YAMAHA ROBOT. User s Manual ENGLISH. E42-Ver. 1.00

Transcription

1 YAMAHA ROBOT User s Manual ENGLISH E E42-Ver. 1.00

2

3 Introduction Thank you for purchasing a YAMAHA Robot Controller. This manual contains the dual robot installation and operating cautions. Please read this manual carefully to ensure that installation and operation are performed in a safe and correct manner. Introduction

4 4 MEMO

5 General Contents Introduction Chapter 1 DUAL ROBOT OVERVIEW Contents 1.1 About the dual robot Dual robot selection requirements Dual robot types Dual drive functions 1-3 Chapter 2 DUAL ROBOT SETTINGS 2.1 Robot and axis settings Dual robot axis parameter settings 2-2 Chapter 3 FLIP-X RIGID DUAL 3.1 Robot installation Mounting accuracy Using a mechanical reference position Origin sensor installation Absolute resets When not storing the main and sub axis positional relationship data When storing the main and sub axis positional relationship data Robot operation cautions "Origin incomplete" status At servo on FLIP-X rigid dual axis parameters 3-6 Chapter 4 FLIP-X FLEXIBLE DUAL 4.1 Robot installation Mounting accuracy Using a mechanical reference position Origin sensor installation 4-2 i

6 4.2 Absolute resets 4-3 Contents 4.3 Robot operation cautions "Origin incomplete" status At servo on FLIP-X flexible dual axis parameters 4-6 Chapter 5 PHASER RIGID DUAL 5.1 Robot installation Mounting accuracy Using a mechanical reference position Origin sensor installation Return-to-origin operations Robot operation cautions "Origin incomplete" status At servo on PHASER rigid dual axis parameters 5-4 Chapter 6 PHASER FLEXIBLE DUAL 6.1 Robot installation Mounting accuracy Using a mechanical reference position Origin sensor installation Return-to-origin operations Robot operation cautions "Origin incomplete" status At servo on PHASER flexible dual axis parameters 6-5 Chapter 7 TROUBLESHOOTING 7.1 FLIP-X rigid dual and PHASER rigid dual FLIP-X flexible dual and PHASER flexible dual 7-2 ii

7 Chapter 1 DUAL ROBOT OVERVIEW Contents 1.1 About the dual robot Dual robot selection requirements Dual robot types Dual drive functions 1-3

8

9 1.1 About the dual robot 1.1 About the dual robot The YAMAHA dual robot can be defined as a single robot model with two axes which are controlled as one axis by the controller. One of the dual robot's two axes is called the "main axis" (reference axis) which is controlled in the same manner as at a single-axis robot, and the other axis is called the "sub axis", and is controlled in a follow-up manner relative to the main axis. The dual robot differs from previous cartesian robots in the following ways: (1) The dual robot offers a two-axis thrust. (2) The dual robot offers improved positioning accuracy and stability at stops. However, due to force interference which occurs between the main and sub axes, simultaneous positioning in systems which employ this "linked and parallel axes" format is difficult to achieve. YAMAHA's rcx series robot controller overcomes this problem by featuring dual drive functions which can be used to drive the dual robot, thereby enabling relatively easy simultaneous control of the two linked axes. 1 Dual robot overview System configuration illustration OP.1 MOTOR XM RCX222 TEMP RGEN B/A BAT ROB I/O SRV ERR RDY E-STOP ACIN L N RPB L1 N1 OP.2! SAFETY EXT.E-STOP PIN11-12 YM SD/COM 1-1

10 1.2 Dual robot selection requirements 1.2 Dual robot selection requirements 1 Dual robot overview YAMAHA's RCX Series robot controller offers four dual drive function types, and the appropriate drive function must be specified in accordance with the dual robot model and application to be used. Moreover, the selected dual drive function must be suitable for the dual robot's linkage configuration. The following table shows the suitable dual drive functions and dual robots which correspond to the various applications. Model Application Dual robot type Dual drive functione FLIP-X series PHASER series Increased thrust, etc. Rigid dual FLIP-X rigid dual Increased thrust, highaccuracy positioning, etc. Flexible dual FLIP-X flexible dual Increased thrust, etc Rigid dual PHASER rigid dual Increased thrust, highaccuracy positioning, etc. Flexible dual [Example] When using as a dual robot to increase the F14-20 thrust: A "rigid dual" type dual robot is selected. The "FLIP-X rigid dual" dual drive function is selected. PHASER flexible dual See the following sections for more information regarding dual robot types and dual drive functions. 1.3 Dual robot types Dual robots are divided into the two types shown below depending on how the main and sub axes are linked. The appropriate dual robot type must be selected in accordance with its intended application. To do this, refer to the selection table shown in section 1.2 "Dual robot selection requirements". 1-2 Rigid dual This dual robot type features a highly rigid linkage of the main and sub axes which allows the two axes to operate as a single axis. This robot configuration is suitable when using the "rigid dual" dual drive function. This type is used primarily to increase the thrust. Flexible dual This dual robot type features either a rotary or slide mechanism at the main and sub axes linkage area to prevent force interference between the two linked axes, or functions as a dual robot with the two axes unlinked. This robot configuration is suitable when using the "flexible dual" dual drive function. This type is used primarily to increase thrust, and for high-accuracy positioning, etc. MEMO For further details, refer to the subsequent chapters for each dual robot type.

11 1.4 Dual drive functions 1.4 Dual drive functions Dual drive functions are divided into the four types shown below. YAMAHA specifies the dual drive function setting at the factory in accordance with the intended purpose of the dual robot to be used. To verify that the dual drive function is suitable for the robot's intended purpose, refer to the selection table in section 1.2 "Dual robot selection requirements". FLIP-X rigid dual This dual drive function is suitable for FLIP-X series rigid dual type robot operations. Main axis positioning is controlled in the same manner as on single-axis robots, with sub axis control occurring in a follow-up manner relative to the main axis. This dual drive function is used to increase thrust at "rigid dual" type dual robots with simple axis linkage configurations. Using this dual drive function at dual robots with low linkage rigidity could result in abnormal operation. Moreover, this dual drive function does not offer high-accuracy positioning. 1 Dual robot overview FLIP-X flexible dual This dual drive function is suitable for FLIP-X series flexible dual type robot operations. Because the main and sub axes are controlled in the same manner as on single-axis robots, the positioning accuracy is higher than that of FLIP-X rigid dual. This dual drive function is used to increase thrust and for high-accuracy positioning. This function is also used in cases where the main and sub axes are not linked. Using this dual drive function at "rigid dual" type dual robots with simple and high rigidity linkage configurations makes normal operation difficult to achieve due to force interference between the main and sub axes. Therefore, this dual drive function can be used only at "flexible dual" type dual robots with linkage configurations which prevent force interference. PHASER rigid dual This dual drive function is suitable for PHASER series rigid dual type robot operations. Main axis positioning is controlled in the same manner as on single-axis robots, with sub axis control occurring in a follow-up manner relative to the main axis. In the same manner as the "rigid dual" type dual drive function, this PHASER rigid dual function is suitable for dual robots with simple linkage configurations, where the intended purpose is simply to increase thrust. Using this dual drive function at dual robots with low linkage rigidity could result in abnormal operation. Moreover, this dual drive function does not offer high-accuracy positioning. 1-3

12 1.4 Dual drive functions 1 Dual robot overview PHASER flexible dual This dual drive function is suitable for PHASER series flexible dual type robot operations. Because the main and sub axes are controlled in the same manner as on single-axis robots, the positioning accuracy is higher than that of PHASER rigid dual. This dual drive function is used to increase thrust and for high-accuracy positioning. This function is also used in cases where the main and sub axes are not linked. Using this dual drive function at "rigid dual" type dual robots with simple and high rigidity linkage configurations makes normal operation difficult to achieve due to force interference between the main and sub axes. Therefore, this dual drive function can be used only at "flexible dual" type dual robots with linkage configurations which prevent force interference. MEMO For further details, refer to the subsequent chapters for each dual robot type. 1-4

13 Chapter 2 DUAL ROBOT SETTINGS Contents 2.1 Robot and axis settings Dual robot axis parameter settings 2-2

14

15 2.1 Robot and axis settings 2.1 Robot and axis settings All the required dual robot and axis settings are factory set at YAMAHA prior to shipment, and do not require further setting by the user. At the programming box,select (SYSTEM) (PARAM) to display the screen shown below, then verify that the dual robot setting is specified. Dual robot setting check (for F14H-20) 2 Dual robot settings If the dual robot setting has been specified as shown in the above figure, the axis relationships are as shown in the following table. F14H-20 Dual Controller's screen indication X Y Z R Delivery specification chart indication X1 axis X2 axis Y-axis Z-axis Programming box display M1 M1 M2 M3 Controller recognition (parameter, point data)) X-axis Y-axis Z-axis As shown in the above table, the X1 and X2 axes representing the dual robot are recognized as a single axis by the controller. Therefore, the dual robot's parameter and point settings are specified only for the X-axis, with settings specified for the Y-axis and Z-axis only if another robot exists. Be aware that settings are specified for only one axis at the dual robot. For the axis relationships, refer to the controller's screen indication and the delivery specification indication. The X1 axis is called the "main" axis, and the X2 axis is called the "sub" axis. n NOTE Dual robot settings can be specified only in the "X and Y" or "Z and R" combinations indicated at the controller screen. 2-1

16 2.2 Dual robot axis parameter settings 2.2 Dual robot axis parameter settings 2 Dual robot settings All the required dual robot axis parameter settings are factory set at YAMAHA prior to shipment, and do not require further setting by the user in order to operate the robot. The dual robot axis parameters are all read-only parameters. When parameter changes are required, the following procedure must first be performed. [Procedure] 1) Press the programming box's [Emergency Stop] button to establish an emergency stop status. 2) In the "SYSTEM" mode, press the (PARAM) key. 3) While holding down the key, press (PASSWRD). 4) Press, then press. Changing read-only parameters The above procedure allows the read-only parameters to be changed. From the programming box, select (SYSTEM) > (PARAM) > (AXIS), then make the desired parameter changes. MEMO Because the dual robot axis parameter content varies according to the dual robot model, refer to dual robot specific chapters for details. 2-2

17 Chapter 3 FLIP-X RIGID DUAL Contents 3.1 Robot installation Mounting accuracy Using a mechanical reference position Origin sensor installation Absolute resets When not storing the main and sub axis positional relationship data When storing the main and sub axis positional relationship data Robot operation cautions "Origin incomplete" status At servo on FLIP-X rigid dual axis parameters 3-6

18

19 3.1 Robot installation 3.1 Robot installation Mounting accuracy The main and sub axes must be mounted with adequate accuracy in order to operate the dual robot. In cases where robots are shipped with the main and sub axes already linked, their parallelism and linkage squareness are factory-adjusted. Therefore, when being mounted at the work site, an adequate degree of parallelism can be obtained by securing the main axis first, and then slowly moving the sub axis by hand until it is aligned with the main axis. If the main and sub axes linkage is performed by the user, the parallelism and squareness must be adjusted. An insufficient parallelism and squareness may activate the "17.4: Over load" alarm. An extremely low main and sub axes rigidity can result in poor sub axis positioning accuracy. MEMO For details concerning the installation accuracy, please contact your YAMAHA representative. 3 FLIP-X rigid dual Using a mechanical reference position In dual robot operations, the use of a mechanical reference position is recommended in order to align the main and sub axis positions. The "17.28: Dual P.E. counter overflow" alarm may occur if an excessive positional deviation exists between the main and sub axis when the servo is turned on. Should this alarm occur, the presence of a mechanical reference position simplifies recovery. A mechanical reference position also simplifies absolute reset operations. 3-1

20 3.1 Robot installation Origin sensor installation Origin sensors are installed at the main and sub axes (1 sensor each). When installed by YAMAHA, the position of these origin sensors are factory-adjusted. After installing the robot, perform the section 3.2 "Absolute resets" procedure to verify that the sensors are operating properly. 3 FLIP-X rigid dual In cases where the user installs origin sensors, changes their positions, or replaces them, etc., the origin sensor positions must then be adjusted. First, install the sub axis origin sensor so that it switches on before (by 1/2 or more of the lead length) the main axis origin sensor at absolute resets. Also install the main and sub axis origin sensors in a manner which provides a position where they can switch on simultaneously at absolute resets (see figure below). After completing the above procedure, perform the section 3.2 "Absolute resets" procedure to adjust the origin sensor positions. Robot installation (FLIP-X rigid dual) Absolute reset direction Main axis Sensor dogs Sub axis Origin sensor The main and sub axes are each equipped with one sensor. Set the sub axis origin sensor so that it switches on before (by 1/2 or more of the lead length) the main axis origin sensor. Also set the sensors so that they can switch on simultaneously at operations. Main and sub axes link Be sure that the link rigidity is not excessively low, as this will reduce the repeated positioning accuracy. Parallelism An overload alarm may occur if the main and sub axes parallelism and linkage squareness are deviated. 3-2

21 3.2 Absolute resets 3.2 Absolute resets Dual robots require absolute resets just as standard single-axis robots do. An absolute reset allows the user to "teach" the origin position when an "origin incomplete" status occurs. An absolute reset moves the robot in its return-to-origin direction in order to detect the origin position. For absolute reset details, refer to the "YAMAHA RCX142 Robot Controller User's Manual" or the "YAMAHA RCX222 Robot Controller User's Manual". FLIP-X rigid dual robots use a sensor method for absolute resets. When an absolute reset is executed, the main axis detects the origin sensor, and then stops at the motor s electrical reference position following robot movement of no more than 1/4 the lead length. This position is the main axis origin position. The sub axis origin position is determined by a follow-up operation keyed to the main axis. Moreover, the "dual offset" axis parameter setting can be specified in order to save the main and sub axis positional relationship in memory. Execute an absolute reset using the procedure described below When not storing the main and sub axis positional relationship data 3 FLIP-X rigid dual The absolute reset completion position is the main axis origin position. The sub axis origin position is determined by its follow-up operation keyed to the main axis. 1 Set the sub axis origin sensor so that it switches on before (by 1/2 or more of the lead length) the main axis origin sensor. 2 Specify "0" as the "dual offset" axis parameter setting. (see section 3.4 "FLIP-X rigid dual axis parameters"). 3 Restart the controller. 4 Execute an absolute reset and verify the machine reference value. 5 If the machine reference value is outside the 25 to 75 range, adjust the position of the main axis origin sensor. 6 Repeat steps 4 5 above until the machine reference value is within the 25 to 75 range, then verify that the distance between the main and sub axis origin sensors is not less than 1/2 the length of the lead. Also position the main and sub axis origin sensors so that they can switch on simultaneously at absolute resets. (See section "Origin sensor installation".) This completes the procedure. Turn the power on and re-execute return-to-origin to verify that the adjustments are OK. Absolute reset must be re-executed if the origin sensors are moved, or if the absolute reset related parameters are changed. In such cases, execute the absolute reset using the procedure described above. 3-3

22 3.2 Absolute resets n Note When using an RCX141 or RCX221 controller, return-to-origin must be re-executed if the power has been turned off When storing the main and sub axis positional relationship data 3 FLIP-X rigid dual Although the absolute reset completion position is the main axis origin position, the sub axis position is automatically adjusted by the amount of the "dual offset" axis parameter setting value. 1) Main axis origin sensor position adjustment 1 This procedure is the same as that described in section ) Sub axis origin sensor position adjustment 2 Specify "-2" as the axis parameter "dual offset" setting. (See section 3.4 "FLIP-X rigid dual axis parameters".) 3 Restart the controller. 4 Execute an absolute reset and verify the machine reference value. 5 If the machine reference value is outside the 25 to 75 range, adjust the position of the sub axis origin sensor. 6 Repeat steps 4 5 above until the machine reference value is within the 25 to 75 range, then verify that the distance between the main and sub axis origin sensors is not less than 1/2 the length of the lead. Also position the main and sub axis origin sensors so that they can switch on simultaneously at absolute resets. (See section "Origin sensor installation".) 3) Dual offset setting 7 Specify "-1" as the "dual offset" axis parameter setting. (See section 3.4 "FLIP-X rigid dual axis parameters".) 8 Turn the power off, align the main and sub axis positions, then turn the power on again. 9 Execute an absolute reset and verify the machine reference value. 10 Enter the following value as the "dual offset" axis parameter setting: [Dual offset] = [Machine reference x ] Decimal values should be rounded off to the nearest whole number. This completes the procedure. Turn the power on and re-execute absolute reset to verify that the adjustments are OK. After each subsequent absolute reset, the sub axis position is automatically adjusted so that the main and sub axes mutual positional difference conforms to the "dual offset" axis parameter setting value. Be aware that the sub axis position adjustment occurs after the absolute reset completion. 3-4

23 3.3 Robot operation cautions For details regarding the axis parameter dual offset, see section 3.4 "FLIP-X rigid dual axis parameters". Absolute reset must be re-executed if the origin sensors are moved, or if the absolute reset related parameters are changed. In such cases, execute the absolute reset using the procedure described above. n Note When using an RCX141 or RCX221 controller, return-to-origin must be re-executed if the power has been turned off. 3.3 Robot operation cautions "Origin incomplete" status If an "origin incomplete" status occurs due to an incomplete absolute reset, due to the robot cable being disconnected from the controller, or due to an absolute reset related parameter change, the main and sub axis positional relationship which existed immediately after power ON is maintained. After an absolute reset completion, the positional relationship is adjusted in accordance with the "dual offset" axis parameter setting value. 3 FLIP-X rigid dual At servo on If the sub axis position is deviated from the main axis position when the servo is turned on while in an absolute reset completed condition, the sub axis position is automatically adjusted immediately after the servo is turned on. The larger the deviation at this time, the faster the sub axis movement, and this could pose a possible hazard to workers. To prevent this hazard, the "17.28: Dual P.E. counter overflow" alarm occurs if the distance between the main and sub axes equals or exceeds a prescribed value immediately following a servo on. In cases where large deviations are possible during a servo free-run condition due to a low rigidity linkage of the main and sub axes, etc., the "servo parameter 3" (axis parameters) reference value should be set low to trigger an alarm, thereby ensuring safety. (See section 3.4 "FLIP-X rigid dual axis parameters".) If the alarm is activated, adjust the main and sub axis positions, then perform a restart. 3-5

24 3.4 FLIP-X rigid dual axis parameters 3.4 FLIP-X rigid dual axis parameters This section explains the FLIP-X rigid dual axis parameters. All the FLIP-X rigid dual axis parameters are all read-only parameters. Setting these parameters requires that they first be changed to a write-enabled status by the procedure described in chapter 2, section 2.2 "Dual robot axis parameter settings". 3 FLIP-X rigid dual Kdvp Specifies the servo gain setting for the main and sub axes speed deviation. Although a higher setting value improves the sub axis follow-up operation keyed to the main axis, vibration and abnormal noise may occur if the setting value is too high. The appropriate setting value varies according to the robot model and the robot installation conditions (main and sub axes linkage, etc.). Setting range : 0 to 255 Default setting: Varies according to the robot model MEMO Always consult with a YAMAHA representative before changing this setting value. Kdpp Specifies the servo gain setting for the main and sub axis position deviation. A higher setting value improves the sub axis follow-up operation keyed to the main axis, and improves the sub axis positioning accuracy at stops. A higher setting is particularly effective when the main and sub axes linkage rigidity is low. However, abnormal noise and vibration may occur if the setting value is too high. The appropriate setting value varies according to the robot model and the robot installation conditions (main and sub axes linkage, etc.). Setting range : 0 to 255 Default setting: Varies according to the robot model MEMO Always consult with a YAMAHA representative before changing this setting value. 3-6

25 3.4 FLIP-X rigid dual axis parameters Dual offset Specifies the mutual position difference which serves as the reference for the main and sub axes. When specified, the sub axis position is automatically adjusted so that the difference between the main and sub axis positions conforms to this setting value. The setting value is calculated by the following formula: Dual offset = Main and sub axes mutual position difference [pulse] x Decimal values should be rounded off to the nearest whole number. n Note Be aware that the sub axis position adjustment occurs after the absolute reset completion. Adjustment by "dual offset" setting Motor's electrical angle reference position Main axis Main axis sensor ON position Return-to-origin direction Return-to-origin completion position 3 FLIP-X rigid dual Sub axis Sub axis sensor ON position Main and sub axes mutual position difference If the sub axis position is deviated at return-to-origin completion, it is automatically adjusted to this setting value. The adjustment shown above does not occur if the "dual offset" is set to 0, -1, or -2. Instead, these settings specify the following special functions. (1) "0" setting Disables the sub axis position adjustment following an absolute reset completion. The main axis machine reference displays as the machine reference. Units: [%] (2) "-1" setting Disables the sub axis position adjustment following an absolute reset completion. The main and sub axes mutual position difference displays as the machine reference. Units: [Pulse] (3) "-2" setting Disables the sub axis position adjustment following an absolute reset completion. The sub axis machine reference displays as the machine reference. Units: [%] 3-7

26 3.4 FLIP-X rigid dual axis parameters The above functions are used with respect to the "dual offset" setting. For details, see section "When main and sub axis positional relationship is saved in memory". Dual axis polarity Specifies the sub axis movement direction relative to the main axis. If a minus-setting is specified, the sub axis moves in the same direction as the main axis. If a plus-setting is specified, the sub axis moves the opposite direction as the main axis. 3 FLIP-X rigid dual Servo parameter 3 Specifies the threshold value where the "17.28: Dual P.E. counter overflow" alarm is activated. This alarm is activated if the main and sub axis position deviation exceeds this threshold value. Setting range : 0 to [pulse] (A setting of "0" is processed as the maximum setting value.) Default setting: 0 3-8

27 Chapter 4 FLIP-X FLEXIBLE DUAL Contents 4.1 Robot installation Mounting accuracy Using a mechanical reference position Origin sensor installation Absolute resets Robot operation cautions "Origin incomplete" status At servo on FLIP-X flexible dual axis parameters 4-6

28

29 4.1 Robot installation 4.1 Robot installation Mounting accuracy The main and sub axes must be mounted with adequate accuracy in order to operate the dual robot. In cases where robots are shipped with the main and sub axes already linked, their parallelism is factory-adjusted. Therefore, when being mounted at the work site, an adequate degree of parallelism can be obtained by securing the main axis first, and then slowly moving the sub axis by hand until it is aligned with the main axis. If the main and sub axes linkage is performed by the user, the parallelism must be adjusted. An insufficient parallelism may activate the "17.4: Over load" alarm. The FLIP-X flexible dual robot must have a linkage configuration which prevents force interference between the main and sub axes. Failing to provide this configuration, or providing an insufficient configuration could result in a "17.4 Over load" alarm occurrence during robot operation. Also note that the preventive configuration may also reduce positioning accuracy. (See section "Origin sensor installation".) MEMO For details concerning the installation accuracy, please contact your YAMAHA representative Using a mechanical reference position 4 FLIP-X flexible dual In dual robot operations, the use of a mechanical reference position is recommended in order to align the main and sub axis positions. The "17.28: Dual P.E. counter overflow" alarm may occur when the servo is turned on if an excessive positional deviation exists between the main and sub axes. Should this alarm occur, the presence of a mechanical reference position simplifies recovery. A mechanical reference position also simplifies absolute reset operations. 4-1

30 4.1 Robot Installation Origin sensor installation Origin sensors are installed at the main and sub axes (1 sensor each). When installed by YAMAHA, the position of these origin sensors are factory-adjusted. After installing the robot, perform the section 4.2 "Absolute resets" procedure to verify that the sensors are operating properly. In cases where the user installs origin sensors, changes their positions, or replaces them, etc., the origin sensor positions must be adjusted. If the main and sub axes are linked, their origin sensors should be positioned as close to the same position (at both the main axis and sub axis sides) as possible. An appropriate length is also required at the sensor dogs. (see the figure below) 4 After completing the above procedure, perform the section 4.2 "Absolute resets" procedure to adjust the origin sensor positions. FLIP-X flexible dual Robot installation (FLIP-X flexible dual) Main axis Absolute reset direction Sub axis Origin sensors The main and sub axes are each equipped with one sensor. Position the two sensors as close to the same position (at both the main axis and sub axis sides) as possible. Sensor dogs An appropriate length is required. Main and sub axes linkage area A configuration is required to prevent force interference between the main and sub axes. 4-2

31 4.2 Absolute resets 4.2 Absolute resets Dual robots require absolute resets just as standard single-axis robots do. An absolute reset allows the user to "teach" the origin position when an "origin incomplete" status occurs. An absolute reset moves the robot in its return-to-origin direction in order to detect the origin position. For absolute reset details, refer to the "YAMAHA RCX142 Robot Controller User's Manual" or the "YAMAHA RCX222 Robot Controller User's Manual". FLIP-X flexible dual robots use a sensor method for absolute resets. When an absolute reset is executed, the main and sub axes detect the origin sensors, and then stops at the motor s electrical reference position following robot movement of no more than 1/4 the lead length. This position represents the main axis and sub axis origin positions. Moreover, a "dual offset" axis parameter setting can be specified in order to adjust either the main or sub axis. Execute an absolute reset using the procedure described below. 4 1) Main axis origin sensor position adjustment 1 Specify "0" as the "dual offset" axis parameter setting. (see section 4.4 "FLIP-X Flexible Dual Axis Parameters"). 2 Restart the controller. 3 Execute an absolute reset and verify the machine reference value. 4 If the machine reference value is outside the 25 to 75 range, adjust the position of the main axis origin sensor. 5 Repeat steps 3 4 above until the machine reference value is within the 25 to 75 range. FLIP-X flexible dual 2) Sub axis origin sensor position adjustment 6 Specify "-2" as the "dual offset" axis parameter setting. (See section 4.4 "FLIP-X Flexible Dual Axis Parameters".) 7 Restart the controller. 8 Execute an absolute reset and verify the machine reference value. 9 If the machine reference value is outside the 25 to 75 range, adjust the position of the sub axis origin sensor. 10 Repeat steps 8 9 above until the machine reference value is within the 25 to 75 range, and verify that the origin sensors are located at approximately the same position on both main and sub axes. This completes the procedure. Perform a restart, then re-execute return-to-origin to verify that there are no adjustment problems. If further main or sub axis origin position adjustment is desired, continue with the procedure described in item 3) "Dual offset setting". 4-3

32 4.2 Absolute resets 3) Dual offset setting The "dual offset" axis parameter setting can be used to specify an offset from the main axis or sub axis origin position. A plus-value [pulse] "dual offset" setting can be specified to obtain a sub axis plusdirection offset, and a minus-value [pulse] setting can be specified to obtain a main axis plus-direction offset. Be aware that the offset-subject axis is moved by the amount of the "dual offset" setting value following movement to the origin position. For details regarding the "dual offset" axis parameter setting, see section 4.4 "FLIP-X Flexible Dual Parameters". 4 FLIP-X flexible dual This completes the procedure. Perform a restart, then re-execute absolute reset to verify that there are no adjustment problems. If the main or sub axis origin sensors are moved, or if the absolute reset related parameters are changed, absolute reset must be re-executed using the procedure described above. n Note When using an RCX141 or RCX221 controller, return-to-origin must be re-executed if the power has been turned off. 4-4

33 4.3 Robot operation cautions 4.3 Robot operation cautions "Origin incomplete" status If an "origin incomplete" status occurs due to an incomplete absolute reset, due to the robot cable being disconnected from the controller, or due to an absolute reset related parameter change, the main and sub axis positional relationship which existed immediately after power ON is maintained. After an absolute reset completion, the positional relationship is adjusted in accordance with the "dual offset" axis parameter setting value At servo on If the sub axis position is deviated from the main axis position when the servo is turned on while in an absolute reset completed condition, the sub axis position is automatically adjusted immediately after the servo is turned on. The larger the deviation at this time, the faster the sub axis movement, and this could pose a possible hazard to workers. To prevent this hazard, the "17.28: Dual P.E. counter overflow" alarm occurs if the distance between the main and sub axes equals or exceeds a prescribed value immediately following a servo on. In cases where large deviations are possible during a servo free-run condition, the "servo parameter 3" (axis parameter) reference value should be set low to trigger an alarm, thereby ensuring safety. (See section 4.4 "FLIP-X Flexible Dual Axis Parameters".) If the alarm is activated, adjust the main and sub axis positions, then perform a restart. 4 FLIP-X flexible dual 4-5

34 4.4 FLIP-X flexible dual axis parameters 4.4 FLIP-X flexible dual axis parameters This section explains the FLIP-X flexible dual axis parameters. Setting these parameters requires that they first be changed to a write-enabled status by the procedure described in chapter 2, section 2.2 "Dual Robot Axis Parameter Settings". 4 Dual offset Specifies the main axis or sub axis position at an absolute reset completion. The desired offset distance is specified in [pulse] units, and that offset is applied relative to the main axis or sub axis origin position following an absolute reset completion. Following a return-to-origin completion, the origin based positional relationship is maintained. (1) Plus-value setting Offsets the main axis in the plus-direction. (2) Minus-value setting Offsets the main axis in the plus-direction. FLIP-X flexible dual n Note Absolute reset operation with "dual offset" setting Return-to-origin completion position Origin position Plus-direction movement occurs by the setting value [pulse] amount. Sub axis (or "main axis" when setting is a minus value) Be aware that the offset-subject axis movement occurs (by the amount of the "dual offset" setting value) after movement to the origin position is completed. Dual axis polarity Specifies the sub axis movement direction relative to the main axis. If a minus-setting is specified, the sub axis moves in the same direction as the main axis. If a plus-setting is specified, the sub axis moves the opposite direction as the main axis. Servo parameter 3 Specifies the threshold value where the "17.28: Dual P.E. counter overflow" alarm is activated. This alarm is activated if the main and sub axis position deviation exceeds this threshold value. Setting range : 0 to [pulse] (A setting of "0" is processed as the maximum setting value.) Default setting: 0 4-6

35 Chapter 5 PHASER RIGID DUAL Contents 5.1 Robot installation Mounting accuracy Using a mechanical reference position Origin sensor installation Return-to-origin operations Robot operation cautions "Origin incomplete" status At servo on PHASER rigid dual axis parameters 5-4

36

37 5.1 Robot installation 5.1 Robot installation Mounting accuracy The main and sub axes must be mounted with adequate accuracy in order to operate the dual robot. In cases where robots are shipped with the main and sub axes already linked, their parallelism and linkage squareness are factory-adjusted. Therefore, when being mounted at the work site, an adequate degree of parallelism can be obtained by securing the main axis first, and then slowly moving the sub axis by hand until it is aligned with the main axis. If the main and sub axis linkage is performed by the user, the parallelism and squareness must be adjusted. An insufficient parallelism and squareness may activate the "17.4: Over load" alarm. PHASER rigid dual robots use a stroke end method for return-to-origin operations. The main and sub axis positions must therefore be adjusted so that main and sub axes contact occurs simultaneously, and the linkage squareness must also be adequately adjusted. Improper position and squareness adjustments can increase the sub axis motor load when contact occurs, possibly causing malfunctions. (See section "Origin sensor installation" for further details.) An extremely low main and sub axes linkage rigidity can result in poor sub axis positioning accuracy. MEMO For details concerning the installation accuracy, please contact your YAMAHA representative. 5 PHASER rigid dual Using a mechanical reference position In dual robot operations, the use of a mechanical reference position is recommended in order to align the main and sub axis positions. The "17.28: Dual P.E. counter overflow" alarm may occur when the servo is turned on if an excessive positional deviation exists between the main and sub axes. Should this alarm occur, the presence of a mechanical reference position simplifies recovery. A mechanical reference position also simplifies absolute reset operations. 5-1

38 5.1 Robot installation Origin sensor installation PHASER rigid dual robots do not require origin sensors because the return-to-origin operation uses a stroke end method. Robot installation (PHASER rigid dual) Return-to-origin direction Main axis Sub axis Origin sensor Origin sensors not required because the return-to-origin operation uses a stroke end method. 5 PHASER rigid dual Parallelism An overload alarm may occur if the main and sub axes parallelism and linkage squareness are deviated. Main and sub axes link Due to the stroke end method return-to-origin operation, the main and sub axis positions and squareness must be carefully adjusted to ensure that contact occurs at both axes simultaneously. Also be sure that the link rigidity is not excessively low, as this will reduce the repeated positioning accuracy. 5-2

39 5.2 Return-to-origin operations 5.2 Return-to-origin operations Dual robots require return-to-origin operations just as standard single-axis robots do. A return-to-origin moves the robot to a fixed point specified in advance and clears the controller's position data to zero. When a return-to-origin is executed, the robot moves in its return-to-origin direction in order to detect the origin position. For return-to-origin details, refer to the "YAMAHA RCX141 Robot Controller User's Manual" or the "YAMAHA RCX221 Robot Controller User's Manual". PHASER rigid dual robots use a stroke end method for return-to-origin operations. When a return-to-origin is executed, the main axis moves until contact is made with the robot end, and then it returns, with stopping at the motor's electrical reference position. This position is the main axis origin position. The sub axis operation and origin position is determined by follow-up operation keyed to the main axis. Care should be taken with regard to the main and sub axes link when performing a returnto-origin. (See section 4.1 "Robot installation" for details.) The machine reference is factory-adjusted and requires no further adjusting by the user. 5.3 Robot operation cautions "Origin incomplete" status If an "origin incomplete" status occurs due to an incomplete return-to-origin, due to the robot cable being disconnected from the controller, or due to a return-to-origin related parameter change, the main and sub axis positional relationship which existed immediately after power ON is maintained. After a return-to-origin completion, the origin based positional relationship is maintained. 5 PHASER rigid dual At servo on If the sub axis position is deviated from the main axis position when the servo is turned on while in a return-to-origin completed condition, the sub axis position is automatically adjusted immediately after the servo is turned on. The larger the deviation at this time, the faster the sub axis movement, and this could pose a possible hazard to workers. To prevent this hazard, the "17.28: Dual P.E. counter overflow" alarm occurs if the distance between the main and sub axes equals or exceeds a prescribed value immediately following a servo on. In cases where large deviations are possible during a servo free-run condition due to a low rigidity linkage of the main and sub axes, etc., the "servo parameter 3" (axis parameters) reference value should be set low to trigger an alarm, thereby ensuring safety. (See section 5.4 "PHASER Rigid Dual Axis Parameters".) If the alarm is activated, adjust the main and sub axis positions, then perform a restart. 5-3

40 5.4 PHASER rigid dual axis parameters 5.4 PHASER rigid dual axis parameters This section explains the PHASER rigid dual axis parameters. All the PHASER rigid dual axis parameters are all read-only parameters. Setting these parameters requires that they first be changed to a write-enabled status by the procedure described in chapter 2, section 2.2 "Dual Robot Axis Parameter Settings". Kdvp Specifies the servo gain setting for the main and sub axes speed deviation. Although a higher setting value improves the sub axis follow-up operation keyed to the main axis, vibration and abnormal noise may occur if the setting value is too high. The appropriate setting value varies according to the robot model and the robot installation conditions (main and sub axes linkage, etc.). Setting range : 0 to 255 Default setting: Varies according to the robot model 5 PHASER rigid dual Kdpp MEMO Always consult with a YAMAHA representative before changing this setting value. Specifies the servo gain setting for the main and sub axis position deviation. A higher setting value improves the sub axis follow-up operation keyed to the main axis, and improves the sub axis positioning accuracy at stops. A higher setting is particularly effective when the main and sub axes linkage rigidity is low. However, abnormal noise and vibration may occur if the setting value is too high. The appropriate setting value varies according to the robot model and the robot installation conditions (main and sub axes linkage, etc.). Setting range : 0 to 255 Default setting: Varies according to the robot model MEMO Always consult with a YAMAHA representative before changing this setting value. Dual axis polarity 5-4 Specifies the sub axis movement direction relative to the main axis. If a minus-setting is specified, the sub axis moves in the same direction as the main axis. If a plus-setting is specified, the sub axis moves the opposite direction as the main axis. Servo parameter 3 Specifies the threshold value where the "17.28: Dual P.E. counter overflow" alarm is activated. This alarm is activated if the main and sub axis position deviation exceeds this threshold value. Setting range : 0 to [pulse] (A setting of "0" is processed as the maximum setting value.) Default setting: 0

41 Chapter 6 PHASER FLEXIBLE DUAL Contents 6.1 Robot installation Mounting accuracy Using a mechanical reference position Origin sensor installation Return-to-origin operations Robot operation cautions "Origin incomplete" status At servo on PHASER flexible dual axis parameters 6-5

42

43 6.1 Robot installation 6.1 Robot installation Mounting accuracy The main and sub axes must be mounted with adequate accuracy in order to operate the dual robot. In cases where robots are shipped with the main and sub axes already linked, their parallelism is factory-adjusted. Therefore, when being mounted at the work site, an adequate degree of parallelism can be obtained by securing the main axis first, and then slowly moving the sub axis by hand until it is aligned with the main axis. If the main and sub axes linkage is performed by the user, the parallelism must be adjusted. An insufficient parallelism may activate the "17.4: Over load" alarm. PHASER flexible dual robot must have a linkage configuration which prevents force interference between the main and sub axes. Failing to provide this configuration, or providing an insufficient configuration could result in a "17.4 Over load" alarm occurrence during robot operation. Also note that this preventive configuration may also reduce positioning accuracy. (See section "Origin Sensor Installation".) MEMO For details concerning the installation accuracy, please contact your YAMAHA representative Using a mechanical reference position In dual robot operations, the use of a mechanical reference position is recommended in order to align the main and sub axis positions. The "17.28: Dual P.E. counter overflow" alarm may occur when the servo is turned on if an excessive positional deviation exists between the main and sub axes. Should this alarm occur, the presence of a mechanical reference position simplifies recovery. A mechanical reference position also simplifies absolute reset operations. 6 PHASER flexible dual 6-1

44 6.1 Robot installation Origin sensor installation Origin sensors are installed at the main and sub axes (1 sensor each). When installed by YAMAHA, the position of these origin sensors are factory-adjusted and should not be changed by the user. An origin sensor readjustment is required, however, if the robot is reconfigured or moved. In such cases, please contact your YAMAHA representative. Robot installation (PHASER flexible dual) Return-to-origin direction Main axis Sub axis Origin sensors Origin sensors are installed at the main and sub axes (1 sensor each). Do not change their factory-adjusted positions. 6 Sensor dogs An appropriate length is required. PHASER flexible dual Main and sub axes linkage A configuration which frees the main and sub axes is required in order to prevent force interference between these axes. 6-2

45 6.2 Return-to-origin operations 6.2 Return-to-origin operations Dual robots require return-to-origin operations just as standard single-axis robots do. A return-to-origin moves the robot to a fixed point specified in advance and clears the controller's position data to zero. When a return-to-origin is executed, the robot moves in its return-to-origin direction in order to detect the origin position. For return-to-origin details, refer to the "YAMAHA RCX141 Robot Controller User's Manual" or the "YAMAHA RCX221 Robot Controller User's Manual". PHASER flexible dual robots use a sensor method for return-to-origin operations. When a return-to-origin is executed, the main and sub axes each detect their origin sensors, followed by movement to the Z-phase, with a stop occurring at the motor's electrical reference position. These respective positions are the main and sub axis origin positions. Moreover, the "dual offset" and "servo parameter 5" axis parameter settings can be specified to adjust the main or sub axis position. Use the following procedure to perform a return-to-origin operation. 1) Origin sensor position adjustment The origin sensor positions are factory-adjusted for both the main and sub axes, and require no further adjustment. 2) "Dual offset" setting The "dual offset" and "servo parameter 5" axis parameter settings can be used to offset the main or sub axes from their origin positions. "Servo parameter 5" set as "0" A plus-value "dual offset" setting value [pulse] offsets the sub axis in the plusdirection. A minus-value "dual offset" setting value [pulse] offsets the main axis in the plusdirection. "Servo parameter 5" set as other than "0" If the sum of the "dual offset" and "servo parameter 5" setting values is a plus value, the sub axis is offset in the minus direction. If the sum of the "dual offset" and "servo parameter 5" setting values is a minus value, the main axis is offset in the minus direction. n Note Be aware that the axis offset occurs (by the amount of the "dual offset" setting) after movement to the origin position is completed. 6 PHASER flexible dual For details regarding the axis parameter dual offset and servo parameter 5, see section 6.4 "PHASER flexible dual axis parameters". 6-3

46 6.3 Robot operation cautions This completes the procedure. Perform a restart, then re-execute return-to-origin to verify that there are no adjustment problems. Return-to-origin must be re-executed if the origin sensor position has been moved, or if the return-to-origin related parameters have been changed. In this case, re-execute return-to-origin using the procedure described above. 6.3 Robot operation cautions "Origin incomplete" status If an "origin incomplete" status occurs due to an incomplete return-to-origin, due to the robot cable being disconnected from the controller, or due to a return-to-origin related parameter change, the main and sub axis positional relationship which existed immediately after power ON is maintained. After a return-to-origin completion, the positional relationship is adjusted in accordance with the "dual offset" and "servo parameter 5" axis parameter setting values At servo on 6 PHASER flexible dual If the sub axis position is deviated from the main axis position when the servo is turned on while in an absolute reset completed condition, the sub axis position is automatically adjusted immediately after the servo is turned on. The larger the deviation at this time, the faster the sub axis movement, and this could pose a possible hazard to workers. To prevent this hazard, the "17.28: Dual P.E. counter overflow" alarm occurs if the distance between the main and sub axes equals or exceeds a prescribed value immediately following a servo on. In cases where large deviations are possible during a servo free-run condition, the "servo parameter 3" (axis parameter) reference value should be set low to trigger an alarm, thereby ensuring safety. (See section 4.4 "FLIP-X Flexible Dual Axis Parameters".) If the alarm is activated, adjust the main and sub axis positions, then perform a restart. 6-4