SCORBOT-ER 9
User Manual
Catalog #100066 Rev. B
Copyright 2003 Intelitek Inc.
SCORBOT-ER 9
Catalog # 100066 Rev. B
March 1996
Every effort has been made to make this book as complete and accurate as possible. However, no
warranty of suitability, purpose, or fitness is made or implied. Intelitek is not liable or responsible
to any person or entity for loss or damage in connection with or stemming from the use of the
software, hardware and/or the information contained in this publication.
Intelitek bears no responsibility for errors that may appear in this publication and retains the right
to make changes to the software, hardware and manual without prior notice.
Safety Warning!
Use the SCORBOT ER-9 with extreme caution.
The SCORBOT ER-9 can be dangerous and can cause severe injury.
Setup up a protective screen or guard rail around the robot to keep people away from its
working range.
INTELITEK INC.
444 East Industrial Park Drive
Manchester NH 03109-537
Tel: (603) 625-8600
Fax: (603) 625-2137
Web site www.intelitek.com
Table of Contents
CHAPTER 1
CHAPTER 2
CHAPTER 3
CHAPTER 4
Unpacking and Handling
Unpacking the Robot . . . . . . . . . . . . . . . . . . . . . 1-1
Handling Instructions . . . . . . . . . . . . . . . . . . . . . 1-2
Acceptance Inspection . . . . . . . . . . . . . . . . . . . . 1-2
Repacking for Shipment . . . . . . . . . . . . . . . . . . . 1-3
Specifications
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Work Envelope . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Safety
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installation
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Controller and Computer/Terminal Setup . . . . . . . . 4-1
Robot Setup . . . . . . . . . . . . . . . . . . . . . . . 4-1
SCORBOT-ER IX Installation . . . . . . . . . . . . . . . . 4-3
Controller Installation . . . . . . . . . . . . . . . . . . 4-3
Robot Installation . . . . . . . . . . . . . . . . . . . . 4-3
Homing the Robot . . . . . . . . . . . . . . . . . . . . 4-4
Gripper Installation . . . . . . . . . . . . . . . . . . . . . . 4-5
Pneumatic Gripper . . . . . . . . . . . . . . . . . . . . 4-5
DC Servo Gripper . . . . . . . . . . . . . . . . . . . . 4-7
Activating the Gripper . . . . . . . . . . . . . . . . . . 4-8
CHAPTER 5
CHAPTER 6
Operating Methods
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ACL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ACLoff-line . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SCORBASE Software . . . . . . . . . . . . . . . . . . 5-2
Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive System
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
DC Motor Structure . . . . . . . . . . . . . . . . . . . 6-3
SCORBOT-ER IX Motors . . . . . . . . . . . . . . . . 6-4
Harmonic Drive Gears . . . . . . . . . . . . . . . . . . . . 6-5
Harmonic Drive Gear Ratios . . . . . . . . . . . . . . . 6-6
Axis Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . 6-7
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CHAPTER 7
Position and Limit Devices
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Encoder Resolution . . . . . . . . . . . . . . . . . . . 7-3
End of Travel (Limit) Switches . . . . . . . . . . . . . . . . 7-4
Hard Stops . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Home Switches . . . . . . . . . . . . . . . . . . . . . . . 7-6
CHAPTER 8
CHAPTER 9
Wiring
Robot (Power) Cable and Connector . . . . . . . . . . . . 8-2
Encoder Cable and Connector . . . . . . . . . . . . . . . . 8-3
Maintenance
Daily Operation . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . 9-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9-2
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
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Unpacking and Handling
This chapter contains important instructions for unpacking and inspecting the
SCORBOT-ER IX robot arm.
)
Read this chapter carefully before you unpack the SCORBOT-ER IX robot and
controller.
Unpacking the Robot
The robot is packed in expanded foam, as shown in Figure 1-1.
To protect the robot during shipment, a metal plate holds the gripper- mounting
flange to the robot base. The plate is fixed to the flange with three bolts and to the
base with two bolts. Use a 3mm hex socket wrench to detach these bolts.
CHAPTER
1
Save these bolts and the plate
for shipment.
Save the original
packing materials
shipping carton. You
may need them later for
shipment or for storage
of the robot.
and
. You will need them should you repack the robot
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Figure 1-1: SCORBOT-ER IX in Packing
Handling Instructions
The robot arm weighs 38 kilos (83 pounds). Two people are needed to lift or
move it.
Lift and carry the robot arm by grasping its body and/or base. Do not lift or
carry the robot arm by its upper arm or forearm.
Acceptance Inspection
After removing the robot arm from the shipping carton, examine it for signs of
shipping damage. If any damage is evident, do not install or operate the robot.
Notify your freight carrier and begin appropriate claims procedures.
The following items are standard components in the
Make sure you have received all the items listed on the shipment’s packing list. If
anything is missing, contact your supplier.
Item Description
SCORBOT-ER IX
Robot Arm
Gripper
ACL Controller-B
Teach Pendant
Software
Documentation
: 2 options
: optional
SCORBOT-ER IX
Includes: Cabling with air hoses; Hardware for mounting robot: 3
M8x60 bolts; 3 M8 washers; 3 M8 nuts.
Pneumatic Gripper
Hardware for mounting gripper: 6 4Mx8 screws.
Electric DC Servo Gripper
mounting gripper: 4 M4x10 screws.
Includes: Power Cable 100/110/220/240VAC; RS232 Cable;
3 driver cards for 6 axes.
Optional:
Emergency By-Pass Plug (required when TP not connected)
Additional driver cards for control of up to 12 axes;
Auxiliary multiport RS232 board, cable and connectors.
Includes: mounting fixture; connector adapter plug;
Teach Pendant for Controller-B User’s Manual
ATS (Advanced Terminal Software) diskette;
includes
SCORBASE
SCORBOT-ER IX User’s Manual
ACL
ACL for Controller-B Reference Guide
ATS for Controller-B Reference Guide
ACLoff-line User’s Manual
SCORBASE Level 5 for Controller-B Reference Guide
ACLoff-line
Level 5 Software diskette
Controller-B User’s Manual
includes: pneumatic solenoid valve;
with encoder includes: Hardware for
software
package.
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Repacking for Shipme nt
Be sure all parts are back in place before packing the robot.
When repacking the robot for shipping, bolt the flange and base to the metal
plate. Failure to do so may result in irreversible damage to the arm, particularly
to the Harmonic Drive transmissions. Also be sure to secure the cables around the
foam spool.
The robot should be repacked in its original packaging for transport.
If the original carton is not available, wrap the robot in plastic or heavy paper. Put
the wrapped robot in a strong cardboard box at least 15 cm (about 6 inches)
longer in all three dimensions than the robot. Fill the box equally around the unit
with resilient packing material (shredded paper, bubble pack, expanded foam
chunks).
Seal the carton with sealing or strapping tape. Do not use cellophane or
masking tape.
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This page in te nt io na ll y le ft bla nk.
SCORBOT-ER IX 1 - 4 User’s Manual
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CHAPTER
Specifications
The following table gives the specifications of the SC ORBOT-ER IX robot arm.
Robot Arm Specifications
Mechanical Structure Vertical articulated, enclosed casting
Number of Axes 5 plus gripper
2
Axis Movement
Axis 1: Base rotation
Axis 2: Shoulder rotation
Axis 3: Elbow rotation
Axis 4: Wrist pitch
Axis 5: Wrist roll
Maximum Operating Radius 691mm (27.2") without gripper
End Effector: options:
Hard Home Fixed position on all axes
Feedback Incremental optical encoders with index pulse
Actuators DC servo motors
Transmission Harmonic Drive gears and timing belts
Maximum Payload 2 kg (4.4 lb.), including gripper
Position Repeatability
Weight 38 kg (83 lb.)
Ambient Operating Temperature 2°–40°C (36°–104°F)
Axis Range Effective Speed
270° 79°/sec 112°/sec
145° 68°/sec 99°/sec
210° 76°/sec 112°/sec
196° 87°/sec 133°/sec
737° 166°/sec
Pneumatic Gripper
Electric DC Servo Gripper
±
0.09mm (0.0035")
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Structure
Axis No. Joint Name Mo tio n Motor No.
The SCORBOT-ER IX is a vertical articulated robot, with five revolute joints. With
gripper attached, the robot has six degrees of freedom. This design permits the
end effector to be positioned and oriented arbitrarily within a large work space.
Figures 2-1 and 2-2 identify the joints and links of the mechanical arm.
Each joint is driven by a permanent magnet DC motor via a Harmonic Drive gear
transmission and timing belt.
The movements of the joints are described in the following table:
1 Base Rotates the body. 1
2 Shoulder Raises and lowers th e up pe r ar m . 2
3 Elbow Raises and low er s th e fo re ar m . 3
4 Wrist Pitch Raises and lowers the end effector. 4
5 Wrist Roll Rotates the end effector. 5
Figure 2-1: SCORBOT-ER IX Joints
SCORBOT-ER IX 2 - 2 User’s Manual
Figure 2-2: SCORBOT-ER IX Links
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Work Envelope
The length of the links and the degree of rotation of the joints determine the
robot’s work envelope. Figure 2-3 shows the dimensions and reach of the
SCORBOT-ER IX, while Figure 2-4 gives a top view of the robot’s work envelope.
The base of the robot is normally fixed to a stationary work surface. It may,
however, be attached to a slidebase, resulting in an extended working range.
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Figure 2-3: Operating Range (Side View)
SCORBOT-ER IX 2 - 4 User’s Manual
Figure 2-4: Operating Range (Top View)
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The SCORBOT-ER IX is a potentially dangerous machine. Safety during operation
is of the utmost importance. Use extreme caution when working with the robot.
Precautions
The following chapters of this manual provide complete details for proper
installation and operation of the SCORBOT-ER IX. The list below summarizes the
most important safety measures.
1. Make sure the robot base is properly and securely bolted in place.
2. Make sure the cable from the body to the base can move freely during all
movements of the robot’s base axis.
Safety
CHAPTER
3
3. Make sure both the encoder cable and the robot power cable are properly
connected to the controller before it is turned on.
4. Make sure the robot arm has ample space in which to operate freely.
5. Make sure a guardrail or rope has been set up around the SCORBOT-ER IX
operating area to protect both the operator and bystanders.
6. Do not enter the robot’s safety range or touch the robot when the system is in
operation.
7. Press the controller’s EMERGENCY switch before you enter the robot’s
operating area.
8. Turn off the controller’s POWER switch before you connect any inputs or
outputs to the controller.
)
To immediately abort all running programs and stop all axes of motion, do any of
the following:
press the teach pendant’s EMERGENCY button;
use the ACL command A <Enter>;
press the controller’s red EMERGENCY button.
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Warnings
1. Do not operate the SCORBOT-ER IX
User’s Manual and the
safety guidelines outlined for both the robot and the controller.
ACL
Controller-B
until you have thoroughly studied both this
User’s Manual. Be sure you follow the
2. Do not install or operate the
•
Where the ambient temperature drops below or exceeds the specified limits.
•
Where exposed to large amounts of dust, dirt, salt, iron powder, or similar
substances.
•
Where subject to vibrations or shocks.
•
Where exposed to direct sunlight.
•
Where subject to chemical, oil or water splashes.
•
Where corrosive or flammable gas is present.
•
Where the power line contains voltage spikes, or near any equipment which
generates large electrical noises.
3. Do not abuse the robot arm:
•
Do not operate the robot arm if the encoder cable is not connected to the
controller.
•
Do not overload the robot arm. The combined weight of the workload and
gripper may not exceed 2kg (4.4 lb.). It is recommended that the workload be
grasped at its center of gravity.
SCORBOT-ER IX under any of the following conditions:
•
Do not use physical force to move or stop any part of the robot arm.
•
Do not drive the robot arm into any object or physical obstacle.
•
Do not leave a loaded arm extended for more than a few minutes.
•
Do not leave any of the axes under mechanical strain for any length of time.
Especially, do not leave the gripper grasping an object indefinitely.
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Installation
Preparations
Before you make any cable connections, set up the system components according
to the following “Preparation” instructions.
Controller and Computer/Terminal Setup
Place the controller and computer at a safe distance from the robot—well outside
the robot’s safety range.
Make sure the setup complies with the guidelines defined in the chapter,
“Safety,” in the ACL
Controller-B
User’s Manual.
CHAPTER
4
Robot Setup
Refer to Figures 4-1, 4-2 and 4-3.
1. Set up the SCORBOT- ER I X
on a sturdy surface with at
least one meter of free space
all around the robot.
2. Note that the robot cable
clamp is located at the
midpoint of the robot’s
horizontal range. Using this
midpoint as a reference, set
up the robot so that it faces in
the proper direction—
towards the application or
machine it will serve.
3. Fasten the base of the robot to
the work surface with three sets
of M8 bolt, washer and nut.
Figure 4-1: Robot Safety Range
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Make sure the robot is securely bolted in place. Otherwise the robot could
become unbalanced and topple over while in motion.
4. Grasp the robot body and turn the robot to each extreme of its base axis.
)
Make sure the segment of cable from
the body to the base is not
obstructed, and/or cannot become
caught under a corner of the robot’s
platform or work surface during all
movements of the base axis.
Make sure the robot is mounted on a
surface large enough to provide
support for this segment of the robot
cable during all movements of the
base axis.
5. Set up a guardrail or rope around the
SCORBOT-ER IX operating area to
protect both the operator and
Figure 4-2: Robot Base Layout
bystanders.
SCORBOT-ER IX 4 - 2 User’s Manual
Figure 4-3: Robot Setup
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SCORBOT-ER IX Installation
Controller Installation
Perform the installation procedures detailed in the following sections of
Chapter 2, “Installation,” in the Controller-B User’s Manual:
•
Computer/Terminal–Controller Installation
•
Power On
•
Controller Configuration
)
When the Peripheral Setup screen appears at the end of the controller
configuration, select Gripper Connection: None. (You will change this setting
after the gripper is installed.) Refer to the section, “Peripheral Devices and
Equipment--Robot Gripper,” in the Controller-B User’s Manual.
Robot Installation
)
Before you begin, make sure the controller POWER switch is turned off.
The robot cable has a number of connectors. Connect them to the controller
according to following three steps. Refer to Figure 4-4.
1. Connect the green/yellow wire to the Safety Ground:
Unscrew and remove the ground nut and washer from the Safety Ground stud.
Place the ground wire terminal onto the stud, then replace and tighten the washer
and nut.
2. Plug the the D37 connector into the Robot Encoders port.
Tighten the retaining screws on the connector.
3. Plug the 19-pin round connector into the Robot Power port.
AIR HOSES
(for pneumatic
gripper only)
2
3
1
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Figure 4-4: Robot—Controller Cable Connections
Note: When disconnecting the robot from the controller, do it in the reverse order; that
is:
•
Disconnect the 19-pin round Robot Power connector.
•
Disconnect the 37-pin Encoders connector.
•
Disconnect the ground wires.
Homing the Robot
After you have completed the robot installation, execute the robot’s Home
routine, as described below.
)
The robot must be homed before you mount the gripper.
)
Before you begin the homing procedure, make sure the robot has ample space in
which to move freely and extend its arm.
1. Turn on the controller. Turn on the computer.
2. From the ATS diskette or directory, activate the ATS software. Type:
ats <Enter>
If the controller is connected to computer port COM2, type:
ats /c2
3. When the ATS screen and > prompt appear, you may proceed.
4. Give the ACL command to home the robot. Type:
home <Enter>
The monitor will display:
WAIT!! HOMING...
During the Home procedure, the robot joints move and search for their home
positions in the following sequence: shoulder, elbow, pitch, roll, base.
If home is found, a message is displayed:
HOMING COMPLETE (ROBOT)
If the HOME process is not completed, an error message identifying the failure is
displayed. For example:
*** HOME FAILURE AXIS 3
If the home switch is found, but not the encoder’s index pulse, the following
message is displayed:
* * * INDEX PULSE NOT FOUND AXIS 2
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Gripper Installation
The gripper is attached to the flange at the end
of the robot arm whose layout is shown in
Figure 4-5.
Pneumatic Gripper
The pneumatic gripper, shown in Figure 4-6,
is controlled by a 5/2 solenoid pneumatic
valve which is activated by one of the
controller’s relay outputs. The valve may be
12VDC or 24VDC and can draw its power
from the controller’s User Power Supply.
)
The robot must be homed before you mount the
gripper.
1. Using a hex wrench and six M4x8 socket
screws, attach the gripper to the robot arm
flange.
Figure 4-5: Gripper Mounting
Flange Layout
2. Connect the coiled double hose from the
gripper to the quick coupling on the robot’s
forearm, as indicated in Figure 4-7.
3. Refer to Figure 4-8.
•
Connect the two transparent 1/4" O.D.
hoses from the robot cable to the CYL
ports on the pneumatic valve.
•
Connect a 5 bar/90 PSI air supply to the
IN port on the valve.
4. Refer to Figure 4-9.
Figure 4-6:
Pneumatic Gripper
Connect the valve to the controller’s User
Power Supply as follows:
•
Connect the black wire to a common terminal.
•
Connect the red wire to the normally open (NO) terminal of any unused relay
output.
5. Connect 12VDC or 24VDC (in accordance with your valve’s specification) to the
common (C) terminal of the same relay output, as shown in Figure 4-9.
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6. Attach the valve to the controller or any other metalic surface by means of the
valve’s magnetic base.
Figure 4-8: Pneumatic Solenoid Valve
Figure 4-7:
Gripper Connectors
SCORBOT-ER IX 4 - 6 User’s Manual
Figure 4-9: Valve—Controller Connections
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DC Servo Gripper
The electric DC servo gripper is shown in the inset in Figure 4-10.
)
The robot must be homed before you mount the gripper.
Refer to Figures 4-10 and 4-11.
1. Using a 3 mm hex wrench and four M4x10 socket screws, attach the gripper to
the gripper mounting flange at the end of the robot arm.
2. Connect the gripper cable to the electrical connector on the robot arm.
Make sure the connector is oriented as shown in Figure 4-10.
3. Make sure the gripper cable is positioned as shown in Figure 4-11.
4. Carefully execute the robot HOME command. Stay close to the teach pendant or
controller. If the gripper cable becomes entangled or excessively stretched during
the homing, abort the procedure immediately.
5. The gripper has a rotation of ±270°. Do not attempt to move the gripper beyond
this limit.
6. At the end of each work session (before turning off the controller), or before
homing the robot, make sure the gripper’s position is as shown in Figure 4-11.
)
Axis 6 is reserved by default controller configuration for a servo gripper. To
connect a different device as axis 6, you must change the system configuration by
means of the ACL command CONFIG.
Figure 4-10: Connecting Gripper to SCORBOT-ER IX
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Figure 4-11: Connecting Gripper to SCORBOT-ER IX
Activating the Gripper
1. Activate ATS. Press <Ctrl>+F3 to activate the Peripheral Setup screen.
2. Change the robot gripper definition according to the gripper you have installed.
Refer to the section, “Peripheral Devices and Equipment--Robot Gripper,” in
Chapter 2 of the ACL
3. Open and close it in order to verify that it is functioning. The following
commands work for both the electric and the pneumatic gripper.
Controller-B
User’s Manual.
PC
Type:
open <Enter>
The gripper opens.
Type:
close <Enter>
The gripper closes.
TP
Key in:
Open/Close
The Open/Close key toggles the gripper between its open and closed states.
programs you have just written.
SCORBOT-ER IX 4 - 8 User’s Manual
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CHAPTER
5
Operating Methods
The SCORBOT-ER IX robot can be programmed and operated in a number of
ways.
Software
ACL
The ACL
through the basic commands for operating and programming the robot.
ACL, Advanced Control Language, is an advanced, multi-tasking robotic
programming language developed by Eshed Robotec. ACL is programmed onto a
set of EPROMs within Controller-B, and can be accessed from any standard
terminal or PC by means of an RS232 communication channel.
ACL features include the following:
Controller-B User’s Manual
Direct user control of robotic axes.
User programming of robotic system.
Input/output data control.
Simultaneous and synchronized program execution
(full multi-tasking support).
Simple file management.
includes two chapters which guide you
The
ACL Reference Guide for Controller-B
examples of the ACL commands and functions.
ATS
ATS, Advanced Terminal Software, is the user interface to the ACL controller.
ATS is supplied on diskette and operates on any PC. The software is a terminal
emulator which enables access to the ACL environment from a PC host computer.
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provides detailed descriptions and
ACLoff-line
ATS features include the following:
Short-form controller configuration.
Definition of peripheral devices.
Short-cut keys for command entry.
Program editor.
Backup manager.
Print manager.
The ATS Reference Guide for Controller-B is a complete guide to ATS.
ACLoff-line is a preprocessor software utility, which lets you access and use
your own text editor to create and edit ACL programs even when the controller is
not connected or not communicating with your computer.
After communication is established, the Downloader util ity let s you transfer your
program to the controller. The Downloader detects the preprocessor directives,
and replaces them with a string or block of ACL program code.
ACLoff-line also enables activation of ATS, Advanced Terminal Software, for
on-line programming and system operation.
ACLoff-line is described fully in the ACLoff-line User’s Manual.
SCORBASE Software
SCORBASE Level 5 is a robot control software package which is supplied on
diskette with the controller. Its menu-driven structure and off-line capabilities
facilitate robotic programming and operation.
SCORBASE runs on any PC system and communicates with ACL, the
controller’s internal language, by means of an RS232 channel.
The SCORBASE Level 5 for Controller-B Reference Guide provides detailed
descriptions and examples of the SCORBASE commands.
Teach Pendant
The teach pendant is a hand-held terminal which is used for controlling the
SCORBOT-ER IX
practical for moving the axes, recording positions, sending the axes to recorded
positions and activating programs. Other functions can also be executed from the
teach pendant.
robot and peripheral equipment. The teach pendant is most
The Teach Pendant for Controller-B User’s Manual fully describes the various
elements and functions of the teach pendant.
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CHAPTER
Drive System
The three main elements of the SCORBOT-ER IX drive system are shown in Figure
6-1:
•
DC electrical motor
•
Harmonic Drive gear
•
Timing belt and pulleys
Figure 6-1 shows the drive system for axes 1 through 4 of the SCORBOT ER-IX.
The roll axis (axis 5) transmission does not contain the pulleys and timing belt;
only a Harmonic Drive is used.
)
Note that the illustrations of components shown in this chapter are for descriptive
purposes, and may not be the actual components used in the SCORBOT-ER IX.
6
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Figure 6-1: The SCORBOT-ER IX Drive System
Motors
The SCORBOT-ER IX robot arm is driven by DC electric motors. These actuators
converts signals from the controller (electric power) into rotations of the motor
shaft (mechanical power).
A robot arm such as the SCORBO T- ER I X imposes severe requirements on the
actuators, such as the following:
•
The robot motor must rotate at different speeds, and with a high degree of
accuracy. For example, if the robot is to be used for a spray painting
application, it must be able to accurately follow the defined path at the
specified speed.
•
The robot motor must allow fine speed regulation so that the robot will
accelerate and decelerate as required by the application.
•
The robot motor must supply large torques throughout its speed range and
also when the joint is stationary.
•
The robot motor must be able to stop extremely quickly without overshooting
the target position, and perform rapid changes in direction.
•
Since mounting motors on the robot arm adds to the robot’s weight and
inertia, the robot motors must be light and compact, yet powerful. As shown
in Figure 6-2, the motors of the
SCORBOT-ER IX
are located on the axes
they drive, with a two-stage (axes 1–4) or one-stage (axis 5) transmission.
SCORBOT-ER IX 6 - 2 User’s Manual
Figure 6-2: Motor Locations in SCORBOT-ER IX
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DC Motor Structure
The principles of operation of electrical motors in general, and DC motors in
particular, are based on an electrical current flowing through a conductor situated
within a magnetic field. This situation creates a force which acts on the conductor.
Figure 6-3 shows the basic structure and components of a DC motor comparable
to the structure of the motors used in the SCORBOT-ER IX . This motors has three
main components:
•
Stator: This is a static component which creates the magnetic field. The
stator may be a permanent magnet, or an electromagnet consisting of a coil
wound around thin iron plates.
•
Rotor: This is the component which rotates within the magnetic field. The
external load is connected to the rotor shaft. The rotor is generally composed
of perforated iron plates, and a conducting wire is wound several times
around the plates and through the perforations. The two ends of the conductor
are connected to the two halves of the commutator, which are connected to
the electric current via the brushes.
•
Brushes: These connect the rotating commutator to the electric current
source.
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Figure 6-3: Basic Structure of a DC Motor
SCORBOT-ER IX Motors
The SCORBOT ER-IX uses permanent magnet DC motors to drive the axes.
Axes 1, 2 and 3 of the SCORBOT ER-IX are powered by the motor shown in
Figure 6-4. Axes 4 and 5 are powered by the motor shown in Figure 6-5.
These motors are able to move at extremely high rates of revolution, to move
loads with high torques, and (with encoder attached) to achieve a very high
resolution.
Peak Rated Torque 143 oz.in 27.8 oz.in
Rated Torque 32 oz.in 12.5 oz.in
Maximum Operating Speed 4000 rpm 4500 rpm
Weight 1.29 k / 2.84 lb 0.28 k / 0.62 lb
Motor Specifications
Motor Axes 1, 2, 3 Motor Axes 4, 5
SCORBOT-ER IX 6 - 4 User’s Manual
Figure 6-4: Motor on Axes 1, 2 and 3
Figure 6-5: Motor on Axes 4 and 5
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Harmonic Dr ive Gears
The Harmonic Drive transmission used in the SCORBOT-ER IX , shown in Figure
6-6, offers a very high gear ratio.
The Harmonic Drive gears used in the SCORBOT-ER IX have four main
components:
•
Circular spline:
a solid steel ring, with internal gear teeth, usually fixed to the robot link.
•
Wave generator:
a slightly elliptical rigid disk, which is connected to the input shaft, with a ball
bearing mounted on the outer side of the disk.
•
Flexspline:
a flexible, thin-walled cylinder, with external gear teeth, usually connected to
the output shaft.
•
Dynamic spline: a solid steel cylinder, with internal gear teeth.
The external gear teeth on the flexspline are almost the same size as the internal
gear teeth on the circular spline except there are two more teeth on the circular
spline, and the teeth only mesh when the wave generator pushes the flexspline
outwards.
Because the wave generator is elliptical, the flexspline is pushed out in two
places. As the motor rotates the input shaft, the wave generator rotates and the
location of meshing teeth rotates with it. However, because there are two less
teeth on the flexspline, it has to rotate backwards slightly as the wave generator
rotates forwards. For each complete rotation of the input shaft, the flexspline
moves
backwards by
two teeth.
Figures 6-7 and
6-8 show the
different steps
in this process.
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Figure 6-6: Harmonic Drive Structure
Harmonic Drive Gear Ratios
As in all gears, the gear ratio of the Harmonic Drive is the ratio of the input speed
to the output speed. If the number of teeth on the flexspline is Nf, then for every
revolution of the input shaft, the output shaft rotates by 2/Nf of a revolution (that
is, two teeth out of Nf teeth). Hence:
HD gear ratio =
The Harmonic Drive gear ratios for each of the SCORBOT-ER IX axes are as
follows:
Axis 1 — 161:1
Axis 2 — 160:1
Axis 3 — 160:1
Axis 4 — 100:1
Axis 5 — 100:1
1
2
N
N
f
=
2
f
Figure 6-7: Operation of the Harmonic Drive
Figure 6-8: Operation of the Harmonic Drive
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Axis Gear Ratios
Referring again to Figure 6-1, the transmission of axes 1 through 4 consists of
two stages: the timing belt drive, and the Harmonic Drive.
The overall gear ratio of the output shaft which moves the axis is therefore
expressed as:
NT × NHD = N
AXIS
Where:
N
is the belt drive ratio (that is, the radii ratio):
T
N
is the Harmonic drive ratio, as described above.
HD
N
is the overall gear ratio of the axis.
AXIS
SCORBOT-ER IX Gear Ratios
N
T
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
1.33 : 1 161 : 1 214.13 : 1
1.52 : 1 160 : 1 243.8 : 1
1.33 : 1 160 : 1 213.33 : 1
1.8 : 1 100 : 1 180 : 1
100 : 1 100 : 1
N
HD
Pulley
Pulley A
B
N
AXIS
Thus, one rotation (360°) of axis 3, for example, requires 213.33 rotations of the
motor shaft. The actual movement of the axis, however, is limited by the arm’s
mechanical structure.
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This page in te nt io na ll y le ft bla nk.
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Position and Limit Devices
This chapter describes the various elements in the SCORBOT-ER IX which play a
part in the positioning of the robot arm and the limiting of its motion.
Encoders
The location and movement of each SCORBOT-ER IX axis is measured by an
electro-optical encoder attached to the motor which drives the axis. The encoder
translates the rotary motion of the motor shaft into a digital signal understood by
the controller.
•
Encoders
•
End of Travel Switches
•
Hard Stops
•
Home Switches
CHAPTER
7
Figure 7-1 shows the encoder mounted on a
SCORBOT-ER IX motor.
The encoder used on the SCORBOT-ER IX
contains a single light emitting diode (LED)
as its light source. Opposite the LED is a
light detector integrated circuit. This IC
contains several sets of photodetectors and
the circuitry for producing a digital signal. A
perforated, rotating disk is located between
the emitter and detector IC.
Figure 7-1:
SCORBOT-ER IX Encoder
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As the encoder disk rotates between
the emitter and detectors, the light
beam is interrupted by the pattern of
“bars” and “windows” on the disk,
resulting in a series of pulses received
by the detectors.
The SCORBOT-ER IX encoders have
512 slots, as shown in Figure 7-2. An
additional slot on the encoder disk is
used to generate an index pulse
(C-pulse) once for each full rotation of
the disk. This index pulse serves to
determine the home position of the axis.
SCORBOT-ER IX Encoder Disk
Figure 7-2:
The photodetectors are arranged so that,
alternately, some detect light while
others do not. The photodiode outputs are then fed through the signal processing
circuitry, resulting in the signals A, A, B, B, I and I, as shown in Figure 7-3.
Comparators receive these signals and produce the final digital outputs for
channels A, B and I. The output of channel A is in quadrature with that of
channel B (90° out of phase), as shown in Figure 7-4. The final output of channel
I is an index pulse.
When the disk rotation is counterclockwise (as viewed from the encoder end of
the motor), channel A will lead channel B. When the disk rotation is clockwise,
channel B will lead channel A.
Figure 7-3: Encoder Circuitry Figure 7-4: Encoder Output Signals
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Encoder Resolution
From the quadrature signal the SCORBOT-ER IX controller measures four counts
for each encoder slot, thus quadrupling the effective resolution of the encoder.
The resolution of the encoder is expressed as:
360°
SE =
Where:
SE is the resolution of the encoder.
n is the number of counts per encoder revolution.
The encoders used in the SCORBOT-ER IX have 512 slots, generating 2048 counts
per motor revolution. The encoder resolution is therefore:
SE =
When the encoder resolution is divided by the overall gear ratio of the axis, the
resolution of the joint is obtained.
Since the encoder is mounted on the motor shaft, and turns along with it, the
resolution of the joint is expressed as:
n
360°
2048
= .176°
S
S
JOINT
=
N
E
AXIS
Thus, for example, the resolution of joint 3 of the SCORBOT-ER IX is therefore as
follows:
SJ3 =
0.176°
213.33
= 0.000825°
The resolution is the smallest possible increment which the control system can
identify and theoretically control. The accuracy of the axis—that is, the precision
with which it is positioned—is affected by such factors as backlash, mechanical
flexibility, and control variations.
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End of Travel (Limit) Switches
The SCORBOT-ER IX uses limit switches to prevent the joints from moving
beyond their functional limits. When a control error fails to stop the axis at the
end of its working range, the limit switch serves to halt its movement. The switch
is part of an electric circuit within the robot arm, independent of the robot
controller.
The limit switches used in the SCORBOT-ER IX are
shown in Figure 7-5.
Each of axes 1 through 4 has two limit switches:
one at each end of the axis’ working range.
Axis 5 (roll) has no travel limit switches; it can
rotate endlessly. When a gripper is attached to axis
5, its movements are controlled and limited by
means of software only (encoder).
The limit switches are mounted on a disk which is
attached to the robot’s frame. The disk for axis 3 is
shown in Figure 7-6.
The output shaft of the Harmonic Drive moves
relative to the microswitch disk.
Figure 7-5:
SCORBOT-ER IX
Limit Switch
As the joint moves, a cam
on the Harmonic Drive
output shaft reaches a point
at which it forces the
actuating button of the limit
switch into a position which
activates the switch.
LIMIT
SWITCH
CAM
LIMIT SWITCH
DISK
Figure 7-6: Limit Switch Activation
ACTUATING
BUTTON
LIMIT
SWITCH
HARMONIC
DRIVE OUTPUT
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As shown in Figure 7-7A,
when limit switch 1 is
activated (that is, when the
button is depressed), the relay
contact opens and the relay is
deenergized. The motor
cannot move the joint beyond
this point. The diode allows
the motor to reverse
direction, thus permitting the
joint to move away from the
limit switch.
When the limit switch is
activated, it causes a control
error, resulting in the
activation of COFF (control
off mode), and an impact
protection message.
CON (control on mode) must
be activated and the robot
arm must be manually moved
(using keyboard or teach
pendant) away from the
impact condition.
A
B
Figure 7-7: Axis Limit Circuit
As long as the axis has not reached one of its limits, the relay contact remains
closed, and the diode has no effect on the circuit, as shown in Figure 7-7B.
Current can flow in either direction; the motor is thus able to rotate in either
direction.
Hard Stops
When the software limits and/or the end of travel switches fail to halt the
movement of the robot arm, it is possible that the momentum of the robot arm
will drive it until it reaches its mechanical limit.
When the joint reaches this hard stop, the impact protection and thermic
protection processes detect an error, thus activating COFF.
CON must be activated and the robot arm must be manually moved away from
the impact condition.
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Home Switches
The SCORBOT-ER IX uses an optical home switch on each axis to identify the
fixed reference, or home, position.
The home switch is mounted on the same disk as the end of travel switches, and a
“flag” is attached to the Harmonic Drive output shaft, as shown in Figure 7-8.
During the homing procedure, the robot joints are moved, one at a time. Each axis
is moved until the flag cuts the beam of light. When that occurs, the optical
detector on each joint sends a specific signal to the controller.
Once the home switch location has been detected, the axis motor continues to
rotate until its encoder produces an index pulse. The point at which that occurs is
the axis home position.
OPTICAL
HOME
AXIS NOT AT HOME
LIMIT
SWITCH
FLAG
OPTICAL
HOME
AXIS AT HOME
Figure 7-8: Home Switch Activation
HARMONIC DRIVE
LIMIT
SWITCH
DISK
FLAG
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CHAPTER
Wiring
Figure 9-1 is a schematic diagram of the SCO RBOT- ER IX cable connections.
8
Figure 8-1: SCORBOT-ER IX Cabling
The wire braid which connects the robot to the controller contains a power (robot)
cable and an encoder cable.
The body, upper arm and forearm links each contain a printed circuit board
(PCB). The motors, encoders, limit switches and home switches for each axis are
directly connected to one of these three internal PCBs. Two wire braids connect
the PCBs. Each PCB transfers power to the motors to which it is directly
connected, and receives signals from the corresponding limit and home switches.
When a limit switch is triggered, the PCB automatically cuts off power to the
motor that drives the axis. In addition, each PCB transfers power to the next PCB
and sends encoder and home switch signals to the previous PCB.
The robot and encoder cable are directly connected to PCB 18100. The robot
cable supplies power to the PCB and the encoder cable carries information from
the encoders and the home switches for all six axes to the controller.
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Robot (Power) Cable and Connector
Figure 8-2 shows the Burndy 19 pin male connector
that joins the power cable to the controller’s back
panel.
The robot cable contains 12 leads. The following
table details the connector pin functions and cable
wiring.
Robot (Power) Cable Wiring and Connector
Figure 8-2: Burndy 19 Pin
Connector
Pin
ID
A Motor 1 – black M0_A
M Motor 1 + red M0_B
C Motor 2 – brown M1_A
L Motor 2 + orange M1_B
E Motor 3 – yellow M2_A
H Motor 3 + purple M2_B
B Motor 4 – light blue M3_A
K Motor 4 + blue M3_B
D Motor 5 – grey M4_A
J Motor 5 + pink M4_B
F Motor 6 – white M5_A
G Motor 6 + green M5_B
Pin Description
Robot Side (J1)
Beldan
Color
Pin Description
Controller Side (P1)
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Encoder Cable and Connector
The encoder cable, which connects the controller to
the motor encoders and optical home switches,
contains 36 leads.
Figure 8-3 shows the D37 female connector that joins
the encoder cable to the controller’s back panel.
The following table details the connector pin functions
and describes the cable wiring.
Encoder Cable and D37 Connector
Figure 8-3:
D37 Connector
Pin
ID
1+5V
8 COMMON yellow COMMON 0
5 CHA1 (E n co d e r P u l s e A) green CHA 0
6 CHB1 (E n c od e r P u l s e B ) white CHB 0
7 CHC1(Encoder Index Pulse) black CHC 0
31 MSWITCH (Home Switch) blue MSWITCH
1+5V
12 COMMON yellow COMMON 1
9 CHA2 (E n co d e r P u l s e A) green CHA 1
10 CHB2 (Encoder Pulse B) white CHB 1
11 CHC2 (Encoder Index Pulse) black CHC 1
32 MSWITCH (Home Switch) blue MSWITCH
1+5V
16 COMMON yellow COMMON 2
Pin Description
Robot Side (J1)
Axis
1
2
Telephone
Cable Color
red +5V
red +5V
red +5V
Controller Side (J2)
Pin Description
13 CHA3 (En c o d e r P u l se A ) green CHA 2
14 CHB3 (Encoder Pulse B) white CHB 2
15 CHC3 (Encoder Index Pulse) black CHC 2
33 MSWITCH (Home Switch) blue MSWITCH
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3
Encoder Cable and D37 Connector
Pin
ID
2+5V
Pin Description
Robot Side (J1)
Axis
Telephone
Cable Color
Controller Side (J2)
red +5V
Pin Description
20 COMMON yellow COMMON 3
17 CHA4 (En c o d e r P u l se A ) green CHA 3
4
18 CHB4 (Encoder Pulse B) white CHB 3
19 CHC4 (Encoder Index Pulse) black CHC 3
34 MSWITCH (Home Switch) blue MSWITCH
2+5V
red +5V
24 COMMON yellow COMMON 4
21 CHA5 (En c o d e r P u l se A ) green CHA 4
5
22 CHB5 (Encoder Pulse B) white CHB 4
23 CHC5 (Encoder Index Pulse) black CHC 4
35 MSWITCH (Home Switch) blue MSWITCH
2+5V
red +5V
28 COMMON yellow COMMON 5
25 CHA6 (En c o d e r P u l se A ) green CHA 5
6
26 CHB6 (Encoder Pulse B) white CHB 5
27 CHC6 (Encoder Index Pulse) black CHC 5
36 MSWITCH (Home Switch) blue MSWITCH
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The maintenance and inspection procedures recommended below will ensure the
best possible performance of the robot over an extended period.
Daily Operation
At the start of each working session, check the robot and controller, in the
following order:
1. Before you power on the system, check the following items:
•
The installation meets all safety standards.
•
All cables are properly and securely connected.
Cable connector screws are fastened.
Maintenance
CHAPTER
9
•
The gripper is properly connected.
The air supply (for a pneumatic gripper) is functioning properly.
•
Any peripheral devices or accesssories which will be used, such as the teach
pendant or a remote emergency button, are properly connected to the
controller.
2. After you have powered on the system, check the following items:
•
No unusual noises are heard.
•
No unusual vibrations are observed in any of the robot axes.
•
There are no obstacles in the robot’s working range.
3. Bring the robot to a position near home, and activate the Home procedure. Check
the following items:
•
Robot movement is normal.
•
No unusual noise is heard when robot arm moves.
•
Robot reaches home position in every axis.
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Periodic Inspection
The following inspections should be performed regularly:
•
Check robot mounting bolts for looseness using a wrench. Retighten as
needed.
•
Check all visible bolts and screws for looseness using a wrench and
screwdriver. Retighten as needed.
•
Check cables. Replace if any damage is evident.
The following robot components may require replacing after prolonged use of the
robotic arm causes them to wear or fail:
DC Servo Motors
Motor Brushes
Timing Belts
V-Rings
Harmonic Drives
Cross-Roller Bearings
Troubleshooting
Whenever you encounter a problem with your system, try to pinpoint its source
by exchanging the suspected faulty component—for example, robot, controller,
teach pendant, cable—with one from a functioning system.
In general, when trying to determine the source of a malfunction, first check the
power source and external hardware, such as controller switches, LEDs and cable
connections. Then check fuses; you may also open the controller to check
components, according to the procedures and instructions detailed in the
Controller-B User’s Manual.
In addition, make sure the controller is properly configured for the robot and
gripper, the software commands have been correctly issued, and system
parameters are properly set.
All troubleshooting procedures described in the section can be performed by the
user.
)
Do not attempt to open the robot arm. There are no user-serviceable parts inside.
If you are unable to determine and/or correct the problem, contact your service
representative. Only qualified technicians may remove and/or replace robot
components.
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1. Controller’s MOTORS switch does not turn on; the green LED does not light.
•
Make sure the Emergency button is released.
•
Turn off the controller, disconnect it from the power source, and open the
cover.
Check the 0.5A (SB) fuse (marked FAN/POWER/RELAYS)
2. Controller functioning, but the robot cannot be activated.
•
Make sure an obstacle is not blocking the robot.
•
Make sure the controller’s MOTORS switch is on and the green LED is lit.
•
Make sure the controller is in the control off (COFF) state. Then activate the
control on (CON) state from PC or TP.
•
Make sure all robot and encoder cables are properly connected.
•
Check driver card fuses. Each driver card has a pair of LEDs and a pair of
fuses (accessible from controller back panel). The upper LED and fuse
correspond to the axis number at the top of the card; the lower LED and fuse
correspond to the axis number at the bottom of the card.
Both LEDs on each card in use should be lit, indicating that power is being
supplied to the axis driver. If one of the LEDs is not lit, remove the fuse for
the corresponding axis and examine it. (To remove the fuse, press it in and
rotate counter-clockwise.)
3. Robot does not find Home position in one or all of the axes.
•
Make sure the homing command was properly issued.
•
Make sure all robot and encoder cables are properly connected.
•
If the robot has just undergone maintenance or repair, use the command
ZSET. Then issue the home command.
•
Make sure system homing parameters have not been erased.
Make sure system homing parameters are properly set.
Refer to the ACL Reference Guide.
•
Check whether the optical home switch for this axis is functioning.
Manually move the faulty axis (from teach pendant or keyboard) and check
the value of system variable HS[n] (where n is the index of the axis). The
value of HS will change to either 1 or 0 (defined by parameter 560+axis)
when the home switch is detected.
To help you perform this test, prepare and continuously run a simple ACL
program, as follows:
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LABEL 1
PRINTLN HS[
]
n
DELAY 20
GOTO 1
If the value of HS does not change, possible causes:
Faulty arm circuitry.
Faulty optical switch; optical switch not properly mounted.
Faulty driver circuitry
Problem in controller power supply unit +5V1.
4. One of the axes does not function.
•
Check the driver card LED for this axis at the back of the controller. If the
LED is not lit, check the corresponding fuse.
•
Check the motor drive circuitry.
•
Check the encoder:
Enter the command SHOW ENCO to display the encoder readings.
Enter the command COFF (to disable servo control) and then physically move
the axis in question in both directions.
The encoder reading should rise for rotation in one direction and fall for
rotation in the opposite direction. If this does not occur, there is a problem in
the encoder or its circuitry.
If the encoder readings do not change, check whether the encoder connector is
properly connected to the rear controller panel.
The problem may be caused by faulty encoder connectors on the robot’s
internal PCB’s.
5. Motors suddenly stop. No message on screen. No response to keyboard entries.
•
Check the power source.
•
Make sure the MOTORS power switch is on; make sure the Emergency
button is not depressed.
•
Turn off the controller and open up the cover. Turn on the controller.
Check the yellow “watchdog” LED on the main board. If it is lit, it indicates
that that one of the following fuses on the power supply unit has blown out:
+12VA, –12VA, +12VDR, –12VDR.
Turn off the controller and disconnect it from the power source. Check each
of these four fuses. Replace the blown fuse.
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6. Errors in the repeatability of the robot.
•
Try to identify the faulty axis. If many or all axes are faulty, look for an
electrical noise source in your environment.
•
Check the controller’s ground and the robot’s ground connection to the safety
ground terminal at the back of the controller.
•
Check the encoder.
Bring the robot to a starting position. Using a pencil, draw a fine, continuous
line on the robot which crosses from the cover of one link to the cover of the
adjacent link at the joint in question.
Enter the command SHOW ENCO to display the encoder readings.
Enter the command COFF (to disable servo control) and then physically move
the axis to another position. Then return to the starting position marked by the
line you drew. Check the encoder reading for the axis again. It should be
within 5 counts of the previous reading; if not, the encoder needs to be
replaced.
7. Unusual noise.
•
Loose screws.
•
Poor lubrication.
•
Ratcheting.
•
Worn motor brushes.
•
Worn timing belt.
•
Damaged harmonic drive.
8. Unusual smell.
•
A motor has burnt out and needs to be replaced.
9. Axis/axes vibrating, too weak to carry load, motion not smooth, or jerks during or
at end of motion.
•
System parameters are not properly adjusted.
Refer to the ACL Reference Guide.
•
Problem in axis driver card(s) in the controller.
Refer to the Controller-B User’s Manual.
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10. Pneumatic gripper does not respond.
•
•
•
Messages
Following is a alphabetical listing of system messages which indicate a problem
or error in the operation of the robot arm. Refer to the ACL Reference Guide for
additional error messages.
Axis disabled.
Check that all air hoses are connected properly.
Make sure the gripper is connected to the proper controller output.
Check the relay output to which the gripper is connected.
Check whether the relays have been switched (LED is lit):
In output OFF, NC is shorted to COM, NO is disconnected from COM.
In output ON, NO is shorted to COM, NC is disconnected from COM.
If outputs have not been switched, check the flat cable in the controller
connecting the main board (J17) and the I/O card.
(1) A movement command could not be executed because servo control of the
arm has been disabled (COFF).
(2) A previous movement of the arm resulted in an Impact or Trajectory error,
thereby activating COFF and disabling the arm.
Check the movements of the robot, and correct the command(s).
CONTROL DISABLED.
Motors have been disconnected from servo control. Possible causes:
(1) COFF (control off) command was issued.
(2) CON (control on) has not been issued; the motors have not been activated.
(3) A previous error (such as Impact Protection, Thermic Overload or
Trajectory Error) activated COFF, thereby disabling the arm.
*** HOME FAILURE AXIS n.
The homing procedure failed for the specified axis. Possible causes:
(1) The home microswitch was not found.
(2) The motor power supply is switched off.
(3) Hardware fault on this axis.
Home on group/axis not done.
You attempted to move the arm to a recorded positions, or to record a
position, before homing was performed on the group or axis.
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*** IMPACT PROTECTION axis
n
The controller has detected a position error which is too large. The system
aborted all movements of that axis group, and disabled all axes of t hat group. The
user routine CRASH, if it exists, has been executed. Possible causes:
(1) An obstacle prevented the movement of the arm.
(2) An axis driver fuse has blown.
(3) The motor power switch is turned off.
(4) An encoder fault.
(5) A mechanical fault.
(6) The axis is not connected.
Determine and correct the cause of the position error. Then reenable servo
control of the motors (CON), and restart the program.
INDEX pulse not found axis n
The index pulse of the encoder was not found during the homing of the
specified axis. Possible causes:
(1) The distance between the index pulse and the home switch transition
position has changed, due to a mechanical fault on the axis or a maintenance
procedure (such as replacement of the motor, motor belt, encoder, or gear).
Enter the command ZSET. Then retry homing.
(2) Index pulse faulty.
Check the encoder and wiring.
*** LOWER LIMIT AXIS
n.
During keyboard or TP manual movement of the specified axis, its encoder
attained its minimum allowed value.
Move the axis in the opposite direction.
Motor power switch is OFF.
Be sure the controller’s MOTORS switch is on. Activate CON. Then repeat
the motor or movement command.
No hard homing axis n.
The specified axis has not been configured for hard homing.
Use the HOME command (instead of HHOME). OR
Check the type of homing suitable for that axis. If necessary, change the
system parameters to allow hard homing of the axis.
No homing.
The h o m i n g p a r amet e rs fo r t h e axis (PAR 460+axis and PAR 600+axis) are set
to 0; as a result, the homing procedure will not be performed on the axi s.
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*** OUT OF RANGE axis
n
An attempt was made to record a position (HERE, HEREC, etc. ) while the
robot arm was out of its working envelope.
Manually move the arm to a location within its working envelope. Then
repeat the command.
*** THERMIC OVERLOAD axis
n
Through a software simulation of motor temperature, the system has detected
a dangerous condition for that motor. The system aborted all movements of
that axis group, and disabled all axes of that group. The user routine CRASH,
if it exists, has been executed. Possible causes:
(1) The arm attempted to reach a position, which could not be reached due to
an obstacle (for example, a position defined as being above a table, but
actually slightly below the table’s surface). The impact protection is not
activated because the obstacle is close to the target position. However,
integral feedback will increase the motor current and the motor will overheat,
subsequently causing the Thermic Protection to be activated.
(2) An axis driver is faulty or its fuse has blown.
(3) The robot arm is near to the target position, but does not succeed in
reaching it, due to a driver fault. The software will then detect an abnormal
situation.
(4) The Thermic Protection parameters are improperly set, or have been
corrupted by improper loading of parameters.
Check the positions, the axis driver card and parameters. Reenable servo
control of the motors ( CON ).
*** TOO LARGE SPEED axis n.
Possible causes:
(1) The controller has detected a movement which is too fast; that is, the
required displacement of the encoder, as calculated from the speed limit
parameter, PAR 180+axis, is too great.
(2) Since the trajectory is not calculated prior to a linear or circular
movement, the linear or circular movement may cause one of the joints to
move too fast.
Lower the value of speed for that movement.
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*** TRAJECTORY ERROR !
During movement, the robot arm reached its envelope limits, and the system
aborted the movement. This may occur when executing the following types of
movements: linear (MOVEL), circular (MOVEC) , MOVES, and SPLINE.
Since the trajectory is not computed prior to motion, the movement may
exceed the limits of the working envelope.
Modify the coordinate values of the positions which define the trajectory.
*** UPPER LIMIT AXIS
n
During keyboard or TP manual movement of the specified axis, its encoder
attained its maximum allowed value.
Move the axis in the opposite direction.
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