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Motoman UP Series Manual

Xrc controller
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/QVQOCP :4% %QPVTQNNGT
5GPUQT (WPEVKQP
/CPWCN
HQT 725-:5GTKGU 4QDQVU
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Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
142645-1
August 31, 2003
2
Final

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  • Page 1 /QVQOCP :4% %QPVTQNNGT 5GPUQT (WPEVKQP /CPWCN HQT 725-:5GTKGU 4QDQVU Part Number: 142645-1 Release Date: August 31, 2003 Document Version: Document Status: Final Motoman, Incorporated 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-Hour Service Hotline: (937) 847-3200...
  • Page 2 The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman, Inc. ©2003 by MOTOMAN All Rights Reserved Because we are constantly improving our products, we reserve the right to change specifications without...

  • Page 3: Table Of Contents

    Wiring........................... 2-1 Real-time Path Correction Function ................3-1 Real-time Speed Correction Function ................4-1 Shift Amount Creation Function..................5-1 Search Function......................6-1 Calibration ........................7-1 Sensor Output Status Display ..................8-1 Sensor Parameters......................9-1 Alarm List ........................10-1 MOTOMAN Sensor Function...
  • Page 4 NOTES Sensor Function MOTOMAN...

  • Page 5: Introduction

    • Motoman UP130, XRC Manipulator Manual (P/N 142107-1) Customer Service Information If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200. Please have the following information ready before you call: • Robot Type (UP6, SK16X, etc.) •...
  • Page 6 INTRODUCTION NOTES Sensor Function MOTOMAN...

  • Page 7: Safety

    We recommend that all personnel who intend to operate, program, repair, or use the robot system be trained in an approved Motoman training course and become familiar with the proper operation of the system. This safety section addresses the following: •...

  • Page 8: Standard Conventions

    NOTE: Information appearing in a NOTE caption provides additional information which is helpful in understanding the item being explained. Sensor Function MOTOMAN...

  • Page 9: General Safeguarding Tips

    • Safety fences and barriers • Light curtains • Door interlocks • Safety mats • Floor markings • Warning lights Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately. MOTOMAN Sensor Function...

  • Page 10: Installation Safety

    Do not make any modifications to PART 1. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY! • Some operations require standard passwords and some require special passwords.

  • Page 11: Operation Safety

    This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modifications. Check and test all changes at slow speed. MOTOMAN Sensor Function...

  • Page 12: Maintenance Safety

    (Input and Output) modifications. Check and test all changes at slow speed. • Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs). Sensor Function MOTOMAN...
  • Page 13 FOR SENSOR FUNCTION Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN-¨¨¨ INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR’S MANUAL YASNAC XRC OPERATOR’S MANUAL for BEGINNERS The YASNAC XRC operator’s manuals above correspond to specific usage.
  • Page 14 M A N D A T O R Y • This manual explains the sensor function of the YASNAC XRC system and general operations. Read this manual carefully and be sure to understand its contents before handling the YASNAC XRC. •...
  • Page 15 NOTES FOR SAFE OPERATION Read this manual carefully before installation, operation, maintenance, or inspection of the YASNAC XRC. In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”,or ”PROHIBITED”. Indicates a potentially hazardous situation which, if not avoided, W A R N I N G could result in death or serious injury to personnel.
  • Page 16 W A R N I N G • Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the playback panel or program- ming pendant are pressed. When the servo power is turned off, the SERVO ON READY lamp on the playback panel and the SERVO ON LED on the programming pendant are turned off.
  • Page 17 • Read and understand the Explanation of the Alarm Display in the setup manual before operating the manipulator. Definition of Terms Used Often in This Manual The MOTOMAN manipulator is the YASKAWA industrial robot product. The manipulator usually consists of the controller, the playback panel, the programming pen- dant, and supply cables.
  • Page 18 Descriptions of the programming pendant and playback panel keys, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters printed on them are Pendant denoted with [ ]. ex. [ENTER] Symbol Keys The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture.

  • Page 19: Sensor Function

    Sensor Function 1.1 Real-time Path Correction Function ......1-1 1.2 Real-time Speed Correction Function ..... . .1-1 1.3 Shift Amount Creation Function .
  • Page 20 Search Function 6.1 Detection Results ......... . 6-2 6.2 Search Operation with Multiple Channels .

  • Page 21: Real-Time Path Correction Function

    1.1 Real-time Path Correction Function 1 Sensor Function The sensor function corrects the manipulator path and speed, measures distance, and detects position using a sensor such as the displacement sensor or the torque sensor. The analog signals output from a sensor are connected to the XRC, and various controls are performed according to the input voltage.

  • Page 22: Search Function

    1.4 Search Function Search Function The search function moves a manipulator according to the input signal from a sensor, and stops the manipulator when the input signal reaches a designated level. The sensor monitors the manipulator operation, and stops the manipulator at the moment of completing the operation.
  • Page 23 1.4 Search Function 3. According to the calculated difference, the program is modified to proceed the opera- tion.
  • Page 24 1.4 Search Function...

  • Page 25: Analog Input Signal Connection

    2.1 Analog Input Signal Connection 2 Wiring Analog Input Signal Connection Connect analog output signals of each sensor to the analog input terminals on the optional base board. Connect the signals to the sensors in the following manner. 1. Provide an analog input cable for the connection between the sensor and the XRC. Connect the cables as shown below.
  • Page 26 2.1 Analog Input Signal Connection Sensor 1 X C P 0 2 C N 0 5 Analog voltage output AIN 0 Analog output GND G N D Sensor 2 AIN 1 Analog voltage output Analog output GND G N D Sensor 3 AIN 2 Analog voltage output...

  • Page 27: Direct In Signal Connection

    2.2 Direct IN Signal Connection Direct IN Signal Connection Connect the sensor section to the servo control section for the transmission of the detection signals for the search function. When the search function is not used, this wiring is not neces- sary.
  • Page 28 2.2 Direct IN Signal Connection XCP02 XIU01 CN04 CN06 DIN1+ DIN1- P O U T 1 DIN2+ 5 m A P O U T C O M DIN2- P O U T 2 DIN3+ 5 m A P O U T C O M DIN3- DIN4+ DIN4-...

  • Page 29: Real-Time Path Correction Function

    3 Real-time Path Correction Function The real-time path correction function corrects the motion path of the manipulator according to the input signal from a sensor. To start path correction, execute a real-time path correction start instruction (ACORON). To end it, execute a real-rime path correction end instruction (ACOROF). During path correction, the manipulator moves in the motion instructed by a move instruction with the correction amount output from the sensor section.

  • Page 30: Correction Amount

    3.1 Correction Amount Correction Amount For the deviation of the analog input, the correction amount is calculated in the following for- mula. • Where V > V nosens offset = R × ( V - V nosens offset • Where V >...

  • Page 31: Correction Direction

    3.2 Correction Direction Correction Direction The direction in which the path is to be corrected can be determined in the following three ways. • Tool coordinate • Forward direction • Optional direction The correction from the sensor is executed on the coordinates specified by ACORON and SACORON instructions (real-time path correction start instructions).

  • Page 32: Forward Direction

    3.2 Correction Direction 3.2.2 Forward Direction The correction is executed toward the forward direction of move instruction in execution. Sensor Input Channel Correction Direction (specify at registration of instruction) Forward direction Forward direction (CH1) STEP N STEP N+1 3.2.3 Optional Direction The motion path is corrected in the direction determined by two reference points.

  • Page 33: Monitoring Of Sensor Input Voltage

    3.3 Monitoring of Sensor Input Voltage Monitoring of Sensor Input Voltage To prevent the manipulator from deviating excessively from its path, the analog signals are monitored during the path correction. When the path correction starts, the signals are monitored according to a specified sensor monitor condition file.

  • Page 34: Display Of Sensor Monitor Condition File

    3.3 Monitoring of Sensor Input Voltage 1: Stops the path correction and moves the manipulator toward the taught steps. After the end of a step is detected by distance monitoring, the path correction restarts. Error detected Manipulator motion path Distance monitor zone S T E P N S T E P N + 1...

  • Page 35: Instructions For The Real-Time Path Correction Function

    3.4 Instructions for the Real-time Path Correction Function Instructions for the Real-time Path Correction Function 3.4.1 ACORON and SACORON Instructions The ACORON and the SACORON are instructions to start the real-time path correction. Use the SACORON in a coordinated job. <Format>...

  • Page 36: Registration Of The Acoron Instruction

    3.4 Instructions for the Real-time Path Correction Function Registration of the ACORON Instruction Operation Move the cursor to the address area Press [INFORM LIST] Select {SENSOR} Select {ACORON} Press [SELECT] Set the conditions in the detail edit display Press [ENTER] two times Explanation The instruction list dialog box appears.

  • Page 37: Acorof And Sacorof Instructions

    3.4 Instructions for the Real-time Path Correction Function Set the correction conditions. • Editing in “CORRECT COORD”. Move the cursor to the “CORRECT COORD”, and press [SELECT]. The following selection dialog box appears. J O B EDIT DISPLAY UTILITY DETAIL EDIT A C O R O N C O R R E C T C O O R D T F MON COND FILE SCF#() 1...

  • Page 38: Acorch And Sacorch Instructions

    3.4 Instructions for the Real-time Path Correction Function The sensor instruction list dialog box appears. ACORON ACOROF ACORCH AOVRON AOVROF GETSFT SCALIB Sensor Instruction List Dialog Box An ACOROF instruction appears in the input buffer line. 3.4.3 ACORCH and SACORCH Instructions The ACORCH and the SACORCH are instructions to change the real-time path correction conditions.

  • Page 39: Registration Of The Acorch Instruction

    3.4 Instructions for the Real-time Path Correction Function Registration of the ACORCH Instruction Operation Move the cursor to the address area Press [INFORM LIST] Select {SENSOR} Select {ACORCH} Press [SELECT] Set the conditions in the detail edit display Press [ENTER] two times Explanation The instruction list dialog box appears.
  • Page 40 3.4 Instructions for the Real-time Path Correction Function Set a condition to be changed. • Selecting a condition to be changed Move the cursor to either the “THRESHOLD CH” or “THRESHOLD VOLT”. The fol- lowing selection dialog box appears. J O B E D I T D I S P L A Y U T I L I T Y...

  • Page 41: Real-Time Speed Correction Function

    4 Real-time Speed Correction Function During playback of the manipulator, the real-time speed correction function corrects the speed according to the signals from a sensor. To start speed correction, execute a real-time speed correction start instruction (AOVRON). To end it, execute a real-time speed correction end instruction (AOVROF).

  • Page 42: Override Ratio

    4.1 Override Ratio Override Ratio The override ratio is calculated as follows. • Where V > V nosens offset = 100 • Where V > V > - V nosens offset nosens offset = R × ( V ) + 100 nosens offset •...

  • Page 43: Instructions For The Real-Time Speed Correction Function

    4.2 Instructions for the Real-time Speed Correction Function Instructions for the Real-time Speed Correction Function 4.2.1 AOVRON Instruction The AOVRON is an instruction to start the real-time speed correction. <Format> • ‚ A O V R O N TCH#( ) T V = •Threshold channel No.

  • Page 44: Aovrof Instruction

    4.2 Instructions for the Real-time Speed Correction Function The detail edit display appears. J O B E D I T D I S P L A Y U T I L I T Y D E T A I L E D I T A O V R O N T H R E S H O L D C H T C H # ( )

  • Page 45: Shift Amount Creation Function

    5.1 Shift Amount 5 Shift Amount Creation Function The shift amount creation function detects a distance between a manipulator and a workpiece using a displacement sensor to calculate the shift amount on the base coordinate system. <Job Example> 001 NOP 002 MOVJ VJ=25.00 003 MOVL V=100 004 SCALIB TCH#(1)

  • Page 46: Getsft Instruction

    5.3 GETSFT Instruction GETSFT Instruction The GETSFT is an instruction to create the shift amount. <Format> G E T S F T • ‚ ƒ TCH#( ) T V = P,LP,..•Threshold channel No. Specifies the sensor input channel to be used for the creation of the shift amount. 1 to 3: CH1 to CH3 0 or No specification: The shift amounts of all the channels (directions) on the specified coordinate system are averaged to calculate a shift amount.

  • Page 47: Registration Of The Getsft Instruction

    5.3 GETSFT Instruction 5.3.1 Registration of the GETSFT Instruction Operation Move the cursor to the address area Press [INFORM LIST] Select {SENSOR} Select {GETSFT} Press [SELECT] Set the conditions in the detail edit dis- play Press [ENTER] two times Explanation The instruction list dialog box appears.
  • Page 48 5.3 GETSFT Instruction...

  • Page 49: Search Function

    6 Search Function When the analog signal changes according to the position of manipulator, the serch function monitors the analog signal while the manipulator moves in linear interpolation. When the detected value exceeds the set value, the detection result and the detected position are saved and the manipulator is stopped.

  • Page 50: Detection Results

    6.1 Detection Results Detection Results After the search operation, the detection results are registered in the system variables. System Contents Variable $B02 Detection 0: Not detected 1: Detected $PX002 Detected position (pulse) $PX003 Detected position (base axis orthog- onal value) Search Operation with Multiple Channels Normally in the search operation, one search detection channel is monitored.

  • Page 51: Asrch Instruction

    6.3 ASRCH Instruction ASRCH Instruction The ASRCH is an instruction to start the search operation with a move instruction. <Format> • ‚ ƒ … A S R C H SCH#( ) T V = R I S E D I S = „...

  • Page 52: Registration Of The Asrch Instruction

    6.3 ASRCH Instruction 6.3.1 Registration of the ASRCH Instruction Operation Move the cursor to the instruction area Move the cursor to a move instruction where a search instruction is to be registered Press [SELECT] two times Select {UNTIL} Select {ASRCH} Set the conditions in the detail edit display Press [ENTER] two times...

  • Page 53: Calibration

    7.1 SCALIB Instruction 7 Calibration Some sensors have a characteristic that changes the analog output according to an external factor such as temperature change. With this function, the amount that an analog signal changes is set in the offset value for compensation, so each function can be used appropi- ately.

  • Page 54: Registration Of The Scalib Instruction

    7.1 SCALIB Instruction 7.1.1 Registration of the SCALIB Instruction Operation Move the cursor to the address area Press [INFORM LIST] Select {SENSOR} Select {SCALIB} Press [SELECT] Set the conditions in the detail edit dis- play Press [ENTER] two times Explanation The instruction list dialog box appears.

  • Page 55: Entering An Offset Value

    7.2 Entering an Offset Value Entering an Offset Value Follow the explanation in Section 8.2 “Editing in Sensor Output Status Display”. All Channels Calibration Follow the explanation in Section 8.3 “Calibration of All Sensor Input Channels”.
  • Page 56 7.3 All Channels Calibration...

  • Page 57: Sensor Output Status Display

    8.1 Calling Sensor Output Status Display 8 Sensor Output Status Display D A T A E D I T D I S P L A Y U T I L I T Y S E N S O U T S T A T U S : S L 1 C H I N P U T O F F S E T D E A D Z O N E C O N N E C T...

  • Page 58: Calibration Of All Sensor Input Channels

    8.3 Calibration of All Sensor Input Channels Calibration of All Sensor Input Channels Operation Select {DATA} under the top menu Select {ALL CH CALIBRATION} Explanation The calibration menu appears. D A T A D A T A E D I T D I S P L A Y U T I L I T Y A L L C H C A L I B R A T I O N...

  • Page 59: Sensor Parameters

    9 Sensor Parameters (SxE) Initial Setting Contents Value Range Application specification Sensor input channel specification 0 : No specification 1: AN0 5: AN4 2: AN1 6: AN5 3: AN2 7: AN6 4: AN3 8: AN7 Resolution For real-time path correction, [0.01 mm/V] For real-time speed correction, [0.1 %/V] Dead zone [mV]...
  • Page 60 Initial Setting Contents Value Range For analog input signal and correction amount D0: Low-pass filter D1: Fuzzy control (valid only for path correction) Sampling interval [msec] 1 to 10 General-purpose output signal No. at search detection Direct IN signal No. at search detection Combination at execution of search operation by multiple sensors D0 : CH1...

  • Page 61: Alarm List

    10 Alarm List Alarm Message Cause Remedy ROM ERROR Check error in ROM (memory) for Replace the XCP02 1003 (XCP02) sensor program board. ANALOG INPUT Cannot read the analog input Check the cable. FAULT (XCP02) value on the XCP02 board cor- Replace the XCP02 [Decimal Data] rectly.
  • Page 62 10-2...
  • Page 64 BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD. 30 Xue Yuan Road, Haidian, B eijing P.R. China Post Code: 100083 Phone 86-10-6233-2782 Fax 86-10-6232-1536 SHOUGANG MOTOMAN ROBOT CO., LTD. 7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area, Beijing 100076, P.R. China Phone 86-10-6788-0551...

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