Arc Welding Solution

With
Yaskawa Motoman
 Robot Lineup Compatible with Arc Welding Application (YRC1000)
YASKAWA’s 6 Axis Arc Welding Robot Models
30

25

20
AR1730
capacity(kg)

25kg payload
Load

15

10
AR2010
AR1440 12kg payload
5
AR700 AR900 12kg payload
8kg payload 7kg payload
0

600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Maximum
reach(Mm)
★ Achieve greater flexibility for your welding operation with Increased degree of freedom of robot posture
allows to always take the most effective welding posture for even very large and complex (shape) works
★ Improve productivity with increased speed!
Features and Specifications of Arc Welding Robot
“MOTOMAN-AR1440, AR1730, AR2010”
When robot moves like angle θ
AR1440, AR1730, AR2010 moves likeℓ1,
Competitors move likeℓ2
Arch shaped arm ℓ 2

B-axis

500mm+α
(competitor)
100mm ℓ 1

T-axis (P point）

500mm

Reduce the interference

with peripheral facility
and work θ
500mm

Work piece

No interference

Internal torch cabling type External torch cabling type

Benefit Benefit
Minimizes interference with surrounding equipment, as End of torch is at extension from center of T-axis,
torch cable is stored internally in the U-arm which is optimal for circular welding robot motion
 Design Advantage
• Streamlined, arch shaped arm
increases agility and minimizes
interference with workpiece.
• Fast – increases productivity
and reduces cycle time.
• 12-kg payload robot support a
verity of torches sensors and
accessories
• Sigma 7 motors providing high
reliability.
• Controlled by the compact
YRC1000 controller.
 Design Advantages
• Easy to use teach
pendant with intuitive
menus and graphical
interface.
• Light weight programing
pendent
• Industrial Grade touch
screen.
• Robust cable of 8 meters
 Standard Options Available for
Welding
• Operation status checking function
• Job monitoring function
• Robot monitoring function
• Welding line management form
• VMAX function
• 3D graphic displaying function
 Function standard
Operation status checking function
Overview /merit

Check robot operation status on pendant easily. It can help you change
production plan.

Check past operation status easily!!

Displaying Items
・Operation time
・IO stop time
・Saving energy time
・Alarm stopped time

X-axis
・Unite: time（Past 96 hours）
・Unite: day （Past 100 days）
・Unite: month (Past 50 months）
 Function standard
Job monitoring function
Overview and merit

Be able to monitor robot inside data just use playback. It can help you to
modify job by monitoring results.

① Job monitoring results screen (unite: job)

②Job diagnostic result screen(Unit: axis)
Display number of playback, operation time, IO stopped
Display each axis reducer`s life, load factor, maximum
time, saving energy time
speed
モニタ履歴機能 2015/05/22

R1:
トルクオーバ

1.JBI：ライン10 ：ステップ3 S軸 Check load factor rate

1.JBI：ライン20 ：ステップ6 L軸
2.JBI：ライン30 ：ステップ8 U軸
among each jobs and steps
③Monitoring items（load factor rate）over history screen
(Be able to know jobs` line and step which are over initial easily.
setting value)
 Function standard
Monitoring robot function
Overview and merit

Set threshold on torque value, external force value and axis speed.
Can use this function such as implement other jobs when torque value is
exceed the threshold.

Can use it on this situation as

example
Set threshold
and general Threshold
signal

ON
Torque,
OFF etc.

General signal
General signal turns on when value
Example: Monitor torque value when
is over threshold
doing pressing work. Set work as
completed when torque is exceed torque.
 Function standard
Welding line management form
Overview and merit

Display welding command among several welding section and robot operation
information on programing pendant. It helps check welding condition easily.

《Merit》
・Check and modify welding condition in one
screen. Open several screen is not required.
・Display welding section only which helps to
check welding section.
・Check welding condition every robot
operating steps.
 Function standard
Display 3D graphic function
Overview and merit

Check robot operation and limited operation area of function safety on pendant
by 3D graphic.

limited operation area of

function safety Teaching point/posture
Display step
Operation orbit/posture of numbers
robot

Operation
command
section

IO output
Check limitedoperation Implement command Check job teaching points
area of function safety and moving robot is not
easily. Check robot operation required.
#Another Functional safety function is
required
orbit during machine rock
operation.
 standard
Preventive maintenance function for hardware
Overview and Merits

This function estimate the lifespan of hardware and suggest to exchange it before it is
broken, which can be utilized for knowing the maintenance timing and preventative
maintenance.

Lifespan estimation by monitoring the running time and frequency

Signal Output
The signal is output
and the sign change from ○ to ●
when the unit displayed in the window is judged
that it should be exchanged.

“WARNING”
Displays the unit which should be exchanged.
(The message is displayed also.)

■Message
operating time of cooling fan has approached a regulated
value
 Contents(3)
standard
Preventive maintenance function for Speed Reducer Large classification

Overview and Merits

The speed reducer diagnosis function provides the user with the information to predict the failure of a speed
reducer.
Diagnosis by Torque Amplitude
Warning signals can be output when motor torque amplitude exceeds the warning level
based on the fact that torque amplitude become bigger as the reducer of its axis deteriorate.
Graphically showing the transition of torque amplitude make it very easy to set the warning level.0000

Torque Amplitude
(Deteriorative 3 Warning
Reducer) Levels
Torque
Amplitude
(Normal When the torque
Reducer) amplitude
exceeds the
中
warning level,
低
the warning
signal can be
Normal Reducer output.
Deteriorative Reducer Torque
Amplitude
Torque Waveform Torque Amplitude Graph on Pendant
Diagnosis by Life Span Estimation
Reducer life span is estimated by the torque and speed of each axis during operation,
and the time to replace a reducer is informed.

Necessary equipment Related document

<< Hardware >> << Software >> YRC1000 INSTRUCTIONS (RE-CTO-A221)
Nothing Standard function
 standard
High-sensitivity shock detection function

Overview and Merits

The shock detection sensitivity has been greatly improved, minimizing the
damage of the workpiece and equipment in such cases where wrong
program is selected and the workpiece is misset etc...

Improved
detection Enable to detect the interference
with the workpiece faster. Reduce Reduce the deformation
sensitivity volume of the workpiece,
the pressing volume of the robot to
minimize the damage to the equipment and torch at
High-speed
equipment. the time of impact.
detection
Minimize the contact between the
workpiece and robot at the time of
Improved impact. Reduce recover time
stopping method Prevent the plastic deformation of the after the impact
workpiece, minimizing the damage.
Concerning the manipulators specific for Arc welding application, reading tool load information
prepared by Yaskawa will enhance the detection sensitivity, minimizing the torch deformation
volume.
 standard
Logging function
Overview and Merits

“History of programming pendant operation can be

checked!”
This function stores and displays the data edit such as editing data of the robot
controller program (job) and welding condition, and the history (log) of programming
pendant operation such as job execution.
This function also facilitate troubleshooting by ensuring the data traceability.
Logging target
Data edit (200)
Job
Concurrent IO ladder
Various condition files
Edit of parameters, variables, and others

Pendant operation (200)

Power ON/OFF, Mode change,
Log list Log external memory (load and save), and others
detail
Job execute(200)
It is also possible to extract and display only Job start
the log of data edit or pendant operation or job Job stop
execute. (inlcluding the factor of job stop(HOLD, ESP…))
 standard
Alarm details displaying function

Overview and Merits

In addition to alarm number and its name, enables to show the alarm Contents
breakdown including “content”, “cause” and “measure”.
Displays possible causes of the occurring alarm in descending order of frequency to
help users find the countermeasure for each cause immediately.

User can specify the window to be shown Page

Alarm No. Alarm explanation
in case of alarm occurrence;
￭ ALARM window (standard)
￭ ALARM HISTORY window (standard)
⇒ Press [SELECT] key to show ALARM DETAILS Alarm title
window Same as alarm window data
￭ ALARM DETAIL (parameter set) (Ordinary window)
Alarm content
If there are some possible causes and
[Right/Left] button
countermeasures for an alarm, press [Left/Right]
buttons or [Left / Right] keys to see next “cause” and Cause
“measure”. The “cause” and “measure” are
displayed in the order to be executed. Cause

If multiple alarms occur simultaneously, press [Page]

button or key to switch to next alarm.

[Return] [Page] button

button [Reset] button
 standard
Weld line coordinate Function(Torch Angle Display)
Overview and Merits

It can be executed JOG operation along a weld line, While

teaching.
An torch angle important welding quality is displayed on PP.
Tz ARROW A Angle display
Z INTERLOCK＋Z Torch angle

Tx

Y
ARROW B
Ty
Y ARROW B
Travel angle

X
X
ARROW A

《Merits》 It can operate easy along a weld line, can modify teaching torch or travel
angle.
 standard
Welding Path Shift Function
Overview and Merits

The welding path shift function shifts the welding path to upper board direction/lower
board direction.

UB: Upper board

direction
LB: Lower board
《Merit》 direction
Usually, the welding path is taught when it is deviated slightly from the joint of boards.
This function can perform welding the deviating path by teaching the joint of boards and set
deviating amount as the shifting amount to Arc Start Condition File.
 standard
Gas preflow / afterflow function
Overview and Merits

Enable to set gas preflow time and gas afterflow time for Arc start condition and end condition
respectively, improving the welding quality at the time of arc start.

■ Gas preflow ■ Gas afterflow

<Merits>Enable to apply the gas to the tip of the wire at the time of arc Enable to prevent oxidation of wire tip after welding is completed
start by setting the gas preflow time as an arc start condition. end by setting gas afterflow time as an arc end condition
Assure stable welding quality soon after arc Assure stable welding quality at the time of next arc
start start
 standard
Weld condition slope up / down function
Overview and Merits

Easy to realize high-speed arc welding by specifying slope up and slope down for Arc start
condition
and Arc end condition, respectively.
■ Slope Up ■ Slope Down

<Merits>Enable to specify slope condition for current, voltage and weld speed each as arc start condition.
In existing function, if welding speed is simply raised, the bead at the welding start part / end part cannot be stably
applied.
With this function, the speed can be raised smoothly, enabling to apply the bead at the welding start part / end part
stably.
Easy to improve speed with this condition file
 X350 Power Source with Yaskawa
Reduced Generation of Spatter by torch angle synchro Welding
Welding Condition
Wire diameters :1.2mm Torch angle : 0°,20°, 40°
welding speed: 80cm/min Welding current : 180A
Calculating the
welding Optimal
parameters Torch Angle 0 20 40
based on the
torch angle Disable (mg) 81 92 259
YRC1000
Send the optimal Enable (mg) 81 87 101
welding parameters
to the X350
Spatter
0.3

Quantity of Spatter(g)
Output the optimal 0.25
waveform from the
0.2
parameters
0.15
MOTOWELD-X350
0.1
It was newly equipped with the Overview of the welding 0.05
synchro welding function of waveform change
0
performing automatically the Waveform
appropriate welding waveform
Waveform 0０度
degree ２０度
20 degrees ４０度
40 degrees
Torch Angle
adjusted in accordance with the
posture of the welding torch. シンクロ無し シンクロ有り
Enable
Disabl
Shorten the adjustment time of the
e
welding conditions change, it will
At lap joint, the overall occurrence sputtering at the time of
also contribute to the weld quality welding
improvement.
three times weld length 20cm collected
X350
Variable Pulse Waveform Heat & Wave Form Control
When welding while decreased the voltage to suppress the The current value and the voltage value are in real time
concentration, the undercut measures, and the heat input detected by using the HAWC function, and the instruction
of the arc, the welding was not steady and a large amount current value and the instruction voltage value are
of spatters were generated so far. corrected. Change in
The welding that it stabilizes and the amount of the spatter . wire
is a little can be done by the variable pulse control even in extension by
Arc start
the state to have decreased the voltage. position defective
Arc end
teaching position Change in
<Test contents> wire
The underbody part goods of the car were actually welded, extension by
and the welding bead externals were confirmed. transformatio
n of work
• Welding condition Gas : MAG Current : 170A Voltage : Tip position
23V Robot speed : 90cm/min

This function doesn't correct the robot position

Current

Without
HAWC
Old method bead (Old
method) The current The current
changes by the changes by the
Current change in the change in the wire
wire extension. extension.
With variable pulse
Use
control, bead is HAWC
achieved to be flat. (by
RL350)

Variable Pulse bead

 Yaskawa and Fronius
Fronius and Yaskawa Motoman have worked together to develop this
extraordinary breakthrough in the world of robotic welding. The WeldCom
2.0 interface is only available with Motoman’s latest DX200, YRC 1000
controller and the Fronius TPSi

WeldCom 2.0 allows access to process libraries, arc start and end
conditions, display of live welding parameters, modifications to process
parameters, and the capability to adjust new Fronius TPSi features such as
Arc Length Stabilizer and Penetration Stabilizer. All of this is done through
Motoman’s teach pendant.

The Fronius TPSi power-source produces superior weldments by

monitoring and adjusting the arc 200 times faster than the previous
Fronius TPS line of power sources. There are also new options for welding
processes such as Pulse Multi Control (PMC) and Low Spatter Control (LSC).
The Motoman YRC1000 controller features many improvements including a
Small, lightweight programming pendant with a color touch screen and
multiple window display capability. Combining these two incredible
technologies with a superior interface will help reduce set up time,
increase production, and improve weld quality.
Compatibility With Fronius