YASKAWA Motoman DX200 Instructions Manual

Part Number: 174506-1CD

Revision: 0

MANUAL NO.

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DX200 OPTIONS

INSTRUCTIONS

For MotoFit Function Engineering Support Tool

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain

for future reference.

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Terms of Use and Copyright Notice

customers to assist in the operation of Motoman robots, related equipment

and software This manual is copyrighted property of Yaskawa and may

not be sold or redistributed in any way. You are welcome to copy this

document to your computer or mobile device for easy access but you may

not copy the PDF files to another website, blog, cloud storage site or any

other means of storing or distributing online content.

Printed in the United States of America

First Printing, 2015

Yaskawa America, Inc.

Motoman Robotics Division

100 Automation Way

Miamisburg, OH 45342

Phone: 937-847-6200

www.motoman.com

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MANDATORY

• This manual explains MotoFit function engineering support tool.

Read this manual carefully and be sure to understand its contents

before handling the DX200.

• General items related to safety are listed in the Chapter 1: Safety of

the DX200 Instructions. To ensure correct and safe operation,

carefully read the DX200 Instructions before reading this manual.

CAUTION

• Some drawings in this manual are shown with the protective covers

or shields removed for clarity. Be sure all covers and shields are

replaced before operating this product.

• The drawings and photos in this manual are representative

examples and differences may exist between them and the

delivered product.

• YASKAWA may modify this model without notice when necessary

due to product improvements, modifications, or changes in

specifications. If such modification is made, the manual number will

also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA

representative 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.

• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your

product’s warranty.

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We suggest that you obtain and review a copy of the ANSI/RIA National

Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA

R15.06-2012). You can obtain this document from the Robotic Industries

Association (RIA) at the following address:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: (734) 994-6088

FAX: (734) 994-3338

www.roboticsonline.com

Ultimately, well-trained personnel are the best safeguard against

accidents and damage that can result from improper operation of the

equipment. The customer is responsible for providing adequately trained

personnel to operate, program, and maintain the equipment. NEVER

ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR

REPAIR THE EQUIPMENT!

We recommend approved Yaskawa training courses for all personnel

involved with the operation, programming, or repair of the equipment.

This equipment has been tested and found to comply with the limits for a

Class A digital device, pursuant to part 15 of the FCC rules. These limits

are designed to provide reasonable protection against harmful

interference when the equipment is operated in a commercial

environment. This equipment generates, uses, and can radiate radio

frequency energy and, if not installed and used in accordance with the

instruction manual, may cause harmful interference to radio

communications.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or

inspection of the DX200.

In this manual, the Notes for Safe Operation are classified as

“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

Even items described as “CAUTION” may result in a serious accident in

some situations.

At any rate, be sure to follow these important items

WARNING

Indicates a potentially hazardous

situation which, if not avoided, could

result in death or serious injury to

personnel.

CAUTION

Indicates a potentially hazardous

situation which, if not avoided, could

result in minor or moderate injury to

personnel and damage to equipment.

It may also be used to alert against

unsafe practices.

MANDATORY

Always be sure to follow explicitly the

items listed under this heading.

PROHIBITED

Must never be performed.

NOTE

To ensure safe and efficient operation at all times, be sure

to follow all instructions, even if not designated as

"CAUTION" and "WARNING".

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Notes for Safe Operation

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WARNING

• Before operating the manipulator, check that servo power is turned

OFF when the emergency stop buttons on the front door of the

DX200 and programming pendant are pressed.

When the servo power is turned OFF, the SERVO ON LED on the

programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit

cannot stop the manipulator during an emergency. The manipulator

should not be used if the emergency stop buttons do not function.

Figure 1: Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all

items which could interfere with the operation of the manipulator.

Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Figure 2: Release of Emergency Stop

TURN

• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the manipulator

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Keep in mind the emergency response measures against the

manipulator’s unexpected motion toward you.

– Ensure that you have a safe place to retreat in case of

emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the P-point maximum

envelope of the manipulator and that you are in a safe location

before:

– Turning ON the DX200 power

– Moving the manipulator with the programming pendant

– Running the system in the check mode

– Performing automatic operations

Injury may result if anyone enters the P-point maximum envelope of the

manipulator during operation. Always press an emergency stop button

immediately if there are problems. The emergency stop buttons are

located on the right of the front door of the DX200 and the programming

pendant.

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Definition of Terms Used 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.

In this manual, the equipment is designated as follows.

CAUTION

• Perform the following inspection procedures prior to

conducting manipulator teaching. If problems are found,

repair them immediately, and be sure that all other necessary

processing has been performed.

– Check for problems in manipulator movement.

– Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the

DX200 cabinet after use.

The programming pendant can be damaged if it is left in the

manipulator’s work area, on the floor, or near fixtures.

• Read and understand the Explanation of the Warning Labels in the

DX200 Instructions before operating the manipulator.

Equipment Manual Designation

DX200 controller DX200

DX200 programming pendant Programming pendant

Cable between the manipulator and the

controller

Manipulator cable

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Description of the Operation Procedure

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Descriptions of the programming pendant, buttons, and displays are

shown as follows:

Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • "

means that the cursor is moved to the object item and the SELECT key is

pressed, or that the item is directly selected by touching the screen.

Registered Trademark

In this manual, names of companies, corporations, or products are

trademarks, registered trademarks, or brand names for each company or

corporation. The indications of (R) and TM are omitted.

Equipment Manual Designation

Programming

Pendant

Character Keys/

Symbol Keys

The keys which have characters printed on

them are denoted with [ ].

ex. [ENTER]

Axis Keys/

Number Keys

“Axis Keys” and “Number Keys” are generic

names for the keys for axis operation and

number input.

Keys pressed

simultaneously

When two keys are to be pressed

simultaneously, the keys are shown with a “+”

sign between them, ex. [SHIFT]+[COORD]

Displays The menu displayed in the programming

pendant is denoted with { }.

ex. {JOB}

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Customer Support Information

If you need assistance with any aspect of your MotoFit Engineering

Support Tool, please contact Motoman Customer Support at the following

24-hour telephone number:

For routine technical inquiries, you can also contact Motoman Customer

Support at the following e-mail address:

When using e-mail to contact Motoman Customer Support, please provide

a detailed description of your issue, along with complete contact

information. Please allow approximately 24 to 36 hours for a response to

your inquiry.

Please have the following information ready before you call Customer

Support:

techsupp[email protected]

NOTE

Please use e-mail for routine inquiries only. If you have an

urgent or emergency need for service, replacement parts,

or information, you must contact Motoman Customer

Support at the telephone number shown above.

• System MotoFit Engineering Support Tool

• Robots MH12

• Primary Application ___________________________

• Controller DX200

• Software Version Access this information on the

Programming Pendant’s LCD

display screen by selecting {MAIN

MENU} - {SYSTEM INFO} -

{VERSION}

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX200 controller

data plate

(937) 847-3200

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Table of Contents

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Table of Contents

1 Outline of Function .......................................................................................................................... 1-1

1.1 MotoFit Function Engineering Support Tool ...................................................................... 1-1

1.2 Automatic Adjustment Function of Force Control Parameter............................................. 1-2

1.2.1 Force control......................................................................................................... 1-2

1.2.2 Adjustment Method............................................................................................... 1-3

1.3 MotoFit Teach Guidance Function..................................................................................... 1-5

1.4 Force Sense Basic Command ........................................................................................... 1-6

2 System Configuration...................................................................................................................... 2-1

2.1 System Configuration......................................................................................................... 2-1

2.2 User Interface .................................................................................................................... 2-2

2.3 Target Robot ...................................................................................................................... 2-2

3 Operation Procedure....................................................................................................................... 3-1

3.1 Initial Settings..................................................................................................................... 3-1

3.1.1 Setting DX200 ......................................................................................................3-1

3.1.2 Setting PC ............................................................................................................ 3-1

3.2 MotoFit Teach Operation ...................................................................................................3-2

3.2.1 Outline of Operation Step ..................................................................................... 3-2

3.2.2 Detailed Operation Step ....................................................................................... 3-3

3.2.2.1 Startup of FSE-Tool................................................................................. 3-3

3.2.2.2 Setting Force Condition File .................................................................... 3-5

3.2.2.3 Automatic Adjustment of Force Control Parameter ............................... 3-10

3.2.2.4 TOUCH Command Teach ..................................................................... 3-21

3.2.2.5 FIT Command Teach............................................................................. 3-29

3.2.2.6 INSERT Command Teach..................................................................... 3-35

3.2.2.7 Creating MotoFit JOB............................................................................ 3-43

3.3 Teach of Force Sense Basic Command .......................................................................... 3-49

3.3.1 Outline of Teach Operation of Force Detection .................................................. 3-49

3.3.2 Details of Teach Operation of Force Detection................................................... 3-49

3.3.2.1 Creating JOB ......................................................................................... 3-49

3.3.2.2 Threshold Setting by Data Logging ....................................................... 3-51

3.3.2.3 Operation Check ................................................................................... 3-56

4 Interface Panel................................................................................................................................ 4-1

5 Monitor Information ......................................................................................................................... 5-1

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6 Operation Condition Data ............................................................................................................... 6-1

6.1 Force Condition File Data .................................................................................................. 6-1

6.2 Adjustment Condition Data ................................................................................................ 6-2

6.3 MotoFit Command Argument Data.................................................................................... 6-4

6.4 Backup of Teach Data ....................................................................................................... 6-7

6.5 Data for Setting Detection Threshold................................................................................. 6-9

7 General Output and Variables ........................................................................................................ 7-1

8 Error of Automatic Adjustment Function of Force Control Parameter............................................. 8-1

9 Alarm List of FSE-Tools .................................................................................................................. 9-1

10 Version........................................................................................................................................ 10-1

11 Precautions................................................................................................................................. 11-1

11.1 Operation during Force Control ..................................................................................... 11-1

11.2 Cancel Operation during Execution of Adjustment Operation or MotoFit Function ....... 11-1

11.3 Communication Error..................................................................................................... 11-1

11.4 Limitation due to Using Environment ............................................................................. 11-1

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1 Outline of Function

1.1 MotoFit Function Engineering Support Tool

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1 Outline of Function

1.1 MotoFit Function Engineering Support Tool

The MotoFit function is an application using force control, attaching with

the 6-axis force sensor. It realizes the optimum fit operation by the

combination of commands as "TOUCH (Push of workpiece)", "FIT

(Search)", and "INSERT (Insertion)" (refer to DX200 OPTIONS

INSTRUCTIONS for MotoFit (168845-1CD)).

During the force control, the robot moves based on the force condition file

in DX200. On the other hand, during the operation of each command, the

robot moves based on the command argument.

The MotoFit Function Engineering Support Tool (abbreviated as FSE-

Tool) is a tool to support teaching the MotoFit function. It operates on the

PC connected with the robot controller.

The common FSE-Tool can be used for the FS100 and the DX200.

Fig. 1-1: Operation of MotoFit Function

In FSE-Tool, operation according to the teach guidance on the PC screen

will create the force condition file and a JOB added MotoFit command.

The guidance is mainly on the automatic adjustment of force control

parameters in the force condition file, and argument setting of the MotoFit

command. The former function is called as the automatic adjustment

function of force control parameter, and the latter function is called as the

MotoFit teach guidance function. They adjust to the optimum parameters

suitable for the robot configuration or workpiece form and materials in

operation, realizing a precise fit operation. Note that, however,

adjustment may be hard to apply to such a workpiece of unstable shape

due to its insufficient hardness.

Realizing fit work by the operation command optimum to the insertion status

TOUCH

(Successful) INSERT

(Successful)

TOUCH

(Failed)

FIT(Successful)

FIT(Failed)

INSERT

(Failed)

6-axis force sensor

PC DX200

Programming

Pendant (PP)

Robot 6-axis

force sensor

MotoFit Function

The MotoFit

Function

Engineering

Support Tool

(FSE-Tool)

force condition

file

JOB

Automatic Adjustment of

Force Control Parameter

Argument setting of MotoFit command

(MotoFit teach guidance function)

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1.2 Automatic Adjustment Function of Force Control Parameter

1.2 Automatic Adjustment Function of Force Control

Parameter

1.2.1 Force control

The MotoFit function uses the impedance control shown in the formula (1)

as a model of force control. The impedance control parameter has M

(Mass parameter), D (Damping parameter), and K (Spring parameter) as

shown in the following figure, and the robot behavior receiving the external

force depends on these values. In the MotoFit function, these values are

fixed as M = 1 [kg, kgm2], and k = 0 [N/m, Nm]. The damping parameter,

D, is automatically adjusted so that it can quickly follow the command

according to the certain force command. The units described in the

parentheses show translational direction for the former and rotational

direction for the latter.

(1)

Fref[N,Nm]: Force command value

Ffb[N,Nm]: Force feedback value

M[kg,kgm2]: Mass parameter

D[Ns/m,Nms]: Damping parameter

K[N/m,Nm]: Spring parameter

Fig. 1-2: Impedance Control Model

fbref FFxKxDxM

−=Δ+Δ+Δ



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1 Outline of Function

1.2 Automatic Adjustment Function of Force Control Parameter

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1.2.2 Adjustment Method

The operation of the automatic adjustment function of force control

parameter consists of the following two steps. The parameters with the

asterisk mark (*) are the adjustment condition data, and listed in Table 6-2

"Adjustment Condition Data" on page 6-3.

1. Tuning Step 1

Obtains a limit value of damping parameter to maintain the stable

contact condition of the workpiece during the contact time Tc1 [sec]*

with a small force, without divergent. After starting from the initial

damping parameter Dinit*, adjustment is performed to obtain the

value in which the force waveform has no emission.

Fig. 1-3: Operation of Tuning Step 1

2. Tuning Step 2

In this step, the force command is given to allow repetitive contact of

workpiece, enabling to automatically adjust to the damping

parameter so that the response of force FB, the force toward the

force command at that time, becomes excellent. As operation, the

following sequence is repeated; "The Push operation is performed

with force command Fref* during the contact time Tc2 [sec]*, and

then the force command is set to zero during the interval time Ti

[sec]*". Searching is started from the damping parameter obtained

in the Tuning Step 1, and the damping parameter is adjusted to the

value in which the settling time of the force FB (time until the force

FB follows the command) is the shortest. The adjustment continues

until the contact count reaches the upper limit Nmax* or until the

search width of the damping parameter becomes the completion

judgment threshold Ethr*.

Fig. 1-4: Operation of Tuning Step 2

Force

Small

Force

Time

Force

Small

Force

Time

OK (Stable contact) NG (Unstable contact)

Divergent (applying force increases)

Rattling

Adjust to a

convergent value

Damping changed

by amplitude

Force

Repeats

contacts

Force sensor

Workpieces

Time

Adjust to damping

property of early follow

Force

command Force

response

Condition B

(Optimum value)

Condition C

(Response delay)

Condition A

(Vibrational)

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1 Outline of Function

1.2 Automatic Adjustment Function of Force Control Parameter

By executing the Tuning Steps 1 and 2, adjust three translational

axes (X, Y, Z) and three rotational axes (Rx, Ry, Rz). Both

adjustment operations, translational and rotational, are shown in the

figure below. In the rotational adjustment, the side of the workpiece

contacts to another.

Fig. 1-5: Translational and Rotational Adjustment Operation

When there is no workpiece and accordingly no contact occurs,

exceeding Over Distance (Translate) Mo_trans* and Over Distance

(Rotate) Mo_rot* stops the operation due to excessive travel

distance.

(a) Adjustment in

translational direction

(b) Adjustment in

rotational direction

Workpiece

Control

points

Stops if Over Distance

(Rotate) Mo_rot 

is exceeded

Stops if Over Distance

(Translate) Mo_trans

is exceeded

(a) Adjustment in

translational direction

(b) Adjustment in

rotational direction

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1 Outline of Function

1.3 MotoFit Teach Guidance Function

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1.3 MotoFit Teach Guidance Function

In the parameters of MotoFit function commands, the following values

should be set (for details, refer to DX200 OPTIONS INSTRUCTIONS for

MotoFit (168845-1CD). Among them, the parameters with the asterisk

mark* need to be the values suitable for the shape of workpiece. Follow

the guidance, and determine the set value by executing the MotoFit

command and performing the measurement.

(1) TOUCH

Arg1: Force condition file No.

Arg2: Touch force threshold

Arg3: Approach speed

Arg4: Force command value

Arg5: Insertion length threshold

Arg6: Touch length* (See the right figure)

Arg7: After - TOUCH, time - out time

(2) FIT

Arg1: Force condition file No.

Arg2: Force command value

Arg3: Insertion length threshold

Arg4: Search operation pattern

Arg5: Search force command value

Arg6: Search vibration cycle*

(See the right figure)

Arg7: Search operation start direction

designation

Arg8: Search operation time

(3) INSERT

Arg1: Force condition file No.

Arg2: Force command value

Arg3: Insertion length threshold 1*

(See the right figure)

Arg4: Insertion length threshold 2*

(See the right figure)

Arg5: Unchoke operation designation

Arg6: Unchoke operation force command

Arg7: Unchoke operation force

command cycle

Arg8: Unchoke operation start direction

designation

Arg9: Unchoke operation time

Touch

length

Search vibration

cycle (Seach width)

Insertion

length

threshold 1

Insertion

length

threshold 2

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1 Outline of Function

1.4 Force Sense Basic Command

Force sense basic command is a command which targets relatively simple

tasks such as pressing with constant force or stopping the operation when

detecting the force which exceeds the specified force. This can be used

for the error detection such as the case that the different force from the

normal state is applied as described below.

OK

NG

X

Z

Tape

Plate

Pressing with

constant force

Movement

Protrusion

Robot arm head

Force sensor

Tool

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2 System Configuration

2.1 System Configuration

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2 System Configuration

2.1 System Configuration

The hardware consists of the robot, DX200, 6-axis force sensor,

Programming Pendant (hereinafter called as "PP"), and the teach PC. At

the shipment, the force sensor is attached to the arm pit, the sensor board

is attached to the bus in DX200, and the power 24 V DC for the sensor is

attached inside the case at the side of DX200. Connect the force sensor

and the sensor board using the RS422 cable after delivery. The teach PC

should be prepared by the customer.

The operation of teach, and the monitoring of force, position, and status

are available on PC. Only when performing adjustment or operation of

MotoFit, the operation can be started by the start button on the PP

interface panel (hereinafter called as "I/F Panel"). From the security

reason, during the robot operation by PP, no one can start operation from

PC.

Processing of MotoFit or adjustment operation is packaged as MotoPlus

Application Program (refer to DX200 OPTIONS INSTRUCTIONS User's

Manual for New Language Environment MotoPlus 166241-1CD).

Processing operation is executed according to the button operation from

PC.

Fig. 2-1: Hardware Configuration

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2 System Configuration

2.2 User Interface

The user interface is designed by using LabVIEW of National Instruments

Corporation. Installing the run-time engine of LabVIEW version that

designed the execution file enables to use the PC even without LabVIEW

installed. Ensure to use the run-time engine, LVRTE2011f3std.exe in the

distributed CD-ROM. There is no need of paying license fee for LabVIEW

to use the execution file. The required PC specification is shown in the

table below.

2.3 Target Robot

The target robot types for assembly application are as follows:

MH12

Table 2-1: Required PC specification

OS Windows XP,7

CPU 1.5 GHz or more

RAM 1 GB or more

Screen Resolution 1024 x 768 pixels or more

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3 Operation Procedure

3.1 Initial Settings

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3 Operation Procedure

3.1 Initial Settings

3.1.1 Setting DX200

The software (the MotoPlus application execution file; MotoFitFS.out) of

the MotoFit function and FSE-Tool (MotoPlus application), and force

condition file (FCON.CND) are shipped with being loaded to DX200. If the

execution file or force condition file is deleted by mistake, load the data

from the distributed CD-ROM.

3.1.2 Setting PC

1. Set the IP address to "192.168.255.9", and the subnet mask to

"255.255.255.0".

2. Copy the FSE-Tool folder in the CD-ROM to the PC.

3. Install the runtime engine, LVRTE2011f3std.exe in FSE-Tool folder in

the CD-ROM. It will be required when the application is started up in

the PC without LabVIEW installed.

4. In starting up FSE-Tool, execute the file, FSE-Tool.exe in the FSE-Tool

folder in the distributed CD-ROM.

5. Initial IP address of DX200 is “192.168.255.1”.

Change the address written to the file, FSE-Tool.ini in the FSE-Tool

folder.

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YASKAWA Motoman DX200 Instructions Manual

YASKAWA Motoman DX200 Instructions Manual

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