Arc Welding Application

Transcription

1 Robot System Solutions Arc Welding Application Compatible with YRC1 Robot Controller Solution Certified for ISO91 and ISO141 QMS Accreditation R9 JQA-813 JQA-EM22

2 Robot System Solutions Find smart solutions for your production site with YASKAWA s cutting-edge robot systems. Improve welding quality AR Increase productivity Reduce time for start-up and equipment maintenance for diversified applications Make equipment compact Improve work efficiency Improve equipment installation, operation, and maintenance Standardization of equipment 2

3 Solution YASKAWA has the answer We can meet our customers diverse with a wide range of functions and components. Application examples Large and long workpieces, automobile suspensions, construction machines, agricultural equipment, shipbuilding, steel beams, etc. See application examples on page 4 and. AR Series Manipulators See Solution 1 MOTOPOS Series Positioner See Solution 4 YRC1 Robot Controller See Solution 2 Total Solution MOTOPAC Series Welding Package See Solution 3 AR7 AR9 AR144 AR173 YRC1 3

4 Application Examples YASKAWA s extensive know-how in robotics technologies can meet the requirements of a wide range of systems. Welding of small parts Executed in minimum installation space Our MOTOMAN robots achieve high-quality welding of small parts in a compact cell. By using welding robots with a 7-mm reach, small parts can be welded in minimum installation space. The layout of each cell can be changed easily by installing a robot controller and a welding power source inside the cell. High-quality welding of small parts in a compact cell Welding of long parts (ex. exhaust system parts) High productivity and high-quality welding By combining two MOTOMAN robots with welding positioner MOTOPOS, it is possible to execute station twin coordinated welding. This enables high productivity and high-quality welding even for long exhaust system parts. The positioner first adjusts the workpiece s angle and position. Next, the two robots weld the workpiece by coordinating their movements with the movements of the positioner. Station twin coordinated welding 4

5 Application High-density welding of automotive parts (underbody parts, etc.) High productivity and high-quality welding By combining three MOTOMAN robots with the welding positioner MOTOPOS for coordinated motion, it is possible to achieve high-density, high-quality welding of automotive parts. Moreover, it leads to shorter cycle time as three robots weld simultaneously. Arc welding robot (coordination between three robots) The positioner holds the workpiece at an optimum position and angle, as it coordinates its movements with the movements of the robots to achieve high-speed and high-quality welding. Workpiece Two-axis positioner Coordination between three robots and welding positioner Welding of construction machinery parts Simplification of transfer equipment and high-quality welding Construction machinery parts can be welded efficiently using three MOTOMAN robots that operate in coordination with one another. The two handling robots pick up the workpiece to transfer to optimum welding position. This enables to weld at optimum position, securing steady welding quality. The robots transfer the workpiece upon completion of welding, which simplifies transfer equipment. Workpiece Welding by one robot To achieve high-quality welding, two robots are used to hold a workpiece and another robot is used to weld. Hold workpiece with two robots Coordinated welding without jig

6 Solution 1 Robot :AR7 and AR9, Compact and High Speed Increase productivity Achieve high productivity with number 1 payloads and speeds in their classes A wide range of sensors and torches can be mounted with 7 kg/8 kg payloads (class number 1) and 38% greater allowable moment. Speeds of all axes have been increased by 39% (max.). Acceleration/deceleration control has been improved to achieve maximum reduction of acceleration/deceleration times for all robot postures. Make equipment compact Slim and easy to use body and arm structure enabling efficient installation space Slim manipulator body requires minimum installation space (minimizes L and U axis offset). Power cable can be connected at the bottom section, which reduces interference with walls when compared with cable connections on the side of the manipulator. Increased maximum reach and horizontal reach enables manipulator to operate in wider work areas. Slim, straight, and symmetrical arm design minimize interference with peripheral devices, even in small spaces. Reduced interference radius when S-axis is turning Former model: MH(L)SⅡ Interference radius 182 mm New model: AR7 and AR9 Interference radius 14 mm Reduced interference radius when the wrist is turning Power cable connection on the side and bottom (optional) of the manipulator Former model: MH(L)SⅡ Interference radius 73 mm New model: AR7 and AR9 Interference radius 67 mm Improve equipment installation, operation, and maintenance Easy maintenance Zero position data can be saved without the need to connect to a battery when replacing wire harness. Number of cables and connectors have been reduced for better work efficiency. Reduced wiring time Power cable is reduced to one cable, which reduces wiring time. Easy-to-clean design Manipulator surface is designed to prevent adherence of dust. Rounded shape and smooth surface 6

7 Solution 1 Robot :AR144, AR173, and, World s Highest Speed in their Classes Increase productivity Achieve high productivity with number 1 payload and speed in its class Productivity of customers equipment can be improved significantly with the robot s high speed (highest speed in 12 kg and 2 kg payload classes). Acceleration/deceleration control has been improved to achieve maximum reduction of acceleration/deceleration times for all robot postures. Various sensors and servo torches can be mounted with it s high payload. Make equipment compact Hollow arm structure enabling internal/external cable storage Reduced air-cut time The maximum speed of AR173 has been increased by 3% (max.) compared with the former model. : Maximum speed of AR144 and has been increased by 1% (max.) compared with the former model. Hollow arm structure to store cables reduces operation restriction due to cable interference, simplifies teaching, and eliminates cable disconnection caused by interference. Either a internally mounted or externally mounted torch cable can be selected. We provide the optimum cable installation for your workpieces and equipment. Welding power cables can be stored in the S-axis, which enables smart external cabling. Best accessibility in its class Slim and hollow arm design minimizes interference with peripheral devices even in small spaces. Arm design minimizes interference with surrounding equipment. Hollow arm R-axis hollow arm: mm dia. Reduced interference area T-axis hollow arm: mm dia. Former model New model Minimized interference radius of the wrist Former model: MA144 Interference radius 136 mm MA21 Interference radius 136 mm New model: AR144 Interference radius 12 mm AR173 Interference radius 138 mm Interference radius 12 mm Improve equipment installation, operation, and maintenance Easy maintenance Zero position data can be saved without the need to connect to a battery when replacing wire harness. Number of cables and connectors have been reduced for better work efficiency. Reduced wiring time Power cable is reduced to one cable, which reduces wiring time. 7

8 MOTONAN- AR Series Specifications AR7 AR9 Dimensions Units: mm : P-point Maximum Envelope R199 C Effective working envelope B L U R B T A 199 S R727 P-point Install attachments to this range dia. Fitting Depth: View A Connector for internal user I/O wiring harness: LF13WBRB-2S Matching connector: LF13WBLP-2PAHIROSE (provided by users) is the operating limit when a matching connector is attached. 2 Air inlet (Rc1/4 tapped hole, with pipe plug) View B Connector for internal user I/O wiring harness: LF13WBRB-2P Matching connector: LF13WBP-2SHIROSE (provided by users) View C 6.3 dia. Fitting Depth:3 2 Air outlet (M tapped hole, with pipe plug) is the operating limit when air or the optional solenoid valve is used R233 C 17 B 4 L U R B T A P-point 233 S R Install attachments to this range 6.3 dia. Fitting Depth: dia. Fitting Depth: View A Connector for internal user I/O wiring harness: LF13WBRB-2S Matching connector: LF13WBLP-2PAHIROSE (provided by users) 2 Air outlet 11 (M tapped hole, with pipe plug) View B Connector for internal user I/O wiring harness: LF13WBRB-2P Matching connector: LF13WBP-2SHIROSE (provided by users) 2 Air inlet (Rc1/4 tapped hole, with pipe plug) View C 8 Specifications AR7 AR9 Type YR-1-6VX8-A YR-1-6VX7-A Controlled Axis 6 (vertically articulated) 6 (vertically articulated) Payload 1 8 kg 7 kg Repeatability 2 ±.2 mm ±.3 mm Range of Motion S -axis (turning) L -axis (lower arm) U -axis (upper arm) R -axis (wrist roll) B -axis (wrist pitch/yaw) T -axis (wrist twist) Maximum Speed S -axis (turning) 7.94 rad/s, 4 /s 6.4 rad/s, 37 /s L -axis (lower arm) 6.72 rad/s, 38 /s. rad/s, 31 /s U -axis (upper arm) 9.7 rad/s, 2 /s 7.1 rad/s, 41 /s R -axis (wrist roll) 9.9 rad/s, /s 9.9 rad/s, /s B -axis (wrist pitch/yaw) 9.9 rad/s, /s 9.9 rad/s, /s T -axis (wrist twist) 17.4 rad/s, 1 /s 17.4 rad/s, 1 /s Allowable Moment R -axis (wrist roll) 17 N m 17 N m B -axis (wrist pitch/yaw) 17 N m 17 N m T -axis (wrist twist) 1 N m 1 N m Allowable Inertia (GD 2 /4) R -axis (wrist roll). kg m 2. kg m 2 B -axis (wrist pitch/yaw). kg m 2. kg m 2 T -axis (wrist twist).2 kg m 2.2 kg m 2 Approx. Mass 32 kg 34 kg IEC Protection Class IP67 Ambient Conditions Temperature C to +4 C Humidity 2% to 8%RH (non-condensing) Vibration 4.9 m/s 2 or less Others Free from corrosive gas or liquid, or explosive gas or liquid Free from excessive electrical noise (plasma) Free from strong magnetic fields Power Requirements 3 1 kva Mounting 4 Floor, ceiling, wall, tilt 1: U arm payload capacity will vary according to payload carried by wrist. 2: Conforms to ISO : Varies in accordance with applications and motion patterns. 4: There are motion limitations on S-axis for wall, tilt mounting type. Note: SI units are used for the specifications.

9 AR144 AR173 Solution R41 B R U L S R T B P-point dia. A dia. 4 1 dia dia. Fitting Depth: 1 dia. View A Position of the internal connector main key Air inlet (A) (Rc3/8 tapped hole, with pipe plug) Connector for internal user I/O wiring harness: JL-2A2-29PC (with cap) Matching connector: JL-6A2-29S (provided by users) View B Air inlet (A) (Rc3/8 tapped hole, with pipe plug) Position of the internal connector main key Connector for internal user I/O wiring harness: JL-2A2-29SC (with cap) Matching connector: JL-6A2-29P (provided by users) R46 B R U R T B P-point L S A dia dia. 1 dia. 4 View A Air inlet (A) (Rc3/8 tapped hole, with pipe plug) Connector for internal user I/O wiring harness: JL-2A2-29SC (with cap) Matching connector: JL-6A2-29P (provided by users) Main key Air inlet (A) (Rc3/8 tapped hole, Position of with pipe plug) the internal connector main key dia. Fitting Depth: 1 dia. Connector for internal user I/O wiring harness: JL-2A2-29PC (with cap) Matching connector: JL-6A2-29S (provided by users) View B Specifications AR144 AR173 Type YR-1-6VXH12-A1 YR-1-6VXH2-A1 Controlled Axis 6 (vertically articulated) 6 (vertically articulated) Payload 1 12 kg 2 kg Repeatability 2 ±.6 mm ±.6 mm Range of Motion S -axis (turning) L -axis (lower arm) U -axis (upper arm) ( ) R -axis (wrist roll) ( 1 +1 ) ( 1 1 ) B -axis (wrist pitch/yaw) ( ) ( 13 9 ) 6 T -axis (wrist twist) ( ) ( ) Maximum Speed S -axis (turning) 4.3 rad/s, 26 /s 3.67 rad/s, 21 /s L -axis (lower arm) 4.1 rad/s, 23 /s 3.67 rad/s, 21 /s U -axis (upper arm) 4.3 rad/s, 26 /s 4.63 rad/s, 26 /s R -axis (wrist roll) 8.2 rad/s, 47 /s 7.33 rad/s, 42 /s B -axis (wrist pitch/yaw) 8.2 rad/s, 47 /s 7.33 rad/s, 42 /s T -axis (wrist twist) 12.2 rad/s, 7 /s 1.44 rad/s, 88 /s Allowable Moment R -axis (wrist roll) 22 N m 2 N m B -axis (wrist pitch/yaw) 22 N m 2 N m T -axis (wrist twist) 9.8 N m 32 N m Allowable Inertia (GD 2 /4) R -axis (wrist roll).6 kg m kg m 2 B -axis (wrist pitch/yaw).6 kg m kg m 2 T -axis (wrist twist).17 kg m kg m 2 Approx. Mass 1 kg 2 kg IEC Protection Class Body: IP4, Wrist: IP67 Ambient Conditions Temperature C to +4 C Humidity 2% to 8%RH (non-condensing) Vibration 4.9 m/s 2 or less Others Free from corrosive gas or liquid, or explosive gas or liquid Free from exposure to water, oil, or dust Free from excessive electrical noise (plasma) Free from strong magnetic fields Power Requirements 3 1. kva 2. kva Mounting 4 Floor, ceiling, wall, tilt 1: U arm payload capacity will vary according to payload carried by wrist. : The value in the parenthesis is the motion range when the manipulator is used 2: Conforms to ISO together with MOTOPAC. 3: Varies in accordance with applications and motion patterns. 6: The plus and minus values will be switched when the manipulator is mounted on the 4: There are motion limitations on S-axis for wall, tilt mounting type. ceiling and used together with MOTOPAC. Note: SI units are used for the specifications. 9

10 MOTONAN- AR Series Specifications Dimensions Units: mm : P-point Maximum Envelope 2 83 R61 R U R T B A dia dia. 1 dia. Position of the internal connector main key Air inlet (A) (Rc3/8 tapped hole, with pipe plug) dia. Fitting Depth: 4 View A 1 dia. Air inlet (B) (Rc3/8 tapped hole, with pipe plug) Welding power source s terminal board Connector for internal user I/O wiring harness: JL-2A2-29PC (with cap) Matching connector: JL-6A2-29S (provided by users) View B B L S P-point 139 M1 tapped hole (2 holes) (depth: 18mm) (pitch: 1.) M1 tapped hole (2 holes) (depth: 12mm) (pitch: 1.) 1 Specifications Type YR-1-6VXH2-A11 Controlled Axis 6 (vertically articulated) Payload 1 12 kg Repeatability 2 ±.8 mm Range of Motion S -axis (turning) L -axis (lower arm) U -axis (upper arm) R -axis (wrist roll) (-1 +1 ) B -axis (wrist pitch/yaw) ( ) 6 T -axis (wrist twist) ( ) Maximum Speed S -axis (turning) 3.67 rad/s, 21 /s L -axis (lower arm) 3.67 rad/s, 21 /s U -axis (upper arm) 3.84 rad/s, 22 /s R -axis (wrist roll) 7.9 rad/s, 43 /s B -axis (wrist pitch/yaw) 7.9 rad/s, 43 /s T -axis (wrist twist) 12.2 rad/s, 7 /s Allowable Moment R -axis (wrist roll) 22 N m B -axis (wrist pitch/yaw) 22 N m T -axis (wrist twist) 9.8 N m Allowable Inertia (GD 2 /4) R -axis (wrist roll).6 kg m 2 B -axis (wrist pitch/yaw).6 kg m 2 T -axis (wrist twist).17 kg m 2 Approx. Mass 26 kg IEC Protection Class Body: IP4, Wrist: IP67 Ambient Conditions Temperature C to +4 C Humidity 2% to 8%RH (non-condensing) Vibration 4.9 m/s 2 or less Others Free from corrosive gas or liquid, or explosive gas or liquid Free from exposure to water, oil, or dust Free from excessive electrical noise (plasma) Free from strong magnetic fields Power Requirements 3 2. kva Mounting 4 Floor, ceiling, wall, tilt 1: U arm payload capacity will vary according to payload carried by wrist. : The value in the parenthesis is the motion range when the manipulator is used 2: Conforms to ISO together with MOTOPAC. 3: Varies in accordance with applications and motion patterns. 6: The plus and minus values will be switched when the manipulator is mounted on the 4: There are motion limitations on S-axis for wall, tilt mounting type. ceiling and used together with MOTOPAC. Note: SI units are used for the specifications.

11 Solution 2 Solution 2 YRC1 Robot Controller Four Features Programming Pendant YRC1 Robot Controller Make equipment compact Standardization of equipment Smallest size in the world reduces installation space This 12 L compact size controller does not require a transformer and has built-in external axis amplifiers for three axes. Former models YRC1 Global standardization (Universal size) Common size for use in Japan and overseas. Available with specifications for Europe (CE certified) and North America (UL certified). Overseas models do not require a transformer to adapt to the required power supply voltage. Realized this size by building in three external axes and eliminating the need for a transformer. Improve work efficiency Improve work efficiency New motion control (high precision and high speed) Reduce time required for confirmation process with minimized track changes caused by differences in motion speeds. Reduce time for teaching since it is now possible to specify the distance where the corner operation should start. Successfully carry out corner operation under suppressed speed changes with simple settings. Lighter programming pendant with better operability Weighs only 73 g, the lightest programming pendant in its class, with improved cable installation. Can confirm robot positions and postures on the 3D robot model display. Touch screen allows intuitive operation to easily move the cursor and scroll. YRC1 Robot Controller Specifications Items Specifications Configuration Dust proof IP4 (area of backside duct fan: IP2X) Dimensions 98 (W) 427 (D) 49 (H) mm 12 L Approx. Mass 7 kg max. (External axis amplifiers for up to three axes can be built in.) Cooling System Indirect cooling Ambient Temperature During operation: C to +4 C, During storage: 1 C to +6 C Relative Humidity 9% max. (non-condensing) Altitude 2 m (with temperature derating) Derating condition of over 1 m: max. ambient temperature decreases 1% per 1 m. Power Supply Japan: three-phase 2 VAC to 24 VAC (+1% to 1%), /6 Hz (±2%) Asia and Europe: three-phase 38 VAC to 44 VAC (+1% to 1%), /6 Hz (±2%) (neutral grounding) North America: three-phase 38 VAC to 48 VAC (+1% to 1%), /6 Hz (±2%) (neutral grounding) Grounding Grounding resistance: 1 Ω or less for 2-V class, 1 Ω or less for 4-V class Digital I/Os Specialized signals: 19 inputs and 6 outputs General signals: 4 inputs and 4 outputs (32 transistor outputs, 8 relay outputs) Positioning System Serial communications (absolute encoder) Programming Capacity JOB: 2, steps, 1, instructions CIO ladder: 2, steps max. Expansion Slots PCI express: 2 slots LAN (Connection to Host) 2 (1BASE-T/1BASE-TX) Interface RS-232C: 1ch Control Method Software servo control Drive Units SERVOPACK for AC servomotors Programming Pendant Specifications Items Specifications Dimensions 12 (W) 3 (D) 299 (H) Approx. Mass.73 kg Material Reinforced plastics Operation Device Select keys, axis keys, numerical/application keys, mode selector switch with keys (mode: teach, play, and remote), emergency stop button, enable switch, compact flash card interface device (compact flash is optional.), USB port (USB 2., 1 port) Display.7-inch TFT color LCD, touch panel VGA pixels (alphanumeric characters, Chinese characters, Japanese letters, and others) IEC Protection Class IP4 Cable Length Standard: 8 m, max.: 36 m (with optional extension cable) 11

12 Solution 2 Ideal Arc Welding Functions of the YRC1 Simple settings to achieve accurate welding angles Welding Line Coordinate System Jog Operation Function: Torch Angle Display The YRC1 allows jog operation in a direction based on the welding line (welding line coordinate system) during teaching. Also, the torch angle, which is important for welding quality, is displayed on the programming pendant. The manipulator can be moved by inputting the torch angle and travel angle in the ARC INFORMATION. Z Tz Interlock + Z View A Torch angle Tx Angle display Y View B Y View B Ty Travel angle X View A X Simple settings to adjust welding conditions Welding Conditions Guide Function (Optional) The YRC1 allows the automatic calculation of welding conditions without having to actually weld. Firstly, this simplifies the setting of welding power source conditions. Secondly, you can set the calculation result to the welding start conditions file with one click of a button. Finally, the time taken to set welding conditions can be reduced. Pressing Write sets the calculated current value and voltage value to the welding start conditions file. Pressing Calculate calculates the current value and voltage value. 12

13 Solution 2 Improve welding quality Graphical arc monitor function (Optional) You can check the welding conditions, job information, and robot motion information of the YRC1, displayed on the programming pendant. You can also automatically back up welding-related data to an external memory device. This allows to check welding conditions, manage data, and investigate the cause of welding defects. Welding status can be checked. Displays the torch angle required for high-quality welding. On-screen contents can be selected. Measurement can be triggered by a signal or an arc interruption. Automatic external data backup is possible. You can monitor welding conditions and job information in wave or number form, and check the welding status. Measurement can be triggered by a signal or an arc interruption, and the cause of welding defects can be analyzed. You can manage data by automatically backing up welding conditions, job, signal, and register information to an external memory device. Check welding conditions quickly Check welding conditions and other information, and make changes for teaching, all on the same display. With the YRC1, you can check and correct welding conditions, as well as other information on just one display. Moreover, you can easily make changes to welding commands and robot motion information for multiple welding segments, using table format as shown below. You can also improve welding quality by checking in real-time, actual welding condition values while welding is in progress. Weld Control Sheet Job: ARC_1 L : 4 S : 3 Weld locations: 3 Total welding length: 9 mm Total welding time: s Predicted total welding length: 9 mm Total welding time: s Welding line No. Line No. Welding conditions File No. Current A Voltage V User file No. Weld method No. Speed cm/min Actual value Current A Voltage V Weld length mm Check welding conditions and other information and make changes for teaching, on just one display. Confirmation is possible only for welding segments. Welding status can be confirmed simultaneously for the current robot execution step. 13

14 Solution 3 Welding Power Source and Welding Package Features Easy Setup Each component is carefully developed and selected for different types of workpieces and welding methods. As a result, the best robotic system can be easily installed. YASKAWA offers a full range of services to support your. Achieve High-quality Welding High-quality welding can be achieved by combining MOTOMAN robots with the latest digitally controlled welding power source (MOTOWELD). This enables optimum welding control for a wide variety of welding methods. Features of Our New Welding Power Source MOTOWELD-X3 Synchronized Welding Function High-quality welding Spatter reduced by fully synchronized robot operation and waveform control. Calculates the optimal welding parameters from the torch angle. YRC1 Sends optimal welding parameters to the welding power source. Outputs optimal welding waveform from the waveform parameters. Effect of Synchronized Welding Function MOTOWELD-X3 Significantly limits the increase in spatter caused by adjusting the torch angle. Torch angle Image showing spatter when torch angle is adjusted Spatter quantity (g) Without synch With synch.3 (Spatter increase rate) % % %.87 2 Torch angle 24.7% Significantly limits spatter Welding waveform image Limits the increase in spatter by adjusting the torch angle. Welding condition Welding power source: 18 A Wire diameter: 1.2 mm Gas: MAG Torch position: drag angle, 2, 4 Welding speed: 8 cm/min Welding method number: 1 Short-circuit welding 14

15 Solution 3 Features of MOTOWELD-X3 & AC Unit (XACU) & DC welding AC welding MOTOWELD-X3 Faster Welding and Lower Weld Defect Rates XACU AC unit increases welding volume and suppresses heat input, which improves welding quantity, increases welding speed, and reduces defect rates. Better Aluminum Bead Appearance Smut reduced by % for aluminum welding. Creates smooth beads and ripples. AC welding AC unit (XACU) AC welding Defect Burn-through Example: Stainless steel, sheet thickness: 1 mm, gap: 1 mm, speed: 1 cm/min No burn-through Select the ideal device for your When the workpiece you want to weld changes, or the adjustment of welding conditions becomes too difficult, you can attach an AC unit to the MOTOWELD-X3. This removes the need to buy a new welding power source. Suppressing smut Creates smooth beads and ripples. Features of MOTOPAC-WL3+ Welding Robot Package for Ultra-low Spatter SERVOPACK box Servo torch MOTOWELD-X3 The EAGL welding minimizes spatter The EAGL welding maximizes productivity and improves the welding quality. EAGL welding: Enhanced Arc robot welding for Low spatter. This is a technology to reduce spatter greatly. : In sync with a welding waveform, control a welding wire that repeat sending and sending back. Superior quality & higher productivity Reduced spatter by a forced short circuiting transfer Conventional MIG, MAG, and CO2 welding EAGL welding Wire feeding direction Generates spatter Forward direction only Generates spatter CO2 welding Spatter reduced over 9% Comparison of spatter amount Conventional welding EAGL welding Welding conditions Gas: CO₂ Wire diameter: 1.2 mm Torch angle: Perpendicular to panel Welding speed: 8 cm/min Amount of spatter 91% down!! 94% down!! 96% down!! 97% down!! 1A 18A 2A 2A Welding current Reduce spatter at wire retraction 1

16 Solution 3 A Complete Lineup of Welding Power Sources and Welding Packages Functions MOTOPAC-WL3&AC UNIT Welding power source: X3 & AC unit (XACU) AC short circuiting welding AC pulsed arc welding MOTOPAC-WR1 Welding power source: SR3 Short-circuit welding MOTOPAC-WL3+ Welding power source: X3, servo torch, SERVOPACK box Short-circuit welding for ultra-low spatter (EAGL welding) Pulsed arc welding MOTOPAC-WL3 New welding power source: X3 RL3 succession model Low spatter short-circuit welding MOTOPAC-WH4 Pulsed arc welding Welding power source: RP Short-circuit welding Pulsed arc welding MOTOPAC-WR2 Welding power source: SR Short-circuit welding Main workpieces Vehicle body/seat Vehicle suspension, etc. Construction machine, farm machine, etc. Shipbuilding, steel frame, etc. Target thickness mm A Class Welding power source MOTOWELD-X M8 Eyebolts MOTOPAC-WL3 This package uses the MOTOWELD-X3 welding power source. The secondary switching circuit installed in the welding power source reduces spatter caused by short circuiting and enables highquality welding. : When welding aluminum, the torch and torch cable set and conduit cables for aluminum welding must be used. Output terminal (-) Output terminal (+) Stay brackets Ratings and Specifications for MOTOWELD-X3 Specifications For Japan and other Asian countries Model YWE-X3-CC (compliant with China Compulsory Certification) Rated Input Voltage Three-phase 2-22 VAC ±1% Three-phase 38-4 VAC ±1% (Voltage selectable at the back terminal) Rated Frequency /6 Hz Rated Input 18 kva/1 kw Rated Output Current 3 A to 3 A Rated Output Voltage 12 V to 36 V Rated Operation Rate 6% (for 1 minutes) Applicable Welding Method Pulsed MAG/MIG welding, CO2/MAG/MIG short circuiting arc welding Applicable Wire Diameter.8 mm/.9 mm/1. mm/1.2 mm Applicable Welding Material Iron, stainless steel, aluminum Dimensions (W D H) mm Approx. Mass kg : Does not include projecting parts such as eyebolts or screws. Welding power source MOTOWELD-X3 supporting EAGL welding MOTOPAC-WL3+ This package uses the MOTOWELD-X3 welding power source that supports EAGL welding. The EAGL welding reduces spatter and enables high-quality welding. : When welding aluminum, the torch and torch cable set and conduit cables for aluminum welding must be used. : Cannot be used in combination with the AC Unit (XACU). 16 AC Unit (XACU) compatible with MOTOWELD-X3 welding power source Rated Input Voltage Rated Frequency Rated Input Rated Output Current Three-phase 2-22 VAC ±1% Three-phase 38-4 VAC ±1% (Voltage selectable at the back terminal) /6 Hz 18 kva/1 kw 3 A to 3 A MOTOPAC-WL3& AC UNIT This package uses the MOTOWELD-X3 welding power source and an AC Unit (XACU). This combination of the existing welding method and AC welding can enhance the performance of the complicated welding process of thin sheets. : When welding aluminum, the torch and torch cable set and conduit cables for aluminum welding must be used. Ratings and Specifications for AC Unit (XACU) Specifications For Japan and other Asian countries Rated Output Voltage 12 V to 36 V Model YWE-XACU-CC (compliant with China Compulsory Certification) Rated Operation Rate 6% (for 1 minutes) Applicable Welding Method Pulsed MAG/MIG welding, CO /MAG/MIG short circuiting arc welding, AC pulsed MAG/MIG welding, CO2/MAG/MIG AC short circuiting arc welding.8 mm/.9 mm/1. mm/1.2 mm Iron, stainless steel, aluminum mm 4 kg Applicable Wire Diameter Applicable Welding Material Dimensions (W D H) Approx. Mass : Does not include projecting parts such as eyebolts or screws.

17 Solution 3 Welding power source MOTOWELD-SR M8 Eyebolts MOTOPAC-WR1 This package uses the MOTOWELD-SR3 welding power source Output terminal (-) Output terminal (+) Stay brackets A Class Welding power source MOTOWELD-RP Ratings and Specifications for MOTOWELD-SR3 Specifications For Japan and other Asian countries Model YWE-SR3-AJ(not compliant with China Compulsory Certification) Rated Input Voltage Rated Frequency Rated Input Rated Output Current 37 Three-phase 2-22 VAC ±1% Three-phase VAC ±1% /6 Hz 2 kva/1 kw 3 A to 3 A 82 M1 Eyebolts Rated Output Voltage 12 V to 36 V Rated Operation Rate 6% (for 1 minutes) Applicable Welding Method CO2 short circuiting arc welding, MAG short circuiting arc welding Applicable Wire Diameter.8 mm/.9 mm/1. mm/1.2 mm Applicable Welding Material Iron only Dimensions (W D H) mm Approx. Mass 4 kg : Does not include projecting parts such as eyebolts or screws. MOTOPAC-WH4 This package uses the MOTOWELD-RP welding power source. The operation rate of 1% enables prolonged continuous welding operation. 1 1: A water-cooled torch is required for continuous welding operations with a high operation rate. 2: When welding aluminum, the torch and torch cable set and conduit cables for aluminum welding must be used. Output Output terminal (-) terminal (+) Stay brackets Welding power source MOTOWELD-SR Ratings and Specifications for MOTOWELD-RP Specifications For Japan and other Asian countries Model YWE-RP-AJ (not compliant with China Compulsory Certification) YWE-RP-CC (compliant with China Compulsory Certification) Rated Input Voltage Rated Frequency Rated Input Rated Output Current Three-phase 2-22 VAC ±1% Three-phase VAC ±1% /6 Hz 27 kva/24.3 kw 3 A to A 37 3 M1 Eyebolts Rated Output Voltage 12 V to 4 V Rated Operation Rate 1% (for 1 minutes) Applicable Welding Method Applicable Wire Diameter MOTOPAC-WR2 Pulsed MAG/MIG welding, CO /MAG/MIG short circuiting arc welding.8 mm/.9 mm/1. mm 1.2 mm/1.4 mm/1.6 mm Iron, stainless steel, aluminum mm 7 kg Applicable Welding Material Dimensions (W D H) Approx. Mass : Does not include projecting parts such as eyebolts or screws. This package uses the MOTOWELD-SR welding power source. Use this package when the required current and operation rate cannot be obtained with a 3A welding power source Output Output terminal (+) terminal (-) Stay brackets Ratings and Specifications for MOTOWELD-SR Specifications For Japan and other Asian countries Model YWE-SR-AJ (not compliant with China Compulsory Certification) YWE-SR-CC (compliant with China Compulsory Certification) Rated Input Voltage Rated Frequency Rated Input Rated Output Current Three-phase 2-22 VAC ±1% Three-phase VAC ±1% /6 Hz 29 kva/26 kw 3 A to A Rated Output Voltage 12 V to 4 V Rated Operation Rate 8% (for 1 minutes) Applicable Welding Method CO2 short circuiting arc welding, MAG short circuiting arc welding Applicable Wire Diameter 1. mm/1.2 mm/1.4 mm/1.6 mm Applicable Welding Material Iron only Dimensions (W D H) 3 68 mm Approx. Mass 6 kg : Does not include projecting parts such as eyebolts or screws. 17

18 Solution 3 MOTOPAC Package Components Standard Package Components MOTOMAN-AR144, AR173, with externally mounted torch cable MOTOMAN-AR144, AR173, with internally mounted torch cable Shield gas YRC1 8 8 Pail pack For MOTOMAN-AR7, AR9 When using AC unit Shield gas 1 2 YRC1 8 Pail pack To YRC List of MOTOPAC Package Components No. Device Default specifications 1 Welding power source Select from MOTOWELD-X3,-SR3,-RP,-SR Torch and torch cable set When using a 3 A welding power source When using a A welding power source MOTOMAN- AR144,173,21 MOTOMAN-AR7,9 MOTOMAN- AR144,173,21 With internally mounted torch cables YMSA-3R [from CORPORATION (air-cooled, with shock sensor)] With externally mounted torch cables TK38R-SS [from CORPORATION (air-cooled, with shock sensor)] TK39R-SS [from CORPORATION (air-cooled, with shock sensor)] With internally mounted torch cables YMSA-R [from CORPORATION (air-cooled, with shock sensor)] With externally mounted torch cables TK8R-SS [from CORPORATION (air-cooled, with shock sensor)] Wire feeder 1 YWE-WFR42DX2 Installation parts for S-axis When using a 3 A welding power source 6 sq power cable When using a A welding power source 8 sq power cable Positive ( ) power cable When using a 3 A welding power source 6 sq m When using a A welding power source 8 sq m Negative ( ) power cable When using a 3 A welding power source 6 sq m When using a A welding power source 8 sq m Cable for wire feeder control (between manipulator and welding power source) m 8 Negative ( ) cable for voltage detection (between manipulator and jig) m ( This cable is not included when using MOTOWELD-SR3, SR with a 1 m or shorter power cable.) Welding I/F cable (between robot When using MOTOWELD-X3, -RP LAN cable controller and welding power source) When using MOTOWELD-SR3, -SR Welding I/F cable 4 1 Conduit cable N3 3 m [from CORPORATION] Gas hose SLD hose (nominal dia. 6mm) 1 m [from Bridgestone Corp.] Shock sensor cable (used only when AR7 or AR9 is selected) 1 m AC unit (XACU) (used only when MOTOPAC-WL3&AC UNIT is selected) 1: The wire feeder cannot be placed on the manipulator when using the AR7 or AR9. Users must prepare a stand for the wire feeder. 2: An optional joint component should be used when placing the AC unit on top of the X3.

19 Solution 3 Package Components for MOTOPAC-WL3+ For MOTOMAN-AR144, AR173, Shield gas YRC1 8 6 Pail pack For MOTOMAN-AR7, AR Shield gas YRC1 1 6 Pail pack List of MOTOPAC Package Components No. Device Default specifications 1 Welding power source MOTOWELD-X3 SERVOPACK box Select from 2 V or 4 V Servo torch set + shoulder unit/ joint unit WFE2WD-TSS3R [from CORPORATION (air-cooled, with shock sensor)] Installation parts for S-axis 6 sq power cable Cable for servo torch Cable for base side m Positive ( ) power cable 6 sq m 8 Negative ( ) power cable 6 sq m Negative ( ) cable for voltage detection (between manipulator and jig) m 1 Welding I/F cable (between robot controller and welding power source) LAN cable Conduit cable N3 3 m [from CORPORATION] Gas hose SLD hose (nominal dia. 6mm) 1 m [from Bridgestone Corp.] Shock sensor cable (used only when AR7 or AR9 is selected) 1 m : The joint unit cannot be placed on the manipulator when using AR7 or AR9. Users must prepare a stand for the joint unit. 19

20 Solution 3 Components and Devices Standard Package Internally Mounted Torch Cable for 3 A (Standard) 424. YMSA-3R with shock sensor YMSA-ACC3R with shock sensor AR144,AR YMSA-38R with shock sensor YMSA-ACC38R with shock sensor AR144,AR YMXA-3R without shock sensor YMXA-ACC3R without shock sensor AR144,AR YMXA-38R without shock sensor YMXA-ACC38R without shock sensor AR144,AR dia dia dia dia BINZEL icatminig3-3sn 3 with shock sensor N chip (internally mounted) icatminig3-3sd 3 with shock sensor D chip (internally mounted) AR144 AR BINZEL icatminig3-38n 38 with shock sensor N chip (internally mounted) icatminig3-38d 38 with shock sensor D chip (internally mounted) AR144 AR173 Internally Mounted Torch Cable for A (Standard) 436. YMSA-R with shock sensor AR144,AR YMSA-8R with shock sensor AR144,AR dia dia dia dia. Externally Mounted Torch Cable for 3 A (Standard) YXSA-R without shock sensor AR144,AR dia YXSA-8R without shock sensor AR144,AR dia TK39R-SS with shock sensor AR7,AR9 2 dia dia. TK38R-SS with shock sensor ACC38R-SS with shock sensor AR144,AR dia. TK38R-LESS without shock sensor ACC38R-LESS without shock sensor AR144,AR Externally Mounted Torch Cable for A (Standard) WL3+ Package Externally Mounted Torch Cable for 3 A (Standard) dia. TK8R-SS with shock sensor AR144,AR dia. TK8R-LESS without shock sensor AR144,AR WFE2WD- TSS3R with shock sensor AR7, AR9 AR144, AR173 2 dia WFE2WD- TSS38R with shock sensor AR7, AR9 AR144, AR173 2 dia. 1 2 Note: Please contact your YASKAWA representative about other torches.

21 Solution 3 Power Cable Cable for Wire Feeder Control Negative (-) Cable for Voltage Detection Welding I/F Cable:LAN Cable Welding I/F Cable Conduit Cable Gas Hose This cable can be used as a positive (+) power cable (between a manipulator and a welding power source) as well as a negative (-) power cable (between a welding power source and a welding jig). Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. This positive (+) power cable must be the same length as the feeder control cable. Selectable materials, thicknesses, and lengths Material: WCT or E-WCT Thickness: 6 sq, 8 sq, or 1 sq Length: m (standard), 1 m, 1 m, or 2 m Note: Cables are also available in 1-m increments. This signal cable connects a manipulator with a welding power source and controls the wire feeder. Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. If you change the length of this cable, the length of the positive (+) power cable must also be changed. If you use the MOTOWELD-SR3, -SR welding power source, obtain a voltage detection cable separately. Selectable lengths Without an encoder signal conversion unit: m (standard), 7 m, or 1 m With an encoder signal conversion unit: 1 m, 1 m, or 2 m This cable connects a manipulator with a welding jig and detects welding voltage. Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. If you change the length of this cable, the length of the negative (-) power cable must also be changed. When using the MOTOWELD-SR3 or -SR welding power source, this cable connects a welding power source with a welding jig. Selectable lengths Length: For X3 m (standard), 1 m For SR3, SR, RP m (standard), 1 m, 1 m, 2 m This signal cable connects a robot controller with a welding power source and controls the welding power source. Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. This cable is used with the MOTOWELD-X3 or -RP with digital controls. Selectable lengths Length: m (standard), 1 m,1 m, 2 m This signal cable connects a robot controller with a welding power source and controls the welding power source. Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. This cable is used with the MOTOWELD-SR3 or -SR, or MOTOWELD-RP with analog controls. Selectable lengths Length: 4 m (standard), m, 1 m,1 m, 2 m Note: The YWE-AIF-1 must be purchased separately when using the RP with analog controls. This cable connects a manipulator with a spool container for welding wire. Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. Selectable cable types and lengths Length: N3 (1 m to 1 m max. in 1-m increments, standard 3 m), N (1 m to 1 m max. in 1-m increments), Simplified type (1 m to 2 m max. in 1-m increments) [from CORPORATION] This hose connects the manipulator and gas cylinder. Selectable lengths Length: 1 m (standard), 2 m, 3 m Optional Devices Air Valve Unit Feeder Roller Gas Regulator Cable Stands and Reel Units This valve unit is used to supply air to a welding torch with a wire clamp. Selectable lengths Length: Signal cable 1 m, 2 m This is a set of optional rollers for the wire feeder. Be sure to order the correct size rollers for your wires. (A set of rollers for diameter 1. mm and 1.2 mm wires is installed in the wire feeders when shipped.) Selectable wire diameter Wire diameter :.8 mm dia.,.9 mm dia., 1.4 mm dia., 1.6 mm dia. (.8 mm and.9 mm dia., 1.4 mm and 1.6 mm dia.) [from CORPORATION] Note: Available in a set of two rollers (one set/wire feeder) This gas regulator controls the pressure of shield gas contained in the gas cylinder that can be used for both CO2 and MAG welding. When using it for CO2, an antifreeze heater can be used by connecting the heater to a 1 VAC power source. This option includes a cable stand that secures the conduit cable, and a reel unit that holds the wire reel. Selectable reel units Mounted on cable stand [from YASKAWA] Mounted on floor [from CORPORATION] Water Circulator This is a water circulation device for water-cooled torches. A single-phase 2 VAC must be used for this device. Selectable types WR1 [from CORPORATION] Water hose length: 1 m, 1 m, 2 m 21

22 Solution 4 Welding Positioner MOTOPOS is a welding positioner that is exclusive for MOTOMAN. It supports high-quality welding by securing optimal welding postures. Wide Variety of Products We have an extensive model lineup, including models with a payload of 2 kg to kg, models with one to two axes, and cantilever models that can weld the back of workpieces. Choose an optimum turntable and positioner for your production line to improve welding quality and efficiency. Cantilever type D2B-C DB-C DB-C1 (Space-saving model) 2 D2F Number of Axes 1 D2B S2B DB D7B SE (High-speed model) SB S1B T2E (High-speed model) T2B TB SF SB-A3 (Low-cost model) 2 2 Features Payload kg Wide Variety of Products Our product lineup features one-axis positioners and two-axis positioners with a wide range of payloads, as well as turntables. We can recommend optimal positioners for each customer s system, depending on the type of application. High Precision A single controller that exclusively controls MOTOMAN enables highly accurate coordinated operation by applying a control system designed specially for MOTOMAN robots and MOTOPOS. Coordinated welding with MOTOPAC-W series arc welding package and MOTOPOS The robot and MOTOPOS weld in coordination at a constant speed, allowing the workpiece and the torch to keep the best posture at all times. This reduces partial penetration and distortion, and greatly improves welding quality. : The MOTOPAC-W series is a welding package that includes a robot, a welding power supply, and a torch. 22

23 Solution 4 One-axis Positioners Standard : One axis, 2//1 kg payload Specifications MOTOPOS-SF MOTOPOS-SE Payload kg kg Type Standard Standard With Rotary Joint Model YR-MPSF-A YR-MPSE-A YR-MPSE-B Allowable Overhang 34 mm (from the rotating plate with a kg load) 34 mm (from the rotating plate with a kg load) Rotational Angle Max. Rotational Speed 3.32 rad/s (19 /s) 4.71 rad/s (27 /s) Allowable Moment 9.6 N m 9.6 N m Allowable Moment of Inertia (GD 2 /4) 3 kg m 2 3 kg m 2 Repeatability ±. mm (R=2 mm) ±.1 mm (R=2 mm) Approx. Mass 1 kg 1 kg Internal I/O Wire. mm 2 6 cables Internal Air Hose 3/8 inch 2 hoses Power Requirements.3 kva. kva Specifications MOTOPOS-SB-A3 MOTOPOS-S1B Payload kg 1 kg Type Optional Mounting Base Type 2 Standard With Rotary Joint Model YR-MPSB-A3 YR-MPS1B-A YR-MPS1B-B Allowable Overhang 34 mm (from the rotating plate with a kg load) 6 mm (from the rotating plate with a 1 kg load) Rotational Angle Max. Rotational Speed 2.18 rad/s (12 /s) 1.92 rad/s (11 /s) Allowable Moment 9.6 N m 24 N m Allowable Moment of Inertia (GD 2 /4) 3 kg m 2 2 kg m 2 Repeatability ±.1 mm (R=2 mm) ±.2 mm (R=2 mm) Approx. Mass 11 kg 3 kg Internal I/O Wire. mm 2 6 cables Internal Air Hose 3/8 inch 2 hoses Power Requirements.3 kva.8 kva 1: Endless rotation is available as an option. 2: Mounting bases are optional. Note: Secondary terminals for welding are provided as a standard feature. Two-axis Positioners One-axis Turntable Standard : Two axes, 2//7 kg payload Standard : One axis, 2/ kg payload Specifications MOTOPOS-D2F MOTOPOS-DB MOTOPOS-D7B Payload 2 kg kg 7 kg Type Standard Standard With Rotary Joint Standard With Rotary Joint Model YR-MPD2F-A YR-MPDB-A YR-MPDB-B YR-MPD7B-A YR-MPD7B-B Rotational Angle Max. Rotational Speed 3.32 rad/s (19 /s) 2.8 rad/s (16 /s) 2.8 rad/s (16 /s) Allowable Moment 196 N m 392 N m 686 N m Allowable Moment 17 kg m of Inertia (GD 2 /4) 44 kg m 2 7 kg m 2 Rotational Angle Max. Rotational Speed 3.14 rad/s (18 /s) 1.4 rad/s (8 /s) 1.4 rad/s (8 /s) Allowable Moment 39 N m 1274 N m 2842 N m Allowable Moment kg m of Inertia (GD 2 /4) 2 kg m 2 2 kg m 2 Repeatability.1 mm (R=2 mm).1 mm (R=2 mm).1 mm (R=2 mm) Approx. Mass 26 kg 24 kg 3 kg Rotation Axis Tilted Axis Internal I/O Optional Wire Internal Air Hose Optional. mm 2 12 cables AWG19 22 cables. mm 2 6 cables. mm 2 12 cables AWG19 22 cables. mm2 6 cables 3/8 inch 1 hose 3/8 inch 2 hoses 3/8 inch 1 hose 3/8 inch 2 hoses Power Requirements.4 kva.6 kva 1.1 kva : Endless rotation is available as an option. Note: Secondary terminals for welding are provided as a standard feature. Specifications MOTOPOS-T2B/TB Payload 2 kg kg Type (Standard) YR-MPT2B-A YR-MPTB-A Allowable Moment 612 N m 73 N m Allowable Moment of Inertia (GD 2 /4) 22 kg m 2 4 kg m 2 Rotational Angle Max. Rotational 1.4 rad/s (8 /s) Speed 1. rad/s (6 /s) Repeatability ±.3 mm (R=1 mm) Approx. Mass 4 kg 9 kg Internal I/O Wire Internal Air Hose Mounting Floor-mount only Power.8 kva Requirements Note: Refer to the "Turntable/Positioner MOTOPOS Series" (KAE-C94-431) catalog for details on other turntables and positioners..8 kva : For safety, a lock mechanism is provided at, 9, 18, and 27. Note: Secondary terminals for welding are provided as a standard feature. 23

24 Sales Department HEAD OFFICE 2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyushu, Fukuoka 86-4, Japan Phone: Fax: YASKAWA America, Inc. (Motoman Robotics Division) 1 Automation Way, Miamisburg, OH 4342, U.S.A. Phone: Fax: YASKAWA Europe GmbH (Robotics Division) Yaskawastrasse 1, 8391, Allershausen, Germany Phone: Fax: YASKAWA Nordic AB Verkstadsgatan 2, Box 4,SE-38 2 Torsas, Sweden Phone: Fax: YASKAWA Electric (China) Co., Ltd. 22F, One Corporate Avenue, No.222 Hubin Road, Huangpu District, Shanghai 221, China Phone: Fax: YASKAWA SHOUGANG ROBOT CO., LTD. No.7 Yongchang North Road, Beijing E&T Development Area China 1176 Phone: Fax: YASKAWA India Private Ltd. (Robotics Division) #426, Udyog Vihar Phase-IV, Gurgaon, Haryana, India Phone: Fax: YASKAWA Electric Korea Corporation 3F, Three IFC, 1 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 7326 Phone: Fax: YASKAWA Electric Taiwan Corporation 12F, No.27, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan Phone: Fax: YASKAWA Electric (Singapore) PTE Ltd 11 Lorong Chuan, #4-2A New Tech Park, Singapore 6741 Phone: Fax: YASKAWA Electric (Thailand) Co., Ltd. 9, 1st-th Floor, Flourish Building, Soi Ratchadapisek 18, Ratchadapisek Road, Huaykwang, Bangkok 131, Thailand Phone: Fax: PT. YASKAWA Electric Indonesia Secure Building-Gedung B Lantai Dasar & Lantai 1 Jl. Raya Protokol Halim Perdanakusuma, Jakarta 1361, Indonesia Phone: Fax: In the event that the end user of this product is to be the military and said product is to be employed in any weapons systems or the manufacture thereof, the export will fall under the relevant regulations as stipulated in the Foreign Exchange and Foreign Trade Regulations. Therefore, be sure to follow all procedures and submit all relevant documentation according to any and all rules, regulations and laws that may apply. Specifications are subject to change without notice for ongoing product modifications and improvements. 216 YASKAWA ELECTRIC CORPORATION LITERATURE NO. CHEP C C <4>- Published in Japan April