Injection Machine Robot

7/27/2019 Injection Machine Robot

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OPERATION MANUALTAKE-OUT ROBOTFor operation staff

This manual provides information on the followingmodels.z RA Seriesz RA - Series

z RA Series

z RA - Series

CAUTIONDeliver this manual for the relateddepartment.

Read this manual before operation.

Version 1.1


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Greetings

Thank you for purchasing a Yushin take-out robot. We strive every day to develop andmanufacture take-out robots that are one step ahead of competition and we are confident that

you will be satisfied with your new take-out robot. In order to use your new take-out robot to itsfullest potential, please read this manual carefully and use the take-out robot correctly.

We will continue our efforts to improve our technology and services so that we can provideyou with even better products in the future. We look forward to your ongoing patronage.

Yushin Precision Equipment Co., Ltd.


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Taking the Robot abraodz When the entire take-out robot or any part therof is to be taken abroad after delivery to the

original purchaser, the purchaser must obtain legal permission to export the robot accordingto the laws in both the exporting country and the importing country. Yushin Precision Equip-ment Co., Ltd. will assume no responsibility whatsoever if the purchaser exports the robotwithout following the required procedures.

Disclaimersz The content of this manual is subject to change without notice.z While every effort has been made to ensure the accuracy of the information in this manual,

we invite you to inform us if any errors or questionable content is discovered.z The various data included in this manual is intended to serve as reference data concerning

the take-out robot. Yushin Precision Equipment Co., Ltd., is not regally bound in any way

whatsoever by these data.z Yushin Precision Equipment Co., Ltd., assumes no responsibility whatsoever for damage or

lost profits resulting from modifications, disassembly, misuse, inadequate installation environ-ment, or any other situation beyond our control.

z Yushin Precision Equipment Co., Ltd., assumes no responsibility whatsoever for damage or lost profits resulting from the use of this equipment.

Trademarksz The company names and product names mentioned in this manual are trademarks or regis-

tered trademarks of the respective companies.z The copyrights associated with the freeware UNLHA32.DLL are held by the author thereof,

namely Micco.


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INTRODUCTION

Thank you for purchasing a Yushin take-out robot. This take-out robot is designed to be

part of a fully automated manufacturing system for plastic parts. When used in conjunction

with an injection molding machine, this take-out robot can be used as a single automatic

means to handle such processes as taking the molded products out of the injection mold-

ing machine and casing the products.

In order to use the take-out robot efficiently and to its full potential, read this operation

manual before using the take-out robot. After reading the manual, keep it in a convenient

location for easy reference.

Take-out robot manuals

The following manuals are provided.

z Operation manual (This manual)This manual, provided for an operation staff, explains how to operate the take-outrobot.

z Data maintenance manualThis manual is intended for mold data management personnel and a robot installation/maintenance staff. It explains how to teach the take-out robot and how to manage themold data.

This manual explains the procedures for the RA, RA - , RA and RA - series take-

out robots. Although the shape and size of each take-out robot series may vary, the proce-

dures are exactly the same.

z The operator station screens and the descriptive illustrations are described based on RAseries.


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Safety symbols

This manual employs the following safety symbols for the safety of operation.

Pay special attention to the messages with these symbols when reading this manual.

In addition to the above symbols and messages, the following symbol is used to give sup-

plemental information or advice.

z This symbol is used to give supplemental information or advice.

Each safety symbol has the following meaning.

CAUTION

DANGER

WARNING

Inflammables Electric shock Biting of fingers

Hightemperature

Dont do this Dont cause fire Dont touchDontdisassemble

Do this Ground terminalDisconnect plug

A danger notice with this symbol indicates an imminently hazardous

situation which, if not avoided, will result in death or serious injury.

A warning notice with this symbol indicates a potentially hazardous

situation which, if not avoided, could result in death or serious injury.

A caution notice with this symbol indicates a potentially hazardoussituation which, if not avoided, may result in minor/moderate injury

or property damage.

This symbol indicates that you should be careful

in handling workpieces.

This symbol indicates that a certain action is

prohibited.

This symbol indicates that a certain action should

be done.


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Safety notices related to take-out robot operation

z Do not enter the robot motion area when the take-out robot is in operation.

z The robot motion area is indicated by the shaded portion in the figure below. Install a safety fence sothat personnel will not enter this area. A serious accident could result if someone enters the robotmotion area during Auto operation.

DANGER

Motion area


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z Stay away from the safety fence and the robot motionarea when the take-out robot is in operation. Do not

climb over the fence or lean objects against it.

z Do not open or remove the safety fence or the safetygate while the take-out robot is in operation. Alwaysoperate the take-out robot from outside the safetyfence.

z Do not place objects on the operator station or inadvert-

ently press the deadman switch with your hand. Axisoperation will be enabled, presenting the danger of accidental operation.

z Do not use highly flammable sprays near the take-out

robot. A fire could result.

WARNING


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z If an air leak is discovered in the pneumatic tubing, stopthe take-out robot immediately. Then inform the mainte-

nance personnel designated by the take-out robotsafety supervisor or contact us.

z Check the following before turning ON the take-outrobot control power and the main power.

No persons are in the robot motion area.

The touch panel and other tools are located in their specified positions.

No foreign objects are on the moving frame of thetake-out robot.

z If any of the following cases occurs, immediately stopoperation and turn OFF the control power and the main

power. Then inform the maintenance personnel desig-nated by the take-out robot safety supervisor or contactus. Continued operation could result in a fire.

Smoke rises from the take-out robot or control boxor the outside surface of the take-out robot is abnor-mally hot.

An abnormal noise is heard.

Water or other substance has gotten inside thetake-out robot.

z If anything abnormal occurs while the injection moldingmachine and the take-out robot are in operation, pressthe emergency stop switch immediately. Then informthe maintenance personnel designated by the take-outrobot safety supervisor or contact us.

WARNING


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z Only those personnel designated by the take-out robotsafety supervisor are allowed to open the cover or

panel of this unit. Improper actions could result in elec-tric shock.

z Do not use air that contains any of the substances indi-cated below. Also, make sure these substances are notcontained in the surrounding air. Use only clean air.

Organic solvents

Phosphate-base hydraulic oil.

Sulfur dioxide gas

Chroline gas

Deteriorated compressor oil

Acids

z Do not overturn the operator station, drop the touchpanel controller or CF card, or otherwise subject theseitems to severe physical shock.

WARNING

CAUTION


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z Do not cut or otherwise damage the pneumatic tubing.Damaged tubing could result in air leakage.

z Avoid overcrowding of the equipment. Make sure thereis sufficient space for the robot motion area and thesafety fence.

z Do not operate the take-out robot when not feeling well.

z Make sure that the operation environment is as follows:

Temperature: 0 C to +40 C(32 F to 104 F)

Storage temperature: -15 C to +65 C(5 F to 149 F)

Humidity: 35 % RH to 85 % RH(without drew formation)

There are to be no corrosive gases or floating particlesof electrically conductive material around the take-outrobot.

CAUTION


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z When lowering the take-out arm in manual mode, makesure the take-out arm does not contact the mold.

Be sure to operate the take-out arm from outside thesafety fence.

z Do not use any operating fluid other than compressedair.

z Use the correct pneumatic pressure.

Pneumatic pressure: 3.9 to 4.9 10 5 Pa (Gauge)

z Provide a handbook consisting of guidelines regarding

the following items and make sure that every operator observes them.

Signs used when a group of persons works together

Signs used between take-out robot operators andoperators of linked equipment.

CAUTION

C o m p r

e s s e d

a i r

G u i d e l i n

e


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z When the take-out robot is not going to be used for sev-eral days or longer, turn OFF the control power and the

main power and pull out the plug to ensure safety.Otherwise, insulation deterioration may cause electricshock or current leakage.

z Wear appropriate clothing when operating the take-outrobot. Remove neckties and other ornamental items or secure them so that they do not hang outside of your clothing.

z Before initiating take-out robot operations, select some

dedicated operators who have undergone trainingregarding take-out robot operation and a safety super-visor to observe the operation. Furthermore, allow onlythose operators designated by the safety supervisor todisassemble the take-out robot.

CAUTION


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Safety notices related to connecting the power supply

z

Do not touch the power plug with wet hands.Otherwise, electric shock may result.

z

Do not connect or disconnect the plug from the plugsocket with control power turned ON. Otherwise, theplug may be damaged, causing a fire, or the take-outrobot may be damaged.

z Always hold the plug when removing the plug from theplug socket. Pulling the power cable may damage thecable, resulting fire or electric shock.

zDo not cut, damage, or modify the power cable. Also,do not pull, bend, or place a heavy object on it. A dam-aged cable could be the cause of fire or electric shock.

WARNING


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z Do not use an extension cable with an insufficient rat-ing. Otherwise, abnormal heating or burning may result.

z Before connecting the cables, be sure to turn OFF thecontrol power. Otherwise, electric shock or mechanicaldamage may result.

z Remove any dust that is attached to the plug or plug

socket. If the dust is not removed, dampness mayeventually cause a small current to flow through it,resulting in abnormal heat or fire.

WARNING


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DANGER, WARNING, and CAUTION labels

The take-out robot is provided with DANGER, WARNING, and CAUTION labels as shown

in the figure below. Be sure to observe the information on these labels when operating,

inspecting, or performing maintenance on the take-out robot. Do not deface these labels. If

any of these labels peels off or becomes dirty or torn, replace it.

Robot willcome down.Do notenter robotoperating area.

High speedmovingRobot(s).Do notenter robotoperating area.

DANGER DANGER

D-3E D-1E

WARNINGMovingbelt(s).Do notoperatewith guardremoved.W-3E

CAUTIONDO READ AND FOLLOW UNDERMENTIONED CAUTIONS IN ORDER TO PREVENT ANY ACCIDENTS, INJURY OR DAMAGES.DO CHECK MACHINE SAFETY BEFORE OPERATING OR REPAIR OR MAINTENANCE AND DO NOT ADJUST SPEED OR

SET POSITION BY 1 MAN. DO PROVIDE 2 MEN AND 1 MAN MUST WATCH OTHER.DO NOT STAND UP NOR HEAD UP NOR PLACE HANDS AGAINST CHUCK HEAD OR OTHER MOVING MECHANISM AT ANY TIME

WHILST ELECTRICAL OR AIR POWER IS SUPPLIED. DO NOT PLACE FOOT ON MACHINE AT ANY TIME.DO NOT REACH INTO THE AREA WHERE MACHINE IS MOVING NOR ADJUST MACHINE WHILST OPERATION.DO NOT OPEN NOR REMOVE NOR BYPASS SAFETY COVER AND OTHER SAFETY DEVICES.DO USE EXACT AND GENUINE PARTS AND SIZE OF BOLT, NUT AND SCREW MUST BE METRIC MEASUREMENT. (ISO)DO TURN OFF ELECTRICAL AND AIR POWER BEFORE REPAIR OR MAINTENANCE.DO WEAR HARD SAFETY HAT AND SAFETY SHOES AND PAY SPECIAL ATTENTION FOR SAFETY WHEN WORKING FOR

SETTING, ADJUSTING, REPAIR, MAINTENANCE OR SHIFTING MACHINE.DO KEEP FACE AND HANDS AWAY FROM HIGHLY HEATED AREA SUCH AS HOTMELT TANK, CONNECTIONS, NOZZLE

OR HOSE OF BASE CUP APPLICATOR AND MOTOR IN ORDER TO PREVENT SEVERE BURN OR INJURY.DO PERIODICALLY SUPPLY GREASE AND LUBRICATING OIL.DO PERIODICALLY INSPECT AND MAKE SURE THAT LIMIT SWITCHES AND SENSORS PROPERLY WORK.DO PERIODICALLY INSPECT AIR HOSES, HOTMELT HOSES, CABLES AND JOINTS FOR FRACTURES OR OTHER DAMAGES.DO PERIODICALLY INSPECT BOLTS, NUTS AND SCREWS AND TIGHTEN IF THEY ARE LOOSE.DO PERIODICALLY INSPECT ELECTRIC CIRCUIT TO DETECT LEAKAGE.DO STOP MACHINE AND TURN OFF ELECTRICAL AND AIR POWER WHEN ANY DEFECTS ARE FOUND AND REPAIR.DO NOT REMOVE THIS CAUTION MARK FROM THIS MACHINE.MAKER / SUPPLIER OF MACHINE WILL NOT BE RESPONSIBLE FOR ANY LIABILITY ARISING OUT OF USE OF ROBOT WHICH

ARE MODIFIED WITHOUT APPROVAL OF MAKER / SUPPLIER.BY MAKER / SUPPLIER : YUSHIN PRECISION EQUIPMENT CO., LTD. 8. 1987

WARNINGCheck loosened or brokenbolts caused by machinevibration.

Specified TighteningTorque

M8M10M12M14M16M20M24

2958.898137255490843

( 300)( 600)(1000)(1400)(2600)(5000)(8600)

. . .

. . .

. . .

. . .

. . .

. . .

. . .

(Material Equivalent to SS400)Nm(Kgf cm)

W-12E


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Robot willcome down.Do notenter robotoperating area.

High speedmovingRobot(s).Do notenter robotoperating area.

DANGER DANGER

D-3E D-1E



High voltage.Before servicingturn off,lock out / tag outmain power disconnect.

DANGER

WARNING

Do notdisassemble.

W-1E

D-5E


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High voltage.Before servicingturn off,lock out / tag outmain powerdisconnect.

DANGERWARNING

Do notdisassemble.

W-1E D-5E

CAUTION IN USE

Make a team of two people to adjust the speed or position. One does the adjustment, while the other keeps a close watch for safety.

Keep yourself away from the movable section of therobot. Do not touch or a djust the robot while it isrunning.

Before starting maintenance, be sure to turn thepower off and shut the air off.

Maker / supplier of machine will not be responsiblefor any liability arising out of use of robot whichare modified without approval of maker / supplier.

YUSH IN PR ECIS ION E QUIPM ENT C O., LT D.


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CONTENTS1 GENERAL DESCRIPTION

1.1 Component configurations .................................... .................................. ...... 211.1.1 Configuration .................................................... ................................................. 211.1.2 Robot body and control box ....................................................... ....................... 22

1.1.3 Operator station ................................................................................................. 231.1.4 Interface connector and dummy connector ............................................. .......... 241.1.5 Touch panel controller ................................................... .................................... 251.1.6 CF card ............................................................. ................................................. 29

2 START-UP AND SHUT-DOWN

2.1 Pre-operation check .......................................................... .............................. 31

2.2 Operation flow outline ............................... ................................... .................. 32

2.3 Quick start .................................. ..................................... ................................. 33

2.3.1 From start-up to Auto operation .................................................. ....................... 332.3.2 Shut-down ............................................................................................... .......... 39

2.4 Operation using multi-function screen ............................. ............................ 402.4.1 Start-up ............................................................. ................................................. 402.4.2 Shut-down ............................................................................................... .......... 42

2.5 Emergency stop ....................................... ................................... .................... 432.5.1 Emergency stop ...................................................... .......................................... 432.5.2 Emergency stop condition reset ................................................................. ....... 44

2.6 Long-term shut-down .................................. ..................................... .............. 45

2.6.1 Shut-down ............................................................................................... .......... 452.6.2 Start-up ....................................................... ....................................................... 46

2.7 Basic features and screen navigation of touch panel controller ................ 482.7.1 Screen area ............................................................................. .......................... 482.7.2 Screen layout ....................................................... ............................................. 512.7.3 Operation screen ............................................................................... ................ 532.7.4 Index screen .................................................................................. .................... 542.7.5 Sub menu window screen .......................................................... ....................... 552.7.6 Pulldown button ............................................................................. .................... 56

3 CONFIRM OPERATION3.1 Confirm operation description ........................................ ............................... 59

3.2 Confirm operation ............................ .................................. ............................. 60

4 AUTO OPERATION

4.1 Easy operation ................................ ................................... .............................. 624.1.1 Easy operation description ...................... ................................................... ....... 624.1.2 Easy operation ................................................. ................................................. 624.1.3 Easy operation screen ................................................................................... .... 65


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4.2 Multi-function operation ........................... .................................. .................... 664.2.1 Multi-function operation description ................................................................... 664.2.2 Multi-function operation .............................................. ....................................... 664.2.3 Multi-function screen .................. .......................................................... ............. 694.2.4 One-cycle operation ............ .......................................................... .................... 70

4.3 Production complete message ........... ..................................... ...................... 73

4.4 Maintenance alarm display ....................................................... ...................... 73

4.5 Buzzer setting ................................ ................................... ............................... 74

4.6 Sampling ................................ ................................... .................................... ... 74

4.7 Discharge motion ....................................... .................................. ................... 74

4.8 Casing reset .................................. ................................. .................................. 75

5 MANUAL OPERATION

5.1 Manual operation description ..................................... .................................. . 76

5.2 Manual operation screen ........................... .................................. ................... 765.3 Axis operation ............. ................................... ..................................... ............ 79

5.4 Valve operation .................................. .................................. ............................ 81

6 TROUBLESHOOTING

6.1 Error message screen .................................... ...................................... ........... 83

6.2 Error messages ........................................... ................................... ................. 84


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1 GENERAL DESCRIPTION

1.1 Component configurations

1.1.1 Configuration

This take-out robot consists of the following.

z Robot bodyz Control boxz Operator stationz Interface connector and dummy connector

z In this manual, the above mentioned components are referred to collectively as the take-out robot.

z The operator station screens and descriptive illustrations are described based on the RAseries.

Control box

To control box

Robot body

To injectionmolding machine

To power supply

Operator station

Interfaceconnector

Injection moldingmachine

Dummy connector


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1.1.2 Robot body and control box

z The operator station screens and descriptive illustrations are described based on the RAseries.

Junction boxThis box houses the solenoidvalve and the remote I/O.

Pressure sensor This sensor detects theproduct suction status.

Spacer

Sub arm unitThis arm unit raises and lowers the runner chuck.

Runner chuckThis chuck grips the runner.

Kick frameThis is a guide frame for movement in the kickdirection.

Flip cylinder This cylinder flips the end-of-arm tool 90 degrees.

Main arm unitThis arm unit raises andlowers the end-of-arm tool.

Pneumatic filter unit

Tr aver se axis

Control boxThis box houses the servo controller.

Sub arm kick axis

Main arm kick axis

Main arm descent axis

Sub arm descent axis

This is a guide frame for

movement in the traversedirection.

Breaker

Traverse frame


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1.1.3 Operator station

CAUTION

z Precautions regarding the operator stationThe operator station houses the control circuit unit and other precision parts. If the controlcircuit unit is damaged, the touch panel controller and the control box will not work and,consequently, the take-out robot cannot be controlled. Be sure to observe the following

precautions. Place the operator station in a stable, level place which is free of vibration. Do not turn the operator station over, slam objects into it, or in any other way apply

physical shock to it. Otherwise the control circuit unit may be damaged. Do not move the operator station while its power is ON. Otherwise the CF card may be

crushed, and stored program data may be lost.

No. Item Description

1 Control power switch Use this switch to turn ON and OFF the control power.2 Touch panel controller Touch buttons and icons on the touch panel screen with fingers or the

touch pen.

3 Control power lamp This lamp lights when the control power is ON.

4 Emergency stop switch Press this switch to stop the take-out robot in an emergency.

5 PC card slots Insert a CF card equipped with the adapter. Insert the CF card into theleft slot.

6 Operator station deadmanswitch

When the touch panel controller is dismounted from the operator station,this switch is released to render the take-out robot axes inoperative for preventing accidents.

Operator station backside


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1.1.4 Interface connector and dummy connector

7 Touch panel controller connector

This connector connects the touch panel controller and the operator sta-tion.

8 Robot connector This connector connects the take-out robot and the operator station.

9 COM port

10 USB port Connects an USB camera and the operator station.

11 LAN port Connects a take-out robot to the network using LAN cable.


1 Interface connector The interface connector serves as an interface between the take-outrobot and the injection molding machine.

2 Dummy connector The injection molding machine can be used independently by insertingthe dummy connector in place of the take-out robot connector.



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1.1.5 Touch panel controller

WARNING

z When the touch panel controller is placed on the operator station, the deadman switch onthe operator station is pressed so that take-out robot operations are enabled. Do not care-lessly touch the touch panel. Otherwise the robot body will move.

CAUTION

z Precautions regarding touch panel controller The touch panel controller holds precision parts including the liquid crystal display. The liq-uid crystal display is made of glass. Be sure to observe the following precautions. Do not drop or apply physical shock to the touch panel controller. When holding the touch panel controller, be sure to pass your hands through the hand

strap. When not holding the touch panel controller, be sure to place it on the operator station

properly, as shown in the figure in section < 1.1.3 Operator station >. Do not place objects on the touch panel controller or press it with excessive force. Oth-

erwise, the glass of the liquid crystal display may break. Do not press the touch panel surface with sharp objects. Otherwise, the surface may be

scratched or the touch panel controller may be damaged. Do not pull on the cable connecting the touch panel controller to the operator station.

Otherwise, the cable may break or the connector may be damaged.

z While the backlight is OFF, it does not turn ON even if you touch the screen. Press the

backlight switch to turn ON the backlight.


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1 Emergency stop switch Press this switch to stop the take-out robot in an emergency while using

the touch panel controller.2 Power lamp This lamp lights when the control power is ON.

3 Backlight lamp This lamp lights when the backlight of the touch panel is OFF.

4 Backlight switch Use this switch to turn ON and OFF the backlight of the touch panel.

Screen operation is disabled when the backlight is OFF. Turn OFF the

backlight when cleaning the touch panel surface.

5 Stop button Press this button to stop Auto operation.

6 Start/Pause button Press this button to start/pause Auto operation.

7 Step forward button Press this button to move the robot one step forward while in Auto one-

cycle operation or confirm operation.8 Step backward button Press this button to move the robot one step backward while in Auto

one-cycle operation or confirm operation.

9 Manual operation button Use this button to move axes in manual operation. Use the enter button

at the center to change axes.

10 Touch panel

(LCD: Liquid crystal display)

This section displays buttons, icons and operation guides. Touch the

displayed buttons and icons with your finger or a touch pen.

11 Hand strap Use this hand strap when using the touch panel controller off the opera-

tor station.


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How to hold the touch panel controller

1 Pass your arm through the handstrap to hold the touch panelcontroller.

To hold the controller with the oppo-site hand from the drawing, attachthe hand strap on the opposite side.

2 Touch the screen softly.Keep pressing the deadman switchwhen moving axes in manual opera-tion.

z Operation other than manual axis operation is allowed without the deadman switchesbeing pressed.

Deadman switchesThey are attached inside the protectionguard in order to prevent misoperation.

Guard

Deadman switches


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How to use the touch pen

CAUTION

z Do not touch the touch panel surface with sharp objects such as ball point pens or mechanical pencils. Be sure to use the attached touch pen when touching the touch panelsurface with other than fingers.

1 Pull out the touch pen from thetouch panel controller.

2 Touch or write down on thesurface softly.Keep pressing the deadman switchwhen moving axes in manual opera-tion.

Touch Pen

Deadman switches


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1.1.6 CF card

CF cards are used for storing and copying the mold data.

CF card insertion

CAUTION

z Precautions regarding CF cards

Observe the following precautions to avoid erasing important data: Do not drop, bend, or apply strong physical shock to CF cards. Otherwise the card may

be damaged.

Avoid using or storing CF cards in places exposed to high or low temperatures or directsunlight.

1 Insert a CF card into the adapter.

2 Insert the adapter into the leftslot of the operator station withthe arrow side turned upward.

z Normally, a dummy card is inserted into the slot. When using a CF card, remove thedummy card from the slot.

z Insert a CF card with the adapter into the left slot. The right slot is reserved for networkingoption.

z Be sure to insert a dummy card when you do not use a CF card.

Adapter

CF card


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CF card removal

CAUTION

z Never push the eject button while the CF card is being accessed. The CF card may bedamaged and the data stored on the CF card may be lost.

1 After making sure that thecontroller is not accessing theCF card (for writing or loading

data), push the eject button to

remove the CF card.

2 Remove the CF card from theadapter. Adapter

CF card


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2.1 Pre-operation check

Before starting up the take-out robot, check the following items.z Check that the pneumatic pressure is set as specified [3.9 to 4.910 5 Pa (Gauge)].z Check that the pneumatic filter is clean and free of clogging. A brown color indicates clogging.z Check the pneumatic tubing for air leakage. A hissing sound indicates leakage.z Check each solenoid valve for air leakage. A hissing sound indicates leakage.

After starting up the take-out robot, check the following items.z Check that the emergency stop switch on the touch panel controller functions normally.z Check that the emergency stop switch on the operator station functions normally.z Open the mold of the injection molding machine to the mold open limit. Move the take-out

robot descent arm down to the descent position in manual operation. Close the mold in themold set mode or the preparation mode of the injection molding machine and make sure thatthe mold cannot be closed any further.

WARNING

z When something about the take-out robot seems abnormal, contact the personnel desig-nated by the safety supervisor or us.

CAUTION

z Make sure that the descent arm does not hit the mold when moving it down into the mold.

Emergency stop switch

Air leakagefrom solenoid valve

Air leakage frompneumatic tubing

Proper pneumaticpressure

Filter clogging


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2.2 Operation flow outline

Below is an outline of the operation flow after starting up the take-out robot.

z This manual does not provide a detailed explanation of the teaching procedure.Rather it assumes teaching has been completed and concentrates on how to operate thetake-out robot in Auto mode using the designated mold data. For details regarding teach-

ing, refer to the Data Maintenance Manual .

WARNING

z Only those personnel designated by the take-out robot safety supervisor are allowed toperform teaching operations. Insufficient knowledge, training, or experience could lead toan accident.

Control power ON

Confirm operation

Auto operation


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2.3 Quick start

2.3.1 From start-up to Auto operation

DANGER

z Before turning ON the control power, make sure no persons or obstacles exist in the robotmotion area.

z Be sure to perform operation from outside the safety fence.

CAUTION

z Auto operation cannot be executed without mold data. Check with the personnel desig-nated by the take-out robot safety supervisor to make sure the correct mold data has beenselected and that teaching for the selected mold data has been completed.

1Make sure the take-out robot and the injec-

tion molding machine are connected withthe interface connector and make sure the

plant power supply to the take-out robot is

ON.If the interface connector is not connected,request assistance from one of the personnel des-ignated by the take-out robot safety supervisor.

2 Remove the cover shown right and turn ONthe breaker inside the control box.3 Reinstall the cover after turning ON thebreaker.

Interface connector

Dummy connector

Control box

Cover


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CAUTION

z Do not turn the control power ON and OFF in rapid succession. When the control power must be turned ON and OFF repeatedly, wait at least 60 seconds before turning it ONagain after turning it OFF.

4 Turn the control power switch clockwise.The control power turns ON and the control power lamp lights.

After a few moments, the messagerequiring to perform the confirmoperation appears. The lamp of the[Confirm] (confirm operation) buttonblinks.

5Touch the [Confirm] button.

After the servo power is turned ON,the take-out robot starts to move tothe waiting position.

The message Moving to Waitposition appears while the robotmoves to the waiting position.

Control power switch

Control power lamp


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When the move to the waiting posi-tion completes, the lamp of the [Start/Stop] button blinks.

z If you finished the last operation on the multi-function screen or touch the [Multi menu]

(multi-function menu) button, the following screen appears.See < 4.2.1 Multi-function operation description > for details.

CAUTION

z If the take-out robot may hit injection molding machine while moving to the waiting posi-tion, touch the [Stop] button and stop the robot motion. Then move the robot body to asafe position in manual mode.

z See < 5.1 Manual operation description > regarding how to perform manual opera-tion.


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6 Touch the [Start/Stop] button.The confirm operation starts.

The information display window dis-plays the message Confirm Opera-

tion in progress.

To pause operation, touch the[Start/Stop] button.

To stop operation, touch the [Stop]button.

z The multi-function screen appears if the [Multi menu] (Multi function menu) button istouched. See < 4.2.1 Multi-function operation description > for details.

A message appears when theconfirm operation completes and the[Auto] (Auto operation) button blinks.


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7 Touch the [Auto] (Auto opera-tion) button.The robot starts to move to the wait-ing position.

The message Moving to Waitposition appears while the robot

moves to the waiting position.

When the move to the waiting posi-tion completes, the [Start/Stop] but-ton blinks.

CAUTION

z If the take-out robot may hit the injection molding machine while moving to the waitingposition, touch the [Stop] button and stop the robot motion. Then move the robot body to asafe position in manual mode.



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8 Touch the [Start/Stop] button. Auto operation starts.

The information display window dis-plays the message Auto Operation

in progress.



To stop operation after one cycle of operation completes, touch the[Cycle Stop] button.

The [Auto] (Auto operation) buttonblinks when Auto operation com-pletes.

z The multi-function screen appears if the [Multi menu] (Multi function menu) is touched.See < 4.2.1 Multi-function operation description > for details.

z See < 4.5 Buzzer setting > regarding how to operate the [Alarm] button.z See < 4.6 Sampling > regarding how to operate the [Reject] button.z See < 4.7 Discharge motion > regarding how to operate the [Sampling] button.z See < 4.8 Casing reset > regarding how to operate the [Casing Reset] button.


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2.3.2 Shut-down

1 Move the take-out robot to the waiting position or another safe position in manualoperation.


CAUTION

z Do not turn OFF the control power when the take-out robot is in operation, screen pagesare changing or the controller is accessing the CF card. Otherwise, the data on the CF

card may be lost.z Do not turn the control power ON and OFF in rapid succession. When the control power

must be turned ON and OFF repeatedly, wait at least 60 seconds before turning it ONagain after turning it OFF.

2 Turn the control power switch counterclock-wise.The control power lamp goes off and so does thetouch panel display.

3 Remove the cover shown right and turn OFFthe breaker inside the control box.4 Reinstall the cover after turning OFF thebreaker.


Control power lamp

Control box

Cover


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2.4 Operation using multi-function screen

2.4.1 Start-up

DANGER


1 Make sure the take-out robot and the injec-tion molding machine are connected withthe interface connector and make sure the


ON.If the interface connector is not connected,

request assistance from one of the personnel des-ignated by the take-out robot safety supervisor.

2 Remove the cover shown right and turn ONthe breaker inside the control box.

3 Reinstall the cover after turning ON thebreaker.

Interface connector

Dummy connector

Control box

Cover


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CAUTION



After a few moments, the operationscreen appears.

z If you finished the last operation on the easy operation screen, the following screenappears. See < 2.3 Quick start > for details.


Control power lamp


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2.4.2 Shut-down

1 Move the take-out robot to the waiting position or another safe position in manualoperation.


CAUTION

z Do not turn OFF the control power when the take-out robot is in operation, screen pagesare changing or the controller is accessing the CF card. Otherwise, the data on the CF

card may be lost.z Do not turn the control power ON and OFF in rapid succession. When the control power

must be turned ON and OFF repeatedly, wait at least 60 seconds before turning it ONagain after turning it OFF.

2 Turn the control power switch counterclock-wise.The control power lamp goes off and so does thetouch panel display.

3 Remove the cover shown right and turn OFFthe breaker inside the control box.

4 Reinstall the cover after turning OFF thebreaker.


Control power lamp

Control box

Cover


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2.5 Emergency stop

If the take-out robot seems likely to come in contact with a person or the mold, you can

stop the take-out robot by pressing the emergency stop switch.

2.5.1 Emergency stop

z When an error message appears on the touch panel, report it to the personnel designatedby the take-out robot safety supervisor or us.

1 When the emergency stop switch on theoperator station or the touch panel control-ler is pressed, the take-out robot immedi-

ately stops.

Simultaneously, the error message windowappears on the screen.

This is all for the procedure.

Emergency stop switches


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2.5.2 Emergency stop condition reset

WARNING

z Before resetting the emergency stop condition, have the personnel designated by thetake-out robot safety supervisor confirm that the cause of the emergency stop has beenremoved.

1 Turn the emergency stop switch on theoperator station or the touch panel control-ler clockwise.

The emergency stop switch returns to its originalposition.

2 Touch the [Reset] button on the error message window.

z When the confirm operation is required, the screen displays the message indicating toperform confirm operation.

Emergency stopswitches


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2.6 Long-term shut-down

This section explains how to shut down and start up the take-out robot before and after

long periods of inactivity, such as vacations and plant shut-down.

2.6.1 Shut-down

1 Move the take-out robot to the waiting position or another safe position in manualoperation.z See < 5.1 Manual operation description > regarding how to perform manual opera-

tion.

CAUTION

z Do not turn OFF the control power when the take-out robot is in operation, screen pagesare changing or the controller is accessing the CF card. Otherwise, the data on the CFcard may be lost.


2Turn the control power switch counterclock-

wise.The control power lamp goes off and so does thetouch panel display.

3 Remove the cover shown right and turn OFFthe breaker inside the control box.

4 Reinstall the cover after turning OFF thebreaker.


Control power lamp

Control box

Cover


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2.6.2 Start-up

5 Turn OFF the plant power supply to the take-out robot.

6Remove the operator station power plug from the receptacle.

CAUTION

z Before starting up the take-out robot, perform the pre-operation checks explained in < 2.1Pre-operation check > .

DANGER


1 Insert the operator station power plug into the receptacle.

2 Turn ON the plant power supply to the take-out robot.

3 Make sure the take-out robot and the injec-tion molding machine are connected withthe interface connector and make sure the


ON.If the interface connector is not connected,

request assistance from one of the personnel des-ignated by the take-out robot safety supervisor.

Interface connector

Dummy connector


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4 Remove the cover shown right and turn ONthe breaker inside the control box.

5Reinstall the cover after turning ON the

breaker.

CAUTION



After a few moments, the operationscreen appears.

z When you finished the last operation on the multi-function screen, the multi-functionscreen appears.

Control box

Cover


Control power lamp


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2.7 Basic features and screen navigation of touch panelcontroller

The take-out robot is operated using the touch panel controller.

Buttons and other items displayed on the touch panel vary depending on the screens

(functions).

2.7.1 Screen area

This section describes the screen areas using the input signal monitor screen as anexample.

No. Item

A Top banner

B Top group tab menu (left side tab menu) area

C Sub group tab menu (upper side tab menu) area

D Icon tab menu (lower side tab menu)E Main area

z Each of the tabs in the top group tab menu area is assigned a specific access level. Touchtabs for your level to display the operative function tabs.


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Top group tab menu

Item Description

Operator Operator level operators are allowed to use this icon. Touching this button dis-

plays the following sub group icons.z [Auto], [Manual], [Monitor]

Setup Setup level operators are allowed to use this icon. Touching this button dis-plays the following sub group icons.z [Setup], [Teaching], [Manual], [Prod Mon.], [Monitor], [Print],

[Instruction], [Information]

Teaching Teaching level operators are allowed to use this icon. Touching this button dis-

plays the following sub group icons.z [Teaching], [Setup], [New Data], [Manual], [L.T.T], [Prod.note],

[Prog.note], [Monitor], [Print], [Information]

Maintenance Maintenance level operators are allowed to use this icon. Touching this button

displays the following sub group icons.z [DataControl], [History], [Manual], [Reference], [Teaching],

[Alarm/Date], [Monitor], [Print], [Information]

Program Programmer level operators are allowed to use this icon. Touching this button

displays the following sub group icons.z [Manage], [Flexible], [Prog. note]

Manager Manager level operators are allowed to use this icon. Touching this button dis-

plays the following sub group icons.z [SystemSetup], [OS Control], [Setup]

Tools Use this menu to access the functions such as Memo and Address book.

Touching this button displays the following sub group icons.z [CameraPhn], [Memo], [Mail], [Add. book]

DownStream Use this icon to control the downstream equipment (optional).

z Set password levels for each function to limit accessible operators.


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Basic screen navigation steps

Access to your desired screen involves the following three basic steps:

1Select the desired button from

the top group tab menu (left sidetab menu).

2 Select the desired button fromthe sub group tab menu (upper side tab menu).

3 Select the desired button fromthe icon tab menu (lower side tabmenu).


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2.7.2 Screen layout

This section shows the screen layout and describes screen elements

No. Items Function1 Logo and date field Displays the logo and the current date.

2 Program No. field Displays the current program number.

3 Mold data No. field Displays the number of the currently selected mold data.

4 Sub group tab Displays sub group icons.

5 Program name field Displays the name of the current motion program.

6 Product name field Displays the product name of the currently selected mold.

7 Operator name field Displays the name of the current operator. You can select an operator from the list of several registered operators .

8 Mold data change button This button turns orange when mold data are changed.Use this button to save the mold data in memory.

9 Language select button Use to select a language.

10 Contact list window displaybutton

Touch to display the window informing you of a contact list

11 Icon tab Displays icon buttons or tab menu required for each screens. (No iconbuttons nor tab menu appears on the easy operation screen.)


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Icons

Icon is a graphical symbol that represents the purpose of an available function. Each of the icon buttons on this touch panel consists of an icon and an explanatory icon title(button name).

Buttons

The icon buttons are divided into the following three types:

z Buttons whose functions are executed when touchedThis type of buttons include those blinking or having button names indicated on them.Touching one of these buttons provides the corresponding motion to the take-out robotor takes you to the specified screen.

Example: [Confirm](Confirm operation) button, [Index] button, [Stop] button during Auto operation

z Buttons for setting a value or conditionThis type of buttons feature a yellow background.Example: Valve buttons, speed setting buttons

z Buttons which are inoperativeThis type of buttons include those being grayed out.

A button with a grayed out icon indicates the button is inoperative. No operation isexecuted if such buttons are touched.Example: [Auto] button displayed immediately after the control power is turned ON

No. Items Function

12 Top group tab Each of the tabs in the top group tab menu area is assigned aspecific access level. Touch tabs for your level to display theoperative function tabs.

13 Pulldown button If you touch one of icons displayed by touching the pulldown button, the

corresponding informaiton screen appears.14 [Help] button Touch to open the Help screen.

15 [Index] button Touch to open the Index screen.


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2.7.3 Operation screen

The operation screen is the opening screen that appears after the control power is turnedON.The operation screen allows you to complete a series of operation steps from confirmoperation to Auto operation.

z See < 2.7.1 Screen area > for details.

No. Item Function

1 Screen display switch button Use to switch between the easy operation screen and the multi-functionscreen.

2 Operation buttons Use to start or stop operation. (If a button is inoperative, it is grayed out.)

3 Setting buttons Use to perform settings.

4 Data display window This window on the easy operation screen displays messages. On themulti-function screen, select a tab among Axis Info, Casing andProd. Monitor to display the desired data.

5 Mainte Info/[Detail] button Displays maintenance data.Touch the [Detail] button to display the details.


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2.7.4 Index screen

Touch the [Index] button to access the Index screen.This screen displays all the available icons.You can access any screen from the Index screen except during Auto operation.

The Index screen is divided into seven groups of buttons: the Operator group, the Setupgroup, the Teaching group, the Maintenance group, the Program group, the Manager

group, and theTools group.

Scroll bar

The scroll bar appears at the right side or bottom of the screen if the screen has several

pages. To scroll the screen up or down, use the arrow buttons at the edge of the scroll bar

or area inside the scroll bar.

z This screen is helpful when you are not sure where the desired icon button belongs.z Touch a button among each group to display the corresponding screen. If the screen

contains selection menus, the sub menu selection screen appears. Grayed out buttons,however, do not function.

WARNING

z Only those personnel designated by the take-out robot safety supervisor are allowed toperform operation for the Setup, Teaching, Maintenance, Program, Manager and Tools,accessible from the Index screen. Insufficient knowledge, training, or experience couldlead to an accident.

Scroll bar


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2.7.5 Sub menu window screen

The sub menu window appears if the button on the top group tab menu (left side tab

menu) is touched.

Basic navigation

z This screen is effective when you know which top group button the desired button belongs.

1Touch the button on the top

group tab menu.

Sub menu window


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2.7.6 Pulldown button

Icons on the pulldown menu displayed by touching the pulldown button allow you toaccess the corresponding data window anytime. A selected data window appears as apop up screen. Touch the [Close] button to close the pop up screen and returns to theinitial screen.

2 Select the desired icon buttonfrom the sub menu window.

z The pulldown menu contains the following icons:

Data check Production notes

Input

Output

Flags

Information


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Basic navigation

1 Touch the pulldown button.

Icons appear on the pulldown menu.

2 Select the desired icon.

3 Touch the [Close] button at theupper right corner of the windowto close the window.


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4 Touch the pulldown button toclose the pulldown menu.


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3 CONFIRM OPERATION

3.1 Confirm operation description

After the take-out robot is started up, Auto operation will not start unless confirm operation

is executed.During confirm operation, the take-out robot completes one cycle of motion based on the

teaching data, moving slowly at a fixed speed from waiting position to waiting position.

Before starting Auto operation, be sure to execute confirm operation and make sure that

the selected mold data are appropriate.

z Confirm operation uses the fixed speed. The speed for confirm operation, therefore, willnot change even after speed data has been changed using the speed buttons.


z See < 4.1.2 Easy operation > regarding how to perform easy operation.z See < 4.2.2 Multi-function operation > regarding how to perform muti-function oper-

ation.

CAUTION

z Mold data is required for confirm operation. Confirm operation cannot be executed withoutmold data. Contact the personnel designated by the take-out robot safety supervisor.


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3.2 Confirm operation

DANGER

z Before performing confirm operation, make sure that no persons or obstacles exist in therobot motion area.

z If the mold is open, the take-out robot starts confirm operation even if the safety gate of the

injection molding machine is open. Be sure to operate the take-out robot from outside thesafety fence.

1 After the control power is turnedON, the operation screenappears and the [Confirm]

(confirm operation) button

blinks.

2 Touch the [Confirm] (confirmoperation) button.The take-out robot starts to move tothe waiting position.


CAUTION



Easy operation screen

Multi-function screen


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After the move to the waiting positioncompletes, the [Start/Stop] buttonblinks.

3Touch the [Start/Stop] button.

Confirm operation starts.


To stop operation, touch the [Stop]button.Confirm operation ends after onecycle of operation to the waitingposition completes.

After confirm operation completes,

the take-out robot goes into Autostandby mode and the [Auto] (Autooperation) button blinks.

z The confirm operation screen has the same configuration and functions as the Auto opera-tion screen. See < 4.1.2 Easy operation > and < 4.1.3 Easy operation screen > ,or < 4.2.2 Multi-function operation > and < 4.2.3 Multi-function screen > for details.


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4 AUTO OPERATION

4.1 Easy operation

4.1.1 Easy operation description

Easy operation is the operation mode in which you proceed on actual production using thesimplified screen configuration.The take-out robot is operated based on the specified mold data (teaching data) whileinterlocking with the injection molding machine and the stocker.

4.1.2 Easy operation

z See < 4.2.2 Multi-function operation > regarding how to perform multi-function oper-ation.

CAUTION

z Mold data is required for Auto operation. Auto operation cannot be executed without mold

data. Contact the personnel designated by the take-out robot safety supervisor.z The [Auto] (Auto operation) button is disabled immediately after the take-out robot is

started up. Be sure to perform confirm operation. (See < 3.2 Confirm operation >regarding how to perform confirm operation.)However, you can change settings on the function selection screen. Consult with the per-sonnel designated by the take-out robot safety supervisor regarding the function selectionscreen.

DANGER

z Before starting Auto operation, make sure that no persons or obstacles exist in the robotmotion area.

1 Perform confirm operation after the control power is turned ON.

z See < 3.2 Confirm operation > regarding how to perform confirm operation.


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2 Touch the [Easy menu] button onthe operation screen.The easy operation screen appears.

3Touch the [Auto] (Auto opera-

tion) button.The take-out robot starts to move tothe waiting position.




CAUTION

z If the take-out robot may hit injection molding machine while moving to the waiting posi-tion, touch the [Stop] button and stop the robot motion. Then move the robot body to asafe position in manual mode.



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The information display window dis-plays the message Auto Operation

in progress. while in Auto operation.

To pause operation, touch the[Start/Stop] button. The take-outrobot restarts operation if the[Start/Stop] button is touchedagain.


To stop operation after one cycle of operation completes, touch the[Cycle Stop] button. The take-outrobot stops after completing onecycle of operation.


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4.1.3 Easy operation screen

The easy operation screen has following functions.

Button functions

z Both Auto operation and confirm operation use the same functions on this screen.

No. Item Function

1 [Easy menu] button Touch to change the display into the easy operation screen.

2 [Multi menu] button Touch to change the display into the multi-function screen.

3 [Start/Stop] button Touch to start or pause operation.

Touching the blinking button starts operation.

Touching the lit button pauses operation.

4 [Stop] button Touch to stop operation.

5 [Cycle Stop] button Touch to stop Auto operation without outputting the cycle start signal for

the next cycle.

6 [Alarm] button Use to set whether or not to use buzzer sound when an error occurs.

7 [Casing Reset] button Touch to stop current casing and starts casing to a new pallet. Use this

button to start casing to a new pallet.

8 [Sampling] button Touch to release a product at the sampling position. (Optional)

9 [Reject] button Touch to discharge rejects.

10 [Detail] button Touch to display details of maintenance.


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4.2 Multi-function operation

4.2.1 Multi-function operation description

Multi-function operation is the operation mode in which you can proceed on actual opera-tion using the detailed screen configuration.The take-out robot is operated based on the specified mold data (teaching data) whileinterlocking with the injection molding machine and the stocker.

4.2.2 Multi-function operation

z See < 4.1.2 Easy operation > regarding how to perform easy operation.

CAUTION

z Mold data is required for Auto operation. Auto operation cannot be executed without molddata. Contact the personnel designated by the take-out robot safety supervisor.

z The [Auto] (Auto operation) button is disabled immediately after the take-out robot is

started up. Be sure to perform confirm operation. (See < 3.2 Confirm operation >regarding how to perform confirm operation.)However, you can change settings on the function selection screen. Consult with the per-sonnel designated by the take-out robot safety supervisor regarding the function selectionscreen.

DANGER

z Before starting Auto operation, make sure that no persons or obstacles exist in the robotmotion area.




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2 Touch the [Multi menu] button onthe operation screen.The multi-function screen appears.

3Touch the [Auto] (Auto opera-

tion) button.The take-out robot starts to move tothe waiting position.




CAUTION




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To pause operation, touch the[Start/Stop] button. The take-out

robot restarts operation if the[Start/Stop] button is touchedagain.


To stop operation after one cycle of operation completes, touch the[Cycle Stop] button. The take-outrobot stops after completing onecycle of operation.


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4.2.3 Multi-function screen

The multi-function screen has following functions.

Button functions

z

Both Auto operation and confirm operation use the same functions on this screen.

No. Item Function

1 [Easy menu] button Touch to change the display into the easy operation screen.

2 [Multi menu] button Touch to change the display into the multi-function screen.

3 [Step FWD] button Touch to move the robot one step forward while in pause.

4 [Step BWD] button Touch to move the robot one step backward while in pause.

5 [Start/Stop] button Touch to start or pause operation.Touching the blinking button starts operation.Touching the lit button pauses operation.

6 [Stop] button Touch to stop operation.

7 [Cycle Stop] button Touch to stop Auto operation without outputting the cycle start signal for

the next cycle.

8 [Reject] button Touch to discharge rejects.

9 [Sampling] button Touch to release a product at the sampling position. (Optional)

10 [Alarm] button Use to set whether or not to use buzzer sound when an error occurs.

15 16 17 18 19


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4.2.4 One-cycle operation

You can perform one cycle of operation using the multi-funtion screen before the take-outrobot starts operation or is at a halt.

No. Item Function

11 [Detail] button Touch to display details of maintenance.

12 [Prod. Monitor] button Touch to display the production state.

13 [Input] button Touch to display the input signal states.

14 [Output] button Touch to display the output signal states.

15 [Flags] button Touch to display the states of other than input/output signals.

16 [Pos.Comp.] button Touch to set descent/backward positions for the main arm and the sub

arm.

17 [PosRevise] button Touch to revise setting values for each position.

18 [Speed] button Touch to set speeds.

19 [Timer] button Touch to set timers.

DANGER

z Before starting one-cycle operation, make sure that no persons or obstacles exist in therobot motion area.




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2 Touch the [Multi menu] button onthe operation screen.The multi-function screen appears.

3 Touch the [1 Cycle Op] (onecycle operation) button.The take-out robot starts to move tothe waiting position.



CAUTION




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4 Touch the [Start/Stop] button.One-cycle operation starts.

To pause operation, touch the[Start/Stop] button. The take-out

robot restarts operation if the[Start/Stop] button is touchedagain.


After one-cycle operationcompletes, the take-out robot goesinto Auto standby mode


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4.3 Production complete message

If the production number is set in advance, a message appears when production of sched-uled number of products completes. The take-out robot stops Auto operation.Contact the personnel designated by the take-out robot safety supervisor if the message

appears.

4.4 Maintenance alarm display

Messages reminding the operator of regular maintenance works appear on the screenwhen starting up Auto operation around the time for those works to be performed.Contact the personnel designated by the take-out robot safety supervisor. Touch the[Confirm] button to turn ON the servo power.

z It is possible to set so that the take-out robot continues operation even after the schedulednumber of products are produced. Consult with the personnel designated by the take-outrobot safety supervisor regarding the production complete message.

z It is possible to set so that messages will not appear on the screen. Consult with the per-sonnel designated by the take-out robot safety supervisor regarding the maintenancealarm messages.


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4.5 Buzzer setting

You can set whether or not to use the alarm buzzer when an error occurs even during Autooperation. The alarm buzzer is factory set to Sound.Every time the [Alarm] button is touched, the setting changes between Sound and No

sound.

z Alarm buzzer Sound : Indicator lamp of the button turns green.z Alarm buzzer No sound : Indicator lamp of the button goes off.

4.6 Sampling

Sampling refers to releasing of products at the sampling position established in advance ina teaching procedure so that the products can be inspected. (Optional)Every time the [Sampling] button is touched, the setting changes between Release sam-ple and Not release sample. When the indicator lamp inside a button is not blinking butis normally lit, however, you cannot cancel the sampling motion even if you touch the[Sampling] button again.

z Move to the samping position in the next release motion: Indicator lamp of the button blinks in green.

z Releasing sample product

: Indicator lamp of the button illuminates.z Not release sample products at the sampling position

: Indicator lamp of the button goes off.

4.7 Discharge motion

Discharge motion refers to releasing of rejects after operation start-up at the dischargeposition established in advance in a teaching procedure so that rejects are distinguishedfrom the good products.Every time the [Reject] button is touched, the setting changes between Discharge rejectand Not discharge reject.

z Discharge reject : Indicator lamp of the button turns green.z Not discharge reject : Indicator lamp of the button goes off.


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4.8 Casing reset

During Auto operation, casing reset is used to discontinue casing of the current case (pal-let) and start casing a new case.

CAUTION

z When operating with a stocker, be sure to provide a new case (pallet) to prevent placingproducts onto already placed products.

1 Touch the [Casing Reset] buttonon the operation screen. As for the multi-function screen,touch the [Casing] tab inside theinformation display window to displaythe [Casing Reset] button.

2 Select the casing data to reset.Touch the[ ] button to the right of Sel Casing Data (select casing

data) inside the displayed window.

3 Touch the [CaseReset] button.The data will not be reset until therobot arrives at the waiting positionafter completing one cycle operation.

Easy operation screen

Multi-function screen


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5 MANUAL OPERATION

5.1 Manual operation description

In addition to Auto operation mode, the take-out robot can also be operated in manual

operation mode. Manual operation mode allows you to move a particular part of the robotbody independently for moving the robot to the waiting position while it is at a halt and

performing recovery work from an emergency stop.

5.2 Manual operation screen

The manual operation screen appears if the [Manual] (manual operation) tab is touched.

Each axis and valve can be controlled on this screen.

DANGER

z Before starting manual operation, make sure no persons or obstacles exist in the robotmotion area.

z

Be sure to perform manual operation from outside the safety fence.

No. Item Function

1 Operation buttons Each axis moves to the direction pointed with each arrow. When either

the [Main-Arm] or [Sub-Arm] axis selection button is selected, descent

and kick axes can be controlled.

2 [Axis Operation] button Touch to change the display into the screen for axis control.

3 [Valve Control] button Touch to change the display into the screen for valve control.


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4 Axis select buttons Touch one of these buttons to select an axis to control. The button of a

selected axis turns yellow.

5 [Free Mode] button Every time this button is touched, the setting changes between Free

mode ON and Free mode OFF.

The indicator lamp of the button turns green. Each axis of the take-out

robot can be moved to the stroke limit regardless of positions set in a

teaching procedure. Use this mode when performing teaching, mainte-

nance or coping with the unexpected.

The indicator lamp of the button goes off. Each axis stops at positions

set in a teaching procedure.

6 Button icon You can use manual operation button on the touch panel controller when

this button icon is displayed.

7 View change button Every time this button is touched, the display view changes between theoperator side view and the rear side view.

8 Speed setting buttons

[1] to [4]

Set manual operation speed in four steps; from [1] (slow) to [4] (fast). A

selected speed number button turns yellow.

9 Inching distance setting Sets the inching distance in manual operation. Touch the [ ] button to

display three selection items;0.1mm, 1mm and 10mm.

10 Axis position display Displays the positions of all axes in millimeters. The axis name, currentvalue and max value are displayed from left to right. The yellow back-

ground indicates the currently selected axis.

11 Deadman switch display This button appears when the deadman switch is OFF. This button does

not appear when the deadman switch is ON.

No. Item Function

[Rear side view]


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Manual operation in free mode

The take-out robot can be moved to the plus or minus direction within the robot motion area if you

turn ON the free mode (the indicator lamp of the button turns green) and touch an axis operation

button.

The take-out robot can be moved to the plus or minus direction within the range of the teaching posi-tions (but not beyond that range) if you turn OFF the free mode (the green lamp of the button goes

off) and touch an axis operation button .

Take-out position

Descent position

Kick return position

Product release position


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5.3 Axis operation

z In order to move the axes, one of the deadman switches must be turned ON. There is onedeadman switch on the operator station surface and two deadman switches at the back of the touch panel controller. The deadman switch is ON if either one is pressed.

1 Access the manual operation screen in any of the following manners:1) Touch the [Manual] button on the Index screen;2) Select [Operator] among the top group tab menu. Then select [Manual] among the sub group

tab menu;

3) Touch the button of [Operator] among the top group tab menu. Then touch the [Manual]

button inside the sub menu window;

2 Place the touch panel controller on the operator station or holdthe touch panel controller andpress a deadman switche with

your thumb so that the deadman

switch is ON.The deadman switch display disap-pears if the deadman switch ispressed. Deadman switches

Keep pressing one of the deadman switches.

Guard


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3 Select the axis you wish to moveusing the axis select buttons.The selected axis operation buttonturns into yellow from blue.

You can also change axes using theenter button at the center of themanual operation button on thehandheld controller.

4 Move the axis using operationbuttons.Select the axis motion speed among[1] (slow) to [4] (fast).

CAUTION

z Pay attention to the motion prohibition area. The arm unit cannot be moved downwardinside the motion prohibition area.


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5.4 Valve operation

Control valves using the valve name buttons on the valve control screen.

The valve name buttons and the corresponding valve functions are as follows.

Button name ON (Yellow background) OFF (Blue background)

Product flip End-of-arm tool flip End-of-arm tool flip return

Product vacuum suction Vacuum suction ON Vacuum suction OFF

Product chuck Product chuck close Product chuck open

Runner chuck *1 Runner chuck close Runner chuck open

Sprue chuck Sprue chuck close Sprue chuck open

Pitch adjustment Pitch adjustment ON Pitch adjustment OFF

*1 This button only applies when the robot has a sub arm.

1 Touch the [Valve Control] buttonon the manual operation screen.

2 The valve control screenappears.The valve control screen displays thevalve names.


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3 Touch the desired valve namebutton.The background changes betweenblue and yellow every time the buttonis touched.

OFF : Blue backgroundON : Yellow background

Touch the [Signal] button to

check the state of input and out-

put signals.Signal ON : Indicator lamp turns

ONSignal OFF : Indicator lamp turns

OFF

Touch the [Vacuum] button to

check and set vacuum pres-

sures.

WARNING

z Only those who are designated by the take-out robot safety supervisor can set the vacuumpressure.


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6 TROUBLESHOOTING

6.1 Error message screen

The error message window appears on the screen if an error occurs.


1 Error name This section displays the name of the error.

2 Error code This section displays the error code.

3 Message This section displays the message showing how to clear the error.

4 Incident time This section displays the time at which the error occurred according tothe internal clock of the operator station.

5 [Reset] button Touch this button to reset and close the error display window.

6 [Silence] button Touch this button to turn off the buzzer sound.

7 [Switch] button When an error occurs during Auto operation, touch this button to checkthe number of blocks or steps where an error occurred.

CAUTION

z When the alarm buzzer setting is set to No Sound, the alarm buzzer does not sound.Consult with the personnel designated by the take-out robot safety supervisor before start-ing operation.


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6.2 Error messages

CAUTION

z When the error message window appears, report the error number and error name to thepersonnel designated by the take-out robot safety supervisor. Do not attempt to eliminatethe error without receiving instructions from the personnel designated by the take-out

robot safety supervisor.

Error NO. Error name0001 Command Number Error 0002 Command Parameter Error 0003 Jog Operation Error 0004 Servo Command Error 0005 Home Return Incomplete Error 1117 Motion Prohibition Area Err. 11118 Motion Prohibition Area Err. 2

1119 Motion Prohibition Area Err. 31120 Watch-dog Timer Up Err 1121 Command Not Allowed in Warning1311 ID Collation Error 1312 Parameter Collation Error 1313 Servo Connection Error 1314 Cannot Reset Pos. Module Err. (Cannot reset positioning module error)1315 Servo Driver Error 1316 Emergency Stop1317 Cannot Execute Positioning1319 Body No. Collation Error 1320 Data Version Error 1321 Servo Power OFF Detected1338 Manual Operation Error 1339 Auto Operation Error 1340 Emergency Stop reset error


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z The errors listed on the following pages have an additive digit ranging from 1 to 5 in front of the error number.Report all five digits of the error number, including the additive digit inside the in thefollowing tables, to the personnel designated by the take-out robot safety supervisor.

Error No. Error name0012 Driver Alarm Input Detected

0013 CW Limit Input Detected

0014 CCW Limit Input Detected

0015 Plus Limit Error (Encoder)

0016 Minus Limit Error (Encoder)

0017 Over Speed Detected

0018 Over Acceleration Detected

0019 Variation Error

0031 Plus Limit Err. (Command Pos.)

0032Minus Limit Err. (Command Pos.)

0041 Home Position Search Error

0051 Encoder Absolute Error

0052 Position Data Overflow

0053 Position Data Read Error

0061 Positioning Completed Time Out

0099 Servo OFF During Motor Drive

0999 Internal Calculation Error

9999 Emergency Stop

2001 Plus Limit Error

2003 Minus Limit Error

2005 Speed Limit Error

2007 Over Speed Detected Error

2009 Over Accel Detected Error (Over acceleration detected error)

2011 Variation Error Detected Error

2013 Motor Rotation Direction Error

2016 Position Loop Range Error

2017 Speed Feed Fwd Coefficient Err (Speed feed forward coefficient error)

2018 Encoder Type Selection Error

2019 Encoder Multiplication Error

2020 Speed to Voltage Ratio Error

3031 Setting Speed Error

3033 Target Position Error

3035 Target Position Mode Error 3036 Acceleration Time Error

3037 Acceleration Mode Select Err.

3038 Acceleration Parameter 1 Error

3039 Acceleration Parameter 2 Error

3040 Deceleration Time Error

3041 Deceleration Mode Select Err.

3042 Deceleration Parameter 1 Error

3043 Deceleration Parameter 2 Error

3044 Positioning Time Out Error

3046 Course-Auxil. Mode Select Err.


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Error No. Error name3047 Course-Auxil. Mode Select Err.

3048 Start-up Mode Selection Error

3049 Position Detected Mode Error

3050 Position Detected Set Value Er

5002 Parameter checksum Error

5003 Main Circuit Detector Error

5004 Parameter Setting Error

5005 Combination Error

5008 Scale Pitch Setting Error

5016 Overcurrent or Heat Sink Overheated

5048 Regenerative Error

5050 Regenerative Overload

5051 Main Circuit Wiring Error

5064 Overvoltage

5065 Undervoltage

5081 Overspeed

5082 Vibration Alarm

Injection Machine Robot

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