Safety and Notice. 1. Safety Information. 2. Description Related to Safety

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2 Safety and Notice 1. Safety Information Safety Responsibility and Effect This safety information neither contains how to design, install and run a complete workstation or production line, nor ensure the whole system safety. In order to guarantee the safety of human body, all machines must be designed and installed according to the industrial safety regulations. Users of HIWIN robot have the responsibility to design and install the safety devices in compliance with the industrial safety regulations, used to protect the safety of human body. In compliance with the safety information on industrial robot described in this manual can't guarantee that HIWIN robot will not occur any safety problems. Connection of external safety device Besides the built-in safety loop, the robot also provides an interface for external safety device, which can receive external signals to control the robot. 2. Description Related to Safety I. Safety Symbol Please carefully read and make sure to follow this manual before operating the robot. The following are the safety symbol used in this manual. Symbol Description Not following the description of this symbol will cause serious personal injury. Please make sure to follow those requirements to ensure safety. Not following the description of this symbol will cause personal injury or product damage. In order to guarantee the safe use of this product, please follow this regulation strictly. Not following the description of this symbol will result in improper operation. In order to guarantee the safe use of this product, please make sure to follow this regulation. 1

3 II. Safety Grade The following symbols are frequently used for safety notice. Please carefully read the following notices and always follow them before operating the robot. C01UE Do not store the machine in the environment with corrosion and flammable gas or close to the flammable object. Do not operate the machine in the environment with moisture, water or grease. Do not operate the machine at the place where the strong vibration or strong impact occurs. Do not immerse the electric wires into grease or water. Do not connect and operate the machine with wet hands. Please ensure the controller is grounded. Keep hands from the inside of the controller while it is connecting to the power or during operation. Do not touch the heat sink, the power supply or the computer while it is operating because of high temperature. Be sure power is disconnected prior to move, connect, check and maintain the controller, and ensure to operate under the condition of no electrical shock risk. The emergency stop switch must be installed in an appropriate location can be operated easily. When the robot acts abnormally, it could immediately stop the robot from causing serious safety problems. Do not open the controller cover without permission. If you have any questions, please contact our engineers. 2

4 Do not stand on the product or put heavy objects on it. Do not block the vent or put foreign objects into it. Please ensure the controller is fixed on the base. Do not pull the connector violently or twist the electric wires strongly. Do not frequently switch the power switch and the control button. Please ensure the robot, the emergency stop switch and the controller are function properly before performing any work. Do not shut off the power switch during the operation. Do not open, modify, disassemble and maintain the machine without permission. The power must be disconnected when the machine does not operate in a long time. All operations must be executed by the trained staff. The controller must be kept away from high voltage or components that may generate electromagnetic field which will lead to robot malfunction or damage. When the robot is used to demonstrate, the speed should keep low and always keep an eye on the operating condition to prevent the workpiece from dropping or the operator from the danger. Do not turn off the power of the controller when modifying the program or parameter. Otherwise, the data stored in the controller will be damaged. 3

5 3. Safety Notice I. Safety Risk i. Installation Ordinary Risk The installation procedures must follow this manual. The emergency stop switch must be installed at the place easy to operate, so that can immediately stop the robot system. The person who installs the robot must be trained and authorized. Always follow the installation and safety requirements described in this manual to ensure personal safety.. Risk without electric shock A safety area must be set outside the working range of the robot, and a safety device must be used to inhibit the personnel without permission. After the brake of a servo motor is released, the robot will be moved by the gravity and it may damage the operator. When installing or disassembling any mechanical parts, be aware of falling parts which may damage the operator. Be aware of high temperature produced by the controller. Do not allow any action of climbing the robot. ii. End effector The end effector can be classified as two types: A. Gripper: Used to load and unload, such as pneumatic gripper, electric gripper and vacuum sucker. B. Tool: Used to process, such as welding, cutting and surface treatment. C01UE The gripper-type end effector should prevent the workpiece from dropping or damaging when the robot presents the power error or other errors. More attention should be paid at the design stage. The end effector could be equipped with the control unit. The position must be noted to avoid the robot interference when installing. 4

6 iii. Pneumatic and Hydraulic Systems The tool-type end effector is usually equipped with high voltage, high temperature or active shaft. Special attention should be paid during the operation. More attention should be paid to the pressure remained in the pneumatic and hydraulic systems after the power is disconnected. The internal pressure must be released before the pneumatic and hydraulic systems are maintained. When the pneumatic and hydraulic systems are operated, the clamped workpiece could drop owing to the insufficient pressure or gravity. The pneumatic and hydraulic systems must be equipped with the relief valve, so that can be applied in an emergency. C01UE More attention should be paid to the pressure in the pneumatic and hydraulic systems several times more than the atmosphere pressure. iv. Risk caused by the working environment The industrial robots can be applied for the different industrial environments. All operating procedures must be specified by the professional evaluation and according to the industrial safety regulations. Maintenance must be conducted by trained personnel who clearly understand the procedures for the whole system and other possible risks. When the operating procedures are interrupted, the special attention should be paid during the troubleshooting. 5

7 II. Emergency Stop Definition The driver power and the control system will be disconnected to stop all actions during the emergency stop. All power sources will be disconnected while in the emergency stop. If you want to restart the procedures, you should reset the emergency stop switch. Emergency stop presents the immediate stop: Immediately stop the robot system, and disconnect the driver power. The emergency stop switch is used for emergency stop only. Avoid using the emergency stop instead of the normal stop procedure to shut off the robot system, or it may cause unnecessary damage to the robot system. Emergency Stop Switch The HIWIN robot is equipped with two emergency stop switches, where one is installed on the teach pendant and the other is directly connected to the controller via the wires. If other emergency stop switches are required, other connection can be applied for the same purpose. Based on the relevant industrial safety regulations, the emergency stop switch is directly connected to the controller of the robot via the physical wires. C01UE

8 Content 1. Introduction Target Group Robot References Representation of warnings and notes Safety Description Trademark Product Description Software Overview HIWIN ROBOT SYSTEM SOFTWARE (HRSS) Overview Safety General Relevant Staff Workspace, Safety Zone and Danger Zone Stop Trigger Safety Function Safety Function Overview Safety Function System Mode Selection Safety Device Emergency Stop Device Logout from Higher-level Safety Control System External Emergency Stop Device Enabling Switch External Enable Device External Safety Run Stop

9 External Safety Stop T1 Velocity Monitoring Additional Safety Device Jog Run Software Limit Switch Label on Robot External Safety Device Safety Measure General Safety Measure Transport Operation and Re-operation Manual Mode Simulation Automatic Mode Maintenance and Repair Decommissioning, Warehousing and Disposal Safety Measure for Single Point of Control Operation Teach Pendant Front view Rear View Remove and Insert Teach Pendant HRSS Interface Status Bar Status Display Submit Encoder Keyboard Connect to Control System, and Start HRSS C01UE

10 4.4. Open Main Menu Change User Group Change Run Coordinate System JOG Manual Move Jog Velocity Change BASE/TOOL Coordinate Teach Pendant Configuration Jogging velocity Ratio Axis-specific jogging with the jog keys Cartesian jogging with the jog keys Teach Pendant Alignment Display Display Actual Position Display Digital Input/Output Display Remote Input/Output Display External Functional Input/Output Display System Status Input/Output Display Robot Simulation Screen Display Counter Variable Display Timer Variable Communication TCP/IP Communication RS232 Communication Start-up and Recommission Check Parameters C01UE

11 5.2. Mastering Mastering Method Calibration Tool calibration TCP calibration: XYZ 4-Point Method Enter Value Base calibration point Method Enter Value Program Management Document Navigator Open Program HRL STRUCTURE Home Position Start Program Select Program Running Program Running Set Program Ratio Driver status Decoder Status Display Start a Program (Manual) Start a Program (Auto) Start External Auto Run Edit Program Delete Program Line Additional editing functions Backup and Recovery Data C01UE

12 Backup Data Recovery Data Motion Program Design Motion Overview Point-to-point (PTP) Motion LIN Motion CIRC Motion Blend LIN and CIRC Motion Singular Point Programming with inline forms Name in Inline Form Programming for PTP, LIN and CIRC Motion Programming for PTP Motion Programming for LIN Motion Programming for CIRC Motion Variable Configuration Declare a Variable Use Counter Variable Use Timer Variable Programming for Logic Command Input/Output OUT WAIT WAIT FOR LOOP IF C01UE

13 While Communication Configuration RS Ethernet Error Message Error Message for System Error Message for Motion Controller Error Message for Motor Driver C01UE

14 1. Introduction 1.1. Target Group This reference is designed for the users who have the following knowledge: With basic knowledge for the robot We recommend our customers be trained on HIWIN so that can use our products in the best way. For the training information, please our website or directly obtain from our branch Robot References The robot references comprise the following parts: Articulated Robot RA605 Controller Manual Articulated Robot RA605 Manipulator Manual Each copy of guide is independent Representation of warnings and notes Please carefully read and indeed obey this manual before operating the robot. In addition, the following symbols must be understood to avoid the personal danger and product damage. Symbol Description If you don t obey the description of this symbol, the major injury could take place. In order to guarantee the safe use of this product, please indeed follow this regulation. If you don t obey the description of this symbol, the major injury or product damage could take place. In order to guarantee the safe use of this product, please indeed follow this regulation. If you don t obey the description of this symbol, the improper product operation could take place. In order to guarantee the safe use of this product, please indeed follow this regulation. 13

15 1.4. Safety Description Please carefully read the following notices and indeed obey them before operating the robot. Please turn off all power prior to the maintenance and service. The end-effector must be firmly installed on the robot to prevent workpiece from dropping during the operation, which could cause person injury or danger. It is recommended the way in this manual be applied when the robot is transported. The other ways to transport could cause the robot to drop and injury. A device that can immediately stop the procedure in progress is prepared. Provide the external fence for the workstation to avoid contacting the operator when the robot runs. Check the robot and the emergency stop switch normally work prior to the operation. The operation of the robot in the conditions not allowed could cause the danger of the human body or machine failure. The robot is indeed fixed. The unstable installation of the robot could cause the position shift and vibration. Don't excessively bend the cable. Otherwise, the bad contact could take place. In order to ensure the weight of the workpiece, it must not exceed the rated payload of the robot and tolerant torque. Otherwise, the driver alarm or failure could take place. Don t modify without permission or employ original parts. If you don t obey, it could cause error or failure. 14

16 All operations must be executed by the trained staff. The cables should be kept away from noise. If they are placed near noise, the robot could shift or fail. The velocity of the robot should be kept as low as possible, and the operating condition is observed at any time. Otherwise, the workpiece could drop or the operator will suffer from the danger. Don't turn off the power of the controller when you modify the program or parameter. Otherwise, the internal data will be damaged Trademark Windows is a trademark of Microsoft Corporation. WordPad is a trademark of Microsoft Corporation. 15

17 2. Product Description 2.1. Robot Overview The robot comprises the following parts: Robot Controller Teach Pendant Cable Software Figure 2.1 Robot illustration 1 Robot 2 Cable 3 Control System 4 Teach Pendant 16

18 2.2. Software Overview Overview Some of the following software will be applied: HRSS Windows XP Embedded 2.3. HIWIN ROBOT SYSTEM SOFTWARE (HRSS) Overview Description The HIWIN Robot System Software (HRSS) is in charge of all basic functions for the robot. Path planning I/O management Data and file management HRSS The interface for HIWIN's interface is called as HIWIN ROBOT SYSTEM SOFTWARE (HRSS). Features: User management Program editor Robot language Inline forms for programming Message display Configuration windows etc. According to the user setting, the operation interface could be different from the standard type. 17

19 3. Safety 3.1. General Responsibility description The equipment described in this document not only can be the robot, but also one of components. Components of robot: Robot Control System Teach Pendant Cable Software The robots meet the current level of technology and safety regulations. Even so, in violation of employment could cause the injury of human body, the damage of the robot system and other equipment. The robot can be run only when it is at the normal state and the safety device is installed. You must follow the references and the installation description supplied by the shipment. The failure related to the safety must be solved in time. The HIWIN is dedicated to provide the reliable safety information, but we don't take responsibility. Although all operations are conducted according to the safety operation, the robot can't guarantee it will not cause the loss of human body and property. Without our written permission, the robot must not be modified. The accessories (tools and software) not belonged to the HIWIN could be brought into the robot. If the robot is damaged by these parts, the providers should take responsibility. Except for the safety section, other safety hints are included in this reference. These must be noted too. The robot is employed according to the regulations. The robot only allows mentioning the purpose of the section "Specified Purpose" in the operation instruction or the installation instruction. For other information, please see the section "Specified Purpose" in the operation instruction or the installation instruction. Other usages are not allowed. The manufacturers will not take responsibility for this loss. The providers take risk only. The usages must follow the operation instruction and the installation instruction, especially the maintenance. 18

20 Violation All usages which don't meet the regulation are not allowed, including: Transport people and animals Auxiliary tools for climbing Operation outside the permissible operating parameters Usages in the explosive environment Usages without safety device Outdoor usages Conformance Statement and Installation Description This robot can allow running when the following prerequisites are satisfied: The robots have been integrated into the equipment. Or the robots have been integrated with other machines into the equipment. Or the robots have been equipped with all safety functions and safety devices. Conformance Statement The system providers must prepare a copy of conformance statement in compliance with machinery directive for the whole equipment. The robots can be run only according to the national laws, regulations and standards. Installation Description The robots are installed with the machinery directive when not supplied as the whole set. The system providers should keep the installation description and appendix as a part of technical documents. 19

21 Concept of usage STOP 0, STOP 1 and STOP 2 are defined according to EN :2006. Concept Axis range Stopping distance Workspace Operator (User) Danger zone Teach Pendant Robot Safety zone Description The allowable motion is in unit of degree or mm. The motion of each axis must be defined. Stopping distance = reaction distance + braking distance The stopping distance is a part of danger zone. The robot can move in the workspace, which is derived from the individual axis ranges. The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. The danger zone includes the workspace and the stopping distance. The teach Pendant provides the operations and functions for the robot and program. Mechanical devices and electrical components The safety zone is out of the danger zone. 20

22 STOP STOP 0 Concept Safe Stop STOP 1 Safe Stop STOP 2 STOP TYPE 0 STOP TYPE 1 STOP TYPE 2 Description The safe stop is a kind of stop monitoring. It doesn't stop the robot, but monitors whether the axis is still. If the axis moves during the safety stop, STOP 0 will be triggered. The safety stop can be triggered by the external trigger. If the safety stop is triggered, the control system will trigger an output via a bus. If all axes don't stop during triggering the safety stop and STOP 0, that output will be triggered as well. A stop triggered and executed by the control system. The control system immediately disconnects the brake driver and power. Hint: That stop type in file is called as STOP 0. The safe stop is a kind of stop triggered and monitored by the control system. That brake process is executed by the control system and components independent on the safety. Upon the robot is still, the control system will disconnect the brake driver and power supply. If STOP 1 is triggered, the control system will trigger an output via a bus or it can be triggered by external signal. Hint: That stop type in file is called as STOP 1. The safe stop is a kind of stop triggered and monitored by the control system. That brake process is executed by the control system and components independent on the safety. The drive is kept at the connection state, and the brake is turned on. Upon the robot stops, the stop will be triggered. If STOP 2 is triggered, the control system will trigger an output via a bus or it can be triggered by external signal. Hint: That stop type in file is called as STOP 2. The drive device is immediately disconnected, and the brake is activated. The robot and the external axis (optional) perform path-oriented breaking. Note: That stop type in file is called as STOP TYPE 0. The robot and the external axis (optional) perform path-maintaining breaking. The drive device is disconnected in one second, and the brake is activated. Note: That stop type in file is called as STOP TYPE 1. The drive device isn't disconnected, and the brake isn't activated. The robot and the external axis (optional) pass a slope to brake. Note: That stop type in file is called as STOP TYPE 2. 21

23 Concept System provider (equipment integration) T1 T2 External axis Description The system providers indicate those who can integrate the robots into the whole equipment according to the safety and conduct a trial-run. Manual reduced velocity test (<= 250 mm/s) Manual quick-velocity test (allowance > 250 mm/s) Not belong to the robot but the motion axis controller by the control system, for example, HIWIN S linear guideway and turn-tilt table 3.2. Relevant Staff Define the following staff or group for the robot: Operator Work staff All persons who work on the robot must carefully read and understand the references related to the safety sections. Provider The providers must follow the labor laws, including: The providers must fulfill the obligation to monitor. The providers must periodically provide training and instruction. Work Staff The relevant staff should describe the work, the scale and the potential danger prior to the work, as well as periodically the instruction. In addition, the instruction must be made again when each accident takes place or after the technology is modified. The relevant staff includes: System providers The users can be classified as: 1. Operators 2. Engineers 3. Experts Only the trained staff can install, replace, configure, operate, serve and maintain according to the operation guide for each component on the robot. 22

24 System provider The robot must be integrated into a set of equipment by the system providers according to the safety. The system providers must take responsibility for the following works: Install the robot Connect the robot Evaluation the risk Use the necessary safety function and safety device Issue conformance statement Stick CE label Prepare for the operation guide User The user must satisfy the following conditions: The user must receive the training. The operations on the robot are executed by the professional persons only, who are trained, have the knowledge and experience, get familiar with the regulations, correctly determine the work and identify the potential risk. Illustration The tasks can be assigned according to the following table. No. Function Operator Engineer Expert Function table 1 File x x o 2 Configuration>User group o o o 3 Display x o o 4 Diagnosis>Logbook o o o 5 Start-up>Calibrate x x o 6 Start-up>Master x x o 7 Start-up>Robot data x o o 8 Start-up>Network Config x x o 9 Start-up>RS-232 x x o Interface 11 Message box o o o 12 Velocity configuration x o o C01UE

25 No. Function Operator Engineer Expert 13 Tool/base coordinate x x o 14 Position configuration for teach pendant x o o 15 Change JOG coordinate system x o o 16 Manual reduced velocity JOG x o o 17 On-screen keyboard o o o 18 Remove teach pendant x o o 19 Step execution x x o 20 Programming o o o 21 Program selection o o o 22 Modify program x x o 23 Tool/base calibration x o o 24 IO operation x o o 25 Functional IO modifycation x x o C01UE Only the professional staff can be allowed for the electrical or mechanical work on the robot. 24

26 3.3. Workspace, Safety Zone and Danger Zone The Workspace must be limited within the minimum range. The safety devices (such as the safety door) must be located in the safety zone. The robot and the external axis (optional) are braked to stop in the danger zone during the stop. The danger zone includes the Workspace and the stroke to stop the robot and the external axis (optional). That area where the safety devices can pass should be protected from the loss of the staff or the property Workspace 2. Robot 3. Stopping distance 4. Safety zone Figure 3.1 Illustration of axis A1 25

27 3.4. Stop Trigger The robot will stop when the failure information appears during the operation or monitoring. The following table lists the relation of the stop response and run. Trigger T1,T2 AUT, AUT EXT Release the Start Button STOP 2 - Press the Stop Button STOP 2 (stop 2) Disconnect the drive device STOP 1 (stop 2) No "run allowance" at input STOP 2 (stop 2) Disconnect the control system (power disconnection) STOP 0 (stop 2) Internal failure in the control system not related to the safety STOP 0 or STOP 1 (depend on the failure reason) Operating mode changed SAFETY STOP 2 Open the safety door (safety device) - SAFETY STOP 1 Release Enabling Switch SAFETY STOP 2 - Press Enabling Switch or failure SAFETY STOP 1 - Trigger T1,T2 AUT, AUT EXT Trigger emergency stop SAFETY STOP 1 The failure in the control system or peripheral SAFETY STOP Safety Function Safety Function Overview The robot provides the following safety functions: Operation Selection Safety Device (= used for an interface that locks the isolated safety device) Emergency Stop Device Enabling Switch External Safety Run Stop External Safety Stop 1 External Safety Stop 2 T1 monitoring 26

28 The robot can provide the following functions: The Emergency Stop Button must be pressed once every six months. The safety functions are involved in the following components: The control system in PC Teach Pendant Cabinet control unit (CCU) In addition, there are interfaces for external components and other control systems If the safety guards and the safety functions are not functioned, the robot could cause the loss of the staff or the property. When the safety and the safety device are cancelled to start or removed, the robot will not be allowed to run. When you plan the machine, the safety functions have to be planned and designed. The robot must be integrated into the system Safety Function System The control system is a unit to control the PC. It can connect with safety and monitoring signals. Work on the control system: Disconnect the driver, trigger the brake. Monitor the braking ramp. Stop monitoring (after stop) T1 monitoring Evaluate the signals related to the safety Trigger outputs related to the safety Mode Selection The robot can run in the following modes: Manual reduced velocity (T1) Manual high velocity (T2) Automatic (AUT) Automatic External (AUT EXT) Don't change the run during programming. If the run is changed during programming, the robot will be stopped by STOP 2. 27

29 Mode Application Velocity T1 T2 AUT AUT EXT Used for run test, programming and instruction Used for run test Used for robot without the higher-level controllers Used for the robot with the higher-level controllers (For example, PLC) Program verification: Programmed velocity, maximum 250 mm/s Manual reduced velocity: Manual reduced velocity speed, maximum 250 mm/s Program verification: Programmed velocity Manual reduced velocity: Unable to run Programming run: Programmed velocity Manual reduced velocity: Unable to run Programming run: Programmed velocity Manual reduced velocity: Unable to run C01UE Safety Device The signal for the safety device is used to lock the isolated device. Without this signal, automatic mode can't be applied. If the signal is lost during automatic mode (For example, the safety door is opened.), the robot will stop by STOP 1. In the Manual reduced velocity (T1) and Manual high velocity (T2), the safety device will not activate. After the signal lost appears, it will not be allowed only closing the safeguards to resume automatic operation but need to confirm. The system provider must take responsibility. It can avoid auto running when the staff stays in the danger zone and ignores to close the safety door. The danger zone where is set in advance must be actually checked. The confirmation for such setting is not allowed (automatically confirm when the safety device is closed). If this point is not noted, it could cause the person death, severe body damage or the property loss. 28

30 Emergency Stop Device The Emergency Stop Device is located at the Emergency Stop Button on the Teach Pendant. You must press this button when the danger situation or the emergency situation takes place. When you press this button, the robot will: Stop by STOP 1. If you want to continuously operate, you must rotate the Emergency Stop Button to unlock it. C01UE If the tools or other devices connected to the robot could cause the danger, they must be connected to the emergency stop loop at the machine side. If this regulation doesn't follow, it could cause the person death, the severe body damage or the property loss. An external emergency stop device should be installed at least to ensure it can be applied even though the teach pendant has been removed Logout from Higher-level Safety Control System If the control system connects to the higher-level one, that connection will be interrupted when it is disconnected. At this time, the control system will send a signal, so that the higher-level system will not trigger the emergency stop from the main machine. The system providers must take the risk evaluation into account. When the control system closes, the situation where the emergency stop isn't triggered is dangerous and how to respond the danger. If this isn't considered, it could cause the death or the severe body injury. When the control system closes, the Emergency Stop Button on the Teach Pendant will not enable. The providers should take responsibility to cover the Teach Pendant or remove it from the robot. The purpose is to avoid the confusion of the valid and invalid emergency stop devices. If that measure isn't noted, it could cause the person death, the severe body damage or the property loss. 29

31 External Emergency Stop Device The emergency stop devices must be installed on the workstation where the robot moves or other dangerous situation may take place. The system integrator is responsible for ensuring that. At least one external emergency stop device is installed to ensure the emergency stop device can be used even though the Teach Pendant has been unplugged. The external emergency stop device connects to the customer interface. The external emergency stop devices are not included in the scope of supply of the industrial robot Enabling Switch There are two Enabling Switches installed on the Teach Pendant. The enabling switches have three positions: Not pressed Center position Pressed (panic position) Only when an Enabling Switch is kept in the center position, the robot can run in the test run. Release an Enabling Switch to trigger a STOP 2. Press an Enabling Switch to trigger a STOP 1. Two Enabling Switches can be temporarily kept in the center position, so that can move an Enabling Switch to the other. If two Enabling Switches are kept in the center position for longer time, a safety stop will be triggered after several seconds. When the Enabling Switch fails (clamp), the robot can stop according to the following methods: Press the Enabling Switch. Press the Emergency Stop Device. Release the START key. C01UE No tapes or other materials are used to fix the Enabling Switch or using other ways to influence the functions. Otherwise, it could cause death, severe body injury or property loss External Enable Device When many people stay in the dangerous zone, the Enabling Switch must be applied. It can connect to the user interface on the control system. The Enabling Switch is not included in the scope of supply of the industrial robot. 30

32 External Safety Run Stop The safety stop can be triggered by the input on the user interface. When the external signal is FALSE, that state always keeps. When the external signal is TRUE, the robot can be operated again. No more confirmation is required here External Safety Stop The velocity on TCP is monitored in T1. If the velocity exceeds 250 mm/s owing to the failure, the STOP 0 will be triggered T1 Velocity Monitoring The velocity on TCP is monitored in T1. If the velocity exceeds 250 mm/s owing to the failure, the STOP 0 will be triggered Additional Safety Device Jog Run The control system can jog to complete a program in the manual reduced velocity (T1) and manual high velocity (T2). This means: you must hold an Enabling Switch and Start button to complete a program. Release an Enabling Switch to trigger a STOP 2. Press an Enabling Switch to trigger a STOP 1. Release a START button to trigger a STOP Software Limit Switch The axis ranges of all manipulator and positioner axes are limited by means of adjustable limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the manipulator/positioner cannot hit the mechanical end stops Label on Robot All nameplates, descriptions, figures and marks are related to the robot safety. They can't be modified or removed without permission. The label on the robot includes: Warning description Safety figure Name plate Rating Plate C01UE

33 External Safety Device The safety devices must be installed in such a way that the personnel cannot enter the dangerous zone. The providers should take responsibility for that work. The isolated safety devices must conform to the following requirements: In compliance with EN 953. Avoid the personnel entering the dangerous zone and not easily go over. Firmly fixed and endure the expected run and the environment influence. No danger exists and causes. The minimum distance to the dangerous zone. The safety door (maintenance door) must conform to the following requirements: Minimum quantity The lock (such as the switch for safety door) is connected to the input of the safety device by the switch for safety door or PLC. The switch device, the switch and ON/OFF must conform to Type III of EN ISO and performance level d. Depending on the dangerous situation: The safety door can be additionally installed a lock device, so that it can be opened only when the robot safely stops. The acknowledge button for the safety door is installed outside the area where the safety device is isolated. Other devices must be installed in the machine according to the standards and regulations. The following table is the safety function should be activated in the run. Safety function T1 T2 AUT AUT EXT Safety Device - - ON ON Emergency Stop Device ON ON ON ON Enabling Switch ON ON - - Reduced velocity during program ON verification Jog Run ON ON - - Software Limit Switch ON ON ON ON C01UE

34 3.7. Safety Measure General Safety Measure The robot can be used only when it is at the good status and the safety consensus. The improper operation will cause the person damage and property loss. Although the control system has been disconnected and protected, it should consider the robot could run. The wrong installation (such as over-load) or the mechanical damage (such as brake failure) will cause the robot or the external axis to sink. If you operate the disconnected robot, you must drive the robot and the external axis to a position where will not run with or without load. If this possibility does not occur, the robot and the external axis must correspond to the safety protection. C01UE In the conditions where the safeguards and the safety device are not fully functioned, the robot could cause the person or property loss. In the conditions where the safeguards and the safety device are cancelled or removed, the robot isn't allowed to run. Staying under the robot system could cause the death or severe injury. Don't stay under the robot system! It could cause the death or the severe body injury if staying under the robot system. No one can be allowed staying here! Teach Pendant The providers must guarantee only the authorized persons can operate the robot with the Teach Pendant. If many Teach Pendants are connected to the machine, you must note each Teach Pendant can correspond to the robot without the confusion. The providers should take responsibility to remove the Teach Pendant from the robot and keep it well. The storage department should be away from the operator view and the contact range. The purpose is to avoid the confusion of the valid and invalid emergency stop devices. If you don t follow this regulation, it could cause the death, the severe body damage or the property loss. External keyboard and mouse The external keyboard and mouse can be applied only when the prerequisites match: Applied for the operation or maintenance. Disconnected the drive device. No person staying in the dangerous zone. Only when an external keyboard and/or mouse are connected, the Teach Pendant will not be applied. 33

35 Upon the run is applied or the maintenance is completed or the Teach Pendant is connected, an external keyboard and/or mouse must be removed. Failure The operation steps when the robot fails: Disconnect the control system, and protect (such as padlock) from restarting without permission. Hang the corresponding label to identify the failure. Record the failure. Eliminate the failure and check. Modify The safety requirements must be checked after the robot is changed. The check must obey the national and regional labor safety regulations. In addition, the performances of all safety circuits must be tested. The new or changed program must be tested in the manual reduced velocity mode (T1). The robot must be tested in the manual reduced velocity mode (T1) after changed. This is applicable to all components and changes, including software and configuration. The robot must be tested in the manual reduced velocity mode (T1) after changed. This is applicable to all components and changes, including software and configuration Transport Robot Attention should be paid to transport the robot. It must be transported according to the operation or installation guide. Control System The control system should be kept at the vertical state when transported and placed. The vibration or the collision must be avoided during the transportation, so that can prevent the control system from the damage. The control system must be transported according to the operation or installation guide Operation and Re-operation The machine and the devices must be checked once before applying to the run at the first time to ensure they are complete and function, so that can safely run and identify the failure. The check must obey the national and regional labor safety regulations. In addition, the performances of all safety circuits must be tested. The password for the identification of engineer and expert used on the HRSS must be changed before applying to the run, and only allowed notifying the authorized person. 34 C01UE

36 The control system has been arranged for the robot. If the cables are incorrectly connected, the robot and the external axis (optional) could receive the wrong data to cause the person injury or machine damage. If a machine comprises many robots, the cables should be connected to the robot and the corresponding control systems. If the assemblies in the robot don't belong to the components supplied by HIWIN (such as cables), the provider should ensure these components will not influence the safety function or they will not be applied. If the temperature in a cabinet of the control system has the larger difference than the ambient one, water could condensate to damage the electronic products. In the circumstance which the temperature in a cabinet of the control system accompanies with the ambient one, the control system can apply for the run. Function check The following must be checked before operation and re-operation: General check: Must ensure: Correctly place and fix the robot according to the operation manual. No foreign objects or damaged, fallen and loosened components exist in the robot. All safety devices have been correctly installed and functioned. The robot power matches with local supply voltage and mains type. The grounding leads and potential balance leads have the sufficient capacity and have been correctly connected. The cables have been connected, and the plugs have been locked. Check safety function: The following safety functions must be tested to ensure the normal work: Emergency Stop Device (the Emergency Stop Button on the Teach Pendant) External Emergency Stop Device (input and output) Enabling Switch (in the test run) Safety Device All inputs and outputs related to the safety External safety functions Check the reduced velocity control system: The steps to check this item are as follows: 1. Program a linear track to reach the maximum velocity. 2. Ensure the track length % adjust to run the robot along the track in T1, and test the time with a stopwatch. 35

37 No persons are allowed staying in the dangerous zone during the track run lest the death or severe body damage be caused. 4. The velocity can be calculated according to the track length and the measured execution time. In the circumstances reaching the following results, the reduced velocity control system can normally run: The measured velocity is not greater than 250 mm/s. The robot will run according to the programming track (linear run without offset). Robot data Ensure the data on the nameplate of the control system must be consistent with those on the installation description. In the run, the data must be registered on the nameplate. Do not run the robot if the damaged data are loaded! Otherwise, it will cause the death, the severe body damage or the property loss. You must load the correct data. The safety layout must be checked after the data are changed. The reduced velocity control system must be checked after the data are changed Start Run Mode Description The robot can be set to the run mode by the HRSS. In that mode, the robot can run in T1 without peripheral safety devices. If the connection to the higher-level safety system exists or creates, the control system will lock or end the run mode. Danger The possible danger and risk when applying the run mode: The persons walk into the dangerous zone of the robot. Those operate the robot without permission. In the dangerous circumstance, operate thee external emergency stop device not activated, and the robot isn't disconnected. Measures to avoid the risk in the run mode: Cover or identify the non-function emergency stop devices with a warning plate. If no grilles are installed, the other measures should be taken to avoid the people walking into the dangerous zone of the robot, such as a block band. The management measures must be taken to limit or avoid the application of the run mode. 36

38 Application Apply the run mode according to the regulations: Only the trained maintenance staff can be allowed applying the run mode. When the external safety devices are not installed or applied to run, T1 will be applied to run.at this time, the dangerous zone must be isolated with a block band. Isolate the failure (peripheral failure). C01UE When the run mode is applied, all external safety devices are stayed at the stop status. The maintenance staff must guarantee no person stays in or near the dangerous zone when the safety devices stop. Violation All applications not in compliance with the regulations are in violation and must be forbidden. This place includes the applications of other people except for the maintenance staff. For the loss owing to the violation, HIWIN will not take any responsibility. The providers should take risk Manual Mode The manual mode is used for the trial-run, where indicates all works must be executed when the robot can auto run. The trial-run includes: Jog mode Teaching Programming Program verification The following items should be noted when manually running: If the drive devices are not needed, they must be disconnected to ensure the robot will not be started. New or modified program must be tested in manual reduced velocity mode (T1). The tool, the robot or the external axis (optional) must not contact or extend the grilles. The robot should not jam, short-circuit or drop the workpiece, the tool or other part owing to the operation. All trial-runs must be conducted outside the area where the safety devices isolate. If trial-runs have to be conducted in the area where the safety devices isolate, the following items should be noted: In Manual reduced velocity mode (T1): In the situation not necessary, other people are not allowed staying in the area where the safety devices isolate. 37

39 If many people are needed to stay in the area where the safety devices isolate, the following items must be noted: 1. Each worker must give an Enabling Switch. 2. All persons must not be obstructed to see the robot. 3. It must be guaranteed all persons can see each other. The operators must select an appropriate position, so that can see the dangerous zone and avoid the danger. In manual high velocity mode (T2): This mode can be applied only when it is tested greater than the manual reduced velocity. No teaching and programming are allowed in this run. The operator must ensure the Enabling Switch normally functions before test. The operators must be stayed outside the dangerous zone. No other people can stay in the area where the safety devices are isolated. The operators must take responsibility for this situation Simulation The simulation software doesn't fully match the actual situation. The program from the simulation software must be tested in the manual reduced velocity (T1). If necessary, the program must be modified Automatic Mode The automatic mode is allowed when the following prerequisites of the safety measure are followed. All safety devices have been installed and provided with good function. No persons are allowed staying in the machine. The work procedures must be obeyed. If the reason why the robot stops is unknown, the dangerous zone can be entered only when the emergency stop has been activated Maintenance and Repair Check the necessary safety requirements must match after the maintenance and repair. The national and regional labor safety regulations must be obeyed. In addition, the safety performances have to test for all circuits. The robot function can be normally recovered by the maintenance and repair when the failure. The maintenances include the failure finding and repair. The safety measures should be taken when the robot is run, including: Run outside the dangerous zone. When it is run in the dangerous zone, the providers must take protective measures to ensure the personnel safety. Disconnect the robot and take measures (such as padlock) to avoid restart. If it is run in the situation where the control system is connected, the providers must take protective measures to ensure the person safety. C01UE

40 If it is run in the situation where the control system is connected, it can run in T1 only. The operations under run must be identified with a label on the robot. This label should be kept at the same place during the pause. The Emergency Stop Device must stay at the start status. If the safety function or the safety device is closed due to the maintenance, it must be immediately connected. C01UE The main switch must be disconnected and the measures should be taken to avoid the reconnection before the energized components on the robot are operated! And then it must ensure no voltage exists. Only the trigger of the emergency stop, the safety stop or the disconnection of the drive device are not allowed before the energized components are operated because the next generation drive system will not disconnect the robot power in this condition. Some components are still energized to cause the death or severe body damage. The damaged components must be replaced by those with the same model number or equivalent ones identified by HIWIN. Control system Although the control system has been disconnected, the components connected to the peripherals could be energized. Therefore, the external power must be disconnected if operating on the control system. After the control system is disconnected, there is over 50 V (up to 780 V) on the different components in several minutes. In order to avoid lethal damage, the operation is not allowed during this period. No water and dust must be prevented from entering the control system. Dangerous objects The safety measures when the dangerous objects are applied: Avoid contacting skin in long time and frequently. Avoid inhaling mist and gas. Clean and care your skin. In order to ensure the safe operation of the product, it is recommended the user periodically inquire the safety information from the hazardous object manufacturer. 39

41 Decommissioning, Warehousing and Disposal The decommissioning, warehousing and disposal for the robot must follow the national laws, regulations and standards Safety Measure for Single Point of Control Overview If the specific components are installed on the robot, the safety measures must be taken to ensure the single-point of control (SPOC) can be fully achieved. Components: Decoder PLC Remote Control Tools Bus tools External keyboard/mouse C01UE If necessary, the other safety measures could be taken. They must depend on the situations by the system providers, program designers or machine vendors. Because the system providers understand the safety status of these components, they take responsibility for them to enter the safety status, for example, during the emergency stop. 40

42 4. Operation 4.1. Teach Pendant Front view Function The Teach Pendant is a portable programming device for the robot, which can provide each kind of the programming operation and display. It is equipped with a touch screen: the HRSS can operate by fingers or stylus without an external mouse and an external kieyboard. In that reference, the Teach Pendant is usually called as TP Overview Figure 4.1 Front view of HIWIN s teach pendant No. Description Used to change operation mode and turn on/off the monitor. Only after the key 1 is inserted, the switch can be turned. 2 Emergency Stop Button, used to stop the robot in the emergency. It will lock when the Emergency Stop Button is pressed. 3 Run Button, used for JOG. 4 Velocity adjustment 5 Space Operation Button 41

43 Rear View Overview C01UE Figure 4.2 Rear View of HIWIN s Teach Pendant 1 Enabling Switch 2 Rating Plate Description Component Description Enabling Switch The Enabling Switch has three positions: Not pressed Center position Pressed In T1 or T2, the Enabling Switch must be kept in the center position to start the robot. In the Auto Run and External Auto Run modes, the Enabling Switch will not activate. Rating Plate Rating Plate 42

44 Remove and Insert Teach Pendant Description: Remove the Teach Pendant when the robot is connected. C01UE If you remove the Teach Pendant, you can't stop the robot from the Emergency Stop Button on the Teach Pendant. Therefore, an external Emergency Stop Device must be connected to the control system. The providers should take responsibility to remove the Teach Pendant from the robot and keep it well. The storage department should be away from the operator view and the contact range. The purpose is to avoid the confusion of the valid and invalid emergency stop devices. If you don't note that measure, it could cause the person death, the body damage or property loss. Operation steps Remove 1. Press in the HRSS to remove the Teach Pendant. An information and a counter will be displayed on the HRSS. The counter will countdown 25 seconds. During this period, the Teach Pendant can be removed from the robot controller. If you remove the Teach Pendant without press the button as mentioned above, the emergency stop will be triggered. Only when you insert the Teach Pendant again, the emergency stop will be cancelled. 2. Remove the Teach Pendant from the robot controller. If you don't remove the Teach Pendant in the counting period, this count will be invalid. You can press the remove button again to display the counter. Insert Insert the Teach Pendant to the robot controller. Insert the Teach Pendant at any time. Prerequisite: the same type with the Teach Pendant. After it is inserted 10 seconds, the emergency stop and the Enabling Switch will be recovered. The HRSS will display again. The inserted Teach Pendant will apply for the current run. The current run may not be the same as the run before remove the teach pendant. It could be changed by higher-level controller, for example a master. A user who inserts the Teach Pendant on the robot controller must stay 30 seconds at least. That is to say until the emergency stop and the Enabling Switch are recovered. This can avoid the provisional invalidity of the emergency stop when another user operates in the emergency situation. If you don't note this point, it could cause the person death, the body damage or property loss. 43

45 4.2. HRSS Interface Figure 4.3 HRSS interface No. Description Main Menu 1 Display the Main Menu Error Information Window 2 Display the error information hint according to the default configuration. Program Ratio and Jogging Ratio 3 Determined by program to change the ratio. 4 Status Bar Tool and Base 5 Observe the selected tool and base number. You can click to change the tool or base number. Step motion 6 Step motion and continue motion Teach Pendant Configuration 7 Touch that display to select the relative position where the Teach Pendant faces the robot. 44

46 No Description Coordinate system Button Display the current coordinate system. You can touch it to display all coordinate systems and select another one. Run Button If you select the axis-specific jogging, here will display the axis number (A1to A6). If you select the Cartesian jogging, here will display the direction of the coordinate system (X, Y, Z, A, B, C). Keyboard Button Click to display the keyboard. Remove Button Press this button before you remove the teach pendant. Simulation View Angle Button Shift to simulate the view angle Status button The Status button will dynamically be changed according to the window currently activated by the HRSS. Battery Figure Display the status of absolute encoder s battery. Lock Button When the program is executed, you can use this button to lock or unlock. Next step motion Button Home Button Hold this button to return the robot to the home position Run Control Button Three buttons are used for run, pause and stop the program Status Bar The status bar displays the status which the robot is configured. Overview Figure 4.4 HRSS status bar 45

47 Status Display Submit Encoder Figure Color Description Orange Submit the decoder running. Gray Submit the decoder failure or stop Keyboard The Teach Pendant is equipped with a touch screen. The HRSS can operate by fingers or stylus. There is a keyboard on the HRSS to enter the alphabet and number. Figure 4.5 Illustration of HRSS keyboard 4.3. Connect to Control System, and Start HRSS Operation steps The main switch on the control system is shifted to ON. The operating system and the HRSS will automatically start Open Main Menu Operation steps Click the Main Menu on the Teach Pendant, and then open it. 46

48 Description Property for Main Menu window The Main Menu is displayed at the left field. Click an item to display the next-level function table (e.g. File). Display table or opened interface by pressing the menu button on the upper left. You can directly select these function items again without closing the next-level table. C01UE Figure 4.6 Example: opened next function table 4.5. Change User Group Operation steps 1. Select [Configuration]>[User group] on the Main Menu to display the current user group. 2. If you want to shift the default user group, press [Change]. If you want to shift other user groups, press [Login] to select the user group. 3. If needed, please enter password and login. Description In the HRSS, the functions can be selected according to the user group. There are the following user groups: Operator Operator group This is the default user group. 47

49 Engineer Engineer group This user group is protected by a password. The default password is HIWIN. Expert Expert group This user group is protected by a password. The default password is HIWIN. C01UE No. Function Operator Engineer Expert Function table 1 File x x o 2 Configuration>User group o o o 3 Display x o o 4 Diagnosis>Logbook o o o 5 Start-up>Calibrate x x o 6 Start-up>Master x x o 7 Start-up>Robot data x o o 8 Start-up>Network Config x x o 9 Start-up>RS-232 x x o Interface 11 Message box o o o 12 Velocity configuration x o o 13 Tool/base coordinate x x o 14 Teach Pendant configuration x o o 15 Change coordinate system x o o 16 JOG x o o 17 Small keyboard o o o 18 Remove Teach Pendant x o o 20 Program execution o o o 21 Program selection o o o 22 Modify program x x o 23 Tool/base calibration x o o 24 IO operation x o o 25 Functional IO modification x x o 48

50 4.6. Change Run Don t change the run in the programming period. If it is changed, the robot will stop. Prerequisite The controller doesn t process any program. Insert the key for the mode selector switch. Operation steps 1. Turn the mode selector switch on the Teach Pendant, and display the mode selection. 2. Select the run. 3. The selected mode will be displayed in the status bar of the Teach Pendant. Mode Application Velocity T1 T2 AUT AUT EXT Used for test operation, programming and teaching Used for run test Used for robot without the higher-level controllers Used for the robot with the higher-level controllers (For example, PLC) Program verification: Programmed velocity, maximum 250 mm/s Jog Mode: Jog velocity, maximum 250 mm/s Program verification: Programmed velocity Jog Mode: Unable to run Programming mode: Programmed velocity Jog mode: Unable to run Programming mode: Programmed velocity Jog mode: Unable to run 49

51 4.7. Coordinate System Overview The following Cartesian Coordinate Systems are defined in the control system: ROBOT BASE TOOL Figure 4.8Coordinate System Overview Description ROBROT The ROBROT Coordinate System is a Cartesian one, which is located in the intersection of the first joint and the second joint. It is the origin of Base Coordinate System. In the default, the ROBOT Coordinate System is consistent with BASE one. 50

52 BASE The BASE Coordinate System is a Cartesian one, used to describe the position of workpiece. It is based on ROBROT Coordinate System. In the default, the Base Coordinate System is consistent with ROBOT one. A user can move it to workpiece. C01UE TOOL The TOOL Coordinate System is a Cartesian one, located at the tool center point. In the default, a home of the Tool Coordinate System is located at the flange center point (called as Flange Coordinate System). The Tool Coordinate System is offset to the tool center point by the user. Rotation of robot coordinate system Corner Rotation around axis A Rotate around X axis B Rotate around Y axis C Rotate around Z axis 51

53 4.8. JOG Description There are two kinds of joggings: Cartesian jogging, TCP is jogged in the positive or negative direction along an axis of coordinate system. Axis-specific jogging, each axis can independently be moved in a positive or negative direction. Joint coordinate system Figure 4.9 Axis-specific jogging 52

54 4.9. Manual Move Description All parameters which are used to manually move the robot can be configured in the window of Manual Move Jog Velocity Change Description Manually drag the bar to change the jog velocity. Operation steps 1. Open the JOG velocity window. 2. Change JOG velocity. Figure 4.10 Configuration related to jog BASE/TOOL Coordinate Description View and modify the base or tool coordinate 16 tool and 32 base coordinate systems can be saved in the control system at most. When you apply for the Cartesian jogging, you must select a tool (Tool Coordinate System) and a base (Base Coordinate System). 53

55 Figure 4.11 Base/tool window No. Description 1 Tool coordinate currently selected 2 Parameters relate to selected tool coordinate 3 Base coordinate currently selected 4 Parameters relate to selected base coordinate 5 Recalibrate 6 Directly enter a value on the selected item to calibrate 54

56 Operation steps Open the TOOL/BASE window. You can directly choose the tool/base coordinate system by click on 1 and 3 in figure 4.11 respectively Teach Pendant Configuration Figure 4.12 Window of Teach Pendant configuration Description Define the user s position relative to the robot before you use space button Jogging velocity Ratio Description The jogging velocity ratio is the robot velocity during jogging. It is presented by percentage, based on the maximum velocity when the robot is jogging. That value is 250mm/s. Operation steps 1. Click jogging ratio button. 2. Set the jogging ratio you want. You can set by the +/- button or the adjustor. 3. Touch the area outside the jogging ratio window. The window closes and the ratio is applied, Other method You can use the +/- button at the left side of the Teach Pendant to set the ratio. 55

57 Axis-specific jogging with the jog keys Prerequisite T1 mode Operation steps 1. Select the JOINT as the coordinate system for the jog key. 2. Set jogging velocity ratio. 3. Hold the enabling Switch. 4. Axis A1 to A6 beside the jog keys. 5. Press the +/- button, so that the axis moves toward the positive or negative direction Cartesian jogging with the jog keys Prerequisite T1 mode The tool and base coordinate systems have been selected. Operation steps 1. Select the XYZ as the coordinate system for the jog keys. 2. Manual ratio. 3. Hold the enabling Switch. 4. Axis X, Y, Z and A, B, C will display beside the jog keys. X, Y, Z: Used for linear motion along the axis of the selected coordinate system. A, B, C: Used for rotation motion along the axis of the selected coordinate system. 5. Press the +/- button, so that the axis moves toward the positive or negative direction. C01UE The position where the TCP is at can be displayed as the following method: seletc Main Menu>Display > Actual Position Teach Pendant Alignment Description Adjust according to the user location, so that the direction of TCP movement adapts the rotation of the Teach Pendant. The user location is selected in a unit of angle. The reference point for that angle is on the base. Default: 0. This corresponds to a user standing on the opposite side of the robot. 56

58 Figure 4.13 Teach Pendant configured at 0 and 270 Prerequisite T1 mode Operation steps 1. Open the wondow of Teach Pendant Configuration. Figure 4.14 Window of Teach Pendant configuration 2. Set the position where the Teach Pendant is located at the robot. 3. Close the window of the Teach Pendant configuration. When shifting to the external auto run, the Space Operation Button will be automatically positioned as 0. 57

59 4.10. Display Display Actual Position Operation steps Main Menu>Display>Actual Position Description Display the motor position, the axis angle and the Cartesian coordinate of the current base. Figure 4.14 Window of actual position 58

60 Display Digital Input/Output Operation steps 1. Click the I/O tab on the interface. 2. Click [D.I.] or [D.O.]. Description Figure 4.15 Digital input/output interface No. Description 1 Input/Output No. 2 Simulation, opened as red The input/output simulated signal (can be used when the 3 simulation is selected) ON displays in red and On. OFF displays in white and Off. 4 Input/output name (click 4 to modify) 59

61 Display Remote Input/Output Operation steps 1. Click the I/O tab on the interface. 2. Click [R.I.] or [R.O.]. Description Figure 4.15 Robot input/output interface No. Description 1 Input/Output No. 2 Simulation, opened as red The input/output simulated signal (can be used when the 3 simulation is selected) ON displays in red and On. OFF displays in white and Off. 4 Input/output name (click 4 to modify) 60

62 Display External Functional Input/Output Operation steps 1. Click the I/O tab on the interface. 2. Click [F.I.] or [F.O.]. Description Figure 4.16 External Auto Run input/output interface No. Description 1 Input/Output No. 2 Simulation, opened as red The input/output simulated signal (can be used when the 3 simulation is selected) ON displays in red and On. OFF displays in white and Off. 4 Input/output name 5 Program name Click and hold two seconds to remove the program 61

63 Display System Status Input/Output Operation steps Main Menu>Display > Input/Output Description Figure 4.17 System input/output interface No. 1 Input/Output No. Description 2 The opened input/output signal displays in red and On. OFF displays in white and Off. 3 Input/output name 62

64 Display Robot Simulation Screen Operation steps Click the [Simulation] on the screen. Description Display the posture when the robot runs or simulates the program. Figure 4.18 Robot simulation screen 63

65 Display Counter Variable Operation steps Main Menu>Display>Variable>Counter Description Figure 4.19 Counter interface No. Description 1 Counter No. 2 Counter value 3 Counter name (double-click to change the name) 64

66 Display Timer Variable Operation steps Main Menu>Display>Variable>Timer Description Figure 4.20 Timer interface No. Description 1 Timer No. Timer status 2 On Off 3 Timer value 4 Timer name (double-click to change the name) 65

67 4.11. Communication TCP/IP Communication Description Send and transfer the data by network communication. You can select RC as Client or Server to connect. The communication format has two parentheses, including the value form such as {xxx}. For example, if {123,456} is sent, two sets of value 123 and 456 will be received. Figure 4.21 TCP/IP interface 66

68 No. Description 1 Server/Client configuration 2 Message sending field 3 IP and Port configuration 4 Send message 5 Connect/Disconnect button 6 Exit TCP/IP interface 7 Cancel 8 Set 9 Change IP 10 Without format Operation steps Main Menu>Start-up >Network Config Client 1. Enter the Server s IP and Port 2. Press [Connect]. 3. Display Connection is successful! to represent the connection. Server 1. Enter the port you want to connect. 2. Press [Connect]. 3. Display Server is opened! to present open RS232 Communication Description Send and transfer the data by serial communication. The communication format has two parentheses, including the value form such as {xxx}. For example, if {123,456} is sent, two sets of value 123 and 456 will be received. 67

69 Figure 4.22 RS232 interface No. Description 1 Message sending field 2 Send message 3 Connect/Disconnect button 4 Cancel format 5 RS232 Stop bit 6 RS232 Parity 7 RS232 Data bit 8 RS232 Baud rate Operation steps Main Menu>Start-up>RS Enter RS232 parameters. 2. Press [Connect]. 3. Display Connection is successful! to present the connection success. 68

70 5. Start-up and Recommission 5.1. Check Parameters Description The correct data are loaded. The loaded data must compare with those on the rating plate during the check. If the new data are loaded, the status must fully match with the HRSS. When the data are applied, they can be submitted with the HRSS. If the wrong data is loaded, the robot must not run! Otherwise, it will cause the death, the severe body damage or the property loss. Therefore, the correct data must be loaded. Figure 5.1 Rating Plate Operation steps Main Menu>about 5.2. Mastering Overview Each robot must be mastered. The robot can make the Cartesian motion only after being mastered and move to the programmed position. The mechanical position of the robot will be consistent with that for the encoder during the mastering. Therefore, the robot must be placed on a defined mechanical position, which is the mastering position. The encoder value of each axis will be saved. 69

71 Figure 5.2 Mastering position approximate position A robot must be mastered in the following cases: Situation Before commissioning The value of motor position lost after the maintenance is done such as the replacement of motor If the robot moves without the robot controller (for example, with the release device) Remark After replacement of gear unit After an impact with an end stop at more than 250 mm/s After a collision The old mastering data will be deleted after carrying out a new mastering procedure. 70

72 Mastering Method Description Move each axis, so that can overlap with the mastering mark. Figure 5.3 Move an axis to the mastering position Figure 5.4 Mastering marks Owing to the model number, the position of the mastering marks will be slightly different to the illustration. Prerequisite The jog key has been activated. T1 mode 71

73 Operation steps 1. Select the axis as the coordinate system for the jog keys. 2. Hole the Enabling Switch. The axis A1 to A6 will be dsiplayed beside the jog keys. 3. Press the + or button, so that the axis moves to the positive or negative direction. 4. Start to jog from the axis A1, so that can overlap with the mastering mark. 5. After move the robot, click Main Menu>Start-up>Master>Clear Encoder. C01UE When the simulated robot posture is located beyond the limit to cause motion disabled, please execute [Clear Encoder] first. 1. Master first-axis The first-axis mastering is that a mastering pin is used to fix the plate on the zero axis, and the first-axis velocity is turned to the minimum until the first axis is close to the plate. The first-axis mastering is completed, as shown in Figure Figure Illustration of first-axis mastering 2. Master second-axis The second-axis mastering is that the second-axis velocity is turned to the minimum until the second-axis mastering hole matches with the first-axis one and a mastering rod can be used to position. The second-axis mastering is completed, as shown in Figure Figure Illustration of second-axis mastering 72

74 3. Mastering third-axis The third-axis calibration is that the third-axis velocity is turned to the minimum until the third-axis mastering hole matches with the second-axis one and a mastering rod can be used to position. The third-axis mastering is completed, as shown in Figure C01UE Figure Illustration of third-axis mastering 4. Master fourth-axis The fourth-axis mastering is that the fourth-axis velocity is turned to the minimum until the fourth-axis mastering groove matches with the third-axis one and a mastering key can be used to position. The fourth-axis mastering is completed. A screw can be used to remove the mastering key from the groove after calibrated, as shown in Figure Figure Illustration of fourth-axis mastering 5. Set fifth-axis home The fifth-axis mastering is that the fifth-axis velocity is turned to the minimum until the fifth-axis mastering hole matches with the fourth-axis one and a mastering rod can be used to position. The fifth-axis mastering is completed, as shown in Figure Figure Illustration of fifth-axis mastering 73

75 5.3. Calibration Tool calibration Description When the tool is calibrated, the user will give a set of Cartesian Coordinate System (Tool Coordinate System) to the tool mounted on the flange. The tool coordinate system has its origin at a user-defined point. This point is called as TCP (Tool Center Point). Usually, TCP is located at the working point of the tool. C01UE The calibration method described here must not be used to a fixed tool. Advantage of tool calibration: The tool can rotate along the TCP. The position of TCP will not change. Program running: The track along TCP keeps the programed velocity. 16 tool coordinates can be saved at most. Variable: TOOL[0 15]). The following data will be saved: X, Y and Z: The origin of tool coordinate, relative to flange coordinate, B and C: The rotation of tool coordinate, relative to flange coordinate Figure 5.5 TCP calibration principle 74

76 TCP calibration: XYZ 4-Point Method Description The TCP of the tool to be calibrated is moved to a reference point from 4 different directions. The reference point can be freely selected. The robot controller calculates the TCP from the different flange positions. C01UE The 4 flange positions at the reference point must be sufficiently different from one another.. Figure 5.6 XYZ 4-point method Prerequisite Install the tool to be calibrated on the mounting flange. T1 mode Operation steps 1. Select Start-up > Calibrate -> Tool on Main Menu. 2. Select a value for the tool to be measured, and then press [Measure]. 3. Give a name for the tool to be calibrated. 4. Move TCP to any reference point. Click [Measure], and confirm by pressing the OK button. 5. Move TCP from a different direction to the reference point. Click [Measure], and confirm by pressing the OK button. 6. Repeat Step 5 twice. 7. Press the OK button after completed. The data will be saved. 75

77 Enter Value Description The tool data can be manually entered. Possible data source: 1. CAD 2. External measurement tool 3. Description from tool vendor Prerequisite Known X, Y, Z, A, B and C relative to flange coordinate T1 mode Operation steps 1. Select Start-up > Calibrate -> Tool on Main Menu. 2. Select a value for the tool to be measured. 3. Select the coordinate axis you want to enter, and then press [Set Value]. 4. Give a name for the tool to be measured. 5. Enter a value. 6. Press the OK button after completed. The data will be saved Base calibration Description During base calibration, the user assigns a Cartesian coordinate system (BASE coordinate system) to a work surface or the work piece. The BASE coordinate system has its origin at a user-defined point. If a workpiece has been installed on the mounting flange, the calibration described here will not be applied. Advantages of base calibration: TCP can be jogged along the work plane or the edge of workpiece. Points can be taught relative to base. If the base has to move, for example, because the work plane is moved, these points will be moved as well, but not be taught again. 32 base coordinates can be saved at most. Variable: BASE[0 31]. 76

78 point Method Figure point Method Prerequisite Install a calibrated tool on the mounting flange. T1 mode Operation steps 1. Select Start-up > Calibrate -> Base on Main Menu. 2. Select a number for the base to be calibrated, and then press [Measure]. 3. Give a name for the base to be calibrated. 4. Move TCP to the origin of new base coordinate. Click [Measure], and then confirm by pressing the OK button. 5. Move TCP to a point on positive X axis of new base coordinate. Click [Measure], and then confirm by pressing the OK button. 6. Move TCP to a point with positive Y on the XY plane. Click [Measure], and then confirm by pressing the OK button. 7. Press the OK button after completed. The data will be saved. 77

79 Enter Value Description Known the following values, for example, obtain from CAD: Distance between the base origin and global origin Rotation for base coordinate relative to global coordinate T1 mode Prerequisite Known X, Y, Z, A, B and C relative to the global coordinate system T1 mode Operation steps 1. Select Start-up > Calibrate -> Base on Main Menu. 2. Select a number for the base to be measured. 3. Selett the coordinate you want to enter, and then press [Set Value]. 4. Give a name for the base to be measured. 5. Enter the value. 6. Press the OK button after completed. The data will be saved. 78

80 6. Program Management 6.1. Document Navigator Overview Figure 6.1 Navigator 79

81 Description A user can manage the program in the navigator. No. Description 1 Content structure Document list 2 Display the program in the content structure 3 Open new program 4 Delete program 5 Open program 6 Copy program 7 Rename 8 Add the program to Functional I/O 6.2. Open Program Prerequisite T1 mode, T2, AUT and EXT T2, AUT and EXT can t edit the program. Overview Select or open a program. An editor and a program will be displayed, but not a navigator. The program has been opened: The program can start. Only experts can edit the program. Operation steps 1. Select the program in the navigator and press the Open button. That program will be displayed on the editor. 2. Edit the program. 3. Close the program. 80

82 Description Figure 6.2 Program interface No. Description Cursor & highlighted line 1 That line is highlighted when a cursor is moved on it. 2 Cursor position 3 Program path and filename 4 Basic motion command 5 Determination and loop command 81

83 No. Description 6 Control command (Timer, Counter and Output) 7 Operation control (copy, trim and paste) 8 Exit 6.3. HRL STRUCTURE... 8 LIN P1 CONT Vel= 200 mm/s Acc=50% Tool[3] Base[4] PTP P1 CONT Vel= 100 % Acc=50% Tool[3] Base[4]... Line Description 8 LIN motion 14 PTP motion If the first motion command isn t a default home position or that position is changed, one of the following commands must be used: Complete PTP command Complete LIN command Complete represents all contents which must enter the target points. If you change the home position, all programs will be affected to cause the injury and property loss Home Position The home position is a position where is effective in the range of whole program. It is generally used for the start and end. It is clearly defined, but it does not take critical effect. In default, the home position is located in the control system, and provided with the following values: Axis A1 A2 A3 A4 A5 A6 Angle It can teach other home positions, where must satisfy the following conditions: Good starting position for program execution Good standstill position. For example, the stationary robot must not be an obstacle. If you change the home position, all programs will be affected to cause the injury and property loss. 82

84 6.4. Start Program Select Program Running Operation steps 1. Click Single Step, and execute the Select button. 2. Select Program Running Program Running Program Running Description Continuous The program continuously runs to the end. Single step The program will pause after each line. The unseen lines and the empty lines are included. The Start button must be pressed again for each line Set Program Ratio Description The program ratio is used to set the robot velocity. It is represented with the percentage, based on the programmed velocity. In T1, the maximum velocity is 250mm/s, independent of the setting value. Operation steps 1. Open the velocity window. 2. Set the program ratio you want. The +/- button or scroll can be used to set. 3. Select the area outside the window. Close the window or apply the ratio. Another method The +/- button on the left side of Teach Pendant can be used to set the ratio. 83

85 Driver status The driver status will be dispalyed in the status bar. C01UE Figure Color Description Green Driver ready Gray Driver not ready Decoder Status Display Figure Color Description Orange Decoder is under running. Gray Decoder is not running Start a Program (Manual) Prerequisite Program selected T1 mode or T2 Operation steps 1. Select Program Running. 2. Press the Enabling Switch until it displays the status bar Driver ready : 3. Press the Start button. 4. The program starts to run. 5. If you want to stop a program with manual start, you can press the Stop button or release the Enabling Switch. 84

86 Start a Program (Auto) Prerequisite Program selected AUT C01UE Operation steps 1. Select program running. 2. Press the Start button. 3. The program starts to run. 4. If you want to stop a program in automatic mode, you can press the Stop button Start External Auto Run Prerequisite Program selected EXT AUT Operation steps 1. Select EXT AUT. 2. The program starts to activate from the higher-level control system (PLC). In order to stop the program in EXT Auto Run, please press the Stop button Edit Program Overview A running program can t be edited. The program can t be edited in T2, AUT and EXT AUT. If you edit a selected program in the expert group, a cursor will must be moved to another line from the edited line after edited. This can ensure the contents are saved when the program is closed. 85

87 Delete Program Line Prerequisite Program selected or opened T1 mode C01UE Operation steps 1. Select the program lines which should be deleted. (That program line is not necessary the color background. If a cursor is in the program line, it is ok.) 2. Select Program>Delete. The program lines deleted cannot be recovered again! Additional editing functions More edits below can be adjusted: Copy Prerequisite Program selected or opened Expert group T1 mode Paste Prerequisite Program selected or opened Expert group T1 mode Cut Prerequisite Program selected or opened Expert group T1 mode 6.6. Backup and Recovery Data Backup Data Description This function item not only will create HIWIN/Backup on the USB memory stick, but also the year and date folder as well as content with program. Prerequisite Connect USB memory stick to the control system. 86

88 Operation steps 1. Main Menu>File>Save to USB. 2. Wait for the completion window, and close it. 3. Remove the USB memory stick when the LED indicator turns off Recovery Data Description The same model number and HRSS 2.0 data are allowed loading in the program only. If other files are loaded, the following results could appear: Error information The robot controller unable to run Person injury and property loss Prerequisite Connect USB memory stick with files to the controller. Operation steps 1. Main Menu>File>Load from USB, and then select the program you need. 2. Click Yes to ensure the safety inquiry. The saved files will be recovered on the control system. 3. Remove the USB memory stick when the LED indicator turns off. 4. Reboot the control system. 87

89 7. Motion Program Design 7.1. Motion Overview Program by the following motion: Point-to-point motion (PTP) Linear motion (LIN) Circular motion (CIRC) LIN and CIRC Motion are also called as CP motion (CP = Continuous Path). A start point must be an end point of the previous motion Point-to-point (PTP) Motion The robot guides TCP to the target point along the fastest path. In the general situation, the fastest path is not the shortest one. That means it is not a straight line. Because the axis conducts the rotational motion, the curve path is faster than the straight one. The motion can t be accurately known in advance. C01UE LIN Motion Figure 7.1 PTP motion The robot moves the TCP to the target point along a straight line with defined velocity. 88

90 Figure 7.2 LIN motion 7.4. CIRC Motion The robot moves the TCP to the target point along a circular track with defined velocity. The circular track is defined by a start point, an auxiliary point and a target point. Figure 7.3 CIRC motion 7.5. Blend Blend means the trajectory of TCP between the start and end points will be modified to perform a smooth motion. The TCP will not move accurately to the programmed points between the start and end point. The blend is an option, which can be selected in the motion program. PTP motion TCP will abandon a track which the target point can be reached accurately, and adopt a faster one. When a PTP motion blended too much takes place, the track change can not be foreseen. Besides, the point through which side on the track cannot be forecasted. Figure 7.4 PTP motion and P2 blended 89

91 LIN motion TCP will abandon a track which the target point can be reached accurately, and adopt a shorter one. The modified trajectory will not be an arc. C01UE Figure 7.5 LIN motion and P2 blended CIRC motion TCP will abandon a track which the target point can be reached accurately, and adopt a shorter one. The auxiliary point can always be reached accurately. The modified trajectory will not be an arc. Figure 7.6 CIRC motion and P end blended 7.6. LIN and CIRC Motion Description TCP at the start point of motion could be in the orientation different from the target point. The orientation of TCP will gradually change in the motion. When TCP at the start point of motion is in the same orientation with the target point, the orientation of TCP will remain the same in the motion. 90

92 Figure 7.7 Start point in same orientation of target point Figure 7.8 Start point in different orientation of target point CIRC motion For the CIRC motion, the orientation guide is the same orientation with LIN motion. In the CIRC motion, the control system only considers the orientation of the target point. The orientation of auxiliary point is ignored Singular Point The HIWIN s robot with six freedoms has three kinds of singular point. 1. Overhead singular point 2. Singular point at extended position 3. Singular point at wrist axis In the given state and step order, it is considered as a position of singular point when only one value can't be obtained by the inverse conversion (converted from Cartesian coordinate to articulated coordinate). In this situation, it is the position of singular point when the minimum Cartesian variation could cause the large change of axis angle. 91

93 Overhead For the overhead singular point, the wrist point (the middle point of axis A5) is vertical to the axis A1. The position of the axis A1 can't be sure by the inverse conversion, and it can be any value. At this time, if the inverse motion is performed, the error will appear. Extended position For the singular point at the extended position, the wrist point (the middle point of axis A5) is located in the extension of axis A2 and A3. The robot is located at the edge of the workspace. Although only one axis angle can be obtained by the inverse conversion, the less Cartesian variation will cause the large velocity of the axis A2 and A3. At this time, if the inverse motion is performed, the error will appear. Wrist axis For the singular point of the wrist axis, the axis A4 is parallel with A6, and the axis A5 is within the range ±0.1. The positions of two axes can't ensure by the inverse conversion. Although the axis A4 and A6 can have many positions, the sum of the axis angle is the same. At this time, if the inverse motion is performed, the error will appear. 92

94 8. Programming with inline forms The frequently used commands are provided in HRSS inline forms. These commands can simplify the program design. C01UE The commands can be program without inline forms. The HRL (HIWIN robot language) is used to program Name in Inline Form The program can enter the data name. For example, call the name, the name of motion data set and so on. The name must satisfy the following limits: 30 characters at most Special characters can t be allowed except for $. The first place can not be a number. This limit is not suitable for the output name Programming for PTP, LIN and CIRC Motion Programming for PTP Motion When the motion is programming, it is sure the power supply will not wind or damage when programming to run. Prerequisite Program selected T1 mode Operation steps 1. The TCP move should be configured as the target position. 2. Put a cursor behind, and insert on a line of the motion command. 3. Select Motion>PTP 4. Change the relevant parameters. 5. Press the OK button. Overview Figure 8.1 PTP interface 93

95 Programming for LIN Motion C01UE When the motion is programming, it is sure the power supply will not wind or damage when programming to run. Prerequisite Program selected T1 mode Operation steps 1. The TCP move should be configured as the target position. 2. Put a cursor behind, and insert on a line of the motion command. 3. Select Motion>LIN. 4. Change the relevant parameters. 5. Press the OK button. Overview Figure 8.2 LIN interface Programming for CIRC Motion Prerequisite Program selected T1 mode Operation steps 1. The TCP move should be configured as the arc position. 2. Put a cursor behind, and insert on a line of the motion command. 3. Select Motion>CIRC. 4. Click [SET]. 5. The TCP move should be configured as the target position. 6. Click [SET]. 7. Click [FINSH]. 8. Enter the Paramer interface to change the relevant parameters. 9. Press the OK button. 94

96 Overview Figure 8.3 CIRC interface 8.3. Variable Configuration Declare a Variable Prerequisite Program selected T1 mode Operation steps 1. Put a cursor behind, and insert on a line of the logic command. 2. Select Configure>Variable>REAL. 3. Set the parameters in the interface. 4. Save the command by pressing OK. Overview Figure 8.4 REAL interface No. Description 1 Variable name 2 Initial value 95

97 Use Counter Variable Prerequisite Program selected T1 mode Operation steps 1. Put a cursor behind, and insert on a line of the logic command. 2. Select Configure>Variable>Counter. 3. Set the parameters in the interface. 4. Save the command by pressing OK. Overview Figure 8.5 COUNTER interface Use Timer Variable Prerequisite Program selected T1 mode Operation steps 1. Put a cursor behind, and insert on a line of the logic command. 2. Select Configure>Variable>Timer. 3. Set the parameters in the interface. 4. Add $T_STOP[n]=FALSE on the previous line you want to count. 5. Add $ T_STOP [n]=ture on the next line you want to stop. 6. Save the command by pressing OK. TIMER is based on 1 ms as an unit, where the accuracy is 55 ms. 96

98 Overview Figure 8.6 TIMER interface 8.4. Programming for Logic Command Input/Output Digital Input/Output The control system can manage 24 digital inputs and 24 digital outputs at most. The configuration can depend on the user requirements. Input/output can be managed by the following variables: Input Number $DI[1] $DI[24] Output $DO[1] $DO[24] Number -- $VO[1] $VO[3] Number $RI[1] $RI[8] $RO[1] $RO[8] OUT Prerequisite Program selected T1 mode Operation steps 1. Put a cursor behind, and insert on a line of the logic command. 2. Select Configure> Output>Digital, or other IO output interface. 3. Set the parameters in the Function. 4. Save the command by pressing OK. Overview Figure 8.7 OUTPUT interface 97

99 WAIT Prerequisite Program selected T1 mode Operation steps 1. Put a cursor behind, and insert on a line of the logic command. 2. Select Function> WAIT FOR. 3. Set the parameters in the interface. 4. Save the command by pressing OK. Overview Figure 8.8 WAIT FOR SEC interface WAIT FOR Prerequisite Program selected T1 mode Operation steps 1. Put a cursor behind, and insert on a line of the logic command. 2. Select Function> INPUT. 3. Set the parameters in the interface. 4. Save the command by pressing OK. Overview Figure 8.9 WAIT FOR interface 98

100 8.5. LOOP IF Prerequisite Program selected T1 mode Operation steps 1. Put a cursor behind, and insert on a line of the logic command. 2. Select Function> IF ENDIF> determination. 3. Set the parameters in the interface. 4. Save the command by pressing OK. Overview While Prerequisite Program selected T1 mode Figure 8.10 IF interface Operation steps 1. Put a cursor behind, and insert on a line of the logic command. 2. Select Function> WHILE ENDWHILE> determination. 3. Set the parameters in the interface. 4. Save the command by pressing OK. Overview Figure 8.11 WHILE interface 99