YASKAWA YRC1000 OPERATOR’S MANUAL FOR SPOT WELDING USING AIR GUN

YRC1000

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OPERATOR’S MANUAL

FOR SPOT WELDING USING AIR GUN

Upon receipt of the product and prior to initial operation, read these instructions below thoroughly, and retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN- INSTRUCTIONS YRC1000 INSTRUCTIONS YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC) YRC1000 MAINTENANCE MANUAL YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)

The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual. The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”. The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.

182902-1CD 0

MANUAL NO. RE-CSO-A055

DANGER

• This manual explains the various components of the YRC1000

CAUTION

NOTICE

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system and general operations. Read this manual carefully and be sure to understand its contents before handling the YRC1000.

• General items related to safety are listed in “Chapter 1.Safety” o the YRC1 op

eration, carefully read the YRC1000 Instructions before reading

this manual.

• In some drawings in this manual, the protective covers or shields are removed to show details. Make sure to install all the covers and shields in place before operating this product.

• YASKAWA is not responsible for incidents arisi un

authorized modification of its products. Unauthorized

modification voids the product warranty.

• The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product.

000 INSTRUCTIONS. To ensure correct and

ng from

safe

• YASKAWA may modify this model without notice du

e to product improvements, modifications, or changes in specifications. If such modification is made, the manual number also be revised.

•

If your copy of the manual is damaged or lost, contact a YASKAW re

presentative to order a new copy. The representatives are liste

the back cover. Be sure to tell the representative the manu nu

mber listed on the front cover.

when necessary

will

Notes for Safe Operation

DANGER

WARNING

CAUTION

NOTICE

NOTE

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Read this manual carefully before installation, operation, maintenance, or inspection of the YRC1000.

In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”, or “NOTICE”.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Safety Signs identified by the signal word DANGER should be used sparingly and only for those situations presenting the most serious hazards.

Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. Hazards identified by the signal word WARNING present a lesser degree of risk of injury or death than those identified by the signal word DANGER.

Indicates a hazardous situation, which if not avoided, could result in minor or moderate injury. It may also be used without the safety alert symbol as an alternative to “NOTICE”.

NOTICE is the preferred signal word to address practices not related to personal injury. The safety alert symbol should not be used with this signal word. As an alternative to “NOTICE”, the word “CAUTION” without the safety alert symbol may be used to indicate a message not related to personal injury.

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “DANGER”, “WARNING” and “CAUTION”.

iii

DANGER

• Before operating the manipulator, make sure the servo power is

TURN

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tur

ned OFF by performing the following operations. When the se

er is turned OFF, the SERVO ON LED on the

pow pe

ndant is turned OFF. – Press the emergency stop buttons on the front door of th

YRC1000, on the programming pendant, on the external control device, etc.

–

Disconnect the safety plug of the safety fence. (when in the play mode or in the remote mode).

If operation of the manipulator cannot be stopped in an emergency, personal injury and/or equipment damage may result.

Fig. : Emergency Stop Button

• Before releasing the emergency stop, make sure to remove the obstacle or error caused the emergency stop, if any, and then turn the servo power ON.

Failure to observe this instruction may cause unintended movement of the manipulator, which may result in personal injury.

Fig. : Release of Emergency Stop

programming

rvo

• Observe the following precautions when performing a teaching operation within the manipulator's operating range:

– Be sure to perform lockout by putting a lockout device on

fety fence when going into the area enclosed by the safe

nce. In addition, the operator of the teaching operation mu

fe display the sign tha

other person closes the safety fence. – View the manipulator from the front whenever possible. – Always follow the predetermined operating procedure. – Always keep in mind emergency response measures against the

manipulator’s unexpected movement toward a person. – Ensure a safe place to retreat in case of emergency.

Failure to observe this instruction may cause improper or unintended movement of the manipulator, which may result in personal injury.

• Confirm that no person is present in the manipulator's operating range and that the operator is in a safe location before:

– Turning ON the YRC1000 powe

Moving the manipulator by using the programming penda

– –

Running the system in the check mo Performing automatic operations

–

Personal injury may result if a person enters the manipulator's operating range during operation. Immediately press an emergency stop button whenever there is a problem. The emergency stop buttons are located on the front panel of the YRC1000 and on the right of the programming pendant.

Read and understand the Explanation of the Warning Labels before operating the manipulator.

t the operation is being performed so that no

the

WARNING

• Perform the following inspection procedures prior to conducting

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manipulator teaching. If there is any problem, immediately take necessary steps to solve it, such as maintenance and repair.

– Check for a problem in manipulator movement.

– Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the YRC1000 cabinet after use.

If the programming pendant is left unattended on the manipulator, on a fixture, or on the floor, etc., the Enable Switch may be activated due to surface irregularities of where it is left, and the servo power may be turned ON. In addition, in case the operation of the manipulator starts, the manipulator or the tool may hit the programming pendant left unattended, which may result in personal injury and/or equipment damage.

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables.

In this manual, the equipment is designated as follows.

Equipment Manual Designation

YRC1000 Controller YRC1000

YRC1000 Programming Pendant Programming Pendant

Cable between the manipulator and the controller Manipulator cable

Descriptions of the programming pendant keys, buttons, and displays are

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shown as follows:

Equipment Manual Designation

Programming Pendant

Character Keys /Symbol Keys

Axis Keys /Numeric Keys

Keys pressed simultaneously

Displays The menu displayed in the programming

The keys which have characters or its symbol printed on them are denoted with [ ]. ex. [ENTER]

[Axis Key] and [Numeric Key] are generic names for the keys for axis operation and number input.

When two keys are to be pressed simultaneously, the keys are shown with a “+” sign between them, ex. [SHIFT]+[COORD]

pendant is denoted with { }. ex. {JOB}

Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • • “ means that the cursor is moved to the object item and [SELECT] is pressed, or that the item is directly selected by touching the screen.

Registered Trademark

In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and TM are omitted.

Contents

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1 Spot Welding Application Using an Air Gun.................................................................................... 1-1

1.1 System Overview of Spot Welding System Using an Air Gun ........................................... 1-1

1.2 Function Keys .................................................................................................................... 1-3

1.3 Teaching ............................................................................................................................ 1-5

1.3.1 Manual Spot Welding Function............................................................................. 1-5

1.3.1.1 Manual Dry Spotting................................................................................ 1-5

1.3.1.2 Stroke Switching ..................................................................................... 1-5

1.3.1.3 Welding On/Off........................................................................................ 1-6

1.3.1.4 Resetting Alarms ..................................................................................... 1-7

1.3.2 Registering Work Instructions............................................................................... 1-8

1.3.2.1 GUNCL Instruction .................................................................................. 1-9

1.3.2.2 SPOT Instruction ................................................................................... 1-11

1.3.2.3 STROKE Instruction .............................................................................. 1-14

1.3.2.4 STRWAIT Instruction............................................................................. 1-16

1.4 Setting Welding Conditions (for Air Gun)......................................................................... 1-17

1.4.1 Settings for Manual Spot Welding ...................................................................... 1-17

1.4.2 Spot Welder Condition Data Setting................................................................... 1-19

1.4.3 Spot Gun Condition Data File............................................................................. 1-22

1.5 Spot Welding Diagnosis................................................................................................... 1-25

1.5.1 Spot Welding Diagnosis Window........................................................................ 1-25

1.5.1.1 Setting Tolerance Value........................................................................ 1-25

1.5.1.2 Tip Hit Count Clear................................................................................ 1-26

1.6 Spot Gun Motion Control ................................................................................................. 1-27

1.6.1 Gun Motion Control ............................................................................................ 1-27

1.6.1.1 X Type Gun ........................................................................................... 1-27

1.6.1.2 C Type Gun ........................................................................................... 1-28

1.6.2 Process Timing................................................................................................... 1-30

1.6.2.1 OPERATION MODE = 0

(SINGLE GUN, OPEN → WELDING → OPEN).................................... 1-30

1.6.3 OPERATION MODE = 1

(SHORT OPEN → WELDING → SHORT OPEN).............................................. 1-31

1.6.3.1 OPERATION MODE = 2

(SHORT OPEN → WELDING → FULL OPEN) .................................... 1-32

1.6.3.2 OPERATION MODE = 3

1.6.3.3 OPERATION MODE = 4

(FULL OPEN → WELDING → SHORT OPEN) .................................... 1-33

(FULL OPEN → WELDING → FULL OPEN) ........................................ 1-34

1.6.4 Stroke Change Control Method .......................................................................... 1-35

1.6.4.1 Single Gun, C Double Gun, X Double Cylinder Gun ............................. 1-35

1.6.4.2 X Double Mechanical Stopper Type...................................................... 1-35

1.6.5 I/O Allocation ...................................................................................................... 1-37

1.6.5.1 Input Allocation Window ........................................................................ 1-37

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Contents

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1.6.5.2 Output Allocation Window ..................................................................... 1-38

1.6.5.3 Pseudo Input Signal Window................................................................. 1-39

1.6.6 Allocation Signal Meanings................................................................................. 1-40

1.6.7 Monitor Function for Spot Welding Equipment ................................................... 1-42

1.6.8 Spot Welding Exclusive Signal Allocation List .................................................... 1-43

1.7 Instruction List.................................................................................................................. 1-47

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1 Spot Welding Application Using an Air Gun

Robot Controller

Welder

WELD COND (8 bits max)

Welding Gun

WELD REQUEST

WELD COMPLETION

WELD ERROR

WELD ERROR RESET

WELD ON/OFF

GUN PRESSURE

STROKE CHANGE

DOUBLE STROKE GUN FULL-OPEN DETECTION

(Single Solenoid / Double Solenoid)

DOUBLE STROKE GUN SHORT-OPEN DETECTION

128 64 32 16 8 4 2 1 (8) (7) (6) (5) (4) (3) (2) (1)

8-bit

* Values in parentheses are for discrete.

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1.1 System Overview of Spot Welding System Using an Air Gun

1 Spot Welding Application Using an Air Gun

1.1 System Overview of Spot Welding System Using an Air Gun

An I/O signal diagram of a typical spot welding system is shown below.

Fig. 1-1: I/O Signal Diagram for Spot Welding System

• WELD COND (level signal)

• Sets the welding conditions for the welder.

• The output format can be set as binary or discrete.

• Can handle up to 255 conditions (for binary).

• WELD REQUEST (level/pulse)

Outputs the start instruction to the welder.

• WELD ERROR RESET (level)

Resets the welding alarm status of the welder.

• GUN PRESSURE (level)

Outputs gun pressure instruction to the welding gun.

1-1

1 Spot Welding Application Using an Air Gun

SUPPLE-

MENT

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1.1 System Overview of Spot Welding System Using an Air Gun

• STROKE CHANGE (level)

Select the stroke of the gun.

• In case of single solenoid: Change by 1 signal

• In case of double solenoid: Change by 2 signal

For details on signal contents, refer to chapter 1.6 Spot Gun Motion Control.

For details on I/O allocation, refer to chapter 1.6.5 "I/O Allocation".

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1 Spot Welding Application Using an Air Gun

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1.2 Function Keys

Each function used for spot welding is allocated on [Numeric Key]s of the programming pendant. These keys become available when the WORK HOME POSITION is on the display.

Displays the MANUAL SPOT window.

Displays the WORK HOME POSITION window.

[FWD] + [TASK ORIGIN] With the WORK HOME POSITION window in the teach mode, press these keys to move the manipulator to the work home position.

Displays the SPOT instruction in the input buffer to register welding operations.

[INTERLOCK] + [SPOT] With the MANUAL SPOT window displayed, press these keys to perform manual welding.

Displays the GUNCL instruction in the input buffer to register dry spot welding operations.

[INTERLOCK] + [GUN CLOSE] With the MANUAL SPOT window displayed, press these keys to perform manual dry spot welding.

[INTERLOCK] + [WELD ON/OFF] Press these keys to turn on or off the welding ON/OFF signal.

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1 Spot Welding Application Using an Air Gun

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1.2 Function Keys

Instruction to change the stroke to the short open position when using a double stroke gun: Displays the STROKE SHORT instruction in the input buffer.

The SHORT OPEN POSITION SETTING window appears the first time the key is pressed. The selection No. for the short open position appears from the second time the key is pressed.

[INTERLOCK] + [SHORT OPEN] The movable side electrode moves to the selected short open position.

Instruction to change the stroke to the full open position when using a double stroke gun: Displays the STROKE LONG instruction in the input buffer.

The FULL OPEN POSITION SETTING window appears the first time the key is pressed. The selection number for the full open position appears from the second time the key is pressed.

[INTERLOCK] + [FULL OPEN] The movable side electrode moves to the selected full open position.

[INTERLOCK] + [WELD ALM RESET] A Power Source alarm reset signal is output to the Power Source only while these keys are held down.

The welding conditions, gun pressure and weld request are reset with this function.

However, the following two keys are for the function keys for spot welding with motor gun and not for spot welding with air gun.

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1 Spot Welding Application Using an Air Gun

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1.3 Teaching

In order to use the air gun function, first perform teaching as described below.

1.3.1 Manual Spot Welding Function

To perform manual spot welding, carry out the following operation.

1. Press [0/MANUAL SPOT] of [Numeric Key]s.

2. Press [INTERLOCK] + [SPOT] simultaneously.

To perform manual spot welding, press these keys simultaneously while the MANUAL SPOT window is called up.

The conditions displayed in the MANUAL SPOT window are used for manual spot welding.

Regarding the condition setting, refer to chapter 1.4.1 "Settings for Manual Spot Welding".

When registering the welding instruction [SPOT], the values set in the MANUAL SPOT window are used as the initial data.

1.3.1.1 Manual Dry Spotting

1.3.1.2 Stroke Switching

To perform manual dry spotting, carry out the following operation.

1. Press [0/MANUAL SPOT] of [Numeric Key]s

2. Press [INTERLOCK] + [GUN CLOSE] simultaneously.

To perform manual dry spotting, press these keys simultaneously while the MANUAL SPOT window is called up.

The conditions displayed in the MANUAL SPOT window are used for manual dry spotting.

Note that the numbers specified in the MANUAL SPOT window are used as the initial values for the gun number of the gun to be operated and the gun number used when registering the dry spot instruction GUNCL.

While the key is being pressed, the dry spotting motion is performed. When the key is released, the operation stops.

• Press [INTERLOCK] and [FULL OPEN] simultaneously to switch to the full open position.

• Press [INTERLOCK] and [SHORT OPEN] simultaneously to switch to the short open position.

Note that the numbers specified in the MANUAL SPOT window are used as the initial values for the gun number of the gun to be operated and the gun number used when registering the stroke switching instruction STROKE.

AP parameter specifies whether the stroke signal should be set ON or OFF to make the stroke full open. (The initial setting is OFF.)

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1.3.1.3 Welding On/Off

SUPPLE-

MENT

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1 Spot Welding Application Using an Air Gun

1.3 Teaching

Press [INTERLOCK] and [WELD ON/OFF] simultaneously in the teach mode to turn on or off the welding ON/OFF signal to all connected welders.

A user message appears when the welding ON/OFF signal is turned ON in the teach mode.

During manual spot welding, the welding current flows only when this message appears.

The output destination must be allocated in the spot input/output allocation information window before this function is used.

For information on the signal allocation method, see chapter 1.6.5 "I/O Allocation".

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1.3.1.4 Resetting Alarms

SUPPLE-

MENT

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1 Spot Welding Application Using an Air Gun

1.3 Teaching

The alarm reset signal to all connected welders remains ON while [INTERLOCK] and [WELD ALM RESET] are being pressed simultaneously. The welding conditions, gun pressure and weld request are reset with this function.

The output destination must be allocated in the spot input/output allocation information window before this function is used.

For information on signal allocation method, see chapter 1.6.5 "I/O Allocation".

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1 Spot Welding Application Using an Air Gun

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1.3 Teaching

1.3.2 Registering Work Instructions

The function keys [GUNCL](GUNCL instruction), [SPOT](SPOT instruction), [SHORT OPEN]/[FULL OPEN](STROKE instruction) can be used for registering the work instructions.

The STRWAIT instruction is registered using [INSTRUCTION LIST].

Table 1-1: Registering Work Instructions

Specific Keys Instructions

[GUN CLOSE] GUNCL instruction

[SPOT] SPOT instruction

[SHORT OPEN] [FULL OPEN]

Instructions are registered during the teach mode when the cursor is in the address area of the job content window.

1. Select {JOB} under the main menu.

2. Select {JOB CONTENT}.

STROKE instruction

– The JOB CONTENT window is displayed.

3. Move the cursor to the address area.

1-8

1.3.2.1 GUNCL Instruction

NOTE

GUNCL

GUN#(X)

GUN NO.

X: 1 to 8

X: 0.01 to 655.35 sec.

T=X

GUN PRESSURE TIME

ATT=X

ANTICIPATION CONDITION

X: 0 to 655.35 sec.

(1) (2) (3)

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 Additional Items

1 Spot Welding Application Using an Air Gun

1.3 Teaching

This is the dry spotting instruction. It performs dry spotting for the specified time. The gun performs dry spotting then returns to the start position after the time-up timer counts out. Use this instruction when spotting is required, such as after automatic tip dressing or automatic tip replacement.

Be sure to use this instruction in the short open status with a double stroke gun other than X double stroke mechanical stopper type gun. The instruction controls only one gun at one time. Two guns cannot perform dry spotting simultaneously. When GUNCL instruction is executed, it takes a time for the stroke action and dry spotting time is shortened.

(1) Gun# (X)

Specifies a gun to be pressed.

(2) T = X

Specifies the time when the gun is closed.

(3) ATT = X

Starts execution of GUNCL X second(s) before reaching the move instruction located immediately before it. However, it is necessary to specify “NWAIT” to the move instruction immediately before the GUNCL instruction.

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+ 39 hidden pages

YASKAWA YRC1000 OPERATOR’S MANUAL FOR SPOT WELDING USING AIR GUN

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 System Overview of Spot Welding System Using an Air Gun

1.2 Function Keys

1.3 Teaching

1.3.1 Manual Spot Welding Function

1.3.1.1 Manual Dry Spotting

1.3.1.2 Stroke Switching

1.3.1.3 Welding On/Off

1.3.1.4 Resetting Alarms

1.3.2 Registering Work Instructions

1.3.2.1 GUNCL Instruction