TM Robot TM5 Manual Book

TM5

Guide Book

Hardware Version: 1.00 Software Version: 1.64

Release Date : 2017-10-01

iii

The information contained herein is the property of Techman Robot Corporation (hereinafter referred to as the

Corporation). No part of this publication may be reproduced or copied in any way, shape or form without prior

authorization from the Corporation. No information contained herein shall be considered an offer or commitment.

It may be subject to change without notice. This Manual should be reviewed periodically. The Corporation will not

be liable for any error or omission.

and logos are the registered trademark of TECHMAN ROBOT INC. and the company reserves the

ownership of this manual and its copy and its copyrights.

I Hardware Installation Manual

1. Safety Information

1.1 Overview

1.2 Validation and Liability

1.3 Limitations on Liability

1.4 Warning and Caution Symbols

1.5 General Safety Warning

1.6 Scope of Use

1.7 Risk Assessment

1.8 Emergency Stop

1.9 Joint Rotation without Drive Power

2. Safety Functions and Interface

2.1 Overview

2.2 Safe Stop Time

2.3 Safety-related Limiting Mechanisms

2.4 Singularity/Singular Point

2.5 Safety Setting

2.5.1 Operating Position

2.6 Operating Mode

2.6.1 Auto Mode

2.6.2 Manual Mode

2.6.2.1 Manual Control Mode

2.6.2.2 Manual Trial Run Mode

2.6.3 Changing the Operating Mode

2.7 Hold to Run

2.8 Collaborative Mode and Safety Zone Setup

2.8.1 Collaborative Mode and Parameter Configuration

2.8.2 Collaborative Space Configuration for Safety

3. Transportation

4. System Hardware

4.1 Overview

4.2 System Overview

4.2.1 Robot Arm

4.2.1.1 Robot Range of Motion

4.2.1.2 Robot Arm Maximum Allowed Payload

4.2.1.3 Robot Arm Installation

4.2.2 Robot End Module

4.2.2.1 End Module Components

4.2.2.2 End Flange Surface

4.2.2.3 End Mounting Caution

4.2.2.4 End Indication Light Ring Table

4.2.3 Control Box

4.2.3.1 Robot Stick

5. Electrical Interface

5.1 Overview

5.2 Electrical Warnings and Cautions

5.3 Control Box

5.3.1 Safety Connector

5.3.2 Power Connector

5.3.3 Digital In/Out

5.3.4 Analog In

5.3.5 Analog Out

5.3.6 EtherCAT: For EtherCAT Slave I/O Expansion

5.3.7 USB Port

5.4 Tool End I/O Interface

5.4.1 I/O Terminals

5.4.2 Connecting Tool End Digital Out

5.4.3 Connecting Tool End Digital In

5.4.4 Connecting Tool End Analog In

5.5 Control Box Interfaces

5.6 Control Box Power Interface and Robot Interface

5.6.1 Control Box Power Interface

5.6.2 Robot Interface

6. Maintenance and Repair

7. Warranty Statement

7.1 Product Warranty

7.2 Disclaimer

Appendix A. Stop Time and Distance

Appendix B. Technical Specifications

Hardware Installation Manual

Hardware Version: 1.00 Software Version: 1.64

I Hardware Installation Manual 1. Safety Information2

1. Safety Information

1.1 Overview

This chapter describes important safety information about the Techman Robot. The users and system

integrators of the Techman Robot should carefully read and understand this chapter before using this robot.

1.2 Validation and Liability

The information contained herein neither includes how to design, install, and operate a complete robotic arm

system, nor involves the peripherals which may affect the safety of the complete system. The design and

installation of the complete system must comply with the safety standards and regulations in the country of

use. The integrators of the robot should understand the safety laws and regulations in their countries and

prevent major hazards from occurring in the complete system.

This includes but is not limited to:

• Risk assessment of the whole system;

• Adding other machines and additional safety mechanisms based on the results of the risk assessment;

• Building appropriate safety mechanisms in the software;

• Ensuring the user will not modify any safety-related measures;

• Ensuring all systems are correctly designed and installed;

• Clearly labeling user instructions;

• Clearly marked symbols for installation of the robot arm and the integrator contact details; and

• Collecting all documents into the technology folder, including the risk assessment, and this Manual.

1.3 Limitations on Liability

No safety-related information shall be considered a guarantee by Techman Robot that TM5 will not cause

personnel injury or property damage.

3I Hardware Installation Manual 1. Safety Information

Note

Danger

Warning

This symbol indicates that failure to observe these instructions will lead to death or serious injuries.

This symbol indicates that failure to observe these instructions may lead to injuries.

This symbol indicates that failure to observe these instructions may lead to equipment damage.

Danger

Warning

Note

1.4 Warning and Caution Symbols

The Table below shows the definitions of the warning and caution levels described in each paragraph of this

Manual. Pay close attention to them when reading each paragraph, and observe them to avoid personal

injuries or equipment damage.

I Hardware Installation Manual 1. Safety Information4

1.5 General Safety Warning

The following shows the general warnings and cautions. Note that there may be related warnings and

cautions listed in the remaining sections, in addition to the ones described in this section. Read them

carefully as well.

Danger:

1. Before handling, installation, operating, maintaining and servicing this product, carefully read the

product's specifications and operating manual. Make sure that all conditions meet the requirements of the

specifications and manual to avoid unexpected accidents during use (e.g. improper operation or operating

conditions that exceed the product specifications) that may cause personnel injury or damage to this

product.

2. Before using and installing this product, the installer must perform the necessary risk assessments

based on the conditions of use to avoid serious personal injuries during operation (e.g. Collision between

equipment and personnel) due to improper parameter settings.

Warning:

1. Before using this product, make sure that there is at least 1 or more emergency stop device on the

machine to stop the movement of the robot in case of accidents. Always make sure that the devices are

functioning properly.

2. Prior to assembly and disassembly, or servicing and maintenance of this product, make sure that the

power is disconnected and the rear area is clear before proceeding. Doing so will help prevent injury to

personnel or damage to equipment due to accidental short-circuits or electrocution during use.

3. When operating this product, the operator should not wear loose clothing or other accessories (e.g.

necklaces, ties,and bracelets) to avoid injuries which may happen when said clothes or accessories are

drawn into the machine during operation.

4. In the event of product malfunction, follow the proper procedures and channels to contact qualified

personnel for troubleshooting and repair. To prevent damage to the equipment due to improper disassembly,

the operator is strictly prohibited against attempting to make direct repairs.

5. Before the robot begins operations, make sure that each part is secured in place to prevent any accidents

due to the robot being improperly secured during operation.

6. Before the robot begins operations, always make sure that no personnel or obstacles are within its range

of motion. If the operating environment involves human-machine collaborative work, always perform the

necessary risk assessments before the start of operations.

7. Unauthorized personnel are not allowed to operate this product in order to prevent any possibility of

personal injury or damage to the machine caused by improper operation.

8. Do not install or operate this product in dangerous environments (e.g. in the presence of a strong

magnetic field; dangerous gases; fire, or flammables) to avoid dangers which may occur due to external

conditions during operation.

5I Hardware Installation Manual 1. Safety Information

Note:

1. Personnel approaching or operating the robot should check the machine warning lights before proceeding.

2. After editing the task flow, always start operations in Manual Mode to check that all actions can be

performed correctly during operation before switching the operating mode to Auto.

3. Do not turn off power to the machine while it is in motion unless absolutely necessary.

1.6 Scope of Use

The TM Robot is a collaborative robot with a built-in vision system. The dedicated HMI simplifies robot

deployment and increases its operational flexibility, making it suitable able for the production and

manufacturing industries.

The design of the TM Robot focuses on the safety of the human-machine collaboration. However, the

collaborative robot is intended only for the applications for which risk assessment has been conducted

without any hazards identified. The risk assessment involves the robot and the related peripherals as well

as environment.

The risk assessment has been performed for any use or application and no hazard is found. The use of the

robot for any purpose other than the intended is prohibited. The Corporation shall not in any event be liable

for any conditions including, but not limited to, the following:

- Use in a potentially hazardous environment

- Use in any applications that may threaten human lives

- Use in any application that may cause personal injuries

- Use before completion of the risk assessment

- Use for auxiliary support

- Use when the rated performance cannot be reached

- Use when the reaction time of safety functions is insufficient.

- Use with inappropriate parameters for operations

- Applications which may cause damage to the robot itself

1.7 Risk Assessment

Before using and installing this product, the user must perform the necessary risk assessments based on

the conditions of use. Refer to the regulations specified in the documentation, such as ISO-10218-2, ISO-

12100, and ISO-15066 for details. The purpose of the risk assessment is to predict possible accidents

during the operation, and prevent the occurrence of accidents or reduce the severity of injuries effectively

with appropriate protective measures. Therefore, the scope of the risk assessment must include any oper-

ation of the machine. Once a risk assessment has been conducted, the user may use the relevant external

components (e.g. sensors, emergency stop devices, fencing or other barrier devices) and configuration of

safety-related parameters in the operating system to prevent potential accidents during operations. External

safety-related components should be installed as directed. Refer to Chapter 2 for the safety settings of the

operating system and how other safety components should be used.

I Hardware Installation Manual 1. Safety Information6

TM Robot expressly indicates that the major significant residual risk below may exist:

1. Excessive rotation of the 6th joint may result in the fingers being caught between the rear-end of the

camera module and the 5th joint module.

2. The palm or fingers may get caught between the end module and the body of the robot during robot

motion or Hand Guide Instruction.

3. Injuries due to collision with the robot.

4. Injuries due to being hit, crushed, or pinched between the robot and a hard surface.

5. Injuries caused by loose screws which are used to fix the robot to the base.

6. TM Robot explicitly states that serious residual risk may exist in the following scenarios: There is a risk

that improper configuration of the collaborative zone or safety space, as well as the running of incorrect

projects, may lead to the robot colliding at full speed with the human body within the collaborative space.

1.8 Emergency Stop

If any accidents occur during the operation of the robot, the user can stop all movement by pressing the

Emergency Stop button. When the robot stops, the user must ensure that all fault conditions are eliminated

before manually turning off the limit switch for the Emergency Stop button and restarting the robot.The

Emergency Stop button is only used in critical conditions, to stop the robot during normal operations please

use the Stop button on the system controller.

Once the risk assessment has been conducted, if an Emergency Stop button needs to be installed then the

selected device must comply with the requirements of ISO-60204-1.

1.9 Joint Rotation without Drive Power

1. When the Emergency Stop Button is triggered during the operation of the robot, the control system will

stop its movement and cease supplying sufficient power to its joint actuators to achieve an effect equivalent

to disconnecting the power for actuation to the robot. In this case, the brake at each joint automatically locks

the joint to prevent each joint of the robot from drooping continuously under gravity. If the robot needs to

be moved to clear the fault condition, press and hold the FREE button on the end module of the robot. Two

seconds later, the braking device at the joint will disengage the brakes. Before releasing the FREE button,

the user can move the machine by pushing the joint to clear the fault condition.

When an emergency button is pressed, the robot system issues a command to stop the robot,

and stops supplying sufficient power to its joint actuators for an effect equivalent to disconnecting

the power for the actuation of the robot. In this case, the braking device at each joint automatically

locks the joint. However, before the brake completely stops the robot, the robotic link will, under

the force of gravity, make the unpowered joint slightly droop in the direction of gravity. In this

case, be aware of the possibility that the robot end module may pinch the body or collide with the

surroundings.

Warning

7I Hardware Installation Manual 1. Safety Information

2. If the robot needs to be moved when the power is disconnected (e.g. disengaging packaging posture),

the user can first press the Emergency Stop button while there is no power, then press the Power Button on

the controller to supply power to the system. When the control system is turned on, the light blue indicator

light on the end module will blink. At this time, press the FREE button on the end module to release the

braking device at the joint. The user can move the joint by pushing it.

When overriding the brake during the movement without drive power, note that the robot limb will

droop back down due to the gravity when the FREE button is pressed for 2 seconds. Be sure

to grab the end module securely and prepare for the added weight when you press the FREE

button to unlock the brake. Lift the end module upwards to avoid increasing the severity of injury

if someone is caught under the machine. If the end module can't be held securely or you lack

sufficient strength to prevent the robot arm from lowering, release the FREE button immediately.

Each joint of the robot will be locked again to avoid personal injury or machine damage.

Danger

I Hardware Installation Manual 2. Safety Functions and Interface8

2. Safety Functions and Interface

2.1 Overview

The control system of the Techman Robot features a series of built-in safety-related functions, and provides

an interface for connecting with external safety devices.

For human-machine collaborative tasks, the user or system integrator must configure the safety-

related parameters based on the results of the risk assessment. For tasks during which human

and machine are separated, evaluate the selection and configuration of external protection

equipment. Failure to do so may result in personal injuries or death.

For instructions on how to configure the safety-related parameters in the UI, refer to Section 2.5.

For instructions on how to connect external safety devices to the system, refer to Chapter 5.

Note:

1. The user or system integrator should configure the safety-related parameters based on the

results of the risk assessment.

2. If any of the safety-related functions is triggered, protection stop is activated. Stop time is

provided in Appendix A and this time should be considered as part of the task risk assessment.

The Techman Robot System limits physical values such as offset, speed, force, or even

momentum and power, for the robot arm, tool end, and each movable axis. These are monitored

and protected by dozens of safety-related protection functions through the real-time system. The

figure below lists each protective function.

Location Speed/Momentum Force/Power

Robot

N.A Maximum robot momentum

Maximum robot power

Tool end

N.A Maximum speed of tool end

Force Applied to Tool

Endpoint

Axis 1