OWNER'S MANUAL
Before using the “YP-X” series robot (Be sure to read the following notes.) At this time, our thanks for your purchase of this YAMAHA “YP-X” series robot. The “YP-X” series robot use absolute position detectors that do not require return-to-origin after turning on the controller power. However, when the controller power is turned on in the following cases, return-to-origin must be performed just the very first time. (1) When robot cable was first connected after delivery from YAMAHA.
[2] R axis On the above robots, the customer should set the origin at the desired position. Move the robot to the desired position and set it as the origin while referring to the following section in the robot controller instruction manual. When using DRCX or TRCX controllers: See “9-1-1 Return-to-origin by the search method” in Chapter 9. When using a QRCX controller: See “11-9 Absolute Reset” in Chapter 11.
Introduction Our sincere thanks for your purchase of this YAMAHA robot and controller. The YP-X Series were designed and developed as compact and highspeed Pick and Place (P&P) robots. This manual contains important information on items such as an overview, handling, adjustment, and service of YP-X Series robots to ensure correct and efficient use. Please be sure to read this manual before installing the equipment.
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CONTENTS CHAPTER 1 Using the Robot Safely 1 2 3 4 5 6 7 8 9 10 11 12 13 CHAPTER 2 Functions 1 2 CHAPTER 3 Safety Information................................................... 1-1 Essential Caution Items ........................................... 1-2 Special Training for Industrial Robot Operation ...... 1-8 Robot Safety Functions ............................................ 1-9 Safety Measures for the System ............................. 1-10 Trial Operation ..........................................
CHAPTER 4 Adjustment 1 Outline .................................................................... 4-1 1-1 2 Setting the origin position ....................................... 4-3 2-1 2-2 3 Mark method (R-axis) ..................................................................... 4-4 Stroke end method (X, Z, Y axes) ................................................... 4-5 Adjustment of the belt tension ................................ 4-6 3-1 3-2 3-3 3-4 CHAPTER 5 Robot parameter settings ........
CHAPTER 6 Specifications 1 P & P robot unit....................................................... 6-1 1-1 1-2 1-3 1-4 2 R axis allowable moment/inertia moment ............. 6-18 2-1 2-2 2-3 3 4 5 6 Basic specifications ........................................................................ 6-1 Robot External Views ..................................................................... 6-2 Table of robot control signals .........................................................
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CHAPTER 1 Using the Robot Safely 1 2 3 4 5 6 7 8 9 10 11 12 13 Safety Information ......................................... 1-1 Essential Caution Items .................................. 1-2 Special Training for Industrial Robot Operation .... 1-8 Robot Safety Functions .................................. 1-9 Safety Measures for the System ................... 1-10 Trial Operation ............................................ 1-11 Work Within The Safeguards ....................... 1-12 Automatic Operation ..
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CHAPTER 1 Using the Robot Safely 1 Safety Information Industrial robots are highly programmable, mechanical devices that provide a large degree of freedom when performing various manipulative tasks. To ensure correct and safe use of YAMAHA industrial robots, carefully read this manual and make yourself well acquainted with the contents. FOLLOW THE WARNINGS, CAUTIONS AND INSTRUCTIONS INCLUDED IN THIS MANUAL.
CHAPTER 1 Using the Robot Safely 2 Essential Caution Items Particularly important cautions for handling or operating the robot are described below. In addition, safety information about installation, operation, inspection and maintenance is provided in each chapter. Be sure to comply with these instructions to ensure safe use of the robot. (1) Observe the following cautions during automatic operation. Warning labels 1 (Fig. 1-1) are affixed to the robot.
CHAPTER 1 Using the Robot Safely (3) Follow the instructions on warning labels and in this manual. Warning label 3 (see Fig. 1-3) is supplied with the robot and should be affixed to the robot or a conspicuous spot near the robot. • Be sure to read the warning label and this manual carefully and make your thoroughly understand the contents before attempting installation and operation of the robot.
CHAPTER 1 Using the Robot Safely (4) Do not use the robot in environments containing inflammable gas, etc. WARNING • This robot was not designed for operation in environments where inflammable or explosive substances are present. • Do not use the robot in environments containing inflammable gas, dust or liquids. Explosions or fire could otherwise result. (5) Do not use the robot in locations possibly subject to electromagnetic interference, etc.
CHAPTER 1 Using the Robot Safely (8) Use the following caution items when removing the Z-axis motor. WARNING The Z-axis will drop when the Z-axis motor is removed, possibly resulting in injury. • Turn off the controller and set a support stand under the Z-axis before removing the motor. • Use caution not to allow hands or body to be squeezed or crushed by moving parts on the Z-axis or between the Z-axis and the installation base. (9) Use the following caution during inspection of controller.
CHAPTER 1 Using the Robot Safely (11) Use caution not to touch the cooling fan on the controller rear panel. WARNING • Bodily injury may occur from coming into contact with the cooling fan while it is rotating. • When removing the fan cover for inspection, first turn off the controller and make sure the fan has stopped. (12) Use caution not to touch the high temperature part of the motor. WARNING The motor is extremely hot after automatic operation, so burns may occur if it is touched.
CHAPTER 1 Using the Robot Safely (15) Be sure to make correct parameter settings. ! CAUTION The robot must be operated with correct tolerable moment of inertia and acceleration coefficients according to the manipulator tip mass and moment of inertia. If this is not observed, premature end to the life of the drive units, damage to the robot parts or residual vibration during positioning may result. (16) Do not use the robot for tasks requiring motor thrust.
CHAPTER 1 Using the Robot Safely 3 Special Training for Industrial Robot Operation Companies or factories using industrial robots must make sure that every person, who handles the robot such as for teaching, programming, movement check, inspection, adjustment and repair, has received appropriate training and also has the skills needed to perform the job correctly and safely.
CHAPTER 1 Using the Robot Safely 4 Robot Safety Functions (1) Overload detection This function detects an overload applied to the motor and shuts off the servo power. (2) Overheat detection This detects an abnormal temperature rise in the controller’s driver and shuts off the servo power. If an overload or overheat error occurs, take the following measures. 1. Insert a timer in the program. 2. Reduce the acceleration coefficient.
CHAPTER 1 Using the Robot Safely 5 Safety Measures for the System Since the robot is commonly used in conjunction with an automated system, a dangerous situation is more likely to occur from the automated system than from the robot itself. Accordingly, appropriate safety measures must be taken on the part of the system manufacturer according to the individual system. The system manufacturer should provide a proper instruction manual for safe, correct operation and servicing of the system.
CHAPTER 1 Using the Robot Safely 6 Trial Operation After installation, adjustment, inspection, maintenance or repair of the robot has been done, perform a trial operation using the following procedures. (1) If a safeguard has not yet been provided right after installation of the robot, rope off or chain off around the movement area of the manipulator in place of the safeguard, and observe the following points. q Use stable posts which do not totter easily.
CHAPTER 1 Using the Robot Safely 7 Work Within The Safeguards (1) When work is required inside the safeguard enclosure, always turn off the controller and place a sign indicating that the robot is being adjusted or serviced in order to keep any other person from inadvertently touching the controller switch or operation panel, except for the following cases. 1) Soft limit settings 2) Teaching For items 1), follow the precautions and procedure for each section.
CHAPTER 1 Using the Robot Safely 8 Automatic Operation Automatic operation described here includes all operations in AUTO mode. (1) Check the following before starting automatic operation. q No one is within the safeguard enclosure. w The programming unit and tools are in their specified locations. e The alarm or error lamps on the robot and peripheral equipment do not flash. r The safeguard is securely installed with safety interlocks actuated.
CHAPTER 1 Using the Robot Safely 11 Warranty The YAMAHA robot and/or related product you have purchased are warranted against the defects or malfunctions as described below. Warranty description : If a failure or breakdown occurs due to defects in materials or workmanship in the genuine parts constituting this YAMAHA robot and/or related product within the warranty period, then YAMAHA will repair or replace those parts free of charge (hereafter called "warranty repair").
CHAPTER 1 Using the Robot Safely YAMAHA MOTOR CO., LTD. MAKES NO OTHER EXPRESS OR IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS IN LIEU OF ALL EXPRESSED OR IMPLIED WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR WARRANTIES ARISING FROM A COURSE OF DEALING OR USAGE OF TRADE. YAMAHA MOTOR CO., LTD.
CHAPTER 1 Using the Robot Safely 13 Precautions 1) Accuracy may deteriorate due to external causes such as temperature and humidity and may result in equipment breakdowns. Use of the robot in airconditioned facilities is recommended. Do not use in environments exposed to items such as oil, water, corrosive gases and metal powder etc. 2) When using the robot after an extended period of non-use, warmup the robot for about a 10 minute period with no workpiece installed.
CHAPTER 2 Functions 1 2 P & P robot unit ............................................. 2-1 P & P robot controller....................................
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CHAPTER 2 Functions 1 P & P robot unit The YP320X and YP220BX each have 2 axes: X and Z. The YP330X has 3 axes: X, Y and Z. The YP320XR and YP220BXR have 3 axes: X, Z and R. The YP340X has 4 axes: X, Y, Z and R. They move along the axes as shown in Fig. 2-1 and by adding custom tools, can perform work over a wide range with high accuracy and speed. These robots are ideal for high speed pick and place operations using small parts. X Z (YP320X) X Z Y (YP340X) Fig.
CHAPTER 2 Functions 2 P & P robot controller The YP-X series robots use the QRCX, TRCX, DRCX as their robot controllers. Please refer to the "YAMAHA Robot Controller QRCX, TRCX, DRCX Instruction and Owner's Manual" for detailed information on each robot controller. NOTE The “Y” displayed on the programming unit of the YP320X and YP220BX refers to the robot main unit axis (vertical movement). If data is input to “Y”, the Z axis will move.
CHAPTER 3 Installation 1 Robot Installation Conditions ........................ 3-1 1-1 2 Installation ..................................................... 3-3 2-1 2-2 3 4 Installation environments ................................................ 3-1 Installation frame ............................................................ 3-3 Installing the robot .......................................................... 3-4 Connection of robot cables............................ 3-7 Protective Bonding ......
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CHAPTER 3 Installation 1 Robot Installation Conditions 1-1 Installation environments Be sure to install the robot in the following environments. Items Specifications Allowable ambient temperature 0 to 40°C Allowable ambient humidity 35 to 85% RH (non condensation) Height 0 to 1000 meters above sea level Ambient environments Avoid installing near water, cutting water, oil, dust, metallic chips and organic solvent. Avoid installation near corrosive gas and corrosive materials.
CHAPTER 3 Installation WARNING Do not use the robot in locations subject to excessive vibration. Robot installation bolts may otherwise become loose causing the manipulator to fall over.
CHAPTER 3 Installation 2 Installation Strictly observe all safety precautions and procedures inorder to install the robot correctly and safely. 2-1 Installation frame 1) Prepare a strong, rigid installation frame to absorb large reactive forces that occur during robot operation. ! CAUTION Vibration (resonance) may adversely affect robot operation if this frame is not rigid. 2) The levelness and parallelism of the robot installation surface on the frame must be manufactured to within a precision of ±0.
CHAPTER 3 Installation Installing the robot (1) YP320X, YP320XR installation Eight M8 screw holes (pitch 1.25 mm) are provided in the base section of the YP320X and YP320XR unit. Use four of these holes for the installation. ! CAUTION The plate thickness of the base is 20 mm so make sure the bolts do not exceed this distance and protrude into the robot interior. 1) Drill holes (approx. 10 dia.) into the frame installation surface as shown.
CHAPTER 3 Installation (2) YP330X, YP340X installation Eight M8 screw holes (pitch 1.25 mm) are provided in the base section of the YP330X and YP340X units. Use four of these holes for the installation. ! CAUTION The plate thickness of the base is 20 mm so make sure the bolts do not exceed this distance and protrude into the robot interior. 1) Drill holes (approx. 10 dia.) into the frame installation surface as shown. 2) Tighten with a hex head bolts from the rear side of the frame through the holes.
CHAPTER 3 Installation (3) YP220BX, YP220BXR Four through-holes of 10mm diameter are provided on the bottom plate of the YP220BX and YP220BXR robots. Use these through-holes and M8 bolts when installing these robots. 1) Tap four M8 (thread pitch 1.25mm) holes into the installation base. 2) Secure the robot to the base with M8 hex socket head bolts (tightening torque: 230 to 370kgcm) from inside of the robot frame. 20 YAMAHA 510 10 67 4-φ10 89 11 490 Fig.
CHAPTER 3 Installation 3 Connection of robot cables The robot cables are already attached to the YP-X series robot side. Refer to the "YAMAHA Robot Controller DRCX, TRCX or QRCX Instruction and Owner's Manuals" for connecting to the controller side. M1 M2 X MO CN Y MO CN M1 1 XY DRIVER P1 1 2 2 M2 ZR DRIVER P1 1 2 Z MO CN R MO CN XY PI CN ZR PI CN Fig.
CHAPTER 3 Installation DRCX Robot Cable YP320X Fig.
CHAPTER 3 Installation 4 Protective Bonding WARNING Be sure to ground the robot and controller to prevent electrical shock. WARNING Turn off the controller before grounding the robot. The robot must be grounded as follows: 1) Provide a terminal marked “PE” for the protective conductor of the entire system and connect it to an external protective conductor. In addition, securely connect the ground terminal on the robot to the same protective conductor.
CHAPTER 3 Installation WARNING • Before connecting the cables, check that there are no bends or breaks in the connector pins of the robot cable and that the cables are not damaged. Bent or broken pins or cable damage may cause malfunction of the robot. • Ensure that the controller is off before connecting the robot cable to the controller. WARNING In the QRCX controllers, the MOTOR connectors XM and ZM, and YM and RM each have identical shapes.
CHAPTER 4 Adjustment 1 Outline .......................................................... 4-1 1-1 2 Setting the origin position .............................. 4-3 2-1 2-2 3 Robot parameter settings ................................................. 4-2 Mark method (R-axis) ...................................................... 4-4 Stroke end method (X, Z, Y axes) .................................... 4-5 Adjustment of the belt tension .......................
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CHAPTER 4 Installation 1 Outline Various adjustments, including the origin adjustment, have been completely performed by YAMAHA or the dealer at shipment. If the usage conditions are changed (changes of tools such as the hand) and the P & P robot must be adjusted for this, follow the procedure given in this chapter. ! DANGER • If the adjustment or maintenance procedure calls for operation of the robot, stay out of the working area of the manipulator while it is operating.
CHAPTER 4 Installation 1-1 Robot parameter settings Please take note of the following points when setting parameter data on the robots. (Refer to the DRCX, TRCX or QRCX controller instruction manual.) • Do not set the plus and minus software limits larger than the default settings (operating range as listed in the specifications). This could cause the axis to strike the mechanical stopper and upset the alignment. • Always be sure to make the payload settings.
CHAPTER 4 Installation 2 Setting the origin position All models of the YP-X series use a position detector for absolute reset. The origin position (“0” pulse position) is set by performing absolute reset. Once absolute reset is performed, it is not needed when the power is turned on again. However, absolute reset is required in the following cases. Be especially sure to perform absolute reset for the case of “c” below when the robot has been shipped from the factory.
CHAPTER 4 Installation The mark method or the stroke end method can be used to perform absolute reset for the YP-X series. The mark method is used for the R-axis default setting and the stroke end method is used for the X, Y and Z axis default settings. 2-1 Mark method (R-axis) In the mark method, the robot is moved beforehand to the position where you want to perform absolute reset. That position will be the absolute reset position. (1) Move the robot in jog mode while in servo-on.
CHAPTER 4 Installation 2-2 Stroke end method (X, Z, Y axes) In absolute reset by the stroke end method, the position where the axis tip strikes the mechanical stopper is detected, and absolute reset performed at a position backed off slightly from the stroke end. WARNING Making physical contact with the robot during operation can cause severe injuries. Never enter within the movement range of the robot during absolute reset. ! CAUTION The stroke end method is used for the X, Z and Y axes.
CHAPTER 4 Installation 3 Adjustment of the belt tension Each axis of the YP-X series robots has a belt-driven structure. When this belt is replaced or when it is stretched due to strong external forces (bumping etc.), adjust the belt tension with the following procedure. 3-1 Adjustment of X,Y, Z axis motor belt tension 1) Turn off the controller power. 2) Remove the cover for each axis. 3) Loosen the bolts securing each motor and apply tension to the belt by pulling on the motor.
CHAPTER 4 Installation 3-2 Adjustment of Z axis tip belt tension (YP320X, YP320XR, YP330X, YP340X) 1) Turn off the controller power. 2) Remove the robot Z axis cover. 3) Loosen the bolt securing the belt tensioner as shown in Fig. 4-3 and loosen the belt. 4) Insert a slotted screwdriver into the clearance between the X axis plate and the belt tensioner, and then lever the screwdriver to apply tension to the belt. 5) Apply a load of 0.5 kgf to the center section of the belt for fixing the belt tension.
CHAPTER 4 Installation 3-3 Adjustment of Z axis tip belt tension (YP220BX, YP220BXR) 1) Turn off the controller power. 2) Remove the robot Z axis cover. 3) Loosen the bolt securing the belt tensioner as shown in Fig. 4-4 and loosen the belt. 4) Screw the M6 bolt into the hole located beneath the belt tensioner (L-shaped metal plate) to apply tension to the belt. 5) Apply a load of 0.5 kgf to the center section of the belt for fixing the belt tension. A slack of approximately 2mm is satisfactory.
CHAPTER 4 Installation 3-4 Adjust the X-axis belt tension (YP220BX, YP220BXR) 1) 2) 3) 4) Turn off the controller power. Remove the side cover on the robot unit. Loosen the bolts securing the driven pulley shown in Fig. 4-5. Loosen the belt tensioner (L-shaped metal plate) M5 bolts and apply tension to the belt. 5) As a guide for setting belt tension, check a slack in the belt of about 5mm when a 1kg load is applied to the center of the belt.
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CHAPTER 5 Periodic Inspecition 1 2 Introduction .................................................. 5-1 Inspection ...................................................... 5-3 2-1 2-2 3 Replacement of Motor ................................... 5-5 3-1 3-2 3-3 4 Replacement of X, Y, Z axis motors (YP320X, YP330X, YP340X, YP320XR) ........................... 5-5 Replacement of X and Z axis motor (YP220BX, YP220BXR) ...................................................
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CHAPTER 5 Installation 1 Introduction Periodic inspections and maintenance are extremely important in assuring that the YAMAHA robot will perform safely and efficiently. This chapter covers the procedures by which periodic inspections of the YAMAHA YP-X Series are carried out, as well as the items to be inspected and information on maintenance. ! DANGER • If the adjustment or maintenance procedure calls for operation of the robot, stay out of the working area of the manipulator while it is operating.
CHAPTER 5 Installation WARNING Precautions when handling grease: • Inflammation may occur if they get in the eyes. Before handling them, wear your safety goggles to ensure they will not come in contact with the eyes. • Inflammation may occur if they come into contact with skin. Be sure to wear protective gloves to prevent contact with skin. • Do not take orally or eat. (Eating will cause diarrhea and vomiting.) • Hands and fingers might be cut when opening the container, so use protective gloves.
CHAPTER 5 Installation 2 Inspection 2-1 Daily Checklist The following is a list of maintenance operations that must be performed every day before and after operating the robot. CHECK POINT PROCEDURE Cables Check for scratches, dents, holes and kinks. Motor, Encoder, Deceleration, Check for excessive vibration, noise and, overheating, etc. Ball screw, Bearing Remove all dirt and dust, and apply a thin coat of grease. (X axis) Use Alvania No.
CHAPTER 5 Installation 2-2 Six Month Inspection Inspect the following for the six month inspection, and replace parts if necessary. Inspection or replacement details Inspection or replacement place Main bolts and screws on the P & P Check for looseness. If loose, tighten. robot Check the X, Y, and Z axis timing belts for tension, X, Y and Z axis timing belt scratches and wear.
CHAPTER 5 Installation 3 Replacement of Motor Replace the motor if it generates abnormal sounds or vibrations, causes errors or cannot be positioned correctly.
CHAPTER 5 Installation Bracket Securing bolt Connector Motor shaft Pulley X and Z axes motor Set screw Metal bracket X-axis motor Belt Fig.
CHAPTER 5 Installation 3-2 Replacement of X and Z axis motor (YP220BX, YP220BXR) The X and Z axis motors of the YP220BX and YP220BXR are both attached to a metal bracket. A pulley is attached to the motor shaft by a setscrew. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Turn off the controller power. Remove the side cover on the robot unit. Disconnect the motor power cable and signal cable connectors. Loosen the belt tension and remove the motor from the metal bracket.
CHAPTER 5 Installation 3-3 Replacement of R axis motor (YP220BXR, YP320XR, YP340X) The R-axis motor on the YP220BXR, YP320XR, YP340X is a built-in structure and basically comprised of a stator and rotor. 1) Turn off the controller power. 2) Remove the cover on which a R-axis whip-over cable is attached, and disconnect the motor power cable and signal cable connectors. 3) Remove the four M4 bolts securing the stator, and extract the stator upwards. 4) Remove the plate securing the rotor to the motor shaft.
CHAPTER 5 Installation 4 Belt replacement method Replace the belt if it is damaged, worn or might otherwise interfere with machine operation. ! CAUTION After the belt has been replaced, the origin position must be set again by absolute reset, point data setting rechecked, and belt tension readjusted. 4-1 Replacement of the X and Z axis belts (YP320X, YP330X, YP340X, YP320XR) 1) Turn off the controller power. 2) Remove each of the robot main unit covers. 3) Place marks(with a marker etc.
CHAPTER 5 Installation 4-2 Replacement of Y axis belt (YP330X, YP340X) 1) Turn off the controller power. 2) Remove the robot Y axis cover. 3) Place marks(with a marker etc.) on the pulleys before replacement to limit deviations in point data occurring due to the belt replacement. (Fig. 5-4) 4) Loosen the tension on the belt and remove the belt. 5) Place the new belt on the pulley lining it up with the marks (for synchronizing the positions of the two pulleys) you made in step 3) above.
CHAPTER 5 Installation 4-3 Replacement of Z axis belt (YP220BX, YP220BXR) 1) Turn off the controller power. 2) Remove the side cover on the robot unit.4) 3) Place marks(with a marker etc.) on the pulleys before replacement to limit deviations in point data occurring due to the belt replacement. (Fig. 5-4) 4) Remove the M6 bolts securing the Z-axis motor metal bracket, and remove the belt from the pulley. 5) Remove the M6 bolts shown in Fig. 5-8, and remove the plate securing each shaft.
CHAPTER 5 Installation 4-4 Replacement of X axis belt (YP220BX, YP220BXR) 1) Turn off the controller power. 2) Remove the side cover on the robot unit.4) 3) Place marks(with a marker etc.) on the pulleys before replacement to limit deviations in point data occurring due to the belt replacement. (Fig. 5-4) 4) Loosen the M6 bolts securing the X-axis motor metal bracket, and remove the belt from the pulley. 5) Loosen the bolt securing the driven pulley shown in Fig. 5-8.
CHAPTER 5 Installation 4-5 Replacement of Z axis tip section belt (YP320X, YP330X, YP340X, YP320XR) 1) Turn off the controller power. 2) Remove the robot Z axis cover. 3) Place marks(with a marker etc.) on the pulleys before replacement to limit deviations in point data occurring due to the belt replacement. (Fig. 5-4) 4) Remove the bolts securing the belt tensioner in Fig. 5-9 and remove the belt from the pulley. 5) Remove the plate gripping the belt in Fig. 5-9.
CHAPTER 5 Installation 4-6 Replacement of Z axis tip section belt (YP220BX, YP220BXR) 1) Turn off the controller power. 2) Remove the robot Z axis cover. 3) Place marks(with a marker etc.) on the pulleys before replacement to limit deviations in point data occurring due to the belt replacement. (Fig. 5-4) 4) Remove the bolts securing the belt tensioner in Fig. 5-10 and remove the belt from the pulley. 5) Remove the plate gripping the belt in Fig. 5-10.
5-15 Check installation method. No Check for looseness of robot mechanical parts. Yes Are the robot, tools and workpiece correctly installed? Yes Are cables correctly wired? Are connectors correctly fitted? Check wiring and connectors. No The position deviates after moving the robot or set up of workpiece tool. (1) Check tool and workpiece for warping. (2) Check robot coupling for slipping and belt for teeth skipping.
5-16 No Is external noise large? Yes Take noise reduction measures Securely insert pins or repair defective pins No Are connector pins securely inserted? No Is there electrical discontinuity? Yes Repair Turn power off and check for friction by moving manually Yes Is controller hardware OK? Yes Is motor encoder OK? Yes Is motor resistance OK? Yes Is wiring live? Yes Are wiring and connector securely connected? No Are parameters for controller and robot OK? No Much mechanical frictio
8 3 90K90-62012X 90K90-62213Z KC5-M2256-200 KC5-M2257-100 KC5-M2256-100 KC5-M173H-000 90K80-S15RW0 90K71-0L0167 KC5-M4752-X00 1 2 3 4 5 6 7 8 PART NO. 1 AC SERVO MOTOR AC SERVO MOTOR BELT, 1 BELT, 2 BELT, 1 BELT, 2 LM, BLOCK LM, RAIL CABLE, ROBOT PART NAME YP220BX Spare Parts 4 1 1 1 1 1 1 1 1 1 Q'TY REMARKS 200W (X) 200W (Z) 219UP3M 635UP5M 252UP3M S3M369 SSR15W 2 5 6 7 6 NO.
8 3 1 4 2 5 Q'TY REMARKS PART NAME AC SERVO MOTOR 1 200W (X) AC SERVO MOTOR 1 200W (Z) BELT, 1 1 219UP3M BELT, 2 1 635UP5M BELT, 1 1 252UP3M BELT, 2 1 S3M369 LM, BLOCK 1 SSR15W LM, RAIL 1 CABLE, ROBOT 1 QRCX3 1 TRCX3 CABLE, ROBOT 1 60W (R) MOTOR, COMP. HARNESS, MACHINE 4 1 YP220BXR Spare Parts PART NO. 90K90-62012X 90K90-62213Z KC5-M2256-200 KC5-M2257-100 KC5-M2256-100 KC5-M173H-000 90K80-S15RW0 90K71-0L0167 8 KC4-M4752-X00 KC4-M4753-X00 9 KC4-M2284-B00 10 KC5-M4845-000 NO.
7 1 2 3 4 5 6 NO. PART NO.
PART NO. 1 2 3 4 5 6 KC4-M4881-000 90K90-62212Z KC0-M2256-100 KC0-M2256-000 KC5-M173H-000 90K80-S15RW0 90K71-0L0167 7 KC4-M2284-B00 8 KC4-M4845-200 9 KC4-M4752-X00 KC4-M4753-X00 NO. 9 AC SERVO MOTOR AC SERVO MOTOR BELT, 1 BELT, 1 BELT, 2 LM, BLOCK LM, RAIL MOTOR,COMP.
10 7 8 9 1 2 3 4 5 6 NO. 9 10 KC4-M4881-000 90K90-62212Z KC0-M2256-100 KC0-M2256-000 KC5-M173H-000 90K80-S15RW0 90K71-OL0167 90K90-62012Y KC1-M2256-000 KC4-M4843-100 KC4-M4844-100 KC4-M4752-X00 KC4-M4753-X00 PART NO.
PART NO. 9 10 1 KC4-M4881-000 2 90K90-62212Z 3 KC0-M2256-100 4 KC0-M2256-000 5 KC5-M173H-000 6 90K80-S15RW0 90K71-0L0167 7 90K90-62012Y 8 KC1-M2256-000 9 KC4-M4843-100 KC4-M4844-100 10 KC4-M4752-X00 11 KC4-M2284-B00 12 KC4-M4845-100 NO. 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 Q'TY PART NAME AC SERVO MOTOR AC SERVO MOTOR BELT, 1 BELT, 1 BELT, 2 LM, BLOCK LM, RAIL AC SERVO MOTOR BELT, 1 HARNESS,MACHINE 2 HARNESS,MACHINE 3 CABLE,ROBOT MOTOR,COMP.
CHAPTER 6 Specifications 1 P & P robot unit ............................................. 6-1 1-1 1-2 1-3 1-4 2 R axis allowable moment/inertia moment ... 6-18 2-1 2-2 2-3 3 4 5 6 Basic specifications ......................................................... 6-1 Robot External Views ...................................................... 6-2 Table of robot control signals .......................................... 6-8 Piping and wiring of robot ............................................
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CHAPTER 6 Specifications 1 P & P robot unit 1-1 Basic specifications YP220BX X-axis (fwd/rev) Y-axis (rt/lt.) Z -axis (up/down) R-axis (rotation) X-axis (Note 1) Drive method Motor output No.
Fig. 6-1 YP220BX robot external view Grounding terminal (M4) (φ6) Coupling for air (φ4) Coupling for air MAX600 Robot cable 4-φ10 Bottom plate 490 510 YAMAHA 8-M4×0.7 (for user installation) (same four places on opposite side) 9 10 5 (Note1) 67 20 30 20 11 67 287 13 +X 3 (Note1) +Z 22 Note: Tool plate is detachable. The tool plate is made of aluminum alloy. 89 109 56 21 Note 1: Distance to mechanical stopper Note 2: Return-to-origin on the YP220BX is by absolute reset.
Fig. 6-2 YP220BXR robot external view Grounding terminal (M4) 2-Coupling for air (φ4) 287 5 20 φ22 4-φ10 (Details of tool attachment 1: 1) C1 6 26 M5×0.8 Depth 13 φ8h7 YAMAHA Bottom plate 490 510 469 620 10 67 69 103 5 (Note1) 70 180 +X +Z 3 (Note1) 10 12 89 78 56 Note 1: Distance to mechanical stopper Note 2: Return-to-origin on the YP220BXR is by absolute reset. So the origin position must be set the first time (making initial settings) but after that is not required.
YAMAHA 325 Grounding terminal (M4) 4-Coupling for air (φ4) 70 8-M8×1.25 Depth 20 (Note3) (301) 135 301 YAMAHA YP SERIES (650) 431 80 8 9 103 5 (Note1) 66 14 193 127 242 7.5 10 14.5 57 25 4 (Note1) (57) Z stroke:100 25 34 15 +X 3 (Note1) +Z 15.5 Warning 78 123 102 38 34 (Details of tool attachment 1:1) Note: Tool plate is detachable. The tool plate is made of aluminum alloy. 4-M5×0.
412 Grounding terminal (M4) A Fig. 6-4 YP330X robot external view A YAMAHA 8-M8×1.25 Depth 20 (Note3) 4-Coupling for air (φ4) B 60 319 YAMAHA YP SERIES 12.5 (280) 255 B (319) 175 78 60 5 (Note1) 66 14 193 12 214 4 (Note1) (57) Z stroke:100 2 (Note1) X stroke : 330 +X 16 25 34 15 5 (Note1) 2 (Note1) (Details of tool attachment 1:1) Note: Tool plate is detachable. The tool plate is made of aluminum alloy. 4-M5×0.
A 412 Grounding terminal (M4) Fig. 6-5 YP340X robot external view A YAMAHA 123 319 8-M8X1.25 Depth 20 (Note3) 4-Coupling for air (φ4) B YAMAHA YP SERIES 60 214 71 B (319) 175 5 (Note1) 108 66 60 4 (Note1) Z stroke:100 +X +Z 3 (Note1) 16 15.5 82 102 280 C1 φ22 67 Y stroke : 150 31.5 Width across flat 7 5 (Note1) Warning 78 55 φ8h7 2 (Note1) 40 Note 1: Distance to mechanical stopper M5×0.
A A 325 YAMAHA Fig. 6-6 YP320XR robot external view Grounding terminal (M4) 4-Coupling for air (φ4) B 301 YAMAHA YP SERIES 133 B 70 71 127 180 177 8-M8X1.25 Depth 20 (Note3) (301) 135 5 (Note1) 66 4 (Note1) 80 8 X stroke : 330 2 (Note1) Z stroke:100 3 (Note1) +Z C1 123 φ22 67 Warning 78 φ8h7 40 31.5 MAX.700 M5×0.
CHAPTER 6 Specifications 1-3 Table of robot control signals 1) YP340X, TRCX4, QRCX4 YP330X, YP320XR, YP220BXR and QRCX3 Robot side Connector No S2 1 2 S4 3 S1 4 S3 ZP 5 R1 6 R2 DG 7 1 MB+ Brake ZBK 2 MBS2 1 Resolver 2 S4 3 S1 4 S3 RP 5 R1 6 R2 7 DG Brake MB+ 1 RBK MB2 HLIM GND24 HLIM GND24 1 U 2 ZM V 3 W 1 U 2 V RM 3 W FG Round terminal Signal Resolver Connection Controller side Robot side Signal Connector No No Connector Color/No.
CHAPTER 6 Specifications (Robot side) Fig.
CHAPTER 6 Specifications 2) YP330X, YP320XR, YP220BXR and TRCX3 Signal Resolver Brake Robot side Connector No S2 1 2 S4 3 S1 4 S3 ZP 5 R1 6 R2 DG 7 1 MB+ ZBK 2 MBU 1 ZM 2 V 3 W FG Round terminal Connection Controller side No Connector Color/No.
CHAPTER 6 Specifications (Robot side) Fig.
CHAPTER 6 Specifications 3) YP320X, YP220BX and DRCX, QRCX2 Robot side Connector No S2 1 2 S4 3 S1 4 S3 P1 5 R1 6 R2 DG 7 1 MB+ Brake BK1 2 MBS2 1 Resolver 2 S4 3 S1 4 S3 P2 5 R1 6 R2 7 DG Brake MB+ 1 BK2 MB2 HLIM GND24 HLIM GND24 1 U 2 M1 V 3 W 1 U 2 V M2 3 W FG Round terminal Signal Resolver Connection 6-12 Controller side No Connector Color/No.
CHAPTER 6 Specifications M2 M2 M1 BK2 P2 BK1 P1 M1 (Controller side) (Robot side) Fig.
CHAPTER 6 Specifications 1-4 Piping and wiring of robot User air tubing and wiring have been provided on the YP-X series robots. Use these user air tubing and wiring when installing air chucks (gripper), vacuum pads and other tools. 1) YP320X, YP320XR YAMAHA Air coupling (φ4×4) Cable and air tube extraction port Cable extraction port DANGER Fig. 6-10 User wiring and piping connections As standard features, four air tubes (4mm dia.) and a cable (12 conductors, 0.2 sg.
CHAPTER 6 Specifications 2) YP330X, YP340X YAMAHA Air coupling (φ4×4) Cable and air tube extraction port DANGER Cable extraction port Fig. 6-12 User wiring and piping connections As standard features, four air tubes (4mm dia.) and a cable (12 conductors, 0.2 sg.) are routed through the robot unit as shown below. These are provided for the user so utilize as needed. YAMAHA YP SERIES Fig.
CHAPTER 6 Specifications 3) YP220BX Air coupling (φ4×2) Cable and air tube extraction port Air coupling (φ6×1) Cable extraction port Fig. 6-14 User wiring and piping connections In the standard configuration, one air tube (6mm diameter), two air tubes (4mm diameter) and one cable (12 conductor wires, 0.2sg.) run through the robot unit as shown below. These are provided for the user so feel free to use when needed. Fig.
CHAPTER 6 Specifications 4) YP220BXR Air coupling (φ4×2) Cable extraction port Cable and air tube extraction port Fig. 6-16 User wiring and piping connections As standard features, two air tubes (4mm dia.) and a cable (10 conductors, 0.2 sg.) are routed through the robot unit as shown below. These are provided for the user so utilize as needed. YAMAHA Fig.
CHAPTER 6 Specifications 2 R axis allowable moment/inertia moment 2-1 R axis allowable moment/inertia moment Due to the robot R axis motor and speed reduction gear specifications, there is a limit to the load that can be applied to the R axis. If the robot is operated with this limit exceeded, the above drive parts' lives will decrease and may cause breakage. The limit of the R axis load is expressed with values called the tolerable moment and tolerable inertia moment.
CHAPTER 6 Specifications 2-2 Equation for moment of inertia calculation Usually the R axis load is not a simple form, and the calculation of the moment of inertia is not easy. As a method, the load is replaced with several factors that resemble a simple form for which the moment of inertia can be calculated. The total of the moment of inertia for these is obtained. The objects and calculation methods often used for the calculation of the moment of inertia are shown below. 1.
CHAPTER 6 Specifications 3. When the object's center line is offset from the rotation center. The equation for the moment of inertia, when the center of the cylinder is offset the amount of “x” from the rotation center as shown in Fig. 6-20, is given below. Center line Rotation center J = = ρ π D4h ρ π D2hx2 + 32g 4g WD2 8g + Wx2 g (kg · cm · sec2) h ...(6.3) W : Weight of the cylinder (kg) D x Fig. 6-20 In the same manner for the rectangular column in Fig. 6-21.
CHAPTER 6 Specifications 2-3 Example of moment of inertia calculation It will be assumed that the chuck and workpiece are at a position offset by 10cm from the R axis by the stay, as shown in Fig. 6-22. The moment of inertia is calculated with the following three factors. However, the load material will be aluminum, and the density =0.0026kg/cm3. R Axis 2cm Stay 1cm 2cm 1cm 8cm 4cm 1cm 6cm Chuck Work 4cm 2cm Fig. 6-22 1. Moment of inertia of the stay From Fig.
CHAPTER 6 Specifications 2. Moment of inertia of the chuck When the chuck form resembles that shown in Fig. 6-24: Ws = 0.0026×1×4×6 = 0.06 (kg) 8cm 1cm R Axis From equation (6.4): Jc = 0.06×82 0.06×(12+42) + 12×980 980 = 0.004 (kg · cm · sec2) 4cm 6cm Fig. 6-24 3. Moment of inertia of the workpiece From Fig. 6-25: ρ π D2h Ww = = 4 8cm 0.0026π×22×4 4 R Axis = 0.03 (kg) 4cm From equation (6.3): Jc = 0.03×22 8×980 + 0.03×82 980 2cm = 0.002 (kg · cm · sec2) Fig. 6-25 4.
CHAPTER 6 Specifications 3 Robot allowable duty To prolong the YP-X series robot service life, operate the robot within 80% of the allowable duty ratio Duty (%) = Operating time Operating time+ OFF time × 100 ! CAUTION Service life may be shortened if the robot is used for longer than its allowable duty time.
CHAPTER 6 Specifications 4 Allowable overhang The table below shows the allowable overhang for the YP320X, YP330X, YP220BX robots. This is calculated under the conditions that the Z-axis linear guide travel life is about 20000 km, acceleration is 100%, and maximum speed is 100%. L mm Payload W Allowable Overhang L 0 W 1kg 140mm 1 W 2kg 50mm 2 W 3kg 30mm YAMAHA YP SERIES W kg Fig.
CHAPTER 6 Specifications X-axis droop Because of the one-sided support structure, the YP-X series manipulator arm droops downward slightly when it moves to the X-axis stroke end (forward end). The amount of droop during a maximum stroke on the X-axis is shown in the table below. Payload W YP320X YP330X YP340X YP320XR YP220BX YP220BXR 0 W 1kg 1.0 1.1 1.5 1.4 1.0 1.1 1 W 2kg 1.2 1.3 - - 1.1 - 2 W 3kg 1.4 1.5 - - 1.
CHAPTER 6 Specifications 6 Mechanical stopper A urethane damper is installed to absorb the shock when an impact occurs with the mechanical stopper, so a certain amount of overrun occurs when the robot strikes the mechanical stopper. Use caution and take overrun into account since the end effector may interfere with the robot body and peripheral equipment or the robot body may interfere with the peripheral equipment.
MEMO
OWNER'S MANUAL PICK&PLACE ROBOT Aug. 2006 Ver. 1.02 This manual is based on Ver. 1.02 of Japanese manual. © YAMAHA MOTOR CO., LTD. IM Company All rights reserved. No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO., LTD. Information furnished by YAMAHA in this manual is believed to be reliable. However, no responsibility is assumed for possible inaccuracies or omissions.
