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1、YASKAWA YASKAWAMANUAL NO. RE-CSO-A038 DX100 OPERATORS MANUAL FOR ARC WELDING Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN-? INSTRUCTIONS DX100 INSTRUCTIONS DX100 OPERATORS MANUAL DX100 MA
2、INTENANCE MANUAL The DX100 operators manuals above correspond to specific usage. Be sure to use the appropriate manual. DX100 ii MANDATORY This manual explains the various components of the DX100 system and general operations. Read this manual carefully and be sure to understand its contents before
3、handling the DX100. General items related to safety are listed in Section 1: Safety of the DX100 Instructions. To ensure correct and safe operation, carefully read the DX100 Instruction before reading this manual. CAUTION Some drawings in this manual are shown with the protective covers or shields r
4、emoved 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 produ
5、ct 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 t
6、he 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 products warranty. DX100 iii Notes for Safe Operation Read this manual carefully before installation, o
7、peration, maintenance, or inspection of the DX100. In this manual, the Notes for Safe Operation are classified as “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
8、items. 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 als
9、o 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 “CAU- TION” and
10、“WARNING.” DX100 iv WARNING Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the front door of the DX 100 and programing pendant are pressed. When the servo power is turned off, the SERVO ON LED on the programing pendant is turned off. Injury
11、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 Once the emergency stop button is released, clear the cell of all items whic
12、h 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 EM TURN Observe the following precautions when performing teaching operations within the P-point maximum envelope of the man
13、ipulator: View the manipulator from the front whenever possible. Always follow the predetermined operating procedure. 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 P-point
14、 maximum envelope of the manipulator and that you are in a safe location before: Turning on the power for the DX100. Moving the manipulator with the programming pendant. Running the system in the check mode. Performing automatic operations. Injury may result if anyone enters the working envelope of
15、the manipulator during operation. Always press an emergency stop button immediately if there are problems. The emergency stop button is located on the right of the front door of the DX 100 and programing pendant. DX100 v Definition of Terms Used Often in This Manual The MOTOMAN is the YASKAWA indust
16、rial 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. CAUTION Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found
17、, 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 cabinet of the DX100 after use. The prog
18、ramming pendant can be damaged if it is left in the manipulators work area, on the floor, or near fixtures. Read and understand the Explanation of Warning Labels in the DX100 Instructions before operating the manipulator. EquipmentManual Designation DX100 controllerDX100 DX100 programming pendantPro
19、gramming pendant Cable between the manipulator and the controller Manipulator cable DX100 vi Descriptions of the programming pendant keys, buttons, and displays are shown as follows: Description of the Operation Procedure In the explanation of the operation procedure, the expression “Select “ means
20、that the cursor is moved to the object item and the SELECT key 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 corpor
21、ation. The indications of (R) and TM are omitted. EquipmentManual Designation Programming Pendant Character KeysThe keys which have characters printed on them are denoted with . ex. ENTER Symbol KeysThe keys which have a symbol printed on them are not denoted with but depicted with a small picture.
22、ex. 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 “+”
23、 sign between them, ex. SHIFT+COORD DisplaysThe menu displayed in the programming pendant is denoted with . ex. JOB PAGE GO BACK PAGE GO BACK PAGE GO BACK DX100Contents vii 1 Introduction.1-1 1.1 DX100 Overview1-1 1.2 Programming Pendant.1-2 1.2.1 Programming Pendant Overview1-2 1.2.2 Key Descriptio
24、n 1-3 1.2.2.1 Character Keys .1-3 1.2.2.2 Symbol Keys .1-3 1.2.2.3 Axis Keys and Numeric Keys1-3 1.2.2.4 Keys Pressed Simultaneously.1-3 1.2.3 Programming Pendant Keys.1-4 1.2.4 Programming Pendant Display.1-11 1.2.4.1 Five Display Areas 1-11 1.2.4.2 General-purpose Display Area1-12 1.2.4.3 Main Men
25、u Area1-13 1.2.4.4 Status Display Area.1-13 1.2.4.5 Human Interface Display Area 1-16 1.2.4.6 Menu Area.1-16 1.2.5 Screen Descriptions .1-17 1.2.6 Character Input Operation1-18 1.2.6.1 Character Input .1-18 1.2.6.2 Operation 1-18 1.2.6.3 Alphanumeric Input .1-19 1.2.6.4 Symbol Input .1-20 1.3 Mode1-
26、21 1.3.1 Teach Mode .1-21 1.3.2 Play Mode 1-21 1.3.3 Remote Mode.1-21 1.3.4 Teach Mode Priority .1-21 1.4 Security Mode1-22 1.4.1 Types of Security Modes1-22 1.4.2 Changing Security Modes 1-26 2 Manipulator Coordinate Systems and Operations2-1 2.1 Control Groups and Coordinate Systems2-1 2.1.1 Contr
27、ol Group.2-1 2.1.2 Types of Coordinate Systems 2-2 2.2 General Operations .2-3 2.2.0.1 Check Safety.2-3 2.2.0.2 Select Teach Mode .2-3 DX100Contents viii 2.2.0.3 Select Control Group.2-3 2.2.0.4 Select Coordinate System.2-3 2.2.0.5 Select Manual Speed 2-4 2.2.0.6 Servo ON.2-4 2.2.0.7 Axis Operation.
28、2-4 2.2.0.8 HIGH SPEED 2-4 2.3 Coordinate Systems and Axis Operation.2-5 2.3.1 Joint Coordinates2-5 2.3.2 Cartesian Coordinates2-6 2.3.3 Cylindrical Coordinates.2-7 2.3.4 Tool Coordinates 2-9 2.3.4.1 Selecting Tool2-11 2.3.5 User Coordinates2-12 2.3.5.1 Selecting User Coordinates.2-13 2.3.5.2 Exampl
29、es of User Coordinate Utilization.2-14 2.3.6 External Axis.2-14 2.3.7 Control Point Operation2-15 2.3.7.1 Control Point Change2-18 3 Teaching .3-1 3.1 Preparation for Teaching .3-1 3.1.1 Checking Emergency Stop Buttons3-1 3.1.2 Setting the Teach Lock.3-1 3.1.3 Registering a Job3-2 3.1.3.1 Registerin
30、g Job Names.3-2 3.1.3.2 Registering Jobs3-2 3.1.3.3 Registering Comments3-3 3.1.3.4 Registering Control Groups.3-3 3.1.3.5 Switching to the Teaching Window3-4 3.2 Teaching Operation .3-5 3.2.1 Teaching Window.3-5 3.2.2 Interpolation Type and Play Speed.3-6 3.2.2.1 Joint Interpolation3-6 3.2.2.2 Line
31、ar Interpolation3-7 3.2.2.3 Circular Interpolation .3-8 3.2.2.4 Spline Interpolation3-9 3.2.3 Teaching Steps.3-11 3.2.3.1 Registering Move Instructions.3-11 3.2.3.2 Registering Reference Point Instructions3-17 3.2.3.3 Registering Timer Instructions.3-18 3.2.4 Overlapping the First and Last Steps .3-
32、21 DX100Contents ix 3.3 Checking Steps3-22 3.3.1 FWD/BWD Key Operations3-22 3.3.1.1 Precautions When Using FWD / BWD Operations3-23 3.3.1.2 Selecting Manual Speed .3-25 3.3.1.3 Moving to Reference Point3-26 3.3.1.4 Test Operations.3-26 3.3.1.5 Machine Lock Operation .3-27 3.4 Modifying Steps.3-28 3.
33、4.1 Displaying the JOB CONTENT Window for Editing3-32 3.4.1.1 Currently Called Up Job3-32 3.4.1.2 Calling Up Other Jobs.3-32 3.4.2 Inserting Move Instructions.3-33 3.4.3 Deleting Move Instructions.3-35 3.4.4 Modifying Move Instructions.3-36 3.4.4.1 Modifying Position Data.3-36 3.4.4.2 Modifying Inte
34、rpolation Type.3-36 3.4.5 Undo Operation3-37 3.4.6 Modifying Reference Point Instructions3-38 3.4.6.1 Deleting Reference Point Instructions.3-38 3.4.6.2 Modifying Reference Point Instructions.3-38 3.4.7 Modifying Timer Instructions.3-39 3.4.7.1 Deleting Timer Instructions3-39 3.4.7.2 Modifying Timer
35、 Instructions .3-39 3.5 Modifying Jobs.3-40 3.5.1 Calling Up a Job.3-40 3.5.2 Windows Related to Job.3-40 3.5.3 JOB HEADER Window.3-41 3.5.4 JOB CONTENT Window 3-42 3.5.4.1 COMMAND POSITION Window .3-43 3.5.5 JOB CAPACITY Window3-44 3.6 Editing Instructions 3-45 3.6.1 Instruction Group3-46 3.6.2 Ins
36、erting Instructions 3-47 3.6.3 Deleting Instructions.3-50 3.6.4 Modifying Instructions.3-50 3.6.5 Modifying Additional Numeric Data 3-54 3.6.6 Modifying Additional Items3-55 3.6.7 Inserting Additional Items.3-56 DX100Contents x 3.6.8 Deleting Additional Items3-57 3.7 Editing Jobs .3-58 3.7.1 Selecti
37、ng the Range .3-60 3.7.2 Copying 3-61 3.7.3 Cutting 3-61 3.7.4 Pasting3-62 3.7.5 Reverse Pasting .3-63 3.8 Test Operations .3-64 3.8.1 Test Operation Procedures.3-64 3.9 Other Job-editing Functions.3-65 3.9.1 Editing Play Speed .3-65 3.9.1.1 Modification of Speed Type.3-65 3.9.1.2 Relative Modificat
38、ion .3-65 3.9.1.3 Modification by TRT (Traverse Time)3-67 3.9.2 Editing Interpolation Type.3-69 3.9.3 Editing Condition Files3-70 3.9.4 User Variables3-71 3.9.4.1 Setting Byte, Integer, Double Precision Integer, and Real Type Variables.3-72 3.9.4.2 Setting Character Type Variables3-74 3.9.4.3 Regist
39、ering Variable Name3-75 3.9.4.4 Displaying Position Variables3-76 3.9.4.5 Setting Position Variables3-77 3.9.4.6 Setting Position Variables Using the Numeric Keys3-78 3.9.4.7 Setting Position Variables Using the Axis Keys.3-80 3.9.4.8 Deleting Data Set of Position Variables.3-81 3.9.4.9 Checking Pos
40、itions by Position Variables .3-81 3.9.4.10 Manipulator Types.3-82 3.9.5 Flip/No Flip3-83 3.9.6 R-axis Angle .3-83 3.9.7 T-axis Angle3-84 3.9.8 Front/Back 3-84 3.9.9 Upper Arm/Lower Arm3-86 3.9.10 S-axis Angle3-86 3.9.11 Editing Local Variables.3-87 3.9.11.1 Setting the Number of Local Variables3-89
41、 3.9.12 Search 3-90 3.9.12.1 Line Search .3-91 3.9.12.2 Step Search.3-92 3.9.12.3 Label Search .3-93 DX100Contents xi 3.9.12.4 Instruction Search .3-95 3.9.12.5 Tag Search3-97 4 Playback .4-1 4.1 Preparation for Playback .4-1 4.1.1 Selecting a Job.4-1 4.1.1.1 Calling a Job .4-1 4.1.1.2 Registering t
42、he Master Job .4-2 4.1.1.3 Calling the Master Job.4-4 4.1.2 The PLAYBACK Window4-6 4.1.2.1 Display of Cycle Time4-6 4.1.2.2 Operation Cycle 4-7 4.2 Playback4-10 4.2.1 Playback Operation4-10 4.2.1.1 Selecting the Start Device.4-10 4.2.1.2 Servo On.4-10 4.2.1.3 Start Operation4-10 4.2.2 Special Playba
43、ck Operations4-11 4.2.2.1 Low Speed Operation .4-11 4.2.2.2 Limited Speed Operations.4-12 4.2.2.3 Dry-run Speed Operations 4-12 4.2.2.4 Machine Lock Operation .4-13 4.2.2.5 Check Mode Operation .4-13 4.2.2.6 Weaving Prohibit Setting during Check Mode Operation4-13 4.2.2.7 Cancel All Special Operatio
44、ns.4-14 4.3 Stop and Restart4-15 4.3.1 Hold4-15 4.3.1.1 Using the Programming Pendant4-15 4.3.1.2 Using an External Input Signal (System Input)4-15 4.3.2 Emergency Stop.4-16 4.3.2.1 Restart After Emergency Stop.4-17 4.3.3 Stop by Alarm.4-18 4.3.4 Others.4-19 4.3.4.1 Temporary Stop by Mode Change4-19
45、 4.3.4.2 Temporary Stop by the PAUSE Instruction.4-19 4.4 Modifying Play Speed4-20 4.4.1 Speed Override 4-20 4.4.1.1 Setting Speed Overrides.4-21 4.4.1.2 Modifying Play Speed .4-22 4.4.1.3 Cancelling Speed Override Settings .4-22 4.5 Playback with Reserved Start4-23 DX100Contents xii 4.5.1 Preparati
46、on for Reserved Start.4-23 4.5.1.1 Enabling Reserved Start4-24 4.5.1.2 Registering Reserved Start I/O Signal.4-26 4.5.1.3 Registering Jobs to Stations4-28 4.5.1.4 Deleting Registered Jobs from Stations4-30 4.5.2 Playback from Reserved Start4-31 4.5.2.1 Start Operation4-31 4.5.2.2 Checking Job Reserv
47、ation Status .4-32 4.5.2.3 Resetting Job Reservation 4-33 4.5.3 Hold Operation4-34 4.5.3.1 HOLD on the Programming Pendant.4-34 4.5.3.2 Hold by External Input Signal (System Input)4-34 4.5.3.3 Hold at the Station.4-35 4.6 Displaying Job Stack4-36 5 Editing Jobs.5-1 5.1 Copying Jobs.5-2 5.1.0.1 Copyi
48、ng Jobs on the JOB CONTENT Window5-2 5.1.0.2 Copying Jobs on the JOB LIST Window .5-4 5.2 Deleting Jobs.5-6 5.2.0.1 Deleting Jobs on the JOB CONTENT Window5-6 5.2.0.2 Deleting Jobs on the JOB LIST Window .5-7 5.3 Modifying Job Names 5-8 5.3.0.1 Modifying Job Names on the JOB CONTENT Window.5-8 5.3.0.2 Modifying Job Names on the JOB LIST Window.5-10 5.4 Editing Comments5-12 5.5 Setting Edit Lock on Individual Job Units.5-14 5.6 Enabling the Modification of Position Data Only5-15 6 Convenient Functions .6-1 6.1 One-touch Operation “Direct Open”.6-1 6.2 Parallel