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YAMAHA ROBOT

User’s Manual ENGLISH


E

E42-Ver. 1.02
Introduction

Introduction
Thank you for purchasing a YAMAHA Robot Controller.

This manual contains the dual robot installation and operating cautions. Please read this
manual carefully to ensure that installation and operation are performed in a safe and
correct manner.

1
MEMO

2
General Contents

Contents
Chapter 1 DUAL ROBOT OVERVIEW
1.1 About the dual robot 1-1
1.2 Dual robot selection requirements 1-2
1.3 Dual robot types 1-2
1.4 Dual drive functions 1-3

Chapter 2 DUAL ROBOT SETTINGS


2.1 Robot and axis settings 2-1
2.2 Dual robot axis parameter settings 2-2

Chapter 3 FLIP-X RIGID DUAL


3.1 Robot installation 3-1
3.1.1 Mounting accuracy 3-1
3.1.2 Using a mechanical reference position 3-1
3.1.3 Origin sensor installation 3-2
3.2 Absolute resets 3-3
3.2.1 When not storing the main and sub axis
positional relationship data 3-3
3.2.2 When storing the main and sub axis positional
relationship data 3-4
3.3 Robot operation cautions 3-5
3.3.1 "Origin incomplete" status 3-5
3.3.2 At servo on 3-5
3.4 FLIP-X rigid dual axis parameters 3-6

Chapter 4 FLIP-X FLEXIBLE DUAL


4.1 Robot installation 4-1
4.1.1 Mounting accuracy 4-1
4.1.2 Using a mechanical reference position 4-1
4.1.3 Origin sensor installation 4-2
4.2 Absolute resets 4-3
4.3 Robot operation cautions 4-5

i
4.3.1 "Origin incomplete" status 4-5
4.3.2 At servo on 4-5
4.4 FLIP-X flexible dual axis parameters 4-6
Contents

Chapter 5 PHASER RIGID DUAL


5.1 Robot installation 5-1
5.1.1 Mounting accuracy 5-1
5.1.2 Using a mechanical reference position 5-1
5.1.3 Origin sensor installation 5-2
5.2 Return-to-origin operations 5-3
5.3 Robot operation cautions 5-4
5.3.1 "Origin incomplete" status 5-4
5.3.2 At servo on 5-4
5.4 PHASER rigid dual axis parameters 5-5

Chapter 6 PHASER FLEXIBLE DUAL


6.1 Robot installation 6-1
6.1.1 Mounting accuracy 6-1
6.1.2 Using a mechanical reference position 6-1
6.1.3 Origin sensor installation 6-2
6.2 Return-to-origin operations 6-3
6.3 Robot operation cautions 6-4
6.3.1 "Origin incomplete" status 6-4
6.3.2 At servo on 6-4
6.4 PHASER flexible dual axis parameters 6-5

Chapter 7 SEMI-ABSOLUTE TYPE PHASER RIGID DUAL/FLEXIBLE DUAL


7.1 Semi-absolute 7-1
7.2 Origin sensor installation 7-2
7.3 Absolute search 7-3

Chapter 8 TROUBLESHOOTING
8.1 FLIP-X rigid dual and PHASER rigid dual 8-1
8.2 FLIP-X flexible dual and PHASER flexible dual 8-2

ii
Chapter 1 DUAL ROBOT OVERVIEW

Contents

1.1 About the dual robot 1-1


1.2 Dual robot selection requirements 1-2
1.3 Dual robot types 1-2
1.4 Dual drive functions 1-3
1.1 About the dual robot

1.1 About the dual robot


The YAMAHA dual robot can be defined as a single robot model with two axes which are
controlled as one axis by the controller.
One of the dual robot's two axes is called the "main axis" (reference axis) which is
1

Dual robot overview


controlled in the same manner as at a single-axis robot, and the other axis is called the
"sub axis", and is controlled in a follow-up manner relative to the main axis.
The dual robot differs from previous cartesian robots in the following ways:
(1) The dual robot offers a two-axis thrust.
(2) The dual robot offers improved positioning accuracy and stability at stops.
However, due to force interference which occurs between the main and sub axes,
simultaneous positioning in systems which employ this "linked and parallel axes" format is
difficult to achieve.
YAMAHA's rcx series robot controller overcomes this problem by featuring dual drive
functions which can be used to drive the dual robot, thereby enabling relatively easy
simultaneous control of the two linked axes.

System configuration illustration

OP.1

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22
OP
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RCX2
BAT
B/A

R TEMP ROB
MOTO I/O

XM

ACIN L
N B OP.2
RP
L1
N1

TY
! SAFE
-STOP
EXT.E 12
PIN11-
YM

OM
SD/C

1-1
1.2 Dual robot selection requirements

1.2 Dual robot selection requirements

1 YAMAHA's RCX Series robot controller offers four dual drive function types, and the
appropriate drive function must be specified in accordance with the dual robot model and
application to be used. Moreover, the selected dual drive function must be suitable for
Dual robot overview

the dual robot's linkage configuration. The following table shows the suitable dual drive
functions and dual robots which correspond to the various applications.
Model Application Dual robot type Dual drive functione
Increased thrust, etc. Rigid dual FLIP-X rigid dual
FLIP-X Increased thrust, high-
series accuracy positioning, Flexible dual FLIP-X flexible dual
etc.
Increased thrust, etc Rigid dual PHASER rigid dual
PHASER Increased thrust, high-
series accuracy positioning, Flexible dual PHASER flexible dual
etc.
[Example]
When using as a dual robot to increase the F14-20 thrust:
A "rigid dual" type dual robot is selected.
The "FLIP-X rigid dual" dual drive function is selected.

See the following sections for more information regarding dual robot types and dual drive functions.

1.3 Dual robot types


Dual robots are divided into the two types shown below depending on how the main and
sub axes are linked.
The appropriate dual robot type must be selected in accordance with its intended application. To do
this, refer to the selection table shown in section 1.2 "Dual robot selection requirements".

• Rigid dual
This dual robot type features a highly rigid linkage of the main and sub axes which allows
the two axes to operate as a single axis. This robot configuration is suitable when using
the "rigid dual" dual drive function. This type is used primarily to increase the thrust.

• Flexible dual
This dual robot type features either a rotary or slide mechanism at the main and sub axes
linkage area to prevent force interference between the two linked axes, or functions as a
dual robot with the two axes unlinked. This robot configuration is suitable when using the
"flexible dual" dual drive function. This type is used primarily to increase thrust, and for
high-accuracy positioning, etc.

MEMO
For further details, refer to the subsequent chapters for each dual robot type.

1-2
1.4 Dual drive functions

1.4 Dual drive functions


Dual drive functions are divided into the four types shown below.
YAMAHA specifies the dual drive function setting at the factory in accordance with the
intended purpose of the dual robot to be used. To verify that the dual drive function is
1

Dual robot overview


suitable for the robot's intended purpose, refer to the selection table in section 1.2 "Dual
robot selection requirements".

• FLIP-X rigid dual


This dual drive function is suitable for FLIP-X series rigid dual type robot operations.
Main axis positioning is controlled in the same manner as on single-axis robots, with
sub axis control occurring in a follow-up manner relative to the main axis.
This dual drive function is used to increase thrust at "rigid dual" type dual robots with
simple axis linkage configurations. Using this dual drive function at dual robots with
low linkage rigidity could result in abnormal operation. Moreover, this dual drive
function does not offer high-accuracy positioning.

• FLIP-X flexible dual


This dual drive function is suitable for FLIP-X series flexible dual type robot operations.
Because the main and sub axes are controlled in the same manner as on single-axis
robots, the positioning accuracy is higher than that of FLIP-X rigid dual. This dual drive
function is used to increase thrust and for high-accuracy positioning. This function is
also used in cases where the main and sub axes are not linked.
Using this dual drive function at "rigid dual" type dual robots with simple and high
rigidity linkage configurations makes normal operation difficult to achieve due to force
interference between the main and sub axes. Therefore, this dual drive function can be
used only at "flexible dual" type dual robots with linkage configurations which prevent
force interference.

• PHASER rigid dual


This dual drive function is suitable for PHASER series rigid dual type robot operations.
Main axis positioning is controlled in the same manner as on single-axis robots, with
sub axis control occurring in a follow-up manner relative to the main axis.
In the same manner as the "rigid dual" type dual drive function, this PHASER rigid
dual function is suitable for dual robots with simple linkage configurations, where the
intended purpose is simply to increase thrust. Using this dual drive function at dual
robots with low linkage rigidity could result in abnormal operation. Moreover, this
dual drive function does not offer high-accuracy positioning.

1-3
1.4 Dual drive functions

• PHASER flexible dual


This dual drive function is suitable for PHASER series flexible dual type robot operations.

1 Because the main and sub axes are controlled in the same manner as on single-axis robots, the
positioning accuracy is higher than that of PHASER rigid dual. This dual drive function is used
to increase thrust and for high-accuracy positioning. This function is also used in cases where
Dual robot overview

the main and sub axes are not linked.


Using this dual drive function at "rigid dual" type dual robots with simple and high rigidity
linkage configurations makes normal operation difficult to achieve due to force interference
between the main and sub axes. Therefore, this dual drive function can be used only at
"flexible dual" type dual robots with linkage configurations which prevent force interference.

MEMO
For further details, refer to the subsequent chapters for each dual robot
type.

1-4
Chapter 2 DUAL ROBOT SETTINGS

Contents

2.1 Robot and axis settings 2-1


2.2 Dual robot axis parameter settings 2-2
2.1 Robot and axis settings

2.1 Robot and axis settings


All the required dual robot and axis settings are factory set at YAMAHA prior to shipment,
and do not require further setting by the user.
At the programming box,select

(SYSTEM) – (PARAM)

to display the screen shown below, then verify that the dual robot setting is specified.
2

Dual robot settings


Dual robot setting check (for F14H-20)

S Y S T E M>PAR AM V8 . 4 6

Robo t =MU L T I
M1 = a F 1 4H - 2 0 M 4 =  n o   a x i s
M 1 = a( a s s i s t D 1 )     M 5 =  n o   a x i s
M2 =  n o  a x i s M 6 =  n o   a x i s
M3 =  n o  a x i s ? 0=   ( n o  a x i s )
R OBOT AX I S OT HE R S OP. BR D

If the dual robot setting has been specified as shown in the above figure, the axis
relationships are as shown in the following table.
F14H-20 Dual
Controller's screen indication X Y Z R
Delivery specification chart X1 axis X2 axis Y-axis Z-axis
indication
Programming box display M1 M1 M2 M3
Controller recognition (parameter, X-axis Y-axis Z-axis
point data))

As shown in the above table, the X1 and X2 axes representing the dual robot are
recognized as a single axis by the controller. Therefore, the dual robot's parameter and
point settings are specified only for the X-axis, with settings specified for the Y-axis and
Z-axis only if another robot exists. Be aware that settings are specified for only one axis at
the dual robot.
For the axis relationships, refer to the controller's screen indication and the delivery
specification indication. The X1 axis is called the "main" axis, and the X2 axis is called the
"sub" axis.

n NOTE
Dual robot settings can be specified only in the "X and Y" or "Z and R"
combinations indicated at the controller screen.

2-1
2.2 Dual robot axis parameter settings

2.2 Dual robot axis parameter settings


All the required dual robot axis parameter settings are factory set at YAMAHA prior to
shipment, and do not require further setting by the user in order to operate the robot.
The dual robot axis parameters are all read-only parameters. When parameter changes are

2
required, the following procedure must first be performed.

[Procedure]
Dual robot settings

1) Press the programming box's [Emergency Stop] button to establish an emergency


stop status.

2) In the "SYSTEM" mode, press the (PARAM) key.

3) While holding down the key, press (PASSWRD).

4) Press , then press .

Changing read-only parameters

S Y S T E M>PAR AM V8 . 4 6

Robo t =MU L T I
M1 = aMR 1 6 M 4 =  n o   a x i s
M 1 = a( a s s i s t D 1 )     M 5 =  n o   a x i s
M2 =  n o  a x i s M 6 =  n o   a x i s
M3 =  n o  a x i s ? 0=   ( n o  u s e )
PA S S WR D

The above procedure allows the read-only parameters to be changed.


From the programming box, select

(SYSTEM) > (PARAM) > (AXIS),

then make the desired parameter changes.

MEMO
Because the dual robot axis parameter content varies according to the dual
robot model, refer to dual robot specific chapters for details.

2-2
Chapter 3 FLIP-X RIGID DUAL

Contents

3.1 Robot installation 3-1


3.1.1 Mounting accuracy 3-1
3.1.2 Using a mechanical reference position 3-1
3.1.3 Origin sensor installation 3-2
3.2 Absolute resets 3-3
3.2.1 When not storing the main and sub axis
positional relationship data 3-3
3.2.2 When storing the main and sub axis
positional relationship data 3-4
3.3 Robot operation cautions 3-5
3.3.1 "Origin incomplete" status 3-5
3.3.2 At servo on 3-5
3.4 FLIP-X rigid dual axis parameters 3-6
3.1 Robot installation

3.1 Robot installation

3.1.1 Mounting accuracy


The main and sub axes must be mounted with adequate accuracy in order to operate the
dual robot. In cases where robots are shipped with the main and sub axes already linked,
their parallelism and linkage squareness are factory-adjusted. Therefore, when being
mounted at the work site, an adequate degree of parallelism can be obtained by securing
the main axis first, and then slowly moving the sub axis by hand until it is aligned with the
main axis.
If the main and sub axes linkage is performed by the user, the parallelism and squareness
must be adjusted. An insufficient parallelism and squareness may activate the "17.4: Over
3

FLIP-X rigid dual


load" alarm.
An extremely low main and sub axes rigidity can result in poor sub axis positioning
accuracy.

MEMO
For details concerning the installation accuracy, please contact your YAMAHA
representative.

3.1.2 Using a mechanical reference position


In dual robot operations, the use of a mechanical reference position is recommended in
order to align the main and sub axis positions.
The "17.28: Dual P.E. counter overflow" alarm may occur if an excessive positional
deviation exists between the main and sub axis when the servo is turned on. Should this
alarm occur, the presence of a mechanical reference position simplifies recovery.
A mechanical reference position also simplifies absolute reset operations.

3-1
3.1 Robot installation

3.1.3 Origin sensor installation


Origin sensors are installed at the main and sub axes (1 sensor each).
When installed by YAMAHA, the position of these origin sensors are factory-adjusted.
After installing the robot, perform the section 3.2 "Absolute resets" procedure to verify that
the sensors are operating properly.

In cases where the user installs origin sensors, changes their positions, or replaces them,
etc., the origin sensor positions must then be adjusted.

3
First, install the sub axis origin sensor at a shorter distance (by 1/2 to twice the lead
length) so that it switches on before the main axis origin sensor switches on during
absolute reset. Also install the main and sub axis origin sensors in a manner which
FLIP-X rigid dual

provides a position where they can switch on simultaneously at absolute resets (see figure
below).

After completing the above procedure, perform the section 3.2 "Absolute resets" procedure
to adjust the origin sensor positions.

Robot installation (FLIP-X rigid dual)

Absolute reset direction

Main axis Sub axis


Origin sensor
The main and sub axes are each equipped
with one sensor. Set the sub axis origin
sensor so that it switches on before (by 1/2
Sensor dogs
to twice the lead length) the main axis
origin sensor.
Also set the sensors so that they can switch
on simultaneously at operations.

Main and sub axes link


Be sure that the link rigidity is not exces-
sively low, as this will reduce the repeated
positioning accuracy.
Parallelism
An overload alarm may occur if the main and
sub axes parallelism and linkage squareness
are deviated.

3-2
3.2 Absolute resets

3.2 Absolute resets


Dual robots require absolute resets just as standard single-axis robots do. An absolute reset allows
the user to "teach" the origin position when an "origin incomplete" status occurs. An absolute reset
moves the robot in its return-to-origin direction in order to detect the origin position.
For absolute reset details, refer to the "YAMAHA RCX142 Robot Controller User's Manual"
or the "YAMAHA RCX222 Robot Controller User's Manual".

FLIP-X rigid dual robots use a sensor method for absolute resets. When an absolute reset is
executed, the main axis detects the origin sensor, and then stops at the motor’s electrical
reference position following robot movement of no more than 1/4 the lead length. This 3
position is the main axis origin position. The sub axis origin position is determined by a

FLIP-X rigid dual


follow-up operation keyed to the main axis.
Moreover, the "dual offset" axis parameter setting can be specified in order to save the
main and sub axis positional relationship in memory. Execute an absolute reset using the
procedure described below.

3.2.1 When not storing the main and sub axis positional
relationship data
The absolute reset completion position is the main axis origin position. The sub axis origin
position is determined by its follow-up operation keyed to the main axis.
① Set the sub axis origin sensor so that it switches on before (by 1/2 to twice the lead
length) the main axis origin sensor.
② Specify "0" as the "dual offset" axis parameter setting. (see section 3.4 "FLIP-X rigid
dual axis parameters").
③ Execute an absolute reset and verify the machine reference value.
④ If the machine reference value is outside the 25 to 75 range, adjust the position of
the main axis origin sensor.
⑤ Repeat steps ③ ④ above until the machine reference value is within the 25 to 75
range, then verify that the distance between the main and sub axis origin sensors
is not less than 1/2 or not more than twice the length of the lead. Also position
the main and sub axis origin sensors so that they can switch on simultaneously at
absolute resets. (See section 3.1.3 "Origin sensor installation".)

This completes the procedure.


Absolute reset must be re-executed if the origin sensors are moved, or if the absolute
reset related parameters are changed. In such cases, execute the absolute reset using the
procedure described above.

3-3
3.2 Absolute resets

n Note
When using an RCX141 or RCX221 controller, return-to-origin must be re-executed
if the power has been turned off.

3.2.2 When storing the main and sub axis positional


relationship data

3
Although the absolute reset completion position is the main axis origin position, the sub axis
position is automatically adjusted by the amount of the "dual offset" axis parameter setting value.

1) Main axis origin sensor position adjustment


FLIP-X rigid dual

① This procedure is the same as that described in section 3.2.1.

2) Sub axis origin sensor position adjustment


② Specify "-2" as the axis parameter "dual offset" setting. (See section 3.4 "FLIP-X rigid
dual axis parameters".)
③ Execute an absolute reset and verify the machine reference value.
④ If the machine reference value is outside the 25 to 75 range, adjust the position of
the sub axis origin sensor.
⑤ Repeat steps ③ ④ above until the machine reference value is within the 25 to 75
range, then verify that the distance between the main and sub axis origin sensors
is not less than 1/2 or not more than twice the length of the lead. Also position
the main and sub axis origin sensors so that they can switch on simultaneously at
absolute resets. (See section 3.1.3 "Origin sensor installation".)

3) Dual offset setting


⑥ Specify "-1" as the "dual offset" axis parameter setting. (See section 3.4 "FLIP-X rigid
dual axis parameters".)
⑦ Execute an absolute reset and verify the machine reference value.
⑧ Enter the following value as the "dual offset" axis parameter setting:
[Dual offset] = [Machine reference x 4096 ÷ 100]
Decimal values should be rounded off to the nearest whole number.
⑨ Execute an absolute reset.

This completes the procedure.


After each subsequent absolute reset, the sub axis position is automatically adjusted so
that the main and sub axes mutual positional difference conforms to the "dual offset" axis
parameter setting value. Be aware that the sub axis position adjustment occurs after the
absolute reset completion.
For details regarding the axis parameter dual offset, see section 3.4 "FLIP-X rigid dual axis
parameters".

3-4
3.3 Robot operation cautions

Absolute reset must be re-executed if the origin sensors are moved, or if the absolute
reset related parameters are changed. In such cases, execute the absolute reset using the
procedure described above.

n Note
When using an RCX141 or RCX221 controller, return-to-origin must be re-executed
if the power has been turned off.

c CAUTION
・When setting the "dual offset" to save the main and sub axis positional
 relationship in memory, always set the "return-to-origin direction" parameter
3
 to "-" (minus). If it is set to "+" (plus), the current position will not be calculated

FLIP-X rigid dual


 correctly at power ON, causing a position deviation of the sub axis.
・When turning off the power after setting the "dual offset", always first execute
 an absolute reset and then turn off the power. If the power is turned off
 without executing an absolute reset, the current position will not be
 calculated correctly at power ON, causing a position deviation of the sub axis.

3.3 Robot operation cautions

3.3.1 "Origin incomplete" status


If an "origin incomplete" status occurs due to an incomplete absolute reset, due to
the robot cable being disconnected from the controller, or due to an absolute reset
related parameter change, the main and sub axis positional relationship which existed
immediately after power ON is maintained.
After an absolute reset completion, the positional relationship is adjusted in accordance
with the "dual offset" axis parameter setting value.

3.3.2 At ser vo on
If the sub axis position is deviated from the main axis position when the servo is turned
on while in an absolute reset completed condition, the sub axis position is automatically
adjusted immediately after the servo is turned on. The larger the deviation at this time, the
faster the sub axis movement, and this could pose a possible hazard to workers.

To prevent this hazard, the "17.28: Dual P.E. counter overflow" alarm occurs if the
distance between the main and sub axes equals or exceeds a prescribed value immediately
following a servo on.
In cases where large deviations are possible during a servo free-run condition due to a low
rigidity linkage of the main and sub axes, etc., the "servo parameter 3" (axis parameters)

3-5
3.4 FLIP-X rigid dual axis parameters

reference value should be set low to trigger an alarm, thereby ensuring safety. (See section
3.4 "FLIP-X rigid dual axis parameters".)
If the alarm is activated, adjust the main and sub axis positions, then perform a restart.

3.4 FLIP-X rigid dual axis parameters


This section explains the FLIP-X rigid dual axis parameters.
All the FLIP-X rigid dual axis parameters are all read-only parameters. Setting these

3 parameters requires that they first be changed to a write-enabled status by the procedure
described in chapter 2, section 2.2 "Dual robot axis parameter settings".

■ Kdvp
FLIP-X rigid dual

Specifies the servo gain setting for the main and sub axes speed deviation.
Although a higher setting value improves the sub axis follow-up operation keyed to the
main axis, vibration and abnormal noise may occur if the setting value is too high.
The appropriate setting value varies according to the robot model and the robot
installation conditions (main and sub axes linkage, etc.).
Setting range : Typically 10 to 20
Default setting: Varies according to the robot model

MEMO
Always consult with a YAMAHA representative before changing this setting
value.

■ Kdpp
Specifies the servo gain setting for the main and sub axis position deviation.
A higher setting value improves the sub axis follow-up operation keyed to the main
axis, and improves the sub axis positioning accuracy at stops. A higher setting is
particularly effective when the main and sub axes linkage rigidity is low. However,
abnormal noise and vibration may occur if the setting value is too high.
The appropriate setting value varies according to the robot model and the robot
installation conditions (main and sub axes linkage, etc.).
Setting range : Typically 10 to 20
Default setting: Varies according to the robot model

MEMO
Always consult with a YAMAHA representative before changing this setting
value.

3-6
3.4 FLIP-X rigid dual axis parameters

■ Dual offset
Specifies the mutual position difference which serves as the reference for the main and
sub axes.
When specified, the sub axis position is automatically adjusted so that the difference
between the main and sub axis positions conforms to this setting value. The setting
value is calculated by the following formula:
Dual offset [pulse] = Main and sub axes mutual position difference x 4096 ÷ 100
Decimal values should be rounded off to the nearest whole number.

n Note
Be aware that the sub axis position adjustment occurs after the absolute 3
reset completion.

FLIP-X rigid dual


Adjustment by "dual offset" setting

Return-to-origin direction
Motor's electrical angle Main axis sensor
reference position ON position
Return-to-origin
completion position
Main
axis

Sub
axis
If the sub axis position is
Sub axis sensor deviated at return-to-origin
ON position completion, it is automati-
Main and sub axes mutual
position difference cally adjusted to this setting
value.

The adjustment shown above does not occur if the "dual offset" is set to 0, -1, or -2.
Instead, these settings specify the following special functions.
(1) "0" setting
Disables the sub axis position adjustment following an absolute reset completion.
The main axis machine reference displays as the machine reference.
(2) "-1" setting
Disables the sub axis position adjustment following an absolute reset completion.
The main and sub axes mutual position difference displays as the machine
reference.
(3) "-2" setting
Disables the sub axis position adjustment following an absolute reset completion.
The sub axis machine reference displays as the machine reference.

3-7
3.4 FLIP-X rigid dual axis parameters

The above functions are used with respect to the "dual offset" setting. For details, see
section 3.2.2 "When main and sub axis positional relationship is saved in memory".

■ Dual axis polarity


Specifies the sub axis movement direction relative to the main axis.
If a minus-setting is specified, the sub axis moves in the same direction as the main axis.
If a plus-setting is specified, the sub axis moves the opposite direction as the main axis.

■ Servo parameter 3
Specifies the threshold value where the "17.28: Dual P.E. counter overflow" alarm is

3
activated. This alarm is activated if the main and sub axis position deviation exceeds
this threshold value.
Setting range : 0 to 65535 [pulse]
FLIP-X rigid dual

(A setting of "0" is processed as the maximum setting value.)


Default setting: 0

3-8
Chapter 4 FLIP-X FLEXIBLE DUAL

Contents

4.1 Robot installation 4-1


4.1.1 Mounting accuracy 4-1
4.1.2 Using a mechanical reference position 4-1
4.1.3 Origin sensor installation 4-2
4.2 Absolute resets 4-3
4.3 Robot operation cautions 4-5
4.3.1 "Origin incomplete" status 4-5
4.3.2 At servo on 4-5
4.4 FLIP-X flexible dual axis parameters 4-6
4.1 Robot installation

4.1 Robot installation

4.1.1 Mounting accuracy


The main and sub axes must be mounted with adequate accuracy in order to operate the
dual robot. In cases where robots are shipped with the main and sub axes already linked,
their parallelism is factory-adjusted. Therefore, when being mounted at the work site, an
adequate degree of parallelism can be obtained by securing the main axis first, and then
slowly moving the sub axis by hand until it is aligned with the main axis.
If the main and sub axes linkage is performed by the user, the parallelism must be
adjusted. An insufficient parallelism may activate the "17.4: Over load" alarm.
The FLIP-X flexible dual robot must have a linkage configuration which prevents force
interference between the main and sub axes. Failing to provide this configuration,
or providing an insufficient configuration could result in a "17.4 Over load" alarm
occurrence during robot operation. Also note that the preventive configuration may also 4
reduce positioning accuracy. (See section 4.1.3 "Origin sensor installation".)

FLIP-X flexible dual


MEMO
For details concerning the installation accuracy, please contact your YAMAHA
representative.

4.1.2 Using a mechanical reference position


In dual robot operations, the use of a mechanical reference position is recommended in
order to align the main and sub axis positions.
The "17.28: Dual P.E. counter overflow" alarm may occur when the servo is turned on if
an excessive positional deviation exists between the main and sub axes. Should this alarm
occur, the presence of a mechanical reference position simplifies recovery.
A mechanical reference position also simplifies absolute reset operations.

4-1
4.1 Robot Installation

4.1.3 Origin sensor installation


Origin sensors are installed at the main and sub axes (1 sensor each).
When installed by YAMAHA, the position of these origin sensors are factory-adjusted.
After installing the robot, perform the section 4.2 "Absolute resets" procedure to verify that
the sensors are operating properly.

In cases where the user installs origin sensors, changes their positions, or replaces them,
etc., the origin sensor positions must be adjusted.
If the main and sub axes are linked, their origin sensors should be positioned as close to
the same position (at both the main axis and sub axis sides) as possible. An appropriate
length is also required at the sensor dogs. (see the figure below)

4 After completing the above procedure, perform the section 4.2 "Absolute resets" procedure
to adjust the origin sensor positions.
FLIP-X flexible dual

Robot installation (FLIP-X flexible dual)

Absolute reset direction

Origin sensors
Main axis Sub axis
The main and sub axes are each
equipped with one sensor. Position
the two sensors as close to the same
position (at both the main axis and
sub axis sides) as possible.

Sensor dogs
An appropriate length
is required.

Main and sub axes linkage area


A configuration is required to prevent
force interference between the main and sub axes.

4-2
4.2 Absolute resets

4.2 Absolute resets


Dual robots require absolute resets just as standard single-axis robots do. An absolute reset
allows the user to "teach" the origin position when an "origin incomplete" status occurs.
An absolute reset moves the robot in its return-to-origin direction in order to detect the
origin position.
For absolute reset details, refer to the "YAMAHA RCX142 Robot Controller User's Manual"
or the "YAMAHA RCX222 Robot Controller User's Manual".

FLIP-X flexible dual robots use a sensor method for absolute resets. When an absolute
reset is executed, the main and sub axes detect the origin sensors, and then stops at the
motor’s electrical reference position following robot movement of no more than 1/4 the
lead length. This position represents the main axis and sub axis origin positions.
Moreover, a "dual offset" axis parameter setting can be specified in order to adjust either
the main or sub axis. Execute an absolute reset using the procedure described below.
4

FLIP-X flexible dual


1) Main axis origin sensor position adjustment
① Specify "0" as the "dual offset" axis parameter setting. (see section 4.4 "FLIP-X
Flexible Dual Axis Parameters").
② Execute an absolute reset and verify the machine reference value.
③ If the machine reference value is outside the 25 to 75 range, adjust the position of
the main axis origin sensor.
④ Repeat steps ② ③ above until the machine reference value is within the 25 to 75 range.

2) Sub axis origin sensor position adjustment


⑤ Specify "-2" as the "dual offset" axis parameter setting. (See section 4.4 "FLIP-X
Flexible Dual Axis Parameters".)
⑥ Execute an absolute reset and verify the machine reference value.
⑦ If the machine reference value is outside the 25 to 75 range, adjust the position of
the sub axis origin sensor.
⑧ Repeat steps ⑥ ⑦ above until the machine reference value is within the 25 to 75
range, and verify that the origin sensors are located at approximately the same
position on both main and sub axes.

This completes the procedure.


If further main or sub axis origin position adjustment is desired, continue with the procedure
described in item 3) "Dual offset setting".

4-3
4.2 Absolute resets

3) Dual offset setting


⑨ In the "dual offset" axis parameter, enter the distance [pulse] to be offset.
A plus "dual offset" setting value offsets the sub axis in the plus-direction.
A minus "dual offset" setting value offsets the main axis in the plus-direction.
⑩ Execute an absolute reset. Be aware that the offset-subject axis is moved by the
amount of the "dual offset" setting value following movement to the origin position.
For details regarding the "dual offset" axis parameter setting, see section 4.4 "FLIP-X
Flexible Dual Parameters".

This completes the procedure.


If the main or sub axis origin sensors are moved, or if the absolute reset related parameters

4
are changed, absolute reset must be re-executed using the procedure described above.

n Note
FLIP-X flexible dual

When using an RCX141 or RCX221 controller, return-to-origin must be re-executed


if the power has been turned off.

c CAUTION
When turning off the power after setting the "dual offset", always first execute
an absolute reset and then turn off the power. If the power is turned off without
executing an absolute reset, the current position will not be calculated
correctly at power ON, causing a position deviation of the sub axis.

4-4
4.3 Robot operation cautions

4.3 Robot operation cautions

4.3.1 "Origin incomplete" status


If an "origin incomplete" status occurs due to an incomplete absolute reset, due to
the robot cable being disconnected from the controller, or due to an absolute reset
related parameter change, the main and sub axis positional relationship which existed
immediately after power ON is maintained.
After an absolute reset completion, the positional relationship is adjusted in accordance
with the "dual offset" axis parameter setting value

4.3.2 At ser vo on
If the sub axis position is deviated from the main axis position when the servo is turned
on while in an absolute reset completed condition, the sub axis position is automatically
4

FLIP-X flexible dual


adjusted immediately after the servo is turned on. The larger the deviation at this time, the
faster the sub axis movement, and this could pose a possible hazard to workers.
To prevent this hazard, the "17.28: Dual P.E. counter overflow" alarm occurs if the
distance between the main and sub axes equals or exceeds a prescribed value immediately
following a servo on.
In cases where large deviations are possible during a servo free-run condition, the "servo
parameter 3" (axis parameter) reference value should be set low to trigger an alarm,
thereby ensuring safety. (See section 4.4 "FLIP-X Flexible Dual Axis Parameters".)
If the alarm is activated, adjust the main and sub axis positions, then perform a restart.

4-5
4.4 FLIP-X flexible dual axis parameters

4.4 FLIP-X flexible dual axis parameters


This section explains the FLIP-X flexible dual axis parameters.
Setting these parameters requires that they first be changed to a write-enabled status by
the procedure described in chapter 2, section 2.2 "Dual Robot Axis Parameter Settings".

■ Dual offset
Specifies the main axis or sub axis position at an absolute reset completion.
The desired offset distance is specified in [pulse] units, and that offset is applied relative to
the main axis or sub axis origin position following an absolute reset completion. Following
a return-to-origin completion, the origin based positional relationship is maintained.
(1) Plus-value setting
Offsets the main axis in the plus-direction.

4 (2) Minus-value setting


Offsets the main axis in the plus-direction.
FLIP-X flexible dual

Absolute reset operation with "dual offset" setting

Return-to-origin
completion position
Origin position
+ − Sub axis
(or "main axis" when setting
is a minus value)

Plus-direction movement occurs


by the setting value [pulse]
amount.

n Note
Be aware that the offset-subject axis movement occurs (by the amount of the
"dual offset" setting value) after movement to the origin position is completed.

■ Dual axis polarity


Specifies the sub axis movement direction relative to the main axis.
If a minus-setting is specified, the sub axis moves in the same direction as the main axis.
If a plus-setting is specified, the sub axis moves the opposite direction as the main axis.

■ Servo parameter 3
Specifies the threshold value where the "17.28: Dual P.E. counter overflow" alarm is
activated. This alarm is activated if the main and sub axis position deviation exceeds
this threshold value.
Setting range : 0 to 65535 [pulse]
(A setting of "0" is processed as the maximum setting value.)
Default setting: 0

4-6
Chapter 5 PHASER RIGID DUAL

Contents

5.1 Robot installation 5-1


5.1.1 Mounting accuracy 5-1
5.1.2 Using a mechanical reference position 5-1
5.1.3 Origin sensor installation 5-2
5.2 Return-to-origin operations 5-3
5.3 Robot operation cautions 5-4
5.3.1 "Origin incomplete" status 5-4
5.3.2 At servo on 5-4
5.4 PHASER rigid dual axis parameters 5-5
5.1 Robot installation

5.1 Robot installation

5.1.1 Mounting accuracy


The main and sub axes must be mounted with adequate accuracy in order to operate the
dual robot. In cases where robots are shipped with the main and sub axes already linked,
their parallelism and linkage squareness are factory-adjusted. Therefore, when being
mounted at the work site, an adequate degree of parallelism can be obtained by securing
the main axis first, and then slowly moving the sub axis by hand until it is aligned with the
main axis.
If the main and sub axis linkage is performed by the user, the parallelism and squareness
must be adjusted. An insufficient parallelism and squareness may activate the "17.4: Over
load" alarm.
PHASER rigid dual robots use a stroke end method for return-to-origin operations. The
main and sub axis positions must therefore be adjusted so that main and sub axes contact
occurs simultaneously, and the linkage squareness must also be adequately adjusted.
Improper position and squareness adjustments can increase the sub axis motor load
when contact occurs, possibly causing malfunctions. (See section 5.1.3 "Origin sensor
installation" for further details.)
5
An extremely low main and sub axes linkage rigidity can result in poor sub axis

PHASER rigid dual


positioning accuracy.

MEMO
For details concerning the installation accuracy, please contact your YAMAHA
representative.

5.1.2 Using a mechanical reference position


In dual robot operations, the use of a mechanical reference position is recommended in
order to align the main and sub axis positions.
The "17.28: Dual P.E. counter overflow" alarm may occur when the servo is turned on if
an excessive positional deviation exists between the main and sub axes. Should this alarm
occur, the presence of a mechanical reference position simplifies recovery.
A mechanical reference position also simplifies absolute reset operations.

5-1
5.1 Robot installation

5.1.3 Origin sensor installation


PHASER rigid dual robots do not require origin sensors because the return-to-origin
operation uses a stroke end method.

Robot installation (PHASER rigid dual)

Return-to-origin direction

Origin sensor
Main axis Sub axis Origin sensors not required
because the return-to-origin
operation uses a stroke end method.

Main and sub axes link

5 Due to the stroke end method return-to-origin


operation, the main and sub axis positions and
squareness must be carefully adjusted to ensure
that contact occurs at both axes simultaneously.
PHASER rigid dual

Also be sure that the link rigidity is not excessively


low, as this will reduce the repeated positioning
accuracy.

Parallelism
An overload alarm may occur if the main and sub axes
parallelism and linkage squareness are deviated.

5-2
5.2 Return-to-origin operations

5.2 Return-to-origin operations


Dual robots require return-to-origin operations just as standard single-axis robots do.
A return-to-origin moves the robot to a fixed point specified in advance and clears the
controller's position data to zero. When a return-to-origin is executed, the robot moves in
its return-to-origin direction in order to detect the origin position.
For return-to-origin details, refer to the "YAMAHA RCX141 Robot Controller User's
Manual" or the "YAMAHA RCX221 Robot Controller User's Manual".

c CAUTION
In the case of semi-absolute type PHASER rigid dual robots, an absolute search
is automatically performed by starting a return-to-origin operation. The return-
to-origin movement (described later) does not occur. For details regarding
absolute search movement, refer to Chapter 7, "Semi-absolute type PHASER
rigid dual/flexible dual".

PHASER rigid dual robots use a stroke end method for return-to-origin operations. When a
return-to-origin is executed, the main axis moves until contact is made with the robot end,
5

PHASER rigid dual


and then it returns, with stopping at the motor's electrical reference position. This position
is the main axis origin position. The sub axis operation and origin position is determined
by follow-up operation keyed to the main axis.
Care should be taken with regard to the main and sub axes link when performing a return-
to-origin. (See section 4.1 "Robot installation" for details.)
The machine reference is factory-adjusted and requires no further adjusting by the user.

5-3
5.3 Robot operation cautions

5.3 Robot operation cautions

5.3.1 "Origin incomplete" status


If an "origin incomplete" status occurs due to an incomplete return-to-origin, due to
the robot cable being disconnected from the controller, or due to a return-to-origin
related parameter change, the main and sub axis positional relationship which existed
immediately after power ON is maintained.
After a return-to-origin completion, the origin based positional relationship is maintained.

5.3.2 At ser vo on
If the sub axis position is deviated from the main axis position when the servo is turned
on while in a return-to-origin completed condition, the sub axis position is automatically
adjusted immediately after the servo is turned on. The larger the deviation at this time, the
faster the sub axis movement, and this could pose a possible hazard to workers.

5
To prevent this hazard, the "17.28: Dual P.E. counter overflow" alarm occurs if the
distance between the main and sub axes equals or exceeds a prescribed value immediately
following a servo on.
PHASER rigid dual

In cases where large deviations are possible during a servo free-run condition due to a low
rigidity linkage of the main and sub axes, etc., the "servo parameter 3" (axis parameters)
reference value should be set low to trigger an alarm, thereby ensuring safety. (See section
5.4 "PHASER Rigid Dual Axis Parameters".)
If the alarm is activated, adjust the main and sub axis positions, then perform a restart.

5-4
5.4 PHASER rigid dual axis parameters

5.4 PHASER rigid dual axis parameters


This section explains the PHASER rigid dual axis parameters.
All the PHASER rigid dual axis parameters are all read-only parameters. Setting these
parameters requires that they first be changed to a write-enabled status by the procedure
described in chapter 2, section 2.2 "Dual Robot Axis Parameter Settings".

■ Kdvp
Specifies the servo gain setting for the main and sub axes speed deviation. Although a
higher setting value improves the sub axis follow-up operation keyed to the main axis,
vibration and abnormal noise may occur if the setting value is too high.
The appropriate setting value varies according to the robot model and the robot
installation conditions (main and sub axes linkage, etc.).
Setting range : Typically 10 to 20
Default setting: Varies according to the robot model

MEMO
Always consult with a YAMAHA representative before changing this setting value.

■ Kdpp
5
Specifies the servo gain setting for the main and sub axis position deviation. A higher

PHASER rigid dual


setting value improves the sub axis follow-up operation keyed to the main axis, and
improves the sub axis positioning accuracy at stops. A higher setting is particularly
effective when the main and sub axes linkage rigidity is low. However, abnormal noise
and vibration may occur if the setting value is too high.
The appropriate setting value varies according to the robot model and the robot
installation conditions (main and sub axes linkage, etc.).
Setting range : Typically 10 to 20
Default setting: Varies according to the robot model

MEMO
Always consult with a YAMAHA representative before changing this setting value.

■ Dual axis polarity


Specifies the sub axis movement direction relative to the main axis.
If a minus-setting is specified, the sub axis moves in the same direction as the main axis.
If a plus-setting is specified, the sub axis moves the opposite direction as the main axis.

■ Servo parameter 3
Specifies the threshold value where the "17.28: Dual P.E. counter overflow" alarm is
activated. This alarm is activated if the main and sub axis position deviation exceeds
this threshold value.
Setting range : 0 to 65535 [pulse]
(A setting of "0" is processed as 16384.)
Default setting: 0

5-5
MEMO

5-6
Chapter 6 PHASER FLEXIBLE DUAL

Contents

6.1 Robot installation 6-1


6.1.1 Mounting accuracy 6-1
6.1.2 Using a mechanical reference position 6-1
6.1.3 Origin sensor installation 6-2
6.2 Return-to-origin operations 6-3
6.3 Robot operation cautions 6-4
6.3.1 "Origin incomplete" status 6-4
6.3.2 At servo on 6-4
6.4 PHASER flexible dual axis parameters 6-5
6.1 Robot installation

6.1 Robot installation

6.1.1 Mounting accuracy


The main and sub axes must be mounted with adequate accuracy in order to operate the
dual robot. In cases where robots are shipped with the main and sub axes already linked,
their parallelism is factory-adjusted. Therefore, when being mounted at the work site, an
adequate degree of parallelism can be obtained by securing the main axis first, and then
slowly moving the sub axis by hand until it is aligned with the main axis.
If the main and sub axes linkage is performed by the user, the parallelism must be
adjusted. An insufficient parallelism may activate the "17.4: Over load" alarm.
PHASER flexible dual robot must have a linkage configuration which prevents force
interference between the main and sub axes. Failing to provide this configuration,
or providing an insufficient configuration could result in a "17.4 Over load" alarm
occurrence during robot operation. Also note that this preventive configuration may also
reduce positioning accuracy. (See section 6.1.3 "Origin Sensor Installation".)

MEMO
For details concerning the installation accuracy, please contact your YAMAHA
representative.

6
6.1.2 Using a mechanical reference position

PHASER flexible dual


In dual robot operations, the use of a mechanical reference position is recommended in
order to align the main and sub axis positions.
The "17.28: Dual P.E. counter overflow" alarm may occur when the servo is turned on if
an excessive positional deviation exists between the main and sub axes. Should this alarm
occur, the presence of a mechanical reference position simplifies recovery.
A mechanical reference position also simplifies absolute reset operations.

6-1
6.1 Robot installation

6.1.3 Origin sensor installation


Origin sensors are installed at the main and sub axes (1 sensor each).
When installed by YAMAHA, the position of these origin sensors are factory-adjusted and
should not be changed by the user.
An origin sensor readjustment is required, however, if the robot is reconfigured or moved.
In such cases, please contact your YAMAHA representative.

Robot installation (PHASER flexible dual)

Return-to-origin direction

Origin sensors
Main axis Sub axis
Origin sensors are installed at the main
and sub axes (1 sensor each). Do not
change their factory-adjusted positions.

Sensor dogs

6
An appropriate length is required.
PHASER flexible dual

Main and sub axes linkage


A configuration which frees the main and sub
axes is required in order to prevent force interfer-
ence between these axes.

n Note
In the case of semi-absolute type PHASER flexible dual robots, the origin sensors
are installed at different positions. For details, refer to Chapter 7, "Semi-absolute
type PHASER rigid dual/flexible dual".

6-2
6.2 Return-to-origin operations

6.2 Return-to-origin operations


Dual robots require return-to-origin operations just as standard single-axis robots do.
A return-to-origin moves the robot to a fixed point specified in advance and clears the
controller's position data to zero. When a return-to-origin is executed, the robot moves in
its return-to-origin direction in order to detect the origin position.
For return-to-origin details, refer to the "YAMAHA RCX141 Robot Controller User's
Manual" or the "YAMAHA RCX221 Robot Controller User's Manual".

c CAUTION
In the case of semi-absolute type PHASER flexible dual robots, an absolute
search is automatically performed by starting a return-to-origin operation. The
return-to-origin movement (described later) does not occur. For details
regarding absolute search movement, refer to Chapter 7, "Semi-absolute type
PHASER rigid dual/flexible dual".

PHASER flexible dual robots use a sensor method for return-to-origin operations. When
a return-to-origin is executed, the main and sub axes each detect their origin sensors,
followed by movement to the Z-phase, with a stop occurring at the motor's electrical
reference position. These respective positions are the main and sub axis origin positions.

6
Moreover, the "dual offset" and "servo parameter 5" axis parameter settings can be
specified to adjust the main or sub axis position.
Use the following procedure to perform a return-to-origin operation.

PHASER flexible dual


1) Origin sensor position adjustment
The origin sensor positions are factory-adjusted for both the main and sub axes, and
require no further adjustment.
If the origin position on the main or sub axis needs to be adjusted, make the settings
as described below in "2) Dual offset setting".

2) "Dual offset" setting


In the "dual offset" and "servo parameter 5" axis parameters, enter the distance [pulse]
to offset the main or sub axis.
● "Servo parameter 5" set as "0"
A plus-value "dual offset" setting value [pulse] offsets the sub axis in the plus-
direction.
A minus-value "dual offset" setting value [pulse] offsets the main axis in the plus-
direction.
● "Servo parameter 5" set as other than "0"
If the sum of the "dual offset" and "servo parameter 5" setting values is a plus value,
the sub axis is offset in the minus direction.

6-3
6.3 Robot operation cautions

If the sum of the "dual offset" and "servo parameter 5" setting values is a minus
value, the main axis is offset in the minus direction.

n Note
Be aware that the axis offset occurs (by the amount of the "dual offset"
setting) after movement to the origin position is completed.

For details regarding the axis parameter dual offset and servo parameter 5, see section
6.4 "PHASER flexible dual axis parameters".

This completes the procedure.


Return-to-origin must be re-executed if the origin sensor position has been moved, or if
the return-to-origin related parameters have been changed. In this case, re-execute return-
to-origin using the procedure described above.

6.3 Robot operation cautions

6.3.1 "Origin incomplete" status


If an "origin incomplete" status occurs due to an incomplete return-to-origin, due to
the robot cable being disconnected from the controller, or due to a return-to-origin

6 related parameter change, the main and sub axis positional relationship which existed
immediately after power ON is maintained.
After a return-to-origin completion, the positional relationship is adjusted in accordance
PHASER flexible dual

with the "dual offset" and "servo parameter 5" axis parameter setting values.

6.3.2 At ser vo on
If the sub axis position is deviated from the main axis position when the servo is turned
on while in an absolute reset completed condition, the sub axis position is automatically
adjusted immediately after the servo is turned on. The larger the deviation at this time, the
faster the sub axis movement, and this could pose a possible hazard to workers.
To prevent this hazard, the "17.28: Dual P.E. counter overflow" alarm occurs if the
distance between the main and sub axes equals or exceeds a prescribed value immediately
following a servo on.
In cases where large deviations are possible during a servo free-run condition, the "servo
parameter 3" (axis parameter) reference value should be set low to trigger an alarm,
thereby ensuring safety. (See section 4.4 "FLIP-X Flexible Dual Axis Parameters".)
If the alarm is activated, adjust the main and sub axis positions, then perform a restart.

6-4
6.4 PHASER flexible dual axis parameters

6.4 PHASER flexible dual axis parameters


This section explains the PHASER flexible dual axis parameters.
All the PHASER flexible dual axis parameters are all read-only parameters. Setting these
parameters requires that they first be changed to a write-enabled status by the procedure
described in chapter 2, section 2.2 "Dual robot axis parameter settings".

■ Dual offset (when "servo parameter 5" = "0")


Specifies the main or sub axis position at the return-to-origin completion.
The desired offset distance is specified in [pulse] units, and that offset is applied in the
plus-direction relative to the main axis or sub axis origin position following an absolute
reset completion. Following a return-to-origin completion, the origin based positional
relationship is maintained.

● Plus-value setting
Offsets the sub axis in the plus-direction.
● Minus-value setting
Offsets the main axis in the plus-direction.

Return-to-origin operation with "dual offset" setting

Return-to-origin
completion position
(when "servo parameter 5" is set to "0")
6

PHASER flexible dual


Origin position
+ − Sub axis
(or "main axis" when set as
a minus value)

Plus-direction movement occurs


by the setting value [pulse] amount.

Be aware that the offset-subject axis is moved by the amount of the "dual offset" setting
value after movement to the origin position.
If the "servo parameter 5" axis parameter is set to a value other than "0", the operation
pattern differs from that shown above. For details, refer to the "servo parameter 5"
explanation given below.

■ Servo parameter 5
Adjusts the main or sub axis position at a return-to-origin completion.
The desired offset distance [pulse] can be specified at both the "dual offset" and "servo
parameter 5" settings to offset the main or sub axis in the minus direction relative to its
origin position.
Following a return-to-origin completion, the origin based positional relationship is maintained.

6-5
6.4 PHASER flexible dual axis parameters

● If the sum of the "dual offset" and "servo parameter 5" settings is a plus value
The sub axis is offset in the minus direction.
● If the sum of the "dual offset" and "servo parameter 5" settings is a minus value
The main axis is offset in the minus direction.

Return-to-origin operation with "dual offset" setting


(and with "servo parameter 5" setting other than "0")
Return-to-origin
Origin position completion
+ − Sub axis
(or "main axis" if sum of setting
values is a minus value)

Minus-direction movement the amount


of the setting value sum [pulse]

Be aware that the offset-subject axis is moved by the amount of the "dual offset"
setting value after movement to the origin position.

The "servo parameter 5" setting can only be used when a "dual offset" setting is
specified. When a minus-direction offset is desired, divide the offset distance between
the "dual offset" and "servo parameter 5" settings.

6 ■ Dual axis polarity


Specifies the sub axis movement direction relative to the main axis.
PHASER flexible dual

If a minus-setting is specified, the sub axis moves in the same direction as the main axis.
If a plus-setting is specified, the sub axis moves the opposite direction as the main axis.

■ Servo parameter 3
Specifies the threshold value [pulse] where the "17.28: Dual P.E. counter overflow"
alarm is activated. This alarm is activated if the main and sub axis position deviation
exceeds this threshold value.
Setting range : 0 to 65535 [pulse]
(A setting of "0" is processed as 16384.)
Default setting: Depends on robot model.

6-6
Chapter 7 SEMI-ABSOLUTE TYPE
PHASER RIGID DUAL/FLEXIBLE DUAL

Contents

7.1 Semi-absolute 7-1


7.2 Origin sensor installation 7-2
7.3 Absolute search 7-3
7.1 Semi-absolute

7.1 Semi-absolute
"Semi-absolute" is the name for a simple absolute scale used in the YAMAHA linear single-
axis robot PHASER series. Semi-absolute type single-axis robots use a position detection
scale with a simple absolute search function that automatically searches an absolute
7

SEMI-ABSOLUTE TYPE PHASER RIGID DUAL/FLEXIBLE DUAL


position when return-to-origin is performed. This function allows detecting the absolute
position with just a minimal movement, thus drastically reducing the time needed for return-
to-origin operation by PHASER series robots, especially those with long-stroke movements.
As with other types of single-axis robots, semi-absolute type PHASER rigid dual robots and
PHASER flexible dual robots detect the absolute position by absolute search movement.
In this case, origin sensors must be installed according to the semi-absolute specifications
and the "dual offset" setting must be made properly.

c CAUTION
Methods for "robot installation" and "parameter setting" other than "origin
sensor installation" and "dual offset setting" are the same as those for non-semi-
absolute type robots.

7-1
7.2 Origin sensor installation

7.2 Origin sensor installation

7 In semi-absolute type robots, origin sensors are used to detect the stroke limit during
absolute search movement.
Install one origin sensor each at the stroke end of the main axis and sub axis, and adjust
SEMI-ABSOLUTE TYPE PHASER RIGID DUAL/FLEXIBLE DUAL

the position of each origin sensor so that it switches on before the robot strikes the stroke
end during absolute search movement.
For details regarding the movement in origin sensor detection during absolute search, refer
to 7.3, "Absolute search".

c CAUTION
Origin sensors are not required when the stroke end method is used for return-
to-origin operation.

Origin sensor installation positions for semi-absolute type


PHASER rigid dual/flexible dual robots

Return-to-origin direction
Main axis Sub axis

Origin sensor
Install one origin sensor each at
the stroke end of the main axis
and sub axis.

Sensor dog

7-2
7.3 Absolute search

7.3 Absolute search


Absolute search includes the sensor method and stroke end method. The stroke limit is
detected by absolute search, either using an origin sensor or a torque generated when the
robot reaches the stroke end. The absolute search method can be selected by the "Origin
7

SEMI-ABSOLUTE TYPE PHASER RIGID DUAL/FLEXIBLE DUAL


detection method" axis parameter.
After an absolute search is completed, the absolute position is detected and the origin
position is set to the 0 (zero) position on the simple absolute scale.
The flow of absolute search movements differs depending on whether the stroke limit is
detected or not. The flow of absolute research movements is described below.

1) When not detecting the stroke limit

Absolute search movements (when not detecting stroke limit)

Return-to-origin direction

Absolute search
C A D B start position

Sub axis

Main axis

② Absolute search movement


on main axis

④ Absolute search movement


on sub axis

① Upon starting return-to-origin, the main axis starts an absolute search and moves to
position A in the return-to-origin direction. The sub axis follows the movement of
the main axis. The maximum distance moved from the absolute search start position
to position A is 76mm.
② The movement direction is reversed and the axis continues moving to position B
where the current position on the main axis is determined. Position B is at a point

7-3
7.3 Absolute search

between the absolute search start position and position A.


③ The sub axis starts an absolute search and moves to position C in the return-to-

7 origin direction. The main axis follows the movement of the sub axis. The maximum
distance moved from position B to position C is 76mm.
④ The movement direction is reversed and the axis continues moving to position D
SEMI-ABSOLUTE TYPE PHASER RIGID DUAL/FLEXIBLE DUAL

where the current position on the sub axis is determined. Position D is at a point
between position B and position C.
⑤ When the current positions on the main and sub axes are determined, the main and
sub axes move to the same absolute position.

If the mechanical positions of the main and sub axes are not aligned, adjust the
positional relationship using the "dual offset" axis parameter. For how to set the "dual
offset" parameter, refer to "3) Dual offset setting".

2) When detecting the stroke limit


When the sensor method is used for return-to-origin operation, the origin sensor
position is viewed as the stroke limit during absolute search. The movement direction
is reversed at the time the origin sensor switches on. In the stroke end method, the
movement direction is reversed when the stroke end is detected.
The figure below shows the flow of absolute search movements when the stroke limit
is detected while the main axis moves to position A (see figure in 1)).

Absolute search movements


(when detecting stroke limit during main axis absolute search)

Return-to-origin direction

Limit detection Absolute search


position start position F E

Sub axis

Main axis

③ Absolute search movement


on main axis

7-4
7.3 Absolute search

① Upon starting return-to-origin, the main axis starts an absolute search and moves in
the return-to-origin direction. The sub axis follows the movement of the main axis.
② When the stroke limit is detected, the movement direction is reversed and the axis
continues moving to position E. The maximum distance moved from the stroke limit 7
detection position to position E is 76mm.

SEMI-ABSOLUTE TYPE PHASER RIGID DUAL/FLEXIBLE DUAL


③ The movement direction is again reversed and the axis continues moving to
position F where the current position on the main axis is determined. Position F is at
a point between the stroke limit detection position and position E.

After the current position on the main axis is determined, an absolute search on the
sub axis starts.
Also, in cases where the stroke limit is detected while the sub axis moves to position
C (see figure in 1)) by absolute search, the absolute search movements are the same as
those for detecting the stroke limit on the main axis.

c CAUTION
・When the sensor method is used for return-to-origin operation, the stroke
limit is detected with the origin sensor. In the stroke end method, the
stroke end is detected as the stroke limit.
・When the sensor method is used for return-to-origin operation, the
movement direction is reversed at a timing that either of the main axis
origin sensor or sub axis origin sensor turns on.

3) Dual offset setting


When the current positions on the main and sub axes are determined, the main
and sub axes move to the same absolute position. At this point, if the mechanical
positions of the main and sub axes are not aligned, a difference occurs in their
positional relationship. In some cases, this may cause abnormal operation due to force
interference occurring between the main and sub axes.

Example of sub axis movement after absolute search is completed

Absolute search Stop position


completion position
② Sub axis moves to the same absolute position
  as main axis
ー + Sub axis
10 20 30
① Main axis stops at the absolute search
  completion position
ー + Main axis
10 20 30

7-5
7.3 Absolute search

If the mechanical positions of the main and sub axes are not aligned as shown above,
set the "dual offset" to adjust the positional relationship

7 When the "dual offset" is set and an absolute search is performed, the current positions
on the main and sub axes are determined and then the sub axis moves to the absolute
position that is offset by the mount of the "dual offset" setting.
SEMI-ABSOLUTE TYPE PHASER RIGID DUAL/FLEXIBLE DUAL

(1) Plus-value setting


Offsets the sub axis in the minus-direction.
(2) Minus-value setting
Offsets the sub axis in the plus-direction.

Example of sub axis movement with "dual offset" setting,after absolute


search is completed.

① Set a plus "dual offset" value for the position


Absolute search   deviation between the main and sub axes.
completion position
② After absolute search is completed,
  the sub axis moves from the same absolute
  position as the main axis to the absolute
  position that is offset in the minus direction
  by the amount of the "dual offset" value set in ①.

ー + Sub axis
10 20 30

ー + Main axis
10 20 30

7-6
Chapter 8 TROUBLESHOOTING

Contents

8.1 FLIP-X rigid dual and PHASER rigid dual 8-1


8.2 FLIP-X flexible dual and PHASER flexible dual 8-2
8.1 FLIP-X rigid dual and PHASER rigid dual

Dual robot troubleshooting examples are given below.

8.1 FLIP-X rigid dual and PHASER rigid dual


Problem Cause Corrective Action
1 The "17.21: Origin
sensor failure" alarm
occurs at absolute resets
(return-to-origin).
a) Improperly positioned origin
sensor or sensor dog.
a) Readjust the origin sensor or
sensor dog position (for details,
refer to the "Absolute Resets"
(return-to-origin) sections for
8
each dual robot type).

Troubleshooting
2 Sub axis position is a) Improperly aligned main and a) Realign the axes.
unstable at absolute sub axes.
reset (return-to-origin)
completion. b) Insufficient main and sub axes b) Increase the linkage rigidity.
linkage.
c) No "dual offset" axis parameter c) Specify the appropriate
setting (applies only to the parameter settings (for details,
FLIP-X rigid dual robot). refer to the "Absolute Resets"
(return-to-origin) sections for
each dual robot type).
3 Sub axis repeated a) Improperly aligned main and a) Realign the axes.
positioning accuracy is sub axes.
poor.
b) Insufficient main and sub axes b) Increase the linkage rigidity.
linkage.
c) Insufficient servo parameter c) Contact your YAMAHA
adjustment. representative.
d) Insufficient rigid dual servo d) Contact your YAMAHA
parameter adjustment. representative.
4 Vibration and/or a) Improperly aligned main and a) Realign the axes.
abnormal noise occurs sub axes.
during operation.
b) Insufficient main and sub axes b) Increase the linkage rigidity.
linkage.
c) Insufficient servo parameter c) Contact your YAMAHA
adjustment. representative.
d) Insufficient rigid dual servo d) Contact your YAMAHA
parameter adjustment. representative.
5 The "17.4: Over load" a) Improperly aligned main and a) Realign the axes.
alarm occurs. sub axes.
b) Insufficient main and sub axes b) Increase the linkage rigidity.
linkage.
6 The "17.28: Dual P.E. a) Improperly aligned main and a) Realign the axes.
counter overflow" or sub axes.
"17.6: P.E. counter
overflow" alarm occurs b) Insufficient main and sub axes b) Increase the linkage rigidity.
during operation. linkage.
c) Insufficient rigid dual servo c) Contact your YAMAHA
parameter adjustment. representative.
d) The "servo parameter 3" axis d) Increase the parameter setting
parameter setting is too low. value.
7 The "17.28: Dual P.E. a) Excessive deviation between a) Adjust the main and sub axis
counter overflow" or the main and sub axis positions positions before turning the
"17.6: P.E. counter at power ON. power ON.
overflow" alarm occurs
at power ON. b) Excessive deviation between b) Increase the parameter setting
the main and sub axis positions value.
at power ON.

8-1
8.2 FLIP-X flexible dual and PHASER flexible dual

8.2 FLIP-X flexible dual and PHASER flexible dual


Problem Cause Corrective Action
1 The "17.21: Origin a) Improperly positioned origin a) Readjust the origin sensor or
sensor failure" alarm sensor or sensor dog. sensor dog position (for details,
occurs at absolute resets refer to the "Absolute Resets"

8
(return-to-origin). (return-to-origin) sections for
each dual robot type).

2 Repeated positioning a) The linkage area lacks a a) Change the linkage


accuracy is poor. configuration for preventing configuration.
Troubleshooting

force interference between the


axes.
3 Vibration and/or a) The linkage area lacks a a) Change the linkage
abnormal noise occurs configuration for preventing configuration.
during operation. force interference between the
axes.
b) Insufficient servo parameter b) Contact your YAMAHA
adjustment. representative.
4 The "17.4: Over load" a) The linkage area lacks a a) Change the linkage
alarm occurs. configuration for preventing configuration.
force interference between the
axes.
b) Insufficient servo parameter b) Contact your YAMAHA
adjustment. representative.
5 The "17.28: Dual P.E. a) The linkage area lacks a a) Change the linkage
counter overflow" or configuration for preventing configuration.
"17.6: P.E. counter force interference between the
overflow" alarm occurs axes.
during operation.
b) Insufficient servo parameter b) Contact your YAMAHA
adjustment. representative.
c) The "servo parameter 3" axis c) Increase the parameter setting
parameter setting is too low. value.
6 The "17.28: Dual P.E. a) Excessive deviation between a) Adjust the main and sub axis
counter overflow" or the main and sub axis positions positions before turning the
"17.6: P.E. counter at power ON (this applies only power ON.
overflow" alarm occurs the FLIP-X flexible dual robot).
at power ON.
b) The "servo parameter 3" axis b) Increase the parameter setting
parameter setting is too low. value.

8-2
MEMO
Revision record

Manual version Issue date Description

Ver. 1.00 Jul. 2008 English manual Ver. 1.00 is based on Japanese manual Ver. 1.00.
Ver. 1.01 Dec. 2008 English manual Ver. 1.01 is based on Japanese manual Ver. 1.02.
Ver. 1.02 Oct. 2009 English manual Ver. 1.02 is based on Japanese manual Ver. 1.03.

User's Manual

Oct. 2009
Ver. 1.02
This manual is based on Ver. 1.03 of Japanese manual.

© YAMAHA MOTOR CO., LTD.


IM Business Unit
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. If you find any part unclear in this manual,
please contact YAMAHA or YAMAHA sales representatives.

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