YASKAWA Motoman DX200 User manual

MANUAL NO.

HW1481731 7

DX200/FS100 OPTIONS

INSTRUCTIONS

For MotoFit Function Engineering Support Tool

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and

retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN- INSTRUCTIONS

DX200 INSTRUCTIONS

DX200 OPERATOR’S MANUAL (for each purpose)

DX200 MAINTENANCE MANUAL

FS100 INSTRUCTIONS

FS100 OPERATOR’S MANUAL

FS100 MAINTENANCE MANUAL

The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

The FS100 OPERATOR’S MANUAL above is applicable to both FS100 and FS100L controllers.

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MANDATORY

• This manual explains MotoFit function engineering support tool.

Read this manual carefully and be sure to understand its contents

before handling the DX200/FS100.

• General items related to safety are listed in the Chapter 1: Safety of

the DX200/FS100 Instructions. To ensure correct and safe

operation, carefully read the DX200/FS100 Instructions before

reading this manual.

CAUTION

• Some drawings in this manual are shown with the protective covers

or shields removed for clarity. Be sure all covers and shields are

replaced before operating this product.

• The drawings and photos in this manual are representative

examples and differences may exist between them and the

delivered product.

• YASKAWA may modify this model without notice when necessary

due to product improvements, modifications, or changes in

specifications. If such modification is made, the manual number will

also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA

representative to order a new copy. The representatives are listed

on the back cover. Be sure to tell the representative the manual

number listed on the front cover.

• YASKAWA is not responsible for incidents arising from

unauthorized modification of its products. Unauthorized modification

voids your product’s warranty.

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NOTES FOR SAFE OPERATION

Read this manual carefully before installation, operation, maintenance, or

inspection of the DX200/FS100.

In this manual, the Notes for Safe Operation are classified as “DANGER”,

“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

Even items described as “CAUTION” may result in a serious accident in

some situations.

At any rate, be sure to follow these important items.

DANGER

Indicates an imminent hazardous

situation which, if not avoided, could

result in death or serious injury to

personnel.

WARNING

Indicates a potentially hazardous

situation which, if not avoided, could

result in death or serious injury to

personnel.

CAUTION

Indicates a potentially hazardous

situation which, if not avoided, could

result in minor or moderate injury to

personnel and damage to equipment.

It may also be used to alert against

unsafe practices.

MANDATORY

Always be sure to follow explicitly the

items listed under this heading.

PROHIBITED

Must never be performed.

NOTE

To ensure safe and efficient operation at all times, be sure to

follow all instructions, even if not designated as “DANGER”,

“WARNING” and “CAUTION” .

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<DX200>

WARNING

• Before operating the manipulator, check that servo power is turned

OFF when the emergency stop button on the programming pendant

is pressed.

When the servo power is turned OFF, the SERVO ON LED on the

programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit

cannot stop the manipulator during an emergency. The manipulator

should not be used if the emergency stop buttons do not function.

Fig. : Emergency Stop Button

• In the case of not using the programming pendant, be sure to

supply the emergency stop button on the equipment. Then before

operating the manipulator, check to be sure that the servo power is

turned OFF by pressing the emergency stop button.

Connect the external emergency stop button to the 5-6 pin and 16-

17 pin of the robot system signal connector (CN2).

• Upon shipment of the DX200, this signal is connected by a jumper

cable in the dummy connector. To use the signal, make sure to

supply a new connector, and then input it.

If the signal is input with the jumper cable connected, it does not

function, which may result in personal injury or equipment damage.

• Once the emergency stop button is released, clear the cell of all

items which could interfere with the operation of the manipulator.

Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Fig. : Release of Emergency Stop

TURN

• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the

manipulator:

– Be sure to use a lockout device to the safeguarding when going

inside. Also, display the sign that the operation is being

performed inside the safeguarding and make sure no one closes

the safeguarding.

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Keep in mind the emergency response measures against the

manipulator’s unexpected motion toward you.

– Ensure that you have a safe place to retreat in case of

emergency.

Improper or unintended manipulator operation may result in injury.

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<FS100>

WARNING

• Before operating the manipulator, check that servo power is turned

OFF when the emergency stop button on the programming pendant

is pressed.

When the servo power is turned OFF, the SERVO ON LED on the

programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit

cannot stop the manipulator during an emergency.

Fig. : Emergency Stop Button

• In the case of not using the programming pendant, be sure to

supply the emergency stop button on the equipment. Then before

operating the manipulator, check to be sure that the servo power is

turned OFF by pressing the emergency stop button.

Connect the external emergency stop button to the 5-6 pin and 16-

17 pin of the robot system signal connector (CN2).

• Upon shipment of the FS100, this signal is connected by a jumper

cable in the dummy connector. To use the signal, make sure to

supply a new connector, and then input it.

If the signal is input with the jumper cable connected, it does not

function, which may result in personal injury or equipment damage.

• Once the emergency stop button is released, clear the cell of all

items which could interfere with the operation of the manipulator.

Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Fig. : Release of Emergency Stop

• Observe the following precautions when performing teaching

operations within the manipulator’s operating range:

– Be sure to use a lockout device to the safeguarding when going

inside. Also, display the sign that the operation is being

performed inside the safeguarding and make sure no one closes

the safeguarding.

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Keep in mind the emergency response measures against the

manipulator’s unexpected motion toward you.

– Ensure that you have a safe place to retreat in case of

emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no person is present in the manipulator’s operating

range and that you are in a safe location before:

– Turning ON the FS100 power.

– Moving the manipulator with the programming pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the manipulator’s operating range

during operation. Always press the emergency stop button

immediately if there is a problem.

The emergency stop button is located on the right of the programming

pendant.

Turn

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WARNING

• Confirm that no person is present in the manipulator’s operating

range and that you are in a safe location before:

– Turning ON the power for the controller

– Moving the manipulator with the programming pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the manipulator’s operating range

during operation. Always press an emergency stop button immediately

if there are problems.

The emergency stop button is located on the right side of the DX200/

FS100 programming pendant.

CAUTION

• Perform the following inspection procedures prior to conducting

manipulator teaching. If problems are found, repair them

immediately, and be sure that all other necessary processing has

been performed.

– Check for problems in manipulator movement.

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

• Always return the programming pendant to the hook on the DX200/

FS100 cabinet after use.

The programming pendant can be damaged if it is left in the

manipulator’s work area, on the floor, or near fixtures.

• Read and understand the Explanation of the Warning Labels in the

DX200/FS100 Instructions before operating the manipulator.

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Definition of Terms Used Often in This Manual (DX200)

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the

programming pendant, and the manipulator cables.

In this manual, the equipment is designated as follows:

Definition of Terms Used Often in This Manual

(FS100)

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the FS100 controller,

manipulator cables, the FS100 programming pendant (optional), and the

FS100 programming pendant dummy connector (optional).

In this manual, the equipment is designated as follows:

Equipment Manual Designation

DX200 controller DX200

DX200 programming pendant Programming pendant

Cable between the manipulator and the

DX200 controller

Manipulator cable

Equipment Manual Designation

FS100 controller FS100

FS100 programming pendant Programming pendant

Cable between the manipulator

and the controller

Manipulator Cable

Robot Manipulator

FS100 programming pendant

dummy connector

Programming pendant

dummy connector

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Descriptions of the programming pendant keys, buttons, displays and

keyboard of the PC are shown as follows:

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.

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.

Equipment Manual Designation

Programming

Pendant

Character Keys The keys which have characters printed on

them are denoted with [ ].

e.g. [ENTER]

Symbol Keys The keys which have a symbol printed on them

are not denoted with [ ] but depicted with a

small picture.

e.g. PAGE key

The cursor key is an exception, and a picture is

not shown.

Axis Keys

Numeric Keys

“Axis keys” and “Numeric keys” are generic

names for the keys for axis operation and

number input.

Keys Pressed

Simultaneously

When two keys are to be pressed

simultaneously, the keys are shown with a “+”

sign between them.

e.g. SHIFT key + COORD key

Mode Key Three kinds of modes that can be selected by

the mode key are denoted as follows:

REMOTE, PLAY, or TEACH

Button Three buttons on the upper side of the

programming pendant are denoted as follows:

HOLD button

START button

EMERGENCY STOP button

Displays The menu displayed in the programming

pendant is denoted with { }.

e.g. {JOB}

PC Keyboard The name of the key is denoted.

e.g. Ctrl key on the keyboard

GO BACK

PAGE

SHIFT

TOOL SEL

COORD

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Contents

HW1481731

1 Outline of Function.......................................................................................................................... 1-1

1.1 MotoFit Function Engineering Support Tool ...................................................................... 1-1

1.2 Automatic Adjustment Function of Force Control Parameter ............................................ 1-2

1.2.1 Force control ........................................................................................................ 1-2

1.2.2 Adjustment Method .............................................................................................. 1-3

1.3 MotoFit Teach Guidance Function..................................................................................... 1-5

1.4 Function for Calculation of Force Detection Threshold...................................................... 1-6

2 System Configuration...................................................................................................................... 2-1

2.1 System Configuration ........................................................................................................ 2-1

3 Operation Procedure....................................................................................................................... 3-1

3.1 Installing / Uninstalling FSE-Tool....................................................................................... 3-1

3.1.1 Installing FSE-Tool ............................................................................................... 3-1

3.1.2 Uninstalling FSE-Tool........................................................................................... 3-1

3.2 Setting the IP address ....................................................................................................... 3-2

3.3 Operation for Creating Fitting JOB .................................................................................... 3-5

3.3.1 Outline of Operation Step..................................................................................... 3-5

3.3.2 Detailed Operation Step ....................................................................................... 3-6

3.3.2.1 Startup of FSE-Tool ................................................................................ 3-6

3.3.2.2 Setting Force Condition File.................................................................... 3-8

3.3.2.3 Automatic Adjustment of Force Control Parameter............................... 3-13

3.3.2.4 TOUCH Command Teach ..................................................................... 3-25

3.3.2.5 FIT Command Teach ............................................................................ 3-33

3.3.2.6 INSERT Command Teach..................................................................... 3-39

3.3.2.7 Creating MotoFit JOB............................................................................ 3-47

3.3.2.8 Chage of Unit Scale (only for the FS100).............................................. 3-53

3.4 Teach of Force Sense Basic Command .......................................................................... 3-54

3.4.1 Outline of Teach Operation of Force Sense Basic Command............................ 3-54

3.4.2 Details of Teach Operation of Force Sense Basic Command ............................ 3-54

3.4.2.1 Creating JOB......................................................................................... 3-54

3.4.2.2 Threshold Setting by Data Logging ....................................................... 3-56

3.4.2.3 Operation Check ................................................................................... 3-61

4 Interface Panel................................................................................................................................ 4-1

5 Monitor Information ......................................................................................................................... 5-1

6 Operation Condition Data ............................................................................................................... 6-1

6.1 Force Condition File Data .................................................................................................. 6-1

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Contents

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6.2 Adjustment Condition Data ................................................................................................6-2

6.3 MotoFit Command Argument Data .................................................................................... 6-3

6.4 Backup of Teach Data ....................................................................................................... 6-6

6.5 Data for Setting Detection Threshold................................................................................. 6-8

7 Error of Automatic Adjustment Function of Force Control Parameter............................................. 7-1

8 Alarm List of FSE-Tools .................................................................................................................. 8-1

9 How to Check the Version............................................................................................................... 9-1

10 Precautions ................................................................................................................................. 10-1

10.1 Operation during Force Control ..................................................................................... 10-1

10.2 Cancel Operation during Execution of Adjustment Operation or MotoFit Function ....... 10-1

10.3 Communication Error .....................................................................................................10-1

10.4 Limitation due to Using Environment .............................................................................10-1

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