YASKAWA RM2-755-RDR, Instructions Manual

Page 1: ...tions thoroughly and retain for future reference MOTOMAN RM2 755 RDR POSTIONER INSTRUCTIONS YASKAWA MH T SERIES SIGMA 5 POSITIONER MANUAL CONTROLLER MANUALASSEMBLY OPERATOR S MANUAL GENERAL SUBJECT SP...

Page 2: ...s copyrighted property of YASKAWA and may not be sold or redistributed in any way You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF f...

Page 3: ...ION or NOTICE 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...

Page 4: ...ion and operating instructions and maintenance procedures Be sure to read and understand this instruction manual thoroughly before installing and operating the Positioner Any matter not described in t...

Page 5: ...t from unintentional or unexpected Positioner motion Fig 2 Release of EMERGENCY STOP Button TURN Observe the following precautions when performing teaching operations within the P point maximum envelo...

Page 6: ...ngs and photos in this manual are representative examples and differences may exist between them and the delivered product YASKAWA is not responsible for incidents arising from unauthorized modificati...

Page 7: ...provements 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...

Page 8: ...low the safety labels Also an identification label with important information is placed on the body of the Positioner Prior to operating the manipulator confirm the contents Fig 3 Safety Labels Safety...

Page 9: ...ways be made before any service procedures are done and before any changes are made to options accessories or equipment Any modifications to the Controller unit can cause severe personal injury or dea...

Page 10: ...placed in Emergency Stop E Stop mode whenever it is not in use In accordance with ANSI RIA R15 06 2012 section 4 2 5 Sources of Energy use lockout tagout procedures during equipment maintenance Refer...

Page 11: ...NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE PROGRAM OR REPAIR THE EQUIPMENT We recommend approved YASKAWA training courses for all personnel involved with the operation programming or repair of the equ...

Page 12: ...troller Positioner Cable Equipment Manual Designation Programming Pendant Character Keys The keys which have characters printed on them are denoted with ex ENTER Symbol Keys The keys which have a symb...

Page 13: ...2 1 2 Optional Equipment 2 2 2 2 Materials Required 2 3 2 2 1 Customer Supplied Items 2 3 2 2 2 Customer Supplied Items 2 3 2 3 Positioner Installation 2 4 2 3 1 Site Preparation 2 4 2 3 1 1 Location...

Page 14: ...ions 5 1 6 Maintenance and Troubleshooting 6 1 6 1 Inspection Interval 6 2 6 2 Battery Pack Replacement 6 4 6 3 Grease Replenishment Exchange for Speed Reducers 6 5 6 3 1 Tooling Axes Reducer 6 5 6 3...

Page 15: ...sition 6 14 6 11 2 1 Re Homing Tooling Axes S2 S3 to Flat at the Robot and Operator 6 15 6 12 Troubleshooting 6 16 6 12 1 Positioner 6 16 6 12 2 MotoMount 6 16 7 Recommended Spare Parts 7 1 Appendix A...

Page 16: ...r 5 Load Specifications and Jig Mounting This chapter provides guidelines for customer supplied tooling design Chapter 6 Maintenance and Troubleshooting This chapter provides preventive maintenance re...

Page 17: ...plate orbital axes rotate using servomotors working through gear reduction units that the controller controls All three axes can be driven simultaneously during a sweep motion In addition movement of...

Page 18: ...ld the main cables between the Positioner and Controller be disconnected This battery pack is part of each cable assembly internal to the Positioner that connects each AC servomotor to its associated...

Page 19: ...r to Controller interconnect cables power and encoder One assembly kit for the Controller servo packs etc 1 2 4 Optional Equipment This manual documents a standard Positioner assembly If the Positione...

Page 20: ...spection must be performed by specified personnel Failure to observe this caution may result in electric shock or injury For disassembly or repair contact your representative Do not remove the motor a...

Page 21: ...n s body A shifted or dropped load could result in serious injury or death Always comply with established safety procedures during installation of the Positioner Failure to use a qualified personnel a...

Page 22: ...ociated gear reduction units One spreader beam arc screen Two Positioner to Controller interconnect cables power and encoder One assembly kit for the Controller servo packs etc Shipping bracket liftin...

Page 23: ...llation 2 2 1 Customer Supplied Items Servo motion control unit Incoming power supply Two earth ground cables with two earth ground stakes 2 2 2 Customer Supplied Items Safety Glasses Forklift and or...

Page 24: ...ke sure the thickness of the floor is 200mm or more because any thickness less than 200mm is insufficient for mounting even if the floor is concrete Before mounting the Positioner on the floor check t...

Page 25: ...from excessive vibration Vibration acceleration 4 9m s2 0 5G or less Free from large electrical noise plasma Flatness for installation 0 5mm or less Ensure appropriate space for equipment reviewing F...

Page 26: ...Installation Fig 2 1 Mounting the Positioner to the Floor 250 0 4X 25 THRU 1 0 8X M20 X 2 5 THRU 12X 20 THRU 0 7 0 1240 1190 0 25 0 25 0 50 0 90 0 227 0 410 0 450 0 500 0 550 0 B 330 280 0 230 0 140 0...

Page 27: ...m the shipping skid and inspecting for shipping damage Fig 2 2 Shipping Bolt Removal The Positioner includes shipping bolts and nuts see Fig 2 2 1 Extend the M20 leveling bolts to a point approximatel...

Page 28: ...s body A shifted or dropped load could result in serious injury or death CAUTION Make sure the lifting device is rated for handling the weight of the equipment Refer to Table 4 1 Positioner Technical...

Page 29: ...nsporting the Positioner Crane or Hoist CAUTION Check that the eyebolts are securely fastened on Positioner Use a wire rope strong enough to withstand this weight Refer to Table 4 1 Positioner Technic...

Page 30: ...he floor should be strong enough to support the Positioner Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the Positioner Make sure the thickness o...

Page 31: ...erence only Fig 2 6 Headstock Installation on Floor 2 Place a machinists level on the front of the machined surface of the Headstock without the overhead rail attachment if supplied 3 Adjust the level...

Page 32: ...ipping brackets qty 2 that are attached between the tailstock and the Z beam frame 3 Place a level on top of the tailstock without the overhead rail attachment if supplied 4 Adjust the jam bolts so th...

Page 33: ...and Equipment Anchoring for more details Before mounting the Positioner on the floor check the flatness cracks etc of the floor If there are any cracks on the floor they should be repaired before inst...

Page 34: ...ring The Customer or designated Contractor shall provide and install all required Hilti Anchors or equivalent For the applications listed with Kwik Bolt II Expansion type Anchors other proposed manufa...

Page 35: ...tomer Support Information on page 1 5 2 5 Installation of Safeguarding NOTICE The customer shall supply all tooling fixtures for the Positioner YASKAWA recommends application of a corrosion rust preve...

Page 36: ...tem ensures that safeguards are provided and used in accordance with Sections 6 7 and 8 of this standard The means and degree of safeguarding including any redundancies shall correspond directly to th...

Page 37: ...nd put up a warning sign ex DO NOT TURN ON THE POWER Failure to observe this warning may result in fire or electric shock Wiring must be performed by authorized or certified personnel Failure to obser...

Page 38: ...to the Positioner 1 Check the numbers on both the cables and Positioner base connectors 2 Connect each cable adjusting the cable connector positions to the main key positions of the Positioner and ti...

Page 39: ...e Controller manual for proper connections 2 Connect the encoder cable 3 Connect the IO cable 4 Connect any Optional cables as required 5 Connect the power cable Fig 3 11 Connection between the Positi...

Page 40: ...0M Weight kg 2398 2 2 0M 2513 6 3 0M Shaft End to Shaft End mm 1937 2 0M 2937 3 0M Pin to Pin mm 2000 2 0M 3000 3 0M Max Tooling Length mm 2064 2 0M 3064 3 0M Axis Type Rotation Static Unbalanced Load...

Page 41: ...3523 1CD 4 Basic Specifications 4 1 Basic Specifications List RM2 755 RDR Postioner Max Tooling Envelope mm 1300 Max Tooling Sweep mm 2675 E Stop Response sec 0 561 deg 30 17 SPECIFICATION UNITS RM2 7...

Page 42: ...Dimensions swingarms removed for clarity HEADSTOCK DRIVE ASSY ARC SHIELD ASSY TAILSTOCK SWING ARM ASSY HEADSTOCK DRIVE ASSY FORKLIFT POCKETS HEADSTOCK SWINGARM ASSY FACE PLATE TAILSTOCK ASSY 250 0 4X...

Page 43: ...orking Envelope 4 4 Dimensions and Working Envelope Fig 4 3 Dimensions and Working Envelope 2675 MAX TOOLING SWEEP 1300 MAX TOOLING ENVELOPE ROTATION 2522 25 1476 WORK ROBOT SIDE OPERATOR SIDE 623 623...

Page 44: ...ached with 4 x M12 bolts 10 9 or 8 8 grade Fig 5 1 Details of Jig Mounting Face 5 2 Fixture Specifications Weight of tool and parts are not to exceed rated Positioner capacity Length of the fixture is...

Page 45: ...nance and inspection must be performed by specified personnel Failure to observe this caution may result in electric shock or injury For disassembly or repair contact Customer Support Failure to obser...

Page 46: ...essed air Positioner Axis Motor Connectors 1 000 H 6 000 H 12 000 H Check for loose connections tighten if necessary Positioner Tooling Axis Speed Reducer 12 000 H Grease with YASKAWA P N 132412 1 Mol...

Page 47: ...Table 6 2 Inspection Parts and Grease Used No Grease Used YASKAWA Part Number Inspected Parts 1 Moly White RE00 132412 1 Speed reducers of all axes 2 Mobil CM P Lithium Complex 180144 1 Tailstock swin...

Page 48: ...into the Encoder Battery Pack assembly 5 Install the new battery pack into the motor Fig 6 1 Battery Replacement CAUTION Do not remove power from the main power supply Removing the main power while re...

Page 49: ...Reducers 6 3 1 Tooling Axes Reducer 1 Remove the button head screws in the vent located in the flat surface at the top of the drive assembly Fig 6 2 Tooling Greasing 2 Install the M6 grease fitting in...

Page 50: ...Axis Apply Mobil CM P grease to the grease fitting by using a standard grease gun and pressing the lever 10 times 1 25 g x 10 Fig 6 3 Tailstock Main Axis Grease Fitting 6 3 2 2 Motomount Lubrication I...

Page 51: ...or replacement on a regular basis Do NOT disassemble a Sigma 5 servomotor If suspecting that the servomotor requires maintenance or overhaul contact Customer Support refer to section 1 4 Customer Sup...

Page 52: ...eplacement on a regular basis Do NOT disassemble the reduction gear unit or remove it from its associated AC servomotor If suspecting the Reduction Gear Unit requires maintenance or an overhaul contac...

Page 53: ...s proceed as follows 1 Shut down cell using main disconnect 2 Remove the back panel of the drive assembly 3 Use a flathead screwdriver to disconnect the brush cable s from the ground post Fig 6 5 Fig...

Page 54: ...eze the brush retaining spring and push the brush against the faceplate then release The spring must hold the brush firmly against the face plate Fig 6 6 7 Insert the ground cables onto the ground pos...

Page 55: ...atteries have a long life in this particular application However should one or more of these batteries drop below a certain charge level an indicator will appear on the Programming Pendant display scr...

Page 56: ...ursor to HOME POSITION and press SELECT 6 Press the PAGE OVER key to S1 indicated in top right corner of Programming Pendant display panel 7 Press SELECT 8 Cursor to YES then press SELECT 6 11 1 2 Def...

Page 57: ...S1 A To R1 Mid EX044 170 000 S2 Sweep to Robot mid position S2 To R1 Mid EX045 10 000 S3 Sweep to Operator mid position S3 To Oper Mid EX050 0 000 S1 B Side At Robot S1 B Side Robot EX051 180 000 S2...

Page 58: ...pin see Fig 6 8 Homing Pin Details into the homing pin hole in the tooling plate see Fig 6 9 Tooling Plate Home Zero Position Fig 6 8 Homing Pin Details Fig 6 9 Tooling Plate Home Zero Position 5 Slo...

Page 59: ...Cursor to YES press SELECT The tooling plate is now reset to zero 12 Remove the homing pin from the tooling plate 13 Reinstall the cover 6 11 2 1 Re Homing Tooling Axes S2 S3 to Flat at the Robot and...

Page 60: ...been wired correctly Overload Reduce load or reduce unbalanced load Unstable operation Incorrect wiring Inspect and correct wiring across motor terminals L1 L2 L3 and PE Motor overheats Excessive ambi...

Page 61: ...arts or replacement parts for the Positioner please contact Customer Support Refer to section 1 4 Customer Support Information on page 1 5 NOTICE To replace parts in Rank B or Rank C contact Customer...

Page 62: ...450 182 273 475 174 262 500 168 252 Note HTS Applications assume 1 2 load on headstock 50 mm using MotoMount 2 Rated load based upon 50 maximum bearing moment 3 Maximum load based upon 75 maximum bea...

Page 63: ...IPL Layout The IPL is arranged so that the illustration exploded view for an assembly appears directly above the parts list table for that illustration When this is not possible due to a large illust...

Page 64: ...entry in this column gives the part number for an item Refer to this number when ordering or referencing the part DESCRIPTION An entry in this column gives the description nomenclature for an item num...

Page 65: ...List Fig B 1 Positioner Major Assemblies 2 0M T DETAIL T 44 45 18 53 52 18 20 20 18 47 46 46 48 2 38 37 20 22 19 18 21 10 23 12 27 28 3 17 28 10 27 34 33 35 55 54 15 16 32 30 31 31 30 21 19 18 18 20...

Page 66: ...19 152310 5 PLATE GLAND SPLIT FOAM XRC NX DX 12MM CBL 25X48 PASS THRU ZINC PLATE 3 20 143047 7 PLATE GLAND XRC MRC BLANK 5 21 131275 4 SCREW HHC M20X55 ZP CLASS 8 8 8 22 180047 1 PLATE STRIKER LEVELI...

Page 67: ...166012 2 CAP RECEPTACLE WITH CHAIN SIZE 24 1 54 166408 2 COVER TAILSTOCK HOUSING ROUND HOLE 2 55 130424 5 SCREW BHSC M5 X 12 6 56 131274 8 SCREW HHC M16 X 60 ZP CLASS 8 8 2 57 180545 1 LABEL GREASE MO...

Page 68: ...Positioner Major Assemblies 3 0M T DETAIL T 44 45 18 53 52 18 20 20 18 47 46 46 48 2 38 37 20 22 19 18 21 10 23 27 28 3 17 28 10 27 34 33 35 55 54 15 16 32 30 31 31 30 21 19 18 18 20 22 16 15 56 30 1...

Page 69: ...PLATE GLAND XRC MRC BLANK 5 21 131275 4 SCREW HHC M20X55 ZP CLASS 8 8 8 22 180047 1 PLATE STRIKER LEVELING SCREW 8 23 180130 1 COVER Z BEAM END LH MAIN DRIVE W STUDS RM2 755 1 24 155235 2 LABEL PATEN...

Page 70: ...56 131274 8 SCREW HHC M16 X 60 ZP CLASS 8 8 2 57 180545 1 LABEL GREASE MOBIL CM P No 2 1 58 471376 1 LABEL MOVING PARTS HORIZONTAL 4 59 471359 1 LABEL ROBOT WARNING HORIZONTAL 4 60 471378 1 LABEL ARC...

Page 71: ...RDR Postioner B 9 183523 1CD 183523 1CD Appendix B B 1 Illustrated Parts List Fig B 3 Main Axis Drive Assy 8 17 17 16 18 11 3 11 15 16 19 13 14 12 27 23 5 6 4 7 9 1 28 24 21 25 2 26 21 20 21 29 8 10 7...

Page 72: ...11 172453 1 SCREW BHSC FLANGED M6x1 X 16 ALLOY STL CLASS10 9 9 12 176606 1 BRACKET SHUT OFF VALVE MAIN DRIVE HOUSING MRM2 750 M3XSL RDR 1 13 479296 5 SCREW SHC M5X12 CLASS 12 9 4 14 471009 1 WASHER C...

Page 73: ...5 RDR Postioner B 11 183523 1CD 183523 1CD Appendix B B 1 Illustrated Parts List Fig B 4 Main Drive Assembly 18 17 2 15 9 10 24 3 13 13 8 5 7 4 5 6 9 10 12 16 10 14 22 21 20 19 18 5 11 25 27 27 28 73...

Page 74: ...6 9 130425 2 SCREW BHSC M6 X 10 2 10 470602 1 WASHER CONICAL SPRING GTS6 YS 3 11 156009 3 MOTOR AC SERVO 1 3kW SIGMA 5 1 12 133963 3 BOLT EYE M10 DIN 580 2 13 146123 1 SEAL KIT RV80E 1 14 166944 1 GEA...

Page 75: ...RM2 755 RDR Postioner B 13 183523 1CD 183523 1CD Appendix B B 1 Illustrated Parts List Fig B 5 Tailstock Swing Arm Assembly 1 2 2 5 6 7 10 11 4 8 9 9 8 12 13 12 13 14 14 75 of 104...

Page 76: ...NT 2 4 165038 1 SHAFT BEARING TAILSTOCK SWINGARM 1 5 163886 1 BEARING SPHERICAL PILLOW BLOCK 2 437 ID 1 6 157188 1 RETAINER TAILSTOCK SWINGARM 1 7 132619 3 SCREW FHSC M8x1 25 X 20 1 8 130532 2 SCREW S...

Page 77: ...acteristic and the attained characteristic R15 05 2 or the precision with which a computed or calculated robot position can be attained Accuracy is normally worse than the arm s repeatability Accuracy...

Page 78: ...ion Automatic Mode See Play Mode Axis A direction used to specify the Manipulator motion in a linear or rotary mode ISO 8373 Axis Backlash Play between drive train gears Axis Interference The Axis Int...

Page 79: ...ree dimensional Cartesian coordinate system A robot s TCP position is specified in a Cartesian Coordinate Cartesian Manipulator A Cartesian Manipulator is a Manipulator arm with prismatic joints which...

Page 80: ...rs continually communicate information to the Controller which is used to further guide the Manipulator within the given task Many sensors are used to feed back information about the Manipulator s pla...

Page 81: ...tch R15 06 Control Mode The means by which instructions are communicated to the robot Controllability The property of a system by which an input signal can take the system from an initial state to a d...

Page 82: ...circle with a prismatic joint to raise or lower the circle Not popular in industry D Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Safe...

Page 83: ...quipment that may present a hazard R15 06 Encoder A feedback device in the robot Manipulator arm that provides current position and orientation of the arm data to the Controller A beam of light passes...

Page 84: ...Control Flexibility The ability of a robot to perform a variety of different tasks Force Feedback A sensing technique using electrical signals to control a robot end effector during the task of the e...

Page 85: ...o the desired position Gripper An end effector that is designed for seizing and holding ISO 8373 and grips or grabs an object It is attached to the last link of the arm It may hold an object using sev...

Page 86: ...etailed movement instructions INFORM The robot programming language for YASKAWA robots INFORM language allows the robot user to instruct the robot to use its basic capabilities to fulfill a defined se...

Page 87: ...bots and robotic devices Safety requirements for industrial robots Part 1 Robots A robot specific safety specification that addresses manufacturer requirements functionality required safety performanc...

Page 88: ...ing at 0 degrees b The set of joint positions Joints The parts of the robot arm which actually bend or move K Kinematics The relationship between the motion of the endpoint of a robot and the motion o...

Page 89: ...r may be by an operator a programmable electronic Controller or any logic system for example cam device wired etc ISO 8373 See Wrist and End effector Manual Mode See Teach Mode Material Handling The p...

Page 90: ...not related to personal injury O Off line Programming A programming method where the task program is defined on devices or computers separate from the robot for later input of programming information...

Page 91: ...pulator because it can be used to reduce the amount of work involved in teaching by shifting a taught path or position In the example in the figure below the taught position A is shifted in increments...

Page 92: ...on and deceleration phases of a particular task The robot movement is controlled from one point location in space to another in a Point to Point PTP motion system Each point is programmed into the rob...

Page 93: ...inear and angular position The linear position includes the azimuth elevation and range of the object The angular position includes the roll pitch and yaw of the object See Roll Pitch and Yaw Position...

Page 94: ...most favorable position to observe control and record the desired movements in the robot s memory Proximity Sensor A non contact sensing device used to sense when objects are a short distance away and...

Page 95: ...ape of the work envelope forms a rectangular figure See Work Envelope Reliability The probability or percentage of time that a device will function without failure over a specified time period or amou...

Page 96: ...Coordinate System will be relative to the base of the robot Note that by default the Base Coordinate System and Robot Coordinate System are the same Robot Integrator See Integrator Robot Programming L...

Page 97: ...e risks within the robot system Second Home Position Apart from the home position of the Manipulator the second home position can be set up as a check point for absolute data The initial value of the...

Page 98: ...motions and signals the amount of the motion back to the Controller This process is continued many times per second until the arm is repositioned to the point requested See Servo controlled Robot Shoc...

Page 99: ...ithin the robot system Spline A smooth continuous function used to approximate a set of functions that are uniquely defined on a set of sub intervals The approximating function and the set of function...

Page 100: ...items line numbers cursor instructions additional items comments etc Through beam An object detection system used within a robot s imaging sensor system A finely focused beam of light is mounted at o...

Page 101: ...relative to the base frame Total Index Time Sum of the main axis sweep time and the secondary axis sweep times Tooling Envelope Volume in which the tooling can be present when rotated on its own axis...

Page 102: ...r dimensions of an object through visual feedback such as a television camera W Warning Indicates a potentially hazardous situation which if not avoided will result in death or serious injury Hazards...

Page 103: ...m continually updates the World Model Robots use this World Model to aid in determining its actions in order to complete given tasks Wrist A set of rotary joints between the arm and the Manipulator en...

Page 104: ...ng 100076 China Phone 86 10 6788 2858 Fax 86 10 6788 2878 http www ysr motoman cn YASKAWA ELECTRIC KOREA CORPORATION 35F Three IFC 10 Gukjegeumyung ro Yeongdeungpo gu Seoul 07326 Korea Phone 82 2 784...