Instruction/ maintenance manual of the product 3-axis model Yamaha
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OWNER'S MANUAL.
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CONTENTS CHAPTER 1 Using the Robot Safely 1 Safety Information .................................................................. 1-1 2 Essential Caution Items .......................................................... 1-2 3 Special T raining for Industrial Robot Operation .
10 Setting the Robot .................................................................. 3-22 10-1 Setting the payload ........................................................................ 3-22 10-2 Setting the maximum speed ........................
CHAPTER 7 FXYX 1 Installation .............................................................................. 7-1 1-1 Installation bolt types ....................................................................... 7-1 1-2 Installation bolt nominal length .
3-6 ZFH (Arm type, gantry type, moving arm type 3rd-axis option) XZ 2nd-axis option ......................................................................... 8-17 3-7 ZF L (Arm type, moving arm type, 3rd-axis option/XZ type 2-axis model) ... 8-18 4 User Wiring and User Piping .
4 User Wiring and User Piping ................................................ 9-14 4-1 Cable carrier type ........................................................................... 9-14 4-1-1 Example of wiring and piping methods using cable carrier .
5 Periodic Inspections ........................................................... 10-24 5-1 Replenishing grease to the linear guide ....................................... 10-24 5-2 Replenishing grease to the ball screw ..............................
8-6 Periodic inspection of the ZS/ZRS unit ......................................... 1 1-36 8-6-1 Replenishing grease to the Z-axis ball screw and ball spline ...... 1 1-36 8-6-2 Adjusting the R-axis belt tension (ZRS) ................................
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CHAPTER 1 Using the Robot Safely 1 Safety Information .................................................................. 1-1 2 Essential Caution Items .......................................................... 1-2 3 Special T raining for Industrial Robot Operation .
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1-1 Chapter 1 Using the Robot Safely 1 Safety Information Industrial robots are highly programmable machines that provide a lar ge degree of freedom in mo vement. T o ensure correct and safe use of Y AMAHA robots, carefully read this manual to make yourself well acquainted with the contents.
1-2 Chapter 1 Using the Robot Safely 2 Essential Caution Items Par ticularly important cautions for handling or operating the robot are described belo w . In addition, safety information about installation, operation, inspection and maintenance is provided in each chapter .
1-3 Chapter 1 Using the Robot Safely (3 ) Follow the instructions listed on warning labels and in this manual. WARNING Improper installation or operation can result in serious injury . Read the Instruction Manual and all warning labels before operation.
1-4 Chapter 1 Using the Robot Safely (4) Do not use the robot in environments containing inflammable gas, etc. WARNING • This robot is not designed for operation in environments where inflam- mable of explosive substances are present. • Do not use the robot in environments containing inflammable gas, dust or liquids.
1-5 Chapter 1 Using the Robot Safely (8) Movement of Z-axis at controller power shut off and emergency stop (for ZAS) WARNING The Z-axis will start to rise when the controller power is shut off, the P.
1-6 Chapter 1 Using the Robot Safely (12) Use caution when disassembling and replacing the motor WARNING When disassembling or assembling the motor for a ball-screw drive type robot, a strong magnetic attraction force will be present between the motor stator (fixed coil) and rotor (rotating magnet), causing a risk of pinching hands, etc.
1-7 Chapter 1 Using the Robot Safely (16) Use caution not to touch the controller rear panel cooling fan WARNING • Injury may occur from coming into contact with the cooling fan while it is rotating. • When removing the fan cover for inspection, first turn OFF the control- ler and make sure that the fan has stopped.
1-8 Chapter 1 Using the Robot Safely (21) Be sure to make correct parameter settings - Part 2 ! CAUTION When using a rotary axis (RF , RH, etc.) the robot must be operated with the tolerable moment of inertia and correct acceleration coefficients according to the tip mass and moment of inertia.
1-9 Chapter 1 Using the Robot Safely 3 Special T raining for Industrial Robot Operation Companies or factories using industrial robots must mak e sure that e very person, who handles the robot such as.
1-10 Chapter 1 Using the Robot Safely 4 Robot Safety Functions (1) Overload detection This function detects an ov erload applied to the motor and shuts off the serv o po wer . (2) Overheat detection This detects an abnormal rise in the controller dri ver temper ature and shuts of f the servo po wer .
1-11 Chapter 1 Using the Robot Safely 5 Safety Measures for the System When the robot is commonly used in conjunction with an automated system, dangerous situations are more likely to occur from the automated system than from the robot itself.
1-12 Chapter 1 Using the Robot Safely 6 T rial Run After making installations, adjustments, inspections, maintenance or repairs to the robot, carry out trial run using the follo wing procedures.
1-13 Chapter 1 Using the Robot Safely 7 W ork Within the Safeguard Enclosure (1) When work is required in the safeguard enclosure, always turn the controller power OFF and place a sign indicating that.
1-14 Chapter 1 Using the Robot Safely 8 Automatic Operation (1) Check the following before starting automatic operation. 1. No one is within the safe guard enclosure. 2. The programming unit or tools, etc., are in their specif ied location. 3. The alarm or error lamps, etc.
1-15 Chapter 1 Using the Robot Safely 1 1 W arranty The Y AMAHA robot and/or related product you ha ve purchased are w arranted against the defects or malfunctions as described belo w .
1-16 Chapter 1 Using the Robot Safely Y AMAHA MO TOR CO., L TD. MAKES NO O THER EXPRESS OR IMPLIED W ARRANTIES, INCLUDING ANY IMPLIED W ARRANTY OF MERCHANT ABILITY OR FITNESS FOR ANY P AR TICULAR PURPOSE.
CHAPTER 2 Product Outline 1 Robot ...................................................................................... 2-1 2 Names of each part ................................................................ 2-2 3 Robot Controller .................
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2-1 Chapter 2 Product Outline 1 Robot The robot is conf igured of the standard function X/Y axes (horizontal cartesian slide) and optional function Z-axis (vertical slide) and R-axis (r otation). These configuration ax es can mov e in the following manner .
2-2 Chapter 2 Product Outline 2 Names of each part ■ Arm type with cable carrier ■ Arm type with whipover cable X-axis Y -axis Y -axis motor X-axis stroke cov er Y -axis stroke co ver X-axis motor.
2-3 Chapter 2 Product Outline ■ Gantry type X-axis stroke cov er Y -axis stroke co ver Y -axis motor Y -axis Suppor t axis Suppor t axis installation brack et X-axis motor X-axis F rame brac ket Rob.
2-4 Chapter 2 Product Outline ■ Moving arm type (with cable carrier) ■ Moving arm type (with whipover cable) Cable carrier between XY (The machine harness between XY is wired inside) Y -axis wirin.
2-5 Chapter 2 Product Outline ■ Pole -type with cable carrier ■ Pole -type with whipover cable X-axis wiring box X-axis stroke cov er Cable carrier between XY (The machine harness between XY is wi.
2-6 Chapter 2 Product Outline ■ XZ-type with cable carrier ■ XZ-type with whipover cable Cable carrier between XY (The machine harness between XZ is wired inside) Z-axis wiring box Z-axis motor Z-.
2-7 Chapter 2 Product Outline 3 Robot Controller A RCX40, QRCX, TRCX or DRCX Series robot controller is enclosed with the XY -X Series according to the user’ s order . Refer to the separate “Y AMAHA Robot Controller Instruction Manual” for de- tails on the robot controller .
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CHAPTER 3 Preparing the Robot 1 Robot Installation Environment ............................................... 3-1 2 Unpacking the Robot .............................................................. 3-2 3 Checking the Product ........................
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3-1 Chapter 3 Preparing the Robot 1 Robot Installation Environment WARNING A void installing the robot in locations where the ambient conditions may exceed the allowable ambient temperature or relative humidity , or in envi- ronments where excessive moisture, corrosive gas, metallic powder or dust is generated.
3-2 Chapter 3 Preparing the Robot 2 Unpacking the Robot WARNING The robot and robot controller are heavy . T ake care not to drop these parts or damage the devices while unpacking the packages.
3-3 Chapter 3 Preparing the Robot 3 Checking the Product ! CAUTION Contact your Y AMAHA dealer immediately if any parts are missing or have been damaged during transportation. After unpacking, check the state of the components and the product. An example of the common combination of components is sho wn below .
3-4 Chapter 3 Preparing the Robot Example of combination with TRCX controller Example of combination with DRCX controller Y A M A H A M O T O R C O . , L T D Y A M A H A OWNER'S MANUAL Robot cabl.
3-5 Chapter 3 Preparing the Robot 4 T ransporting the Robot WARNING Serious injury may occur if the robot being transported falls and pins someone under it. • Use a hoist and rope with transporting capacity strong enough to sup- port the robot weight.
3-6 Chapter 3 Preparing the Robot Use of a hoist, dolly or forklift is recommended for transporting the robot or controller . Use suff icient caution when transporting robots with a long stroke or large payload as the y are heavy .
3-7 Chapter 3 Preparing the Robot 5 Installation 5-1 Installation base WARNING If the installation base is not sufficiently rigid and stable, vibration (reso- nance) may occur during operation and adversely affect the robot work. In worst cases the robot might even fall over causing a serious accident.
3-8 Chapter 3 Preparing the Robot 5-2 Installing the Robot Always observ e the safety precautions and the following procedures to ensure that the robot is correctly and safety installed. WARNING • T ake care not to pinch hands, etc., when removing the hoist belt from the X-axis.
3-9 Chapter 3 Preparing the Robot 6 Protective connections WARNING Be sure to ground the robot and controller to prevent electrical shock. WARNING T urn the controller power OFF before starting connecting the ground. The ground terminal position dif fers for each robot.
3-10 Chapter 3 Preparing the Robot 7 Connecting the Robot Cables WARNING 1. The robot cable is the most important cable for controlling the robot. If the connector is insufficiently connected and there are pin contact faults, the robot could malfunction.
3-11 Chapter 3 Preparing the Robot WARNING Arrange the connected robot cable so that it will not get in the way of operator ’ s operations. The operator could trip on the robot cable and be injured. WARNING When connecting the robot cable, insert the robot cable connector straight into the mating connector on the controller .
3-12 Chapter 3 Preparing the Robot 7-1 Connecting with the DRCX controller WARNING When connecting the robot cable, insert the robot cable connector straight into the mating connector on the controller .
3-13 Chapter 3 Preparing the Robot T o robot Robot cable MO T OR connector ROBO T I/O connector DRCX controller XY XM YM Fig. 3-1 Connection to DRCX controller.
3-14 Chapter 3 Preparing the Robot 7-2 Connecting with the TRCX controller 7-2-1 3-axis model WARNING When connecting the robot cable, insert the robot cable connector straight into the mating connector on the controller .
3-15 Chapter 3 Preparing the Robot T o robot Robot cable M OTOR connector ROBO T I/O connector MO TOR connector ROBO T I/O connector X Y Z Z M XM YM Fig.
3-16 Chapter 3 Preparing the Robot 7-2-2 4-axis model WARNING When connecting the robot cable, insert the robot cable connector straight into the mating connector on the controller . Inserting the connector while tilted might cause the pins to make poor contact, causing robot malfunc- tion and the connector itself might even break.
3-17 Chapter 3 Preparing the Robot T o robot Robot cable M OTOR connector M OTOR connector ROBO T I/O connector ROBO T I/O connector X Y XM YM Z R ZM RM Fig.
3-18 Chapter 3 Preparing the Robot 7-3 Connecting to the QRCX or RCX40 controller WARNING When connecting the robot cable, insert the robot cable connector straight into the mating connector on the controller .
3-19 Chapter 3 Preparing the Robot Connect to YAMAHA robot Robot cable 1 2 XM YM ZM RM ZR XY Fig. 3-4 Connection to QRCX controller XM YM XY ZR ZM RM Connect to YAMAHA robot Fig.
3-20 Chapter 3 Preparing the Robot 8 Installing the T ool WARNING The user must responsibly determine the bolt type and tightening torque for the tool installation, and must accurately tighten these. Improper in- stallation could cause the tool to dislocate during operation and lead to serious accidents.
3-21 Chapter 3 Preparing the Robot 9 User Wiring and User Piping ! CAUTION Do not clamp the wires or pipes to the outside of the whipover cable. The whipover cable could sag or break and ultimately be disconnected.
3-22 Chapter 3 Preparing the Robot 10 Setting the Robot 10-1 Setting the payload ! CAUTION Always input an accurate value as an incorrect value can lead to various trou- ble including vibration and a drop in machine life. ! CAUTION When installing a weight other than the tool or workpiece on the robot’ s moving section, add that weight.
3-23 Chapter 3 Preparing the Robot 10-2 Setting the maximum speed When operating a ball scre w driv en robot, the ball scre w's free length will in- crease as the mo vement stroke increases, and the resonance frequency will drop. Thus, the ball scre w may resonate and generate vigorous vibration depending on the motor rotation speed.
3-24 Chapter 3 Preparing the Robot 10-3 Setting the acceleration The acceleration is automatically set for the Cartesian robot XY -X Series when the payload parameter is set, so lar ge vibration will not occur during operation.
3-25 Chapter 3 Preparing the Robot 1 1 Absolute Reset Refer to this section and set the origin position before using the robot. The Cartesian robot XY -X Series uses an absolute method position detector , and thus return-to-origin is not required when the controller po wer is turned ON again.
3-26 Chapter 3 Preparing the Robot ■ Setting the origin position [1] For robot configured of only linear movement axis The above type of robot uses a strok e end detection method as origin return. The motor side stroke end is set as the origin detection position before ship- ment from the factory .
3-27 Chapter 3 Preparing the Robot When MANU AL > RST .ABS > ALL is selected on the MPB screen (see “11-9- 3” in QRCX o wner’ s manual or “11-8-3” in RCX40 owner’ s manual), first per - form absolute reset for the rotating axis and then other linearmov ement axes.
3-28 Chapter 3 Preparing the Robot Slit Origin position label (enclosed with product) Origin position label Example: ZRS Example: RH After setting the origin position, attach the label enclosed with the robot so that it acts as a match mark on the tool side and Robot side.
CHAPTER 4 Periodic Inspections 1 Outline .................................................................................... 4-1 2 Precautions ............................................................................. 4-1 3 Daily inspection ......
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4-1 Chapter 4 Periodic Inspections 1 Outline Implementation of periodic inspections is essential to ensure safe and ef ficient operation of the Y AMAHA robot. The periodic inspection items and procedures for the XY Series are described in this chapter .
4-2 Chapter 4 Periodic Inspections 3 Daily inspection Check the follo wing points before and after robot operation e very day . Make adjustments and replacements as necessary . Check items Check that the safeguard enclosure is securely fixed at the designated position.
4-3 Chapter 4 Periodic Inspections 5 Six-month inspection Check the follo wing points e very six months, and make adjustments or replace- ments as required. Check items Check for looseness, and tighten if necessary. • Check for looseness in the X-axis, Y-axis and Z-axis drive section (ball screw, linear guide).
4-4 Chapter 4 Periodic Inspections 6 Three-year inspection Check the follo wing points once e very three years, and adjust or replenish g rease as necessary . If the robot is used frequently , inspect the robot at an earlier stage. Check items Disassemble and check the harmonic drive.
4-5 Chapter 4 Periodic Inspections 7 Replenishing the grease WARNING Precautions for handling grease • Inflammation may occur if the grease gets into eyes. Always wear protective goggles, etc., to protect eyes when handling the grease. • Inflammation may occur if the grease gets on skin.
4-6 Chapter 4 Periodic Inspections 8 Maintenance and inspection of harmonic drives WARNING The motor and speed reduction gear casing are extremely hot after auto- matic operation, so burns may occur if these are touched.
4-7 Chapter 4 Periodic Inspections ! CAUTION Harmonic drive • Do not apply strong impacts on any part with a hammer , etc. Do not damage or mark the parts by dropping. There is a risk of damage. • The specified performance cannot be attained if a damaged part is used.
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CHAPTER 5 Specifications 1 Specifications ......................................................................... 5-1 1-1 Robot cable ...................................................................................... 5-1 1-2 User I/O cable .....
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5-1 Chapter 5 Specifications 1 Specifications The specif ications of each robot's common parts are sho wn below . 1-1 Robot cable This cable is used to connect the controller and robot.
5-2 Chapter 5 Specifications 3-axis robot cable (For TRCX controller) 0.3sq twisted pair Gray/White 2 34 32 1 1 4 Ring-tongue terminal !5 4 FG GND24 HLIM GND24 HLIM 29 Green Green 10 11 28 16 YM r XM e 0.3sq twisted pair 0.3sq twisted pair 0.3sq twisted pair 0.
5-3 Chapter 5 Specifications 3-axis robot cable (For RCX40 controller) 0.3sq twisted pair Gray/White 2 34 32 1 1 4 Ring-tongue terminal !5 4 FG GND24 HLIM GND24 HLIM GND24 HLIM GND24 HLIM 29 Green Green 10 11 28 29 Green Green 10 11 28 16 YM r XM e 0.
5-4 Chapter 5 Specifications 4-axis robot cable 0.3sq twisted pair Gray/White 2 34 32 1 1 4 Ring-tongue terminal !8 4 FG GND24 HLIM GND24 HLIM 29 Green Green 10 11 28 16 YM e XM e 0.3sq twisted pair 0.3sq twisted pair 0.3sq twisted pair 0.3sq twisted pair 0.
5-5 Chapter 5 Specifications 1-2 User I/O cable The cartesian robot XY -X Series cable carrier type ha ve a signal wire that can be used freely from the X-axis wiring box to the f inal axis wiring box. Controller side T ool side I/O I/O qe wr t Part No.
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CHAPTER 6 PXYX 1 Installation .............................................................................. 6-1 1-1 Installation bolt types ....................................................................... 6-1 1-2 Installation bolt nominal length .
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6-1 Chapter 6 PXYX 1 Installation WARNING Always turn the controller power OFF before installing the robot. Serious accidents might occur if the robot starts to operate during installation. T o install the PXYX robot, tap holes into the installation base and secure the robot to the base with M4 bolts from the inside of the robot.
6-2 Chapter 6 PXYX 1-4 Installation methods WARNING Always use the designated bolt, and securely tighten it with the correct torque. Failure to observe this could cause the robot position to deviate, and could also lead to serious accidents. ! CAUTION T ake care not to catch the shutter when installing the side covers.
6-3 Chapter 6 PXYX 2 Protective Connections WARNING Always ground the robot and controller to prevent electrical shocks. WARNING Always turn the controller power OFF before connecting the ground to prevent electrical shocks.
6-4 Chapter 6 PXYX 2-2 Ground wire Use an A W G14 (2.0mm 2 ) or lar ger ground wire with a total length of 1m or less. Crimp an M4 ring-tongue terminal on the end of the wire connected to the robot. 2-3 Wiring method WARNING Accurately insert the lock washer between the ring-tongue terminal and robot.
6-5 Chapter 6 PXYX 3 Installing the T ool WARNING Always turn the controller power OFF before Installing a tool to prevent an accident. WARNING Before installing a tool, check that the robot is securely fixed to the base.
6-6 Chapter 6 PXYX 4 User Wiring and User Piping WARNING Always turn off the controller before wiring and piping to prevent electri- cal shocks. The methods for leading the wiring and piping to the tool are described in this section. A cable carrier is provided as a standard between the X-Y ax es.
6-7 Chapter 6 PXYX 7) When completed with the wiring, reattach the cov er to the wiring box. Cable carrier specifications ! CAUTION When setting the harness and air tube into the cable carrier , make .
6-8 Chapter 6 PXYX 5 Periodic Inspections The inspection periods and general precautions are described in Chapter 4 Peri- odic Inspections. Always refer to that Chapter before starting this work. WARNING Always turn the controller power OFF before starting periodic inspec- tions.
6-9 Chapter 6 PXYX 5-2 Replenishing grease to the ball screw The X and Y ax es use a ball scre w . Grease must be replenished to this ball screw periodically . Select the grease from the follo wing recommended types. Recommended grease : Alv ania No. 2 (Sho wa Shell) Daphne Eponex No.
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CHAPTER 7 FXYX 1 Installation .............................................................................. 7-1 1-1 Installation bolt types ....................................................................... 7-1 1-2 Installation bolt nominal length .
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7-1 Chapter 7 FXYX 1 Installation WARNING Always turn the controller power OFF before installing the robot. Serious accidents might occur if the robot starts to operate during installation. T o install the FXYX robot, tap holes into the installation base and secure the robot to the base with M6 bolts from the inside of the robot.
7-2 Chapter 7 FXYX 1-4 Installation methods WARNING Always use the designated bolt, and securely tighten it with the correct torque. Failure to observe this could cause the robot position to deviate, and could also lead to serious accidents. 1) T a p M6 coarse scre w thread holes into the installation base where the robot is to be installed.
7-3 Chapter 7 FXYX 2 Protective Connections WARNING Always ground the robot and controller to prevent electrical shocks. WARNING Always turn the controller power OFF before connecting the ground to prevent electrical shocks.
7-4 Chapter 7 FXYX 2-2 Ground wire Use an A WG14 (2.0mm 2 ) or lar ger ground wire with a total length of 1m or less. Crimp an M4 ring-tongue terminal on the end of the wire connected to the robot. 2-3 Wiring method WARNING Accurately insert the lock washer between the ring-tongue terminal and robot.
7-5 Chapter 7 FXYX 3 Installing the T ool WARNING Always turn the controller power OFF before Installing a tool to prevent an accident. WARNING Before installing a tool, check that the robot is securely fixed to the base.
7-6 Chapter 7 FXYX ! CAUTION If the fitting length is less than 8mm, the threads could be damaged during tightening. If the fitting length exceeds 12mm, the bolt end could contact the bottom. NOTE There is a step on the top of the slider . The actual tool installation surface is the shaded section shown a bov e.
7-7 Chapter 7 FXYX 3-2 ZS (3rd-axis option) WARNING Use the tap hole on the end of the shaft only to prevent the tool from dislocating. Do not use only this hole to install the tool. The tool could dislocate and fly off the installation section during robot operation.
7-8 Chapter 7 FXYX 4 User Wiring and User Piping WARNING Always turn off the controller before wiring and piping to prevent electri- cal shocks. 4-1 Cable carrier type A cable carrier is mounted as a standard between the X and Y axes. When using three axes, a cable carrier is also pro vided between the Y and Z axes.
7-9 Chapter 7 FXYX The cable carrier has an outer lid that can be opened and closed easily . Use a flat-tip scre wdri ver to open the lid. Press this lid in to close it. Open and close this lid as necessary . 4) Remov e the two M4 small screws on the Y -axis wiring box, and loosen two places.
7-10 Chapter 7 FXYX 6) Remov e the harness retainer from the Y -axis wiring box. (T wo hexagon sock et bolts M5) Harness retainer 7) ! CAUTION 1. The wires could be damaged if the harness retainer is tightened too much. 2. Manually move the robot by the full stroke before fixing to confirm that the harness and air tube, etc.
7-11 Chapter 7 FXYX 4-1-2 Cable carrier specifications ! CAUTION When setting the harness and air tube into the cable carrier , make sure that the total cross-sectional area of all wires and pipes, including the Y AMAHA cable, inside the cable carrier does not exceed 30% of the cable carrier ’s cross-sectional area.
7-12 Chapter 7 FXYX 4-1-3 User I/O cable specifications ! CAUTION Securely crimp the pin and insert into the pin connector . Failure to do so will prevent the signals and power from being supplied cor- rectly , and may prevent the device from operating correctly .
7-13 Chapter 7 FXYX 5 Periodic Inspections WARNING Always turn the controller power OFF before starting periodic inspec- tions. Serious accidents could occur if the robot starts moving during the periodic inspection.
7-14 Chapter 7 FXYX 4) Using a grease gun, replenish grease from the grease nipple installed on the linear guide bearings. Suf ficient grease has been replenished when ne w gr ease starts to seep out from the clearance between the linear guide bearings and rail.
7-15 Chapter 7 FXYX 2) T urn the controller po wer OFF . 3) Place a sign indicating "W ork In Progress" so that other opera tors do not turn the controller po wer ON. 4) Remov e the stroke cov er . 5) Install the grease nipple onto the ball scre w flange.
7-16 Chapter 7 FXYX Z-axis (ZS) 1) T urn the controller po wer OFF . 2) Place a sign indicating "W ork In Progress" so that other opera tors do not turn the controller po wer ON. 3) Remov e the screws (M4 , 6 scre ws) fixing the cov er, and pull the co ver up- ward and of f.
CHAPTER 8 SXYX 1 Installation .............................................................................. 8-1 1-1 Installation bolt types ....................................................................... 8-1 1-2 Installation bolt nominal length .
5-3 Periodic inspection of the ZS/ZRS unit .......................................... 8-29 5-3-1 Replenishing grease to the Z-axis ball screw and ball spline ........ 8-29 5-3-2 Adjusting the R-axis belt tension (ZRS) .................................
8-1 Chapter 8 SXYX 1 Installation WARNING Always turn the controller power OFF before installing the robot. Serious accidents might occur if the robot starts to operate during installation. The SXYX is installed with one of the follo wing two methods.
8-2 Chapter 8 SXYX 1-3 Tightening torque • T he accur ate tightening torque will differ according to the sea ting face fric- tional coeff icient and the female screw material, etc. The follo wing tightening torque is recommended as a guide. Recommended torque 9.
8-3 Chapter 8 SXYX ■ Method B 1) T a p M6 coarse scre w thread holes into the installation base where the robot is to be installed. Refer to the XY -X Series catalog for the hole positions. 2) Remov e the countersunk head screws (M4, 5 scre ws) fixing the X-axis stroke co ver .
8-4 Chapter 8 SXYX 3) Remov e the X-axis stroke co ver . If the co ver is dif f icult to remov e, manually mov e the Y -axis to the motor side stroke end. The co ver will be easier to remo ve. 4) Fix the robot onto the installation base with the designated bolts.
8-5 Chapter 8 SXYX 2 Protective Connections WARNING Always ground the robot and controller to prevent electrical shocks. WARNING Always turn the controller power OFF before connecting the ground to prevent electrical shocks.
8-6 Chapter 8 SXYX Ground terminal X-axis wiring box Fig. 8-6 Arm type, moving arm type, gantry type with whipover cable specifications 2-2 Ground wire Use an A W G14 (2.0mm 2 ) or lar ger ground wire with a total length of 1m or less. Crimp an M4 ring-tongue terminal on the end of the wire connected to the robot.
8-7 Chapter 8 SXYX 2-3-1 Arm type with cable carrier 1) Remov e the four M4 small screws on the top of the X-axis wiring box, and loosen the M4 small scre w on the end face. Remov e Loosen X-axis wiring box Fig. 8-7 2) Open the X-axis wiring box co ver .
8-8 Chapter 8 SXYX 3) Connect the ground wire to the ground terminal attached to the top of the X-axis wiring box. Ground terminal Ground wire An M4 small scre w with spring washer and lock w asher are attached to the ground terminal.
8-9 Chapter 8 SXYX 2-3-2 Arm type with whipover cable, moving arm type, pole type 1) Remov e the small screws (M4, 4 scre ws) fixing the X-axis wiring box co ver , and remov e the cover . (Refer to Fig. 8-10.) Remove the four M4 screws Fig. 8-10 2) Fix the ring-tongue terminal of the ground wire to the ground terminal in the X-axis wiring box.
8-10 Chapter 8 SXYX 2-3-3 XZ type 1) Remov e the small scre ws (M4, 4 scre ws) fixing the X-axis wiring box cov er , and remov e the cover . (Refer to Fig. 8-12.) Fig. 8-12 2) Fix the ring-tongue terminal of the ground wire to the ground terminal in the X-axis wiring box.
8-11 Chapter 8 SXYX 3 Installing the T ool WARNING Always turn the controller power OFF before Installing a tool to prevent an accident. WARNING Before installing a tool, check that the robot is securely fixed to the base.
8-12 Chapter 8 SXYX 20 90 2- φ 6H7 Depth8 6 (Thread insert depth) 90 32 135 70 11 0 (T olerance between knock (0.02) 8-M6 × 1.0 Depth8 20 8 (Allowable screw depth) 4-M5 × 0.8 Depth7 23.5 19 50 20 Fig. 8-15 Pole type ! CAUTION If the fitting length is less than 6mm, the threads could be damaged during tightening.
8-13 Chapter 8 SXYX 3-2 Moving arm type 2-axis model For the mo ving arm type, an aluminum bracket is a ttached to the end of the Y -axis. Install the tool on this bracket. T welve M6 coarse thread ta p holes and two φ 6 reamer holes are opened on the bracket.
8-14 Chapter 8 SXYX 3-3 ZF (Arm type, moving arm type, 3rd-axis option/XZ type 2- axis model) When using the 3rd-axis model with ZF for the 3rd-axis, install the workpiece onto the ZF slider in the follo wing manner . Four M5 coarse thread tap holes and a φ 5 reamer hole are opened on the slider's workpiece installation surface.
8-15 Chapter 8 SXYX 3-4 RF (Arm type, moving arm type, 4th-axis option/XZ type 3rd-axis option) ! CAUTION Use the tap hole on the end face of the shaft only to prevent the tool from dislocating. Do not use only this hole to install the tool. The tool could dislocate and fly off the installation section during robot operation.
8-16 Chapter 8 SXYX 3-5 ZS/ZRS (Arm type 3/4-axis option, XZ type 2/3-axis model) WARNING Use the tap hole on the end of the shaft only to prevent the tool from dislocating. Do not use only this hole to install the tool. The tool could dislocate and fly off the installation section during robot operation.
8-17 Chapter 8 SXYX 3-6 ZFH (Arm type, gantry type, moving arm type 3rd-axis option) XZ 2nd-axis option When using the 3rd-axis model with ZFH for the 3rd-axis, install the workpiece onto the ZFH frame in the follo wing manner . Four M5 coarse thread tap holes and a φ 5 reamer hole are opened on the frame's workpiece installation surface.
8-18 Chapter 8 SXYX 3-7 ZFL (Arm type, moving arm type, 3rd-axis option/XZ type 2- axis model) When using the 3rd-axis model with ZFL for the 3rd-axis, install the workpiece onto the ZFL slider in the following manner . Six M5 coarse thread tap holes and a φ 5 reamer hole are opened on the slider's workpiece installation surface.
8-19 Chapter 8 SXYX 4 User Wiring and User Piping WARNING Always turn off the controller before wiring and piping to prevent electri- cal shocks. 4-1 Cable carrier type A cable carrier is mounted as a standard between the X and Y axes.
8-20 Chapter 8 SXYX 3) Pass the cables and air tubes through the cable carrier . The cable carrier has an outer lid that can be opened and closed easily . Use a flat-tip scre wdriv er to open the lid. Press this lid in to close it. Open and close this lid as necessary .
8-21 Chapter 8 SXYX 7) ! CAUTION T ake care not to catch the harness or air tube with the cover when installing the covers. Assemble the wiring box co ver at the original position. State with cover installed State of X-axis wiring box when wiring is completed P ass the X-axis wiring through this notch.
8-22 Chapter 8 SXYX 4-1-2 Cable carrier specifications ! CAUTION When setting the harness and air tube into the cable carrier , make sure that the total cross-sectional area of all wires and pipes, including the Y AMAHA cable, inside the cable carrier does not exceed 30% of the cable carrier ’s cross-sec- tional area.
8-23 Chapter 8 SXYX 4-1-3 User I/O cable specifications ! CAUTION Securely crimp the pin and insert into the pin connector . Failure to do so will prevent the signals and power from being supplied cor- rectly , and may prevent the device from operating correctly .
8-24 Chapter 8 SXYX 4-2 Whipover cable type ! CAUTION Do not clamp the wires or tubes to the outside of the independent cable. The independent cable could sag or break and ultimately be disconnected. The signal wires (0.3mm 2 × 7 wires) and air tubes (4 × 2.
8-25 Chapter 8 SXYX 2) When using an air tube, prepare an air coupler for connecting the user air tube with the Y AMAHA air tube. 3) Open the X-axis wiring box co ver . Fig. 8-25 4) Place the required cables and air tubes, etc., in the X-axis wiring box.
8-26 Chapter 8 SXYX 5 Periodic inspections The inspection periods and general precautions are described in Chapter 4 Peri- odic Inspections. Always refer to that Chapter before starting this work. WARNING Always turn the controller power OFF before starting periodic inspec- tions.
8-27 Chapter 8 SXYX 4) Using a grease gun, replenish grease from the grease nipple installed on the linear guide bearings. Suf f icient grease has been replenished when ne w grease starts to seep out from the clearance between the linear guide bearings and rail.
8-28 Chapter 8 SXYX ! CAUTION Always remove the grease nipple after completing the work. Damage or positional deviation could occur if the robot is operated with the grease nipple installed. 1) Prepare the follo wing recommended grease nipple beforehand.
8-29 Chapter 8 SXYX 5-3 Periodic inspection of the ZS/ZRS unit 5-3-1 Replenishing grease to the Z-axis ball screw and ball spline A ball scre w driv e is used for the ZS and ZRS vertical axis. Grease must be replenished to this ball screw per iodically .
8-30 Chapter 8 SXYX 5-3-2 Adjusting the R-axis belt tension (ZRS) W ith the ZRS model, a timing belt is used for the R-axis. If the timing belt tension is week, adjust the belt tension with the follo wing pro- cedures. WARNING There is a risk of injury if fingers, etc.
8-31 Chapter 8 SXYX 7) If the v alue measured in step 4) is smaller than the v alue gi ven in T able 8-1, mov e the R-axis motor so that the tension increases. If lar ger than the value in T able 8-1, mov e the R-axis motor so that the tension decreases.
8-32 Chapter 8 SXYX Replacement period The harmonic driv e replacement period is determined by the total number of wa ve generator rotations. A calculation example is sho wn below . The recommended harmonic driv e replacement period is 8.4 × 10 8 rotations (at usage atmospheric temperature range 0 ° C to +40 ° C).
CHAPTER 9 MXYX 1 Installation .............................................................................. 9-1 1-1 Installation bolt types ....................................................................... 9-1 1-2 Installation bolt nominal length .
MEMO.
9-1 Chapter 9 MXYX 1 Installation WARNING Always turn the controller power OFF before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Install the MXYX by tapping holes into the installation base and securing the robot to the base with M8 bolts from the inside of the robot.
9-2 Chapter 9 MXYX 1-4 Installation methods (Arm type, moving arm type, pole type, gantry type X-axis) WARNING Always use the designated bolt, and securely tighten it with the correct torque. Failure to observe this could cause the robot position to deviate, and could also lead to serious accidents.
9-3 Chapter 9 MXYX 4) Remov e the stroke cov er . If the co ver is dif ficult to remo ve, manually mo ve the Y -axis to the motor side stroke end. T he co ver will be easier to remo ve. If the X-axis stroke is 550mm or less, remo ve the X-axis wiring box before remo ving the stroke cov er .
9-4 Chapter 9 MXYX 1-5 Installation methods (Gantry type support axis) The MXYX and HXYX gantry types hav e a guide rail for support on the Y -axis end so that heavy loads can be handled. When installing, take care to the parallel- ism of the X-axis and guide rail and to the dif ference in height from the installa- tion surface.
9-5 Chapter 9 MXYX 2 Protective Connections WARNING Always ground the robot and controller to prevent electrical shocks. WARNING Always turn the controller power OFF before connecting the ground to prevent electrical shocks.
9-6 Chapter 9 MXYX 2-3 Wiring methods ! CAUTION Be sure to insert the lock washer between the ring-tongue terminal and robot in step3 below . Proper continuity may not be secured if the lock washer is dislocated. 1) Loosen the four M4 small scre ws, and open the X-axis wiring box co ver .
9-7 Chapter 9 MXYX 3 Installing the T ool Install the user tool onto the robot’ s tool installation surface in the follo wing manner . WARNING Always turn the controller power OFF before Installing a tool to prevent an accident. WARNING Before installing a tool, check that the robot is securely fixed to the base.
9-8 Chapter 9 MXYX Fig. 9-8 Arm type, gantry type Fig. 9-9 MXYX pole type 20 90 6 (Thread inser t depth) 20 8 (Allowab le screw depth) 70 110 (T olerance between knock (0.02) 124 140 2- φ 6H7 Depth8 8-M6 × 1.0 Depth8 135 45 50 19 4-M5 × 0.8 Depth7 23.
9-9 Chapter 9 MXYX 3-2 Moving arm type 2-axis model For the mo ving arm type, an aluminum bracket is a ttached to the end of the Y -axis. Install the tool on this bracket. T welve M6 coarse thread ta p holes and two φ 6 reamer holes are opened on the bracket.
9-10 Chapter 9 MXYX 3-3 ZF (Arm type, moving arm type, gantry type 3rd-axis option) When using the 3rd-axis model with ZF for the 3rd-axis, install the workpiece onto the ZF slider in the follo wing manner . Four M5 coarse thread tap holes and a φ 5 reamer hole are opened on the slider's workpiece installation surface.
9-11 Chapter 9 MXYX 3-4 RF (Arm type, moving arm type, 4th-axis option/XZ type 3rd-axis option) ! CAUTION Use the tap hole on the end face of the shaft only to prevent the tool from dislocating. Do not use only this hole to install the tool. The tool could dislocate and fly off the installation section during robot operation.
9-12 Chapter 9 MXYX 3-5 ZFH (Arm type, gantry type, moving arm type 3rd-axis option) XZ 2nd-axis option When using the 3rd-axis model with ZFH for the 3rd-axis, install the workpiece onto the ZFH frame in the follo wing manner . Four M5 coarse thread tap holes and a φ 5 reamer hole are opened on the frame's workpiece installation surface.
9-13 Chapter 9 MXYX 3-6 ZFL (Arm type, moving arm type, 3rd-axis option/XZ type 2- axis model) When using the 3rd-axis model with ZFL for the 3rd-axis, install the workpiece onto the ZFL slider in the follo wing manner . Six M5 coarse thread tap holes and a φ 5 reamer hole are opened on the slider's workpiece installation surface.
9-14 Chapter 9 MXYX 4 User Wiring and User Piping WARNING Always turn off the controller before wiring and piping to prevent electri- cal shocks. 4-1 Cable carrier type A cable carrier is mounted as a standard between the X and Y axes.
9-15 Chapter 9 MXYX 3) Remov e the harness retainer located at the cable carrier outlet. (Hexagon socket bolt M5, 2 bolts) Harness retainer 4) Pass the r equired wires and pipes through the cable carrier . The cable carrier has an outer lid that can be opened and closed easily .
9-16 Chapter 9 MXYX 4-1-2 Cable carrier specifications ! CAUTION When setting the harness and air tube into the cable carrier , make sure that the total cross-sectional area of all wires and pipes, including the Y AMAHA cable, inside the cable carrier does not exceed 30% of the cable carrier ’s cross-sec- tional area.
9-17 Chapter 9 MXYX 4-1-3 User I/O cable specifications ! CAUTION Securely crimp the pin and insert into the pin connector . Failure to do so will prevent the signals and power from being supplied cor- rectly , and may prevent the device from operating correctly .
9-18 Chapter 9 MXYX 4-2 Whipover cable type ! CAUTION Do not clamp the wires or tubes to the outside of the independent cable. The independent cable could sag or break and ultimately be disconnected. The signal wires (0.3mm 2 × 7 wires) and air tubes (4 × 2.
9-19 Chapter 9 MXYX 2) When using an air tube, prepare an air coupler for connecting the user air tube with the Y AMAHA air tube. 3) Open the X-axis wiring box co ver . Fig. 9-17 4) Rubber grommets are attached to the X-axis wiring box. Open holes (or notches) in these grommets, and pass the required cables and air tubes, etc.
9-20 Chapter 9 MXYX 5 Periodic Inspections WARNING Always turn the controller power OFF before starting periodic inspec- tions. Serious accidents could occur if the robot starts moving during the periodic inspection.
9-21 Chapter 9 MXYX 4) Using a grease gun, replenish grease from the grease nipple installed on the linear guide bearings. Suf f icient grease has been replenished when ne w grease starts to seep out from the clearance between the linear guide bearings and rail.
9-22 Chapter 9 MXYX 2) T urn the controller power OFF . NOTE When the ZF unit is attached for the 3rd-axis, the replenishment work can be carried out easier by moving the Z-axis slider to near the motor (near the orig in) and turning the controller po wer OFF .
CHAPTER 10 HXYX 1 Installation ............................................................................ 10-1 1-1 Installation method 1 (Arm type, moving arm type, pole type, gantry type X-axis) .......... 10-1 1-1-1 Installation bolt types .......
4-2 Whipover cable type .................................................................... 10-22 4-2-1 Examples of wiring and piping with Whipover cable ................... 10-22 5 Periodic Inspections ...............................................
10-1 Chapter 10 HXYX 1 Installation WARNING Always turn the controller power OFF before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Install the HXYX by tapping holes into the installation base and securing the robot to the base with M8 bolts from the inside of the robot.
10-2 Chapter 10 HXYX 1-1-3 Tightening torque • The accurate tightening torque will differ according to the seating f ace fric- tional coef f icient and the female screw material, etc. The following tightening torque is recommended as a guide. Recommended torque 22.
10-3 Chapter 10 HXYX Fig. 10-4 ! CAUTION Decorative plates are attached to both ends of the stroke cover . T ake care not to lose these plates. 4) Remov e the stroke cov er . If the cov er is dif f icult to remov e, manually mov e the Y -axis to the motor side stroke end.
10-4 Chapter 10 HXYX 6) After installing, return the stroke co ver and X-axis wiring box to the original positions. ! CAUTION Always install the X-axis wiring box at the original position. The amount of pro- jection from the cable carrier's stroke end could change, or the cable carrier and Y -axis bracket could contact.
10-5 Chapter 10 HXYX 26.5 Fig. 10-6 1-2-3 Tightening torque • The accurate tightening torque will differ according to the seating f ace fric- tional coef f icient and the female screw material, etc. The following tightening torque is recommended as a guide.
10-6 Chapter 10 HXYX 1-3 Installation method 3 (Gantry type support axis) Install the gantry type support axis in the follo wing manner . ! CAUTION Move the X-axis as much as possible, and tighten the bolts where the move- ment is the lightest. Set the X-axis and guide rail parallelism during installation.
10-7 Chapter 10 HXYX 2 Protective Connections WARNING Always ground the robot and controller to prevent electrical shocks. WARNING Always turn the controller power OFF before connecting the ground to prevent electrical shocks.
10-8 Chapter 10 HXYX Fig. 10-8 XZ type 2-2 Ground wire Use an A WG14 (2.0mm 2 ) or lar ger ground wire with a total length of 1m or less. Crimp an M4 ring-tongue terminal on the end of the wire connected to the robot. 2-3 Wiring methods ! CAUTION Accurately insert the lock washer between the ring-tongue terminal and robot.
10-9 Chapter 10 HXYX 3) Connect the ring-tongue terminal of the ground wire to the ground terminal on the robot. An M4 small scre w with spring washer and lock washer ar e attached to the ground terminal. Arrange the parts in the order of the lock washer , ring-tongue terminal and M4 small scre w with spring washer , and then tighten.
10-10 Chapter 10 HXYX 3 Installing the T ool Install the user tool onto the robot’ s tool installation surface in the following man- ner . WARNING Always turn the controller power OFF before Installing a tool to prevent an accident. WARNING Before installing a tool, check that the robot is securely fixed to the base.
10-11 Chapter 10 HXYX 3-1 Arm type, gantry type 2-axis model Eight M8 coarse thread tap holes and two φ 6 reamer holes are opened on the Y -axis slider installation surface. (Refer to Fig. 10-10.) Install the user tool onto the Y -axis slider using these holes.
10-12 Chapter 10 HXYX 3-2 Moving arm type 2-axis model The moving arm type has an aluminum-cast brack et on the end of the Y -axis. Install the tool on this bracket. T welve M8 coarse thread tap holes and tw o φ 6 reamer holes are opened on the bracket.
10-13 Chapter 10 HXYX 3-3 Pole type 2-axis model Four M8 coar se thread tap holes and two $8 reamer holes are opened on the tool installation surface of the Y -axis slider . (Refer to Fig. 10-12.) Install the user tool onto the Y -axis slider using these holes.
10-14 Chapter 10 HXYX 3-4 ZH (Arm type, gantry type, moving arm type 3rd-axis option/ XZ type 2-axis model) ! CAUTION If the fitting length is less than 9mm, the threads could be damaged during tightening. If the screw length exceeds 27mm from the installation surface, the screw could contact the bottom.
10-15 Chapter 10 HXYX 3-5 ZL (Arm type, gantry type, moving arm type 3rd-axis option/ XZ type 2-axis model) When using the 3rd-axis model with ZL for the 3rd-axis, install the workpiece onto the ZL slider in the follo wing manner . Eight M6 coarse thread tap holes and two φ 6 reamer holes are opened on the Y -axis slider .
10-16 Chapter 10 HXYX 3-6 ZPH (Pole type 3rd-axis option) When ZPH is attached for the 3rd-axis of the pole type, install the tool onto the aluminum bracket at the end of the ZP-axis. T welve M6 coarse thread tap holes and tw o φ 6 reamer holes are opened on the bracket.
10-17 Chapter 10 HXYX 3-7 RH (Arm type, moving arm type, gantry type 4th-axis option/ XZ type 3rd-axis option) ! CAUTION When fixing with the tap holes, always fix at several holes. If fixed with only one hole, the loosening torque could act during operation can cause loosening.
10-18 Chapter 10 HXYX 4 User Wiring and User Piping WARNING Always turn off the controller before wiring and piping to prevent electri- cal shocks. 4-1 Cable carrier type A cable carrier is mounted as a standard between the X and Y axes.
10-19 Chapter 10 HXYX 3) Remov e the harness retainer located at the cable carrier outlet. (Hexagon socket bolt M5, 2 bolts) Harness retainer 4) P ass the required wires and pipes through the cable carrier . The cable carrier has an outer lid that can be opened and closed easily .
10-20 Chapter 10 HXYX 4-1-2 Cable carrier specifications ! CAUTION When setting the harness and air tube into the cable carrier , make sure that the total cross-sectional area of all wires and pipes, including the Y AMAHA cable, inside the cable carrier does not exceed 30% of the cable carrier ’s cross-sectional area.
10-21 Chapter 10 HXYX 4-1-3 User I/O cable specifications ! CAUTION Securely crimp the pin and insert into the pin connector . Failure to do so will prevent the signals and power from being supplied cor- rectly , and may prevent the device from operating correctly .
10-22 Chapter 10 HXYX 4-2 Whipover cable type ! CAUTION Do not clamp the wires or tubes to the outside of the independent cable. The independent cable could sag or break and ultimately be disconnected. The signal wires (0.3mm 2 × 7 wires) and air tubes (4 × 2.
10-23 Chapter 10 HXYX 3) Open the X-axis wiring box co ver . Fig. 10-19 4) Rubber grommets are attached to the X-axis wiring box. Open holes (or notches) in these grommets, and pass the required cables and air tubes, etc., through. Crimp the enclosed connectors onto the cables.
10-24 Chapter 10 HXYX 5 Periodic Inspections WARNING Always turn the controller power OFF before starting periodic inspec- tions. Serious accidents could occur if the robot starts moving during the periodic inspection.
10-25 Chapter 10 HXYX 4) Replenish the grease with one of the follo wing methods. Method 1: Using a grease gun, replenish grease from the grease nipple in- stalled on the linear guide bearings. Suf ficient grease has been replenished when ne w gr ease starts to seep out from the clearance between the linear guide bearings and rail.
10-26 Chapter 10 HXYX Replenishment methods Refer to the follo wing procedures and replenish the grease. 1) Remov e the stroke cov er of the axis to w hich grease is to be replenished. 2) Replenish the grease with one of the follo wing methods. ! CAUTION Always remove the grease nipple after replenishing the grease.
CHAPTER 11 FXYBX/SXYBX 1 Installation ............................................................................ 1 1-1 1-1 Installation bolt types ...................................................................... 1 1-1 1-2 Installation bolt nominal length .
7 Adjusting the T iming Belt T ension ....................................... 1 1-22 7-1 Adjusting the drive belt tension ..................................................... 1 1-23 7-2 Adjusting the speed reduction belt tension .....................
11-1 Chapter 1 1 FXYBX/SXYBX 1 Installation WARNING Always turn the controller power OFF before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Install the FXYBX by opening through holes on the installation base and secur - ing with M5 bolts from belo w .
11-2 Chapter 1 1 FXYBX/SXYBX SXYBX Select the under head length so that the scre w length from the bottom of the robot is 9mm or more, 27mm or less. 17 10 Fig. 1 1-2 ! CAUTION Note that the screw will contact the bottom if the screw length from the robot bottom is longer than 27mm.
11-3 Chapter 1 1 FXYBX/SXYBX 2 Protective connections WARNING Always ground the robot and controller to prevent electrical shocks. WARNING Always turn the controller power OFF before connecting the ground to prevent electrical shocks.
11-4 Chapter 1 1 FXYBX/SXYBX The ground terminal for the Whipover cable type is pro vided on the end face of the X-axis wiring box. (Refer to Fig. 11-5.) Fig. 1 1-5 Whipover cable type 2-2 Ground wire Use an A WG14 (2.0mm 2 ) or lar ger ground wire with a total length of 1m or less.
11-5 Chapter 1 1 FXYBX/SXYBX 1) Remo ve the four M4 scre ws from the top of the X-axis wiring box, and loosen the M4 scre w on the end face. Fig. 1 1-6 2) Open the X-axis wiring box co ver . Lift up the back of the wiring box, push it forward and then pull it upw ard and of f.
11-6 Chapter 1 1 FXYBX/SXYBX 4) Return the wiring box co ver to the original position follo wing steps 1 and 2 in re verse. Lead out the ground wire from the user wiring outlet on the end f ace of the X-axis wiring box.
11-7 Chapter 1 1 FXYBX/SXYBX 3 Installing the T ool Install the user tool onto the robot's tool installation surface in the f ollowing manner . WARNING Always turn the controller power OFF before Installing a tool to prerent an accident. WARNING Before installing a tool, check that the robot is securely fixed to the base.
11-8 Chapter 1 1 FXYBX/SXYBX Select the under head length of the bolt for f ixing the tool so that the scre w length from the slider installation surface is 6mm or less. ! CAUTION If the screw length from the installation surface is 8mm or more, the screw could interfere with the stroke cover .
11-9 Chapter 1 1 FXYBX/SXYBX Select the under head length of the bolt for f ixing the tool so that the scre w length from the slider installation surface is 6mm or less. ! CAUTION Note that if the screw length from the installation surface is 16mm or more, the screw will contact the bottom.
11-10 Chapter 1 1 FXYBX/SXYBX 3-4 ZS/ZRS (FXYBX, SXYBX 3/4-axis option ) WARNING Use the tap hole on the end of the shaft only to prevent the tool from dislocating. Do not use only this hole to install the tool. The tool could dislocate and fly off the installation section during robot operation.
11-11 Chapter 1 1 FXYBX/SXYBX 3-5 ZFH (Arm type, gantry type, moving arm type 3rd-axis option) XZ 2nd-axis option When using the 3rd-axis model with ZFH for the 3rd-axis, install the workpiece onto the ZFH frame in the follo wing manner .
11-12 Chapter 1 1 FXYBX/SXYBX 3-6 ZFL (Arm type, moving arm type, 3rd-axis option/XZ type 2- axis model) When using the 3rd-axis model with ZFL for the 3rd-axis, install the workpiece onto the ZFL slider in the follo wing manner . Six M5 coarse thread tap holes and a φ 5 reamer hole are opened on the slider's workpiece installation surf ace.
11-13 Chapter 1 1 FXYBX/SXYBX 4 User Wiring and User Piping WARNING Always turn off the controller before wiring and piping to prevent electri- cal shocks. 4-1 Cable carrier type A cable carrier is mounted as a standard between the X and Y axes. When using 3-axes, a cable carrier is also pr ovided between the Y and Z axes.
11-14 Chapter 1 1 FXYBX/SXYBX 4) Open the Y -axis wiring box cov er . 5) Lay out the wiring in the Y -axis box as necessary . 6) ! CAUTION 1. The wires could be damaged if the harness retainer is tightened too much. 2. Manually move the robot by the full stroke before fixing to confirm that the harness and air tube, etc.
11-15 Chapter 1 1 FXYBX/SXYBX 4-1-2 Cable carrier specifications ! CAUTION When setting the harness and air tube into the cable carrier , make sure that the total cross-sectional area of all wires and pipes, including the Y AMAHA cable, inside the cable carrier does not exceed 30% of the cable carrier ’s cross-sec- tional area.
11-16 Chapter 1 1 FXYBX/SXYBX 4-1-3 User I/O cable specifications ! CAUTION Securely crimp the pin and insert into the pin connector . Failure to do so will prevent the signals and power from being supplied cor- rectly , and may prevent the device from operating correctly .
11-17 Chapter 1 1 FXYBX/SXYBX 4-2-1 Examples of wiring and piping with Whipover cable ! CAUTION Securely crimp the pin and insert into the pin connector . Failure to do so will prevent the signals and power from being supplied cor- rectly , and may prevent the device from operating correctly .
11-18 Chapter 1 1 FXYBX/SXYBX 10) When completed with all wiring work, return each wiring box cov er to the original positions. Sandwich the X-axis wiring and air tube with the protec- ti ve material at the wire lead-out port of each wiring box. ! CAUTION T ake care not to catch the wiring or air couplers when installing the covers.
11-19 Chapter 1 1 FXYBX/SXYBX 5 Changing the Motor Installation Position 5-1 Changing the motor installation position WARNING Always turn the controller power OFF before starting this work. Serious accidents could occur if the robot starts moving during this work.
11-20 Chapter 1 1 FXYBX/SXYBX 4) First attach the belt to the small pulle y , and then fit it onto the lar ge pulle y . 5) T emporarily f ix the motor plate installation bolts while pulling on the motor case. Motor case Motor plate installation bolt 6) Refer to “Chapter 11 7-1-2.
11-21 Chapter 1 1 FXYBX/SXYBX 6 Installing the Cover If the X-axis stroke is long, a slider mechanism is pro vided in the X-axis str ok e cov er . The alignment of the slider and upper cov er must be adjusted when install- ing the co ver .
11-22 Chapter 1 1 FXYBX/SXYBX 7 Adjusting the T iming Belt T ension WARNING The motor and speed reduction gear casing are extremely hot after auto- matic operation, so burns may occur if these are touched. Before han- dling these parts, turn the controller power OFF , wait for a while and check that the part has cooled.
11-23 Chapter 1 1 FXYBX/SXYBX 7-1 Adjusting the drive belt tension ! CAUTION On robot models having a long stroke, a slider is provided in the upper cover . Pull off the upper cover with a parallel movement in the axis movement direc- tion. 1) T urn the controller po wer OFF .
11-24 Chapter 1 1 FXYBX/SXYBX 5) Mov e the slider by hand so that the distance between the slider end face and base block end face is 150mm. Apply a load at the L = 115mm position from the base block end for the FXYBX X-axis, at L = 65mm for the FXYBX Y -axis, and L = 129mm for the SXYBX X and Y axes.
11-25 Chapter 1 1 FXYBX/SXYBX 7-2 Adjusting the speed reduction belt tension 1) T urn the controller po wer OFF . 2) Remov e the end cover . 3) Apply the load listed in T able 11-2 at the center of both pulle ys, and measure the deflection at that point.
11-26 Chapter 1 1 FXYBX/SXYBX 6) Measure the belt tension again with the procedure gi ven in step 3). The belt adjustment is completed if the measured v alue is within the rang e gi ven in T able 11-2. If the measured v alue is not within the range of T able 11-2, re- peat steps 3) to 5).
11-27 Chapter 1 1 FXYBX/SXYBX 8 Periodic inspections The inspection periods and general precautions are described in Chapter 4 Peri- odic Inspections. Always refer to that Chapter before starting this work. WARNING Always turn the controller power OFF before starting periodic inspec- tions.
11-28 Chapter 1 1 FXYBX/SXYBX 5) Loosen the two pulle y set scre ws, and remov e the pulley . 6) Replace the motor , and attach the pulley to the motor . Insert so that the two set scre ws perpendicularly contact the D face of the motor shaft. NOTE The parts can be correctly assembled by projecting the set scre ws by approx.
11-29 Chapter 1 1 FXYBX/SXYBX 3) Remov e cover 1. Cov er 1 4) FXYBX X-axis, SXYB X, Y axes Remov e the belt stay installation bolts (4 bolts, 2 stays), and remove the belt stays from the table. Belt stay Ta b l e Belt stay installation bolt FXYBX Y -axis Remov e the two belt stay installation bolts, and remov e the belt stay from the table.
11-30 Chapter 1 1 FXYBX/SXYBX 6) Attach the ne w belt. 7) First, lead the belt from the top of the idle pulle y , and push it out with a narro w rod, etc. 8) Next, lead the belt thr ough the lower side of the slider and lead it to belo w the driv e pulley .
11-31 Chapter 1 1 FXYBX/SXYBX 8-3 Replacing the speed reduction belt ! CAUTION The position will deviate when the belt is replaced. After replacing the belt, return-to-origin must be carried out and the point data must be reset. Remem- ber the relation of the installation positions when removing any parts.
11-32 Chapter 1 1 FXYBX/SXYBX 8-4 Replacing the slider If the X stroke is 2150mm or more for the FXYBX, or 2450mm or more for the SXYBX, a slider mechanism is provided in the X-axis strok e cover . Use the fol- lowing procedure if the slider needs to be replaced due to wear or damage.
11-33 Chapter 1 1 FXYBX/SXYBX 8-5 Replenishing the grease 8-5-1 Replenishing grease to the linear guide The X-axis, Y -axis and Z-axis (ZF) use a linear guide as the linear guide mecha- nism. Grease must be replenished to this linear guide periodically .
11-34 Chapter 1 1 FXYBX/SXYBX 4) Using a grease gun, replenish grease from the grease nipple installed on the linear guide bearings. Suf f icient grease has been replenished when new grease starts to seep out from the clearance between the linear guide bearings and rail.
11-35 Chapter 1 1 FXYBX/SXYBX 8-5-2 Replenishing grease to the ball screw (ZF) The ZF uses a ball scre w for drive. Grease must be periodically replenished to the ball scre w . Refer to section 8-6. for details on replenishing grease to the ZS/ZRS unit ball scre w .
11-36 Chapter 1 1 FXYBX/SXYBX 8-6 Periodic inspection of the ZS/ZRS unit 8-6-1 Replenishing grease to the Z-axis ball screw and ball spline A ball screw dri ve is used for the ZS and ZRS v ertical axis. Grease must be replenished to this ball scre w periodically .
11-37 Chapter 1 1 FXYBX/SXYBX 8-6-2 Adjusting the R-axis belt tension (ZRS) WARNING There is a risk of injury if fingers, etc., are caught between the drive sec- tion pulley and belt section. Always turn the controller power OFF and carefully carry out the work if these parts may be contacted.
11-38 Chapter 1 1 FXYBX/SXYBX 7) If the v alue measured in step 4) is smaller than the v alue gi ven in T able 11-3, mov e the R-axis motor so that the tension increases. If lar ger than the value in T able 11-3, move the R-axis motor so tha t the tension decreases.
11-39 Chapter 1 1 FXYBX/SXYBX Replacement period The harmonic driv e replacement period is determined by the total number of wa ve generator rotations. A calculation example is sho wn belo w . The recommended harmonic dri ve replacement period is 8.4 × 10 8 rotations (at usage atmospheric temperature range 0 ° C to +40 ° C).
11-40 MEMO.
CHAPTER 12 HXYLX 1 Installation ............................................................................ 12-1 1-1 Installation method 1 (Arm type, moving arm type, pole type, gantry type X-axis) .......... 12-1 1-1-1 Installation bolt types ......
4 User Wiring and User Piping .............................................. 12-15 4-1 Cable carrier type ......................................................................... 12-15 4-1-1 Example of wiring and piping methods using cable carrier ..
12-1 Chapter 12 HXYLX 1 Installation WARNING Always turn the controller power OFF before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Install the HXYLX by tapping holes into the installation base and securing the robot to the base with M8 bolts from the inside of the robot.
12-2 Chapter 12 HXYLX 1-1-3 Tightening torque • The accurate tightening torque will differ according to the seating f ace fric- tional coef f icient and the female screw material, etc. The following tightening torque is recommended as a guide. Recommended torque 22.
12-3 Chapter 12 HXYLX 3) Secure the robot to the base with the specif ied bolts and torque. The bolts and tightening torque are sho wn below . Bolt Tightening torque Hex socket-head M8 bolt, strength: 8.8T, length: longer than 45mm (F17), longer than 50mm (F20) 230kg-cm to 370kg-cm WARNING Be sure to tighten the bolt to the correct torque.
12-4 Chapter 12 HXYLX ● Protective bonding WARNING Always ground the robot and controller unit to prevent electrical shock. A grounding terminal (M4 scre w) is provided inside the cable box, so al ways ground the unit. The position of the grounding terminal is sho wn below .
12-5 Chapter 12 HXYLX 1-2 Installation method 3 (Gantry type support axis) Install the gantry type support axis in the follo wing manner . ! CAUTION Move the X-axis as much as possible, and tighten the bolts where the move- ment is the lightest. Set the X-axis and guide rail parallelism during installation.
12-6 Chapter 12 HXYLX 2 Protective Connections WARNING Always ground the robot and controller to prevent electrical shocks. WARNING Always turn the controller power OFF before connecting the ground to prevent electrical shocks.
12-7 Chapter 12 HXYLX 2-2 Ground wire Use an A WG14 (2.0mm 2 ) or lar ger ground wire with a total length of 1m or less. Crimp an M4 ring-tongue terminal on the end of the wire connected to the robot. 2-3 Wiring methods ! CAUTION Accurately insert the lock washer between the ring-tongue terminal and robot.
12-8 Chapter 12 HXYLX 3 Installing the T ool Install the user tool onto the robot’ s tool installation surface in the following man- ner . WARNING Always turn the controller power OFF before Installing a tool to prevent an accident. WARNING Before installing a tool, check that the robot is securely fixed to the base.
12-9 Chapter 12 HXYLX Select the nominal length of the tool f ixing bolt so that the f itting length of the scre w f ixing the tool is 16mm or more, 25mm or less.(Refer to the cross-section drawings in Fig. 12-5.) ! CAUTION If the fitting length is less than 16mm, the threads could be damaged during tightening.
12-10 Chapter 12 HXYLX 3-3 Pole type 2-axis model Four M8 coar se thread tap holes and two $8 reamer holes are opened on the tool installation surface of the Y -axis slider . (Refer to Fig. 12-7.) Install the user tool onto the Y -axis slider using these holes.
12-11 Chapter 12 HXYLX 3-4 ZH (Arm type, gantry type, moving arm type 3rd-axis option) When using the 3rd-axis model with ZH for the 3rd-axis, install the workpiece onto the ZH frame in the follo wing manner . M6 coarse thread tap holes are opened on the frame's workpiece installation sur - face.
12-12 Chapter 12 HXYLX 3-5 ZL (Arm type, gantry type) When using the 3rd-axis model with ZL for the 3rd-axis, install the workpiece onto the ZL slider in the follo wing manner . Eight M6 coarse thread tap holes and two φ 6 reamer holes are opened on the Y -axis slider .
12-13 Chapter 12 HXYLX 3-6 ZPH (Pole type 3rd-axis option) When ZPH is attached for the 3rd-axis of the pole type, install the tool onto the aluminum bracket at the end of the ZP-axis. T welve M6 coarse thread tap holes and tw o φ 6 reamer holes are opened on the bracket.
12-14 Chapter 12 HXYLX 3-7 RH (Arm type, gantry type 4th-axis option) ! CAUTION When fixing with the tap holes, always fix at several holes. If fixed with only one hole, the loosening torque could act during operation can cause loosening. If the rotary axis RH is attached to the 4th-axis, install the tool onto the shaft at the end of RH.
12-15 Chapter 12 HXYLX 4 User Wiring and User Piping WARNING Always turn off the controller before wiring and piping to prevent electri- cal shocks. 4-1 Cable carrier type A cable carrier is mounted as a standard between the X and Y axes.
12-16 Chapter 12 HXYLX 3) Remov e the harness retainer located at the cable carrier outlet. (He xagon socket bolt M5, 2 bolts) Harness retainer 4) Pass the r equired wires and pipes through the cable carrier . The cable carrier has an outer lid that can be opened and closed easily .
12-17 Chapter 12 HXYLX 4-1-2 Cable carrier specifications ! CAUTION When setting the harness and air tube into the cable carrier , make sure that the total cross-sectional area of all wires and pipes, including the Y AMAHA cable, inside the cable carrier does not exceed 30% of the cable carrier’s cross-sec- tional area.
12-18 Chapter 12 HXYLX 4-1-3 User I/O cable specifications ! CAUTION Securely crimp the pin and insert into the pin connector . Failure to do so will prevent the signals and power from being supplied cor- rectly , and may prevent the device from operating correctly .
12-19 Chapter 12 HXYLX 4-2 Whipover cable type (moving arm type/pole type 3-axis) ! CAUTION Do not clamp the wires or tubes to the outside of the independent cable. The independent cable could sag or break and ultimately be disconnected. The signal wires (0.
12-20 Chapter 12 HXYLX 3) Open the X-axis wiring box (mov able) cover . Y-axis wiring box X-axis wiring box (movable) Fig. 12-15 4) Pass the requir ed cables and air tubes, etc., through the X-axis cable conduit. Crimp the enclosed connectors onto the cable.
12-21 Chapter 12 HXYLX 5 Periodic Inspections WARNING Always turn the controller power OFF before starting periodic inspec- tions. Serious accidents could occur if the robot starts moving during the periodic inspection.
12-22 Chapter 12 HXYLX 4) Replenish the grease with one of the follo wing methods. Method 1: Using a grease gun, replenish grease from the grease nipple in- stalled on the linear guide bearings. Suf f icient grease has been replenished when new grease starts to seep out from the clearance between the linear guide bearings and rail.
12-23 Chapter 12 HXYLX Replenishment methods Refer to the follo wing procedures and replenish the grease. 1) Remov e the stroke cov er of the axis to which grease is to be replenished. 2) Replenish the grease with one of the follo wing methods. ! CAUTION Always remove the grease nipple after replenishing the grease.
12-24 Chapter 12 HXYLX 5-3 Adjusting the timing belt tension (X-axis) 1) T emporarily tighten the motor installation bolt. 2) Remov e the belt cov er , and install the adjustment bolt (M5). Apply belt ten- sion. (Refer to the follo wing photograph.) 3) T ighten the motor fixing bolt.
12-25 Chapter 12 HXYLX 5-4 Replacing the motor (X-axis) ! CAUTION Since a positional shift occurs after replacing the motor , return-to-origin must be performed again and the point data re-specified. When removing the parts, check and mark the part positions versus each other so you can correctly reas- semble the parts later .
12-26 Chapter 12 HXYLX 7) Remov e the f ixing bolts (M6: four bolts) from the pulley connection boss, and pull the pulle y off the motor . (Loosen the bolts while f ixing the surface machined section of the boss with a pair of pliers, etc.) 4-M6 Hexagon bolt 38 Ring Motor Pulley Boss 8) Replace the motor , and install the pulley onto the motor .
12-27 Chapter 12 HXYLX 5-5 Installing and removing the cover 5-5-1 Stroke cover Removing the stroke cover 1) Remov e the fixing scre ws (M4, pan-head) on both ends.
12-28 Chapter 12 HXYLX 5-5-2 Belt cover Removing the belt cover 1) Loosen the he xagon bolts (M4, two bolts) on the front with a spanner or socket wrench. After removing the M4 scre ws on the top, pull the cover up- ward and of f. (Refer to the following photograph.
12-29 Chapter 12 HXYLX 5-5-3 Motor cover Removing the motor cover 1) Cut the Insulock-tie binding the motor cable with a pair of nippers, and re- mov e. 2) Remov e the two M6 hexagon bolts, and pull the motor co ver upw ard and of f . (Refer to the follo wing photograph.
Oct. 2006 V er. 1.08 This manual is based on V er . 1.07 of Japanese manual. © Y AMAHA MOT OR CO., L TD. IM Company All rights reserved. No part of this publication may be reproduced in any form without the permission of Y AMAHA MOTOR CO., L TD. Information furnished by Y AMAHA in this manual is believed to be reliable.
An important point after buying a device Yamaha 3-axis model (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Yamaha 3-axis model yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Yamaha 3-axis model - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Yamaha 3-axis model you will learn all the available features of the product, as well as information on its operation. The information that you get Yamaha 3-axis model will certainly help you make a decision on the purchase.
If you already are a holder of Yamaha 3-axis model, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Yamaha 3-axis model.
However, one of the most important roles played by the user manual is to help in solving problems with Yamaha 3-axis model. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Yamaha 3-axis model along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
