X series robots (YK120X, YK150X) is designed
to provide 24V output and the model name "RCX142-T" is shown on the
serial number label (see Fig. 2-5). Do not connect other controllers to the
YK120X series robot. If operated from a controller other than the RCX142T, the robot's motors may be damaged.
Introduction
The YAMAHA YK120X and YK180 series robots are SCARA type industrial
robots developed based on years of YAMAHA experience and achievements in
the automation field as well as efforts to streamline our in-house manufacturing
systems.
The SCARA robots have a two-joint manipulator consisting of an X-axis arm
and a Y-axis arm, and are further equipped with a vertical axis (Z-axis) and a
rotating axis (R-axis) at the tip of the manipulator. The YK120X and YK180
series robots can be used for a wide range of assembly applications such as
installation and insertion of various parts, application of sealant, and packing
operations.
This owner's manual describes the safety measures, handling, adjustment and
maintenance of YK120X series robots for correct, safe and effective use. Be sure
to read this manual carefully before installing the robot. Even after you have read
this manual, keep it in a safe and convenient place for future reference.
This owner's manual should be used with the robot and considered an integral
part of it. When the robot is moved, transferred or sold, send this manual to the
new user along with the robot. Be sure to explain to the new user the need to read
through this manual.
This owner's manual explains the YAMAHA industrial robots YK120X series
standard models (YK120X, YK150X), clean room models (YK120XC,
YK150XC), and YK180X series (YK180X, YK220X).
Some descriptions of YK120XC and YK150XC are not listed in this manual when
they are the same as standard models. Refer to the descriptions of standard models.
For information on difference between the clean room model and standard model,
refer to the description on the next page.
For details on specific operation and programming of the robot, refer to the separate
"YAMAHA robot controller owner's manual".
NOTES
•
The contents of this manual are subject to change without prior notice.
• Information furnished by YAMAHA in this manual is believed to be reliable.
However, if you find any part unclear or inaccurate in this manual, please
contact YAMAHA sales office or dealer.
YAMAHA MOTOR CO., LTD.
IM Company
Clean Room Models YK120XC, YK150XC
Compared to standard YX120X and YK150X, clean room models differ in the
following points.
1. Robot parameter has been changed. (See section 4 in chapter 2.)
The Z-axis speed is lowered to maintain the degree of cleanliness and the
bellows durability. (This is preset prior to shipment.)
2. Suction couplers have been added. (See section 6 in chapter 3.)
For the suction amount versus degree of cleanliness, see "1-1 Basic
specifications" in chapter 7. For the location of the suction couplers, see "12 External view and dimensions" in chapter 7.
The suction amount for each suction coupler is very important to maintain
the degree of cleanliness and the bellows durability, so always comply with
the instruction.
3. R-axis machine reference adjustment is different.
(See section 3-4-1-2 in chapter 4.)
The structure around the R-axis origin sensor differs from standard
specifications, so the method for adjusting the machine reference is different.
Since the Z-axis bellows type suction tube is attached to the R-axis, care
must be taken when performing return-to-origin so that the suction tube will
not entangle around the R-axis.
4. Different grease is used for the Z-axis drive mechanism.
(See section 4 in chapter 5.)
LG2 grease (NSK) suitable for clean room is used for the Z-axis ball screw,
ball spline and linear bushing shaft.
Use the LG2 clean room grease for periodic maintenance.
5. Specifications and external appearance are somewhat changed.
(See sections 1-1 and 1-2 in chapter 7.)
The X- and Y-axis repeated positioning accuracy and Z-axis maximum speed
are different from standard specifications.
The external appearance and dimensions are different in that the Z-axis
bellows, flexible tube and suction couplers are added.
CONTENTS
CHAPTER 1 Using the Robot Safely
1 Safety Information ...................................................................................1-1
2 Essential Caution Items ...........................................................................1-2
3 Special Training for Industrial Robot Operation .....................................1-10
4 Robot Safety Functions ......................................................................... 1-11
5 Safety Measures for the System ...........................................................1-12
6 Trial Operation .......................................................................................1-13
7 Work Within the Safeguard Enclosure ...................................................1-14
8 Automatic Operation ..............................................................................1-15
9 Adjustment and Inspection ....................................................................1-15
10 Repair and Modification .........................................................................1-15
11 Warranty ................................................................................................1-16
12 CE Marking ............................................................................................1-18
CHAPTER 2 Functions
1 Robot Manipulator ...................................................................................2-1
2 Robot Controller ......................................................................................2-5
3 Robot initialization number list ................................................................. 2-6
4 Parameters for Clean Room Models YK120XC, YK150XC .....................2-7
CHAPTER 3 Installation
1 Robot Installation Conditions ................................................................... 3-1
1-1 Installation environments ...................................................................................... 3-1
1-2 Installation base ................................................................................................... 3-3
2 Installation ...............................................................................................3-5
2-1 Unpacking ............................................................................................................ 3-5
2-2 Checking the product ........................................................................................... 3-6
2-3 Moving the robot ................................................................................................... 3-7
2-4 Installing the robot ................................................................................................ 3-8
3 Protective Bonding ..................................................................................3-9
4 Robot Cable Connection ....................................................................... 3-11
5 User Wiring and User Tubing ................................................................ 3-13
6 Connecting a suction hose (YK120XC, YK150XC) ...............................3-16
7 Attaching The End Effector ....................................................................3-17
7-1 R-axis tolerable moment of inertia and acceleration coefficient ......................... 3-17
7-1-1 Acceleration coefficient vs. moment of inertia (YK120X) ..................................... 3-19
7-1-2 Acceleration coefficient vs. moment of inertia (YK150X) ..................................... 3-21
7-1-3 Acceleration coefficient vs. moment of inertia (YK180X, YK220X) ......................3-23
7-2 Equation for moment of inertia calculation ......................................................... 3-24
7-3 Example of moment of inertia calculation........................................................... 3-27
7-4 Attaching the end effector .................................................................................. 3-29
7-5 Gripping force of end effector ............................................................................. 3-32
8Working Envelope and Mechanical Stopper Positions for Maximum
Working Envelope..................................................................................3-33
CHAPTER 4 Adjustment
1 Overview ..................................................................................................4-1
2 Safety Precautions ..................................................................................4-1
3 Adjusting the origin ..................................................................................4-2
3-1 Absolute reset method ......................................................................................... 4-3
3-1-1 YK120X series (YK120X, YK150X)........................................................................ 4-3
3-1-1-1 Sensor method (R-axis) ........................................................................................ 4-3
3-1-1-2 Stroke end method (X-axis, Y-axis) ...................................................................... 4-4
3-1-1-3 Stroke end method (Z-axis) .................................................................................. 4-6
3-1-2 YK180X series (YK180X, YK220X)........................................................................ 4-7
3-1-2-1 Sensor method (R-axis) ........................................................................................ 4-7
3-1-2-2 Sensor method (X-axis, Y-axis) ............................................................................ 4-8
3-1-2-3 Stroke end method (Z-axis) .................................................................................. 4-9
3-2 Machine reference.............................................................................................. 4-10
3-3 Absolute reset procedures .................................................................................. 4-11
3-3-1 Sensor method (R-axis) ....................................................................................... 4-11
3-3-2 Stroke end method (X and Y axes of YK120X, YK150X) .....................................4-13
3-3-3 Stroke end method (Z-axis).................................................................................. 4-15
3-3-4 Sensor method (X and Y axes of YK180X, YK220X) ...........................................4-16
3-4 Adjusting the machine reference ........................................................................ 4-18
3-4-1 YK120X series (YK120X, YK150X)...................................................................... 4-19
3-4-1-1 Adjusting the R-axis machine reference (YK120X, YK150X) ............................. 4-19
3-4-1-2 Adjusting the R-axis machine reference (YK120XC, YK150XC) ........................ 4-21
3-4-1-3 Adjusting the X-axis machine reference ............................................................. 4-23
3-4-1-4 Adjusting the Y-axis machine reference .............................................................. 4-25
3-4-1-5 Adjusting the Z-axis machine reference ............................................................. 4-27
3-4-2 YK180X series (YK180X, YK220X)...................................................................... 4-30
3-4-2-1 Adjusting the R-axis machine reference (YK180X, YK220X) ............................. 4-30
3-4-2-2 Adjusting the X-axis machine reference ............................................................. 4-32
3-4-2-3 Adjusting the Y-axis machine reference .............................................................. 4-34
3-4-2-4 Adjusting the Z-axis machine reference ............................................................. 4-36
4 Setting the Soft Limits ............................................................................4-39
5 Setting the Standard Coordinates .........................................................4-42
6Affixing Stickers for Movement Directions and Axis Names ..................4-43
7 Removing the Robot Covers .................................................................4-45
CHAPTER 5 Periodic Inspecition
1 Overview ..................................................................................................5-1
2Precautions ..............................................................................................5-2
3 Daily Inspection .......................................................................................5-3
4 Six-Month Inspection ...............................................................................5-5
5 Replacing the Harmonic Drive Grease ....................................................5-8
5-1 Replacement period ............................................................................................. 5-8
CHAPTER 6 Increasing the robot operating speed
1 Increasing the robot operating speed ......................................................6-1
CHAPTER 7 Specifications
1 Manipulator ..............................................................................................7-1
1-1 Basic specification ................................................................................................ 7-1
1-2 External view and dimensions .............................................................................. 7-2
1-3 Robot inner wiring diagram ................................................................................ 7-14
1-4 Wiring table ........................................................................................................ 7-15
MEMO
CHAPTER 1
Using the Robot Safely
1 Safety Information ...................................................................................1-1
2 Essential Caution Items ........................................................................... 1-2
3 Special Training for Industrial Robot Operation .....................................1-10
4 Robot Safety Functions ......................................................................... 1-11
5 Safety Measures for the System ...........................................................1-12
6 Trial Operation ....................................................................................... 1-13
7 Work Within the Safeguard Enclosure ...................................................1-14
8 Automatic Operation .............................................................................. 1-15
9 Adjustment and Inspection ....................................................................1-15
10 Repair and Modification .........................................................................1-15
11 Warranty ................................................................................................1-16
12 CE Marking ............................................................................................1-18
MEMO
1 Safety Information
Industrial robots are highly programmable, mechanical devices that provide a
large degree of freedom when performing various manipulative tasks. To ensure
correct and safe use of YAMAHA industrial robots, carefully read this manual
and make yourself well acquainted with the contents. FOLLOW THE 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 shown classified into the following items.
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the
robot operator, a bystander or a person inspecting or repairing the robot.
CHAPTER 1 Using the Robot Safely
WARNING
Failure to follow WARNING instructions could result in severe injury or death to
the robot operator, a bystander or a person inspecting or repairing the robot.
!
CAUTION
Failure to follow CAUTION instructions may result in injury to the robot operator, a bystander or a person inspecting or repairing the robot, or damage to the
robot and/or robot controller.
Refer to the owner's manual by any of the following methods to operate or adjust
the robot safely and correctly.
1. Operate or adjust the robot while referring to the printed version of the owner's manual (available for an additional fee).
2. Operate or adjust the robot while viewing the CD-ROM version of the owner'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 owner'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 does not understand English, do not permit him to handle the robot.
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CHAPTER 1 Using the Robot Safely
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. Refer to Fig. 2-2 to
Fig. 2-4 in Chapter 2 for the position.
• Install a safeguard enclosure (protective enclosure) to keep any person from
entering within the movement range of the robot and suffering injury due
to being struck by moving parts.
• Install a safety interlock that triggers emergency stop when the door or
panel is opened.
• Install safeguards so that no one can enter inside except from doors or
panels equipped with safety interlocks.
•The warning labels shown in Fig. 1-1 are supplied with the robot and should
be affixed to a conspicuous spot on doors or panels equipped with safety
interlocks.
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. Refer to Fig. 2-2 in Chapter 2 for the position.
Be careful not to let hands or fingers be pinched or crushed by the moving
parts of the robot during transportation or teaching.
WARNING
Moving parts can pinch or crush.
Keep hands away from robot arms.
DANGER
Serious injury or death
will result from impact
with moving robot.
• Keep outside of guard
during operation.
• Lock out power before
approaching robot.
WARNING
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
■Fig. 1-1 Warning label 1 ■Fig. 1-2 Warning label 2
1-2
CHAPTER 1 Using the Robot Safely
(3) Follow the instructions on warning labels and in this manual.
Warn ing label 3 (Fig. 1-3) is affixed to the robot. Refer to Fig. 2-2 to
Fig. 2-4 in Chapter 2 for the position.
• Be sure to read the warning label and this manual carefully and make your
thoroughly understand the contents before attempting installation and operation of the robot.
• Before starting the robot operation, even after you have read through this
manual, read again the corresponding procedures and cautions in this manual
as well as descriptions in the this chapter (Chapter 1, "Using the Robot
Safely").
•Never install, adjust, inspect or service the robot in any manner that does
not comply with the instructions in this manual.
WARNING
Improper installation or operation can result in serious injury or death.
Read owner's manual and all warning labels before operation.
WARNING
Improper Installation or operation
can result in serious injury or
death.
Read owner's manual and all
warning labels before operation.
■Fig. 1-3 Warning label 3
(4) Do not use the robot in environments containing inflammable
gas, etc.
WARNING
• 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 could otherwise result.
(5) Do not use the robot in locations possibly subject to electro-
magnetic interference, etc.
WARNING
Avoid using the robot in locations subject to electromagnetic interference, electrostatic discharge or radio frequency interference. Malfunction may otherwise
occur.
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CHAPTER 1 Using the Robot Safely
(6) Use caution when releasing the Z-axis (vertical axis) brake.
WARNING
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.
(7) Provide safety measures for end effector (gripper, etc.).
WARNING
•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)
WARNING
The Z-axis moves up when the power to the controller or PLC is turned off, the
program is reset, emergency stop is triggered, or air is supplied to the solenoid
valve for the Z-axis air cylinder.
•Do not let hands or fingers get caught and squeezed by moving parts of the
Z-axis.
•Keep the usual robot position in mind so that the Z-axis will not interfere with
obstacles during raising of the Z-axis, except in case of emergency stop.
(9) Use the following caution items when the Z-axis is interfering
with peripheral equipment. (2-axis robots with air driven Z-axis)
WARNING
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.
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CHAPTER 1 Using the Robot Safely
(10)Use caution on Z-axis movement when air supply is stopped. (2-
axis robots with air-driven Z-axis)
WARNING
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.
(11) Use the following caution items when disassembling or replac-
ing the pneumatic equipment.
WARNING
Air or parts may fly outwards if pneumatic equipment is disassembled or parts
replaced while air is still supplied.
•Do service work after first turning off the controller and reducing the air pressure.
•Before reducing the air pressure, place a support stand under the Z-axis (2axis robots with air driven Z-axis) since it will drop under its own weight.
(12)Cautions for removing Z-axis brake or Z-axis motor
WARNING
The Z-axis can drop and cause a hazard when the Z-axis brake or Z-axis motor
is removed.
•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.
(13)Use the following caution during inspection of controller.
WARNING
•When you need to touch the terminals or connectors on the outside of the
controller during inspection, always first turn off the controller power switch
and also the power source in order to prevent possible electrical shock.
•Never touch any internal parts of the controller.
For precautions on handling the controller, refer to the "YAMAHA robot controller owner's manual".
1-5
CHAPTER 1 Using the Robot Safely
(14) Consult us for corrective action when the robot is damaged or
malfunction occurs.
WARNING
If any part of the robot is damaged or any malfunction occurs, continuous operation may be very dangerous. Please consult YAMAHA dealer for corrective
action.
Damage or Trouble Possible Danger
Damage to machine harness or robot cable Electrical shock, malfunction of robot
Damage to exterior of robot
Abnormal operation of robot
(positioning error, excessive vibration, etc.)
Z-axis brake trouble Dropping of load
(15) Use caution not to touch the controller rear panel cooling fan.
Flying outwards of damaged parts during robot
operation
Malfunction of robot
WARNING
•Bodily injury may occur from coming into contact with the cooling fan while it
is rotating.
•When removing the fan cover for inspection, first turn off the controller and
make sure the fan has stopped.
(16) Use caution not to touch the high temperature motor or speed
reduction gear casing.
WARNING
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.
(17) Do not remove, alter or stain the warning labels.
WARNING
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 safeguards.
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CHAPTER 1 Using the Robot Safely
(18)Protective bonding
WARNING
Be sure to ground the robot and controller to prevent electrical shock.
(19)Always connect the robot to the specified controller.
WARNING
The controller for the YK120X series robots (YK120X, YK150X) is designed to
provide 24V output and the model name "RCX142-T" is shown on the serial
number label (see Fig. 2-5). Do not connect other controllers to the YK120X
series robot. If operated from a controller other than the RCX142-T, the robot's
motors may be damaged.
(20)Avoid fastening any cable or tube prepared by the user with the
machine harness, user signal wires or air tubes of the robot.
WARNING
Do not utilize the machine harness, user signal wires or air tubes of the robot to
fasten any cable or tube prepared by the user, as this may break the robot
harness wires or user signal wires causing malfunction of the robot. This will
also result in poor positioning accuracy.
(21)Do not use the robot in locations subject to strong vibrations.
WARNING
Do not operate the robot in locations subject to strong vibrations. The robot
installation bolts might work loose and the robot topple over. The bolts on the
robot body itself might also loosen, causing parts to fall off, etc.
(22)Be sure to make correct parameter settings.
!
CAUTION
The robot must be operated with correct tolerable moment of inertia and acceleration coefficients according to the manipulator tip mass and moment of inertia. If this is not observed, premature end to the life of the drive units, damage to
the robot parts or residual vibration during positioning may result.
(23)Do not use the robot for tasks requiring motor thrust.
!
CAUTION
Avoid using the YK-X series robots for tasks which make use of motor thrust
(press-fitting, burr removal, etc.). These tasks may cause malfunctions of the
robot.
1-7
CHAPTER 1 Using the Robot Safely
(24) Do not apply excessive force to each section.
!
CAUTION
The YK120X series (YK120X, YK150X) and YK180X series (YK180X, YK220X)
are designed to be compact, so the joints could be damaged if excessive force
is applied, for example, during installation of an end effector. Make sure that
excessive force is not applied to the joints.
YK120X, YK150X
Axis
X-axis
Y-axis
R-axis
YK180X, YK220X
Axis
X-axis
Y-axis
R-axis
Tolerable radial load
100N (10.2kgf)
Tolerable radial load
275N (28.1kgf)
150N (15.3kgf)
150N (15.3kgf)
45N (4.6kgf)
45N (4.6kgf)
Tolerable thrust load
100N (10.2kgf)
45N (4.6kgf)
45N (4.6kgf)
Tolerable thrust load
900N (91.8kgf)
600N (61.2kgf)
600N (61.2kgf)
To le ra b le moment load
1.5Nm (15.3kgfcm)
0.45Nm (4.6kgfcm)
0.45Nm (4.6kgfcm)
Tolerable moment load
6.0Nm (61.2kgfcm)
3.3Nm (33.7kgfcm)
3.3Nm (33.7kgfcm)
Tolerable torque
1.7Nm (17.3kgfcm)
0.5Nm (5.1kgfcm)
0.3Nm (3.1kgfcm)
Tolerable torque
9.0Nm (91.8kgfcm)
4.0Nm (40.8kgfcm)
2.2Nm (22.4kgfcm)
(25) Check the machine reference value when the arm struck against
the mechanical stopper.
!
CAUTION
When the arm moves at high speed and strikes against a mechanical stopper
violently, the machine reference value may change. If this has happened, check
the machine reference value. Also check the mechanical stopper for any damage and the origin position for shift. If the machine reference value is outside
the recommended range, adjust the machine reference. In this case, re-teaching may be required if the origin position has shifted.
(26) Use caution not to apply excessive force to the machine har-
ness, user signal cables and air tubes.
!
CAUTION
A positioning error may occur if excessive force is applied to the machine harness, user signal cables or air tubes. A positioning error may also occur if the
machine harness, user signal cables or air tubes have deteriorated due to improper installation environment.
(27) Caution when turning off the robot controller
!
CAUTION
The XY arm positions might move slightly due to the harness reaction force
when the power to the robot controller is turned off, making it difficult to back up
the correct position data. To avoid this, before turning off the power to the robot
controller, press the emergency stop button and check that the robot arms have
completely stopped.
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CHAPTER 1 Using the Robot Safely
(28)Take the following precautions when transporting the robot.
!
CAUTION
If the robot is transported long distances by truck while mounted on an installation
base or packed in a case other than the dedicated carton box in which the robot
was shipped, the bolts installing the robot or the bolts on the robot body itself
might come loose due to vibration. The robot might then topple over or the
parts fall off.
When transporting the robot long distances, use the dedicated case in which
the robot was shipped from our factory.
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CHAPTER 1 Using the Robot Safely
3 Special Training for Industrial Robot Opera-
tion
Companies or factories using industrial robots must make sure that every person,
who operates or 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 YK120X and YK180X series robots fall under the industrial robot
category, the user must observe local regulations and safety standards for industrial
robots, and provide special training for every person involved in robot-related
tasks (teaching, programming, movement check, inspection, adjustment, repair,
etc.).
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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.
Note: The working envelope is the area limited by soft limits.
CHAPTER 1 Using the Robot Safely
(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.
On the X-axis, Y-axis arm, mechanical stoppers are fixed at both ends of the
maximum movement range.
The Z-axis has a mechanical stopper at the upper end and lower end.
No mechanical stopper is provided on the R-axis.
Note: The movement range is the area limited by mechanical stoppers.
WARNING
Axis movement will not stop immediately after the servo power supply is shut
off by emergency stop or other safety functions.
(5) Z-axis (vertical axis) brake
An electromagnetic brake is installed on the Z-axis to prevent the Z-axis
from sliding down when servo power is turned off. This brake is working
when the controller is off or the Z-axis servo power is off even when the
controller is on. The Z-axis brake can be released by means of the programming unit or by a command in the program when the controller is on.
WARNING
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.
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CHAPTER 1 Using the Robot Safely
5 Safety Measures for the System
Since the robot 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 owner's manual for safe, correct operation
and servicing of the system.
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6Trial Operation
After making installations, adjustments, inspections, maintenance or repairs to
the robot, make a trial run using the following procedures.
(1) If a safeguard enclosure has not yet been provided right after installation of
the robot, rope off or chain off around the movement area of the manipulator
in place of the safeguard enclosure, and observe the following points.
1. Use sturdy, stable posts which will not fall over easily.
2. The rope or chain should be easily visible by everyone around the robot.
3. Place a sign to keep the operator or other personnel from entering the
movement range of the manipulator.
(2) Check the following points before turning on the controller.
1. Is the robot securely and correctly installed?
2. Are the electrical connections to the robot correct?
3. Are items such as air pressure correctly supplied?
4. Is the robot correctly connected to peripheral equipment?
5. Have safety measures (safeguard enclosure, etc.) been taken?
6. Does the installation environment meet the specified standards.
(3) After the controller is turned on, check the following points from outside the
safeguard enclosure.
1. Does the robot start and stop as intended? Can the operation mode be
selected correctly?
2. Does each axis move as intended within the soft limits?
3. Does the end effector move as intended?
4. Are the signal transmissions to the end effector and peripheral equipment
correct?
5. Does emergency stop work?
6. Are the teaching and playback functions normal?
7. Are the safeguard enclosure and interlock working as intended?
8. Does the robot move correctly during automatic operation?
CHAPTER 1 Using the Robot Safely
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CHAPTER 1 Using the Robot Safely
7Work Within the Safeguard Enclosure
(1) When work is required inside the safeguard 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) Adjusting the Z-axis machine reference (See Section 3-4-1-5 in Chapter
4.)
2) Setting the Soft Limits (See Section 4 in Chapter 4.)
3) Setting the Standard Coordinates (See Section 5 in Chapter 4.)
4) Teaching
For items 1) to 3), follow the precautions and procedure for each section. To
perform item 4), refer to the description in (2) below.
(2) Teaching
When performing teaching within the safeguard enclosure, comply with the
instructions listed below.
1) Check or perform the following points from outside the safeguard enclosure.
1. Make sure that no hazards are present within the safeguard enclosure
by a visual check.
2. Check that the programming unit MPB operates correctly.
3. Check that no failures are found in the robot.
4. Check that emergency stop works correctly.
5. Select teaching mode and prohibit automatic operation.
2) Never enter the movement range of the manipulator while within the safeguard enclosure.
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8 Automatic Operation
Automatic operation described here includes all operations in AUTO mode.
(1) Check the following before starting automatic operation.
1. No one is within the safeguard enclosure.
2. The programming unit and tools are in their specified locations.
3. The alarm or error lamps on the robot and peripheral equipment do not
flash.
4. The safeguard enclosure is securely installed with safety interlocks 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.
2) Never enter the safeguard enclosure during automatic operation.
3) If an error occurs in the robot or peripheral equipment, observe the following procedure before entering the safeguard enclosure.
1. Press the emergency stop button to set the robot to emergency stop.
2. Place a sign on the start switch, indicating that the robot is being inspected in order to keep any other person from touching the start switch
and restarting the robot.
CHAPTER 1 Using the Robot Safely
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.
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CHAPTER 1 Using the Robot Safely
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 de-
Warranty Period : The warranty period ends when any of the fol-
fects 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").
lowing 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
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 tear 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.
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CHAPTER 1 Using the Robot Safely
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 FROM 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.
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CHAPTER 1 Using the Robot Safely
12 CE Marking
When the YAMAHA robots are exported to or used in EU (European Union)
countries, refer to the separate "YAMAHA robot controller owner's manual" or
"CE marking manual" for related information about CE marking.
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