YASKAWA MOTOMAN Series User manual

MANUAL NO.

HW1485704

YRC1000 OPTIONS

INSTRUCTIONS

FOR ARC WELDING DIAGNOSIS FUNCTION

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

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DANGER

• This manual explains the arc welding diagnosis function of the

YRC1000 system. Read this manual carefully and be sure to

understand its contents before handling the YRC1000. Any matter

not described in this manual must be regarded as "prohibited" or

"improper".

• General information related to safety are described in "Chapter 1.

Safety" of the YRC1000 INSTRUCTIONS. To ensure correct and

safe operation, carefully read "Chapter 1. Safety" of the YRC1000

INSTRUCTIONS.

CAUTION

• In some drawings in this manual, protective covers or shields are

removed to show details. Make sure that all the covers or shields

are installed in place before operating this product.

• YASKAWA is not responsible for incidents arising from

unauthorized modification of its products. Unauthorized

modification voids the product warranty.

NOTICE

• 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.

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NOTES FOR SAFE OPERATION

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”.

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 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.

WARNING 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.

CAUTION

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 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.

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

to follow all instructions, even if not designated as “DAN-

GER”, “WARNING” and “CAUTION".

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DANGER

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

turned OFF by performing the following operations. When the servo

power is turned OFF, the SERVO ON LED on the programming

pendant is turned OFF.

– Press the emergency stop buttons on the front door of the

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

TURN

• 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 the

safety fence when going into the area enclosed by the safety

fence. In addition, the operator of the teaching operation must

display the sign that the operation is being performed so that no

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 power

– Moving the manipulator by using the programming pendant

– Running the system in the check mode

– 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.

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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.

WARNING

• Perform the following inspection procedures prior to conducting

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.

Equipment Manual Designation

YRC1000 controller YRC1000

YRC1000 programming pendant Programming pendant

Cable between the manipulator and the

controller

Manipulator cable

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

shown as follows:

Equipment Manual Designation

Programming

Pendant

Character Keys

/Symbol Keys

The keys which have characters or symbols

printed on them are denoted with [ ].

e.g. [ENTER]

Axis Keys

/Numeric Keys

[Axis Key] and [Numeric Key] 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]+[COORD].

Mode Switch Mode Switch can select three kinds of modes

that are denoted as follows: REMOTE, PLAY or

TEACH.

(The switch names are denoted as symbols)

Button The three buttons on the upper side of the

programming pendant are denoted as follows:

START, HOLD, or EMERGENCY STOP.

(The button names are denoted as symbols)

Displays The menu displayed in the programming

pendant is denoted with { }.

e.g. {JOB}

Numeric keys

Axis keys

Enter key

Mode switch*

Start button* Hold button*

Emergency stop button

Shift key

Page key

Coordinate key

PLAY

REMOTE

TEACH

START

*The button/switch names

are denoted as symbols.

HOLD

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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.

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Contents

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HW1485704

1 Outline of Arc Welding Diagnosis Function.....................................................................................1-1

1.1 Function Outline.................................................................................................................1-1

2 Operation Outline............................................................................................................................ 2-1

2.1 Operation Process of Arc Welding Diagnosis Function .....................................................2-1

2.1.1 JOB Setting...........................................................................................................2-1

2.1.2 Data Setting for Arc Welding Diagnosis................................................................2-3

2.1.3 Displaying / Non-displaying Arc Weld Diagnosis Window ....................................2-5

2.2 Preparation for Arc Weld Diagnosis Window .....................................................................2-6

2.2.1 Diagnosis Mode Setting........................................................................................2-7

3 Operating Arc Weld Diagnosis Window ..........................................................................................3-1

3.1 Selection of JOB ................................................................................................................3-1

3.2 Selection of Bead Number.................................................................................................3-2

3.3 Setting of Threshold for Determining Error ........................................................................3-3

3.4 Setting of Error Output Mode and Signal Number .............................................................3-4

3.5 Setting of Standard Current and Standard Voltage ...........................................................3-5

3.6 Changing of Standard Current and Standard Voltage .......................................................3-7

3.7 Enable/Disable of Diagnosis.............................................................................................. 3-9

4 Saving of Arc Welding Diagnosis Data ...........................................................................................4-1

4.1 Saving of Arc Welding Diagnosis Data ..............................................................................4-1

4.2 Setting for Saving of Arc Welding Diagnosis Data (Automatic) .........................................4-1

4.3 Setting for Saving of Arc Welding Diagnosis Data (Manual)..............................................4-6

4.4 Retry Saving of Data..........................................................................................................4-7

5 Saving Format of Arc Welding Diagnosis Data ...............................................................................5-1

5.1 Saving Data .......................................................................................................................5-1

6 Concurrent I/O Ladder ....................................................................................................................6-1

6.1 Specific Input Signal ..........................................................................................................6-1

6.2 Specific Output Signal........................................................................................................6-1

7 Parameter .......................................................................................................................................7-1

7.1 SC Parameter ....................................................................................................................7-1

7.2 AP Parameter ....................................................................................................................7-2

8 Alarm / Error / Inform.......................................................................................................................8-1

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Contents

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8.1 Alarm List........................................................................................................................... 8-1

8.2 Error Dialogue List ............................................................................................................. 8-1

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1 Outline of Arc Welding Diagnosis Function

1.1 Function Outline

1-1

HW1485704

1 Outline of Arc Welding Diagnosis Function

1.1 Function Outline

This function diagnoses if the welding bead is normal or abnormal based

on the data such as welding current waveforms or welding voltage

waveforms. Notifying the error welding position can prevent a defective

product flowing to the post process, or can indicate the place to adjust at

the adjusting process.

Score mode

Score mode will comprehensively diagnose if the welding bead is normal

or abnormal based on the data from welding current waveforms or welding

voltage waveforms.

Current out-of-range mode

Current out-of range will diagnose if the welding bead is normal or

abnormal based on the differences between the welding current command

value and the effective value.

NOTE The arc welding diagnosis function is not a function to

ensure product quality.

NOTE

The arc welding diagnosis function will determine if the

welding bead is normal or abnormal based on the data such

as welding current waveforms. A normal or abnormal diag-

nosis may be unable to be determined depending on weld-

ing conditions or usage environment. In addition, if tack

welding or welding time is short (less than 2 seconds),

diagnosis will not be possible because the variation in

scores will increase. It can not be used together with

COMARC.

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