User's Manual 6-axis Force/Torque Sensor KMS 40

Transcription

1 User's Manual 6-axis Force/Torque Sensor KMS 40 Hardware Revision: 3 December 2017

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3 Table of Contents 1 Introduction Guarantee Scope of Delivery Available Versions Dimensions and Sensor Coordinate System Nominal Values Nominal Values of the Sensor Mechanical Data Nominal Load and Overload Electrical Data Interfaces and Connections Fuse CAN-Bus (optional) Serial Port according to RS 232 (optional) Power Supply Ethernet Assembly and Initial Startup Mechanical Setup Initial Startup Calibration, Maintenance and Cleaning Sensor Controller Memory Card Communication LEDs Factory Reset Display of System Status Configuration and Diagnosis via the Web Interface Access Restriction for the Web Interface Communication Scripts File Manager Communication Protocol EG Assembly Declaration

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5 1 Introduction The KMS 40 is an intelligent Force/Torque sensor with 6 axes of measurement and an integrated signal processor. It provides measurement data via its integrated Ethernet port. Models with CAN-Bus and RS 232 ports are available as well. Figure 1 shows the sensor s components and connection ports. The sensor is configured via a web interface that runs on any current web browser. System status display Type and serial number Plug for Ethernet connection Plug for power supply and optional second interface Memory card, communication LEDs, bus termination Cover panel Figure 1: Components and connection ports of the KMS 40 2 Guarantee The KMS 40 has a 24 month guarantee from the date of delivery only valid if used appropriately and in regard of scheduled maintenance and calibration intervals. Parts in contact with the media and wear and tear are not covered by the guarantee. Please review our general terms of business, found on our website The sensor is classed as defective when its basic functions (force and torque measurements) in at least one of the six axes are not working. Accuracy and calibration are not included in the guarantee

6 3 Scope of Delivery The scope of delivery includes: Intelligent force/torque sensor KMS 40, calibrated and with the ordered options User Manual CD including Documentation and Firmware Accessories available for the sensor: Power supply cable Centering sleeves Available services for the sensor: Calibration to SI units Please order accessories and services separately. 4 Available Versions The KMS 40 comes in different models depending on the communication interface. Please inform us of your preferred model when ordering your sensor. Communication interface Model Number Ethernet KMS 40-E Ethernet plus CAN-Bus KMS 40-EC Ethernet plus RS-232 KMS 40-ES Different calibrations, measurement ranges or other special arrangements can be made by request. Feel free to ask! - 4 -

7 5 Dimensions and Sensor Coordinate System Figure 2: Dimensions - 5 -

8 6 Nominal Values Exceeding these nominal values can damage the sensor. If in doubt, please clear your application with our technical department before use. 6.1 Nominal Values of the Sensor FS = Fullscale value of the respective sensing axis Operating Data Unit min typ max Comments Measurement Range Mx, My, Mz Measurement Range Fx, Fy, Fz Effective resolution Force/Torue Max. Overload Fx,y,z and Mx,y Nm ± 3.0 N ± 120 N/Nm 0.005/0.001 FS Max. Overload Mz FS 5x 10x Operating the sensor under overload conditions may permanently reduce its accuracy Operating the sensor under overload conditions may permanently reduce its accuracy Absolute Accuracy % FS ± 1.5 ± 2.5 After calibration Repeatability % FS ± 0.5 Deviation of the output signal of 10 concurrent measurements for FZ =½ measurement range at 25 C Hysteresis % FS 3.5 When changing load from -FS to +FS Drift Fx/Fy %FS/h 0.12 Change in measured value between initial load and after 1h at F = 42N Drift Fz %FS/h 2.89 Change in measured value between initial load and after 1h at F = 42N Drift Mx/My %FS/h 2.6 Change in measured value between initial load and after 1h at M = 2Nm Drift Mz %FS/h 0.4 Change in measured value between initial load and after 1h at M = 2Nm Drift over Temperature %FS/K Drift over Temperature of Mz at 2Nm load - 6 -

9 6.1.1 Mechanical Data Parameter Unit min typ max Comments Mass [g] 215 Tightness IP 20 DIN EN Operating Temperature [ C] 5 50 Humidity % 0 90 Non-condensing Nominal Load and Overload The maximum tolerable nominal load is stated separately for each axis and refers to the reference point on the sensor coordinate system. An exceedance of the maximum tolerable nominal load lowers the sensors accuracy and can permanently damage it! 6.2 Electrical Data Parameter Unit min typ max Comments Operating Voltage [VDC] Power Consumption [A] 0.08 Sampling Rate Frames/s 500 Resolution of Measurement Data Bit 16 Interface 10/100 MBit/s Ethernet Optional Interfaces CAN-Bus, RS232 Operation of the sensor above the stated operational voltage can destroy it! A reverse polarity of the operational voltage can destroy the sensor! 6.3 Interfaces and Connections The KMS 40 is equipped with different interfaces for communication. The communication interface is selected via the web interface. Depending on your sensor model (see Chapter 4) you can switch between them here Fuse The KMS 40 is equipped with an integrated safety fuse as a measure against short circuits and reverse polarity. The fuse is soldered to the main circuit board and can only be exchanged by the manufacturer

10 6.3.2 CAN-Bus (optional) The KMS 40 is also available in a version with an additional CAN-Bus interface (see Chapter 4). This particular model also has bus termination. This must be switched on at the bus on the first and last device. The terminal resistance is 120 Ohm and connects CAN-H with CAN-L. The sensor supports a basic protocol to read measured values. For details about this protocol please refer to the KMS 40 CAN Bus Interface Manual. Parameter Unit min typ max Comments Bus-Standard CAN 2.0A, CAN 2.0B Supported Bitrates [kbit/s] 20; 50; 100; 125; 250; 500; 1000 Voltage on Tx and Rx Pins [V] against GND Serial Port according to RS 232 (optional) The KMS 40 is also available in a version with an additional serial port according to RS 232 (see Chapter 4). Please keep in mind that the maximum cable length of 10m for communication via RS 232 should not be exceeded. In a surrounding disturbed by strong electromagnetic fields Parameter Unit min type max Comments Output Level (TxD) [V] ±5.0 ±5.7 Load resistance = 3kΩ Input Voltage Range (RxD) [V] against GND Input Level High [V] against GND Input Level Low [V] against GND Supported Bitrates [kbit/s] 1,2; 2,4; 4,8; 9,6; 19,2; 38,4; 57,6; 115,2; 230,4; 460,8 Data Format 8 bits, no parity, 1 Stop bit (8n1) Flow Control none Power Supply The KMS 40 is powered via a 4-pole M8 plug on its casing, which also holds the optional interface (CAN or RS 232). The connection layout is shown in Figure

11 1 +24V 2 CAN-H RxD 4 CAN-L TxD 3 GND Steckerposition Litze Signal 1 Braun +24V 2 Weiß CAN-H / RxD 3 Blau GND 4 Schwarz CAN-L / TxD Abschirmblech Schirm Figure 3: Connector layout on the power supply plug (view of the plug). Requirements for the power supply: Voltage: Nominal value of the sensor with residual ripple < 150mV SS Current: 2 x Nominal value of the sensor The smaller the residual ripple, the better the performance of the sensor Ethernet The Ethernet port can be used for commands as well as setting parameters via the integrated web interface. It is implemented in a 4-pole M8 socket. Figure 4 shows its layout. 3 RD+ 4 RD- 2 TD- 1 TD+ Steckerposition Litze Signal 1 Braun TD+ 2 Weiß TD- 3 Blau RD+ 4 Schwarz RD- Abschirmblech Schirm Figure 4: Connection layout of the Ethernet plug (view of the socket). Following protocols are currently supported: DHCP (dynamic IP Address), SNTP (Network Time), HTTP (Web Server), NETBIOS (disclosure of the sensor on the network), DNS (termination of the host name), UDP and TCP (command interface). Interface Specifications: - 9 -

12 Parameter Unit min typ max Comments Transmission Standard IEEE Communication Standard UDP/IP, TCP/IP (IPv4), HTTP Transmission Speed [MBit/s] 10; 100 Auto-Negotiated Transmission Type Half-duplex Auto-MDIX yes 7 Assembly and Initial Startup 7.1 Mechanical Setup The threads and centering holes necessary for mounting the KMS 40 are laid out in Chapter 5. The sensor is equipped with a flange on either side similar to DIN norm EN , which is extended by additional fitting holes for better alignment. Please use only alignment pins or centering sleeves for mounting the sensor. The robot and the tool sides are mechanically separated by two joints. These are shown in Figure 5. It is important during installation to leave enough room so both parts can move against each other. Please remember that cables or tubes connecting the sensor to the robot can unnecessarily put load on the sensor. Separation gap Figure 5: Separation gap Maximum screw tightening torque: 6 Nm Avoid external heat sources e.g. the robot joints, since the KMS 40 can lose efficiency here. Danger of overheating! To ensure a problem free use and minimal electromagnetic interference you must earth the sensor via its casing

13 7.2 Initial Startup To startup your KMS 40 initially, please follow these steps: 1. Connect the sensor via the included adapter cable to your Ethernet network. The KMS 40 is factoryset to IP Address: , Subnet Mask: Important: If you are using several KMS 40 sensors on the same network or this address is already taken, you must change the IP-Address accordingly. 2. Connect the sensor to the power supply. 3. The sensor will now boot. The status display will show a blue light, after ca. 6s it will begin blinking white. The sensor will fulfill a quick self-test. Upon completion, the display will blink slower. 4. Open the internet browser on your computer and go to this address: 5. You will see the sensor s configuration interface: 6. Put a load on the sensor. The load on all six axes is displayed in the sidebar

14 7. Other points you should take into account during initial startup: a. Open the page Diagnostics->System State and check the operational voltage of your sensor. b. Chose on page Settings->Command Interface your preferred communication interface for your sensor. c. Create users and their rights on page Settings->System and activate the safety function of the web interface to prevent unauthorized persons from changing the settings. 8 Calibration, Maintenance and Cleaning Factory calibration The sensor s calibration is valid for one year. After expiration, the sensor should be recalibrated by the manufacturer. This is the only way to ensure correct measurement values inside the stated tolerances. Maintenance The sensor has no parts that must be maintained by the user. If a regular calibration is neglected, the sensor should be sent to the manufacturer for maintenance. Cleaning Clean the sensor regularly with a dry cloth to remove all dirt and other debris. Take special care of the separation gaps between the robot and the tool side (see Figure 5 on Page 10). Dirt or debris in the separation gaps inhibit your sensor s functions and can damage it!

15 9 Sensor Controller The KMS 40 is equipped with a powerful integrated sensor controller to digitalize and process the measurement data. The sensor controller is accessible by removal of the side panel, see Figure 6. Through this panel you can access the memory card as well as more control LEDs. The test interface is for use of the manufacturer for programming and test purposes only, and is needed during production. TERMINATION < OFF - ON > Activity LEDs Switch for CAN-Bus termination (optional) microsd card slot Factory reset button Figure 6: Control and display elements for the sensor controller 9.1 Memory Card The KMS 40 s sensor controller is equipped with a MicroSD card slot. All current memory cards up to 2 GB are supported. Memory cards according to SDHC standard are currently not supported. Following information is located on the memory card: The sensor s operating system Configuration data Protocol and log files Scripts and other application specific files in directory /user. The factory installed card has a capacity of 2 GB. The necessary operation software is already installed on the card. User specific files and scripts can be saved in the user directory. Please don t change or delete any files outside of this directory, since the proper function of your sensor cannot be guaranteed. The memory card and the software and files saved on it are necessary for the use of the sensor. If you would like to change memory cards, please copy all files from the original card to the new one before use

16 9.2 Communication LEDs The sensor controller is equipped with 2 additional LEDs to display the communication status (yellow) and access to the integrated memory card (red). SD Card activity (red) Ethernet activity (yellow) Figure 7: Communication LEDs A steady glow from the LEDs shows that the interface/memory card is active. The LEDs flicker in the rhythm of data transfer. The LED layout is shown in Figure Factory Reset The KMS 40 has a button to reset to factory settings, see Figure 6. When pushed, the red LED indicating the memory card status will start blinking. To reset to factory settings, the reset button must be held down until the LED stops blinking (ca. 5s). In the process the current settings (config/system.cfg) are saved on the memory card in config/system.old before the system overwrites them with the factory settings and reboots the sensor. The sensor calibration is not changed by a factory reset. 9.4 Display of System Status The white dot on the side of the KMS 40 is a multicolored light to indicate the system status (Figure 8). The current system status can be determined by the light s color and blinking frequency

17 System status LED Figure 8: Display of system status The following is a list of all display and color possibilities, and their meaning: System Status Boot The device is loading the firmware and preparing for boot. Boot error The device is automatically restarting the boot process Initialization The device is initializing. Ready mode The device is ready for use. In use The device is currently in use and is executing a command or a script. Warning One or more parameters have reached their limits. Please check the system status via the web interface. Error during command execution An error occurred while accepting or executing a command. Critical error An error has occurred (e.g. exceedance of the measurement range, temperature too high, loss of communication, etc.) Critical software error A serious error has occurred and stopped the current process. The device must be rebooted. Display Blue, steady glow Red for about 5s, then steady blue Blinking blue White, pulsating on and off slowly Blinking green Yellow, pulsating on and off quickly Red, pulsating on and off once Red, pulsating on and off quickly Red, blink code: 2 short blinks, long break More LEDs for visualizing access to the memory card and communication activity are located next to the memory card slot under the side panel, see Chapter Configuration and Diagnosis via the Web Interface For configuration, the KMS 40 comes with an integrated web server that offers a configuration and diagnosis interface. To use this, the KMS 40 must be connected via Ethernet. To access the configuration interface, please open your web browser and enter the following address:

18 substituting the zeros for your devices serial number. (Important: your computer must have a mdns service installed, on Windows for example, you can use Apple s Bonjour). The following browsers have been tested to be compatible to the KMS 40 web configuration interface: Firefox 3.5 and higher, Konqueror 3.5 and higher, Safari 4 and higher, Opera 10 and higher, Mobile Safari (ipad from OS 3.1.2), Internet Explorer 8. To display the web interface, your browser must have Javascript enabled. Figure 9: Web interface for configuration and diagnosis With its integrated Help-texts, the web interface is intuitively easy to use. The tabs at the top of the page open up the separate sections

19 9.5.1 Access Restriction for the Web Interface Depending on your network configuration, the KMS 40 is openly visible for everyone on the server and the configuration can therefore be changed by all users. Especially in sensitive or complicated production lines this can be a problem. To restrict access to the web interface and the sensor, you can set up several user accounts with different rights under Settings->System Configuration. When these are activated, each user must identify themselves with an account name and a password (Figure 10). Each user is sorted into one of the following groups: User Standard user. Can t change any settings, only has access to the tabs Diagnostics and Help. Administrator Administrator. Has access to all settings on the web interface. If access restriction is enabled, the sensor will keep protocol on when the sensor was used and who it was used by. Figure 10: Login mask Communication The KMS 40 supports communication via Ethernet UDP/IP and TCP/IP, as well as RS 232 and CAN-Bus, if these options are installed in your device. The interfaces for UDP/IP and TCP/IP support a powerful text

20 based communication protocol, which is explained in detail in the document KMS Command Set Reference Manual. The communication interface can be accessed via the sensors web interface under the tab Settings- >Command Interface Figure 11: Communication settings Scripts The KMS 40 has a powerful script interpreter for the script language Lua, in which you can adjust the sensor specifically to your application. The scripts are saved on the integrated memory card and can be run automatically upon start up. The script interpreter is also configured via the web interface. There you will find an interactive script editor, with which scripts can be directly input and executed (Figure 12). A save function allows you to save your scripts in the user directory on the SD memory card. Scripts must be saved before execution. Via the help tab you can open the Lua 1 command reference in a new window. An additional console window displays data on the print or printf function in the script. This way, the scripts can be easily debugged

21 The command reference, as well as important advice for compiling and using scripts are located in the document KMS Scripting Reference Manual. Figure 12: Interactive script editor File Manager The KMS 40 s web interface allows you to up-, download, rename and delete files in the user directory, see Figure 13. For example you can transfer pre compiled scripts onto the KMS, or even download data series previously recorded by a script to your computer. You can access the file manager by clicking the Scripting->File manager tab in the web interface

22 Figure 13: File manager 9.6 Communication Protocol The KMS 40 uses a text based communication protocol. This simplifies the startup procedure and the implementation in customer-specific applications. The syntax is oriented according to the script language Lua. All commands are transmitted as ASCII strings and must be ended with a line feed character (<LF>, 10 decimal). The currently applied load can be read out like this: Host to KMS: F()<LF> KMS answers: F={ ,-0.315,-5.681,0.428,-0.923,0.003}, <LF> The returned values in curly brackets are force and torque values {Fx, Fy, Fz, Mx, My, Mz} in that order. The torque values are in Nm units and the forces in N. Additionally, the frame s time stamp is returned in units of 1/10 milliseconds. To familiarize yourself with the command set, we recommend you make a Telnet connection to the sensor (e.g. with the free Telnet client software PuTTY 2 for MS Windows) and send several commands by hand as a first step. The complete command set is described in the document KMS Command Set Reference Manual

23 10 EG Assembly Declaration In accordance to the EG Machinery Directive 2006/42/EG, attachment II B Manufacturer Distributor Weiss Robotics GmbH & Co. KG Karl-Heinrich-Käferle-Str. 8 D Ludwigsburg Weiss Robotics GmbH & Co. KG Karl-Heinrich-Käferle-Str. 8 D Ludwigsburg We hereby declare that the following product: Product name: Type: Intelligent 6-Axis Force/Torque Sensor with Ethernet Interface KMS 40-E, KMS 40-EC, KMS 40-ES meets the basic requirements as stated in the Machinery Directive (2006/42/EG). The incomplete device can only be used once it has been established that the machine (in which the incomplete machine is to be installed) also meets the requirements of the Machinery Directive (2006/42/EG). Applied harmonized standards, especially: EN ISO EN ISO Machine Safety Basic terms, general design principles Part 1: Basic terminology and methods Machine Safety Basic terms, general design principles Part 2: Technical guidelines and specifications The manufacturer pledges to transfer the technical documents for the incomplete machine to national authorities upon demand. The specific technical documents for the incomplete machine according to Attachment VII Part B were issued. Responsible for documentation: Dr.-Ing. Karsten Weiß, Phone: +49 (0) Place, Date/Signature: Ludwigsburg, Dezember 2017 Information on the signatory Weiss Robotics GmbH & Co. KG, General Manager

24 Weiss Robotics GmbH & Co. KG. All rights reserved. The technical data mentioned in this document can be changed to improve our products without prior notice. Used trademarks are the property of their respective trademark owners. Our products are not intended for use in life support systems or systems whose failure can lead to personal injury.