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User Guide
10/2018 v 1.0
en
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Copyright and disclaimer
All rights reserved. No parts of this manual may be reproduced in any form without the express written
permission of Mobile Industrial Robots ApS (MiR). MiR makes no warranties, express or implied, in respect
of this document or its contents. In addition, the contents of the document is subject to change without
prior notice. Every precaution has been taken in the preparation of this manual. Nevertheless, MiR
assumes no responsibility for errors or omissions or any damages resulting from the use of the
information contained.
Copyright © 2018 by Mobile Industrial Robots
For more material
,
go to our website
Contact the manufacturer:
Mobile Industrial Robots
Emil Neckelmanns Vej 15F
DK-5220 Odense SØ
www.mir-robots.com
Phone: +45 20 377 577
Email: [email protected]
CVR: 35251235
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Table of contents
1 About this manual ............................................................................................................ 1
1.1 Overview..................................................................................................................... 1
1.2 Document history ....................................................................................................... 1
1.3 Where to find more information ................................................................................ 1
2 Safety................................................................................................................................ 3
2.1 Introduction................................................................................................................ 3
2.2 Safety concept ............................................................................................................ 3
2.3 General safety instructions......................................................................................... 4
2.3 1 Warning notes ................................................................................................. 4
2.3 2 Caution notes................................................................................................... 4
2.4 Intended use............................................................................................................... 4
2.5 Foreseeable misuse .................................................................................................... 5
2.6 Risk assessment .......................................................................................................... 5
2.7 Residual risks .............................................................................................................. 6
2.8 Safety-related functions and interfaces ..................................................................... 6
2.9 Limiting safety-related functions................................................................................ 6
2.10 Safety-related electrical interfaces........................................................................... 7
2.10 1 Safety-related electrical inputs...................................................................... 7
2.10 2 Safety-related electrical outputs ................................................................... 8
2.11 Lithium battery ......................................................................................................... 8
3 Getting started.................................................................................................................. 9
3.1 In the box.................................................................................................................... 9
3.2 Unpacking MiR500.................................................................................................... 10
3.3 Commissioning ......................................................................................................... 13
3.3 1 Powering up................................................................................................... 13
3.3 2 Connecting to the robot interface ................................................................. 16
3.3 3 Driving the robot in Manual mode ................................................................ 17
3.3 4 Checking the hardware status ....................................................................... 18
3.3 5 Charging the robot......................................................................................... 19
3.3 6 Shutting down the robot ............................................................................... 20
3.4 MiR500 control panel ............................................................................................... 21
3.4 1 The Operating mode key ............................................................................... 21
3.4 2 The control panel buttons ............................................................................. 22
3.4 3 MiR500 operating modes .............................................................................. 23
3.4 4 Muting of the personnel detection means.................................................... 23
3.5 Packing for transportation........................................................................................ 24
3.5 1 Preparations .................................................................................................. 24
3.5 2 Battery ........................................................................................................... 24
3.5 3 Packing the robot for transportation............................................................. 24
4 Planning .......................................................................................................................... 26
4.1 Introduction.............................................................................................................. 26
4.2 Analysis of the work environment............................................................................ 26
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4.2 1 What does the robot see? ............................................................................. 26
4.2 2 Possible hazards in the environment............................................................. 28
4.3 Analysis of the users ................................................................................................. 29
4.3 1 Types of users ................................................................................................ 29
4.3 2 Interface and dashboards.............................................................................. 30
4.3 3 Training of the users ...................................................................................... 30
4.4 Creating a safe map .................................................................................................. 31
4.4 1 Optimizing the map ....................................................................................... 31
4.5 Creating simple and safe missions............................................................................ 36
4.6 Error handling ........................................................................................................... 36
4.7 Handover testing ...................................................................................................... 37
5 Product presentation...................................................................................................... 39
5.1 About MiR500........................................................................................................... 39
5.2 Main features of MiR500.......................................................................................... 40
5.3 Identification label.................................................................................................... 41
5.4 MiR500 external parts .............................................................................................. 42
5.5 MiR500 internal parts............................................................................................... 44
5.5 1 Front compartment ....................................................................................... 44
5.5 2 Rear compartment......................................................................................... 45
5.5 3 Side compartments........................................................................................ 47
5.5 4 Top compartments ........................................................................................ 48
5.6 Sensor system........................................................................................................... 49
5.6 1 Safety laser scanners ..................................................................................... 49
5.6 2 3D cameras .................................................................................................... 52
5.6 3 Proximity sensors........................................................................................... 54
5.6 4 Light indicators .............................................................................................. 54
5.7 Internal sensors ........................................................................................................ 56
6 Applications .................................................................................................................... 57
6.1 Overview................................................................................................................... 57
6.2 Mounting a top module............................................................................................ 57
Appendices
A Payload specifications ......................................................................................................60
B Interface specifications .................................................................................................... 62
C Declaration of conformity ................................................................................................ 69
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MiR500 User Guide 10/2018 v.1.0 1
• • • • • •
1 About this manual
1.1 Overview
This document contains the following information:
• How to start up and operate a MiR500 robot.
• Product presentation.
• Typical applications.
• Guidelines for proper maintenance of the robot.
The document is intended for Mobile Industrial Robots’ distributors as well as end users responsible
for the daily operation of the robot.
1.2 Document history
The table in this section shows the version history of this document. Each document version is valid
for a particular software and hardware release. SW and HW stand for the software and hardware
versions of the robot.
1.3 Where to find more information
At mobile-industrial-robots.com, the following extra resources on MiR500 robots are available. To
access the pages in the Distributor site, sign in with your distributor account at http://www.mobile-
industrial-robots.com/en/account.
• Distributor site > Downloads
http://www.mobile-industrial-robots.com/en/account/download/
The section contains the following resources:
• MiR500 Quick Start
The short guide that lets you start operating the robot quickly. This document is in the box
with the robot in the printed format. Available in multiple languages.
• MiR500 Lift Operating guide
The operating guide that describes how to set up and use MiR500 with MiR500 Lift.
• MiR500 EU Pallet Lift Operating guide
The operating guide that describes how to set up and use MiR500 with MiR500 EU Pallet Lift.
• MiRCharge 500 Operating guide
The operating guide that describes how to set up MiRCharge 500 and configure the MiR500
robot for automatic battery charging at the charging station.
• MiR Robot Interface 2.0 Reference Guide
The reference that describes the elements of the MiR robot interface. Available in multiple
languages.
• MiR500 REST API reference.
The REST API reference for the robot.
• CAD drawings.
Click Show CAD-files to see the list of available CAD drawings.
Doc version Release date Description SW HW
1.0 2018-10-29 First edition 2.4.0 1.0
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MiR500 User Guide 10/2018 v.1.0 2
• Certificates.
Click Show Certificates to see the list of certificates for the robot.
• Distributor site > How to
http://www.mobile-industrial-robots.com/en/account/how-to/
This page contains how-to articles that describe how to perform specific tasks with the robot.
• MiR500 product page
http://www.mobile-industrial-robots.com/en/products
This page contains specifications, pictures, and brochures for the robot.
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2 Safety
2.1 Introduction
This information must be read and understood before MiR500 is powered up for the first time. It is
important to read the following safety information in order to operate MiR500 safely.
This manual contains notices you have to observe to ensure your personal safety, as well as to
prevent damage to property. The notices referring to your personal safety are highlighted in the
manual by a safety alert symbol. The notices shown below are graded by signal words to indicate
degree of danger.
2.2 Safety concept
Mobile Industrial Robots ApS disclaims any and all liability if MiR500 or its accessories are damaged, changed
or modified in any way. Mobile Industrial Robots ApS can not be held responsible for any damages caused to
MiR500, accessories or any other equipment due to programming errors or malfunctioning of MiR500.
Indicates an immanently hazardous situation that will result in death or severe personal injury if proper
precautions are not taken.
Indicates a potentially hazardous situation that could result in death or severe personal injury if proper
precautions are not taken.
Indicates a situation that could result in minor personal injury or damage to the equipment if proper
precautions are not taken.
Indicates a situation that could result in property damage if proper precautions are not taken.
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2.3 General safety instructions
This section contains general safety notes. Some safety notes are repeated or further specified in
other sections of the manual and further safety notes are present throughout the manual.
2.3.1 Warning notes
2.3.2 Caution notes
2.4 Intended use
MiR500 is intended to be commissioned and used in an indoors industrial environment where access
for the public is restricted. For details about the environmental conditions under which the robot
should operate, see Technical specifications on our website.
MiR500 is equipped with special safety-related features, which are purposely designed for
collaborative operation, where the robot operates without fences and/or together with humans.
• Ensure proper mounting of loads during transport
Danger of personal injury from overturning robot or falling load.
All accessories and loads mounted on top of the robot should be fastened correctly and meet specifications.
See Payload specifications on page 60.
• Use only the original charger
Danger of personal injury and/or damage to the robot.
Use of other charger than the one supplied by the manufacturer can ruin the battery and may cause fire.
• Update maps to avoid hazards on the route
Danger of personal injury and/or damage to the robot.
Make sure to update maps with areas without drive surfaces such as stairways.
• Do not drive the robot irresponsibly
Danger of personal injury and/or damage to the robot.
The robot should not be driven over edges or in other ways operated irresponsibly.
• Turn off main power immediately after removal of top cover
Risk of personal injury and/or damage to the robot. Turn off main power relay to avoid short circuit. See
Product presentation on page 39.
• Leave robot in enabled state
Be aware that the robot can unexpectedly receive a mission or control signal from the control device and start
moving.
• Use Flight Mode with smartphone control of robot
Risk of personal injury and/or damage to the robot.
If you control the robot with a smartphone, make sure that the phone is set to Flight Mode. An incoming call
on the smartphone will interrupt control of the robot.
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MiR500 can be used with the lift modules MiR500 Lift, MiR500 EU Pallet Lift and pallet racks MiR500
Lift Pallet Rack and MiR500 EU Pallet Rack, or it can be used with a customized top module or top
manipulator. See details for add-ons on our website or in the operating guides.
2.5 Foreseeable misuse
Any use or application deviating from the intended use is deemed to be impermissible misuse. This
includes, but is not limited to:
• Use of the robot to transport people.
Risk of personal injury and/or damage to the robot.
• Gradients above 5% on the route.
Risk of personal injury and/or damage to the robot. The surface grade (ramps etc.) cannot
exceed 5% as this may cause the robot to skid.
• Use outdoor.
Risk of personal injury and/or damage to the robot. MiR500 is designed and intended to use
indoors only.
• Overloading of the robot.
Risk of personal injury and/or damage to the robot. The maximum payload for the load on top
of the robot is 500 kg / 1100 lbs. If exceeded, it may cause overturning, falling load and damage
to the robot.
• Failure to follow the guidelines for commissioning.
See Getting started on page 9 and Planning on page 26.
• Failure to make a risk assessment of the full installation.
See Risk assessment on page 5. This may cause the risks not being fully uncovered. This also
applies to MiR500 with a Lift or EU Pallet Lift installed on top.
• Failure to configure audible and light warning signal(s) according to environment.
The risk reduction is not sufficient.
• Operation outside the permissible operating rating parameters and environmental
specifications.
Risk of instability, impact or tipping over.
• Transportation of liquids or food.
Risk of instability.
• Use in potentially explosive environments.
• Use in medical and life critical applications.
• Use for towing.
• Use on board ships.
Risk of personal injury and/or damage to the robot. Unstable surface caused by moving vessel
may cause the robot to skid.
2.6 Risk assessment
One of the most important steps in achieving a safe installation is to make a risk assessment. The
risk assessment is the responsibility of the individuals who are commissioning MiR500 in the
environment it will be used in. Most often it will be an integrator who also designs and/or builds
work cells or other required infrastructure related to MiR500.
The risk assessment must cover not only MiR500 itself, but also take into account potential top
module/manipulator, load transfer, work cells and the environment it will be used in.
It is recommended that the integrator uses guidelines in ISO 12100, EN 1525, ANSI B56.5 or other
relevant standards to conduct the risk assessment.
The risk assessment should consider two scenarios:
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• Teaching (setup where maps are made and the missions are defined and verified) the robot
while developing the robot installation.
• Normal operation of the robot installation.
In EN 1525, clause 4 there is a list of significant hazards, hazardous situations and events which can
be used for inspiration.
2.7 Residual risks
Mobile Industrial Robots ApS has identified the potential significant hazards listed below as hazards
that must be considered by the integrator. Note that other significant hazards might be present in a
specific robot installation.
• Being run over, drawing-in, trapping or impact if a person steps into the route or walk towards
MiR500 while in motion.
• Crushing, drawing-in or trapping at load transfer stations, work cells or charging stations.
2.8 Safety-related functions and interfaces
MiR500 is equipped with a range of built-in safety-related functions as well as safety-related
electrical interfaces designed for integration with a top module and/or top manipulator. Each safety
function and interface is designed according to the standard ISO 13849-1.
The safety-related functions and interfaces are selected to support compliance with EN 1525.
2.9 Limiting safety-related functions
MiR500 has several built-in safety-related functions that are used to ensure safe operation in the
environment it is designed to be used in.
Advanced control software ensures that locomotion and the drive pattern are within safety related
limits and thereby avoid triggering a safety function. Violations of limits will hence only occur in
exceptional cases. Nevertheless, if a limit is violated, the safety system issues a category 0 stop
(stopping by “immediate removal of power to the machine actuators according to IEC 60204-1”)
followed by a controlled brake which brings MiR500 to a stop.
See Technical specifications on our website for more details.
Collision
avoidance
The collision avoidance safety function ensures that MiR500 will come to a stop before it collides
with a human or object.
The function measures the speed on the two driving wheels and switches between the predefined
protective fields accordingly. The faster the speed, the larger the protective fields will be.
This ensures that MiR500 will be brought to a stop in case a human or object is detected within the
active protective field.
Collision avoidance is automatically deactivated two seconds after the protective field is free.
Safe load
position
The safe load position safety function ensures that MiR500 will not locomote, while MiR500 Lift or
MiR500 EU Pallet Lift is not in the lowest position and hence there is a risk of compromising stability.
The safe load position safety system consists of interlock switches that detect if the lift modules are
in the lowest position or not.
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The input can be used for a customized top module/manipulator when a MiR500 Lift or MiR500 EU
Pallet Lift is not installed.
The safe load position safety function must be manually deactivated by activation of the restart
button.
Overspeed
avoidance
The safety system monitors if the speed of each motor is above limits for maximum speed and hence
an indication of speed control is lost for any reason.
The overspeed avoidance safety function must be manually deactivated by activation of the restart
button.
Stability
The safety system monitors if the speed difference between the two motors are above predefined
limits and hence an indication of speed control is lost for any reason.
The stability safety function must be manually deactivated by activation of the restart button.
Emergency
stop
MiR500 has four emergency stop buttons and an option to connect additional emergency stop
buttons through the electrical interface.
The emergency stop should only be activated in case of an emergency.
Emergency stop must be manually deactivated by activation of the restart button.
2.10 Safety-related electrical interfaces
The robot is equipped with several safety-related electrical inputs and outputs. All safety-related
electrical inputs and outputs are dual channel. They are safe when low, e.g. the emergency stop is
not active when the signal is high (+24V).
2.10.1 Safety-related electrical inputs
External
emergency
stop button
input
This input is for connection of an optional emergency stop button. If activated, the safety system
issues a category 0 stop followed by a controlled brake which brings MiR500 to a stop.
Must be manually deactivated by activation of the restart button.
System
emergency
stop input
This input should be used in case a top manipulator has its own emergency stop circuit. The input
must be used in combination with a system emergency stop output. With this, it is possible to
ensure that activation of any emergency stop button will cause an emergency stop of both MiR500
and top manipulator. If activated, the safety system issues a category 0 stop followed by a controlled
brake which brings MiR500 to a stop.
Must be manually deactivated by activation of the restart button.
Safeguard
stop input
This input can be used to issue a category 0 stop followed by a controlled brake which brings MiR500
to a stop.
Will be automatically deactivated when signal is driven high again.
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Load
handling
position/
position
control of
load
This input can be used to apply the safe load position/position control of load safety function on a
system with customized top module/manipulators. A variety of sensors or interlock switches that
detect load handling position or position of load can be connected and thereby enable the safe load
position safety function.
2.10.2 Safety-related electrical outputs
Locomotion
This safety related output is activated if the robot is in locomotion or intend to locomote within two
seconds.
The safety function is limited to trig if locomotion is detected while the output is
deactivated.
Shared
emergency
stop output
This output should be used in case a top manipulator has its own emergency stop circuit. The output
should be used in combination with a system emergency stop input. With this, it is possible to
ensure that activation of any emergency stop button will cause an emergency stop of both MiR500
and top manipulator.
Activated by a MiR500 emergency stop button or emergency stop input.
2.11 Lithium battery
Lithium batteries are primary power sources with high energy content designed to represent the
highest possible degree of safety.
Potential hazard
Lithium battery packs may get hot, explode or ignite and cause serious injury if they are abused
electrically or mechanically.
Observe the following precautions handling and using lithium batteries:
• Do not short-circuit, recharge or connect with false polarity.
• Do not expose to temperature beyond the specified temperature range or incinerate the battery.
• Do not crush, puncture or disassemble the battery. The battery contains safety and protection devices, which,
if damaged, may cause the battery to generate heat, explode or ignite.
• Do not allow the battery to get wet.
• In the event the battery leaks and the fluid gets into one’s eye, do not rub the eye. Rinse well with water and
immediately seek medical care. If left untreated, the battery fluid could cause damage to the eye.
• Use only the original charger and always follow the instructions from the battery manufacturer.
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MiR500 User Guide, 10/2018 v.1.0 9
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3 Getting started
3.1 In the box
This section describes the content of the MiR500 box.
Figure 3.1. The MiR500 box.
1. The MiR500 robot.
2 MiR500
document folder containing:
• Printed documents:
– MiR500 Quick Start.
– MiR username and passwords.
– CE declaration of conformity.
• USB flash drive with the following content:
– MiR500 User Guide.
– MiR Robot Interface 2.0 Reference guide.
– MiR robot REST API reference.
– MiRCharge 500 Operating Guide.
– MiR500 Lift Operating Guide.
– MiR username and passwords.
– CE declaration of conformity.
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3.2 Unpacking MiR500
Keep the original packaging for the future transportation of the robot.
Step Action
1
Place the box with the robot so that there is 3 m of free space at the front or the back of the box.
This is necessary since the robot drives out of the box on the ramp.
2
Remove the screws that attach the walls of the box to the box lid and the base of the box.
3
Remove the lid from the box.
4
Take the folder with MiR printed documents and the USB drive out of the box.
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5
Remove the walls of the box and the protective foam blocks.
6
Cut the protective straps.
Step Action
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7
Place the lid of the box so that you can use it as a ramp. Align the lid so that it is flush with the
base of the box.
8
Remove the wheel stop board from the pallet to let the robot drive on the ramp.
Step Action
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3.3 Commissioning
Read the Safety chapter before powering up the robot.
Commissioning consists of the following parts:
1. Powering up.
2. Connecting to the robot interface.
3. Checking the hardware status.
4. Charging the robot.
5. Shutting down the robot.
For further steps, refer to the MiR500 User Guide.
3.3.1 Powering up
Follow these steps to power up MiR500
.
Step Action
1
Open the rear maintenance hatch. To open the hatch, push two buttons on the hatch and pull the
hatch.
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2
Turn the battery disconnect switch to position ON.
The Power button turns blue.
3
Close the maintenance hatch.
Step Action
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4
Ensure that all 4 emergency stop buttons are in the released state. Turn an emergency stop button
clockwise to release it.
5
Press the Power button for five seconds.
The robot turns on the yellow indicator lights and starts the software initialization process. When
the initialization process ends, the robot goes into the emergency stop mode.
Step Action
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3.3.2 Connecting to the robot interface
When the robot is on, it enables the connection to its WiFi access point. The name of the access point
appears in the list of available connections on your laptop, tablet, or a phone.
The username and password for the robot’s WiFi access point and for accessing the
web interface are in the MiR username and passwords document. The document is
in the box with the robot.
Follow these steps to connect to the robot interface:
6
Press the Restart button to clear the emergency stop. The robot is ready for operation, the status
lights turn constant yellow.
Step Action
Step Action
1 Using your laptop, tablet, or a phone, connect the WiFi access point of the robot. The access point name has
the following format: MiR_UXXXX.
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3.3.3 Driving the robot in Manual mode
To drive the robot in Manual mode:
1. Put the Operating mode key into the Manual mode (turn to the right).
2. In the robot interface, select the joystick icon.
The joystick control appears.
3. Select Manual control. The Restart button on the robot starts blinking.
4. Press the Restart button. The status lights turn blue indicating that the robot is in
Manual mode.
2 In a browser, go to the address mir.com and sign in.
Step Action
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5. Drive the robot using the joystick.
3.3.4 Checking the hardware status
To check that all hardware components work normally:
1. Sign in to the robot interface. See section Connecting to the robot interface.
2. Go to Monitoring > Hardware health.
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3. Check that all elements on the page have the OK status and that they have green dots
on the left.
For more information, see section Hardware health in the MiR Robot Interface 2.0 Reference Guide.
3.3.5 Charging the robot
To charge MiR500 using the cable charger:
1. Open the maintenance hatch at the back of the robot. To open the hatch, push two
buttons on the hatch and pull the hatch.
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2. Connect the charger cable to the charging connector on the robot.
For information about the charging time, see the robot specifications.
3.3.6 Shutting down the robot
To shut down MiR500:
1. Ensure that the robot is not moving or executing an action.
2. Press the Power button for five seconds.
3. The robot starts the shutdown process. Status lights blink yellow, the Power button
blinks red.
4. When the robot finishes the shutdown process, the status and the signal lights go off,
the Power button turns blue.
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3.4 MiR500 control panel
MiR500
has a control panel in the rear-left corner of the robot.
3.4.1 The Operating mode key
The Operating mode key lets you switch between operating modes.
• Left position: Autonomous mode.
Puts the robot in the Autonomous mode.
• Middle position: Stop.
Stops the robot. The robot blocks the wheels, you cannot start a mission or drive the robot manually.
• Right position: Manual mode.
Puts the robot in the Manual mode.
For more information on operating modes, see section MiR500 operating modes on page 23.
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3.4.2 The control panel buttons
The buttons on the control panel have the following functions.
# Button name
Description
1
Stop Pressing the button stops the robot. After pressing this button, you must
press the Restart button to let the robot continue operating.
Color indication:
• Red: The robot is on.
2
Restart Pressing this button:
• Clears the emergency stop state.
• Lets the robot continue operating after the
• Stop button was pressed.
• Lets the robot continue operating after powering up or after the operating mode
change.
Color indication:
• Blinking red: The robot is waiting for a user action (clear the emergency stop state,
acknowledge the change of operating mode, etc.)
3
Power
Pressing this button for five seconds turns the robot on or shuts it down.
Color indication:
• Blue: The robot is off.
• Blinking green: The robot is starting up.
• Green: Normal operation.
• Red: The robot detected an error.
• Yellow: The battery level is low.
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3.4.3 MiR500 operating modes
MiR500 has the following operating modes:
Manual mode
In this mode, you can drive the robot manually using the joystick in the robot interface. Only one
person can control the robot manually at a time. To ensure that nobody else takes control of the
robot, the robot issues a token to the device on which you activate the Manual mode.
For information about activating this mode, see section Driving the robot in Manual mode on
page 17.
Autonomous mode
In this mode, the robot executes the programmed mission. After switching the key to this mode, you
can remove the key and the robot will continue driving autonomously. The joystick is disabled in the
robot interface.
3.4.4 Muting of the personnel detection means
When performing tasks that require to move very close to surrounding objects, the robot mutes
the personnel detection means. Docking to a pallet rack is the example of such task.
When muting the personnel detection means, the robot does the following:
• Reduces the size of the safety zones.
• Turns the collision detection off.
• Decreases the speed.
• Flashes the yellow indicator lights.
You can also mute the personnel detection means using the robot interface:
1. Put the robot into the Manual mode. See section Driving the robot in Manual mode on
page 17.
2. In the robot interface, in the Joystick control, select Mute personnel detection means.
3. In the prompt dialog, select Yes to acknowledge the muting of personnel detection
means.
4. The status and the signal lights start flashing yellow, the robot is ready to drive with
muted personnel detection means.
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3.5 Packing for transportation
3.5.1 Preparations
Use the original packaging materials when transporting the robot.
The packaging materials are:
• The bottom of the box (the pallet).
• The lid of the box (the ramp).
• The walls of the box.
• The wheel stop board.
• Protective foam blocks: Side blocks and the top layer.
• Protective corner braces. The braces prevent the robot from being damaged by the transport
straps.
• Screws.
3.5.2 Battery
The lithium battery is subject to transport regulations. Make sure that you follow the safety
precautions in this section and the instructions in section Packing the robot for transportation on
page 24. Different regulations apply depending on the mode of transportation: Land, sea, or air.
Contact your distributor for more information.
Lithium batteries are subject to special transportation regulations according to United
Nations Regulation of Dangerous Goods, UN 3171. Special transport documentation is
required to comply with these regulations. This may influence both transport time and
costs.
3.5.3 Packing the robot for transportation
To pack the robot for transportation:
1. Shut down the robot. See section Shutting down the robot on page 20.
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2. Open the rear maintenance hatch.
3. Turn the battery disconnect switch to position OFF.
4. Repeat the steps in section Unpacking MiR500 on page 10 in the reverse order.
Pack and transport the robot in an upright position. Packing and transporting the
robot in any other position voids the warranty.
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• • • • • •
4 Planning
4.1 Introduction
This chapter will go through what needs to be considered before and during the installation of
MiR500 in the company.
Before considering and installing the following, it is worth spending some time defining what tasks
MiR500 must do in the work environment.
The correct setup and thorough training of the users will result in a successful and safe installation
of MiR500.
For more details on the topics below, see MiR Robot interface 2.0 Reference guide.
4.2 Analysis of the work environment
A thorough analysis of the environment where MiR500 is going to be implemented in is necessary
for a successful and safe installation.
4.2.1 What does the robot see?
Before preparing the environment for MiR500, it is worth understanding how the robot works, what
it can see and what it uses for navigation.
MiR500 is an autonomous and collaborative robot. The robot relies on localization techniques to
orient itself in its environment. The robot uses path planning that consists of two parts: a global
planner that does the general path planning between two positions and a local planner that causes
the robot to follow the global path and also take into account the surroundings, so that the robot
avoids dynamic obstacles based on sensor input.
MiR500 has two laser scanners that combined cover 360 degrees in a height of 1700mm above the
floor. The laser scanners serve three main purposes:
• Emergency stop: the laser scanners trigger the emergency stop as part of the SICK Safety system
when an obstacle is within the emergency zone of the laser scanners.
• Mapping: the laser scanners record the environment to gather data that enable the creation of
a map.
• Localization: the laser scanners use data to localize the robot in the map that has been generated
and loaded into MiR500.
Please read Safety on page 3 before going through this chapter.
Please read the Technical specifications on our website for more details on how much space
MiR500 requires to operate safely and successfully.
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Figure 4.1. The laser scanners detect a dynamic object in the bottom left corner.
Figure 4.2. Human eyes see the chair and surrounding details.
Figure 4.3. MiR500’s laser scanners will only detect parts of the chair. Here, the scanners detect the four legs of the
chair in the upper left corner of the map.
Figure 4.4. The 3D camera will detect more details of the chair when it is close enough to it.
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4.2.2 Possible hazards in the environment
This section will go through some of the possible hazards in the environment. The issues with and
solutions to the hazards will be elaborated in Add zones on page 31.
Identifying the potential hazards in the area where MiR500 is going to drive is one of the most
important steps of planning to achieve a safe installation.
For now, be aware of the hazards and consider if similar hazards are present in your work
environment.
Downwards going staircases
MiR500 can not see downwards going staircases and holes in the floor.
Permanent low hanging fixtures
A permanent low hanging fixture could be a machine with a PC attached, for example a screen
attached to an arm that can be moved in several directions. It could also be a boom barrier or boom
gate, as seen near entries in supermarkets.
Large highly dynamic areas
A large highly dynamic area is an area where objects are moved frequently. This could be a production
area where pallets and boxes are often moved back and forth.
Transient work flow areas
A transient work flow area is an area where humans often move around. This could be part of a
production area where people are assembling a product. It could also be an area where forklifts or
other machines are operated.
Doorways and ramps
Going through narrow doorways can cause problems for MiR500 because of the small space. Going
up a ramp can cause similar problems, because of the upwards angle. It can also result in a potential
hazardous situation for the people on the other side of the door, because they might not be able to
see the robot.
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4.3 Analysis of the users
Introducing MiR500 into the company will require some changes to the environment and the people
working with the robot to achieve the optimal benefits. Spending some time defining and preparing
the users will make the robot a much more effective collaborative robot and will form a positive and
safe experience.
It is important to explain to the users what the robot can do, but also what it can not do. For
example,
the robot can transport heavy pallets, but it can not transport people
. Based on the
preparation of the environment, it is also worth explaining what is going to be difficult for the
installation, both in the environment and for some of the users’ work flow.
4.3.1 Types of users
It is important to analyze and consider who is:
• working directly with MiR500?
• working indirectly with MiR500?
• responsible for MiR500?
Direct user
The direct user of MiR500 could be someone who commands the robot to carry out missions and
works closely with the robot. Apart from training on how to use the robot (see Training of the users
on page 30), the direct user will need to make adjustments to his/her work flow to include the robot
in their work. The direct user also needs to know who is responsible for MiR500, so they can get help
if the robot is not running missions as it should.
Indirect user
The indirect user of MiR500 could be someone working in the same environment as the robot, but
not working directly with the robot. This user might need to change their work flow slightly for the
company to make the most out of the robot. For example, if the user walks a certain path several
times a day and this path crosses the robots path several times a day – it might be worth creating
two paths. This way, the robot does not stop several times a day to let the indirect user pass, wasting
valuable work time. It is important to note that MiR500 is a collaborative robot and will always stop,
if someone walks out in front of it.
Shelves
Shelves are often placed in a certain height above the floor on four (or more) posts and will often
appear as dots on a map for MiR500. This may cause the robot to believe that there is enough space
(if the posts are far enough apart) below the shelf to pass through. MiR500 will then plan a path
underneath the shelves, but when it comes closer, the camera will see the obstacle. This could result
in re-planning paths several times a day, thereby wasting valuable work time for the robot.
Pallet Rack
When MiR500 docks to a Pallet Rack, the safety system is temporarily muted. This could cause a
dangerous situation, if a person steps in front of the robot and the Pallet Rack. Furthermore, the Pallet
Rack must be placed according to specific measurements to avoid safety issues.
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Responsible
The person responsible for MiR500 is someone who will know what to do if an issue with the robot
occurs. The person responsible should know the most common errors and how to troubleshoot
them. The responsible should also be instructed in maintenance and inspection of the robot. This
user will need a more thorough basic training and should also know who to reach out to in case he/
she can not solve the issue at hand.
Superuser
The superuser of MiR500 is usually someone from the development department, who understands
how the robot is set up and works with it on a daily basis. The superuser also undergoes continuous
training by Mobile Industrial Robots ApS. A superuser is therefore mainly relevant for bigger
companies.
4.3.2 Interface and dashboards
Based on the considerations in Types of users on page 29, there will most likely be different users
with different tasks using MiR500.
All users of the robot must have a user profile in the system. Users are administered in the Users
section where you set up, edit and delete system users.
To make it as simple as possible for each user, it is worth investing some time in building up a unique
dashboard for each user. Dashboards are an easy way for different user groups to control the robot
giving direct access to their individual key functions.
Consider the following based on previous considerations on users of the robot:
• How many different users are there?
• What tasks do each user have with MiR500?
• What rights (edit and control) should the different users have?
• What functions or widgets should be available for the different users?
For more details on interface and dashboards, see MiR Robot interface 2.0 Reference guide.
4.3.3 Training of the users
It is very important to spend time on training the different users of MiR500. It is unlikely that all users
will need to know all the features of the robot. Teaching should be done at different levels, to make
it as simple as possible for the different users. This way, each user will quickly learn how to use the
robot in the way they need to.
It is also important to establish a chain of communication for MiR500 in the company. This means
that all users (direct, indirect and responsible) always know who to ask, if they have any problems
or questions.
See Handover testing on page 37 for more information on training.
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Figure 4.5. Chain of communication.
4.4 Creating a safe map
After the preliminary analyses of the work environment and the work flows of the people working
there, spending time on creating a good map is important for MiR500 to work safely and efficiently.
Creating a robust, reliable map for dynamic environments will pay off, as the map is the basis of the
robot’s ability to navigate its surroundings. A good map is also the basis for a safe and efficient robot.
4.4.1 Optimizing the map
Add zones
Adding zones to the map can organize efficient robot traffic. There are several different zones that
can optimize the preferred paths and driving behavior of MiR500. For example, a Forbidden zone is
a zone where the robot will never enter. A Blink or Sound zone are zones where the robot either
blinks or makes a sound to catch attention. In a Preferred zone the robot tries to run within a
preferred area taking into account dynamic obstacles. In an Unpreferred zone, the robot tries to
avoid the unpreferred zone but may go into it if there are no other possibilities. A Directional zone
lets you organize the motion of robots by specifying the directions in which the robots can move in
specific zones.
Adding zones to the map can also solve most of the issues with possible hazards in the work
environment.
If you have not created a map before, see MiR Robot interface 2.0 Reference guide and Howto guides on our Distributor website.
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Downwards going staircases
MiR500 can not see downwards going staircases and holes in the floor.
Issue: The 3D camera can not detect downwards going staircases.
Marking a staircase as a wall on
the map will only confuse the robot as it will try to navigate from a wall that is not there.
Solution: Mark staircases and areas surrounding staircases or holes in the floor as Forbidden zones on
the map.
Permanent low hanging fixtures
A permanent low hanging fixture could be a machine with a PC attached, for example a screen
attached to an arm that can be moved in several directions. It could also be a boom barrier or boom
gate, as seen near entries in supermarkets.
Issue: MiR500 will not see these dynamic low hanging fixtures. This could be dangerous with a top
module attached to MiR500.
Solution: Mark the area where the low hanging fixture is located as a Forbidden zone.
Figure 4.6. Forbidden zones are illustrated with a red colour on the map.
Large highly dynamic areas
A large highly dynamic area is an area where objects are moved frequently. This could be a production
area where pallets and boxes are often moved back and forth.
Issue: MiR500 will always plan the shortest path from A to B. If this is through a large highly dynamic
area, the robot will re-plan its path several times. The re-planning happens because the robot will
encounter new dynamic obstacles in the environment often. This can lead to valuable time wasted on
readjusting the path several times a day.
Solution: Mark large highly dynamic areas on the map with for example Unpreferred zones or create
a path guide. In extreme cases, use Forbidden zones.
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Transient work flow areas
A transient work flow area is an area where humans often move around. This could be part of a
production area where people are assembling a product. It could also be an area where forklifts or
other machines are operated.
Issue: MiR500 will stop if a person steps out in front of it. In a transient work flow area, the robot will
stop and reassess its paths many times a day, thereby wasting valuable time.
Solution: Mark transient work flow areas on the map with for example Unpreferred zones or
Forbidden zones, depending on the environment. Directional zones can also be used here to guide
MiR500 in a specific direction.
Figure 4.7. Unpreferred zones (marked with purple) can be used in large highly dynamic areas and transient
work flow areas to solve issues with re-planning of paths.
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Doorways and ramps
Going through narrow doorways can cause problems for MiR500 because of the small space. Going
up a ramp can cause similar problems, because of the upwards angle. Narrow doorways can also
cause dangerous situations for the people working near the robot, as they might be on the other side
of the door and can not see the robot coming.
Issue: MiR500 stops, because a narrow doorway is seen as an obstacle. Due to sensor input, the robot
will not plan a path through a narrow corridor if it has an alternative path. The robot will always stop
if a person steps out in front of it.
Solution: Add a Critical zone to the narrow doorway to force the global planner to make a path
through the corridor. Add blink and beep zones in narrow doorways to attract attention. This will
warn people near the doorway that the robot is coming through.
Figure 4.8. Narrow doorways can be marked with a Blink and/or beep zone (marked with yellow) to warn
people that it is coming through.
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For more details on maps and zones, see MiR Robot interface 2.0 Reference guide.
Shelves
Shelves are often placed in a certain height above the floor on four (or more) posts and will often
appear as dots on a map for MiR500. This may cause the robot to believe that there is enough space
(if the posts are far enough apart) below the shelf to pass through. MiR500 will then plan a path
underneath the shelves, but when it comes closer, the camera will see the obstacle. This could result
in re-planning paths several times a day, thereby wasting valuable work time for the robot.
Issue: MiR500 will only see shelves as dots on the map and believe that it can make a global plan
underneath the shelves.
Solution: Add a Forbidden zone (marked red in the image) around the shelves.
Figure 4.9. The shelves are marked as a Forbidden zone in the map.
Pallet Rack
When MiR500 docks to a Pallet Rack, the safety system is temporarily muted. This could
cause a dangerous situation, if a person steps in front of the robot and the Pallet Rack.
Issue: MiR500 mutes the safety system temporarily when docking to a Pallet Rack. This
could cause a dangerous situation.
Solution: Follow the mounting guidelines and mark the area around the Pallet Rack with
tape or similar. Inform users of or near the robot of the safety issues regarding the Pallet
Rack so they can take their precautions when working near the Pallet Rack.
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4.5 Creating simple and safe missions
After creating a good map, it is worth spending time on creating and testing simple missions for
MiR500 to work safely and efficiently.
Before building the missions, consider how the tasks could be solved in the simplest and safest way.
Create
simple
missions
Creating simple missions will provide a good basis of solving safe and simple tasks. Simple missions
include moving from point A to point B, go to waiting position, go to charge, pick up pallet etc.
Missions
within
missions
A good basis of different missions makes it possible to set up missions inside missions. This way,
simple missions can be re-used in different, bigger and more complex missions.
4.6 Error handling
An error occurs when the robot is conflicted and cannot solve a situation on its own.
Errors include:
• Hardware faults.
• Failed localization.
• Failure to reach destination.
• Unexpected events in the system.
An error causes a full system stop. The robot is paused until a person acknowledges the error and
clears it.
Proper setup of maps and missions effectively prevent most errors.
• Use Try/Catch actions.
• Define forbidden areas.
• Remove noise from maps.
If you have not created a mission before, see MiR Robot interface 2.0 Reference guide and
How-to guides on our Distributor website.
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To clear an error, select the red warning indicator in the interface and select reset.
For more details on setting up missions and error handling, see MiR Robot interface 2.0 Reference
guide
4.7 Handover testing
It is very important to schedule time for handover testing. The new users of MiR500 might have new
questions after they start using the robot or new issues or situations might have appeared.
Handover testing is important because it improves safety, increases users’ happiness with the robot
and increases return of investment.
A good handover ensures that the users:
• Get comfortable with the product.
• Know the robot’s limitations and possibilities.
• Can solve common issues.
• Recognize common errors.
• Know who to contact if they experience issues.
Inform users
As mentioned in Training of the users on page 30, informing users about MiR500 and its functions
at a level that matches their user type (direct, indirect etc.) will help ensure a safe and successful
installation of the robot.
Useful information at different levels could be:
• Safety zones, planning of paths and deviations from planned paths, dynamic obstacles.
• Illustrate that MiR500 will stop before driving into obstacles.
• Daily/weekly/monthly cleaning, maintenance and inspection of robots.
• Changing missions, location of positions, zone areas.
• Color indications of the robot. Waiting for mission, pause, emergency stop, planning, carrying
out mission, charging.
Simulate
common
tasks and
issues
Try to simulate some common day-to-day tasks with MiR500 while the direct users, superuser and
responsible persons use the robot as they would in their daily work.
Common tasks and issues could be:
• Triggering emergency stop and resetting the robot.
• Continue/Pause robot in interface.
• Turning on/off robot.
• Charging the robot, using cable and charging station.
• Manually locate robot on map, adjust localization.
• Manually make robot drive to position and coordinates on map by clicking on the map.
• Run missions, clear missions from queue, see status of missions.
• Maintenance of robot.
• Manual driving.
• Get familiar with dashboard and interface.
• Blocked paths.
• Robot getting stuck in emergency stop when getting pushed into objects or objects being placed
close to robot.
• How to recognize that the robot has a problem with charging.
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• Narrow paths where the robot might find it difficult to pass. This illustrates the importance of
having wide and clear paths for optimal driving of robot.
Future
possibilities
After the initial installation of MiR500, it is a good idea to inform users of other possibilities they
might find useful after having used the robot for some time. This could include:
• Sound and blink zones.
• Preferred zones.
• Directional zones.
• Incorporation with other plant management systems, such as ERP.
• MiR Fleet.
• Rest calls.
Stay in
contact
It is important to stay in contact with the users after the installation of MiR500. Make sure to follow
up with the following in mind:
• If the customer does not call for support, it might be because the robot is running perfectly, but
it might also be because they have problems and gave up on the robot.
• Urge them to contact you with problems, especially in the beginning.
• Contact customers yourself in the beginning to make sure they are happy and the product is
working satisfactorily.
A good handover also includes making a risk assessment. Read more in Risk assessment on
page 5.
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• • • • • •
5 Product presentation
5.1 About MiR500
MiR500 is an autonomous mobile robot that can transport loads up to 500 kg and pallets indoors
within production facilities, warehouses, and other industrial locations.
Users operate MiR500 via a web-based user interface, which is accessed via a browser on a PC,
smartphone or tablet. Each robot has its own network. See Getting connected on page 14. MiR500
can be set up to run a fixed route, be called on demand or perform more complex operations
(missions).
MiR500 performs localization and navigation via a map which can be created or imported the first
time the robot is used. The internal map contains defined locations (office, product delivery,
production hall etc.) that are used for logistical planning. While operating, the safety laser scanners
ensure that the robot avoids dynamic obstacles (people, furniture) that are not mapped.
With a MiRCharge 500, the robot handles moving to a charging station automatically. All it takes is
the definition of a charging mission and a charging position on the map.
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5.2 Main features of MiR500
• Driving in a populated workspace
The robot is designed to operate among people and maneuvers safely and efficiently in even
highly dynamic environments.
• Overall route planning and local adjustments
The robot autonomously navigates to find the most efficient path to its destinations. The robot
adjusts the path when it encounters obstacles which are not on the map (like people and
objects).
• Efficient transportation of heavy loads
The robot is designed to automate transportation of loads up to 500 kg across industries,
allowing employees to focus on higher value activities.
• Sound and light signals
The robot continuously signals with light and sounds indicating its current mode, for example
waiting for job, driving to destination, destination reached or alert mode.
• User friendly and flexible
The web-based user interface, accessed from a PC, tablet or smartphone, gives easy access to
operation and monitoring of the robot and can be programmed without any prior experience.
Different user group levels and tailored dashboards can be set up to suit the different users.
• Alert for ‘lost’
If the robot enters a situation where it is unable to find a path to its destination, it stops, turns
on the yellow-purple running error light and a customer defined ‘catch’ action may be used to
alert people or take other actions.
• Automatic deceleration for objects
The built-in sensors ensure that the robot is slowed down when obstacles are detected in
front of it.
• Optimal surface operations
The robot is made to run on a level, dry floor with a maximum incline of 1% at 0,5 m/s. 3D
cameras detect and avoid objects from 30-3500 mm above floor level.
• Internal map
The robot can either use a floor plan from a CAD system or a map can be created by manual
navigation around the entire site in which the robot is going to operate. When mapping, the
robot’s sensors detect walls, doors, furniture and then creates a map based on this input. After
creation of the map, positions and other features can be added in the map editor.
Add ons
• MiR500 Lift
A lift platform may be mounted on MiR500 enabling it to automate the internal transport of US
standard 40*48 pallets.
• MiR500 EU Pallet Lift
A pallet lift for EU pallets may be mounted on MiR500 enabling it to automate the internal
transport of EU pallets.
• MiR500 Lift Pallet Rack
A pallet rack may be used with MiR500 enabling it to place and pick up US standard 40*48
pallets autonomously from MiR500 Lift Pallet Racks.
• MiR500 EU Pallet Rack
A pallet rack may be used with MiR500 enabling it to place and pick up EU pallets autonomously
from MiR500 EU Pallet Racks.
You can read more about these add-ons on our website or in our operating guides that
can be downloaded from the website.
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5.3 Identification label
The identification label of MiR500 is placed above the MiR controller behind the rear maintenance
hatch.
Figure 5.1. Example of MiR500 CE marking and identification label
• CE
Mobile Industrial Robots ApS declares that MiR500 meets the
requirements of the applicable EC directives. See the appendix
Declaration of conformity on page 69.
• Serial number
The 15-digit serial number is a unique identifier of the robot. The
last four digits form part of the original name of the robot, e.g. MiR
U0008.
• MiR500 1.0
Product name and hardware version.
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5.4 MiR500 external parts
This section presents the parts of MiR500 that are visible on the outside.
Figure 5.2. MiR500 external parts
1. Left cover plate: access to power interface, GPIO
interface and Ethernet interface
8 Proximity sensors: eight pcs., two in each corner
behind corner cover (see Sensor system on page 49)
2. Right cover plate: access to safety interfaces Aux.
safety functions and Aux. Emergency stop
9. 3D depth cameras: two pcs., detect objects in front of
the robot (see Sensor system on page 49)
3. Signal light: eight pcs., two on each corner (see
Sensor system on page 49)
10. Front maintenance hatch: opens to front
compartment (see MiR500 internal parts on page 44)
4 Rear maintenance hatch: opens to rear
compartment (see MiR500 internal parts on
page 44)
11. Front safety laser scanner (see Sensor system on
page 49)
5 Rear safety laser scanner 12. Left-hand side maintenance hatch
6 Right-hand side maintenance hatch 13. Status light: on all four sides of the robot (see Sensor
system on page 49)
7 Emergency stop button: four pcs., two on each side
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Figure 5.3. MiR500 Top cover
1. M12 lifting holes; one in each corner used for
fixation of transportation eye bolts.
2 M8 mooring holes for fixation of top module
The rest of the screw holes visible in the picture are for fixation of the top cover to the robot.
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5.5 MiR500 internal parts
Most internal parts of MiR500 are reached through maintenance hatches that open to different
compartments:
• Front compartment
• Rear compartment
• Side compartments
• Top compartments
5.5.1 Front compartment
The front compartment holds the electronic components that may need regular service or
replacement, such as PC, main control board and safety PLC.
To open the front compartment:
1. Push the two white buttons and pull the hatch.
2. Turn the two levers 180°, then pull out the compartment drawer while holding underneath it
and lifting slightly.
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Overview
The front compartment contains the following main components:
Figure 5.4. MiR500 front compartment
5.5.2 Rear compartment
The rear compartment holds the robot’s battery.
1 Cable chain 5. Loudspeaker
2. Safe Torque Off contactors 6. Power board: controlling power distribution for
motor controller, PC and safety PLC
3. Access point / Router 7. Motor controller
4. Robot CPU 8. Safety PLC
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To open the rear compartment:
1. Push the two white buttons and pull the hatch.
Overview
The rear compartment contains the following main components:
Figure 5.5. MiR500 rear compartment
1. Connectors for proximity sensors 5. Charging connection interface, for external charger
2. Battery disconnect switch, shown in Off position 6. Battery with connector, main power to the robot
3. Connector for status light band 7. Connection interface for MiR Controller
4. Brake release button, shown in On position. When
turned off, the brakes are released, and the robot can
be pushed manually
To get access to the battery, push the white
button and lower the hatch. For replacement,
the battery can be pulled out and disconnected.
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5.5.3 Side compartments
The side compartments contain the right- and left-hand side bogies and drive wheels.
To open a side hatch: turn the two screws 90 ° counterclockwise with a flat-head screwdriver, and
pull the hatch.
Overview
The left- and right-hand side compartments contain the same components.
Figure 5.6. MiR500 side compartment
1. Connector for status light band 2 Drive wheel
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5.5.4 Top compartments
The two top compartments hold interfaces to external units, for example MiR500 EU Pallet lift or
MiR500 Lift.
To open a top compartment, remove four screws and lift off the top cover.
Figure 5.7. The two top compartments contain interfaces for top applications and added safety functions.
Overview
The top compartments contain the following electrical interfaces for top applications. For detailed
information, see Interface specifications on page 62.
Figure 5.8. Interfaces in left and right top compartments
Interface in left top compartment Interfaces in right top compartment
1. Ethernet 1. Auxiliary emergency stop
2. GPIO: General purpose I/O 2. Auxiliary safety functions
3. Power
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5.6 Sensor system
Collaboration between the MiR500 robot’s internal and external sensors ensures that the robot can
navigate in the environment and most importantly secures that it can operate safely among people
and objects like furniture, machines, pallets etc.
This section describes the functionality of the different parts of the sensor system.
The robot is equipped with the following external sensors and indicators:
• Safety laser scanners
• 3D cameras
• Proximity sensors
• Light indicators
5.6.1 Safety laser scanners
Scanner
types
The safety laser scanners on MIR500 are of the type AOPDDR (active opto-electronic protective
device responsive to diffuse reflection). AOPDDR is a protective device that uses opto-electronic
transmission and reception elements to detect the reflection of the optical radiation generated by
the protective device. The reflection is generated by an object in a defined two-dimensional area.
This is a type of ESPE (electro-sensitive protective device). In this User guide, the term safety laser
scanner is used.
Scanner
functions
Two safety laser scanners, diagonally placed on front and rear corners of the robot, scan their
surroundings. Each safety laser scanner has a 270° field of view, overlapping and thus providing a full
360
° visual protection around the robot.
The safety laser scanners serve three purposes:
2. They are used for mapping, see also Planning on page 26 and the MiR Robot interface 2.0
Reference guide which can be downloaded from our website.
3. They are used to localize the robot in the environment and plan routes between points.
4. They continuously scan the surroundings
when the robot operates thereby avoiding collision
with objects and people.
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The safety laser scanners detect objects in a plane approximately 180 mm above ground. Objects
above or below are not detected by the safety laser scanners.
Figure 5.9. The two safety laser scanners together provide a full 360° view around the robot.
When in motion, the safety laser scanners continuously scan the surroundings using a distance of
up to 40 m while taking into account and weighting the viewed objects in a so-called “particle filter”
When mapping, the safety laser scanner’s view is reduced to 20 m to support that maps will get the
highest possible quality.
Figure 5.10. The safety laser scanners see up to 20 m when mapping an area.
Signals from safety laser scanners are combined with input from 3D cameras and proximity sensors
and used to evaluate if an object or person is in the path of travel. In that case, the robot gradually
slows down while trying to avoid the obstacle. If unable to make its way around the obstacle, the
robot stops and waits for clearance.
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Protective
fields
The protective fields are part of the robot’s personnel detection means. The protective fields consist
of individually configured contours. The active protective field is automatically selected based on the
speed of MiR500. A person or object within an active protective field will bring MiR500 to a
protective stop and the robot will remain stopped until the protective field is free.
Figure 5.11. Protective fields of the front and rear safety laser scanners.
Protective
field settings
The following table shows how the protective fields are configured.
Protective fields in the driving direction
Protective fields opposite the driving direction
When the robot moves backwards, the protective fields switch, so that the largest
protective fields are in the driving direction.
The speed/zone rate is configured to comply with the safety standards of MiR500.
If they are changed, Mobile Industrial Robots takes no responsibility for any safety
related incidents, and the warranty becomes void.
Safety fields Speed range Field size
Protective field 1 (innermost) <0.1 m/s 35 cm
Protective field 2 0.1-0.3 m/s 40 cm
Protective field 3 0.3-0.6 m/s 60 cm
Protective field 4 0.6-0.9 m/s 85 cm
Protective field 5 >0.9 m/s 135 cm
Safety fields Speed range Field size
Protective field all speeds 35 cm
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Muted
personnel
detection
means
When docking to pallet rack or a charging station, the protective fields are muted to avoid
unintended activation. Muted protective fields is part of the drive mode Muted personnel detection
means where the robot also slows down the speed. For more information, see Muting of the
personnel detection means on page 23
5.6.2 3D cameras
Two 3D depth cameras positioned on the front of the robot detect objects in front of the robot while
the robot’s local planner continuously adjusts its planned routes around such objects.
The 3D cameras detect objects:
• vertically up to 1700 mm at a distance of 950 mm in front of the robot.
• horizontally in an angle of 114° and 250 mm to the first view of ground.
Figure 5.12. The two 3D cameras can see objects up to 1700 mm above floor height.
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Figure 5.13. The two 3D cameras have a horizontal field of view of 114°.
The cameras’ observations are used as 3D point cloud data. They are not recording recognizable
objects or people.
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5.6.3 Proximity sensors
Proximity sensors placed in all four corners of the robot detect objects close to the floor that cannot
be detected by the safety laser scanners.
Using infrared light, the proximity sensors point downwards and make sure that the robot does not
run into low objects such as pallets and forklift forks.
Figure 5.14. The proximity sensors in the corners of the robot detect objects close to the floor.
5.6.4 Light indicators
The robot uses two types of light indicators to let people in the environment know what the robot
is currently doing or planning to do.
• Status lights: an LED light band on all four sides of the robot uses colors and light motion
patterns to signal the current status of the robot
• Signal lights: the signal lights at the front and back of the robot show people in the environment
if the robot is about to turn a corner or go backwards.
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Status lights
The LED light band running all the way around the robot indicates the robot’s current operational
state. Colors may also be used as part of missions, but as standard, the robot is delivered with the
following setup.
Figure 5.15. MiR500 uses different colors and blink patterns to show its current status.
Signal lights
Signal lights are used to indicate the robot’s immediate motion plans, for example by signaling
forwards-backwards-braking and left-right turns.
The signal lights work similarly to lights used on cars; white at the front, red at the back, and are used
to indicate for example a left or right turn by blinking.
Figure 5.16. Signal lights placed in each corner of the robot indicate for example a right turn.
When the robot drives with muted personnel detection means, for example when docking to a Pallet
Rack, all signal lights blink yellow. For more information, see Muting of the personnel detection
means on page 23
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5.7 Internal sensors
The internal sensor system of the robot consists of the following components:
• Gyroscope (IMU)
Measures the orientation and angular velocity of the robot.
• Motor encoder
Provides closed loop feedback signals by tracking the speed
and/or position of the motor shaft.
• Accelerometer Measures non-gravitational acceleration.
• Wheel encoders Detects wheel movements.
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6 Applications
6.1 Overview
You can install top modules on top of MiR500 for specific applications. For more information about
top modules, go to the following page:
http://www.mobile-industrial-robots.com/en/mir-tradeforum/
For instructions on how to mount top modules and accessories, refer to the application manuals at
the Mobile Industrial Robots website or contact your distributor.
6.2 Mounting a top module
MiR500 has four M10 holes for mounting top modules. Tightening torque: 47 Nm.
Figure 6.1. Mounting holes on the top of MiR500.
Certain top modules may require the installation of an extra emergency stop button
.
Perform risk assessment according to standard ISO 12100.
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Certain top modules may lead to new hazards and/or increased risks which cannot be
eliminated or reduced by the risk reduction measures applied by Mobile Industrial Robots.
Perform risk assessment according to standard ISO 12100.
Stay within the specifications for weight and the payload’s center of gravity, see Payload
specifications on page 35.
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A Payload specifications
The following drawings illustrate the center of mass (CoM) specifications for safe operation at
different payloads.
The specifications apply to payloads of up to 500 kg.
Viewed from the side
Units: mm
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Payload specifications
Viewed from the front
Units: mm
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B Interface specifications
B.1 Introduction
This appendix describes the specifications of the top application interface.
To see where the interfaces are placed on MiR500, please read Product presentation on page 39.
B.2 Electrical Interface Definition
There are five electrical interfaces on MiR500:
•Power
• GPIO
• Ethernet
• Auxiliary Emergency Stop
• Auxiliary Safety Functions
Power
An auxiliary power connection for top applications is provided in the top left-hand side
compartment. See Connector list on page 68 for more information.
Figure B.1. Pin numbers: female connector viewed from the front (left) and wiring diagram (right).
Please read Safety on page 3 for more details on using the electrical interface.
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Figure B.2. Power interface.
GPIO
A GPIO connection is provided in the top left-hand side compartment.
Figure B.3. Pin numbers: male connector viewed from the front (left) and wiring diagram (right).
Pin number Signal name Max. current Remarks
1 48V power 20A Always on when robot is on.
Intended for high power loads
like motors or actuators.
2 GND Ground.
3 48V safe power 20A Turns off in case of a
“protective stop” (emergency
stop).
Intended for high power loads
like motors or actuators.
4 GND Ground.
5 24V 2A Always on when robot is on.
Intended for low power use
like powering an external PLC.
6 GND Ground.
7 Unassigned Unassigned.
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A variety of top applications requires a general purpose and “simple-to-use” digital I/O (GPIO).
The GPIO supports low current/power devices like relays, contactors, lamps and/or separate PLC
units.
Figure B.4. Example of general use of I/O.
The GPIO has the following features:
• Four inputs, for use with 24V, but robust against 48V.
• Four outputs, for use with 24V.
Pin number Signal name Max. current Remarks
1 O1 1A @ 24V Output 1.
2 RTN Protected return.
3 O2 1A @ 24V Output 2.
4 RTN Protected return.
5 O3 1A @ 24V Output 3.
6 RTN Protected return.
7 O4 1A @ 24V Output 4.
8 RTN Protected return.
9 I1 PNP Input 1.
10 24V 24V Protected output.
11 I2 PNP Input 2.
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Figure B.5. GPIO interface.
Ethernet
An Ethernet connection is provided in the top left-hand side compartment.
Figure B.6. Ethernet connection. Pin numbers (left) and wiring diagram (right).
The communication interface is 10/100 Mbit Ethernet using a M12 connector. See Connector list on
page 68.
Various protocols can be supported, e.g. Modbus.
Figure B.7. Ethernet interface.
12 24V 24V Protected output.
13 I3 PNP Input 3.
14 24V 24V Protected output.
15 I4 PNP Input 4.
16 24V 24V Protected output.
17 Unassigned Unassigned.
Pin number Signal name Max. current Remarks
Pin number Signal name
1 TX+
2 RX+
3TX-
4RX-
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B.2.1 Safety interface
Auxiliary
Emergency
Stop
An Auxiliary Emergency Stop connection is provided in the top right-hand side compartment.
Figure B.8. Pin numbers: female connector viewed from the front (left) and wiring diagram (right).
Auxiliary Emergency Stop is designed to support emergency stop and other safety functions.
Figure B.9. Auxiliary Emergency Stop interface.
Auxiliary
Safety
Functions
An Auxiliary Safety Functions connection is provided in the top right-hand side compartment.
Pin number Signal name Remarks
1 Test output
2 Test output
3 E-stop 1 Emergency stop 1.
4 E-stop 2 Emergency stop 2.
5 Reset
6 Safe RTN Safe return.
7 Reset lamp
8 Unassigned Unassigned.
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Figure B.10. Pin numbers: female connector viewed from the front (left) and wiring diagram (right).
Auxiliary Safety Functions is designed to support emergency stop and other safety functions.
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Figure B.11. Auxiliary Safety Functions interface.
Connector
list
We recommend the following connectors for the five different interfaces.
Figure B.12. Connector list
Pin number Signal name Remarks
1 Test output
2 Test output
3 Safeguarded stop 1
4 Safeguarded stop 2
5 Locomotion 1
6 Locomotion 2
7 Shared E-stop out 1 Shared emergency stop out 1.
8 Shared E-stop out 2 Shared emergency stop out 2.
9 Shared E-stop in 1 Shared emergency stop in 1.
10 Shared E-stop in 2 Shared emergency stop in 2.
11 Reduced speed 1
12 Reduced speed 2
13 Unassigned Unassigned.
14 Unassigned Unassigned.
15 Safe RTN Safe return.
16 Unassigned Unassigned.
17 Unassigned Unassigned.
Connector name Connector type
Power M23 6p
GPIO M17 17p
Ethernet M12 4p
Auxiliary
Emergency Stop
M17 8p
Auxiliary Safety
Functions
M17 17p
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C Declaration of conformity
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