Commonplace Robotics Mover 4 User Manual

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Bedienungsanleitung Mover4

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User Guide Mover4 Version 2016/11 (SW V902-09, HWE 2MV23 HWM V05 DOC V15)

Commonplace Robotics GmbH Osterfeldstr. 1 D-49326 Melle Germany ++49 5429 / 374983-4 [email protected] www.cpr-robots.com

The CE sign confirms that this product meets the requirements of the directive 2004/108/EC (EMC) and 2002/95/EC (RohS). The according documentation is deposited at the manufacturer.

Help to save our environment! When reaching the end of lifetime, do not throw the device into the garbage, but bring it to a public recycling place.

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Inhalt

1. Safety Instructions............................................................................................................................. 6

2. Introduction ............................................................................................................................................ 7

2.1 Product .............................................................................................................................................. 7

2.2 Specifications ............................................................................................................................... 8

2.3 System Requirements .............................................................................................................. 8

3. Installation .............................................................................................................................................. 9

3.1 Setting up the Robot ................................................................................................................. 9

3.2 Connecting the Power Supply and the USB Adapter ................................................ 9

3.3 Installation of the CPRog Software ................................................................................. 10

3.4 Installation of the Driver for the USB Adapter............................................................ 12

3.5 Licensing ......................................................................................................................................... 13

4. Robot Arm Mover4 ........................................................................................................................... 14

4.1 Geometry ...................................................................................................................................... 14

4.2 Digital Inputs and Outputs ..................................................................................................... 15

4.3 Mounting Flange for the Gripper ........................................................................................ 15

4.4 Drawing of the Robot Base................................................................................................... 16

5. Moving the Robot Arm with CPRog .......................................................................................... 17

5.1 Introduction .................................................................................................................................. 17

5.2 Navigation using the Mouse................................................................................................. 18

5.3 Moving the Robot with Joypad and Buttons ................................................................ 18

5.4 Moving the Robot using the Graphics ............................................................................ 20

5.5 Connect with the Hardware ................................................................................................ 20

5.6 Reset the Zero Points of the Joints................................................................................... 21

6. Programming the Robot Arm with CPRog ............................................................................ 23

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6.1 Program Elements .................................................................................................................... 23

6.2 Recording a Program using the 3D Interface ............................................................. 24

6.3 Saving and Loading of a Program ..................................................................................... 24

6.4 Replay of a Program ............................................................................................................... 24

6.5 Editing a Program with GraphEdit .................................................................................... 25

6.6 Editing a Program with TextEdit ....................................................................................... 25

7. Configuration ..................................................................................................................................... 28

7.1 Application Configuration.................................................................................................... 28

7.2 Robot Configuration ............................................................................................................... 29

8. Interfacing ........................................................................................................................................... 30

8.1 CRI Interface ............................................................................................................................... 30

8.2 ROS – Robot Operating System ......................................................................................... 31

8.3 Direct Access using the CAN Protocol ............................................................................ 31

9. CAN Protocol Specification ......................................................................................................... 32

10. Error Codes ..................................................................................................................................... 33

11. Troubleshooting ................................................................................................................................ 35

11.1 Installation and Program Start ........................................................................................... 35

11.2 Software CPRog ........................................................................................................................ 35

11.3 Hardware Mover4 .................................................................................................................... 36

12. Language Specification ............................................................................................................ 37

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1. Safety Instructions

 The Mover4 is designed to be used by adolescents and adults

in edutainment and research areas.

 The robot must not be used in industrial production facilities

of in other continuous operation scenarios.

 Do not operate the robot when it is unattended.

 The gripping area exposes the risk of bruises to the fingers,

especially when using the parallel gripper. Keep off during operation! The robot must not operate unattended!

 The robot must not be used by children without the

supervision by adults. Not suited for children below 3 years. Small parts pose choking hazards.

 Sharp or otherwise dangerous tools or parts must not be

mounted on the robot without according safety measures, e.g. housings. This especially comprises milling applications or laser sources.

 Take care for a stable stand of the robot.

 The robot has been designed for indoor use. They do have to

be protected of humidity, dust or excessive solar radiation.

 Do not open the product.

 It is necessary to backup important data before the

installation of the CPRog software.

 Switch of the power supply when the robot is not in use or

unattended.

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2. Introduction

2.1 Product

The Commonplace Robotics Mover4 is a four axis robot for the use in education, entertainment and research environments. The robot can lift a payload up to 500 g with a reach of 500 mm plus gripper.

Pic. 1: Mover4 and the necessary components

The modular set up of the robot connects four joint modules with aluminum profiles. Each joint module contains a servo motor.

The front end of the robot, the flange, allows mounting a gripper or another tool. The robot base has to be fastened on a stand or a table. At the robot base one plug connect with power and the PC, another provides digital IO access.

The cable loom is connected with a 12V/5A DC power supply. The USB adapter connects the control PC with the robots internal communication bus. The CPRog software allows to control and program the robot.

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2.2 Specifications

Nr of Joints 4 servo joints Power Supply 12V DC at max 5 A Power Consumption Paused: 0,5 A / in motion: < 2.5 A. Fuse with 2.5 A in base Communication CAN at 500 kBit/s Reach 455 mm plus gripper Payload 500 g Inputs / Outputs At the base:

3 relay out (max. 24V/1A) and 4 digital in (12 to 24V) via DSub 9 poles male. At the flange: 2 digital Outputs (5V/ 25 mA) und 12V/0,5A supply via Harting SEK 6 poles.

Communication Definition of position setpoints for all four joints with 20

Hz cycle. Reading of the current position and the motor current.

2.3 System Requirements

The control the robot with the CPRog programming environment a PC with Windows operating system is necessary (minimum values):

 Operating System: Windows 7 (32 or 64 Bit) or higher.  .NET-Framework 3.5 or higher and DirectX in Version 9.0c  Processor: 1.6-GHz-Pentium  RAM: 1 GB  Up to 50 MB disk space  1 free USB port for the communication with the robot, another one for joypad

operation

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3. Installation

3.1 Setting up the Robot

The robot has to be placed on a table or stand so that he cannot tumble down.

3.2 Connecting the Power Supply and the USB Adapter

Pic. 2:

Cable loom and USB a

dapter

The cable loom connects the power supply, the USB adapter and the robot as depicted above. All connectors fit only one way. The USB adapter may be white or black, depending on the current type.

When plugging in the USB2CAN adapter, a driver installation assistant may appear. Please refer to section 3.4 for installation guidelines.

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3.3 Installation of the CPRog Software

Insert the CPRog CD into the drive

Depending on your systems configuration the CD menu will open automatically, or you have to start it manually: D:\.autorun\autorun.exe

Choose the first button „CPRog Installation”

Maybe you have to all

ow changes to

be made on your system.

After the installer has started you need to choose between English and German as language.

Then you need to confirm the license agreement.

In the next step y

ou ca

n choose

where to install CPRog. The recommended directory is

c:\CPRog.

When installing in a Windows program directory like

c:\Programme it is possible that

CPRog can only be started as administrator.

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The installation normally takes o

nly

a few seconds.

The installer checks, if DirectX 9.5 is installed. If not it will install theses libraries from the CD or via download. This will take some minutes.

The installation of DirectX 9.5 is necessary even if e.g. DirectX 11 is already installed.

When f

inishing the installation y

can choose to directly start CPRog.

Now you can start CPRog using the link on the desktop or via the start menu.

Installation Failure: The installation assistant checks, if all necessary extensions

are available, especially the .NET-Framework and DirectX 9.5. If this is not the case an error message will appear. DirectX is installed automatically, but the .NETFramework has to be installed manually:

Search in the net for “Microsoft .NET download” and install

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3.4 Installation of the Driver for the USB Adapter

The robot is delivered with the PCAN USB driver from www.peak-system.com. To run the adapter the according driver has to be installed. This can be done from the CPRog installation CD (button “Install USB-CAN adapter”), or using the manufacturers installation CD.

After starting the installation you need to

 accept the license agreement and  set the installation folder.

In the next step please check the PCAN-USB device and the PCAN-View CAN-Bus Monitor as shown on the following picture for installation.

Choose for installation:

 PCAN-USB  PCAN-View

The PCAN-View monitor allows to check if the adapter is connected correctly.

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3.5 Licensing

The CPRog software needs a license key to start. This key is in most cases already integrated into the installation version of CPRog. Nothing has to be done.

If it is not, e.g . because you have installed a demo version, please see the following information. The key, an XML file, has to be stored in the directory

\CPRog\Data\License

The CPRog installer copies the key Demo.xml to the directory. With this key CPRog starts in demo mode. The runtime is limited to 10 minutes; afterwards you need to restart CPRog.

When you do need a license key, please send a short mail with the following information to [email protected]:

 Your Name or the name of the responsible contact person  Your companies / organizations name

We will send you your key via mail. After starting CPRog your licensing data are shown in the main frame and can be shown complete with the Programbutton/License.

Please do not change the content of the license file, this will render it invalid!

A standard license allows the installation and use of CPRog on an arbitrary number of computers in the company or organization of the license holder.

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4. Robot Arm Mover4

4.1 Geometry

Pic. 3: Mover4 simplified side view

The picture shows the joints length of the Mover4 robot arm. Including the gripper the arm reaches 550 mm.

CPRog offers functionalities to limit the workspace, see section 7.2.

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4.2 Digital Inputs and Outputs

The robot base shows a D-Sub plug with several digital inputs and outputs. The pin assignment is shown below.

D-Sub Male: View from the

front on the pins.

24V DIO, D-Sub Male

Pin 1: Out1 24V Pin 2: Out2 24V Pin 3: Out3 24V Pin 4: In1 Pin 5: In2 Pin 6: In3 Pin 7: In4 Pin 8: GND Pin 9: 24V Supply

Pic. 4: Pin assignment at the base digital IO plug

The 24V-DIO-Board provides relays and 12 to 24V digital inputs, allowing to communicate with a PLC on 24V level. The outputs are able to provide 1A each, forwarding the external supply voltage from pin 9. The inputs are 12 to 24V.

Two further digital outputs with TTL-Level can be found on the flange of the robot, see the next section.

4.3 Mounting Flange for the Gripper

The robot flange offers 10 M3 threads to connect gripper or other devices. A plug allows electrical connectivity. Six of the threads are placed on a 15 mm reference circle; the remaining 4 M3 threads are located as shown in the drawing. The plug is a Harting product SEK male 6 poles:

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Pin1: 12V, max 0.5A Pin2 GND Pin3: DOut 11 (5V TTL) Pin4: DOut 12 (5V TTL) Pin5: not connected Pin 6: not connected

Pic. 5: Drawing of the flange

4.4 Drawing of the Robot Base

The robot can be mounted using the M4 through holes.

Pic. 6:

Drawing of the robot b

ase plate

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5. Moving the Robot Arm with CPRog

5.1 Introduction

The CPRog programming environment allows to control and program the Mover robot. Both online and offline working is possible.

Pic. 7:

CPRog

User Interface

In the upper area the three ribbons “Scene”, “Motion” and “Programming” provide access to the main functionalities.

On the left corner information on the robots current state are provided.

On the lower side four sections are found:

 „Log Message“: Messages regarding the programs state  „Info Center“: Shows joint values, the Cartesian position and the motor

currents

 „Jog“: Buttons to move the robot  „Input / Output“: View and set digital IOs

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5.2 Navigation using the Mouse

A 3 button mouse is recommended to navigate in the CPRog 3D environment:

 Left button: Selection of robots and other objects  Middle button: Navigation in the scene

o Rotate: drag the mouse while holding the middle button o Pan: drag the mouse while holding the middle button and pressing

down the CTRL-key

o Zoom: Drag the mouse while holding the middle button and pressing

down the SHIFT-key (zooms to the center of the scene), or turn the mouse wheel (zooms to the current cursor position)

 Right button: Opens the context menu

Alternatively the function of the left mouse button can be changed in the upper menu area at Scene/Navigation. Possibilities are Selection, Rotation, Panning or Zooming.

5.3 Moving the Robot with Joypad and Buttons

The robot can be moved (or “jogged”) manually, as long as no program is running. The main elements are the button to connect the joypad, the combobox to choose the motion type and the override.

Pic. 8:

Elements to jog the robot

When pressing the joystick button CPRog connects with a joypad. Nevertheless, CPRog tries to connect on start up. When the connection succeeded a green ok sign is shown on the joystick button. The device must have the type “Joystick” or “Gamepad”. Further information on the connection trial is provided in the log window.

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The „Joint“ mode allows to turn the single robot axis from A1 to A4. In “Cartesian” mode the robot moves in straight lines following the x, y and z coordinate axis. The rotation is defined with the B commands. In „Cartesian Tool” mode the robot moves aligned to the current tool coordinate system.

The override scales the motion speed between 0 and 100%.

Pic. 9: Buttons to jog the robot in Cartesian mode. In joint mode the buttons change to the axis A1 to A4.

While jogging in Cartesian mode virtual walls can be switched on to limit the motion and thereby avoiding e.g. collisions. See section 7 for details.

When the virtual walls are active the robot blocks further motions when leaving the allowed area. These restrictions do not hold in joint mode.

The most convenient way to move the robot is with a connected joypad, the picture below shows the assignment of keys.

Reference:

1. Change motion mode

2. Change active robot

3. Open / close gripper

4. Record a motion point

5. Change button

assignment: when pressed it is not +X, but +B

Pic. 10: Assignment of keys for the joypad. Upper markings for Cartesian mode, lower for joint mode.

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5.4 Moving the Robot using the Graphics

An alternative to the joypad is to drag the robot in the graphical 3D environment. When selecting a joint of the robot with the left mouse button, the joint outlines blink red. When selecting the joint and moving the mouse with pressed left mouse button this joint will rotate forward or backward, depending on the mouse motion.

Pic. 10: Joint and coordinate system outlines after selecting with the mouse.

The motions are possible in simulation and with the real robot. They are also scaled with the override buttons.

5.5 Connect with the Hardware

The real robot can be controlled in the same way as the simulated one, only the hardware has to be connected before: connect, reset errors and enable motors.

Prerequisites are that the robot is connected via the USB-CAN adapter and the robots supply is running (plugged in, switched on and emergency button released).

Pic. 11:

Buttons to connect to t

he hardware, reset the errors and enable the motors

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Step 1: Connect with the hardware. This step initializes the USB-CAN interface. The LED on the left side of CPRog changes color from grey to red. Below the LED several error messages are displayed.

Step 2: Reset the errors. This button resets the error memory of the joint

module controller in the robot. The joint values are copied from the real robot to the simulation environment. The 3D visualization of the robot has to match the current pose of the real robot now. This has to be verified every time the errors are reset! The LED stays red. The error messages get cleared, only “Motors not enabled“ is remaining. If further error messages remain visible try again and see section

11.3 for possible approaches.

Step 3: Enable the motors. Now the robot can be jogged as described

above. The LED is green now.

5.6 Reset the Zero Points of the Joints

The joint modules of the Mover4 store the last joint value in their memory, so the robot is aware of his current position after being switched on. But if these values are not correct, the joints need to be calibrated. Reasons may be:

 Turning the joints while the robot is without power supply  Stopping the robot with the emergency stop during a motion  …

To calibrate the robot it has to be jogged into a perpendicular position using the joint mode. The sticker on the axis provide assistance, their triangles should be aligned with the structures marks.

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When the robot is in the correct position press “LogoCircle/Configuration/SetJointsToZero” in the upper left menu. Confirm the following dialog with „OK“.

This function takes back the motor enabling, so the error reset and enable motor buttons have to be pressed.

The precision of the calibration is vital for replaying old programs. If theses old programs (recorded before the calibration) show precise motions close to the environment they have to be replayed slowly the first time. It may be necessary to re-teach positions.

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6. Programming the Robot Arm with CPRog

6.1 Program Elements

A Mover4 robot program is build out of the following commands:

Lin The robot moves on a straight line from the

current position to the target position. The velocity is defined in mm/s.

Joint Interpolates the axis from the current position to

the target position in joint coordinates. Velocity is defined as percentage of the maximum joint rotational velocity.

Relative A linear or joint motion with a defined distance

starting at the current position. Velocity in mm/s or percent.

Wait

Waits for a time span defined in s.

Gripper The gripper command open (100%) or closes

(0%) the gripper.

DigitalOut Sets a digital output. The button on the left side

records the current gripper state.

Loop Iterates the included commands until a digital

input is set or the defined number of iterations is reached.

If-Then-Else Executes two different command lines

depending on the state of a digital input.

ExternalMotion Passes control to an external program connected

via sockets, e.g. a vision system. See section Fehler! Verweisquelle konnte nicht gefunden werden. for details.

Sub Allows to call sub programs to structure longer

tasks.

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The complete language specification is found in section Fehler! Verweisquelle konnte nicht gefunden werden. .

6.2 Recording a Program using the 3D Interface

Using the 3D screen a program can be recorded using the joypad or the buttons.

Joypad: Every time the A button (or button 2) on the joypad is pressed a linear command to the current robot position is recorded. If necessary a command to open or close the gripper is added, together with a short break. A sound indicates that the point was recorded.

Program Buttons: If there are still commands in the memory, they can be deleted using the Delete button. Afterwards linear, joint, gripper and break commands can be recorded. The buttons record the current state of the robot or gripper.

Pic. 12:

Buttons

for program generation

6.3 Saving and Loading of a Program

With the button „Save Program” the commands are saved in an XML file in the directory

c:\CPRog\Data\Programs\

or in any other user defined folder. The button to load a program is found in the Motion/Programs area.

6.4 Replay of a Program

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The buttons in the area Motion/Programs allow to replay, pause and stop a program. The replay can be done in single, repeat or step mode.

6.5 Editing a Program with GraphEdit

The button Programming/Editor opens a graphical program editor. This editor allows in a puzzle visualization to adapt and create programs.

Pic. 13:

Graphical program editor

In the upper left area common elements are found, Undo/Redo and Load/Save. Two further buttons need explanation:

 The dust bin deletes the selected puzzle piece  The light bulb updates the program on the current robot to the updated

version. It also saves the program.

New commands can be dragged from the shelf on the upper right corner. They are initialized with the current robot position. Commands can be copied by dragging them with the CTRL key pressed.

6.6 Editing a Program with TextEdit

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Using the button beneath GraphEdit opens the TextEdit Program editor. This editor is more usable for bigger programs and provides more information.

The editor contains a syntax check. Illegal cells are marked red, the syntax for the command is shown in the bottom line as an assistance.

When there are errors in the program it cannot be saved.

Pic. 14: TextEdit program editor

The five picture buttons allow direct interaction:

 Recording a motion command (lin or joint according to the robots current

motion type) with the current robot position

 Recording a break  Recording a gripper command  Deleting the selected line  Setting the selected line as starting point for the next program start

All fields of the commands can be edited directly to e.g. change the velocity. Changes are accepted when clicking on another line or field. A line can be copied with Ctrl-C (or in the Edit menu), Ctrl-V pastes the command again.

All new commands are inserted in the line above the selected line.

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When choosing ‘Save’ from the File menu the current program is written and loaded by the robot. So the robot is again in synch with the text editor.

When choosing ‘Save As’ from the File menu the current program is saved under a different name. The new file is loaded by the robot.

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7. Configuration

7.1 Application Configuration

The application configuration can be done by adapting the parameters in different XML files.

7.1.1

Startup Configuration

The file c:\CPRog\CPRFrontend.xml allows to set the language and the start project.

<Program Language="DE"/> Possible choices are DE and EN. <StartUp Project="..\..\Data\Projects\Mover4Basic.prj" />

7.1.2

Project File

The project file can be found in c:\CPRog\Data\Projects\ The initial position of the view camera is defined in the line:

Offset and Tool of the robot can be changed:

<Robot Name="Mover" Type="CPRMover4" Homepos="-5.0 10.0 130.0 -70.0 0.0 0.0"

OffsetX="0.0" OffsetY="0.0" OffsetZ ="0.0" OffsetRX="0.0" OffsetRY="0.0" OffsetRZ="0.0" Parent="-1" Tool="TwoFingerGripper.xml"/>

Objects in the Virtual Environment can be added, static or active:

<ActivePeripheral Name="Conveyor" Gravity="false" Sensable="false"

Geometry="LN_Conveyor.obj" OffsetX="535" OffsetY="-26" OffsetZ ="0" OffsetRX="0" OffsetRY="0" OffsetRZ="180" GeometryPlatform="LN_ConveyorPlatform.obj" OffsetPlattformX="-240.0" OffsetPlattformY="0.0" OffsetPlattformZ="175.0" TravelX="445.0" TravelY="0.0" TravelZ="0.0"/>

<StaticSceneObject Name="WorkPiece" Gravity="true" Sensable="false"

Geometry="LN_Workpiece.obj" OffsetX="780" OffsetY="-26" OffsetZ ="240" OffsetRX="0" OffsetRY="0" OffsetRZ="0.0"/>

Please refer to the examples to get to know different combinations. The CAD files have to be in .stl (only ASCII) or AliasWavefront .obj format, units are mm.

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7.2 Robot Configuration

For each robot in the CPRog simulation a XML config file exists, e.g.

C:\CPRog\Data\Robots\CPRMover4\CPRMover4.xml

Definition for the velocities in Jog mode:

A virtual cell can be defined as a safety space the robot cannot leave in Cartesian mode:

<VirtualBox active="false" xMin="50.0" xMax="400.0" yMin="-150.0" yMax="250.0"

zMin="10.0" zMax="300.0" />

The cell walls are not active in joint mode.

Also the control parameter of the joint controller can be adapted, e.g. the position and velocity PID settings. This can be done with the button „Load Amp Config” in the program start menu. This button reads a parameter file and transfers the data to the connected robot arm.

Further information on the joint controller and the CAN protocol can be found in the servo controller documentation. Get in touch with CPR to get this documentation: [email protected]

Changing the joint controller configuration requires knowledge of the system. The robot may move in unexpected ways if ill-fitted parameters are uploaded. The robot may damage itself and its environment. Any warranty is void when uploading parameter files not generated by CPR!

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8. Interfacing

8.1 CRI Interface

The CRI interface allows to connect via Ethernet and jog the robot, send motion commands and start programs.

With this setup you can use the CPRog functionalities and implement custom algorithms in a CRI client, e.g. a vision system. Possiblities then are e.g.:

 Send a list of motion or digital out commands to the robot and then start

the assembled program.

 Jog the robot arm by sending jog values.

Motion are possible in joint or Cartesian space.

The CRI documentation and an example CRI client written in C# can be downloaded on our Wiki in the Interfacing section:

http://wiki.cpr-robots.com

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8.2 ROS – Robot Operating System

The Willow Garage Robot Operating System (see www.ros.org) is wide spread in the research community, especially when dealing with service robots. For the Mover4 packages are available to connect with the hardware and to command the robot by joint and position messages. A RViz plugin and a moveIt interface are available. The packages can be downloaded at

https://www.github.com/CPR-Robots

8.3 Direct Access using the CAN Protocol

It is also possible to directly access the Mover4 on CAN field bus level, using a custom control software. The necessary protocol specification is found in the following section.

Code examples can be found on the Wiki in the Interfacing section:

http://wiki.cpr-robots.com

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9. CAN Protocol Specification

The Mover4 uses the CPR-CAN protocol, a custom CAN protocol with 16 bit position data width.

The protocol description is available on our Wiki in the Interfacing section:

http://wiki.cpr-robots.com

Please refer also to the C++ implementations found on www.githu.com/CPR-Robots for code examples. The Mover4 has the standard CAN IDs 0x10, 0x20, 0x30, 0x40 for the four joint modules.

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10. Error Codes

The robot provides two means of error indications, via the inner LED and via the CAN bus.

10.1.1 Red LED on the control module

This LED can be seen through the single holes in the robots hull.

Off: No error One fast blink every second: Restart after brown-out reset. Supply voltage dropped below minimum value. Increase stability of supply. Two fast blinks every second: Restart after watch-dog reset. Microcontroller got stuck. Get in contract with Commonplace Robotics.

Three fast blinks every second: CAN error has occurred

10.1.2 CAN-bus and CPRog status bar

Error

Bit in

error byte

Meaning

Possible action

Bus dead

The CAN bus is not accessable.

Normaly the reason is that the robot does not have power.

Check all plugs and the emergency

button. See wiki.cpr-robots.com, section ‘Troubleshooting’

Brown Out

or Watch Dog

Bit 1

Microcontroller restarted

after a brown out. Supply voltage was too low or µC got stuck.

Increase stability of su

pply

voltage. Reset errors.

VelLag

Velocity Lag

Bit 2

Velocity changes too fast

Reset errors

, enable again. Slower

acceleration.

MNE

Motor not enabled

Bit 3

Not an error. Motor need

s to

be enabled by explicit command

Enable motor when appropriate.

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COM

Comm Watch Dog

Bit 4

Interval without

command

was too long

Provide the position or velocity

commands in a reliable and short enough time interval. Increase maxMissedCom.

LAG

Position Lag

Bit 5

Position is too far away from

the setpoint position

Provide setpoint positions

reachable to the current motor position. Increase maxLag.

ENC

Encoder Error

Bit 6

The sequence of the

quadrature encoder pulses did not fit.

Check connection cable motor

–

motor controller

Over Current

Bit 7

Current value too high

Decrease applied load on mot

or.

Increase maxCurrent.

CAN

CAN Error

Bit8

CAN error occured

CAN bus to crowded? All

connectrions ok?

A normal state after start-up of the board is an error code of 0x1C (Motor not enabled, CommWatchDog, PositionLag) After an error reset the normal state is 0x04 (Motor not enabled). After enabling the motor the status is 0x00, now the motor is ready to move.

To reach this state, the communication has to provide values in a fast and reliable way and, when in position control, in the reach of the motor. These restrictions are taken to prevent unwanted motion due to e.g. a blue screen on the control PC, a broken communication, or programming bugs.

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11. Troubleshooting

This section offers approaches to solve problems and errors in the areas Installation, Software and Hardware. If these measures do not solve your problem please get in contact with us, we are happy to help:

 Mail: [email protected]

Please add a description of the problem, the robots serial number (found at the base) and the three files „install.log“, „startUpLog.txt“ and „logMessages.log“. They are found in c:\CPRog\.

 Phone: ++49 5429 / 37983-4 in Germany, GMT+1

11.1 Installation and Program Start

Error Possible Cause Measures

Error message:

„Windows Version older than XP. Installation stops.“

Is an

older Windows version

running on the computer? CPRog needs Windows XP or higher.

Installation on a computer w

ith

Windows XP or higher.

Program does not start, error

message e.g. „The Application could not be initialized correctly (0xc0000135). “

Is the

Microsoft .NET

Framework missing?

Install the current .NET f

ramework

from the Microsoft homepage

Program does not start, error

message: "CPRog has encountered a problem and needs to close”.

Is and Di

rectX

file missing

These files are necessary for joypad and audio functionalities.

Install

DirectX Version 9.0

c for

your system. Links can be found using any search engine.

Program does not start, error

message: „CPRog does not work any more”

If runn

ng on Windows 7: If

CPRog is installed at c:\Programs or c:\Programs (x86) it can be started only with administrator rights.

Right

click on the CPRog link on the

desktop, choose „start as administrator”

11.2 Software CPRog

Error Possible Cause Measures

Connection loss

The robot expects periodically

a message from the CPRog computer. If this does not have sufficient free computing power, the break between two

Reset the errors and

ree the motors,

restart the program, see section 5.4. Avoid these problems by closing further programs, eventually disabling the network connection and

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messages may be too long.

the virus scanner.

Does not move any more:

Message “Virtual Box violated” and warning sound.

When moving in „Cartesian

Mode” the robot cannot get out of a virtual box. In “Joint Mode“ this is possible, changing back in CartMode may lead to these warnings.

Change to JointMode and move the

robot back into the virtual Box, e.g. into a standard position.

The robot does not connect,

the connect button does not work.

Is the USB

CAN a

dapter

plugged in, are the driver installed? Is the mains adapter plugged and switched on? Is the EmergencyStop button released? Do the green status LEDs in the joint modules blink?

You can find further i

nformation in

the Log-Messages window. The LED of the USB interface provides information:

 LED slow blinking: power on  LED fast blinking: communication

on the bus, ok

 LED on for longer phases:

transmission losses, traffic too high?

The robot does not react to

the joypad

Has it been activated?

Is the

green ok mark on the joystick button?

The Log

Messages window s

hows if

the joypad has been connected correctly. On the joypad: When the red light beneath the mode button of the joypad is on, you have to press the mode button once again.

11.3 Hardware Mover4

Error Possible Cause Measures

Position err

or: the robot

does not proceed to the same positions as before.

The robot can l

ose its joint

values due to unexpected power loss or motions of the joints when the robot is switched off.

Reset the joint zero values

according to section 5.6. Do not disconnect the robot from energy while in motion. Do not move the joints manually.

USB

Interface

is not

recognized

Is the USB interface plugged into

a port where it has not been in before?

With WindowsXP you have to

install the interface driver once for every port it is plugged in. Use the assistant that opens automatically.

No motion, no connection

possible

Check all connections and the

emergency stop. Burnt-out fuse in the robot base?

At the base of

the robot there is a

small fuse cabinet for 5x20 mm microfuses, 3.1 A. The reason for the failure should be known and removed before changing the fuse!

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12. Language Specification

The following nine commands can be combined to form a robot program. A program is a XML file that starts with the lines

<?xml version="1.0" encoding="utf-8"?>  <Program> <Header ProgramName ="CPRog recording" Author="nn" SetUpDate=""

LastChangeDate="" Kinematic="CPRFour"/>

Then the commands follow, the program closes with the line

</Program>

Command Reference

<Linear Nr="2" x="232.93" y="12.2" z="494.01" a="0.05" b="84.25" c="0" vel="70" acc="40" smooth="true"

Descr=""/>

<Joint Nr="1" a1="5.19" a2="-26.08" a3="124.72" a4="-14.39" a5="0" a6="0" velPercent="35" acc="40" smooth="true”

Descr="" />

<Loop Nr="1" Mode="Count" Times="3" Descr=""/> … place the commands to be repeated here <EndLoop Nr="1" />

Alternative:

<Loop Nr="1" Mode="DIn" Local="True" Channel="0" State="True"

Descr=""/>

<If Nr="15" Local="True" Channel="0" Descr=""/> … place the then-commands here <Else/> … place the else-commands here <EndIf/>

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