34175-E0_Robot5250_User.pdf

Printed in Canada

|3034175E00511`~

Automation and Robotics

Servo Robot SystemModel 5250

User Guide34175-E0

AB

AUTOMATION AND ROBOTICS

SERVO ROBOT SYSTEMMODEL 5250

bythe Staff

ofLab-Volt Ltd.

Copyright © 2004 Lab-Volt Ltd.

All rights reserved. No part of this publication may be reproduced,in any form or by any means, without the prior written permissionof Lab-Volt Ltd.

Legal Deposit – Second Trimester 2004

ISBN 2-89289-712-2

SECOND EDITION, MAY 2004

Printed in CanadaNovember 2005

III

Foreword

The Lab-Volt Servo Robot System, Models 5200 and 5250, provide complete andaffordable training in the programming and operation of industrial style robots.Through the curriculum and hands-on experience gained in working with the ServoRobot System, you will learn to create automated work cells ideal for FlexibleManufacturing Systems (FMS) and Computer-Integrated Manufacturing (CIM).

Safety is an important issue, especially in a real working environment. Before youconnect and use the training system, it is important for you to read this manual.

We hope that your learning experience with the Servo Robot System will be the firststep of a successful career in robotics.

IV

V

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI

Section 1 Overview of the Servo Robot System . . . . . . . . . . . . . . . . . . . . 1-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Servo Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Robot Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Hand-Held Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7Emergency Stop Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7External Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Section 2 Installation and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Space Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Section 3 Hand-Held Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Point Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Point Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Wrist R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Wrist P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Ch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Ch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Save Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Control Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4TTL Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4TTL Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5CNC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5CNC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Save Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

x Clears all points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6C Deletes the point beside the cursor . . . . . . . . . . . . . . 3-66 Moves the point beside the cursor over

the preceding point . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67 Moves the point beside the cursor under the next

point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Table of Contents (cont’d)

VI

Task Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Run Once . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Run Forever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Trace Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Clear Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

File Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Save to Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Load from Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Set Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Clr Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Hard Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Free Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Torque Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Hardware Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Soft Limits OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Soft Limits ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Ch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Ch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Key Click . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Save Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Teach Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Gripper Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Gripper Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Wrist CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Wrist CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Wrist Pitch Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Wrist Pitch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Elbow Pitch Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Elbow Pitch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Shldr Pitch Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Shldr Pitch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Base CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Base CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Ch 1 Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Ch 1 Backward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Ch 2 Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Ch 2 Backward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13TTL Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13TTL Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14CNC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14CNC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Save ABS Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Save REL Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Save Control (point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15


VII

Resuming the Servo Robot System after an Emergency Stop . . 3-15

Section 4 Robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Computer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Familiarization with Robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Menu Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Save As . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Revert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Print Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Undo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Redo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Duplicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Select All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Find Next . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Go to Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Go to Bookmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Set Bookmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Run Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Set Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Clear Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Free Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Torque Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Hard Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Download From . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Task Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Point Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10


VIII

Upload to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10New Task Editor . . . . . . . . . . . . . . . . . . . . . . . . 4-10Point Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Release Emergency Stop . . . . . . . . . . . . . . . . . . . . 4-11Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12File Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13CNC Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Tile Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Tile Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Close All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Minimize All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Restore All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Point Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Active Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Context-Sensitive Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

In the Robot Section of the Point Editor in Teach Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

In the Point list Section of the Point Editor and Task Editor Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

In the Left Column of the Task Editor Window . . . . . . . 4-25Programming Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Point-to-Point Programming . . . . . . . . . . . . . . . . . . . . . 4-27Task Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27Copying Points from the Point Editor into

the Task Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27Copying Points from the Robot Controller Memory intothe Task Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27Task Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28Running a Task Program 4-28Editing a Task Program . . . . . . . . . . . . . . . . . . . . . . . . . 4-28Annotating a Task Program . . . . . . . . . . . . . . . . . . . . . . 4-29Deleting Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29Adding Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Section 5 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Section 6 Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2


IX

Appendices A Hand-Held Terminal MenusB Robotics MenusC Task CommandsD Rotary Carousel, Model 5208E Belt Conveyor, Model 5210F Gravity Feeders, Models 5119 and 5121G Pneumatic Feeders, Models 5122 and 5142H Linear Slide, Model 5209I Error Codes of Firmware 5250

X

XI

Introduction

This user guide is designed to provide all the information required to install and usethe Lab-Volt Servo Robot System. It is intended for students, instructors, and thepersonnel in charge of the laboratory equipment.

The user guide is divided into five sections. Section 1 is an overview of the ServoRobot System, Section 2 explains how to install and connect the equipment,Section 3 explains how to use the Hand-Held Terminal, Section 4 explains how toinstall and use Robotics to operate the training system, and Section 5 describes thecare and maintenance required by the Servo Robot.

The appendices show the various menus with their shortcuts, describe the taskcommands, and explain how to connect and use the optional devices.

XII

1-1

Section 1

Overview of the Servo Robot System

Description

The Lab-Volt Servo Robot System consists of the Servo Robot, Robot Controller,Hand-Held Terminal, Grids, Work Surfaces, Emergency Stop module, Robotics tocontrol the Servo Robot from a host computer, and all the accessories required toperform the hands-on exercises of the student manual. These components areshown in Figure 1-1.

Servo Robot

The overall mechanical layout of the Servo Robot is shown in Figures 1-2 and 1-3.

The base supports the arm mechanisms. It houses the motor that provides shoulderrotation.

The shoulder rotates on the base. It houses the motors associated with the gearsand belts that move the other sections of the arm.

The lower end of the upper arm carries the gears and pulleys that drive the forearm,wrist, and gripper.

One end of the forearm is attached to the upper arm and the other end is attachedto the wrist. The upper arm and forearm have up and down motions.

The wrist and gripper work together to pick up parts and move them to the requiredlocations. The wrist moves up and down to control the two-finger gripper. It can alsorotate in a 360-degrees clockwise or counterclockwise direction.

The fingers of the gripper move in an open and close motion. A servo motor turnsa shaft that is attached to a worm gear. The worm gear then drives two spur gears.The fingers are joined to the spur gears and as the gears rotate, the fingers openor close.

The operation of the Servo Robot, also called manipulator or manipulator-arm robot,is controlled using the Hand-Held Terminal or the Robotics® software via the RobotController.

The term Servo Robot comes from the type of motors used by the robot: servomotors. The servo motors of the Servo Robot have a device called an OpticalEncoder that provides feedback to the Robot Controller.


1-2

BASEMOUNTING

WORK SUFACEp/n 6309

ROBOTCONTROLLER

METALLICCAN CANISTERS

FILM

EMERGENCYSTOP MODULE

CABLE

p/n 95921HAND-HELD

p/n 93017 p/n 95922 p/n 93236 p/n 95451TERMINAL

GRIDSHEET

CABLECABLECABLECABLECABLE

p/n 95028

SERVOROBOT

Figure 1-1. Main components of the Servo Robot System.


1-3

BASE

SHOULDER

UPPER ARM

ELBOW

FOREARM

WRIST

GRIPPER

Figure 1-2. Mechanical layout of the Servo Robot (View A).


1-4

MOTOR DRIVE

MOTOR FEEDBACK

INPUT

OUTPUT

LED WHEEL PHOTOTRANSISTOR

MOTOR SHAFT

Figure 1-3. Mechanical layout of the Servo Robot (View B).

The optical encoder consists of a LED (Light Emitting Diode) that sends lightthrough a finely screened code wheel that is rigidly mounted onto the motor shaftas shown in Figure 1-4. A receiver (phototransistor) detects the light changes(light/dark). The light changes are converted into electrical pulses and sent back tothe Robot Controller. The Robot Controller compares the control signal to thefeedback signal to ensure that the position is correct at all times.

Figure 1-4. Optical encoder of a servo motor.


1-5

Robot Controller

The Robot Controller is the brain of the Servo Robot System. It is a specializedcomputer with ports, switches, and programming capabilities that enable it tofunction as a controller.

It contains the inputs and outputs required to send and receive TTL(Transistor-Transistor Logic) signals to/from the external devices and CNC(Computerized Numerical Control) machine tools. The Robot Controller is operatedfrom the Hand-Held Terminal or from Robotics.

As Figure 1-5 shows, the front panel of the Robot Controller includes the following:

C Hand-Held Terminal connector to connect the Hand-Held Terminal.

C Motor Disabled (LED) indicator. The LED lights when the servo motors of theServo Robot are disabled (not torqued condition).

C Motor Enable/Disable pushbutton is used to enable and disable the servo motorsof the Servo Robot. They are enabled (torqued condition) when the button ispressed. This button must be pressed when powering up the system.

C TTL inputs and status indicators (LED). The LED of a TTL input lights when thelevel is high.

C TTL outputs and status indicators (LED). The LED of a TTL output lights whenthe level is high.

C Relays. Each Relay includes a set of normally open (NO) and normally closed(NC) contacts, and status indicator (LED). The LED of a relay lights when it isactivated.

C A floppy disk drive to save and load programs.


1-6

1

[ 20 mA MAX.]TTL

− 500 mA MAX.][ 30 V −

2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4

MTTL

M M

HAND-HELD TERMINAL

MOTOR DISABLED INDICATOR

MOTOR ENABLE/DISABLE PUSH-BUTTON

TTL INPUTS TTL OUTPUTS RELAYS

STATUS INDICATOR (LED)

FLOPPYDISKDRIVE

SERIAL PORT

5250 5250CH 2CH 1CNC 2CNC 1

CNC 1 CNC 2 CHANNEL 1 CHANNEL 2

MOTOR DRIVE OUTPUT

EMERGENCY STOP

MOTOR FEEDBACK INPUT

MAIN POWERCONNECTOR

POWERSWITCH

FUSE ACCESSPANEL

Figure 1-5. Robot Controller - front view.

As Figure 1-6 shows, the rear panel of the Robot Controller includes the connectorsrequired to connect the host computer (serial port), CNC machines (CNC 1 andCNC 2), external devices (CH 1 and CH 2), Servo Robot Motor Drive, Servo RobotMotor Feedback, and Emergency Stop module. It also includes the main powerconnector, power switch and fuse access panel.

Figure 1-6. Robot Controller - rear view.


1-7

LCD SCREEN

FUNCTION INDICATORS

FUNCTION KEYSRUN TEACH ERROR SUSPD

ESC TeachMenu

MainMenu

ClearError

SuspdOper.

A

F

B

G

C

H

D

I

E

J

O

T

N

S

M

R

L

Q

K

P

U

X

V

Y

W

Z

?

/

−

+

(

# *

)1 2 3

4 5 6

7 8 9

0SHIFTESC

DEL

,. ENTER

SPACE

Hand-Held Terminal

The Hand-Held Terminal communicates with the Robot Controller to control theServo Robot and external devices, and create programs.

The Hand-Held Terminal is shown in Figure 1-7, it contains the keys which are usedfor entering alphanumeric characters and selecting special functions, and a LCD(Liquid Crystal Display) to view the instructions entered and the resultingexecutions. All keys are labeled for a specific task. The functions of the Hand-HeldTerminal are explained in Section 3 of this guide.

Figure 1-7. Hand-Held Terminal.

Emergency Stop Module

As Figure 1-8 shows, the Emergency Stop module contains a pushbutton and aLED indicator. When the pushbutton is pressed, all operations are halted, the LEDindicator lights, the Suspd (suspend operation) indicator on the Hand-Held Terminallights, and the Emergency Stop window in Robotics opens (if Robotics is used). Akey is required to release the stop switch to resume operation. The procedures toresume operation are explained in Sections 3 and 4 of this guide.


1-8

LED INDICATOR

PUSH-BUTTON

KEY RELEASE

Figure 1-8. Emergency Stop module.

External Devices

External devices such as a Rotary Carousel (Model 5208), Belt Conveyor (Model5210), Gravity Feeders (Models 5119 and 5121), Pneumatic Feeders (Models 5122and 5142), and Linear Slide (Model 5209) can be added to the Servo Robot System.The operation of these optional devices is described in the appendices of this guide.

2-1

35828-01

C11 C10 C9 C8 C7 C6 C5 C4 C3 C2 C1 C0R11

R10

R9

R8

R7

R6

R5

R4

R3

R2

R1

R0

R7, C9 R7, C9

GRID WORK SURFACE

Section 2

Installation and Connections

Installation

The Servo Robot System is supplied with two Grids and two Work Surfaces to helpyou to position the equipment at specific locations. As Figure 2-1 shows, the Gridsand Work Surfaces have 12 rows and 12 columns. On the Grids, the rows andcolumns are numbered from R0 to R11 and from C0 to C11 respectively.

Figure 2-1. Layout of the Grid and Work Surface.

The row and column numbers are used to locate the equipment. As an example,when it is asked in a procedure to place a film canister at position (R7,C9), thecenter of the film canister must be placed at the intersection of the eighth row fromthe top of the Grid (or of the Work Surface), and the tenth column from the right.

When using the Grids, the Servo Robot must be snapped to the mounting base(steel plate) supplied with the Servo Robot System. First, position the mountingbase on the Grid by centering the small perforations on the base at the desired rowand column intersections, then snap the Servo Robot to the mounting base. To doso, align the push-lock fasteners with the perforations of the mounting base thenfirmly push on the fasteners.

When using the perforated Work Surfaces, do not use the mounting base. Simplyposition and snap the Servo Robot to the Work Surface.


2-2

TOP VIEW SIDE VIEW

Although the Servo Robot is designed to be used with both the Grids and WorkSurfaces, it is strongly recommended to use the Work Surfaces. They are simple touse and less subject to undesirable movements. The Work Surfaces are designedto be used on top of a table. Two Work Surfaces can be joined using the handles(p/n 30036) supplied with the Servo Robot System.

Space Required

The path of points that can be reached by a robot is called the work envelope. Thework envelope of an articulated-arm robot as the one of your training system isshown in Figure 2-2. To allow a secure operation, no wall or obstacle should bepresent in the work envelope, or within 750 mm (30 in) from the base of the ServoRobot in any direction.

Figure 2-2 Work envelope of the Servo Robot.

Connections

This section describes how to connect the components of the Servo Robot System.

Position the Servo Robot and Robot Controller as shown in Figure 2-3.

Note: The position of the Servo Robot is determined relative to theposition of the push-lock fasteners.


2-3

R0, C4

R6, C7

R6, C4

ROBOT CONTROLLER

Figure 2-3. Location of the equipment on the Work Surface.

Before making any connections, ensure that the power switch on the rear panel ofthe Robot Controller is at the off (O) position.

CAUTION!

Do not make or remove any connections to/from the RobotController while the power is on. This could damage the module.

Perform the following steps:

C Connect the Motor Feedback Output on the base of the Servo Robot to the MotorFeedback Input on the Robot Controller using the cable p/n 95922. Refer toFigure 2-4 if necessary.

Note: To ensure correct operation, make sure the connector is all theway in before it is screwed.

C Connect the Motor Drive Input on the base of the Servo Robot to the Motor DriveOutput on the Robot Controller using the cable p/n 95921.

C Connect the Emergency Stop module to the Emergency Stop connector on theRobot Controller.

C Connect the serial port on the Robot Controller to the host computer serial portusing the cable p/n 93017.

C Connect the Robot Controller to an AC power outlet using the cable p/n 95451.


2-4

ROBOTCONTROLLER

(REAR VIEW)

TO COMPUTERSERIAL PORT

TO AN ACPOWER SUPPLY

EMERGENCYSTOP

MODULE

ROBOTSERVO

MOTORFEEDBACKOUTPUT

INPUTDRIVEMOTOR

INPUTFEEDBACKMOTOR

EMERGENCYSTOP

MOTORDRIVEOUTPUT

SERIALPORT

CHANNEL 1

CHANNEL 2CNC 1

CNC 2

1

[ 20 mA MAX.]TTL

− 500 mA MAX.][ 30 V −

2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4

MTTL

M M

ROBOT CONTROLLER(FRONT VIEW)

HAND-HELDTERMINAL

SPACE

ENTER.,

DEL

ESCSHIFT 0

987

654

321)

*#

(

+

−

/

?

Z

W

Y

V

X

U

P

K

Q

L

R

M

S

N

T

O

J

E

I

D

H

C

G

B

F

A

Oper.Suspd

ErrorClear

MenuMain

MenuTeachESC

SUSPDERRORTEACHRUN

C Connect the Hand-Held Terminal to the Hand-Held Terminal connector on thefront panel of the Robot Controller using the cable p/n 95028. Refer to Figure 2-5if necessary.

Figure 2-4. Connections.

Figure 2-5. Connection of the Hand-Held Terminal.


2-5

All cables are now connected and should be securely fastened.

Refer to the appendices of this guide to learn how to connect external devices to thetraining system.

2-6

3-1

LCD SCREEN

FUNCTION INDICATORS

FUNCTION KEYSRUN TEACH ERROR SUSPD

ESC TeachMenu

MainMenu

ClearError

SuspdOper.

A

F

B

G

C

H

D

I

E

J

O

T

N

S

M

R

L

Q

K

P

U

X

V

Y

W

Z

?

/

−

+

(

# *

)1 2 3

4 5 6

7 8 9

0SHIFTESC

DEL

,. ENTER

SPACE

Section 3

Hand-Held Terminal

Description

The Hand-Held Terminal is used to control the operation of the Servo Robot andexternal devices, and create programs. It is a menu driven device that includestactile touch keys, LEDs and a LCD screen, as shown in Figure 3-1. The menusappearing on the LCD screen are quite similar to the menus in Robotics (describedin Section 4).

Figure 3-1. Hand-Held Terminal.

The name and function of the five white keys at the top of the Hand-Held Terminalkeypad are as follows:

C ESC: Backs up one step from the current position in the menu.

C Teach Menu: Displays the Teach menu and activates the keys to manipulate theServo Robot and external device(s) connected to CH 1 and CH 2, and sets theTTL inputs, TTL outputs, CNC inputs, CNC outputs, Relays, and Delay. This isalso in the Teach menu where the position and control points are saved.

C Main Menu: Displays the Main menu from where all support menus for the ServoRobot are accessed.

Hand-Held Terminal

3-2

C Clear Error: Clears the Error indicator on the Hand-Held Terminal. The Errorindicator lights when the system is halted by pressing the emergency stopbutton. Error must be cleared to resume operation.

C Suspd Oper.: Suspends any operation being executed.

The arrow keys at the bottom of the Hand-Held Terminal are used to move througha list of menu options (when present). A table showing the structure of the Hand-Held Terminal menus is shown in Appendix A. Refer to this table to facilitate yourlearning of the various menus of the Hand-Held Terminal.

The description of each Hand-Held Terminal menu is as follows:

Main Menu

The Main menu is the home base that can link you to all the support menus. TheMain menu appears at the end of the start-up process. You can return to this menuby pressing the Esc key once or several times depending on your menu location,or by pressing the Main Menu key.

Note: To select an option in a menu, place the cursor beside the desiredoption using the arrow keys and press the Enter key. Alternatively, youcan press the shortcut key (the character beside the option).

MAIN MENU

1 POINT MANAGER

2 TASK MANAGER

3 FILE MANAGER

4 MOTION CONTROL

5 CONFIGURATION

9 SHUTDOWN

1 Point Manager: Displays the list of the points stored in the Robot Controllermemory. A point list may contain two types of points: position and control points.Once a point list is displayed, you can edit and modify the settings of the pointbeside the cursor by pressing the E key. If the point is a position point, the PointEditor menu will open. If the point is a control point, the Control Editor menu willopen.

Hand-Held Terminal

3-3

Point Editor: Changes the settings of a position point. This menu is accessedby pressing the E key while the cursor is beside a position point in the pointlist.

POINT EDITORN NAME:_____F FLAGS:ABSOLUTE/RELATIVES SPEED:0-991 GRIPPER:_2 WRIST R:_3 WRIST P:_4 ELBOW:_5 SHOULDER:_6 BASE:_7 CH 1:_8 CH 2:_0 SAVE CHANGES

Note: To modify the settings of a position point, place the cursor besidethe parameter, then press the Enter key. Use the arrow keys to move thecursor, and the alphanumeric character keys to enter the new settings.Press the Enter key to confirm your changes then press the 0 key tosave the new settings. It is also possible to save the new settings byplacing the cursor beside the Save Changes option and pressing theEnter key.

N Name: Displays the name of the position point. Using the arrow keysto move the cursor, you can enter a different name (maximum8 characters).

Note: Press the Shift key to access the characters in the dark bluesection of the keys (where present).

F Flags: Indicates if the coordinates of the point are absolute or relative.Absolute means that the coordinates are determined relative to apredetermined position (hard home position). Relative means that theposition coordinates are determined relative to the previous position.

S Speed: Displays the speed setting. The speed can be set between 0and 99.

1 Gripper: Shows the gripper coordinates.

2 Wrist R: Shows the wrist axis coordinates relative to the rotation.

3 Wrist P: Shows the wrist axis coordinates relative to the pitch (up anddown motion).

4 Elbow: Shows the elbow axis coordinates.

5 Shoulder: Shows the shoulder axis coordinates.

Hand-Held Terminal

3-4

6 Base: Shows the base axis coordinates.

7 CH 1: Shows the coordinates of the device connected to CH 1 on theRobot Controller.

8 CH 2: Shows the coordinates of the device connected to CH 2 on theRobot Controller.

0 Save Changes: Saves the current settings.

Control Editor: Changes the settings of a control point. This menu isaccessed by pressing the E key while the cursor is beside a control point inthe point list.

CONTROL EDITORN NAME:_____1 TTL OUTPUT2 TTL INPUT3 RELAY4 CNC 15 CNC 2D DELAY0 SAVE CHANGES

Note: To modify the settings of a control point, place the cursor besidethe parameter, then press the Enter key. Use the arrow keys to move thecursor and the alphanumeric character keys to enter the new settings.Press the Enter key to confirm your changes then press the 0 key tosave the new settings. It is also possible to save the new settings byplacing the cursor beside the Save Changes option and pressing theEnter key.

N Name: Displays the name of the control point. Using the arrow keys tomove the cursor, you can enter a different name (maximum 8 characters).

1 TTL Output: Displays the current level (L low or H high) of the TTLoutputs in the OLD row, and sets the level at which the TTL outputs will beafter this instruction line is executed. The level is set by pressing the TTLoutput number on the keypad. The setting is displayed in the NEW row.

TTL OUTPUTKEY 1 2 3 4 5 6 7 8OLD L L L L L L L LNEW X X X X X X X X

Note: The character X indicates that no level has been assigned.

Hand-Held Terminal

3-5

2 TTL Input: Displays the current level (L or H) of the TTL inputs in theOLD row, and sets the level at which the TTL inputs must be beforeproceeding with the next instruction line in the program. The level is set bypressing the TTL input number on the keypad. The setting is displayed inthe NEW row.

TTL INPUTKEY 1 2 3 4 5 6 7 8OLD L L L L L L L LNEW X X X X X X X X

3 Relay: Displays the current status (activated or deactivated) of theRelays in the OLD row, and sets the status at which the Relays will beafter this instruction line is executed. The status is set [H (activated) or L(deactivated)] by pressing the Relay number on the keypad. The settingis displayed in the NEW row.

RELAYKEY 1 2 3 4OLD L L L LNEW X X X X

4 CNC 1: Displays the current level (L or H) of the CNC 1 inputs andoutputs in the OLD row, and sets the level at which the CNC 1 inputs 1to 4 must be before proceeding with the next instruction line in theprogram. Also sets the level at which the CNC 1 outputs A to D will bewhen this instruction line is executed. The level is set by pressing theCNC 1 input or output number on the keypad. The setting is displayed inthe NEW row.

CNC1 INPUT | OUTPUTKEY 1 2 3 4 A B C DOLD L L L L L L L LNEW X X X X X X X X

5 CNC 2: Displays the current level (L or H) of the CNC 2 inputs andoutputs in the OLD row, and sets the level at which the CNC 2 inputs 1to 4 must be before proceeding with the next instruction line in theprogram. Also sets the level at which the CNC 2 outputs A to D will bewhen this instruction line is executed. The level is set by pressing theCNC 2 input or output number on the keypad. The setting is displayed inthe NEW row.


Hand-Held Terminal

3-6

D Delay: Sets the amount of time in seconds the system will pause beforeproceeding with the next instruction line in the program.

0 Save Changes: Saves the current settings.

x: Clears all points stored in the Robot Controller memory.

CLEAR ALL POINTS

ARE YOU SURE

ENTER TO CONTINUE

ESC TO ABORT

C: Deletes the point beside the cursor.

6: Moves the point (position or control) beside the cursor over the precedingpoint.

7: Moves the point (position or control) beside the cursor under the nextpoint.

2 Task Manager: Runs point-to-point program or clear points.

TASK MENU1 RUN ONCE2 RUN FOREVER3 TRACE POINTS4 CLEAR POINTS

1 Run Once: Executes the current program once.

EXECUTE POINTSRUN ONCE_____

PRESS ESC TO ABORT

2 Run Forever: Executes the current program over and over. Press the Esckey to abort execution.

EXECUTE POINTSRUN FOREVER:_

_____PRESS ESC TO ABORT

Hand-Held Terminal

3-7

3 Trace Points: Executes an instruction line of the current program eachtime the Enter key is pressed. When the last instruction line is executed, theServo Robot returns to the home position.

EXECUTE POINTSTRACE MODE

_____PRESS ESC TO ABORT

4 Clear Points: Delete all points stored in the Robot Controller memory.

CLEAR ALL POINTSARE YOU SURE?

ENTER TO CONTINUEESC TO ABORT

3 File Manager: Enables you to save the program in the Robot Controllermemory to the floppy disk drive, or load a program from the floppy disk drive.

FILE MENU1 SAVE TO DISK2 LOAD FROM DISK

1 Save to Disk: Saves the current program in the Robot Controller memoryto the floppy disk. When the Save File window opens, the cursor is placedbeside the default name SAMPLE suggesting to enter a number. Using thearrow keys to move the cursor, you can enter a different name for theprogram (maximum 8 characters). Press the Enter key to complete theprocess.

SAVE FILEENTER FILENAME

>SAMPLE_

2 Load From Disk: Loads an existing program from the floppy disk into theRobot Controller memory. Press the Enter key then use the arrow keys toselect a file. Press the Enter key to complete the process.

OVERWRITE TASKARE YOU SURE?


Hand-Held Terminal

3-8

4 Motion Control: Controls the home positioning, frees and torques the servomotors, reinitializes the motors, controls the operation of the soft limits.

MOTION CONTROL1 SOFT HOME2 SET SOFT HOME3 CLR SOFT HOME4 HARD HOME5 FREE MOTORS6 TORQUE MOTORS7 HARDWARE RESET8 SOFT LIMITS OFF9 SOFT LIMITS ON

1 Soft Home: Moves the Servo Robot to the position that you assigned assoft home using the Set Soft Home instruction. It is the position the ServoRobot starts its movements from, and where it will come to rest when you tellit to go home after completing the assigned instruction lines.

The soft home position is the same as the hard home position when noposition has been assigned as soft home.

2 Set Soft Home: Sets the current Servo Robot position as the soft homeposition. The default Home point in the point list of the Point Managerchanges to Soft Home point when a position is assigned as soft homeposition.

3 Clr Soft Home: Clears the current soft home position.

4 Hard Home: Moves the Servo Robot to a fixed reference point where theServo Robot goes to reset all its settings. After you press the 4 key to selectthe Hard Home option, press the Enter key within 6 seconds to execute theHard Home instruction.

PERFORM HARD HOME


Note: A program can be developed to be executed once and thendeleted. However, it is usually developed to be used more than once. Inorder to repeat a program, the equipment must be in the same locationand orientation as when you created the position points of the programand the Servo Robot must start in the same position. For this reason, ahard home positioning must be executed at the beginning of eachsession.

5 Free Motors: Removes power from the motors. This corresponds to thefreed condition (not torqued).

Hand-Held Terminal

3-9

6 Torque Motors: Applies power to the motors so they will hold theirpositions. This corresponds to the torqued condition.

7 Hardware Reset: Reinitializes all motors connected to the RobotController. After performing a "Hard Reset" always perform a "Hard Home".

HARDWARE RESETARE YOU SURE?


8 Soft Limits OFF: Disables the soft limits. Press the Enter key when thecursor is beside this option to disable the soft limits. The default setting isOFF.

Note: The soft limits are programmed positions that limit the movementof each articulation of the Servo Robot to prevent excessive movements.

9 Soft Limits ON: Enables the soft limits. Press the Enter key when thecursor is beside this option to enable the soft limits.

5 Configuration: Enables the configuration of the Servo Robot System.

CONFIG MENU1 GRIP:_____2 CH 1:_____3 CH 2:_____4 KEY CLICK:_____5 SHIFT LOCK: OFFS SAVE CONFIG

Note: To configure an element in the Config menu, place the cursorbeside the element, then press the Enter key as required to obtain thedesired parameter. To save the configuration entries, select Save Configthen press the Enter key, or press the S key.

1 Grip: Selects the type of gripper used. The available choices are servo,pneu (pneumatic), elec (electric), and none.

Note: The gripper of your Servo Robot is driven by a servo motor. SelectServo.

2 CH 1: Selects the device connected to CH 1 on the Robot Controller. Theavailable choices are Carousel, L Slide (Linear Slide), and none.

3 CH 2: Selects the device connected to CH 2 on the Robot Controller. Theavailable choices are Carousel, L Slide (Linear Slide), and none.

4 Key Click: Activates or deactivates the beeper of the Hand-Held Terminal.

Hand-Held Terminal

3-10

5 Shift Lock: Locks the Shift key in the activated mode. The default settingis unlock.

Save Config: Saves the current configuration settings. To save theconfiguration entries, select Save Config then press the Enter key, or pressthe S key.

Note: The Robot Controller must be configured to detect the Gripper,Linear Slide, and Rotary Carousel if you have them. The other optionsin the Config menu can be configured whenever you want.

9 Shutdown: Exits the program (firmware) of the Robot Controller. When youselect the Shutdown option, the Message Firmware Shutdown - Turn offController is displayed on the Hand-Held Terminal. The Robot Controller mustbe restarted to resume the system.

Hand-Held Terminal

3-11

Teach Menu

The Teach menu allows the control of the Servo Robot and external devices. Itallows also the creation of point-to-point programs.

TEACH MENU

0 SPEED CONTROL

1 GRIPPER OPEN

H GRIPPER CLOSE

2 WRIST CW

I WRIST CCW

3 WRIST PITCH DOWN

J WRIST PITCH UP

4 ELBOW PITCH DOWN

R ELBOW PITCH UP

5 SHLDR PITCH DOWN

S SHLDR PITCH UP

6 BASE CCW

T BASE CW

7 CH 1 FORWARD

Z CH 1 BACKWARD

8 CH 2 FORWARD

/ CH 2 BACKWARD

F TTL OUTPUT

G TTL INPUT

P RELAY

Q TIME DELAY

X CNC 1

Y CNC 2

. SAVE ABS POINT

# SAVE REL POINT

* SAVE CONTROL

Note: To move the Servo Robot, select the articulation you want tomove in the Teach menu with the up and down arrow keys, or bypressing the shortcut keys, then press and hold the Enter key.Alternatively, you can press and hold the shortcut keys.

Figure 3-2 shows the characters (shortcut keys) associated with each articulationof the Servo Robot. This figure is also screened on the base of the Servo Robot.

Hand-Held Terminal

3-12

UPPER ARM

SHOULDER

BASE

R

6

SI

4J

5

T

2

H

3

1

FOREARM

WRIST

GRIPPER

Figure 3-2. Characters associated with each articulation of the Servo Robot.

0 Speed Control: Sets the speed between 0 and 99. The speed setting is usedfor all movements that follow the setting, or until a new speed setting is made.To set the speed, select the Speed Control option or press the 0 key. In the SetSpeed window, use the numeric keys or the arrow keys to set the Speed value.

To set the tens of units, use the numeric keys or the up (to increase) and down(to decrease) arrow keys. To increase or decrease the speed by one unit, pressthe right or left arrow keys.

SET SPEED

>------------------+<1 099 99

1 Gripper Open: Opens the gripper.

H Gripper Close: Closes the gripper.

Note: To facilitate the use of the Hand-Held Terminal, the movementsassociated with the keys of the second row are in the opposite directionto those of the fifth row. This relation repeats for the third and sixth row.

2 Wrist CW: Rotates the wrist in the clockwise direction.

I Wrist CCW: Rotates the wrist in the counterclockwise direction.

3 Wrist Pitch Down: Lowers the wrist.

J Wrist Pitch Up: Raises the wrist.

4 Elbow Pitch Down: Lowers the forearm.

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R Elbow Pitch Up: Raises the forearm.

5 Shldr Pitch Down: Lowers the upper arm.

S Shldr Pitch Up: Raises the upper arm.

6 Base CCW: Rotates the shoulder in the counterclockwise direction.

T Base CW: Rotates the shoulder in the clockwise direction.

7 CH 1 Forward: Moves the device connected to CH 1 in the forward orclockwise direction.

Z CH 1 Backward: Moves the device connected to CH 1 in the backward orcounterclockwise direction.

8 CH 2 Forward: Moves the device connected to CH 2 in the forward orclockwise direction.

/ CH 2 Backward: Moves the device connected to CH 2 in the backward orcounterclockwise direction.

F TTL Output: Displays the current level (L or H) of the TTL outputs in the OLDrow, and sets the level at which the TTL outputs will be after this instruction lineis executed. The level is set by pressing the TTL output number on the keypad.The setting is displayed in the NEW row.


G TTL Input: Displays the current level (L or H) of the TTL inputs in the OLDrow, and sets the level at which the TTL inputs must be before proceeding withthe next instruction line in the program. The level is set by pressing the TTL inputnumber on the keypad. The setting is displayed in the NEW row.

TTL INPUTKEY 1 2 3 4 5 6 7 8OLD H H H H H H H HNEW X X X X X X X X

P Relay: Displays the current status (activated or deactivated) of the Relays inthe OLD row, and sets the status at which the Relays will be after this instructionline is executed. The status [H (activated) or L (deactivated)] is set by pressingthe Relay number on the keypad. The setting is displayed in the NEW row.

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Q Time Delay: Sets the amount of time in seconds the system will pause beforeproceeding with the next instruction line in the program.

SET DELAY VALUEIN SECONDS

>_

X CNC 1: Displays the current level (L or H) of the CNC 1 inputs and outputs inthe OLD row. Sets the level at which the inputs 1 to 4 must be before proceedingwith the next instruction line in the program. Also sets the level at which theoutputs A to D will be when this instruction line is executed. The level is set bypressing the CNC 1 input or output number on the keypad. The setting isdisplayed in the NEW row.


Y CNC 2: Displays the current level (L or H) of the CNC 2 inputs and outputs inthe OLD row. Sets the level at which the inputs 1 to 4 must be before proceedingwith the next instruction line in the program. Also sets the level at which theoutputs A to D will be when this instruction line is executed. The level is set bypressing the CNC 2 input or output number on the keypad. The setting isdisplayed in the NEW row.


C Save ABS Point: Saves the absolute coordinates of the current position ofthe Servo Robot and external device(s) connected to CH 1 and CH 2. You cansave the point with the default name shown on the display or enter a new namebefore pressing the Enter key (maximum 8 characters). The absolutecoordinates are determined relative to a predetermined position (hard homeposition).

SAVE POSITIONENTER POINT NAME

>POINT1_

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# Save REL Point: Saves the relative coordinates of the current position of theServo Robot and external device(s) connected to CH 1 and CH 2. You can savethe point with the default name shown on the display or enter a new name beforepressing the Enter key (maximum 8 characters). The character r is added besidethe point name in the point list of the Point Manager to indicate that thecoordinates of the point are relative. The relative coordinates are determinedrelative to previous position.


>POINT1_

* Save Control: Save the current settings of the TTL inputs, TTL outputs,Relays, CNC inputs, CNC outputs and delay of the control point. You can savethe point with the default name shown on the display or enter a new name beforepressing the Enter key (maximum 8 characters).

SAVE CONTROLENTER POINT NAME

>CTRL1_

Resuming the Servo Robot System after an Emergency Stop

To resume the Servo Robot System after an emergency stop, perform the followingsteps:

C Ask your instructor to check your setup to remove any dangerous condition, andto release the switch using the appropriate key.

C On the Hand-Held Terminal:

Press the Esc key.

Press the Clear Error key.

Press the Enter key.

The system is now ready to operate.

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4-1

Section 4

Robotics

Introduction

Robotics is a software used to control the operation of the Servo Robot and externaldevices, and create programs.

This section provides the information to install and use Robotics. The ComputerRequirements subsection describes the computer requirements to operate Robotics.The Software Installation subsection deals with the installation of the software onthe hard disk of your computer. The Familiarization with Robotics subsectionexplains how to use the application.

Computer Requirements

The computer requirements are:

C 233 MHz, Pentium II processorC 15 Mb of hard drive spaceC 32 Mb RAMC Serial portC CD-ROM driveC Windows® 98 or higher

Software Installation

Perform the following steps to install Robotics on the hard disk of your computer:

C Close all programs on your computer.

C Insert the Robotics CD-ROM in the CD-ROM drive.

C Choose the Run command in the Start menu of Windows®.

C Type X:\Setup.exe in the command line, then click the OK button, or press theEnter key on the keyboard.

Note: Replace the X by the letter associated with your CD-ROM drive.

C The Welcome to the InstallShield Wizard for Robotics window appears. To startthe installation, click the Next button.

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C The License Agreement window appears. Read the license agreement termscarefully. If you accept the terms, click the Yes button.

C The Choose Destination Location window appears. Setup will install Robotics inthe folder shown. To accept the default folder (recommended), click the Nextbutton. To select a different folder, click the Browse button, then select thedesired folder.

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C The Select Program Folder window appears. Setup will add program icons to theprogram folder listed below. Type a folder name in the Program Folder field, orselect one from the existing folder list, then click the Next button.

C The Start Copying Files window appears. If you are satisfied with the settingsshown, click the Next button to start copying files.

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C The InstallShield Wizard Complete window appears when the installation iscompleted. Click the Finish button to exit the installation process.

Familiarization with Robotics

Robotics is now ready to use. To launch the application, click the Robotics iconappearing on the desktop or choose the Run command in the Start menu ofWindows®, and type X:\Program Files\Lab-Volt\Robotics\Robotics.exe (if you did notaccept the default folder, enter your folder path), and click the OK button or pressthe Enter key on the keyboard.

Note: Replace the X by the letter associated with your hard disk drive.

Robotics allows the manipulation of the Servo Robot through a visual interface. TheHand-Held Terminal is not required to operate the Servo Robot when usingRobotics. However, large programs are often developed with Robotics inconjunction with the Hand-Held Terminal.

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The Hand-Held Terminal is used for the precise moves where you must be placednear the device to record the points, and Robotics for the moves that can be seenfrom the computer and for editing purposes.

The Robot Controller must be turned on and connected to the computer to useRobotics.

Note: The Servo Robot System must be configured. Refer to theOptions menu described in this section.

Main Window

The Main window is the first window you see when Robotics is launched. It includesa menu bar, a tool bar and a status bar.

Main window.

Menu Bar

The description of each option in the menu bar is as follows:

Note: A table showing the structure of the Robotics menus is shown inAppendix B.

File

New: Opens the Program Information window to create a Robotics file(filename.A4).

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Program Information window.

The Program Information window is used to enter general information about thetask program. This includes the name of the author, date, project name, revisionnumber, and comments.

Clicking the OK button saves the information, closes the Program Informationwindow, and opens the Task Editor window.

Task Editor Window

The Task Editor window is where task programs are created. The left columnof the window is where instruction lines are written. The right column is wherethe points are copied from the Point Editor window (described in the PointEditor Window section), or from the Robot Controller before they are used inthe task program. It is not required to use every points in the right columnwhen designing the task program.

Task Editor window.

Open: Opens an existing Robotics file. Up to 10 files can be opensimultaneously.

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Close: Closes the currently open Robotics file. If the current file has beenmodified, a dialog box opens asking if you wish to save the changes beforeclosing the Robotics file.

Save: Saves a file under the current name. If you save a file for the first time, theSave command will work as the Save As command, and a dialog box will openasking you to name the file.

Note: It is recommended to create a folder to save your programs beforeusing Robotics. To create a folder in Windows Explorer, select Folder inthe submenu New of the menu File.

Save as: Saves a file with a different name. A dialog box will open asking you toname the file.

Revert: Deletes the change(s) made to a file by restoring the original version.

Info: Opens the Program Information window that contains the informationrelative to the active task program.

Print: Prints the instruction lines of the active task program.

Print Setup: Opens the Printer Setup window.

Shutdown: Opens the Shutdown window. If you click the Yes button, themessage Shutdown Completed will appear during a few seconds and theprogram (firmware) in the Robot Controller will end. You must restart the RobotController to resume the system.

Shutdown window.

Exit: Closes Robotics. If a file has been modified, a dialog box appears askingyou if you wish to save the changes before exiting Robotics.

Edit

Undo: Reverses the last change. The Undo function can be repeated asnecessary to reverse previous changes.

Redo: Reverses the last Undo action.

Cut: Cuts the selected text and stores it in the Clipboard.

Copy: Copies the selected text and stores it in the Clipboard.

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Paste: Pastes the Clipboard content at the insertion point.

Duplicate: Duplicates the selected text.

Clear: Deletes the selected text.

Select All: Selects all instruction lines in the Task Editor window.

Search

Find: Searches for specific words and phrases in the Task Editor window andlocates the first match.

Find Next: Searches for the next occurrence of the specific words and phrasesin the Task Editor window and locates the match.

Replace: Searches for specific words and phrases in the Task Editor windowand replaces them by new ones.

Go to Line: Moves the cursor to a specific instruction line in the Task Editorwindow.

Go to Bookmark: Moves the cursor to the instruction line where a bookmarkwas set using the Set Bookmark command.

Set Bookmark: Sets a bookmark in an instruction line of a task program.

Robot

Run Task: Compiles the active task program and opens the Run Task window.

Run Task window.

The available options in the Current Status and Task Control sections of theRun Task window are:

Repeat Task check box: Repeats the task program over and over whenenabled (checked). Click the Pause button to stop the execution.

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Repeat Count: Indicates the number of times the task program has repeated.

Line Number: Indicates which instruction line is being executed.

Command: Indicates which command is being executed.

Status: Describes the status of the command which is being executed.

Message field: Displays the messages associated with the execution of thetask program or called by a task command.

Run button: Executes the task program once.

Step button: Executes an instruction line each time the Step button ispressed.

Pause button: Pauses the task program once the execution of the instructionline is completed.

Reset button: Returns to the first instruction line of the task program andwaits.

Close button: Closes the Run Task window.

Motion Control

Soft Home: Moves the Servo Robot and external device(s) connected toCH 1 and CH 2 to the position assigned as the home position using the SetSoft Home command. It is the position the Servo Robot starts its movementsfrom, and where it will come to rest when you tell it to go home aftercompleting the assigned instruction lines.

The soft home position is the same as the hard home position when noposition has been assigned as soft home.

Set Soft Home: Sets the current position of the Servo Robot and externaldevices as the soft home position.

Clear Soft Home: Clears the current soft home position.

Free Motors: Removes power from the motors.

Torque Motors: Applies power to the motors so they will hold their positions.

Hard Home: Moves the Servo Robot to a fixed reference point where theServo Robot goes to reset all its settings.

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Note: A program can be developed to be executed once and thendeleted. However, it is usually developed to be used more than once. Inorder to repeat a program, the equipment must be in the same locationand orientation as when you created the position points of the programand the Servo Robot must start in the same position. For this reason, ahard home positioning must be executed at the beginning of eachsession.

Download from

Task Editor: Opens a Warning window. Once the OK button is clicked,copies the active task program in the Task Editor window to the RobotController memory. All current points in the Robot Controller memory aredeleted when the file is downloaded.

Warning window.

Point Editor: Opens a Warning window. Once the OK button is clicked,copies the content of the Point Editor window to the Robot Controller memory.All current points in the Robot Controller memory are deleted when the file isdownloaded.

Upload to

New Task Editor: Opens the Program Information window. Once the OKbutton is clicked, copies the content of the Robot Controller memory to a newTask Editor window.

Point Editor: Opens a Warning window. Once the OK button is clicked,copies the content of the Robot Controller memory into the Point Editorwindow in Robotics. All current points in the Point Editor window are deletedwhen the file is uploaded.

Warning window.

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Release Emergency Stop: Releases the Emergency Stop status. When theEmergency Stop is activated, the Emergency Stop window appears, and amessage appears in the Controller Status window.

Emergency Stop window.

To resume the Servo Robot System after an emergency stop, perform thefollowing steps:

C Ask your instructor to check your setup to remove any dangerous condition,and to release the switch using the appropriate key.

C Close the Emergency Stop window by clicking on the OK button.

C Close the Run Task window by clicking the Close button (if active).

C Select Release Emergency Stop in the Robot menu.

The system is now ready to operate.

Online: Allows communications between the host computer and the RobotController when enabled. The option must be enabled to operate the ServoRobot using Robotics.

Options

Environment: Opens the Environment folder of the Program Options window.

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Environment folder in the Program Options window.

The options that can be set in the Environment folder are:

Language: Selects the language.

Data Directory: Selects the folder where the Robotics files are saved.Robotics will automatically access this folder when saving or opening a file.

Line Numbers: Displays the instruction line numbers in the Task Editor whenenabled.

Force Uppercase: Forces upper case letters in the Task Editor whenenabled.

Editor Colors: Sets the foreground and background colors for the text andnumbers.

Note: For each folder of the Program Options window, click the Savebutton once the settings and selections are completed to save and applythem. They will be used as default settings the next time Robotics islaunched. Clicking the Cancel button closes the Program Optionswindow without saving the settings.

Hardware: Opens the Hardware folder of the Program Options window.

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Hardware folder in the Program Options window.

The options that can be set in the Hardware folder are:

Gripper: Selects the type of gripper. The available choices are Servo MotorGripper, Pneumatic Gripper, Electric Gripper, and No Gripper Attached.

Note: The gripper of your Servo Robot is driven by a servo motor. SelectServo Motor Gripper.

Channel 1: Selects the device connected to CH 1. The available choices areLinear Slide, Rotary Carousel, and No External Device Connected.

Channel 2: Selects the device connected to CH 2. The available choices areLinear Slide, Rotary Carousel, and No External Device Connected.

Serial Port: Selects the serial port where the Robot Controller is connected(COM1 to COM6).

Transit: Sets the transit speed between 0 and 99. The default value is 75.The transit speed is recommended for long distance when precision is notrequired.

Approach: Sets the approach speed between 0 and 99. The default value is40. The approach speed is recommended when the movement requiresmedium precision.

Precision: Sets the precision speed between 0 and 99. The default value is15. The precision speed is recommended when the movement requiresprecision.

File Server: Opens the File Server folder of the Program Options window.

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File Server folder in the Program Options window.

The options that can be set in the File Server folder are:

Note: The File Server software is used to save and load programs whenusing the Teach Pendant-Controlled Robot System, Model 5100.

Run File Server Software: Runs the File Server software when Robotics islaunched, when enabled.

File Server Program Location: Selects the folder where the File Serversoftware is installed.

Data File Directory: Selects the folder where the File Server saves files.

Serial Port: Selects the serial port where the Teach Pendant Controller isconnected (COM 2 to COM 7).

CNC Software: Opens the folder CNC Software of the Program Options window.

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CNC Software folder in the Program Options window.

The options that can be set in the CNC Software folder are:

CNC Mill Program Location: Selects the folder where the Mill Software isinstalled.

Serial Port: Selects the serial port where the CNC Mill is connected (COM 1to COM 6).

CNC Lathe Program Location: Selects the folder where the Lathe Softwareis installed.

Serial Port: Selects the serial port where the CNC Lathe is connected(COM 1 to COM 6).

Window

Cascade: Arranges all open Task Editor windows in a cascade so that each oneis visible. This reduces and overlaps all currently open windows to create a looksimilar to that of a well-organized filing cabinet. The title bars of all windows arealways visible, and the window closest to the front is active.

Tile Horizontal: Arranges from top to bottom all open Task Editor windows astiles so that each one is visible.

Tile Vertical: Arranges side by side all open Task Editor windows as tiles so thateach one is visible.

Close All: Closes all Task Editor windows.

Minimize All: Minimizes all Task Editor windows.

Restore All: Restores all Task Editor windows.

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Controller Status: Opens the Controller Status window. This window displaysthe status of the inputs and outputs of the Robot Controller.

Note: The Controller Status window will not open if the Online option inthe Robot menu is disabled, or if the Robot Controller is not configured.

Controller Status window.

The Controller Status window shows the following elements:

Inputs: Shows the status of the TTL inputs.

Note: A green LED corresponds to a high level, and a red LEDcorresponds to a low level.

Outputs: Shows the status of the TTL outputs. The level of an output can bechanged by clicking the corresponding LED.

Relays: Shows the status of the Relays. The status of a relay can be changedby clicking the corresponding LED.

Note: A green LED corresponds to the activated status, and a red LEDcorresponds to a non activated status.

CNC 1 Inputs: Shows the status of the CNC 1 inputs.

CNC 1 Outputs: Shows the status of the CNC 1 outputs. The level of anoutput can be changed by clicking the corresponding LED.

CNC 2 Inputs: Shows the status of the CNC 2 inputs.

CNC 2 Outputs: Shows the status of the CNC 2 outputs. The level of anoutput can be changed by clicking the corresponding LED.

Warning Messages: The following warning messages are displayed whenapplicable.

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Robot has not been hard homed.: Indicates that the Servo Robot hasnot been hard homed. A hard home positioning must be executed at thebeginning of each session.

Emergency stop is Activated.: Indicates that the emergency stop buttonhas been pressed. Ask your instructor to check your setup to remove anydangerous condition, and to release the switch using the appropriate key.

Point Editor: Opens the Point Editor window. The Point Editor window is aninterface from where the Servo Robot is controlled and where position andcontrol points are created, saved, and edited. The Point Editor window can beviewed in Teach mode and Edit mode.

Teach Mode: In this mode, the Point Editor window is used to control theServo Robot and external device(s) connected to CH 1 and CH 2, and to saveposition and control points.

Point Editor in Teach mode.

The description of each function in the window is as follows:

Movement Arrows: Moves the articulated sections. To do so, place thecursor on the arrows representing the desired movement while pressingand holding the left button of the mouse. The articulated section will moveas long as the left button is held pressed or until a limit switch is activated.The arrows named Open and Close control the gripper, and the CH 1 andCH 2 arrows control the devices connected to these ports.

Speed: Sets the speed of the Servo Robot and external device(s)connected to CH 1 and CH 2 between 1 and 99.

Edit button: Switches the Point Editor window in Edit mode.

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Replace button: Replaces the point beside the cursor in the point list.

Clicking the Replace button when the cursor is beside a position pointopens the Save Position Point window. This window is described in thissection.

Clicking the Replace button when the cursor is beside a control pointopens the Save Control Point window. This window is described in thissection.

Delete button: Deletes the selected point(s) in the point list.

Drive button: Executes a group of points. To do so, select the group ofpoints you want to execute, then click the Drive button. The Run Pointwindow appears and the group of points is executed starting with the firstselected point. The Run Point window shows the status of the instructionthat is executed and the name of the current point.

Note: To select a group of points, highlight the points by clicking eachpoint while holding the Ctrl key pressed, or by clicking the first and lastpoint of the list while holding the Shift key pressed.

Run Point window.

Move button: Moves the Servo Robot from the current position to a pointin the point list. To do so, click the point where you want the Servo Robotto move then click the Move button. The Run Point window appears, andthe Servo Robot moves directly to the point without executing theintermediate points, if any. If an obstacle is present between the currentposition and the selected point, a collision will occur.

Execute button: Executes all points in the point list. Clicking the Executebutton opens the Run Point window, and all points are executed as shownin the list, from top to bottom.

Move Up button: Moves the position or control point beside the cursorover the preceding point.

Move Down button: Moves the position or control point beside the cursorunder the next point.

Save Position Point button: Opens the Save Position Point window tosave the position coordinates of the current position.

The elements that can be set in the Save Position Point window are:

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Name: Displays a default, also allows a new name to be entered.

Robot check box: Saves the coordinates of the Servo Robot.

External Device check box: Saves the coordinates of the externaldevice(s) connected to CH 1 or CH 2.

Save button: Saves the point with the name shown in the Name field.

Save Position Point window.

Note: The Robot and External Device check boxes allow independentoperation of the Servo Robot and external device(s) connected to CH 1and CH 2. Saving a point when both check boxes are enabled, willcause the Servo Robot and external device(s) to move simultaneously.The default setting of the check boxes is Robot enabled and ExternalDevice disabled.

Cancel button: Closes the window without saving any changes.

Set Control Point button: Opens the Save Control Point window. Sets thestatus of inputs and outputs.

Save Control Point window.

The elements that can be set in the Save Control Point window are:

Name: Names the control point. Accept the default name or enter anew name in the Name field.

Inputs: Sets the level at which the TTL inputs must be beforeproceeding with the next instruction line in the program.

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Note: The level is set by clicking the corresponding LED. A green LEDcorresponds to a high level, a red LED corresponds to a low level, anda blue LED indicates that no level is assigned.

Outputs: Sets the level at which the TTL outputs will be after thisinstruction is executed.

CNC 1 Inputs: Sets the level at which the CNC 1 inputs must be beforeproceeding with the next instruction line in the program.

CNC 1 Outputs: Sets the level at which the CNC 1 outputs will be afterthis instruction line is executed.

CNC 2 Inputs: Sets the level at which the CNC 2 inputs must be beforeproceeding with the next instruction line in the program.

CNC 2 Outputs: Sets the level at which the CNC 2 outputs will be afterthis instruction line is executed.

Relays: Activates or deactivates the Relays. To activate a relay, clickthe corresponding LED. A green LED corresponds to activated, a redLED corresponds to deactivated, and a blue LED indicates that nostatus is assigned.

Delay: Sets the amount of time in seconds the system will pause beforeproceeding with the next instruction line in the program.

Save button: Saves the current settings with the name shown in theName field.

Cancel button: Closes the window without saving any changes.

Edit Mode: In Edit mode, the Point Editor is used to change thecharacteristics of a position or control point.

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Point Editor in Edit mode.

The elements that are editable are:

SpeedGripperWrist PitchWrist RotationElbowShoulder

BaseChannel 1 Channel 2TTL inputsTTL outputsCNC 1 inputs

CNC 1 outputsCNC 2 inputs CNC 2 outputsRelays Delay

To change the characteristics of a point, double click the point name in thepoint list to select it, then click the Edit button.

In the Point Editor window in Edit mode, click the Edit button to enable theedition mode. If the selected point is a position point, the elements in theRobot and External Device sections are edited and can be modified. Enterthe new settings in the field beside the parameter to change, then click theTeach button to save the settings and return the Point Editor window inTeach mode.

If the selected point is a control point, the elements in the Control Pointsection are edited and can be modified by clicking the LEDs, and/orentering a new Delay value. Make the desired changes, then click theTeach button to save the settings and return the Point Editor window inTeach mode.

The description of each function in this window is as follows:

Teach button: Saves the current settings and switches the Point Editorwindow in Teach mode.

Edit button: Edits the various settings to allow changes.

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Delete button: Refer to the description given in the Teach Mode section.

Drive button: Refer to the description given in the Teach Mode section.

Move button: Refer to the description given in the Teach Mode section.

Execute button: Refer to the description given in the Teach Mode section.

Reset button: Cancels the changes without closing the window.

Move Up button: Refer to the description given in the Teach Mode section.

Move Down button: Refer to the description given in the Teach Modesection.

Robot check box: Refer to the description given in the Teach Modesection.

External Device check box: Refer to the description given in the TeachMode section.

Absolute Position check box: When enabled, indicates that the pointcoordinates are absolute. This means that the coordinates are determinedrelative to a predetermined position (hard home position).

When disabled (not checked), indicates that the point coordinates arerelative. This means that the coordinates are determined relative to theprevious position.

Active Tasks: Displays the files that are currently open (maximum 10).

Help

Contents: Enters the Robotics Help.

About: Opens a window which provides general information about Robotics.

Toolbar

The description of each button of the toolbar is as follows:

Exit: Refer to the description given in the File subsection of the Menu Barsection.

Open: Refer to the description given in the File subsection of the Menu Barsection.

Save: Refer to the description given in the File subsection of the Menu Barsection.

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Info: Refer to the description given in the File subsection of the Menu Barsection.

Print: Refer to the description given in the File subsection of the Menu Barsection.

Undo: Refer to the description given in the Edit subsection of the Menu Barsection.

Cut: Refer to the description given in the Edit subsection of the Menu Barsection.

Copy: Refer to the description given in the Edit subsection of the Menu Barsection.

Paste: Refer to the description given in the Edit subsection of the Menu Barsection.

Find: Refer to the description given in the Search subsection of the MenuBar section.

Find and Replace: Searches for specific words and phrases in the TaskEditor window and replaces them by new ones.

Find Next: Refer to the description given in the Search subsection of theMenu Bar section.

Go to Line: Refer to the description given in the Search subsection of theMenu Bar section.

Run Task: Refer to the description given in the Robot subsection of theMenu Bar section.

Contents: Enters the Robotics Help.

Status Bar

The Status bar is shown at the bottom of the Main window. It contains 5 fieldsshowing information about the operation of Robotics.

From left to right, the content of each field is as follows:

C The first field gives information about the operation of the system. It alsodescribes the function of the buttons and options in the menus.

C The second field indicates if the Robot Controller is Online or Offline.

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C The third field indicates the current position of the cursor in the Task Editorwindow (horizontally and vertically).

C The fourth field indicates if the file was modified since the last save operation.

C The last field shows the typing mode: Insert or Overwrite.

Context-Sensitive Menus

Context-sensitive menus are available in Robotics. They are displayed by clickingthe right button of the mouse. The commands available in the context-sensitivemenus depend on the window sections on which the mouse pointer is placed whenthe button is clicked. The commands available in the context-sensitive menus are:

In the Robot Section of the Point Editor in Teach Mode

Speed: Maximum: Sets the speed at 99.

Speed: Transit: Sets the speed at 75. The transit speed is used for longdistance when precision is not required.

Note: The Transit, Approach and Precision Speed values can bechanged. Refer to the description given in the Options subsection of theMenu Bar section.

Speed: Approach: Sets the speed at 40. The approach speed is used whenthe movement requires medium precision.

Speed: Precision: Sets the speed at 15. The precision speed is used whenthe movement requires precision.

Save Point: Saves the absolute coordinates of the point. Refer to thedescription of the Save Position Point button given in the Teach Modesubsection of the Point Editor Window section.

Save Control Pt.: Refer to the description given in the Teach Modesubsection of the Point Editor Window section.

Save Relative Pt.: Saves the relative coordinates of the point. Refer to thedescription of the Save Position Point button given in the Teach Modesubsection of the Point Editor Window section.

Set Soft Home: Refer to the description given in the Motion Controlsubsection of the Robot section.

In the Point List Section of the Point Editor and Task Editor Windows

Move Up: Refer to the description given in the Teach Mode subsection of thePoint Editor Window section.

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Move Down: Refer to the description given in the Teach Mode subsection ofthe Point Editor Window section.

Move to Top: Moves the point beside the cursor to the top of the point list(next to the home or soft home).

Move to Bottom: Moves the point beside the cursor to the bottom of the pointlist.

Rename: Opens the Save Position Point or Save Control Point windowdepending on if the cursor is beside a position or a control point to enter anew name for the point.

Duplicate: Duplicates the selected point.

Replace: Refer to the description given in the Teach Mode subsection of thePoint Editor Window section.

Delete: Refer to the description given in the Teach Mode subsection of thePoint Editor Window section.

Drive To: Refer to the description given in the Teach Mode subsection of thePoint Editor Window section.

Move To: Refer to the description given in the Teach Mode subsection of thePoint Editor Window section.

Move Home: Refer to the description given for the Soft Home option of theMotion Control subsection of the Robot section.

Set Active: Moves the cursor beside the highlighted point. The active pointis the point beside the cursor.

Execute: Refer to the description given in the Teach Mode subsection of thePoint Editor Window section.

In the Left Column of the Task Editor Window

Edit

Redo: Refer to the description given in the Edit subsection of the MenuBar section.

Cut: Refer to the description given in the Edit subsection of the Menu Barsection.

Copy: Refer to the description given in the Edit subsection of the MenuBar section.

Paste: Refer to the description given in the Edit subsection of the MenuBar section.

Robotics

4-26

Duplicate: Refer to the description given in the Edit subsection of theMenu Bar section.

Clear: Refer to the description given in the Edit subsection of the MenuBar section.

Select All: Refer to the description given in the Edit subsection of theMenu Bar section.

Search

Find: Refer to the description given in the Search subsection of the MenuBar section.

Find Next: Refer to the description given in the Search subsection of theMenu Bar section.

Replace: Refer to the description given in the Search subsection of theMenu Bar section.

Go To Line: Refer to the description given in the Search subsection of theMenu Bar section.

Go To Bookmark: Refer to the description given in the Search subsectionof the Menu Bar section.

Set Bookmark: Refer to the description given in the Search subsection ofthe Menu Bar section.

Tools

Clear Undo Buffer: Deletes the content of the Clipboard.

Clear All (without undo): Deletes the selected instruction line(s) but doesnot save to the Clipboard. It is not possible to recall the deleted line(s).

Print: Refer to the description given in the File subsection of the Menu Barsection.

Print Setup: Refer to the description given in the File subsection of theMenu Bar section.

Programming Principles

Two types of programs can be developed with your Servo Robot System: Point-to-Point programs and Task programs.

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4-27

Point-to-Point Programming

Point-to-point programming means moving the Servo Robot (or externaldevice(s) connected to CH 1 and CH 2) through a series of positions (points) andrecording the coordinates of each point. Once all points are recorded, thesequence of points is executed as listed in the point list.

Note that once the execution is launched, the program executes all points. Point-to-point programs may consist in a list of position points and control points. Theycan be created with both the Hand-Held Terminal and Robotics.

Task Programming

Task programs consist in a list of instruction lines. The instruction lines includetask commands and points. Task programming is not possible when using theHand-Held Terminal alone.

To create a task program, the position points are first determined using Roboticsor the Hand-Held Terminal. Then, they are copied into the Task Editor windowwhere they are associated with task commands. All task commands are insertedin the Task Editor window.

Copying Points from the Point Editor into the Task Editor

You can copy a single point or a group of points from the Point Editor to the TaskEditor. To copy a single point, click the point and drag it to the right column of theTask Editor window.

Note: To open the Task Editor window, select New in the File menu. TheProgram Information window will appear. Enter the information and clickthe OK button. Then the Task Editor window will open.

To copy a group of points, use the Shift or Ctrl key to select the desired points.Click the last point while pressing the Shift or Ctrl key and drag the group to theright column of the Task Editor window.

The same methods apply when you copy points in the opposite direction: fromthe Task Editor to the Point Editor.

Copying Points from the Robot Controller Memory into the Task Editor

To copy points from the Robot Controller into the Task Editor, select New TaskEditor in the Upload to submenu from the Robot menu and follow theinstructions.

Note: Once the points are copied in the Task Editor, save the file. It isgood practice to save the file as soon as the points are copied into theTask Editor.

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4-28

Task Commands

Once the points are copied into the right column of the Task Editor window, theymust be selected and copied into the left column where they will be associatedwith task commands to form a program.

Robotics has a powerful set of task commands. The task commands are enteredby placing the cursor beside a line number and by typing the task command,inserting a space, and typing the name of the point: MOVETO POINT3 as anexample.

The name of the point must be exactly the same as the spelling of the point inthe right column. It is not necessary to use every point in the right column.

The description of the task commands available in Robotics is shown inAppendix C.

Running a Task Program

Run the task program by performing the following steps:

C Select Run Task in the Robot menu. If syntax errors are present, the CompileTask window will appear identifying the line where the problem is, and anerror message.

Compile Task window.

C Correct the error and select Run Task again. When the task program is freeof errors, the Run Task window appears.

Click the Step button in the Run Task... window if you desire to execute theinstruction lines one-by-one. The Step button allows you to see how eachinstruction line is executed.

When you are confident with each instruction line, click the Run button.

Editing a Task Program

Like the Point Editor, the Task Editor has editing capabilities.

Note: For adding points, you must use the Point Editor to manipulate theServo Robot to create and save new points.

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4-29

Using the Task Editor you can annotate instruction lines, delete and addinstructions.

Annotating a Task Program

A good practice is to annotate the purpose of the major instruction lines. If theannotation is well done, you will be able to make modifications andimprovements more easily. You can make comments any place in your taskprogram by preceding the comment with a backslash (\).

Deleting Code

To delete characters, select the required character or group of characters thenselect Clear in the Edit menu, or press the Delete key on the keyboard or theScissors icon.

To delete a line space, place the cursor at the beginning of the open line thenpress the Delete key on the keyboard.

Adding Code

You can add code to the task program by placing the cursor where required andtyping the code.

4-30

5-1

Section 5

Safety Procedures

Safety Procedures

Caution!

Follow these recommendations scrupulously when using the trainingsystem.

C The equipment must be installed and connected as described in this guide.

C The installation of heavy equipment such as the Servo Robot, Linear Slide andRotary Carousel, should be made by two people.

C No wall or obstacles should be present within 750 mm (30 in) from the base ofthe Servo Robot.

C The power source must be in accordance with the applicable codes.

C The instructor should visually check the Servo Robot and work area to identifyhazardous conditions before using the system.

C Safety glasses must be worn at all times while operating the equipment.

C Make sure you are not wearing anything that might get caught, such as a tie orjewelry. If your hair is long, tie it out of the way.

C The Emergency Stop module must be easily accessible by the operator at anytime.

C No food or drink is allowed in the laboratory.

C If the equipment does not appear to be operating properly or malfunctions, stopusing it immediately and report the problem to the instructor.

5-2

6-1

Section 6

Care and Maintenance

The Servo Robot of the Servo Robot System requires little maintenance. However,it is important to maintain the gear and belt system clean to insure many hours oftrouble-free operation.

If a problem occurs, do not try to service it yourself as you may void your warranty.If you are uncertain about what may be wrong, call your sales representative or theLab-Volt technical support department.

Lubrication

Once a week, apply one drop of general-purpose lubricating oil at each locationshown in Figure 6-1.

Note: Applying the correct amount of lubricating oil is important. Overlubrication does not help the operation.


6-2

Figure 6-1. Lubrication points.

Belt Tension

Proper tension on each belt is required to obtain precision. The arm on the robotmoves as a result of pulleys and belts working together. Through normal use, beltsmay develop slack due to normal wear.

If an articulation seems loose, one or more belts may need to be tightened. To doso, identify which belt(s) are slack, and loosen the screws of the belt tensioners onboth sides of the arm. The belt tensioners are located in Figure 6-2. Move thetensioner until the belt slack is removed, then tighten the screws. The cover of theshoulder must be removed to access some of the belt tensioners.


6-3

BELT TENSIONERS

BELT TENSIONER

Figure 6-2. Location of the belt tensioners.

6-4

A-1

Appendix A

Hand-Held Terminal Menus

Main Menu

1 Point Manager

Point Editor

N Name:_

F Flags:Absolute

Relative

S Speed:_

1 Gripper:_

2 Wrist R:_

3 Wrist P:_

4 Elbow:_

5 Shoulder:_

6 Base:_

7 Ch 1:_

8 Ch 2:_

0 Save Changes

Control Editor

N Name:_

1 TTL Output

TTL OUTPUTKEY 1 2 3 4 5 6 7 8OLD X X X X X X X XNEW X X X X X X X X

2 TTL Input

TTL INPUTKEY 1 2 3 4 5 6 7 8OLD X X X X X X X XNEW X X X X X X X X

3 Relay

RELAYKEY 1 2 3 4OLD X X X XNEW X X X X

4 CNC 1

CNC1 INPUT | OUTPUTKEY 1 2 3 4 A B C DOLD X X X X X X X XNEW X X X X X X X X

5 CNC 2

CNC2 INPUT | OUTPUTKEY 1 2 3 4 A B C DOLD X X X X X X X XNEW X X X X X X X X

D Delay:_

0 Save Changes

X

CLEAR ALL POINTS ARE YOU SURE?


C Deletes the point beside the cursor.

6 Moves the point beside the cursor over the preceding point.

7 Moves the point beside the cursor under the next point.

2 Task Manager1 Run Once

EXECUTE POINTSRUN ONCE

____PRESS ESC TO ABORT

2 Run Forever

EXECUTE POINTSRUN FOREVER: _


3 Trace Points

EXECUTE POINTSTRACE MODE



A-2

4 Clear Points

CLEAR ALL POINTSARE YOU SURE?


3 File Manager

1 Save to Disk

SAVE FILEENTER FILENAME

_

2 Load From Disk

OVERWRITE TASKARE YOU SURE?


4 Motion Control

1 Soft Home

2 Set Soft Home

3 CLR Soft Home

4 Hard Home

PERFORM HARD HOME


5 Free Motors

6 Torque Motors

7 Hardware Reset

HARDWARE RESETARE YOU SURE?


8 Soft Limits OFF

9 Soft Limits ON

5 Configuration

1 Grip

Servo

Pneu

Elec

None

2 Ch 1

L Slide

Carousel

None

3 Ch 2

L Slide

Carousel

None

4 Key ClickON

OFF

5 Shift LockON

OFF

S Save Config

9 Shutdown

Teach Menu

0 Speed Control

SET SPEED

>------------------+<1 099 99

1 Gripper Open

H Gripper Close

2 Wrist CW

I Wrist CCW

3 Wrist Pitch Down

J Wrist Pitch Up

4 Elbow Pitch Down

R Elbow Pitch Up

5 Shldr Pitch Down


A-3

S Shldr Pitch Up

6 Base CCW

T Base CW

7 Ch 1 Forward

Z Ch 1 Backward

8 Ch 2 Forward

/ Ch 2 Backward

F TTL Output


G TTL Input

TTL INPUTKEY 1 2 3 4 5 6 7 8OLD H H H H H H H HNEW X X X X X X X X

P Relay


Q Time Delay

SET DELAY VALUEIN SECONDS

>_

X CNC 1


Y CNC 2


C Save Abs Point


>POINT1_

# Save Rel Point


>POINT1_

* Save Control

SAVE CONTROLENTER POINT NAME

>CTRL1_

A-4

B-1

Appendix B

Robotics Menus

File

New

Open

Close

Save

Save As

Revert

Info

Print

Print Setup

Shutdown

Exit

Edit

Undo

Redo

Cut

Copy

Paste

Duplicate

Clear

Select All

Search

Find

Find Next

Replace

Go To Line

Go To Bookmark

Set Bookmark

Robot

Run Task

Motion Control

Soft Home

Set Soft Home

Clear Soft Home

Free Motors

Torque Motors

Hard Home

Download from...Task Editor

Point Editor

Upload to...New Task Editor

Point Editor

Release Emergency Stop

Online

Robotics Menus

B-2

Options

Environment

Hardware

File Server

CNC Software

Window

Cascade

Tile Horizontal

Tile Vertical

Close All

Minimize All

Restore All

Controller Status

Point Editor

HelpContents

About

C-1

Appendix C

Task Commands

TASK COMMANDS - QUICK REFERENCE TABLE

Command Parameters Function

CAROUSEL <[0|1]>Starts carousel on CH 1 or CH 2, waits for TTL input x high(1) or low(0)then stops the carousel

CNCINPUT(x,y) <[0|1]> Waits for CNC x (1 or 2), line y high (1) or low (0)

CNCOUTPUT(x,y) <[0|1]> Sets the CNC x (1 or 2), line y to high (1) or low (0)

DELAY <0-999> Delays the execution for xxx seconds

DO <1-9999> Repeats a series of line instructions for a set count

DRIVETO <point> Executes all points in sequence from active to named point

ELSE none Branch point for false condition in IF statement

END none Ends the task

ENDIF none Ends of IF conditional

ERROR <msg> Halts task execution and display a custom error msg

GOSUB <name> Transfers execution to the named subroutine

HOME none Moves to the soft home position

IF <expr> Branch execution on conditional expression

INPUT(x) <[0|1]> Waits for TTL input x high(1) or low(0)

LATHE <filename> Download via the CNC Lathe Software

MESSAGE <msg> Displays a custom message on the task window

MILL <filename> Download via the CNC Mill Software

MOVETO <point> Executes a specified point

OUTPUT(x) <[0|1]> Sets TTL output x to high(1) or low (0)

RELAY(x) <[0|1]> Activates or deactivate Relay x

REPEAT none Ends the WHILE loop statement list

RESTART none Restarts the task program at the first command

RETURN none Ends of the current subroutine

RUNTO <point> Executes a specified point at max speed

SPEED <0-99> Sets an override speed for all subsequent point

SUB <name> Defines the start of a subroutine

UNTIL none Ends the DO loop statement list

WHILE <expr> Begins a loop of statements when <expr> is true

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C-2

COMMAND DESCRIPTION

CAROUSEL

Syntax: CAROUSEL(<integer 1-2>,<integer 1-8>)

Parameters: <[HIGH | LOW]>

Description: The Carousel command is used to control the operation of theRotary Carousel. It causes the Rotary Carousel to rotate one turnor less if the status of a specified TTL input corresponds to adesired level. The values in parentheses indicate the channel (1or 2) where the Rotary Carousel is connected and the TTL input (1-8) to read. The parameter that follows indicates the desired level ofthe TTL input. This command will suspend the rotation of theRotary Carousel if the level matches the command parameter.

Note: <[HIGH | LOW]> can be interchanged with <[ON | OFF]>, <[CLOSE| OPEN]>, or <[1 | 0]>.

Example: 0001: CAROUSEL(1,1) HIGH0002: MOVETO POINT10003: END

Line 1 causes the Rotary Carousel to rotate one turn or less if thelevel detected at TTL input 1 is high. Then the program executesPOINT1 and ends.

CNCINPUT

Syntax: CNCINPUT(<integer 1-2>,<integer 1-4>)


Description: This command reads the specified input on CNC 1 or CNC 2.Usually a channel is used to directly interface with other automationor CNC equipment. The value in parentheses indicates the channel(1 or 2) and the input (1-4) to read. This command will block andsuspend task execution until the read value matches the commandparameter.


Example: 0001: CNCINPUT(1,2) HIGH0002: GOSUB LOAD_PART0003: CNCOUTPUT(1,2) HIGH0004: RESTART

This program shows a simple control loop that might be used withCNC equipment. First, line 1 waits for CNC 1, input 2 to be high,

Task Commands

C-3

then a subroutine that loads a piece of stock into the machineexecutes. Once the stock is loaded, CNC 1, output 2 (or B) is setat high. Finally, the process is restarted.

CNCOUTPUT

Syntax: CNCOUTPUT(<integer 1-2>,<integer 1-4>)


Description: This command controls the specified output on CNC 1 and CNC 2.Usually a channel is used to interface with other automation orCNC equipment. The value in parentheses indicates the channel(1 or 2) and the output (1-4 or A to D) to change. The parameterthat follows indicates the desired status of the output.


Example: 0001: CNCINPUT(1,2) HIGH0002: GOSUB LOAD_PART0003: CNCOUTPUT(1,2) HIGH0004: RESTART

This program shows a simple control loop that might be used withCNC equipment. First, line 1 waits for CNC 1, input 2 to be high,then a subroutine that loads a piece of stock into the machineexecutes. Once the stock is loaded, CNC 1, output 2 is set at high.Finally, the process is restarted.

DELAY

Syntax: DELAY

Parameters: <integer 0-999>

Description: Delay task execution for the value expressed in seconds. If theparameter value is 0, then the task execution is paused until theuser clicks the Run button in the Run Task window.

Example: 0001: MOVETO POINT10002: DELAY 100003: MOVETO POINT20004: DELAY 00005: HOME0006: END

This program executes POINT1 then delays the executionfor 10 seconds. Line 3 executes POINT2 and then the delay stopsexecution. The user then clicks the Run button and the HOME

Task Commands

C-4

command executes. Finally the program terminates at the ENDcommand.

DO

Syntax: DO


Description: This command indicates the start of a series of commands that areto be executed repeatedly. The parameter indicates the number ofrepetitions that the instruction lines between the DO and UNTILcommands are run.

Example: 0001: DO 50002: IF INPUT(3) = LOW0003: END0004: ELSE0005: MOVETO POINT10006: MOVETO POINT20007: MOVETO POINT30008: ENDIF0009: UNTIL

Note: As shown in this example, formatting the instruction linesof the program makes it easier to read.

This program executes POINT1, POINT2 and then POINT3 inorder, 5 times in a row unless TTL input 3 goes low, and then theEND command is executed. This demonstrates that the only wayto stop the execution of the DO loop is by user abort or by insertingan END, RESTART or ERROR command into the loop.

See also: UNTIL

DRIVETO

Syntax: DRIVETO

Parameters: <string point name>

Description: This command operates as a shortcut instead of repeating multipleMOVETO commands. To execute a series of points from theassociated point list, this command will execute every pointbetween the current active point and the point named in thecommand parameter.

The points will be executed in the order that they exist in the pointlist. Normally, you would start the execution of a long sequence ofpoints by first calling the MOVETO command with the first point insequence and then follow that command with a DRIVETO

Task Commands

C-5

command that indicates the last point in the sequence. This cansimplify the task program when a large number of movements mustbe executed in order.

Warning: The points execute in the order they exist in the point list. Changingthe point list will modify how this command executes.

Example: 0001: MOVETO POINT10002: DRIVETO POINT40003: END

Assuming that POINT1, POINT2, POINT3, and POINT4 aredefined in the point list in that order, this program will first executePOINT1. The DRIVETO command will then execute every pointbetween POINT1 up to and including POINT4.

ELSE

Syntax: ELSE

Parameters: None

Description: This command indicates the end of the instruction lines that areexecuted when a TRUE condition is evaluated by a previous IFcommand. The instruction lines that follow the ELSE command areexecuted in the event that the associated IF command evaluateda FALSE value.

Example: 0001: MOVETO POINT10002: MOVETO POINT20003: IF INPUT(1) = HIGH 0004: IF OUTPUT(2) = LOW0005: MESSAGE Turn on the conveyor!0006: ELSE0007: GOSUB LOAD_FROM_CONVEYOR0008: ENDIF0009: ENDIF0010: END

This program shows how to use the IF command and also showsthat you can nest IF commands within each other. Line 3 checks ifTTL input 1 is high and if so, executes the next instruction line.

Line 4 then checks if TTL output 2 is low. If the IF commanddetects that the external device on TTL output 2 is low, then themessage on line 5 is displayed. Conversely, If the IF commanddetects that the external device on TTL output 2 is high, then theexecution will jump to the instruction line that follows the ELSEcommand, which calls a GOSUB to actually run the loading routine.

See also: IF, ENDIF

Task Commands

C-6

END

Syntax: END

Parameters: None

Description: This command ends the execution of the current task. If the RepeatTask check box is checked in the Run Task window, the programwill restart execution at the beginning of the program. Thiscommand can be placed anywhere in the task program but unlessyou are defining subroutines, all instruction lines past the ENDcommand will never be executed.

Example: 0001: MOVETO POINT10002: MOVETO POINT20003: END

See also: MOVETO

ENDIF

Syntax: ENDIF

Parameters: None

Description: This command indicates the end of an IF-ELSE-ENDIF block ofcodes and the execution continues with the next instruction line.For each IF command there must be exactly one matching ENDIFcommand. If there are multiple nested IF commands, each onemust have a matching ENDIF command.

Example: 0001: MOVETO POINT10002: MOVETO POINT20003: IF INPUT(1) = HIGH0004: IF OUTPUT(2) = LOW0005: MESSAGE Turn on the conveyor!0006: ELSE0007: GOSUB LOAD_FROM_CONVEYOR0008: ENDIF0009: ENDIF0010: END

This program shows how to use the IF command and also that youcan nest IF commands within each other. Line 3 checks if TTLinput 1 is high and if so, executes the next instruction line.

Line 4 then checks if TTL output 2 is low. If the IF commanddetects that the external device on TTL output 2 is low, then themessage on line 5 is displayed. Conversely, If the IF commanddetects that the external device on TTL output 2 is high, then the

Task Commands

C-7

execution will jump to the instruction line that follows the ELSEcommand, which calls a GOSUB to actually run the loading routine.

See also: IF, ELSE

ERROR

Syntax: ERROR

Parameters: <string message>

Description: This command will halt the execution of the current task programand the string message provided as a parameter will be displayedin the message area of the Run Task window. The status will beset to display ERROR. Use this command if you want to generatean error in your program if an unexpected condition occurs.

Example: 0001: IF INPUT(1) = LOW0002: ERROR No stock is available0003: ELSE0004: GOSUB LOAD_STOCK0005: ENDIF

This program checks if TTL input 1 is low and if the condition teststrue, the error message appears in the Message field of the RunTask window and the program execution is suspended.

GOSUB

Syntax: GOSUB

Parameters: <string name>

Description: This command calls the named subroutine. Execution will return tothe instruction line that follows the GOSUB command when thesubroutine completes execution. You can call subroutines fromwithin other subroutines.

Example: 0001: IF INPUT(1) = HIGH0002: MESSAGE Loading stock from conveyor.0003: GOSUB LOAD_STOCK0004: ENDIF0005: END0006: SUB LOAD_STOCK0007: MOVETO POINT10008: MOVETO POINT20009: MOVETO POINT30010: RETURN

Task Commands

C-8

This program shows how to define and call subroutines. If TTLinput 1 is high, then the GOSUB routine transfers execution to theinstruction line that follows the SUB command. Lines 7 through 9are then executed and the RETURN command in line 10 will returnexecution back to the instruction line that follows the GOSUBcommand that called this subroutine.

See also: SUB, RETURN

HOME

Syntax: HOME

Parameters: None

Description: Tells the Servo Robot to move to the assigned soft home position.This is the position that is defined by the point named HOME in thepoint list associated with this task. It is the position the Servo Robotstarts its movements from, and where it will come to rest when youtell it to go home. You can modify the point coordinates using theSet Soft Home and Clear Soft Home functions. This command isfunctionally equivalent to calling MOVETO HOME.

Example: 0001: MOVETO POINT10002: HOME0003: END

This program executes POINT1 and then returns to the HOMEposition. HOME is defined as the first point in the point list.

IF

Syntax: IF

Parameters: <expression>

Description: If the expression evaluates to TRUE, the execution continuesnormally with the next instruction line. If the expression is FALSE,the execution continues after the next ELSE command (if used) orENDIF command.

Example: 0001: MOVETO POINT10002: MOVETO POINT20003: IF INPUT(1) = HIGH 0004: IF OUTPUT(2) = LOW0005: MESSAGE Turn on the conveyor!0006: ELSE0007: GOSUB LOAD_FROM_CONVEYOR0008: ENDIF

Task Commands

C-9

0009: ENDIF0010: END

This program shows how to use the IF command and also showsthat you can nest IF commands within each other. Line 3 checks ifTTL input 1 is high and if so, executes the next instruction line.

Line 4 then checks if TTL output 2 is low. If the IF commanddetects that the external device on TTL output 2 is low, then themessage on line 5 is displayed. Conversely, If the IF commanddetects that the external device on TTL output 2 is high, then theexecution will jump to the instruction line that follows the ELSEcommand, which calls a GOSUB to actually run the loading routine.

See also: ELSE, ENDIF

INPUT

Syntax: INPUT(<integer 1-8>)


Description: This command reads the TTL inputs. The value in parenthesesindicates the input to read and the parameter that follows thecommand indicates the desired status. This command will blockand suspend task execution until the read value matches thecommand parameter.


Example: 0001: MOVETO POINT10002: INPUT(4) LOW0003: MOVETO POINT20004: END

This program executes POINT1 and then waits until TTL input 4 islow then POINT2 is executed and the program ends.

LATHE

Syntax: LATHE

Parameters: <string filenamepath>

Description: This command executes the external program associated with theLATHE command set in the Options window. The filenameparameter is passed as a parameter to this program so that theCNC Lathe software will automatically download the file to a CNCLathe.

Task Commands

C-10

Example: 0001: GOSUB LOAD_STOCK \Load stock into CNC Lathe0002: LATHE sample_part.l4 \Download the part program to the

Lathe0003: CNCINPUT(1,1) HIGH \Wait for the CNC Lathe to signal

completion0004: END

This program shows how to use the LATHE command to downloada CNC Lathe program. This command is used when integrating theServo Robot System with CNC Lathe machinery.

MESSAGE

Syntax: MESSAGE

Parameters: <string message>

Description: This command will display the string parameter data in theMessage field of the Run Task window. This command does notstop the execution of the program so if you need the user torespond to your message, follow this command with a DELAY 0command.

Example: 0001: IF INPUT(1) = HIGH0002: MESSAGE Loading stock from conveyor.0003: GOSUB LOAD_STOCK0004: ENDIF

This program checks if TTL input 1 is high. If the condition teststrue, a message is sent to the user in the Message field of the RunTask window, and the LOAD_STOCK subroutine is executed.

MILL

Syntax: MILL

Parameters: <string filenamepath>

Description: This command executes the external program associated with theMILL command set in the Options window. The filename parameteris passed as a parameter to this program so that the CNC MillSoftware will automatically download the file to a CNC Mill.

Example: 0001: GOSUB LOAD_STOCK \Load stock into CNC Mill.0002: MILL sample_part.m4 \Download the part program to the

Mill.0003: CNCINPUT(1,1) HIGH \Wait for the Mill to signal

completion.0004: END

Task Commands

C-11

This program shows how to use the MILL command to downloada CNC Mill program. This command is used when integrating theServo Robot System with CNC Mill machinery.

MOVETO

Syntax: MOVETO


Description: This command causes the execution of either a position point or acontrol point.

Example: 0001: MOVETO POINT10002: END

This program executes POINT1 and then terminates.

OUTPUT

Syntax: OUTPUT(<integer 1-8>)


Description: This command controls the status of the TTL outputs. The value inparentheses indicates the output to change and the parameter thatfollows indicates the new status of the output.


Example: 0001: OUTPUT(1) HIGH0002: DELAY 50003: OUTPUT(1) LOW0004: END

This program sets TTL output 1 at high, delays for 5 seconds andthen sets the output at low.

RELAY

Syntax: RELAY(<integer 1-4>)

Parameters: <[CLOSE | OPEN]>

Description: This command controls the status of the relays. The value inparentheses indicates which relay is being controlled and theparameter that follows indicates the desired status: activated(close) or deactivated (open).

Task Commands

C-12

Note: <[CLOSE | OPEN]> can be interchanged with <[ON | OFF]>,<[HIGH | LOW ]>, or <[1 | 0]>.

Example: 0001: RELAY(1) CLOSE0002: DELAY 50003: RELAY(1) OPEN0004: END

This program activates Relay 1, delays for 5 seconds and thendeactivates the relay.

REPEAT

Syntax: REPEAT

Parameters: None

Description: Indicates the end of a WHILE loop. When the loop reaches thiscommand, execution will jump back to the associated WHILEcommand for reevaluation of the original WHILE expression.

Example: 0001: MOVETO POINT10002: WHILE INPUT(4) = HIGH \ Stock is available from

feeder.0003: GOSUB LOAD_STOCK0004: OUTPUT(2) LOW0005: GOSUB MOVE_STOCK0006: OUTPUT(2) HIGH0007: REPEAT0008: END

This program shows how you might load stock from a feeder, moveit somewhere, and repeat the operation until the stock feeder setsTTL input 4 at low. As long as TTL input 4 remains high, theinstruction lines between the WHILE and REPEAT commands willbe executed repeatedly.

See also: WHILE

RESTART

Syntax: RESTART

Parameters: None

Description: This command instructs the software to abort the current executionof the task and to restart from the beginning of the program. Unlikethe END command, RESTART ignores the status of the RepeatTask check box in the Run Task... window.

Task Commands

C-13

Example: 0001: MOVETO POINT10002: MOVETO POINT20003: RESTART0004: MOVETO POINT30005: END

In this program, instruction lines 4 and 5 will never be executed.

RETURN

Syntax: RETURN

Parameters: None

Description: This command defines the end of a subroutine. When thiscommand is executed, the subroutine being executed exits and theexecution will resume at the instruction line that follows the GOSUBcommand. Only one RETURN command is allowed in a subroutineand it must be the last command in the subroutine.

Example: 0001: IF INPUT(1) = HIGH0002: MESSAGE Loading stock from the conveyor.0003: GOSUB LOAD_STOCK0004: ENDIF0005: END0006: SUB LOAD_STOCK0007: MOVETO POINT10008: MOVETO POINT20009: MOVETO POINT30010: RETURN

This program shows how to define and call subroutines. If TTLinput 1 is high, then the GOSUB routine transfers the execution tothe instruction line that follows the SUB command. Lines 7 through9 are then executed and the RETURN command in line 10 willreturn execution back to the instruction line that follows the originalGOSUB command that called this subroutine.

See also: GOSUB

RUNTO

Syntax: RUNTO


Description: This command tells the Servo Robot to execute either a position orcontrol point. If the point is a position point, the movement will beexecuted at maximum speed. The Speed value that was definedfor the point is ignored.

Task Commands

C-14

Example: 0001: MOVETO POINT10002: RUNTO POINT20002: END

This program will execute POINT1 and POINT2. If POINT2 is nota control point, the speed will be set at 99 (maximum value),overriding the Speed value saved in the position point.

See also: MOVETO, END

SPEED

Syntax: SPEED


Description: This command allows you to set an override Speed value for theinstruction lines that follow the line containing this command. Allposition point moves will be executed at this new speed. Theposition points that follow a SPEED command set at 0 will be attheir own defined speeds.

Example: 0001: MOVETO POINT10002: MOVETO POINT20003: SPEED 200004: MOVETO POINT10005: SPEED 00006: MOVETO POINT20007: END

In this program, the first two instruction lines move the Servo Robotto POINT1 and POINT2 normally. The speed override in line 3means that the MOVETO command in line 4 will move at a speedof 20 instead of the previously defined speed of the point. Line 5will disable the speed override and so the MOVETO on line 6 willmove at the speed set in POINT2. This example assumes thatPOINT1 and POINT2 are not control points. The override Speedvalue has no effect on control points.

See also: MOVETO, END

SUB

Syntax: SUB

Parameters: <string name>

Description: This command defines the name and the starting location of asubroutine. All instruction lines that follow this command belong tothe named subroutine until the RETURN command indicates the

Task Commands

C-15

end of the subroutine. Subroutines should always be defined afterthe END command and separate from each other. Subroutines cancall other subroutines, but be warned that an infinite loop can occurwhen a subroutine calls itself.

Example: 0001: IF INPUT(1) = HIGH0002: MESSAGE Loading stock from conveyor.0003: GOSUB LOAD_STOCK0004: ENDIF0005: END0006: SUB LOAD_STOCK0007: MOVETO POINT10008: MOVETO POINT20009: MOVETO POINT30010: RETURN

This program shows how to define and call subroutines. If TTLinput 1 is high, then the GOSUB routine transfers execution to theinstruction line that follows the SUB command. Lines 7 through 9are then executed and the RETURN command in line 10 will returnexecution back to the instruction line that follows the originalGOSUB command that called this subroutine.

See also: GOSUB, RETURN

UNTIL

Syntax: UNTIL

Parameters: None

Description: This command indicates the end of a DO loop sequence and if thenumber of passes through the DO loop is less than the DOcommand parameter, execution jumps to the original DOcommand.

If the number of passes is greater than the number in the DOcommand, the execution continues with the instruction line thatfollows the UNTIL command.

Example: 0001: DO 50002: IF INPUT(3) = LOW0003: END0004: ELSE0005: MOVETO POINT10006: MOVETO POINT20007: MOVETO POINT30008: ENDIF0009: UNTIL

Task Commands

C-16

This program executes POINT1, POINT2 and then POINT3 inorder, 5 times in a row unless TTL input 3 goes LOW, and then theEND command is executed. This demonstrates that the only wayto stop the execution of the DO loop is by user abort or by insertingan END, RESTART or ERROR command into the loop.

See also: DO

WHILE

Syntax: WHILE

Parameters: <expression>

Description: This command evaluates the expression. If it is true, it executes theinstruction lines that follow, up to the REPEAT command. Whenthe REPEAT command is reached, execution will return to theWHILE command in which the expression will be evaluatedrepeatedly until the expression fails.

Notes: The expression value is only evaluated by the WHILE command.Changing the status of the inputs/outputs inside this command willnot cause the loop to exit immediately.

Example: 0001: MOVETO POINT10002: WHILE INPUT(4) = HIGH \Stock is available from feeder0003: GOSUB LOAD_STOCK0004: OUTPUT(2) LOW0005: GOSUB MOVE_STOCK0006: OUTPUT(2) HIGH0007: REPEAT0008: END

This program shows how you might load stock from a feeder, moveit somewhere, and repeat the operation until the stock feeder setsTTL input 4 at low. As long as TTL input 4 is high when the WHILEcommand on line 2 executes, the instruction lines between theWHILE and REPEAT commands will be executed repeatedly.

See also: REPEAT

Conditional Statements

The IF and WHILE commands use a parameter called an expression, which is astatement that when evaluated will produce a Boolean TRUE or FALSE value.

A simple expression might look like this:

IF ... TRUE (IF the expression INPUT(1) = HIGH is TRUE as an example)... instruction lines ...

Task Commands

C-17

ELSE... instruction lines ...

ENDIF

If the evaluated expression is true, the program will execute the instruction linesfollowing it up to the ELSE command, where the execution would jump to theinstruction line following the ENDIF command. In this example you can see that theinstruction lines that fall between the ELSE and ENDIF are not executed becausethe evaluated expression is true.

In all Robotics expressions, a general form is followed. This form is CMD <leftexpression> <conditional> <right expression>. CMD is either the IF or WHILEcommand. These are the only two commands that support expressions.

The <left expression> and <right expression> are both values. These can be adirect value of 1 or 0 (or any of the legitimate replacements for these values:HIGH/LOW, ON/OFF, CLOSE/OPEN). Additionally, the expressions can be thevalue returned by any of the following commands: INPUT(x), OUTPUT(x),RELAY(x), CNCINPUT(x,y) or CNCOUTPUT(x,y). All of these commands will returneither a 0 or 1 to indicate the current status of the input/output line.

The <conditional> defines how to compare the two expressions. The followingvalues are available:

CONDITIONAL STATEMENTS

=, == or EQ Equivalent

<>, != or NEQ Not equivalent

<= or LEQ Less than or equal

>= or GEQ Greater than or equal

< or LT Less than

> or GT Greater than

&& or AND Boolean AND (True if <left> = 1 and <right> = 1)

|| or OR Boolean OR (True if <left> = 1 or <right> = 1)

XOR Boolean XOR (Exclusive Or) True only if <left> is not equal to <right>

NAND Boolean NAND (Not And) True only if <left> = 0 and <right> = 0

C-18

D-1

LIMITSWITCH

[12 V − − 60 mA]

NORMALLYOPENTERMINAL

NORMALLYCLOSEDTERMINAL

COMMONTERMINAL

LOCATIONPINS

PLATTER

CURSORDISK

Appendix D

Rotary Carousel, Model 5208

Description

The Rotary Carousel of the Servo Robot System is shown in Figure D-1. It consistsof a rotating platter mounted on a base. The Rotary Carousel is provided with a limitswitch to detect the presence of objets on the platter.

Figure D-1. Rotary Carousel, Model 5208.

The Rotary Carousel is also provided with a "cursor" disk. The cursor disk is locatedover the center of the platter. It is used to locate a reference position. To do so,rotate the cursor disk to align the line on the cursor disk with one of the lines on theplatter.

The Rotary Carousel is designed to be used with the Grids and the perforated WorkSurfaces. When used with the Work Surfaces, the Rotary Carousel is located usingtwo location pins under the base.

Connection

The Rotary Carousel connects to CH 1 or CH 2 on the Robot Controller as shownin Figure D-2.

Note: Do not make or modify any connection while the RobotController is on.


D-2

TO THE TTL INPUTS

CNC 1 CNC 2 CH 1 CH 2 5250 5250

REAR VIEWROBOT CONTROLLER

Figure D-2. Connection of the Rotary Carousel.

The limit switch contacts connect to the TTL inputs on the Robot Controller. Theblue terminal corresponds to the normally closed (NC) terminal of the limit switch,the yellow terminal corresponds to the normally open (NO) terminal, and the blackterminals correspond to the common terminal.

Configuration

Once the connection is made, the Robot Controller must be configured to detect theRotary Carousel. To configure the Robot Controller when using Robotics, select theHardware option in the Options menu. Select Rotary Carousel in the selection fieldof the channel where the Rotary Carousel is connected. Click the Save button tosave the configuration.

To configure the Robot Controller when using the Hand-Held terminal, press the5 key in the Main menu to select Configuration. In the Configuration menu, place thecursor beside the channel number where the Rotary Carousel is connected, pressthe Enter key as required to select Carousel. Press the S key to save theconfiguration.

Operation

The Rotary Carousel is driven by a servo motor mounted in the base. The plattercan rotate either in the clockwise or counterclockwise direction. Its operation iscontrolled by clicking the CH 1 or CH 2 arrow in Robotics, or by pressing the 7 orZ key if the Rotary Carousel is connected to CH 1, or the 8 or / keys if it isconnected to CH 2 when using the Hand-Held Terminal.

The Carousel command can also be used to control the operation of the RotaryCarousel. Refer to Appendix C to obtain more information on how to use thiscommand.


D-3

Like the Servo Robot, the Rotary Carousel must be hard homed at the beginning ofeach session. Make sure that the parts are removed from the platter when executinga hard home positioning.

The speed is controllable the same way as the motors of the Servo Robot.

The position of the platter of the Rotary Carousel is saved as for the Servo Robot.Clicking the Save Position Point button in the Point Editor window of Robotics,opens the Save Position Point window. There are two check boxes in this window:Robot and External Device. Enable the External Device check box if you are savingthe coordinates of the Rotary Carousel.

Save Position Point window.

The Robot and External Device check boxes allow independent operation of theServo Robot and external device(s) connected to CH 1 and CH 2. When both checkboxes are enabled, the Servo Robot and external devices are controlledsimultaneously.

It is not possible to save the coordinates of the Servo Robot and Rotary Carouselindependently using the Hand-Held Terminal alone. The points created using theHand-Held Terminal must be transferred in the Point Editor of Robotics. Each pointmust be edited and the check boxes enabled or disabled as required.

D-4

E-1

SWITCHLIMIT

CONTROL PANEL

PINLOCATION

Appendix E

Belt Conveyor, Model 5210

Description

The Belt Conveyor of the Servo Robot System is shown in Figure E-1. It consistsof a belt which is driven by a servo motor. The Belt Conveyor is provided with a limitswitch to detect the presence of parts on the belt. It is movable; there are severalsets of mounting positions found along both sides of the conveyor chassis.

Figure E-1. Belt Conveyor, Model 5210

The Belt Conveyor is designed to be used with the Grids and the perforated WorkSurfaces. When used with the Work Surfaces, the location guide must be installedon the Belt Conveyor. The guide is also movable, and it uses the same mountingholes as the limit switch.

Connection

The Belt Conveyor connects to an AC power outlet. The STOP, MOTOR, andDIRECTION external inputs connect to the TTL outputs of the Robot Controller.

The limit switch contacts connect to the TTL inputs of the Robot Controller. The blueterminal corresponds to the normally closed (NC) terminal of the limit switch, theyellow terminal corresponds to the normally open (NO) terminal, and the blackterminals correspond to the common terminal.


E-2

+

INPUT

LOW

HIGH

LOGIC

EXT.

REVERSE

FORWARD +

EXT. INPUT

STOP

SLOW FAST

BELT CONVEYOR

SPEED+

DIRECTION

DISENGAGE

EXT.

MOTOR

ENGAGE

EXT. INPUT

5210

[ TTL ] [ TTL ]

[ TTL ]

Operation

The Belt Conveyor can be operated either by switches mounted on the controlpanel, or by control signals applied to its TTL inputs. The control signals areprovided by the TTL outputs of the Robot Controller.

The control panel of the Belt Conveyor is shown in Figure E-2. As the figure shows,the operating parameters that can be controlled on the control panel are the speed(SPEED), the logic level of the TTL input (STOP) at which the conveyor stops,motor engage/disengage (MOTOR), and belt direction (DIRECTION).

Figure E-2. Control panel of the Belt Conveyor.

Speed

The SPEED potentiometer controls the speed of the belt from Slow to Fast. At theSlow position, the belt of the conveyor is stopped.

Stop

The Logic switch is used to select the TTL level required at the input Stop toremotely stop the conveyor. When the Logic switch is set at High, the conveyorstops on a high level. Conversely, when the Logic switch is set at Low, it stops ona low level.


E-3

Motor

The Motor switch is used to select between three operating modes:

C Engage: In this mode, the motor of the Belt Conveyor is torqued and theconveyor runs if the settings of the Stop section correspond to a run condition.If the settings of the Stop section correspond to a stop condition the motor isstopped but remains torqued.

C Disengage: In this mode, the motor is stopped and freed (not torqued).C Ext.: The operation is controlled remotely by a signal applied to the Ext. Input.

When the level at the Ext. Input is high, the conveyor operates as in the Engagemode. Conversely, when the level is low, it operates as in the Disengage mode.

Direction

The Direction switch is used to select between three operating modes:

C Forward: In this mode, the belt of the conveyor goes from right to left (whenfacing the control panel).

C Reverse: In this mode, the belt of the conveyor goes from left to right.C Ext.: The operation is remotely controlled by a signal applied to the Ext. Input.

When the level of the Ext. Input is high, the direction of the belt is in the Forwardmode. Conversely, when the level is low, it is in the Reverse mode.

E-4

F-1

LOCATIONPIN

MODEL 5119 MODEL 5121

Appendix F

Gravity Feeders, Models 5119 and 5121

Description

The Gravity Feeders of the Servo Robot System are shown in Figure F-1. TheModel 5119 is designed to feed square parts having 50 x 50 x 25 or 37. 5 mm (2 x2 x 1 or 1.5 in), and the Model 5121 is designed to feed cylindrical parts similar inform and dimensions to film canisters.

Figure F-1. Gravity Feeders, Models 5119 and 5121

The Gravity Feeders are designed to be used with the Grid and the perforated WorkSurfaces. When used with the Work Surfaces, the Gravity Feeders are locatedusing the location pins at the back of the modules.

Connection

The limit switch contacts connect to the TTL inputs on the base of the Servo Robot.The blue terminal corresponds to the normally closed (NC) terminal of the limitswitch, the yellow terminal corresponds to the normally open (NO) terminal, and theblack terminals correspond to the common terminal.

Gravity Feeders, Models 5119 and 5121

F-2

Operation

The Gravity Feeders work on the principle that when a part is removed from thefeeder, the force of gravity will bring the next piece down to where the Servo Robotcan grasp it. The limit switch sends a signal when the feeder is empty. Usually, theServo Robot will stop and wait until the feeder is filled before continuing on.

When using the Gravity Feeder, Model 5121, it is suggested to add coins in the filmcanisters to improve stability.

G-1

PNEUMATICFEEDER CONTROLLER

MODEL 5149

PNEUMATICFEEDER

MODEL 5122

FEEDERSECTION

STORAGESECTION

SLIDER

Appendix G

Pneumatic Feeders, Models 5122 and 5142

Description

The Pneumatic Feeders of the Servo Robot System are shown in Figure G-1.Theywork very much on the same principle as the gravity feeders but have theadvantage of the force of air to propel the parts. Their operation is controlled by thePneumatic Feeder Controller, Model 5149 (one controller is required for eachfeeder).

Figure G-1. Pneumatic Feeder and Controller, Models 5122 and 5149.

The Pneumatic Feeder, Model 5122, is designed to feed square parts having 50 x50 x 12.5 mm (2 x 2 x 0.5 in) and the Model 5142 is designed to feed cylindricalparts having a diameter of 19 mm (0.75 in) and a length of 50 mm (2 in).

The Pneumatic Feeders are designed to be used with the Grids and the perforatedWork Surfaces. When used with the Work Surfaces, the Pneumatic Feeders arelocated using the location pins under the modules.


G-2

S2

BA

S1

A

S1

− 60 mA][12 V −

S2-A S2-B

B

PNEUMATIC FEEDER CONTROLLER

MAX. MIN.MAX. MIN.

SLIDER

RETRACTSPEEDPORT BSPEED

EXTENDPORT A

INPUTS

21

5149

PORT A PORT B

PNEUMATIC TUBES

SLIDERSPEEDCONTROLS

PORT A

PORT B

INPUT 2INPUT 1

Connection

To connect a Pneumatic Feeder, perform the following steps:

Note: Do not place any parts in the storage section of thePneumatic Feeder now.

C Connect S1 on the Pneumatic Feeder to input 1 on the Pneumatic FeederController as shown in Figure G-2.

Figure G-2. Connection of the Pneumatic Feeders.

C Connect S2-A on the Pneumatic Feeder to input 2 on the Pneumatic FeederController as shown in Figure G-2.

C Connect port A on the Pneumatic Feeder to port A on the Pneumatic FeederController with a pneumatic tube as shown in Figure G-2. Tighten theconnectors.

C Connect port B on the Pneumatic Feeder to port B on the Pneumatic FeederController with a pneumatic tube as shown in Figure G-2. Tighten theconnectors.

C Connect the Air Supply Inlet on the Pneumatic Feeder Controller to an AirSupply Source as shown in Figure G-3. Note that the Air Supplied Source is notincluded with the Pneumatic Feeders.

Note: Do not apply compressed air to the Pneumatic Feedernow.


G-3

[12 V −40 PSI MAX.

275 kPa MAX.

AIRSUPPLY

POWERINPUT

− 60 mA]

TO AN ACPOWERSUPPLY

AC-TO-DC ADAPTOR

TO AN AIRSUPPLY SOURCE(NOT INCLUDED)

AIR SUPPLYINLET INPUT

DC POWER

PNEUMATIC FEEDERCONTROLLER (REAR VIEW)

Figure G-3. Connection of the Pneumatic Feeder Controller (rear view).

C Connect the AC-to-DC adaptor to an AC power outlet and the other extremityof the lead to the DC Power Input on the Pneumatic Feeder Controller, asshown in Figure G-3.

Limit switch S2-B connects to the TTL inputs on the Teach Pendant.

Operation

Pneumatic Feeders

The Pneumatic Feeders, Models 5122 and 5142, have three limit switches to detectthe presence of parts: S1, S2-A, and S2-B.

Switch S1 detects the presence of parts in the storage section, it is located at thebottom of the storage section. The contact of switch S1 is normally open (NO),meaning that it is open when the storage section is empty.

Switch S2-A detects the presence of parts in the feeder section, it is located at thebottom of the feeder section. The contact of switch S2-A is normally closed (NC),meaning that it is closed when the feeder section is empty.

Switches S1 and S2-A are used to control the operation of the Pneumatic FeederController.

Switch S2-B is located at the bottom of the feeder section. The contact of switch S2-B is normally open (NO), meaning that it is open when the feeder section is empty.Switch S2-B is used to control the level of a TTL input.


G-4

S2

BA

S1

S2

BA

S1

(a)

(b)

FEEDERSECTION

AVAILABLEPART

STOREDPARTS

STORAGESECTION

SLIDER INTHE EXTENDED

POSITION

SLIDER INTHE RETRACTED

POSITION

CYLINDERROD

PNEUMATICCYLINDER

Pneumatic Feeder Controller

The Pneumatic Feeder Controller, Model 5149, includes a solenoid operatedpneumatic valve. When the solenoid of the valve is energized, air flows through thevalve to port A of the Pneumatic Feeder. This causes the slider to extend to pusha new part as shown in Figure G-4a.

When the solenoid of the valve is not energized, air flows through the valve to port Bof the Pneumatic Feeder. This causes the slider to retract as shown in Figure G-4b.

Figure G-4. Schematic diagram of the Pneumatic Feeder, Model 5122.

The solenoid of the pneumatic valve is energized only when the contacts of bothswitches S1 and S2-A are closed as shown in Figure G-5. The only way to obtainthis condition is when the feeder section is empty but not the storage section.


G-5

S1 S2-A

1 2

INPUTS

PNEUMATICVALVE

SOLENOID

+

−

Figure G-5. Electrical diagram of the Pneumatic Feeder Controller, Model 5149.

The operation is summarized in Table G-1.

SWITCH S1 SWITCH S2-AAIR IS

SUPPLIEDTO PORT

SLIDER

closed(parts in the storage section)

open(parts in the feeder section)

B retracts

closed(parts in the storage section)

closed(feeder section empty)

A extends

open(storage section empty)

open(parts in the feeder section)

B retracts

open(storage section empty)

closed(feeder section empty)

B retracts

Switch S1 is normally open (NO)

Switch S2-A is normally closed (NC)

Table G-1. Slider movement versus the status of switches S1 and S2-A.

Speed Setting

The extension and retraction speeds of the slider can be set via the SPEED controlknobs on the Pneumatic Feeder Controller. The SPEED control consists in a flowcontrol valve that controls the air flow which is directed to the cylinder ports. Thespeed increases with air flow.

To set the extension and retraction speed, perform the following steps:

C Ensure that the Pneumatic Feeder is connected as described in theConnection section of this appendix.

C Place five parts in the storage section and one in the feeder section.

C Set the Extend and Retract Speed control knobs at MIN.

C Apply compressed air to the Pneumatic Feeder Controller.


G-6

Note: The air pressure applied to the Pneumatic FeederController should not exceed 275 kPa (40 psi).

C Manually remove the available part from the feeder section.

Note: With the Speed control knobs at the MIN. position, theslider will not move or very little.

C Slowly turn the Extend Speed control knob in the counterclockwise directionto increase the extension speed of the slider.

C Once the part is in the feeder section, turn slowly the Retract Speed controlknob in the counterclockwise direction to increase the retraction speed.

C Remove the new part in the feeder section and repeat the last two stepsuntil you obtain a smooth movement in both directions.

Note: For the Pneumatic Feeder, Model 5142, make sure the partwill not be thrown out of the feeder.

H-1

METALLICMOBILE

BASE

BEARINGLINEAR

PINSLOCATION

Appendix H

Linear Slide, Model 5209

Description

The Linear Slide of the Servo Robot System is shown in Figure H-1. It consists ofa mobile metallic base on which the Servo Robot is mounted (screwed). The mobilebase slides on two transverse shafts via four linear ball bearings. The base is drivenby a servo motor via a lead screw.

Figure H-1. Linear Slide.

The servo motor is similar to the ones that drive the Servo Robot and its control isalso quite similar.

The Linear Slide is designed to be used with the Grid and the perforated WorkSurfaces. When used with the Work Surfaces, the Linear Slide is located using thelocation pins under the extremity sections of the module.


H-2

CNC 1 CNC 2 CH 1 CH 2 5250 5250

ROBOT CONTROLLERREAR VIEWLINEAR SLIDE

Connection

The Linear Slide connects to CH 1 or CH 2 on the Robot Controller as shown inFigure H-2.

Note: Do not make or modify any connection while the RobotController is on.

Figure H-2. Connection of the Linear Slide.

Configuration

Once the connection is made, the Robot Controller must be configured to detect theLinear Slide. To configure the Robot Controller when using Robotics, select theHardware option in the Options menu. Select Linear Slide in the selection field of thechannel where the Linear Slide is connected. Click the Save button to save theconfiguration.

To configure the Robot Controller when using the Hand-Held terminal, press the5 key in the Main menu to select Configuration. In the Configuration menu, place thecursor beside the channel where the Linear Slide is connected, and press the Enterkey as required to select L Slide. Press the S key to save the configuration.

Operation

The Linear Slide is controlled by clicking the CH 1 or CH 2 arrow in Robotics or bypressing the 7 or Z keys if it is connected to CH 1, or the 8 or / keys if it is connectedto CH 2 if you are using the Hand-Held Terminal.

As the Servo Robot and Rotary Carousel, the Linear Slide must be hard homed atthe beginning of each session.

CAUTION!

Make sure the Servo Robot has sufficient free space to execute a hard homepositioning in all positions of the Linear Slide.

The speed is controllable the same way as the motors of the Servo Robot.


H-3

Since the position of the Servo Robot depends on the position of the mounting baseof the Linear Slide, their positions must be saved simultaneously. The Robot andExternal Device check boxes of the Point Editor in Robotics must always be enabledwhen saving a position point.

H-4

I-1

Appendix I

Error codes of Firmware 5250

*EMERGENCY STOP*: Emergency Stop is pushed. Turn the key to deactivate itand press "Clear Error" on the Teach Pendant to clear the error.

*LIMIT ERROR*: G=Gripper, R=Wrist Rotation, P=Wrist Pitch, E=Elbow,S=Shoulder, B=Base, 1=External motor #1, 2=External motor #2. This problemhappens when a limit switch is activated. It is normally self-correcting (the robotmoves in the opposite direction to clear the limit switch). If the limit switch is notcleared automatically, use the teach pendant to safely move the axis away from thelimit switch.

*SYSTEM ERROR*: An illegal instruction has occurred. To correct this problem, thecontroller must be turned off. Then turn it on to reboot it.

*CONTROL ERROR*: One of the motor controllers has failed to execute acommand. This is probably due to a faulty component inside the controller.

MOTORS APPEAR TO BE FREED. CHECK MOTOR RELEASE SWITCH: Thisproblem happens when then motor drives cannot send signals to the motors. Tocorrect this problem, verify the "MOTORS" button on the front panel of the controller.Make sure that the button is pushed on the "Enabled" position and that the red LEDmarked "Disabled" is turned off.

*MOTOR ERROR* MOTOR STALL: G=Gripper, R=Wrist Rotation, P=Wrist Pitch,E=Elbow, S=Shoulder, B=Base, 1=External motor #1, 2=External motor #2. One ofthe motors has reached a position error causing it to stall. This happens when therobot has tried to move an object but has not been able to move it because theobject is too heavy.

*FILE ERROR*: The teach pendant has not been able to open or save a file.

ROBOT ERROR USER ABORT: The user aborted during a programmed taskmovement by using the ESC button of the teach pendant.

ROBOT ERROR RUN POINT REFUSED: The programmed point cannot bereached because its information is corrupted (bad speed, bad positions, etc...) or therobot is already executing a task

.

Documents

34175-E0_Robot5250_User.pdf