Universal Robots UR3, CB3 User Manual

Name: Universal Robots UR3
Brand: Universal Robots
SKU: 2572614
Rating: 4.5 (2 reviews)

4.5 (2)

User Manual

UR3/CB3

Original instructions (en)

User Manual

UR3/CB3

Version 3.1 (rev. 17782)

Original instructions (en)

Serial number UR3:

Serial number CB3:

The information contained herein is the property of Universal Robots A/S and shall not be reproduced in whole or in part without prior written approval of Universal Robots A/S. The information herein is subject to change without notice and should not be construed as a commitment by Universal Robots A/S. This manual is periodically reviewed and revised.

Universal Robots A/S assumes no responsibility for any errors or omissions in this document.

The Universal Robots logo is a registered trademark of Universal Robots A/S.

UR3/CB3

Version 3.1 (rev. 17782)

Contents

Preface	ix
What do the Boxes Contain . . . . . . . . . . . . . . . . . . . . . . . .	ix
Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . .	x
How to Read This Manual . . . . . . . . . . . . . . . . . . . . . . . .	x
Where to Find More Information . . . . . . . . . . . . . . . . . . . . . .	x

I	Hardware Installation Manual			I-1
1	Safety			I-3
	1.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . .		I-3
	1.2	Validity and Responsibility . . . . . . . . . . . . . . . . . . . . . .		I-3
	1.3	Limitation of Liability. . . . . . . . . . . . . . . . . . . . . . . .		I-4
	1.4	Warning Symbols in this Manual . . . . . . . . . . . . . . . . . . . .		I-4
	1.5	General Warnings and Cautions . . . . . . . . . . . . . . . . . . . .		I-5
	1.6	Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . .		I-7
	1.7	Risk Assessment. . . . . . . . . . . . . . . . . . . . . . . . . .		I-7
	1.8	Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . .		I-8
	1.9	Movement Without Drive Power. . . . . . . . . . . . . . . . . . . .		I-8
2	Transportation			I-11
3	Mechanical Interface			I-13
	3.1	Workspace of the Robot . . . . . . . . . . . . . . . . . . . . . . .		I-13
	3.2	Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .		I-13
4	Electrical Interface			I-19
	4.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . .		I-19
	4.2	Electrical warnings and cautions . . . . . . . . . . . . . . . . . . . .		I-19
	4.3	Controller I/O . . . . . . . . . . . . . . . . . . . . . . . . . .		I-21
		4.3.1	Common speciﬁcations for all digital I/O . . . . . . . . . . . . . .	I-21
		4.3.2	Safety I/O . . . . . . . . . . . . . . . . . . . . . . . . .	I-22
		4.3.3	General purpose digital I/O. . . . . . . . . . . . . . . . . . .	I-26
		4.3.4	Digital input from a button . . . . . . . . . . . . . . . . . . .	I-26
		4.3.5	Communication with other machines or PLCs . . . . . . . . . . . .	I-27
		4.3.6	General purpose analog I/O. . . . . . . . . . . . . . . . . . .	I-27
		4.3.7	Remote ON/OFF control . . . . . . . . . . . . . . . . . . . .	I-29
	4.4	Tool I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . .		I-30
		4.4.1	Tool Digital Outputs . . . . . . . . . . . . . . . . . . . . .	I-31
		4.4.2	Tool Digital Inputs . . . . . . . . . . . . . . . . . . . . . .	I-32
		4.4.3	Tool Analog Inputs . . . . . . . . . . . . . . . . . . . . . .	I-32

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	4.5	Ethernet. . . . . . . . . . . . . . . . . . . . . . . . . . . . .		I-33
	4.6	Mains connection . . . . . . . . . . . . . . . . . . . . . . . . .		I-34
	4.7	Robot connection . . . . . . . . . . . . . . . . . . . . . . . . .		I-35
5	Safety-related Functions and Interfaces			I-37
	5.1	Limiting Safety-related Functions . . . . . . . . . . . . . . . . . . .		I-37
	5.2	Safety Modes . . . . . . . . . . . . . . . . . . . . . . . . . . .		I-39
	5.3	Safety-related Electrical Interfaces . . . . . . . . . . . . . . . . . . .		I-39
		5.3.1	Safety-related Electrical Inputs . . . . . . . . . . . . . . . . . .	I-39
		5.3.2	Safety-related Electrical Outputs . . . . . . . . . . . . . . . . .	I-41
6	Maintenance and Repair			I-43
	6.1	Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . .		I-43
7	Disposal and Environment			I-45
8	Certiﬁcations			I-47
	8.1	Third Party Certiﬁcations . . . . . . . . . . . . . . . . . . . . . .		I-47
	8.2	Declarations According to EU directives . . . . . . . . . . . . . . . . .		I-47
9	Warranties			I-49
	9.1	Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . .		I-49
	9.2	Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . .		I-49
A	Stopping Time and Stopping Distance			I-51
	A.1	CATEGORY 0 stopping distances and times. . . . . . . . . . . . . . . .		I-51
B	Declarations and Certiﬁcates			I-53
	B.1	CE Declaration of Incorporation (original) . . . . . . . . . . . . . . . .		I-53
	B.2	Safety System Certiﬁcate. . . . . . . . . . . . . . . . . . . . . . .		I-54
	B.3	Environmental Test Certiﬁcate. . . . . . . . . . . . . . . . . . . . .		I-55
	B.4	EMC Test Certiﬁcate . . . . . . . . . . . . . . . . . . . . . . . .		I-56
C	Applied Standards			I-57
D	Technical Speciﬁcations			I-63

II PolyScope Manual			II-1
10 Introduction			II-3
10.1	Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . .		II-3
	10.1.1	Installing the Robot Arm and Control Box. . . . . . . . . . . . . .	II-3
	10.1.2	Turning the Control Box On and Off . . . . . . . . . . . . . . . .	II-4
	10.1.3	Turning the Robot Arm On and Off . . . . . . . . . . . . . . . .	II-4
	10.1.4	Quick Start . . . . . . . . . . . . . . . . . . . . . . . . .	II-4
	10.1.5	The First Program . . . . . . . . . . . . . . . . . . . . . .	II-5
10.2	PolyScope Programming Interface . . . . . . . . . . . . . . . . . . .		II-6
10.3	Welcome Screen . . . . . . . . . . . . . . . . . . . . . . . . . .		II-8
10.4	Initialization Screen . . . . . . . . . . . . . . . . . . . . . . . .		II-9

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11 On-screen Editors		II-11
11.1	On-screen Keypad . . . . . . . . . . . . . . . . . . . . . . . . .	II-11
11.2	On-screen Keyboard . . . . . . . . . . . . . . . . . . . . . . . .	II-12
11.3	On-screen Expression Editor . . . . . . . . . . . . . . . . . . . . .	II-12
11.4	Pose Editor Screen . . . . . . . . . . . . . . . . . . . . . . . . .	II-13

12 Robot Control			II-17
12.1	Move Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . .		II-17
	12.1.1	Robot . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-17
	12.1.2	Feature and Tool Position . . . . . . . . . . . . . . . . . . . .	II-18
	12.1.3	Move Tool . . . . . . . . . . . . . . . . . . . . . . . . .	II-18
	12.1.4	Move Joints. . . . . . . . . . . . . . . . . . . . . . . . .	II-18
	12.1.5	Freedrive . . . . . . . . . . . . . . . . . . . . . . . . .	II-18
12.2	I/O Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		II-19
12.3	MODBUS client I/O . . . . . . . . . . . . . . . . . . . . . . . .		II-20
12.4	AutoMove Tab . . . . . . . . . . . . . . . . . . . . . . . . . .		II-20
12.5	Installation ! Load/Save . . . . . . . . . . . . . . . . . . . . . .		II-22
12.6	Installation ! TCP Conﬁguration . . . . . . . . . . . . . . . . . . .		II-23
	12.6.1	Adding, modifying and removing TCPs . . . . . . . . . . . . . .	II-23
	12.6.2	The default and the active TCP. . . . . . . . . . . . . . . . . .	II-23
	12.6.3	Teaching TCP position . . . . . . . . . . . . . . . . . . . . .	II-24
	12.6.4	Teaching TCP orientation . . . . . . . . . . . . . . . . . . . .	II-25
	12.6.5	Payload . . . . . . . . . . . . . . . . . . . . . . . . . .	II-25
	12.6.6	Center of gravity . . . . . . . . . . . . . . . . . . . . . . .	II-25
12.7	Installation ! Mounting. . . . . . . . . . . . . . . . . . . . . . .		II-26
12.8	Installation ! I/O Setup . . . . . . . . . . . . . . . . . . . . . .		II-27
12.9	Installation ! Safety . . . . . . . . . . . . . . . . . . . . . . . .		II-28
12.10	Installation ! Variables . . . . . . . . . . . . . . . . . . . . . . .		II-28
12.11	Installation ! MODBUS client I/O Setup . . . . . . . . . . . . . . . .		II-29
12.12	Installation ! Features . . . . . . . . . . . . . . . . . . . . . . .		II-32
12.13	Conveyor Tracking Setup . . . . . . . . . . . . . . . . . . . . . .		II-35
12.14	Installation ! Default Program . . . . . . . . . . . . . . . . . . . .		II-36
	12.14.1 Loading a Default Program . . . . . . . . . . . . . . . . . . .		II-37
	12.14.2 Starting a Default Program . . . . . . . . . . . . . . . . . . .		II-37
	12.14.3 Auto Initialization . . . . . . . . . . . . . . . . . . . . . .		II-37
12.15	Log Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		II-38
12.16	Load Screen . . . . . . . . . . . . . . . . . . . . . . . . . . .		II-38
12.17	Run Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		II-41
13 Programming			II-43
13.1	New Program . . . . . . . . . . . . . . . . . . . . . . . . . .		II-43
13.2	Program Tab . . . . . . . . . . . . . . . . . . . . . . . . . . .		II-44
	13.2.1	Program Tree . . . . . . . . . . . . . . . . . . . . . . . .	II-44
	13.2.2	Program Execution Indication . . . . . . . . . . . . . . . . . .	II-45
	13.2.3	Undo/Redo Buttons . . . . . . . . . . . . . . . . . . . . .	II-45
	13.2.4	Program Dashboard. . . . . . . . . . . . . . . . . . . . . .	II-45

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13.3	Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-46
13.4	Command: Empty . . . . . . . . . . . . . . . . . . . . . . . . .	II-47
13.5	Command: Move . . . . . . . . . . . . . . . . . . . . . . . . .	II-48
13.6	Command: Fixed Waypoint . . . . . . . . . . . . . . . . . . . . .	II-51
13.7	Command: Relative Waypoint. . . . . . . . . . . . . . . . . . . . .	II-53
13.8	Command: Variable Waypoint . . . . . . . . . . . . . . . . . . . .	II-54
13.9	Command: Wait . . . . . . . . . . . . . . . . . . . . . . . . . .	II-55
13.10	Command: Set . . . . . . . . . . . . . . . . . . . . . . . . . .	II-55
13.11	Command: Popup . . . . . . . . . . . . . . . . . . . . . . . . .	II-56
13.12	Command: Halt . . . . . . . . . . . . . . . . . . . . . . . . . .	II-57
13.13	Command: Comment . . . . . . . . . . . . . . . . . . . . . . . .	II-57
13.14	Command: Folder . . . . . . . . . . . . . . . . . . . . . . . . .	II-58
13.15	Command: Loop . . . . . . . . . . . . . . . . . . . . . . . . .	II-58
13.16	Command: SubProgram . . . . . . . . . . . . . . . . . . . . . . .	II-59
13.17	Command: Assignment . . . . . . . . . . . . . . . . . . . . . . .	II-60
13.18	Command: If . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-61
13.19	Command: Script . . . . . . . . . . . . . . . . . . . . . . . . .	II-62
13.20	Command: Event . . . . . . . . . . . . . . . . . . . . . . . . .	II-63
13.21	Command: Thread . . . . . . . . . . . . . . . . . . . . . . . . .	II-64
13.22	Command: Pattern . . . . . . . . . . . . . . . . . . . . . . . . .	II-64
13.23	Command: Force . . . . . . . . . . . . . . . . . . . . . . . . .	II-66
13.24	Command: Pallet . . . . . . . . . . . . . . . . . . . . . . . . .	II-69
13.25	Command: Seek . . . . . . . . . . . . . . . . . . . . . . . . . .	II-70
13.26	Command: Start/Stop Conveyor Tracking . . . . . . . . . . . . . . . .	II-73
13.27	Command: Suppress . . . . . . . . . . . . . . . . . . . . . . . .	II-74
13.28	Graphics Tab . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-74
13.29	Structure Tab . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-75
13.30	Variables Tab . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-76
13.31	Command: Variables Initialization . . . . . . . . . . . . . . . . . . .	II-77
14 Setup Screen		II-79
14.1	Language and Units . . . . . . . . . . . . . . . . . . . . . . . .	II-80
14.2	Update Robot. . . . . . . . . . . . . . . . . . . . . . . . . . .	II-81
14.3	Set Password . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-82
14.4	Calibrate Screen . . . . . . . . . . . . . . . . . . . . . . . . . .	II-83
14.5	Setup Network . . . . . . . . . . . . . . . . . . . . . . . . . .	II-83
14.6	Set Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-84
15 Safety Conﬁguration		II-85
15.1	Changing the Safety Conﬁguration . . . . . . . . . . . . . . . . . . .	II-86
15.2	Safety Synchronization and Errors . . . . . . . . . . . . . . . . . . .	II-86
15.3	Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-87
15.4	Safety Checksum . . . . . . . . . . . . . . . . . . . . . . . . .	II-88
15.5	Safety Modes . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-88
15.6	Freedrive Mode . . . . . . . . . . . . . . . . . . . . . . . . . .	II-89
15.7	Password Lock . . . . . . . . . . . . . . . . . . . . . . . . . .	II-89
15.8	Apply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-89

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15.9	General Limits . . . . . . . . . . . . . . . . . . . . . . . . . .	II-90
15.10	Joint Limits . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-93
15.11	Boundaries. . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-94
	15.11.1 Selecting a boundary to conﬁgure. . . . . . . . . . . . . . . . .	II-95
	15.11.2 3D visualization . . . . . . . . . . . . . . . . . . . . . . .	II-95
	15.11.3 Safety plane conﬁguration . . . . . . . . . . . . . . . . . . .	II-96
	15.11.4 Tool Boundary conﬁguration . . . . . . . . . . . . . . . . . .	II-99
15.12	Safety I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . .	II-101
Glossary		II-103
Index		II-105

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Preface

Congratulations on the purchase of your new Universal Robot, UR3.

The robot can be programmed to move a tool, and communicate with other machines using electrical signals. It is an arm composed of extruded aluminum tubes and joints. Using our patented programming interface, PolyScope, it is easy to program the robot to move the tool along a desired trajectory.

What do the Boxes Contain

When you order a complete robot, you receive two boxes. One contains the the robot arm and the following items are included in the other one:

•Control box with teach pendant;

•Mounting bracket for the control box;

•Mounting bracket for the teach pendant;

•Key for opening the control box;

•Mains cable compatible with your region;

•Tool cable;

•Stylus pen with laser;

•UR production test certiﬁcate;

•This manual.

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Where to Find More Information

Important Safety Notice

The robot is partly completed machinery (see 8.2) and as such a risk assessment is required for each installation of the robot. It is particularly important that all of the safety instructions in chapter 1 are followed.

How to Read This Manual

This manual contains instructions for installing and using the robot. It consists of the following parts:

Hardware Installation Manual: The mechanical and electrical installation of the robot.

PolyScope Manual: Programming of the robot.

This manual is intended for the integrator who is expected to have a basic level of mechanical and electrical training. It is also helpful, though not necessary, to be familiar with elementary concepts of programming. No special knowledge about robots in general or Universal Robots in particular is required.

Where to Find More Information

The support website (http://support.universal-robots.com/), available to all UR distributors, contains additional information, such as:

•Other language versions of this manual;

•PolyScope Manual updates after the PolyScope is upgraded to a new version.

•The Service Manual with instructions for troubleshooting, maintenance and repair of the robot.

•The Script Manual for advanced users.

UR3/CB3

Version 3.1 (rev. 17782)

Part I

Hardware Installation Manual

1 Safety

1.1Introduction

This chapter contains important safety information, which must be read and understood by the integrator of UR robots.

The ﬁrst subsections in this chapter are more general and the later subsections contain more speciﬁc engineering data relevant for setting up and programming the robot.

It is essential that all assembly instructions and guidance provided in other chapters and parts of this manual are observed and followed.

Special attention shall be paid to text associated with warning symbols. See Chapter 5 for detailed descriptions of the safety-related functions and interfaces.

1.2Validity and Responsibility

The information does not cover how to design, install and operate a complete robot application, nor does it cover all peripheral equipment that can inﬂuence the safety of the complete system. The complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.

The integrators of UR robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that any signiﬁcant hazards in the complete robot application are eliminated.

This includes, but is not limited to:

•Making a risk assessment for the complete system;

•Interfacing other machines and additional safety devices if deﬁned by the risk assessment;

•Setting up the appropriate safety settings in the software;

•Ensuring that the user will not modify any safety measures;

•Validating that the total system is designed and installed correctly;

•Specifying instructions for use;

•Marking the robot installation with relevant signs and contact information of the integrator;

•Collecting all documentation in a technical ﬁle.

Guidance on how to ﬁnd and read applicable standards and laws is provided on http://support.universal-robots.com/

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1.4 Warning Symbols in this Manual

1.3Limitation of Liability

Any information given in this manual regarding safety must not be construed as a warranty by UR that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with.

1.4Warning Symbols in this Manual

The table below deﬁnes the captions specifying the danger levels used throughout this manual. The same warning signs are used on the product.

DANGER:

This indicates an imminently hazardous electrical situation which, if not avoided, could result in death or serious injury.

DANGER:

This indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.

WARNING:

This indicates a potentially hazardous electrical situation which, if not avoided, could result in injury or major damage to the equipment.

WARNING:

This indicates a potentially hazardous situation which, if not avoided, could result in injury or major damage to the equipment.

WARNING:

This indicates a potentially hazardous hot surface which, if touched, could result in injury.

CAUTION:

This indicates a situation which, if not avoided, could result in damage to the equipment.

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1.5 General Warnings and Cautions

1.5General Warnings and Cautions

This section contains some general warnings and cautions. Some of which are repeated or explained in different parts of the manual. Other warnings and cautions are present throughout the manual.

DANGER:

Make sure to install the robot and all electrical equipment according to the speciﬁcations and warnings found in the Chapters 3 and 4.

WARNING:

1. Make sure the robot arm and tool are properly and securely bolted in place.

2.Make sure the robot arm has ample space to operate freely.

3.Make sure that safety measures and/or robot safety conﬁguration parameters have been set up to protect both programmers, operators and bystanders, as deﬁned in the risk assessment.

4.Do not wear loose clothing or jewellery when working with the robot. Make sure long hair is tied back when working with the robot.

5.Never use the robot if it is damaged.

6.If the software prompts a fatal error, immediately activate emergency stop, write down the conditions that led to the error, ﬁnd the corresponding error codes on the log screen, and contact your supplier.

7.Do not connect any safety equipment to normal I/O. Use safety-related interfaces only.

8.Make sure to use the correct installation settings (e.g. Robot mounting angle, weight in TCP, TCP offset, safety conﬁguration). Save and load the installations ﬁle along with the program.

9.The freedrive function (Impedance/back-drive) shall only be used in installations where the risk assessment allows it. Tools and obstacles shall not have sharp edges or pinch points. Make sure that all people keep their heads and faces outside the reach of the robot.

10.Be aware of robot movement when using the teach pendant.

11.Do not enter the safety range of the robot or touch the robot when the system is in operation.

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1.5 General Warnings and Cautions

11.Collisions can release high portions of kinetic energy, which

are signiﬁcantly higher at high speeds and with high payloads. (Kinetic Energy = 12 Mass Speed2)

12.Combining different machines might increase hazards or create new hazards. Always make an overall risk assessment for the complete installation. When different safety and emergency stop performance levels are needed, always choose the highest performance level. Always read and understand the manuals for all equipment used in the installation.

13.Never modify the robot. A modiﬁcation might create hazards that are unforeseen by the integrator. All authorized reassembling shall be done according to the newest version of all relevant service manuals. UNIVERSAL ROBOTS DISCLAIMS ANY LIABILITY IF THE PRODUCT IS CHANGED OR MODIFIED IN ANY WAY.

14.If the robot is purchased with an extra module (e.g. euromap67 interface) then look up that module in the respective manual.

WARNING:

1.The robot and controller box generate heat during operation. Do not handle or touch the robot while in operation or immediately after operation. To cool the robot down, power off the robot and wait one hour.

2.Never stick ﬁngers behind the internal cover of the controller box.

CAUTION:

1. When the robot is combined with or working with machines capable of damaging the robot, then it is highly recommended to test all functions and the robot program separately. It is recommended to test the robot program using temporary waypoints outside the workspace of other machines. Universal Robots cannot be held responsible for any damages caused to the robot or to other equipment due to programming errors or malfunctioning of the robot.

2.Do not expose the robot to permanent magnetic ﬁelds. Very strong magnetic ﬁelds can damage the robot.

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1.6 Intended Use

1.6Intended Use

UR robots are industrial and intended for handling tools and ﬁxtures, or for processing or transferring components or products. For details about the environmental conditions under which the robot should operate, see appendices B and D.

UR robots are equipped with special safety-related features, which are purposely designed for collaborative operation, where the robot operates without fences and/or together with a human.

Collaborative operation is only intended for non-hazardous applications, where the complete application, including tool, work piece, obstacles and other machines, is without any signiﬁcant hazards according to the risk assessment of the speciﬁc application.

Any use or application deviating from the intended use is deemed to be impermissible misuse. This includes, but is not limited to:

•Use in potentially explosive environments;

•Use in medical and life critical applications;

•Use before performing a risk assessment;

•Use where the rated performance levels are insufﬁcient;

•Use where the reaction times of the safety functions are insufﬁcient;

•Use as a climbing aid;

•Operation outside the permissible operating parameters.

1.7Risk Assessment

One of the most important things that an integrator needs to do is to make a risk assessment. The robot itself is partly completed machinery, as the safety of the robot installation depends on how the robot is integrated (E.g. tool, obstacles and other machines).

It is recommended that the integrator uses guidelines in ISO 12100 and ISO 10218-2 to conduct the risk assessment.

The risk assessment shall consider two scenarios:

•Teaching the robot while developing the robot installation;

•Normal operation of the robot installation.

If the robot is installed in a non-collaborative installation (E.g. when using a hazardous tool) the risk assessment might conclude that the integrator needs to connect additional safety devices (E.g. an enable device) to protect him while programming.

Universal Robots has identiﬁed the potential signiﬁcant hazards listed below as hazards which must be considered by the integrator. Note that other signiﬁcant hazards might be present in a speciﬁc robot installation.

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1.9 Movement Without Drive Power

1.Entrapment of ﬁngers between robot foot and base (joint 0).

2.Entrapment of ﬁngers between wrist 1 and wrist 2 (joint 3 and joint 4).

3.Penetration of skin by sharp edges and sharp points on tool or tool connector.

4.Penetration of skin by sharp edges and sharp points on obstacles near the robot track.

5.Bruising due to stroke from the robot.

6.Sprain or bone fracture due to strokes between a heavy payload and a hard surface.

7.Consequences due to loose bolts that hold the robot arm or tool.

8.Items falling out of tool, e.g. due to a poor grip or power interruption.

9.Mistakes due to different emergency stop buttons for different machines.

Information on stopping times and stopping distances are found in appendix A.

1.8Emergency Stop

Activate the emergency stop button to immediately stop all robot motion.

Emergency stop shall not be used as a risk reduction measure, but as a secondary protective device.

The risk assessment of the robot application shall conclude if more emergency stop buttons must be connected. Emergency stop buttons should comply with IEC 60947-5-5, see more in section 4.3.2.

1.9Movement Without Drive Power

In the unlikely event of an emergency situation where one or more robot joints need to be moved and robot power is either not possible or unwanted, there are two different ways to force movements of the robot joints:

1.Forced back-driving: Force a joint to move by pushing or pulling the robot arm hard (500 N). Each joint brake has a friction clutch which enables movement during high forced torque.

2.Manual brake release (only for Base, Shoulder and Elbow joints): Remove the joint cover by removing the few M3 screws that ﬁx it. Release the brake by pushing the plunger on the small electromagnet as shown in the picture below.

WARNING:

1. Moving the robot arm manually is intended for urgent emergencies only and might damage the joints.

2.If the brake is released manually, gravitational pull can cause the robot arm to fall. Always support the robot arm, tool and work item when releasing the brake.

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2 Transportation

Transport the robot in the original packaging. Save the packaging material in a dry place; you may need to pack down and move the robot later on.

Lift both tubes of the robot arm at the same time when moving it from the packaging to the installation place. Hold the robot in place until all mounting bolts are securely tightened at the base of the robot.

The controller box shall be lifted by the handle.

WARNING:

1. Make sure not to overload your back or other bodyparts when the equipment is lifted. Use proper lifting equipment. All regional and national guidelines for lifting shall be followed. Universal Robots cannot be held responsible for any damage caused by transportation of the equipment.

2.Make sure to mount the robot according to the mounting instructions in chapter 3.

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3Mechanical Interface

The robot consists essentially of six robot joints and two aluminum tubes, connecting the base with the tool of the robot. The robot permits the tool to be translated and rotated within the workspace. The next section describes the basics of mounting the various parts of the robot system.

Electrical installation instructions in chapter 4 must be observed.

3.1Workspace of the Robot

The workspace of the UR3 robot extends 500 mm from the base joint. It is important to consider the cylindrical volume directly above and directly below the robot base when a mounting place for the robot is chosen. Moving the tool close to the cylindrical volume should be avoided if possible, because it causes the joints to move fast even though the tool is moving slowly, causing the robot to work inefﬁciently and the conduction of the risk assessment to be difﬁcult.

Front

Tilted

3.2Mounting

Robot Arm The robot arm is mounted using four M6 bolts, using the four 6.6 mm holes on the base. It is recommended to tighten these bolts with 9 N m torque. If very accurate repositioning of the robot arm is desired, two Ø5 holes are provided for use with a pin. Also, an accurate base counterpart can be purchased as an accessory. Figure 3.1 shows where to drill holes and mount the screws.

The robot connector cable can be mounted through the side or through the bottom of the base.

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3.2 Mounting

WARNING:

Remember to insert the rubber plugs in all mounting holes in the robot base to avoid entrapment of ﬁngers.

Mount the robot on a sturdy surface strong enough to withstand at least ten times the full torque of the base joint and at least ﬁve times the weight of the robot arm. Furthermore the surface shall be vibration free.

If the robot is mounted on a linear axis or a moving platform then the acceleration of the moving mounting base shall be very low. A high acceleration might cause the robot to stop, thinking it bumped into something.

DANGER:

Make sure the robot arm is properly and securely bolted in place.

The mounting surface shall be sturdy.

CAUTION:

If the robot is bathed in water over an extended time period it might be damaged. The robot should not be mounted in water or in a wet environment.

Tool The robot tool ﬂange has four M6 thread holes for attaching a tool to the robot. The holes need to be tightened with 9 N m. If very accurate repositioning of the tool is desired, the Ø6 hole is provided for use with a pin. Figure 3.2 shows where to drill holes and mount the screws.

DANGER:

1. Make sure the tool is properly and securely bolted in place.

2. Make sure that the tool is constructed such that it cannot create a hazardous situation by dropping a part unexpectedly.

Control Box The control box can be hung on a wall, or it can be placed on the ground. A clearance of 50 mm on each side is needed for sufﬁcient airﬂow. Extra brackets for mounting can be bought.

Teach Pendant The teach pendant can be hung on a wall or on the control box. Extra brackets for mounting the teach pendant can be bought. Make sure that no one can trip over the cable.

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3.2 Mounting

Figure 3.1: Holes for mounting the robot. Use four M6 bolts. All measurements are in mm.

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3.2 Mounting

Figure 3.2: The tool output ﬂange, ISO 9409-1-50-4-M6. This is where the tool is mounted at the tip of the robot. All measures are in mm.

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3.2 Mounting

DANGER:

1.Make sure that the control box, teach pendant, and cables do not come into contact with liquids. A wet control box could cause death.

2.The control box and teach pendant must not be exposed to dusty or wet environments that exceed IP20 rating. Pay special attention to environments with conductive dust.

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