“Learning Material –Painting Robot”

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Created By : Alif Prayoga

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 Robot control sequence Diagram

Interlock

Controller
Conveyor

Robot
Buzzer
Lamp
PCS

PC
Rellay
MCP panel

Highspeed
Device Net
PLC : 1756-L72S counter
module
E-Net
module

Safety Barrier DeviceNet

Rellay Encoder
Photo Sensor
Light Curtain
Limit Switch
Door switch

1734-ADN Yaskawa Robot

E-Stop

OP Desk MIP Scanner 1756-L72S

( DX 200)
Module
Conveyor

safety device
ASH
PCS

Fire

Servo Amp

Turbin Board

Rellay
GNM
MPX3500

Interlock Robot
Pneumatic panel

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 Controller robot

 DX200
DX200 consists of the painting unit part and the standard unit part.

Painting Unit

Standard Unit

The robot controller has a built-in microcomputer that controls all motion of the robot by saving motion signals when
teaching and sending these signals to the manipulator. The power unit that supplies power to the manipulator is also
built into the robot controller.

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DEVICE BOARD OVERVIEW

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 Board function description

1. Power on unit (JZRCR-YPU51-1)

The power ON unit consists of the power ON control circuit board (JARCR-YPC21-1) and the main circuit contactor and the line
filter. It turns the main circuit control contactor ON and OFF using the signal for the servo power control from the machine safety
I/O logic circuit board, and supplies power(3-phase AC200/220V) to the converter. The power supply (single phase
AC200/220V) is supplied to the control power ON unit via the line filter.

2. Control Power Supply Unit (JZNC-YPS21-E)

This unit (JZNC-YPS21-E) supplies the DC power (DC5V, DC24V) for control (system, I/O, break). It is also equipped with the
input function for turning the control power supply ON and OFF.
3. Robot IF circuit board (JANCD-YIF01-2E)
The robot I/F circuit board (JANCD-YIF01-2E) controls the entire robotic system. It is connected to the CPU circuit board (JANCD-
YCP21-E) with a PCI bus interface on the back circuit board, and to the major axes control circuit board (SRDA-EAXA21A) with
high-speed serial transmissions.
4. Machine safety CPU circuit board (JANCD-YSF21-E)
This circuit board (JANCD-YSF21-E) performs I/O processing or diagnosis processing for the safety sequence, and it is connected
with the CPU circuit board (JANCD-YCP21-E) by the PCI Express bus I/F in the back circuit board. It is also connected with the
machine safety I/O logic circuit board by the high speed serial communications (two lines).

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 Board function description

5. Universal I/O Unit (JANCD-YIO21-E)

Four digital I/O connectors for the robot universal I/O are provided: 40 inputs and 40 outputs. The I/Os are divided into two
types: universal I/O and specific I/O. The I/O assignment differs depending on the application. Specific I/O is a signal in
which the part is decided in advance. Specific I/O is used when the external operation equipment such as positioner controller
and centralized controller control the manipulator and related equipment as a system. Universal I/O are mainly used as
timing signals for the manipulator and peripheral devices in jobs that require robot motion.

6. Brake Circuit Board (JANCD-YBK21-3E)

The break control circuit board controls ON/OFF of the breaks of total nine axes (Robot + external axes) according to the
command signal from the major axes cotrol circuit board (SRDA-EAXA21A).
7. Major Axes Control Circuit Board (SRDA-EAXA21A)
The major axes control circuit board controls the servomotors of the manipulator’s six axes. It also controls the converter and the
PWM amplifiers. Mounting an external axes control circuit board of an option (SRDA EAXB21A) makes it possible to control the
servomotor of nine axes, including the robot axes.
8. Converter (SRDA-COA30A21B-E)
The converter (SRDA-COA30A21B-E) exchanges the power supply (3-phase: AC200/220V) supplied by the power ON unit for DC
power supply and supplies the power to the amplifier module (PWM amplifiers).

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 Board function description

9. Machine Safety I/O Logic Circuit Board (JANCD-YSF22-E)

I/O Logic Circuit Board (JANCD-YSF22-E) This circuit board contains dual processing circuits for safety signal and the I/O
circuit for the un-safety signal. It processes external safety signals with the dual processing circuits and control ON/OFF of
the main circuit control contactor of the power ON unit according to conditions.

10. Amplifier Module (SRDA-SDA ☐ A01A-E)

The amplifier module exchanges the DC power supply supplied by a converter for a 3-phase motor power source and outputs
to each servo motor.
11. Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E)
The machine safety terminal block circuit board (JANCD-YFC22-E) is for the system external signal to connect with the safety
I/O signals.

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Pneumatic Air Panel

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 Shaping Air Diagram

 Shaping Air (lpm)

S/A Controller

Joint to Quick Disconnect

Hose size Hose size
Ф16x12 Ф10x8 Vortex : 24A, 24B

Hose size Straight : 25

Ф16x12 Hose size
Ф10x8
S/A Sensor S/A A.O.P.R

3-types O-Ring in inner shroud

Air Panel ROBOT(EPX2900)

(Out BOOTH) (In BOOTH)

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 Turbine air line View

 Turbin Board control

Speed Air Sol
The purpose of the module is to control and visualize
(SOLENOID V/V) the rotation of an air turbine. The turbine shaft drives a
spraying basket used to spray fine paint droplets.
Turbine speed instructions are generated by the turbine
Joint to Quick Disconnect
speed control module from a 0 /10V input set-point and
forwarded to the proportional solenoid valve.

Good to Know
Phonic Reading
Compressed air (adjustable pressure) passes through a
Electric Signal
pipe and reaches the turbine. The wailing sound
Sound Wave
Air Panel ROBOT(EPX2900) produced by the rotating turbine is collected by the
(Out BOOTH) (Out BOOTH) microphone and transmitted to the turbine speed
control module where the phonic signal is amplified
Maximum Speed before being sent to the “speed measuring” device.
Excessive turbine speed can cause considerable damage to the turbine. The speed must not exceed 65000 rpm. Phonic signal amplification can be adjusted through
potentiometer P11.

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 Connection Diagram  Adjustment – Set Point

220 V

TN 5071 power
supply board

Inside robot
External setpoint 15VDC 24VDC
24VDc Turbin speed optical
reading
Optoelectric case

Stop Signal
Turbin Turbin speed Phonic Turbin
Speed overriding
signal speed reading
PLC
control Proportional
“OK board” solenoid valve
monitoring signal module Turbin speed control
signal
Breaking
Turbin speed pattern Braking control signal solenoid valve
(0/6V )

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 Turbin speed control Connection

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 High voltage – Internal charge diagram

1 Control module GNM 2000

2 Low voltage connection

3 Dump return line connected to the ground

potential
4 High voltage unit UHT 157

5 Supplies of paints and rinsing product

connect to the ground potential.
6 Paint fittings connected to the ground
potential into the atomizer
7 Safety distance (area around and atomizer
head from the parts with high
voltage,outer cover, bell cup, etc

Receives a low voltage supply that it converts into high voltage for charging the atomized paint particles; these are attracted to
the surface to be painted, which has a ground connection.

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 GNM200
The GNM 200 control module is used to manage the high voltage generated by an electronic device known as the
High Voltage Unit (HVU).

List of Parameters  Fault

There are three types of fault: startup faults, minor faults and major faults.
• Startup faults can be reset by switching the mains power supply to the GNM 200 OFF
then ON again.
• Minor faults can be reset by switching a trigger ON/OFF. Pressing key x confirms that
the message has been read.
• To reset after a major fault:
1 - the trigger must be switched OFF
2 - the mains power supply to the GNM 200 must be switched OFF/ON
3 - the trigger must be switched ON
 Example major fault

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 GNM 200 A  UHT 157

 Electrical Input  Electrical characteristics

 Spare parts
 Electrical Output

Good to know !
What is dielectric grease function ?
•Helps prevent voltage leakage
•Helps insulate the electrical connection in frigid conditions
•Protects against water damage
•Protects against corrosion
•Protects against dirt and grime
•Protects against heat damage
•Protects against material bonding
•Protects against electrical overheating

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 High voltage connection diagram

Annalog command

HV Trigger ON

Low voltage cable Terminal Low voltage cable

PLC Voltage feedback GNM 200
Cable color : Black line block Cable color : Red and white color

Current feedback

HV OK Signal

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  High voltage Connection

Pin connector B

High voltage output

100kV 200 μA

Pin connector C UHT 157

Low voltage cable

Low Voltage Box

C B

Pin connector A

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 High voltage Connection

Pin connector A

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 Paint Flow

Bell Wash Block PUMP Dump

 CCV-B
Sol
Is a compact and modular design allows adding
Air
several components . Each slice allows the use of
Pump Dump RF_BOCK two CCV valve for paint flow.

 A.O.P.R
Paint Supply
The regulator absorbs the variations of paint
PPH Dump pressure generated by the supply system (pulsation
effect) and adjusts the target flow for accuracy. For
Sol
Air
a given pilot air pressure of the regulator, the paint
flow will also depend on the pressure drop
downstream of the regulator (on sprayer side)
Rinsing Block
PPH Dump

FGP Sol FGP Dump  FGP

It controls fluid flow, enabling high paint
CCV_B A.O.P.R FGP RF_Block quality through precise paint discharge and
Color Air Fluid Reverse PPH 707
Change Operated Gear Flush Hi-TE EC 50 transfer.
Valve Pressure Pump Block
Block Regulator  RF-Block
6-COLORS 3Bar setting 6cc/1cycle PPH Dump Reverse Flush is a block that allows dumping and
Pump Dump
Paint Supply rinsing the product supply system without going
through the sprayer.

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 FGP Diagram
Power In

Encoder signal

MCP
PLC Explosion proof servo Motor
FGP
200w (FMAEX-02-AA00)

Digital in
Digital Out
Analog in Device Net
Analog out Paint Supply
Encoder signal
Servo motor for
Servo amp Power Out
FGP

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 Servo Amp Connection

13 Stop/Run

15 CCW lim
18 Servo ON
20 Servo alarm

21 Servo ready

22 Speed OK

24 In Common
25 In Common
27 Servo Speed Command
33 GND

38 Alarm Reset

39 E-Stop
40 CW lim

46 Tourque Out

47 Zero Speed

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 PC & Driver Communication software

Software Name : P-DORI

RS232C

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 PC-Type Serial Communication Cable Line View

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 Interlock

Hard wire connection

Air Panel Controller

 Interlock robot
Robot to Fire Fire to Robot Robot to Conv Conv to Robot Robot to PCS PCS to Robot Robot to booth booth to Robot

- Fire condition Robot E-Stop Conv Running To PCS production Input common Robot E-Stop Booth
condition
- - Robot E-Stop Input Common To PCS Idle PCS 1-5 ready
- -
- - Body In pemit In position spare PCS spare
- -

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  Interlock Conveyor

 Electrical drawing  Electrical drawing

Conveyor interlock to robot Robot interlock to
Conveyor

SC1 running (F1002CR)

Robot ready (CR0E8)
SC1 no fault (F1006CR)
Robot E-Stop OK(CR0E9)
SC2 running (F1012CR)
SC2 no fault (F1016CR)

 Device Picture
 PLC Logic  Device Picture  PLC Logic

Need picture
rellay

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  Interlock PCS
 Electrical drawing
PCS interlock to robot  Electrical drawing Robot interlock to PCS
To PCS production (CR0EB)
CKP ready (F4702CR) To PCS Idle (CR0EC)
BC1 ready (F5102CR) (1756-OB32)
BC2 ready (F5104CR) - CKP Work and sleep signal
BC3 ready (F5106CR) - BC1 Work and sleep signal
BC4 ready (F5108CR) - BC2 Work and sleep signal
BC5 ready (F5110CR) - BC3 Work and sleep signal
CC ready (F5402CR) - BC4 Work and sleep signal
- BC5 Work and sleep signal
- CC Work and sleep signal
 PLC Logic
 PLC Logic

 Devie Picture  Device Picture

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  Electrical drawing Interlock Fire  Electrical drawing
Interlock Booth

Booth air condition OK

 PLC Logic

 PLC Logic

 Devie Picture  Devie Picture

Picture rellay

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 DeviceNet

PLC DeviceNet

Point I/O Point I/O Point I/O

DeviceNet DeviceNet DeviceNet
1734-ADN 1734-ADN 1734-ADN

Call Air
Servo Remote Play Teach External Alarm Purge Minor
master Etc Pressure Etc
ON mode Mode Mode start reset complete alarm
job alarm

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 DeviceNet
PRIMER (1756-DNB-DN1)

1756-DNB-DN1  Device NODE

DEVICE NODE
R1 DX200 9
R2 Robot 11
R1 SOL 49
R2 SOL 50
L1 DX200 1

L1 SOL 48
OP 26

MIP 26
SCANNER 27

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 DeviceNet
PRIMER (1756-DNB-DN2)

1756-DNB-DN2

 Device NODE

DEVICE NODE
SAD1 9

SAD2 11

R1 AP 49
R2 AP 50

L1 AP 1

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 DeviceNet Node
 BASE (1756-DNB-DN1)  BASE (1756-DNB-DN2)  CLEAR (1756-DNB-DN1)  CLEAR (1756-DNB-DN2)
DEVICE NODE DEVICE NODE
DEVICE NODE DEVICE NODE
R1 DX200 9 SAD1 50
R1 DX200 9 SAD1 50
R2 DX200 11 SAD2 51
R1 SOL 49 SAD2 51
R3 DX200 13 R1 AP 25
L2 Robot 11 R1 AP 25
R1 SOL 49 R2 AP 30
L2 SOL 50 L2 AP 5
R2 SOL 50 R3 AP 35
L1 DX200 1 L1 AP 1
R3 SOL 51 L1 AP 1
L1 SOL 48
L1 DX200 1 L3 AP 10
OP 25
L3 DX200 5 L4 AP 15

L4 DX200 7
OPD 25
L1 SOL 45
L3 SOL 47
L4 SOL 48
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Module I/O 1734-ADN is common device that use to connect I/O from robot to PLC

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 Robot Software Interface

Cimon Paint Table

• Robot move and job • Sequence

• Robot, conv, booth alarm • Body definition
• Interlock status • Color definition
• I/O signal monitoring • Atomizer parameter
• Device status monitoring • Alarm parameter
• Robot external control • System parameter
• Device bypass • Auto id

*Cimon : Monitoring and control *Paint Table : Parameter setting

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  Cimon

Screen view

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 Cimon

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 Function window screen
In the PLC menu is a collection of
signal node status or topology in
the robot system
This is a collection of interlock
states on the robot. namely
interlocks from ASH, PCS, and
Conveyor
This is a collection of robot
interference signal status in
each robot
This menu does not use
"BLANK"
In this menu is a display for set
and actual parameters such as
Flow rate, Turbine speed, HV,
Shapping water parameters.
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In this menu is a display for the
pilot valve manual trigger or
parameter checking manually.
In this menu is a collection of unit
data that has finished the spray
process
In this menu is a display to display all
zones or areas such as Clear robot ,
Primary and base. This can be
accessed on all PCs in the Robot area
In this menu is a display to display
a zone or area according to the PC
robot.
In this menu is a collection of
alarm messages from what has
happened or is currently
happening
In this menu is a collection of
switches or commands for By pass
robot, Trun On/Off Spray, and
commands for checking Flow rate
In this menu is a collection of switches
or commands for By pass robot, Trun
On/Off Spray, and commands for
checking Flow rate
In this menu is a trend to find out
the auto ID sensor, Body Re-check
and the database for barcodes.
The barcode data base is only
listed on the Primary Robot PC.
In this menu is a collection of
commands for maintenance, to by-
pass Light curtain, to degrade mode
and also to by-pass interlock ASH.
  Paint Table

toolsbar on Paint table

to setting parameter

Login to modify

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 Every robot, have 40 slot data whose can
editable and connected to PLC when you
download it after changing

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 Communication Line paint table

Command &
Feedback • ROBOT

 PLC Robot (Device Net) Parameter Setting

Communication & Interface and • Paint Table

Feedback communication

Actually for Setting control

• PLC PCS (Device Net)
for robot we can use in Paint
table but not all only some
data and parameter which
engineer want to show up in
Paint Table

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 ROBOT PLC

 PLC controller specification

 Ip address of PLC robot

Robot Primer PLC : 10.137.9.64
Robot Base PLC : 10.137.9.65
Robot Clear PLC : 10.137.9.66

 Device on backplane PLC on MCP

Module for safety device

Communication module
Module DeviceNet
Highspeed counter module
Module digital Input

Module digital Output

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Robot program consist of 5 program and 1 safety program

Contain all of routing sequence and interlock spray robot

Contain program of operator control desk
Contain Sequence and interlock proses robot
Contain Sequence and interlock proses robot
Contain Sequence and interlock proses robot

Contain Signal and program from safety device

In program “Zone” have 9 routine

Contain program jump sub routine to other routine

Contain all of robot alarm, conveyor alarm, booth condition alarm, and PCS alarm
Contain Robot condition, PCS condition, Device net condition, and scanner condition
Contain all of routing and data spray car type and color processing
Contain sequence and process ghost mode
Contain signal Data MIP input, robot input, encoder input , HMI input
Contain MIP processing program
Contain HMI output, indicator output, to robot output
Contain data processing robot zone spray
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In program “OPDESK” have 5 routine

Contain program jump sub routine to other routine

Contain Output indicator in OP desk
Contain input robot status
Contain Program control operation OP desk
Contain all output signal from OP desk

In program “RBT” have 11 routine

Contain program jump sub routine to other routine

Contain Alarm robot
Contain Feedback and send signal analog to FGP,HV,Spray,Turbin
Contain program from and to HMI
Contain Signal input robot
Contain Signal Output robot
Contain status robot in production and status job robot
Contain program rinse robot
Contain status operational robot, status control robot, robot position, E stop robot
Contain program control sequence spray, GNM and atomizer
Contain body data definition

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 Thank you

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