YASKAWA YRC1000 Operator's Manual

Or spot welding using motor gun

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Instructions manual (493 pages)

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Summary of Contents for YASKAWA YRC1000

Page 1 YRC1000 MAINTENANCE MANUAL YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS) The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual. The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”. The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.
Page 2 If such modification is made, the manual number will also be revised. • If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.
Page 3 Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the YRC1000. In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”, or “NOTICE”. Indicates an imminently hazardous DANGER situation which, if not avoided, will result in death or serious injury.
Page 4 Immediately press an emergency stop button whenever there is a problem. The emergency stop buttons are located on the front panel of the YRC1000 and on the right of the programming pendant. Read and understand the Explanation of the Warning Labels before operating the manipulator.
Page 5 Definition of Terms Used Often in This Manual The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables.
Page 6 Descriptions of the programming pendant keys, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters or its Pendant /Symbol Keys symbol printed on them are denoted with [ ]. ex. [ENTER] Axis Keys [Axis Key] and [Numeric Key] are generic /Numeric Keys...
Page 7: Table Of Contents
Contents 1 Spot Welding Application Using a Motor Gun................. 1-1 1.1 System Overview (Motor Gun) ..................1-1 Function Keys ........................1-3 1.3 Setting of Motor Gun......................1-5 1.3.1 Posture of Motor Gun ................... 1-6 1.3.2 Basic Configuration ....................1-6 1.3.3 Setting of Pulse to Stroke Conversion Data ............1-6 1.3.4 Tentative Setting of Torque to Pressure Conversion Data ........
Page 8 Contents 1.5.6.1 Job Creating Procedures for Pressure Instruction Registration .... 1-57 1.5.6.2 Registering Steps .................. 1-59 1.6 Playback (Motor Gun) ...................... 1-60 1.6.1 Check Run ......................1-60 1.6.2 Execute Welding....................1-60 1.7 Welding Instruction (SVSPOT Instruction)............... 1-61 1.7.1 Registration of Welding Instruction (SVSPOT Instruction) ......... 1-61 1.7.2 Setting of Gun Pressure ..................
Page 9 Contents 1.11.2 Teaching Type Setting ..................1-95 1.11.3 Tip Dress Condition ..................1-95 1.11.4 Dressing Position Teaching Operation ............. 1-99 1.11.5 Tip Dress Instruction..................1-101 1.11.5.1 Tip Dress Instruction (SVDRESMOV) Flow ........1-102 1.11.5.2 Suspend and Restart of the Tip Dress Operation ......1-103 1.11.5.3 Individual Control Instruction to a Dresser and a Gun.......
Page 10 Contents 1.13.2.1 Gun Change Instruction ..............1-140 1.13.2.2 Signal Status to Execute GUNCHG Instruction......... 1-140 1.13.2.3 Gun Change Job ................1-142 1.13.2.4 Gun Changing Timing................ 1-144 1.13.3 Touch Teaching Function ................1-145 1.13.3.1 Setting the Workpiece Thickness ............1-145 1.13.3.2 Registering and Confirming Positions by Touch Teaching....1-148 1.13.4 Signal Dry Spot....................
Page 11: Spot Welding Application Using A Motor Gun
Spot Welding Application Using a Motor Gun System Overview (Motor Gun) Spot Welding Application Using a Motor Gun System Overview (Motor Gun) An I/O signal diagram of a typical system is shown below. Fig. 1-1: Spot Welding System I/O Signal Diagram WELDING Power Controller...
Page 12 Spot Welding Application Using a Motor Gun System Overview (Motor Gun) • Welding conditions (level signals) • Sets the welding conditions for the welder. • The output format can be set as binary or discrete. • Can handle up to 255 conditions in binary. 8 bits (7) (6) (5) (4)
Page 13: Function Keys
Spot Welding Application Using a Motor Gun Function Keys Function Keys Each function used for spot welding is allocated on the [NUMERIC KEY]s of the programming pendant. Displays the MANUAL PRESS window. Displays the WORK HOME POSITION window. [FWD] + [TASK ORIGIN] With the WORK HOME POSITION window in the teach mode, press these keys to move the manipulator to the work home position.
Page 14 Spot Welding Application Using a Motor Gun Function Keys The SHORT OPEN POSITION SETTING window appears the first time this key is pressed. The selection No. for the short open position is replaced by pressing this key while the SHORT OPEN POSITION SETTING window is appeared.
Page 15: Setting Of Motor Gun
Spot Welding Application Using a Motor Gun Setting of Motor Gun Setting of Motor Gun Set up the motor gun by following the procedures below. The dynamic characteristics of the motor gun need to be automatically identified by the Motor Gun Auto Turning function so that the pressurization is executed by the optimum pressure torque instruction for the each motor gun.
Page 16: Posture Of Motor Gun
Spot Welding Application Using a Motor Gun Setting of Motor Gun When executing the welding instruction, the weld complete signal may be already turned ON at the beginning of the welding instruction. At that time, "AL4621: WELD COM- PLETE SIGNAL ERROR" may occur. To prevent the alarm, set the item "WELD COMPLETE OFF WAIT TIME"...
Page 17: Tentative Setting Of Torque To Pressure Conversion Data
Spot Welding Application Using a Motor Gun Setting of Motor Gun 1.3.4 Tentative Setting of Torque to Pressure Conversion Data In order to use Motor Auto Tuning function, it is necessary to set the torque to pressure conversion data of the Gun Condition file tentatively. Normally, the tentative setting is already set.
Page 18 Spot Welding Application Using a Motor Gun Setting of Motor Gun 2. Set the pressure value to the pressure file. – As the unit of this pressure, specify torque(%). – Specify 5(%) to the touch speed of the pressure file. 3.
Page 19: Register The Base Position For Wear Detection (Fixed Side)
Spot Welding Application Using a Motor Gun Setting of Motor Gun 1.3.5 Register the Base Position for Wear Detection (Fixed Side) Register the base position for wear detection by following the procedures below. Mount a new tip Clear the base position for the wear detection.
Page 20: Execution Of Motor Gun Auto Tuning Function
Spot Welding Application Using a Motor Gun Setting of Motor Gun 1.3.6 Execution of Motor Gun Auto Tuning Function By referring to the following procedures, execute Motor Gun Auto Tuning. This function automatically repeats applying pressure to identify the dynamic characteristics parameter of the motor gun. This identification takes 5 to 10 minutes.
Page 21 Spot Welding Application Using a Motor Gun Setting of Motor Gun 3. Select the gun number using [PAGE] or {PAGE}. 4. Change the mode to the play mode, and then press [SERVO ON READY] . – The servo power is turned ON, then {EXECUTE} button appears. –...
Page 22 Spot Welding Application Using a Motor Gun Setting of Motor Gun 5. Press {EXECUTE} button. – If the wear compensation has not been executed, the confirmation dialog to prompt performing the wear compensation will appear. Refer to chapter 1.3.5 "Register the Base Position for Wear Detection (Fixed Side)", and execute the wear compensation.
Page 23 Spot Welding Application Using a Motor Gun Setting of Motor Gun 6. Select “YES” in the dialog box. – The MOTOR GUN AUTO TUNING operation is executed. – The status of MOTOR GUN AUTO TUNING operation can be confirmed by the SPECIFIED OUTPUT signal (#50906). •...
Page 24 Spot Welding Application Using a Motor Gun Setting of Motor Gun During the MOTOR GUN AUTO TUNING operation, the fol- lowing operations are not available: • Moving to other windows • Key operation • Operations by the start button • External start operation •...
Page 25 Spot Welding Application Using a Motor Gun Setting of Motor Gun – The MOTOR GUN AUTO TUNING operation is stopped or suspended in case one of the following operation is executed. {Stop: Impossible to continue} • Emergency stop • Mode change –...
Page 26 Spot Welding Application Using a Motor Gun Setting of Motor Gun – After MOTOR GUN AUTO TUNING operation is successfully done, a confirmation dialog box for registration appears as shown in the figure below. Then, move to step 8. – In case there is a possibility of false detection of touch due to high friction torque of the gun, a dialog box appears as shown in the figure below to notify an error in MOTOR GUN AUTO TUNING operation.
Page 27 Spot Welding Application Using a Motor Gun Setting of Motor Gun 7. Select “OK”. – A message “The false detection of touch may occur by friction torque of motor gun. Check the factor of high friction torque.” appears. – If no failure is found to the gun, set the touch pressure a higher value than the value of friction torque value.
Page 28: Confirmation Of Motor Gun Auto Tuning Operation Status
Spot Welding Application Using a Motor Gun Setting of Motor Gun The result of the MOTOR GUN AUTO TUNING operation is stored in the MOTOR GUN AUTO TUNING file. And the MOTOR GUN AUTO TUNING file is stored in FILE/ NOTE GENERAL DATA.
Page 29: Clearance Of Motor Gun Auto Tuning Setting
Spot Welding Application Using a Motor Gun Setting of Motor Gun 1.3.8 Clearance of MOTOR GUN AUTO TUNING Setting When re-setting the gun condition file due to the change of the gun, etc, clear the Motor Gun Auto Tuning setting by following the procedures below.
Page 30 Spot Welding Application Using a Motor Gun Setting of Motor Gun 5. Select “YES”. – {STATUS} changes from {COMPLETE} to {INCONPLETE}. – The data will not be deleted if “NO” is selected. 1-20 30 of 198...
Page 31: Setting Of Torque To Pressure Conversion Data
Spot Welding Application Using a Motor Gun Setting of Motor Gun 1.3.9 Setting of Torque to Pressure Conversion Data After the execution of Motor Gun Auto Turning function, by following the procedure below, re-measure the pressure and reset the torque to pressure conversion data.
Page 32: Alarm
Spot Welding Application Using a Motor Gun Setting of Motor Gun 1.3.10 Alarm Alarm Message Cause Remedy 4708 Motor Gun Auto Tuning Motor Gun Auto Tuning operation Motor Gun Auto Tuning function by is not executed is not executed but SVSPOT following the procedures below.
Page 33: System Setting (Motor Gun)
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) System Setting (Motor Gun) The items to be determined at the system setting, such as the gun and the welder, are specified in the system setting files. 1.4.1 Gun Condition File The gun characteristics are set in the gun condition file.
Page 34 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1. GUN NO. Shows the No. of the gun to be used. When using two guns or more, select the No. by pressing [PAGE]. 2. SETTING Shows whether the gun condition file has been set or not. For the file where the values have not been entered, “NOT DONE”...
Page 35 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 12. GUN INSTALLATION STATUS Set the gun installation status. Select “ROBOT-HANDLE” or “FIXED”. 13. TOOL NO. Displayed after validating the “AUTO TOOL. NO. SELECT FOR GUN” on the APPLICATION CONDITION SETTING window when “12.GUN INSTALLATION STATUS”...
Page 36 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) Operation  1. Select {SPOT WELDING} from the main menu. 2. Select {GUN CONDITION}. – GUN CONDITION window appears. 3. Select a gun No. by pressing [PAGE]. 1-26 36 of 198...
Page 37 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 4. Select the item to be set. – For “GUN TYPE,” pressing [SELECT] displays “C-GUN,” “X-GUN (SINGLE ARM MOVE)” and “X-GUN (DOUBLE ARM MOVE)” alternately. 5. Enter the numerical value, and press [ENTER]. 1-27 37 of 198...
Page 38: Entering Pulse To Stroke Conversion Data
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.1.1 Entering Pulse to Stroke Conversion Data To specify the gun stroke in mm, enter data about the relationship between the gun axis motor encoder pulse value and the gun stroke (mm).
Page 39: I/O Signals For A Motor Gun
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.2 I/O Signals for a Motor Gun 1.4.2.1 Major I/O signal (Motor Gun) Table 1-1: Input Signals to YRC1000 Signal Contents Standard Setting Display Setting WELD COMPLETE Shows that the welder completed...
Page 40 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) Table 1-2: Output Signals from YRC1000 Signal Contents Standard Setting Window Setting WELDING Sets the welding conditions for the welder. Welder 4 bits Welder I/F CONDITION • The output format can be set as binary or...
Page 41: Welding I/F File
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.2.2 Welding I/F File The welder characteristics are set in the welding I/F file. 1. WELDER NO. Shows the number of the welder to be used. When using two welders or more, select the welder No. by pressing [PAGE].
Page 42 WELDING CONDITION PARITY and WELDIG CONDITION are outputted at the same time. Settings of the odd/even number parity is performed using the parame- ter. (For the details, refer to “ YRC1000 GENERAL OPERATOR’S MANUAL (RE-CSO-A051) 8.10.3.4 AxP006: PARITY SPECIFICATION FOR WELDING CONDITIONS”.) 11.
Page 43 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) Welder Start Timing  • When the weld cond output type is set to “LEVEL”: 1st pressurization 2nd pressurization Open Speed command Torque command Speed commnad & Torque command Close Weld Complete...
Page 44 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) • When the weld cond output type is set to “PULSE”: 2nd pressurization 1st pressurization Open Speed command Torque command Speed commnad & Torque command Close Weld Complete Weld Cond Output Time When WST=0 Welding...
Page 45 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) • When the weld cond output type is set to “START SIGNAL”: 1st pressurization 2nd pressurization Open Speed command Torque command Speed commnad & Torque command Close Weld Complete Weld Cond When WST=0 Output Time...
Page 46 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) Operation  1. Select {SPOT WELDING} from the main menu. 2. Select {WELDER IF}. – The WELDER IF window appears. 3. Select a welder No. by pressing [PAGE]. 4. Select the item to be set. 5.
Page 47: I/O Allocation
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.2.3 I/O Allocation  I/O Allocation Window 1. DRY TIP DRESS (WITHOUT PRESSING) Use this signal to execute the tip dresser instruction (SVDRESMOV) without pressure of the gun. Refer to chapter 1.11.6 "Dry Tip Dressing Operation".
Page 48 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) Operation  1. Select {SPOT WELDING} from the main menu. 2. Select {I/O ALLOCATION}. – The I/O ALLOCATION window appears. 1-38 48 of 198...
Page 49 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 3. Select the signal No. to be set. – The number can now be entered. 4. Enter the numerical value and press [ENTER]. Be sure that the allocated user signals are not used in the NOTE any JOBs.
Page 50: Pseudo Input Signal Window
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.2.4 PSEUDO INPUT SIGNAL Window The following signals can be validated in the PSEUDO INPUT SIGNAL window. • TMR COOL WTR ERR (timer cooling water error) • GUN COOL WTR ERR (gun cooling water error) •...
Page 51: Registering The Operation Tool
The registration method of operation tool differs depending on whether it is a single arm move gun or a double arm move gun. Considering the following cases, refer to “YRC1000 INSTRUCTIONS (RE-CTO-A221) 8.3 Tool Data Setting” for the tool coordinate value and tool data setting.
Page 52: When Using A Double Arm Move Gun
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.3.2 When Using a Double Arm Move Gun Register the tool coordinate value so that TCP is the contact position of the both fixed side tip and movable side tip. Set the tool posture data so that the direction from the lower side tip to the upper side tip is positive (+) side of Z-axis.
Page 53: Setting The Software Limit Value
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.4 Setting the Software Limit Value For the motor guns, the position where the new tip contacts each other is set as the zero-point (pulse = 0), and the pulse software limit is set at further pressing position from the zero-point.
Page 54: Setting The Lost-Tip Detection Value
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.5 Setting the Lost-tip Detection Value The gun-axis pulse can be monitored to output the signal when the tips of motor gun are detached. Shank position of the new tip Shank Shank motion range when the tip becomes worn...
Page 55: Gun Detail Setting File
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.6 Gun Detail Setting File Set the special gun related setting in the GUN DETAIL SETTING window.  Gun Detail Setting Window 1. GUN No. Shows the gun No. to use. When using two guns or more, select the gun No.
Page 56 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) –In case of SVGUNCL with TWC-A/TWC-AE tag, the gun closes by the set speed in the “5. FINAL TOUCH SPEED” from the beginning until it detects the contact to the work. (2) SVGUNCL with TWC-B/TWC-BE tag.
Page 57 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) (1) SVSPOT or SVGUNCL without TWC-B/TWC-BE tag. The touch reference position is the last touch position detected by the dry spot touch motion of the wear detection (Refer to chapter 1.12.2.1 Dry Spot Touch Motion).
Page 58 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) Operation  1. Select {SPOT WELDING} from the main menu. 2. Select {GUN DETAIL SETTING}. – The GUN DETAIL SETTING window appears. 3. Select the gun No. by pressing the [PAGE] button. 4.
Page 59: Application Condition Setting
Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 1.4.7 Application Condition Setting Regarding the miscellaneous items for the spot (motor gun) application, set them in the APPLICATION CONDITION SETTING window.  Application Condition Setting 1. CLEARANCE TEACHING METHOD Set the teaching method of the clearance teaching function.
Page 60 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 3. WEAR DETECT METHOD Set the method of wear detection. Select from the two methods below. RIN: Operates the wear detection by using a sensor. TOUCH: Operates the wear detection by performing the board touch. 4.
Page 61 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 7. THICKNESS DETECTION FUNCTION Set “VALID” or “INVALID” of the THICKNESS DETECTION FUNCTION. Refer to chapter 1.13.7.4 Group Output for more details. 8. THICKNESS ERROR NOTICE Set the action when the thickness error occurs. ALARM: Raise an alarm when the thickness error occurs.
Page 62 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 15. WELD COMPLETE OFF WAIT TIME When “14. WELD COMPLETE DETECT METHOD” is “STATUS”, set- ting becomes valid. The controller waits for the setting time until the weld complete signal is turned OFF if it is already turned ON at beginning of the welding instruc- tion.
Page 63 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) 28. ERROR CODE BIT (WELD1) The items are shown according to the set numbers in the “2.MAX NUM- BER OF WELDER CONNECT”. Specify the signal by a bit (up to 16-bit) which is used as error code among the signals from the NADEX welder when NADEX welder gener- ates an error.
Page 64 Spot Welding Application Using a Motor Gun System Setting (Motor Gun) Operation  1. Select {SPOT WELDING} from the main menu. 2. Select {APPLI COND.}. – The APPLICATION CONDITION SETTING window appears. 3. Select the item to set. 4. Input the value, and press [ENTER]. 1-54 64 of 198...
Page 65: Before Teaching
Spot Welding Application Using a Motor Gun Before Teaching Before Teaching Before using the motor gun, confirm the following operation instructions. 1.5.1 Manual Spot For manual spot, perform the following operations. 1. Press [0/MANUAL SPOT] of the [Numeric Key]. 2. Press [INTERLOCK] + [./SPOT]. –...
Page 66: Open/Close Of Motor Gun
– Each time [EX.AXIS] is pressed, the objective external axis alternates. 3. Press [FAST] or [SLOW] key to select the axis manual speed. – Refer to “YRC1000 GENERAL OPERATOR’S MANUAL (RE-CSO- A051) 2.2.0.5 Select Manual Speed” for the details. 4. Press [S+] or [S-].
Page 67: Creation Of Job
Spot Welding Application Using a Motor Gun Before Teaching 1.5.6 Creation of Job This section explains how to prepare a job for a robot axis and a gun axis. 1.5.6.1 Job Creating Procedures for Pressure Instruction Registration 1. Select {JOB} under {Main Menu}. 2.
Page 68 Spot Welding Application Using a Motor Gun Before Teaching (Example Case) Robot: R1, Gun-Axis: S1 Select “R1+S1” for a control group 5. Press [ENTER] – Refer to “YRC1000 GENERAL OPERATOR’S MANUAL (RE-CSO- A051) 3.1.3 Registering a Job” for the details. 1-58 68 of 198...
Page 69: Registering Steps
Spot Welding Application Using a Motor Gun Before Teaching 1.5.6.2 Registering Steps  When using SVSPOT instruction Register steps in the following procedures. Tip on the movable side Workpiece Tip on the fixed side 1. Register the positions from 1 to 4 as steps 1 to 4. 2.
Page 70: Playback (Motor Gun)
Spot Welding Application Using a Motor Gun Playback (Motor Gun) Playback (Motor Gun) This section explains about the check run and the actual welding. 1.6.1 Check Run Confirm the taught path in a the check run. Dry run is possible during the check run operation because welding instructions such as SVSPOT are not carried out in the check run operation.
Page 71: Welding Instruction (Svspot Instruction)
Spot Welding Application Using a Motor Gun Welding Instruction (SVSPOT Instruction) Welding Instruction (SVSPOT Instruction) 1.7.1 Registration of Welding Instruction (SVSPOT Instruction) Press [/SPOT] on the programming pendant to register SVSPOT instruction. SVSPOT GUN#(1) PRESS#(1) WTM=1 WST=1 1. Gun No. Specifies a gun No.
Page 72: Setting Of Gun Pressure
Spot Welding Application Using a Motor Gun Welding Instruction (SVSPOT Instruction) Welder startup timing  Open Gun motion Close Pressure Weld sigal In case of touch motion (WST=0) Weld sigal In case of the 1st pressure (WST=1) Weld signal In case of the 2nd pressure (WST=1) 1.7.2 Setting of Gun Pressure The pressure for welding can be specified by the pressure file selected by...
Page 73 Spot Welding Application Using a Motor Gun Welding Instruction (SVSPOT Instruction) 5. 1ST TO 4TH END CONDITION Shows the corresponding pressurization condition at each level. Select either “PRESS” or “END WAIT”. PRESS TIME: Apply pressure for a time specified at “6” item on this window.
Page 74 Spot Welding Application Using a Motor Gun Welding Instruction (SVSPOT Instruction) 3. Select a file number by pressing [PAGE]. 4. Select an item to be specified. 5. Input a numeric value and press [ENTER]. – For {END CONDITION}, “PRESS TIME” and “END WAIT” alternate each time [SELECT] is pressed.
Page 75: Welding Current And Welding Time Settings
Spot Welding Application Using a Motor Gun Welding Instruction (SVSPOT Instruction) • If the touch speed is too fast, the gun axis may bounce. Reduce the speed to be slower than the present value. • Modified settings are deleted in case following operations are executed while editing the gun pressure.
Page 76: Setting The Gun Stroke Motion Speed
Spot Welding Application Using a Motor Gun Welding Instruction (SVSPOT Instruction) 1.7.4.2 Setting the Gun Stroke Motion Speed 1. Select {SPOT WELDING} on the {Main Menu}. 2. Select {GUN DETAIL SETTING}. – The GUN DETAIL SETTING window appears. 3. Select a gun No. by pressing [PAGE]. 4.
Page 77: Dry Spot (Motor Gun)
Spot Welding Application Using a Motor Gun Dry Spot (Motor Gun) Dry Spot (Motor Gun) For dressing a tip and mounting a tip, a gun motion to apply pressure without welding (dry spot) is required. Dry spot can be also registered in a job to be executed. 1.8.1 Registration of Dry Spot Instruction (SVGUNCL Instruction) Register SVGUNCL instruction by pressing [2/GUN CLOSE] among the [Numeric Key] on the programming pendant.
Page 78: Dry Spot Pressure Setting
Spot Welding Application Using a Motor Gun Dry Spot (Motor Gun) 1.8.2 Dry Spot Pressure Setting The pressure for dry spot is specified by the pressure file selected by the SVGUNCL instruction.  PRESSURE window 1. FILE NO. Shows the dry spot pressure file No. Select a number by pressing [PAGE].
Page 79 Spot Welding Application Using a Motor Gun Dry Spot (Motor Gun) As for a value to “7”, set a value so that the following equal- ity to be true. 1000 <= 1ST to 4TH PRESS NOTE If the gun pressure is not set following the above mentioned instructions, the actual pressure over the specified pressure cannot be guaranteed.
Page 80 Spot Welding Application Using a Motor Gun Dry Spot (Motor Gun) Table 1-4: PRESS (N) END CONDITION 1ST PRESS 2000 0.50 2ND PRESS 2200 0.50 3RD PRESS 0.00 4TH PRESS 0.00 Tip dresser rotating signal PRE CUT TIME = 1.0 (sec) and END CUT TIME = 1.0 (sec) Dry spot pressure 2000 2200 1000...
Page 81: Workpiece Transfer Function Using A Motor Gun
Spot Welding Application Using a Motor Gun Dry Spot (Motor Gun) 1.8.3 Workpiece Transfer Function Using a Motor Gun 1.8.3.1 Operation Flow Chart With the dry spot instruction, workpieces can be transferred. When this instruction is performed, the force control for grasping a workpiece and the tip wear compensation are available so that the workpiece can be stably handled using a motor gun.
Page 82: Instruction For Grasping/Releasing Workpieces
Spot Welding Application Using a Motor Gun Dry Spot (Motor Gun) 1.8.3.2 Instruction for Grasping/Releasing Workpieces SVGUNCL　GUN#(1) PRESSCL#(1) ON 1. Instruction for grasping/releasing workpieces 2. GUN#(1) Specifies the gun No. to grasp the workpiece. 3. PRESSCL#(1) Specifies a dry spot condition file (pressure for grasping workpiece set- ting) No.
Page 83 Spot Welding Application Using a Motor Gun Dry Spot (Motor Gun) 5. Move the cursor to {SVGUNCL} and press [SELECT] twice. – DETAIL EDIT window appears. (For transferring workpieces, adding the transfer tag is required on this window.). – When “UNUSED” is selected for {WEAR DETECT}, the following dialog box appears.
Page 84: Manual Operation For Grasping/Releasing Workpieces
Spot Welding Application Using a Motor Gun Dry Spot (Motor Gun) 7. Press [INSERT] and then press [ENTER]. (1) The window returns to JOB CONTENT window after pressing [ENTER]. (2) The instruction can be inserted by pressing [ENTR] while LED indicator is lit by pressing [INSERT].
Page 85: Manual Pressure
Spot Welding Application Using a Motor Gun Manual Pressure Manual Pressure Manual pressure window  1. GUN NO. Specifies the gun number to execute pressurization. 2. PRESS MEASUREMENT MODE Select “ENABLE” when measuring the pressure with a force gauge. For the gun closing speed, just before the upper and lower tips to con- tact, the gun decreases its speed till the speed to the final touch speed specified on GUN DETAIL SETTING window.
Page 86 Spot Welding Application Using a Motor Gun Manual Pressure 8. MANUAL DRY SPOT MODE Pressurizing method for the dry spot is specified by selecting either “FILE” or “CST PRESS”. With this procedure, “TOUCH SPEED” and “PRESSURE” are specified as follows. •...
Page 87 Spot Welding Application Using a Motor Gun Manual Pressure Operating procedures  1. Press [0/MANUAL SPOT] of the [Numeric Key]. – MANUAL PRESS window appears. 2. Select an item to set. 3. Input a value, and press [ENTER]. – To {WELDER STARTUP TIMING(WST)}, press [SELECT] to alternate “TOUCH MOTION”, “1ST PRESSSURE”...
Page 88: Clearance Move Instruction (Svspotmov Instruction)
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) After teaching this instruction at the welding points, execution of all the following operations become enabled by this instruction only. 1. Moving to a position short before the welding operation point. (moving to a clearance position) 2.
Page 89: Setting The Teaching Type
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10.2 Setting the Teaching Type The following three types of settings are available; the lower-tip teaching, the upper-tip teaching, and the gun-close teaching. Follow the procedures to select one out of the three types before teaching the welding point.
Page 90 Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 3. Select {CLEARENCE TEACHING METHOD}. – Move the cursor to {CLEARENCE TEACHING METHOD} and press [SELECT]. A selection dialog box for the teaching methods appears. – Three teaching methods are available. •...
Page 91: Setting The Clearance Files
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10.3 Setting the Clearance Files In this section, setting procedures of various data to the clearance file are explained. • When selecting “UPPER TIP” or “LOWER TIP” as the clearance teaching method, setting of {TICKNESS} in the clearance file before teaching the welding point is required.
Page 92 Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) – Amount of clearance and operation conditions can be set. – There are three moving patterns. • MOVE&CLOSE • SQUARE • MOVE&OPEN – {DISTANCE TO UPPER TIP(IN)} and {DISTANCE TO LOWER TIP(IN)} are the amount of clearance for closing motion.
Page 93: Operations For Teaching Welding Points
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) – After entering each value, press [ENTER] to set the value. 1.10.4 Operations for Teaching Welding Points The following describes the outline of the procedure for teaching the welding point.
Page 94 Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) When registering pressure instructions (SVSOPT, SVGUNCL, SVSPOTMOV and SVDRESMOV),create a job SUPPLE- MENT which includes a gun axis control group. 3. Press [SHIFT] + [MOTION TYPE] to display SVSPOTMOV. –...
Page 95: Clearance Move Instruction
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10.5 Clearance Move Instruction The following describes the clearance move instruction. SVSPOTMOV V=1000.0 PLIN=1 PLOUT=1 CLF#(1) GUN#(1) PRESS#(1) WTM=1 WST=1 WGO=1 SVSPOTMOV : Clearance move instruction V=1000.0 : Linear motion speed for clearance (1000.0mm/s for this example)
Page 96: Clearance Move
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10.6 Clearance Move The following describes the clearance move.  When the positioning level (PLIN) is used Table 1-5: Job Example: Work 1 0000 0001 MOVJ VJ=100.0 →...
Page 97 Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) When the positioning level (PLOUT) is used  Table 1-6: Job Example: Work 1 0000 → 1 0001 MOVJ VJ=100.0 → 2 0002 SVSPOTMOV V=1000.0 PLOUT=0 CLF#(1) GUN#(1) PRESS#(1) WTM=1 WST=1 →...
Page 98: Press Teaching Function
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10.7 Press Teaching Function 1.10.7.1 Operation Flow Chart Teaching of the clearance move instruction can be executed while the gun is applying pressure. The following shows the operation flow chart for this function. Start Select “GUN CLOSE”...
Page 99: Procedure For Registering The Position
In case it doesn’t appear, press [8] to switch the indication. – The taught position is registered after the wear compensation amount of the gun axis is added. Yaskawa recommends that the pressure is applied in the level which the gun axis does not bend when teaching.
Page 100: Setting The Gun Pushing Coefficient
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10.7.4 Setting the Gun Pushing Coefficient By setting a value to the gun pushing coefficient, the position of the gun is registered after subtracting the pressure pushing value from the gun position when executing press teaching.
Page 101 Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 3. Set a value to {GUN PUSHING COEF}. – Set the value (0 to 10.0 [mm/1000N]) to the gun pushing coefficient to compensate the registering position when press teaching is performed.
Page 102: Work Search Function
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10.8 Work Search Function The workpiece position over the tool Z-axis direction can be automatically detected. 1.10.8.1 Operating procedures 1. Manually move the motor gun to the welding point. 2.
Page 103: Parameter
Spot Welding Application Using a Motor Gun 1.10 Clearance Move Instruction (SVSPOTMOV Instruction) 1.10.8.2 Parameter SICxG175: Threshold of the workpiece detection by the movable side tip Specifies the threshold of workpiece detection by the movable side tip 0: 10 [N] Others: SICxG175 [N] ...
Page 104: Tip Dressing Instruction (Svdresmov Instruction)
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) As well as the clearance move instruction (SVSPOTMOV Instruction), all the following operations become available only by this instruction after teaching this instruction at a dressing position. 1.
Page 105: Teaching Type Setting
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11.2 Teaching Type Setting The teaching type setting procedures are same as that of the clearance move instruction (SVSPOTMOV). Refer to chapter 1.10.2 "Setting the Teaching Type" . 1.11.3 Tip Dress Condition The pressure, clearance and dressing conditions when the tip dress instruction (SVDRESMOV) is executed are set on the tip dress condition...
Page 106 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 6. END CONDITION “PRESS TIME” and “DRESS LENGTH” can be selected as the condition for ending the operation. – When “PRESS TIME” is selected Pressing time is designated. When “0”...
Page 107 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) {DRESSOR}. 16. ROTATION DIRECTION Set a rotating direction of the servo dresser. 17. ROTATION SPEED (1ST PRESS) 18. ROTATION SPEED (2ND PRESS) Set a rotating speed of the servo dresser. When the tip dress instruction (SVDRESMOV) is started, the dresser rotates at a rotation speed (1st press), and the speed shifts to a rotation speed (2nd press) when the gun pressure is changed to the 2nd press...
Page 108 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) Operating procedures  1. Select {SPOT WELDING} on the {Main Menu}. 2. Select {TIP DRESS CONDITION}. – TIP DRESS CONDITION window appears. 3. Select a file No. by pressing [PAGE]. 4.
Page 109: Dressing Position Teaching Operation
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11.4 Dressing Position Teaching Operation 1. Select {JOB} on the {Main Menu}. 2. Select {JOB}. – JOB CONTENT window appears. When registering a pressure instruction (SVSPOT, NOTE SVGUNCL, SVSPOTMOV or SVDRESMOV), create a job in which a gun axis control group is included.
Page 110 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 3. Press [SHIFT] + [MOTION TYPE] to indicate SVSPOTMOV. 4. Press [MOTION TYPE] to indicate SVDRESMOV . – Changing the motion type with [MOTION TYPE] is available only while the manipulator is in operation status ([ROBOT] LED light is in lit status).
Page 111: Tip Dress Instruction
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11.5 Tip Dress Instruction Following shows the tip dress instruction. SVDRESMOV V=500.0 VCL=100.0 VOP=100.0 PLIN=0 PLOUT=0 GUN#(1) DRS#(1) 1. Speed Set the speed. 2. Gun pressure speed Set the closing speed for the manipulator and the gun before dressing operation.
Page 112: Tip Dress Instruction (Svdresmov) Flow
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11.5.1 Tip Dress Instruction (SVDRESMOV) Flow Move to the clearance position Closing Apply Opening Dresser Dresser rotation start operation pressure operation rotation finish Rotation wait time Rotation request Dresser rotation speed Dresser...
Page 113: Suspend And Restart Of The Tip Dress Operation
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11.5.2 Suspend and Restart of the Tip Dress Operation – In case the execution of the tip dress instruction (SVERESMOV) is suspended with Hold operation after the gun close motion is started, the robot and the gun will stop after they move to the clearance position.
Page 114 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) DRESSOF Instruction  Use this instruction when stopping the rotation of the dresser. DRESSOF DRS#(1) 1. Tip dress condition Specifies the tip dress condition file number About DRESSOF instruction –...
Page 115: Wear Detection With Tip Dressing Instruction
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11.5.4 Wear Detection with Tip Dressing Instruction By adding tags for wear detection (TWC-A, TWC-C) to Tip Dressing Instruction (SVDRESMOV Instruction), amount of wear is detected. SVDRESMOV GUN#(1) DRS#(1)
Page 116 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) DRESSER THICKNESS setting  1. On APPLICATION CONDITION SETTING window, select “GUN CLOSE” at {CLEARANCE TEACHING METHOD}. 2. Contact the fixed side tip to the servo dresser, and then press [INTERLOCK] + [8] to apply pressure.
Page 117: Dry Tip Dressing Operation
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11.6 Dry Tip Dressing Operation {DRY TIP DRESS (WITHOUT PRESSING)} and {DRY TIP DRESS (WITHOUT DRESSING)} signals enable dry tip dressing operation. For the settings of this signal, refer to chapter 1.4.2.3 I/O Allocation.
Page 118: Tip Dress Supervision
Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 1.11.7 Tip Dress Supervision On this window, dress length, dress time, servo dresser starting torque and dressing torque can be monitored. Furthermore, by setting the allowable values and universal output signal numbers, designated signal can be turned ON in case one of the above mentioned values exceeded the value in {TOLERANCE}.
Page 119 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) TIP DRESS COND. Window  1. DRESS LENGTH (CURRENT, TOLERANCE, SETTING(OUT#)) Current length for dressing operation is indicated. Tolerance range for this operation: 0.00 to 9.99 mm –...
Page 120 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) 4.DRESSING TORQUE(CURRENT, TOLERANCE, SETTING (OUT#)) Servo dresser average torque absolute data measured between the pressure reach time and pressure complete time is indicated. Tolerance range for this operation: 0 to 300% –...
Page 121 Spot Welding Application Using a Motor Gun 1.11 Tip Dressing Instruction (SVDRESMOV Instruction) Operating procedures  1. Select {SPOT WELDING} on the {Main Menu}. 2. Select {TIP DRESS SUPERVISION}. – TIP DRESS SUPERVISION window appears. 3. Select a COND No. by pressing [PAGE]. 4.
Page 122: Tip Wear Detection And Wear Compensation (Motor Gun)
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.1 Wear Detection and Wear Compensation Operation Flow Chart Mount a new tip Teach the manipulator operation position Clear the base positions.
Page 123: Wear Detection
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.2 Wear Detection This section explains the method to detect the tip wear amount by dry spot touch motion and movable side tip detection. After registering the wear base position, do not change the pressure condition settings used for the wear detection dry NOTE...
Page 124 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.2.2 Movable Side Tip Detection The gun axis position is acquired when the movable side (upper) tip passes the sensor. The movable side tip detection operation is carried out by a SVGUNCL (dry spot) instruction.
Page 125: Dry Spot Touch Motion
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.2.3 Example of Wear Detection Dry spot touch motion Movable side tip detecting motion Movable side tip Sensor Sensor (light emitting side) (light receiving side) Fixed side tip ...
Page 126: Spot Supervision Window Setting
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.3 Spot Supervision Window Setting Shows the tip wear amount, etc. Also, the wear amount detection relevant settings can be performed. Spot supervision window ...
Page 127 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 5. WEAR (F) Present wear amount at the fixed side tip is indicated. The value is updated when the wear detection is finished. Also, the universal output signal specified at {SETTING (OUT#)} is turned ON when the value in {CURRENT} has exceeded the value in {TOLERANCE}.
Page 128 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 18. WEAR DETECT SENSOR POLARITY Set the polarity of the sensor signal used for the movable side tip detect- ing motion (wear detecting motion (TWC=B)). Select {ON ->...
Page 129 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) Manual clearing procedures of weld count and wear amount  1. Select {DATA} in the menu area. 2. Select {CLEAR W.COUNT/WEAR}. 3. Select “YES”. 1-119 129 of 198...
Page 130 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) Clearing the wear detection base position  After modifying the wear detection motion, etc. clear this value. 1. Select {DATA} in the menu area. 2.
Page 131: Wear Compensation
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.4 Wear Compensation The manipulator motion and the gun stroke are adjusted according to the amount of tip wear. Wear compensation is performed to the following positions. –...
Page 132: Tip Wear Compensation For Fixed Gun
The + direction of the Z-axis must be directed towards the movable tip. User coordinates The YRC1000 has the External Reference Point Control Function (the function to execute teaching or playback operation with the manipulator TCP set to a point in space).
Page 133: User Coordinate Number Setting
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.5.2 User Coordinate Number Setting 1. Select {SPOT WELDING} on the {Main Menu}. 2. Select {GUN CONDITION}. 3. Move the cursor to {GUN INSTALLATION STATUS} and press [SELECT].
Page 134: Example Of Compensation
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.5.3 Example of Compensation The manipulator motion and the gun stroke are adjusted according to the amount of tip wear. Wear compensation is performed to the following positions. –...
Page 135: Teaching Positions With A Worn Tip
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.6 Teaching Positions with a Worn Tip When teaching positions with a worn tip, the teaching position is registered, adjusted by tip wear amount. 1.12.6.1 Teaching Example Workpiece Tip with 5 mm wear...
Page 136: Wear Amount Loading
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.7 Wear Amount Loading Detected wear amount can be loaded in a job. The wear amount is stored in the system D variable ($D). Use GETS instruction and load the wear amount.
Page 137: Tip Mounting Position Error Detection
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.8 Tip Mounting Position Error Detection The cause of the pressure position error when pressure is applied can be sorted to two causes; tip wear and tip mounting position error. By handling the causes separately, the real wear amount of tip itself can be handled to decide the tip ideal replacing timing.
Page 138: Tip Mounting Position Error Detection Flow Chart
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.8.1 Tip Mounting Position Error Detection Flow Chart  When the wear amount is imported to a tip mounting position error after a wear amount detection job is executed. Mount a new tip Teach a manipulator motion positions Clear the base positions...
Page 139 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) When the tip mounting position error is detected with a job for tip  mounting position error detection. Mount a new tip Teach a manipulator motion position Clear the base positions (Refer to 1.12.3) Execute wear detection job or...
Page 140: Tip Mounting Position Error Detection
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.8.2 Tip Mounting Position Error Detection The method to execute the tip mounting position error detection operation by dry spot touch motion and by movable side tip detection motion are described here.
Page 141 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) When the tip mounting position error is detected with a job for tip  mounting position error detection. By adding tags for tip mounting position error detection (TWC-AE, TWC- BE) to the dry spot instruction (SVGUNCL), tip mounting position errors can be detected.
Page 142: Job Examples
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.8.3 Job Examples Dry spot touch motion Movable side tip detecting motion Movable side tip Plate Fixed side tip  When the wear amount is imported to a tip mounting position error after a wear amount detection job is executed.
Page 143: Importing The Tip Mounting Position Error
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) Teach the following two positions to be the same position. • in the job for tip mounting position error detection: the position short before the dry spot touch motion –...
Page 144 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) – SPOT SUPERVISION window appears. 3. Select a gun No. by pressing [PAGE]. 4. Select {DATA} -{IMPORT T.M.ERROR}. 1-134 144 of 198...
Page 145 Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 5. Select “YES”. 1-135 145 of 198...
Page 146: Monitoring The Failure Of Mounting Tips
Spot Welding Application Using a Motor Gun 1.12 Tip Wear Detection and Wear Compensation (Motor Gun) 1.12.8.5 Monitoring the Failure of Mounting Tips The failure of mounting tips can be monitored by the following parameters. A1P56 : Universal output for the failure of mounting tips A1P57 : Limit of tip mounting position error (movable side) [μm] A1P58 : Limit of tip mounting position error...
Page 147: Other Functions Using A Motor Gun
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.1 Motor Gun Stroke The motor gun stroke is classified into two; full open and short open. 1.13.1.1 Registering the Full-open/Short-open Position Eight stroke positions can be registered for full open and short open respectively.
Page 148: Registering The Current Position
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.1.2 Registering the current position 1. Press [3/FULL OPEN] or [-/SHORT OPEN] of the numeric keys. – FULL OPEN POS SET window (or SHORT OPEN POS SET window) appears.
Page 149: Moving To Full-Open/Short-Open Position
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.1.4 Moving to Full-open/Short-open Position 1. Press [3/FULL OPEN] or [-/SHORT OPEN] of the numeric keys. – FULL OPEN POS SET window (or SHORT OPEN POS SET window) appears.
Page 150: Gun Change
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.2 Gun Change 1.13.2.1 Gun Change Instruction Gun change is executed by the GUNCHG (gun change) instruction. GUNCHG GUN#(1) PICK 1.Gun No. 2. Designation of connecting or disconnecting a gun When “PICK (gun connected)”...
Page 151 ON, the servo power supply for the gun motor turns ON when the servo is turned ON. If the signal status indicates that the gun is not connected when YRC1000 controller is turned ON, the servo power supply for the robot motor turns ON when the servo is turned ON, but the servo power supply for the gun motor is not turned ON.
Page 152: Gun Change Job
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.2.3 Gun Change Job The following example explains the gun change job. Input Signal Output Signal Gun Chuck Gun connect/disconnect SOL OUT1 Gun Unchuck Gun 1 cover open/close SOL OUT2 Coupling confirmation...
Page 153 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun Job name: GUN 1 PLACE Control group: R1 MOVJ VJ=30 Moves to the standby position. WAIT IN#(3)=ON Confirms ATC coupling. WAIT IN#(4)=OFF Confirms Gun 1 absence.
Page 154: Gun Changing Timing
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.2.4 Gun Changing Timing The timing to change a gun is illustrated below. PLACE Gun Status PICK Coupling Confirmation Gun ID No. Signal CHUCK Connect/Disconnect SOL UNCHUCK Gun Chuck Gun Unchuck...
Page 155: Touch Teaching Function
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.3 Touch Teaching Function Even if the fixed tip position cannot be visually confirmed when teaching, it is possible to register the position where the fixed tip touches the workpiece by moving the movable tip to touch the workpiece.
Page 156 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun Operation  1. Select {SPOT WELDING} in the {Main Menu}. 2. Select {GUN DETAIL SETTING}. – GUN DETAIL SETTING window appears. 3. Select a gun No. by pressing [PAGE]. 4.
Page 157 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 5. Enter a numerical value, and press [ENTER]. 1-147 157 of 198...
Page 158: Registering And Confirming Positions By Touch Teaching
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.3.2 Registering and Confirming Positions by Touch Teaching 1. Select {JOB} on the {Main Menu}. 2. Select {JOB}. 3. Move the manipulator to the welding position. 4.
Page 159: Signal Dry Spot
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.4 Signal Dry Spot Gun-pressure can be applied by inputting an external signal. Gun-pressure can be applied by an external signal for dry NOTE spot only. Welding cannot be carried out by an external signal.
Page 160 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun  DRY SPOT SIGNAL(FILE) • After the signal is input, pressurizing is started. • Pressure is applied according to the settings in the dry spot pressure file specified by {PRESSURE FILE NO.} •...
Page 161: Gun Pressure Compensation Function
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.5 Gun Pressure Compensation Function 1.13.5.1 Operation Flow Chart With the gun pressure compensation function, the gun pressure can be kept stable even when the motor gun posture changes. The following shows the operation flow chart for the gun pressure compensation.
Page 162: Overview
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.5.2 Overview The following describes outline of the gun pressure compensation function. The pattern 1 is shown in the fig. 1-3; applying pressure downwards, and the pattern 2 is shown in the fig. 1-4; applying pressure upwards. In case of the pattern1, since the pairs of pressure and torque data (twelve pairs at maximum) is set with the gun pressurizing downwards (see fig.
Page 163 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun Fig. 1-5: GUN CONDITION File (Downward Pressure) Fig. 1-6: Pressure-to-torque Conversion (For Pattern 1) Toque Measured values Calculated by interpolation Pressure (kgf) 1-153 163 of 198...
Page 164 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun For the pattern 2 shown in fig. 1-4Pattern 2 (Applying Pressure Upwards), the weight of the motor gun itself may cause deviation of pressure. Using the gun pressure compensation function, by setting one pressure compensation value (see fig.
Page 165: Setting The Pressure Compensation Value
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.5.3 Setting the Pressure Compensation Value The following describes settings for pressure compensation value of pattern 2. For details on the data registration of pattern 1; applying pressure downwards (settings for pressure-to-torque conversion value), refer to chapter 1.3.9 "Setting of Torque to Pressure Conversion Data".
Page 166 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 3. Select {PRESSURE COMPENSATION}. – By Specifying the pressure for compensation (0 to 9999N) at PRESSURE COMPENSATION, the pressure is compensated when the motor gun changes its posture. –...
Page 167: Compensation Of Gun Arm Bend For C-Gun And X-Gun (Single Arm Move)
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.6 Compensation of Gun Arm Bend for C-Gun and X-Gun (SINGLE ARM MOVE) The gun arm bend at pressurizing can be compensated by the corrective manipulator motion. Compensation motion in the tool Z+ direction for (K ×...
Page 168: Compensation Example
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 4. Select “GUN ARM BEND DOEF.” – GUN ARM BEND DOEF. Set the compensation amount for gun arm bend per 1000N pressure. 5. Enter a numerical value, and press [ENTER]. If “0”...
Page 169: Disabling Gun Arm Bend Compensation
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.6.3 Disabling Gun Arm Bend Compensation The gun arm bend compensation can be disabled at each SVSPOT/ SVSPOTMOV instruction. Set the gun arm bend compensation disabling tag (BCOFF tag) to SVSPOT/SVSPOTMOV instruction to disable it.
Page 170: Welding Conditions Group Output Function
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.7 Welding Conditions Group Output Function 1.13.7.1 Operation Flow Chart With the welding conditions group output function, a group signal is output to the welder during welding. The following shows the operation flow chart for the welding conditions group output function.
Page 171 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 3. Select the desired item. – Set {GROUP OUTPUT}. Enter the LSB output number to the start and MSB output number to the end. 4. Input the numerical value and press [ENTER]. 1-161 171 of 198...
Page 172: Setting The Group Output Tag
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.7.3 Setting the Group Output Tag The following describes the settings for the group output. When the job contents are displayed, by pressing [SHIFT] + [MOTION TYPE], the instruction in the input line can be switched from the normal motion interpolation (MOVJ, MOVL, MOVC, MOVS) to the clearance move interpolation.
Page 173: Group Output
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 6. Select {WELD GRP OUT}. – Press [SELECT] to display the selection dialog box. (The initial value is “UNUSED.”) (1) Select {WGO=}. (2) Set the output value. 7.
Page 174: Workpiece Thickness Detection Function
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.8 Workpiece Thickness Detection Function 1.13.8.1 Outline The workpiece thickness detection function monitors the thickness of workpiece to be welded at the every SVSPOT instruction and SVSPOTMOV instruction.
Page 175: Instruction
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.8.2 Instruction  SVSPOT (Spot Welding Instruction) To use the workpiece thickness detection function, set the tag for the function to SVSPOT/SVSPOTMOV instruction. WST= SVSPOT WTM= GUN# ( ) PRESS# ( ) BWS=...
Page 176: Operation Procedures
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.8.3 Operation Procedures  Setting of Workpiece Thickness Monitoring • Set the mode switch of programming pendant to the teach mode. • Set the security mode to the edit mode or management SUPPLE- mode to edit job data.
Page 177 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 2. Set SVSPOT/SVSPOTMOV instruction. – Move the cursor to the “SVSPOT/SVSPOTMOV” and press [SELECT]. – Press [SELECT] again to display DETAIL EDIT window. – Move the cursor to “THICKNESS” and press [SELECT]. Then, select “TH=”...
Page 178 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 3. Set the workpiece thickness (TH). – Move the cursor to “THICKNESS”, and press [SELECT]. – Enter a value and press [ENTER]. 1-168 178 of 198...
Page 179 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 4. Set the allowable workpiece thickness (THA, THM). – Set THA= 0 to 100 [%] (THA: Specifies the allowable range for the detected workpiece thickness by using a percentage.) or THM= 0.0 to 10.0 [mm] (THM: Specifies the allowable range for the detected workpiece thickness by using an absolute value).
Page 180 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun Setting of Workpiece Thickness Measurement  • Set the mode switch of programming pendant to the Play mode. SUPPLE- • When it is in the thickness measure mode, whether the MENT detected thickness is within the allowable range or not is not monitored.
Page 181 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 3. Select {THICKNESS MEASURE} under {UTILITY}. – “Thickness measure mode” appears in the message display area. The {THICKNESS MEASURE} is displayed with an asterisk mark 1-171 181 of 198...
Page 182 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun • Universal signal can be used to switch to the measure mode. • When using the universal signal to switch to the thickness measure mode, perform the following settings to “THICK- NESS CHECK MODE SELECT GIN#”...
Page 183 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 4. Execute the job. – The “TH” tag value of SVSPOT instruction will be rewritten with the detected workpiece thickness, the value when the pressure reaches the touch pressure, at each weld point.
Page 184 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun Execution of Workpiece Thickness Monitoring  • Set the mode switch of programming pendant to the play mode. SUPPLE- MENT • Cancel the thickness measure mode. * Refer to How to Cancel Thickness Measure Mode .
Page 185 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun By modifying the following items on APPLICATION CONDITION SETTING window, the universal output is output by pulse (pulse width: 100 msec) instead of generating alarms when the result of comparing is NG. •...
Page 186: Related Functions
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.8.4 Related Functions  Signal Output during Thickness Measure Mode During the thickness measure mode, the universal output set in the parameter S4C165 is turned ON. For example, if the parameter S4C168 is 20 (S4C168=20), OUT20 is turned ON.”.
Page 187 Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun – SPOT SUPERVISION window appears. 2. Set the value to the setting “M” of “THICKNESS DETECTED”. Set the register number when outputting the detected thickness value to register.
Page 188: Notes
Spot Welding Application Using a Motor Gun 1.13 Other Functions Using a Motor Gun 1.13.8.5 Notes 1. It is recommended that the "TH" tag of SVSPOT/SVSPOTMOV instruction be set just before thickness measurement after teaching operation. If the “TH” tag is specified before that, the alarm “Thickness Error” may occur during test operation, which results in less operating efficiency.
Page 189: Automatic Tool Number Select Function For Guns
JOB does not include a robot or gun, the tool remains unchanged. Also, even if a tool is selected by this function, it can be manually changed to other ones. (Refer to “YRC1000 GENERAL OPERATOR’S MANUAL (RE-CSO-A051) 2.3.4.1 Selecting Tool”.) The correspondence of a gun and a tool number needs to be performed in the gun condition file.
Page 190: Loading The Dx100 Motor Gun Condition File
Some files in the DX100 motor gun condition files cannot be loaded to the YRC1000 due to different formats. Thus, load the DX100 condition files in the table below to the YRC1000 by using the {LOAD DX100 SPOT FILES} in the sub-menu of the {EX. MEMORY} in the main menu.
Page 191 Spot Welding Application Using a Motor Gun 1.14 Loading the DX100 Motor Gun Condition File – The Load DX100 Spot Files window appears. 2. Select {FOLDER SELECT} tab. 3. Select the connecting device in the DEVICE SELECT combo box. 1-181 191 of 198...
Page 192 Spot Welding Application Using a Motor Gun 1.14 Loading the DX100 Motor Gun Condition File 4. Select the folder containing the files to be loaded in the FOLDER SELECT list. 5. Select {FILE SELECT} tab. 1-182 192 of 198...
Page 193 Spot Welding Application Using a Motor Gun 1.14 Loading the DX100 Motor Gun Condition File 6. Select the item(s) to load in the YRC1000 file list. 7. Press {LOAD} in the bottom right in the window. – The confirmation dialog appears.
Page 194 Spot Welding Application Using a Motor Gun 1.14 Loading the DX100 Motor Gun Condition File 8. Press {LOAD} in the dialog box. – The selected condition files are loaded. 9. Press {CLOSE} in the dialog box. – The dialog box is closed. 10.
Page 195: The Instruction List (Motor Gun)
Spot Welding Application Using a Motor Gun 1.15 The Instruction List (Motor Gun) 1.15 The Instruction List (Motor Gun) The following table shows the instruction list regarding the motor gun. • <> indicates numerical or alphabetical data. • If multiple items are shown in one section, select one of the items. SVSPOT Function Executes the gun pressure and welding.
Page 196 Spot Welding Application Using a Motor Gun 1.15 The Instruction List (Motor Gun) SVGUNCL Function Executes the gun pressure. Additional GUN# () 1 to 12 Item PRESSCL# () 1 to 32 WP=, 1 to 9999N PRESSSTWC (), DRS# (<...
Page 197 Spot Welding Application Using a Motor Gun 1.15 The Instruction List (Motor Gun) SVDRESMOV Function Executes the motion to the clearance position, the gun pressure and the dress. Additional V= 0.1 to the max Item speed mm/sec VCL= 0.1 to the max speed mm/sec VOP=...
Page 198 FOR SPOT WELDING USING MOTOR GUN HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802 YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Europe GmbH Robotics Divsion )

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