R-30iA DispenseTool Operator Manual

FANUC > series

OPERATORS MANUAL

B-82594EN-4/01

DISPENSE TOOL

R-30*A CONTROLLER

FANUC > series

OPERATORS MANUAL

B-82594EN-4/01

R-30*A CONTROLLER

(Volume 1 of 2)

DISPENSETOOL

FANUC > series

OPERATORS MANUAL

B-82594EN-4/01

R-30*A CONTROLLER

(Volume 2 of 2)

DISPENSETOOL

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content. This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual. No part of this manual may be reproduced in any form. All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japans Foreign Exchange and Foreign Trade Law. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as impossible.

B-82594EN-4/01 TABLE OF CONTENTS

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TABLE OF CONTENTS

Volume 1 of 2

1 INTRODUCTION .....................................................................................1 1.1 MANUAL PLAN ............................................................................................. 2 1.2 WORKERS .................................................................................................... 5 1.3 GENERAL SAFETY PRECAUTIONS............................................................ 6 1.4 SAFETY PRECAUTIONS............................................................................ 11

2 OVERVIEW ...........................................................................................17 2.1 APPLICATION TOOL SOFTWARE............................................................. 19

2.1.1 System Setting........................................................................................................19 2.1.2 Jog Feed of the Robot.............................................................................................19 2.1.3 Program ..................................................................................................................19 2.1.4 Test Operation (Test Execution) ............................................................................20 2.1.5 Automatic Operation (Operation Execution) .........................................................20

2.2 ROBOT........................................................................................................ 21 2.3 CONTROLLER ............................................................................................ 22

2.3.1 Teach Pendant ........................................................................................................23 2.3.1.1 Display Screen of the Teach Pendant ................................................................ 28

2.3.2 Operator Panel ........................................................................................................32 2.3.3 Remote Controller ..................................................................................................33 2.3.4 CRT/KB..................................................................................................................33 2.3.5 Communication ......................................................................................................33 2.3.6 Input/Output ...........................................................................................................34 2.3.7 Peripheral I/O .........................................................................................................34 2.3.8 Motion of the Robot ...............................................................................................35 2.3.9 Emergency Stop Devices........................................................................................35 2.3.10 Extended Axis ........................................................................................................35

3 SETTING UP THE HANDLING SYSTEM .............................................36 3.1 I/O................................................................................................................ 37

3.1.1 Digital I/O...............................................................................................................43 3.1.2 Group I/O ...............................................................................................................50 3.1.3 Analog I/O..............................................................................................................54

3.2 ROBOT I/O .................................................................................................. 59

TABLE OF CONTENTS B-82594EN-4/01

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3.3 PERIPHERAL I/O ........................................................................................ 63 3.4 OPERATORS PANEL I/O........................................................................... 74 3.5 I/O Link SCREEN ........................................................................................ 77

3.5.1 I/O Link List Screen ...............................................................................................77 3.5.2 Model B Unit List Screen.......................................................................................78 3.5.3 Signal Count Setting Screen...................................................................................80

3.6 I/O CONNECTION FUNCTION ................................................................... 82 3.7 SIMULATED INPUT SKIP FUNCTION........................................................ 84 3.8 SETTING AUTOMATIC OPERATION ......................................................... 86

3.8.1 Robot Service Request (RSR) ................................................................................87 3.8.2 Program Number Selection (PNS) .........................................................................90 3.8.3 Prog Select Screen..................................................................................................94 3.8.4 Cell Interface I/O..................................................................................................102

3.9 SETTING COORDINATE SYSTEMS ........................................................ 108 3.9.1 Setting a Tool Coordinate System........................................................................110 3.9.2 Setting a User Coordinate System........................................................................121 3.9.3 Setting a Jog Coordinate System..........................................................................132

3.10 SETTING A REFERENCE POSITION....................................................... 138 3.11 JOINT OPERATING AREA ....................................................................... 142 3.12 USER ALARM ........................................................................................... 144 3.13 VARIABLE AXIS AREAS........................................................................... 146 3.14 SPECIAL AREA FUNCTION ..................................................................... 148 3.15 SYSTEM CONFIG MENU ......................................................................... 152 3.16 SETTING THE GENERAL ITEMS............................................................. 159 3.17 OTHER SETTINGS ................................................................................... 161

4 PROGRAM STRUCTURE...................................................................162 4.1 PROGRAM DETAIL INFORMATION......................................................... 165

4.1.1 Program Name......................................................................................................165 4.1.2 Program Comment................................................................................................166 4.1.3 Subtype.................................................................................................................166 4.1.4 Group Mask..........................................................................................................167 4.1.5 Write Protection ...................................................................................................167 4.1.6 Interruption Disable..............................................................................................168

4.2 LINE NUMBER, PROGRAM END SYMBOL, AND ARGUMENT .............. 171 4.3 MOTION INSTRUCTIONS ........................................................................ 174

4.3.1 Motion Format......................................................................................................175 4.3.2 Position Data ........................................................................................................177


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4.3.3 Feedrate ................................................................................................................184 4.3.4 Positioning Path....................................................................................................187 4.3.5 Additional Motion Instructions ............................................................................188

4.4 PALLETIZING INSTRUCTIONS................................................................ 202 4.4.1 Palletizing Instruction...........................................................................................202 4.4.2 Palletizing Motion Instruction..............................................................................203 4.4.3 Palletizing End Instruction ...................................................................................203

4.5 REGISTER INSTRUCTIONS..................................................................... 204 4.5.1 Register Instructions.............................................................................................205 4.5.2 Position Register Instructions...............................................................................207 4.5.3 Position Register Axis Instructions ......................................................................208 4.5.4 Arithmetic Palletizing Register Instructions.........................................................210

4.6 I/O INSTRUCTIONS.................................................................................. 212 4.6.1 Digital I/O Instructions.........................................................................................212 4.6.2 Robot I/O Instructions ..........................................................................................213 4.6.3 Analog I/O Instructions ........................................................................................215 4.6.4 Group I/O Instruction ...........................................................................................216

4.7 BRANCH INSTRUCTIONS........................................................................ 217 4.7.1 Label Instruction...................................................................................................217 4.7.2 Program End Instruction ......................................................................................218 4.7.3 Unconditional Branch Instructions.......................................................................218 4.7.4 Conditional Branch Instructions...........................................................................219 4.7.5 Arguments ............................................................................................................223

4.8 WAIT INSTRUCTIONS.............................................................................. 233 4.8.1 Time-specified Wait Instruction...........................................................................233 4.8.2 Conditional Wait Instructions ..............................................................................233

4.9 SKIP CONDITION INSTRUCTION............................................................ 237 4.10 OFFSET CONDITION INSTRUCTION ...................................................... 240 4.11 TOOL OFFSET CONDITION INSTRUCTIONS......................................... 241 4.12 FRAME INSTRUCTIONS .......................................................................... 242 4.13 PROGRAM CONTROL INSTRUCTIONS.................................................. 244

4.13.1 Halt Instruction.....................................................................................................244 4.13.2 Abort Instruction ..................................................................................................244

4.14 OTHER INSTRUCTIONS .......................................................................... 245 4.14.1 RSR Instruction ....................................................................................................245 4.14.2 User Alarm Instruction .........................................................................................246 4.14.3 Timer instruction ..................................................................................................246


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4.14.4 Override Instruction .............................................................................................247 4.14.5 Comment Instruction ............................................................................................247 4.14.6 Message Instruction..............................................................................................247 4.14.7 Parameter Instruction............................................................................................248 4.14.8 Maximum Speed Instructions...............................................................................251

4.15 MULTIAXIS CONTROL INSTRUCTIONS ................................................. 252 4.15.1 Program Execution Instruction.............................................................................252

4.16 OPERATION GROUP INSTRUCTIONS.................................................... 253 4.16.1 Asynchronous Operation Group Instruction ........................................................253 4.16.2 Synchronous Operation Group Instruction...........................................................254

5 PROGRAMMING.................................................................................255 5.1 TIPS ON EFFECTIVE PROGRAMMING................................................... 257

5.1.1 Motion Instructions ..............................................................................................257 5.1.2 Predefined Position...............................................................................................259

5.2 TURNING ON THE POWER AND JOG FEED.......................................... 261 5.2.1 Turning On the Power and Turning Off the Power..............................................261 5.2.2 Three-Mode Switch..............................................................................................263 5.2.3 Moving the Robot by Jog Feed ............................................................................269

5.3 CREATING A PROGRAM ......................................................................... 277 5.3.1 Registering a Program ..........................................................................................278 5.3.2 Changing a Standard Motion Instruction .............................................................283 5.3.3 Teaching a Motion Instruction .............................................................................285 5.3.4 Teaching an Supplementary Motion Instruction ..................................................287 5.3.5 Teaching a Control Instruction.............................................................................290 5.3.6 TP Start Prohibition..............................................................................................296

5.4 CHANGING A PROGRAM ........................................................................ 299 5.4.1 Selecting a Program..............................................................................................299 5.4.2 Changing a Motion Instruction.............................................................................300 5.4.3 Changing a Control Instruction ............................................................................312 5.4.4 Program Edit Instructions.....................................................................................314

5.5 PROGRAM OPERATION .......................................................................... 332 5.5.1 Changing Program Information............................................................................332

5.6 BACKGROUND EDITING ......................................................................... 337 5.7 SINGULAR POINT CHECK FUNCTION ................................................... 348

6 EXECUTING A PROGRAM.................................................................349 6.1 PROGRAM HALT AND RECOVERY ........................................................ 350


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6.1.1 Halt by an Emergency Stop and Recovery...........................................................351 6.1.2 Halt by a Hold and Recovery ...............................................................................352 6.1.3 Halt Caused by an Alarm .....................................................................................353

6.2 EXECUTING A PROGRAM....................................................................... 357 6.2.1 Starting a Program................................................................................................357 6.2.2 Robot Motion .......................................................................................................358 6.2.3 Resuming a Program ............................................................................................361

6.3 TESTING ................................................................................................... 366 6.3.1 Specifying Test Execution....................................................................................367 6.3.2 Step Test ...............................................................................................................368 6.3.3 Continuous Test....................................................................................................373 6.3.4 Program Look/Monitor.........................................................................................375

6.4 MANUAL I/O CONTROL ........................................................................... 377 6.4.1 Forced Output.......................................................................................................377 6.4.2 Simulated I/O .......................................................................................................379 6.4.3 Standby Release ...................................................................................................380

6.5 OPERATING THE HAND MANUALLY ...................................................... 382 6.6 AUTOMATIC OPERATION ....................................................................... 384

6.6.1 Automatic Operation by Robot Start Request (RSR)...........................................385 6.6.2 Automatic Operation with Program Number Selection (PNS).............................387 6.6.3 External Override Selection Function ..................................................................390

6.7 ONLINE POSITION MODIFICATION ........................................................ 392

7 STATUS DISPLAY..............................................................................398 7.1 LEDS ON THE TEACH PENDANT............................................................ 399 7.2 USER SCREEN......................................................................................... 400 7.3 REGISTERS.............................................................................................. 401 7.4 POSITION REGISTERS............................................................................ 403 7.5 PALLETIZING REGISTERS ...................................................................... 407 7.6 CURRENT POSITION ............................................................................... 408 7.7 SYSTEM VARIABLES ............................................................................... 411 7.8 PROGRAM TIMER.................................................................................... 413 7.9 SYSTEM TIMER........................................................................................ 415 7.10 EXECUTION HISTORY............................................................................. 416 7.11 MEMORY USE STATUS DISPLAY ........................................................... 418

8 FILE INPUT/OUTPUT .........................................................................420 8.1 FILE INPUT/OUTPUT UNITS.................................................................... 421


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8.1.1 Memory Card .......................................................................................................424 8.1.2 USB Memory .......................................................................................................425

8.2 SETTING A COMMUNICATION PORT..................................................... 430 8.3 FILES......................................................................................................... 435

8.3.1 Program File .........................................................................................................435 8.3.2 Default Logic File ................................................................................................436 8.3.3 System File/Application File................................................................................436 8.3.4 Data File ...............................................................................................................436 8.3.5 ASCII File ............................................................................................................437

8.4 SAVING FILES .......................................................................................... 438 8.4.1 Saving with Program Selection Screen ................................................................438 8.4.2 Saving all the Program Files Using the File Screen .............................................440 8.4.3 Saving with a Function Menu ..............................................................................444 8.4.4 File Manipulation .................................................................................................446

8.5 LOADING FILES........................................................................................ 449 8.5.1 Loading Using the Program Selection Screen......................................................449 8.5.2 Loading a Specified Program File Using the File Screen ....................................451

8.6 PRINTING FILES....................................................................................... 457 8.7 AUTOMATIC BACKUP.............................................................................. 461

8.7.1 Overview of Automatic Backup...........................................................................461 8.7.2 Usable Memory Cards..........................................................................................461 8.7.3 Setting of Automatic Backup ...............................................................................462 8.7.4 Perform Automatic Backup..................................................................................464 8.7.5 Version Management............................................................................................465 8.7.6 Restore the Backup...............................................................................................466

8.8 IMAGE BACKUP FUNCTION.................................................................... 467

9 UTILITY ...............................................................................................470 9.1 MACRO INSTRUCTION............................................................................ 471

9.1.1 Setting Macro Instructions ...................................................................................472 9.1.2 Executing Macro Instructions ..............................................................................478

9.2 SHIFT FUNCTIONS .................................................................................. 484 9.2.1 Program Shift Function ........................................................................................485 9.2.2 Mirror Shift Function ...........................................................................................491 9.2.3 Angle-input Shift Function...................................................................................495

9.3 COORDINATE SYSTEM CHANGE SHIFT FUNCTIONS.......................... 502 9.4 SOFT FLOAT FUNCTION ......................................................................... 508 9.5 CONTINUOUS ROTATION FUNCTION.................................................... 515


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9.6 POSITION REGISTER LOOK-AHEAD EXECUTION FUNCTION............. 521 9.7 OPERATION GROUP DO OUTPUT FUNCTION...................................... 524 9.8 TIME BEFORE FUNCTION....................................................................... 526 9.9 DISTANCE BEFORE FUNCTION ............................................................. 532

9.9.1 Overview ..............................................................................................................532 9.9.2 Specification.........................................................................................................532 9.9.3 Configuration .......................................................................................................532 9.9.4 Instruction.............................................................................................................533 9.9.5 Entering Distance before ......................................................................................542 9.9.6 Caution and Limitations .......................................................................................546 9.9.7 System Variables ..................................................................................................547 9.9.8 Error Codes...........................................................................................................548

9.10 STATE MONITORING FUNCTION ........................................................... 549 9.11 AUTOMATIC ERROR RECOVERY FUNCTION ....................................... 558

9.11.1 Overview ..............................................................................................................558 9.11.2 Outline of the Automatic Error Recovery Function .............................................558 9.11.3 Defining a Resume Program ................................................................................562 9.11.4 Teaching the RETURN_PATH_DSBL Instruction .............................................563 9.11.5 Setting the Automatic Error Recovery Function ..................................................564 9.11.6 Flowchart for Resuming a Suspended Program ...................................................573 9.11.7 Manual Operation Screen of the Automatic Error Recovery Function ................574 9.11.8 Execution of the Resume Program from The Teach Pendant and Test Mode......577 9.11.9 Changing Conditions for Executing the Resume Program...................................577 9.11.10 Other Specifications and Restrictions ..................................................................577 9.11.11 Warnings ..............................................................................................................579

9.12 REMOTE TCP FUNCTION........................................................................ 580 9.12.1 Summary ..............................................................................................................580 9.12.2 Setup.....................................................................................................................582

9.13 HIGH-SENSITIVITY COLLISION DETECTION......................................... 586 9.13.1 Overview ..............................................................................................................586 9.13.2 Specification.........................................................................................................586 9.13.3 High-Sensitivity Collision Detection ...................................................................586 9.13.4 Cautions................................................................................................................587

9.14 LOAD SETTING ........................................................................................ 588 9.14.1 Overview ..............................................................................................................588 9.14.2 Motion Performance Screens ...............................................................................588 9.14.3 Program Instructions ............................................................................................590


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9.15 LOAD ESTIMATION.................................................................................. 592 9.15.1 Overview ..............................................................................................................592 9.15.2 Operating Procedure.............................................................................................592 9.15.3 Load Estimation Procedure (for 6-Axis Robots)..................................................592 9.15.4 Calibration Procedure (for 6-Axis Robots) ..........................................................597 9.15.5 Other Related Matters...........................................................................................601

9.16 COLLISION DETECTION for AUXILIARY AXIS........................................ 602 9.16.1 General .................................................................................................................602 9.16.2 Caution .................................................................................................................602 9.16.3 Initial Setting ........................................................................................................602 9.16.4 Tuning Procedure .................................................................................................603

9.17 GRAVITY COMPENSATION..................................................................... 605 9.17.1 System Variables ..................................................................................................605 9.17.2 MOTION Screen ..................................................................................................605

9.18 PASSWORD FUNCTION .......................................................................... 607 9.18.1 Overview of the Password Function.....................................................................607 9.18.2 Password Operations by the Install User..............................................................609 9.18.3 Disabling the Password Function .........................................................................613 9.18.4 Password Operations by Program Users and Setup Users ...................................614 9.18.5 Password Configuration File ................................................................................618

9.18.5.1 Overview ......................................................................................................... 618

9.18.6 XML Syntax for Password Configuration Files...................................................620 9.18.7 Password Log .......................................................................................................624 9.18.8 Screen Restrictions According to Password Level...............................................626 9.18.9 Password Auto Login Function............................................................................629

9.19 SOFT PANEL ............................................................................................ 630 9.19.1 Application-Specific Soft Panel Function ............................................................630 9.19.2 Custom I/O ...........................................................................................................631

9.20 MIXED LOGIC INSTRUCTION.................................................................. 633 9.21 PMC MONITOR FUNCTION ..................................................................... 653 9.22 PMC EDIT FUNCTION .............................................................................. 656 9.23 OPERATION LOG BOOK (OPTION)......................................................... 659

9.23.1 Overview ..............................................................................................................659 9.23.2 Recorded Events...................................................................................................662 9.23.3 Setting Up Book ...................................................................................................665 9.23.4 Operations ............................................................................................................666 9.23.5 Extended Alarm Log ............................................................................................671


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9.23.5.1 Setup ................................................................................................................ 671 9.23.5.2 How to display alarm log................................................................................. 672

9.24 ORIGINAL PATH RESUME....................................................................... 674 9.25 PROGRAM TOOLBOX.............................................................................. 680

9.25.1 Cross Car Mirror Shift..........................................................................................680 9.25.2 Flip Knuckle .........................................................................................................684 9.25.3 Soft Limit Setting .................................................................................................687

10 PALLETIZING FUNCTION..................................................................690 10.1 PALLETIZING FUNCTION ........................................................................ 691 10.2 PALLETIZING INSTRUCTIONS................................................................ 694 10.3 TEACHING THE PALLETIZING FUNCTION............................................. 696

10.3.1 Selecting a Palletizing Instruction ........................................................................697 10.3.2 Inputting Initial Data ............................................................................................698 10.3.3 Teaching a Stacking Pattern .................................................................................705 10.3.4 Setting Path Pattern Conditions............................................................................712 10.3.5 Teaching a Path Pattern ........................................................................................716 10.3.6 Notes on Teaching the Palletizing Function.........................................................720

10.4 EXECUTING THE PALLETIZING FUNCTION .......................................... 721 10.4.1 Palletizing Register...............................................................................................722 10.4.2 Controlling the Palletizing Function by a Palletizing Register ............................724

10.5 MODIFYING THE PALLETIZING FUNCTION........................................... 725 10.6 PALLETIZING FUNCTION WITH EXTENDED AXES ............................... 727 10.7 PALLETIZING ALL-POINT TEACHING..................................................... 728

11 FANUC iPendant ................................................................................730 11.1 OVERVIEW ............................................................................................... 731 11.2 APPEARANCE AND OPERATIONS ......................................................... 732

11.2.1 Appearance and Switches.....................................................................................732 11.2.2 Key Switches........................................................................................................733 11.2.3 Status Window .....................................................................................................734 11.2.4 Splitting the Screen ..............................................................................................735 11.2.5 Changing the Operation Target Screen ................................................................738 11.2.6 Internet Browser Screen .......................................................................................739 11.2.7 Screen Selection Menu and Screen Menus on the Edit Screen ............................742 11.2.8 Status Subwindow ................................................................................................743

11.2.8.1 Current position display................................................................................... 744 11.2.8.2 Operator panel status display........................................................................... 744 11.2.8.3 Safety signal status display .............................................................................. 745


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11.2.9 Color Display According to the Alarm Severity ..................................................745 11.3 TOUCH PANEL ......................................................................................... 747 11.4 SETTING UP iPendant .............................................................................. 748 11.5 RESTRICTIONS........................................................................................ 761

12 DISPENSE TOOL................................................................................762 12.1 OVERVIEW ............................................................................................... 763

12.1.1 Controller .............................................................................................................763 12.1.1.1 Type III analog output ..................................................................................... 763 12.1.1.2 Motion ............................................................................................................. 763

12.2 DISPENSETOOL COMMON SETUP ........................................................ 764 12.2.1 Setting Up DispenseTool Configuration ..............................................................764 12.2.2 Flow Rate Control ................................................................................................767

12.2.2.1 Overview ......................................................................................................... 767 12.2.2.2 Speed compensation ........................................................................................ 767 12.2.2.3 Flow type ......................................................................................................... 772 12.2.2.4 Flow rate calculation (traditional method)....................................................... 772 12.2.2.5 Flow rate calculation: 2PNT (two point calibrated calculation method) ......... 774

12.2.3 Setting Up Schedules............................................................................................775 12.2.4 Process Timing Protocols .....................................................................................780

12.2.4.1 Overview ......................................................................................................... 780 12.2.4.2 Generic Dispense system response time at a corner ........................................ 780 12.2.4.3 Equipment ant-time and additional ant-time.................................................... 781 12.2.4.4 Effects of using positive gun on ant-time ........................................................ 781 12.2.4.5 Effects of using negative gun on ant-time ....................................................... 782 12.2.4.6 Effects of positive bead shaping ant-time........................................................ 782 12.2.4.7 Effects of negative bead shaping ant-time....................................................... 783 12.2.4.8 Effects of pre-pressure time............................................................................. 783 12.2.4.9 Effects of seal start offset ................................................................................ 784 12.2.4.10 Effects of seal end offset.................................................................................. 784 12.2.4.11 Corner adjustment............................................................................................ 784 12.2.4.12 Generic dispense process signal timing protocols ........................................... 785

12.2.5 Setting Up Equipment Information ......................................................................786 12.2.6 Equipment Calibration .........................................................................................789

12.2.6.1 Overview ......................................................................................................... 789 12.2.6.2 Flow rate control calibration............................................................................ 790 12.2.6.3 Bead shaping air (atomizing air) calibration.................................................... 795 12.2.6.4 Maximum analog out (meter)/maximum meter speed calibration ................... 799 12.2.6.5 Material pressure calibration ........................................................................... 804 12.2.6.6 Two point (2PNT) flow rate calibration .......................................................... 809

12.2.7 Setting Up Equipment I/O....................................................................................815 12.2.8 Gun Purge.............................................................................................................821


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12.2.9 Channel 2 Analog Control Setup..........................................................................822 12.2.9.1 Concepts .......................................................................................................... 823 12.2.9.2 Setup and calibration ....................................................................................... 828 12.2.9.3 Timing diagram ............................................................................................... 833

12.2.10 Nonlinear Flow Model .........................................................................................833 12.2.11 Error Status Summary ..........................................................................................834

12.2.11.1 Group 1 ............................................................................................................ 835

12.3 SETTING UP THE CELL ........................................................................... 838 12.3.1 DispenseTool Cell Communication Setup ...........................................................838 12.3.2 DispenseTool Cell Interface I/O Signals ..............................................................840

12.3.2.1 Overview ......................................................................................................... 840 12.3.2.2 DispenseTool cell interface input signals ........................................................ 842 12.3.2.3 DispenseTool cell interface output signals ...................................................... 845 12.3.2.4 Setting up DispenseTool cell interface I/O signals.......................................... 849

12.3.3 Interference Zone Setup .......................................................................................850 12.3.3.1 Interference zone setup overview .................................................................... 850 12.3.3.2 Cell controller setup......................................................................................... 851 12.3.3.3 Teach pendant program example..................................................................... 852 12.3.3.4 Macro commands............................................................................................. 853

12.3.4 DispenseTool Cell Controller Error Recovery .....................................................854 12.4 PLANNING AND CREATING A PROGRAM.............................................. 858

12.4.1 Planning a Program ..............................................................................................858 12.4.1.1 Application program guidelines for DispenseTool.......................................... 858 12.4.1.2 Guidelines for using sub type program............................................................ 858

12.4.2 Writing and Modifying a Program .......................................................................859 12.4.2.1 Creating and writing a new DispenseTool program ........................................ 859 12.4.2.2 Defining predefined positions in DispenseTool programs .............................. 867

12.5 PROGRAM ELEMENTS............................................................................ 871 12.5.1 Overview ..............................................................................................................871 12.5.2 Program Header Information................................................................................872

12.5.2.1 Overview ......................................................................................................... 872 12.5.2.2 Sub type ........................................................................................................... 875 12.5.2.3 Cycle Time....................................................................................................... 877 12.5.2.4 Last cycle time................................................................................................. 878 12.5.2.5 Gun on time ..................................................................................................... 878 12.5.2.6 Last gun on time .............................................................................................. 878 12.5.2.7 Material volume............................................................................................... 878 12.5.2.8 Last material volume ....................................................................................... 878 12.5.2.9 Default user frame ........................................................................................... 878 12.5.2.10 Default tool frame............................................................................................ 879 12.5.2.11 Equipment number........................................................................................... 879


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12.5.3 Dispensing Instructions ........................................................................................879 12.5.3.1 Overview ......................................................................................................... 879 12.5.3.2 Dispense (seal) start instructions ..................................................................... 880 12.5.3.3 Dispense (seal) end instructions ...................................................................... 880

12.5.4 Program Control Instructions ...............................................................................880 12.5.4.1 Error program instruction for DispenseTool ................................................... 880 12.5.4.2 Resume program instruction for DispenseTool ............................................... 881

12.6 TESTING A PROGRAM AND RUNNING PRODUCTION ......................... 882 12.6.1 OVERVIEW.........................................................................................................882 12.6.2 Program Pause and Recovery...............................................................................883

12.6.2.1 ERROR_PROG and RESUME_PROG........................................................... 883 12.6.2.2 DispenseTool fault recovery procedures ......................................................... 886

12.6.3 Test Cycle.............................................................................................................891 12.6.3.1 Test cycle setup................................................................................................ 891 12.6.3.2 Controlling WET/DRY mode manually .......................................................... 893

12.6.4 Soft Panel .............................................................................................................894 12.6.4.1 Soft panel overview ......................................................................................... 894 12.6.4.2 General and application-specific soft panel functions ..................................... 894

12.6.5 Maintenance and Repair .......................................................................................896 12.6.6 Enabling or Disabling Joint Motion Warning ......................................................897

12.7 STATUS DISPLAYS AND INDICATORS................................................... 898 12.7.1 Status Indicators ...................................................................................................898

12.7.1.1 Teach pendant status indicators ....................................................................... 898 12.7.1.2 DispenseTool status ......................................................................................... 899 12.7.1.3 Application status ............................................................................................ 901 12.7.1.4 Program status for DispenseTool..................................................................... 902

12.8 PROGRAM AND FILE MANIPULATION ................................................... 904 12.8.1 Manipulating Files................................................................................................904

12.8.1.1 Backing up files ............................................................................................... 904

12.9 ADVANCED FUNCTIONS......................................................................... 905 12.9.1 Error Recovery (Option) ......................................................................................905

12.9.1.1 DispenseTool-specific information.................................................................. 905

12.10 NEMO PUMP............................................................................................. 908 12.10.1 Overview ..............................................................................................................908 12.10.2 Limitations............................................................................................................908 12.10.3 Setting Up Process Axes ......................................................................................909 12.10.4 Setting Up DispenseTool Configuration ..............................................................911 12.10.5 Setting Up NEMO Pump Information..................................................................913 12.10.6 Setting Up Schedules............................................................................................915 12.10.7 NEMO Pump Status .............................................................................................917


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12.10.8 Resetting Pulse Coder Alarms..............................................................................918 12.10.9 Error Status Summary ..........................................................................................919

12.11 ISD GEAR METER.................................................................................... 921 12.11.1 OVERVIEW.........................................................................................................921 12.11.2 SETTING UP PROCESS AXES..........................................................................921 12.11.3 Setting up Dispense Configuration.......................................................................926 12.11.4 SETTING UP ISD I/O .........................................................................................927 12.11.5 SETTING UP EQUIPMENT INFORMATION ..................................................930 12.11.6 SETTING UP ISD INFORMATION...................................................................933 12.11.7 ISD TRANSDUCER FINE TUNING..................................................................934 12.11.8 ERROR STATUS SUMMARY...........................................................................939

Volume 2 of 2

APPENDIX

A SPOT I/O SEQUENCE ........................................................................947 A.1 SPOT I/O SEQUENCE .............................................................................. 948 A.2 SPOT MACRO........................................................................................... 952 A.3 WELD MODE............................................................................................. 954 A.4 MULTI APPLICATION ............................................................................... 956 A.5 APPLICATION STATUS............................................................................ 958 A.6 ALARM RECOVERY ................................................................................. 959 A.7 DISABLE FAULT CHECKING ................................................................... 963

B APPENDIX ..........................................................................................967 B.1 START MODE ........................................................................................... 968

B.1.1 Start Up Methods..................................................................................................968 B.1.2 Initial Start............................................................................................................969 B.1.3 Controlled Start ....................................................................................................970 B.1.4 Cold Start..............................................................................................................972 B.1.5 Hot Start ...............................................................................................................974

B.2 MASTERING ............................................................................................. 975 B.2.1 Jig Mastering ........................................................................................................977 B.2.2 Mastering at the Zero-degree Positions................................................................979 B.2.3 Quick Mastering ...................................................................................................981 B.2.4 Single Axis Mastering ..........................................................................................984 B.2.5 Setting Mastering Data .........................................................................................987


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B.3 SOFTWARE VERSION ............................................................................. 989 B.4 ROBOT AXIS STATUS.............................................................................. 992 B.5 DIAGNOSIS SCREEN............................................................................... 998

B.5.1 Outline ..................................................................................................................998 B.5.2 About Reducer Diagnosis.....................................................................................998 B.5.3 Procedure..............................................................................................................999 B.5.4 Each Item............................................................................................................1000

B.6 WORLD FRAME ORIGIN ........................................................................ 1004 B.7 I/O MODULE SETTING ........................................................................... 1005 B.8 SETTINGTHE FSSB LINE....................................................................... 1011

B.8.1 Definition of FSSB line......................................................................................1011 B.8.2 Setting 1 (FSSB line)..........................................................................................1012 B.8.3 Setting 2 (Number of total axes on FSSB line 1) ...............................................1012 B.8.4 Setting 3 (Hardware start axis) ...........................................................................1012 B.8.5 Setup Examples ..................................................................................................1013

B.8.5.1 Example 1 ...................................................................................................... 1013 B.8.5.2 Example 2 ...................................................................................................... 1014 B.8.5.3 Example 3 ...................................................................................................... 1015

B.9 POSITIONER SETUP.............................................................................. 1016 B.10 EXTENDED AXIS SETUP ....................................................................... 1022 B.11 INDEPENDENT ADDITIONAL AXIS BOARD (NOBOT) STARTUP

PROCEDURE.......................................................................................... 1028

C ALARM CODES ................................................................................1033 C.1 DESCRIPTION OF AN ALARM CODE TABLE ....................................... 1034 C.2 ALARM CODES....................................................................................... 1045

D SYSTEM VARIABLES ......................................................................1234 D.1 FORMAT OF A SYSTEM VARIABLE TABLE.......................................... 1235 D.2 SYSTEM VARIABLES ............................................................................. 1237

B-82594EN-4/01 1.INTRODUCTION

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1 INTRODUCTION This chapter explains the manual plan and the safety precautions that must be observed in working with the FANUC Robot. Contents of this chapter

1.1 MANUAL PLAN .........................................................................2 1.2 WORKERS...................................................................................5 1.3 GENERAL SAFETY PRECAUTIONS .......................................6 1.4 SAFETY PRECAUTIONS.........................................................11

1.INTRODUCTION B-82594EN-4/01

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1.1 MANUAL PLAN

About this manual FANUC Robot series (R-30iA CONTROLLER) Operators Manual. This manual describes how to operate the FANUC Robot, an all-purpose compact robot. It is controlled by the FANUC R-30iA controller (called the robot controller hereinafter) containing the FANUC Robot software. This manual describes the following items for manipulating workpieces with the robot: Setting the system for manipulating workpieces Operating the robot Creating and changing a program Executing a program Status indications Alarm codes and system variables

Using this manual Each chapter of the manual describes a single operation of the robot. The user can select and read chapters describing required operations. The user can understand all the information presented in this the manual in five or six hours if he or she reads it from cover to cover once.

Chapter 1 Introduction

Describes how to use this manual and the safety precautions that must be observed in working with the robot. All users must read the safety precautions.

Chapter 2 Overview

Gives a basic knowledge of the robot. It describes the basic configuration of the robot and the system for Robot.

Chapter 3 Setting the System for Robot

Describes the procedure for setting the system for Robot including input/output, coordinate system, and reference position.

Chapter 4 Program Structure

Describes the program structure and the syntax of program instructions.

Chapter 5 Creating a Program

Describes how to design, create, change, delete, and copy a program. It also describes the procedures for turning the power on and moving the robot by jog feed.

Chapter 6 Executing a Program

Describes how to execute and stop a program. It also describes the test operation, automatic operation, and recovery from the alarm state.

Chapter 7 Status Indications

Describes how to check the operating status of the robot, using the status indicator LEDs.

Chapter 8 File Input/Output

Describes how to store, read, and print a program file or system file.

Chapter 9 Utility

Describes additional utility functions, macro functions, program shift and mirror shift.

Chapter 10 Palletizing Function

Describes the setting and executing of palletizing function.

Chapter 11 FANUC iPendant Describes the FANUC iPendant.

Chapter 12 Dispense Tool

Describes the Dispense Tool function.

Appendix Describes lists of the menus, screens, program instructions and detail of program. Alarm Codes and System Variables

Lists the alarm codes and system variables.


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Identification For editions and order files of software, read the following sections:

Item to be checked Section Edition of your software B.3 Software Version Order No. of your software A.1 List of Menus

Specifications of products

For memory statuses or software option list, see the following sections:

Item to be checked Section Memory status 7.11 Memory Use Status Display Software option list A.1 List of Menus Menu displayed when an option is selected

A.1 List of Menus

Program instruction that can be used when an option is selected

A.3 List of Program Instructions

Related manuals

The following manuals are available:

OPERATORS MANUAL (This manual)

Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Functions, operations and the procedure foroperating the robot. Programming procedure, interface and alarm. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.

Robot controller

MAINTENANCE MANUAL

Topics: Installing and activating the system, connecting the mechanical unit to the peripheral device and maintenance the robot.

Mechanical unit

Operators/ Maintenance manual

Topics: Installing and activating the robot, connecting the mechanical unit to the controller, maintaining the robot. Use: Guide to installation, activation, connection, and maintenance.


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Notation This manual contains safety precautions against injury and property damage. Those precautions are labeled Warning or Caution, according to the degree of importance. Supplementary explanation is given under Note. Before starting to use a robot, carefully read the Warning, Caution, and Note.

WARNING Failure to follow the instruction given under Warning

can cause fatal or serious injury to the user. This information is indicated in bold type in a box so that it can be easily distinguished from the main body of this manual.

CAUTION

Failure to follow the instruction given under Caution can cause injury to the user or property damage. This information is indicated in a box so that it can be easily distinguished from the main body of this manual.

NOTE The information given under Note is a

supplementary explanation, which is neither a warning nor a caution.

Carefully read and save this manual.


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1.2 WORKERS A robot cannot do anything alone. The robot can operate only after it is equipped with a hand or other device and connected with peripheral equipment to form a system. Give considerations for the safety of not only the robot but also the entire system. When using the robot, provide a safety fence and other safety measures. FANUC defines the system personnel as indicated below. Check which worker should be trained in a specialist robot course.

Operator The jobs of an operator are: Turning on and off the system Starting and stopping programs of a robot Recovering the system from an alarm state The operator must not enter the area enclosed by the safety fence to do his or her work.

Programmer or teaching operator The jobs of the programmer or teaching operator include the jobs of the operator and the following: Teaching of a robot, adjustment of the peripheral equipment, and

other work that must be done in the area enclosed by the safety fence

The programmer or teaching operator should be trained in a specialist robot course.

Maintenance engineer The jobs of the maintenance engineer include the jobs of the programmer and the following: Repair and maintenance of the robot The maintenance engineer should be trained in a specialist robot course.


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1.3 GENERAL SAFETY PRECAUTIONS This section lists general safety precautions. Before starting to use the robot, read the precautions. The subsequent sections of the manual indicate other precautions. Take each of the precautions.

General rules WARNING

1 When the robot is used, the following precautions should be taken. Otherwise, the robot and peripheral equipment can be adversely affected, or workers can be severely injured. - Avoid using the robot in a flammable

environment. - Avoid using the robot in an explosive

environment. - Avoid using the robot in an environment full of

radiation. - Avoid using the robot under water or at high

humidities. - Avoid using the robot to carry a person or animal. - Avoid using the robot as a stepladder. (Never

climb up on or hang from the robot.) 2 Robot personnel must wear the following safety

articles: - Clothing suitable for each job - Safety shoes - Helmet

NOTE Programmers and maintenance staff should be

trained in a suitable course at FANUC.

Notes on installation

WARNING The robot should be transported and installed by

accurately following the procedures recommended by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers.

CAUTION

In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, the speed should be gradually increased to check the operation of the robot.


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Notes on operation

WARNING Before the robot is started, it should be checked that

no one is in the area of the safety fence. At the same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation.

CAUTION

Operators should be ungloved while manipulating the operators panel or teach pendant. Operation with gloved fingers could cause an operation error.

NOTE Programs, system variables, and other information

can be saved on memory card or floppy disks. Be sure to save the data periodically in case the data is lost in an accident. (See the file input/output section for saving the data.)

Notes on programming

WARNING Programming should be done outside the area of

the safety fence as far as possible. If programming needs to be done in the area of the safety fence, the programmer should take the following precautions: - Before entering the area of the safety fence,

ensure that there is no risk of dangerous situations in the area.

- Be prepared to press the emergency stop button whenever necessary.

- Robot motions should be made at low speeds. - Before starting programming, check the entire

system status to ensure that no remote instruction to the peripheral equipment or motion would be dangerous to the user.

CAUTION

After programming is completed, a text execution should be given according to a specified procedure. (See the section of program execution on this manual). During the text execution, workers must stay out of the safety fence.


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NOTE Programmers should be trained in a suitable course

at FANUC.

Notes on maintenance WARNING

1 During maintenance, the robot and system should be in the power-off state. If the robot or system is in the power-on state, a maintenance operation could cause a shock hazard. If necessary, a lock should be provided to prevent any other person from turning on the robot or system. If maintenance needs to be executed in the power-on state, the emergency stop button should be pressed.

2 When replacing a part, the maintenance worker should read the manuals for the controller and the mechanical unit and learn the replacement procedure beforehand. If a wrong procedure is followed, an accident may occur, causing damage to the robot and injury to the worker.

3 When entering the area enclosed by the safety fence, the maintenance worker should check the entire system to make sure that no dangerous situations are present. If the worker needs to enter the area of the fence while a dangerous situation exists, the worker should always take extreme care and check the current system status.

4 A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may cause a fire.

5 When a motor or brake is removed, the robot arm should be supported with a crane or other equipment beforehand so that the arm would not fall during the removal.

6 If a robot motion is necessary during maintenance, the following precautions should be taken: - Reserve an escape route. During the

maintenance, always check the motions of the whole system so that the escape route will not be blocked by the robot or peripheral equipment.

- Always pay attention to risk of dangerous situations and get prepared to press the emergency stop button whenever necessary.


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WARNING 7 When a motor, decelerator, or other heavy load is

handled, a crane or other equipment should be used to protect maintenance workers from excessive load. Otherwise, the maintenance workers would be severely injured.

CAUTION

1 Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent dangerous falls.

2 The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot would be adversely affected. In addition, a misstep can cause injury to the worker.

3 The following parts are heated. If a maintenance worker needs to touch such a part in the heated state, the worker should wear heat-resistant gloves or use other protective tools. - Servo motor - Inside the control unit

4 When a part is replaced, all bolts and other related components should put back into their original places. A careful check must be given to ensure that no components are missing or left unmounted.

5 Before the maintenance of the pneumatic system is started, the supply pressure should be shut off and the pressure in the piping should be reduced to zero.

6 After a part is replaced, a text execution should be given for the robot according to a predetermined method. (See the program execution of this manual.) During the text execution, the maintenance staff should work outside the safety fence.

7 After the maintenance is completed, spilled oil or water and metal chips should be removed from the floor around the robot and within the safety fence.

8 When a part is replaced, care must be taken to prevent dust from entering the robot.


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NOTE 1 Each maintenance worker or inspection worker

should be trained in a suitable course at FANUC. 2 Maintenance should be done under suitable light.

Care must be taken that the light would not cause any danger.

3 The robot should be periodically inspected. (Refer to the manual for the controller or the mechanical unit.) A failure to do the periodical inspection can adversely affect the performance or service life of the robot and also may cause an accident.


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1.4 SAFETY PRECAUTIONS

Safety precautions Unlike ordinary automatic machines, robots have arms and wrists which can be moved in all operation space. A robot is quite flexible, but on the other hand, it is quite dangerous. The robot is usually connected with peripheral equipment to comprise an automated system. Users must take safety precautions for the entire system. The safety precautions are described below.

Safety precautions related to installation and layout Use warning lamps and other provisions to indicate that the robot

is operating.

Fig. 1.4 (a) Alarm Indications

Put a protective fence with safety door around the system so that

only the operator can enter the operating area by the door. Design the system so that it will stop when the door is opened.

NOTE 1 Connect the *FENCE input signal to the safety door.

Refer to the maintenance manual for explanations about how to connect.

2 When the *SFSPD (safety speed) input signal is turned off, the control unit halts the robot.

Put a protective fence so that the motion range of the robot is

surrounded completely. Moreover, put the controller outside of the protective fence.


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Fig. 1.4 (b) Safety fence

Install an emergency stop button where it will be readily

accessible to the operator.

NOTE Upon receiving an emergency stop signal, the

controller immediately stops the robot.

Fig. 1.4 (c) Safety Plug

Safety precautions related to system design

Install a safety joint between robot wrists. If an abnormal external force is applied to the robot, the safety joint breaks and the robot stops.

NOTE When the hand break (*HBK) input signal goes off,

the controller immediately stops the robot. Hand breakage detection can be disabled when the *HBK input

signal is off. This can be set on the system setting screen. See the section of the system config menu.

Ground all peripheral units properly.


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When a desired operating area is smaller than the maximum operating area of the robot, the desired area can be specified by parameters.

The robot receives interlock signals sent from remote equipment. Upon receiving a signal indicating the operating status of the remote equipment, the robot can stop or halt.

When required, install a lock so that only authorized personnel can switch the power on.

NOTE The circuit breaker on the control unit door is

designed such that power-on can be disabled by setting a padlock.

Fig. 1.4 (d) Locking the Circuit Breaker

Safety precautions related to inspection and maintenance

Before starting the inspection or maintenance, turn off the controller. Lock the circuit breaker or place a guard to prevent someone else from switching the power on.

Before disconnecting the pneumatic system, release the supply pressure.

Before starting an inspection in which the electrical system of the robot need not be operated, press the emergency stop button.

When carrying out an inspection in which the robot needs to be operated, carefully observe the motion of the robot. Immediately press the emergency stop button whenever required.

Fig. 1.4 (e) Emergency Stop Button


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Safety precautions related to transportation When carrying the robot or another unit on a carrier such as a

crane or fork lift, securely fasten the robot to the carrier. Carefully inspect the crane, fork lift, other carrying equipment,

and carrying handle on the product.

Fig. 1.4 (f) Carrying the Robot

Safety precautions related to operation

All robot system operators are requested to attend FANUC training courses to learn the safety precautions and functions of the robot.

Before beginning to program the robot, make sure that there are no abnormal or dangerous conditions around the robot and peripheral equipment.

Before working within the operating area of the robot, even when the robot is not running, switch the power off or press the emergency stop button. Place a guard to prevent someone else from entering the operating area of the robot or activating the robot from the operators panel.

While programming the robot in its operating area, place a guard so that the robot can be immediately stopped in an emergency.

Fig. 1.4 (g) Danger Monitoring by Two Persons


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Table 1.4 Safety precautions item Operator Workshop Transportation and installation

Avoid dangerous behavior. Wear working clothes, safety shoes, and a safety helmet.

Keep the workshop neat, tidy, and clean. Install a protective fence and warning indications. Provide ventilation. Never bring flammable material to the workshop.

Keep the transportation lane free from obstacles. When carrying the robot or another unit on a carrier such as a fork lift or crane, securely fasten it to the carrier. Keep a sufficient operating area. Make connection s properly.

Operation Maintenance and inspection Hand Attend training classes. Master the operating procedures. Exclude unauthorized personnel.

Use only FANUC products for repair. Before starting maintenance or inspection, turn the power off. Close the controller door.

Inspect and take care of cables. Check the pneumatic pressure. Inspect the hand mechanism.

Fig. 1.4 (h) Safety Clothes and Safety Helmet

Before approaching the robot to program it, hold the teach pendant

in your hand, press the deadman switch, and set the teach pendant enable switch on.

NOTE If the deadman switch is released while the teach

pendant enable switch is on, the robot immediately stops.

Fig. 1.4 (i) Deadman switch and Teach pendant enable switch


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Before moving the robot by jog feed, carefully observe the operation of the jog keys and the robot.

Before moving the robot by jog feed, sufficiently lower the feedrate override of the robot.

B-82594EN-4/01 2.OVERVIEW

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2 OVERVIEW This chapter shows the basic configuration of the FANUC Robot System and briefly describes the functions of each component. Contents of this chapter

2.1 APPLICATION TOOL SOFTWARE........................................19 2.2 ROBOT.......................................................................................21 2.3 CONTROLLER..........................................................................22

2.OVERVIEW B-82594EN-4/01

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A FANUC robot system consists of the tool software for manipulating workpieces, the mechanical unit of the robot itself (FANUC Robot series), and the Robot control unit. The FANUC robot offers outstanding performance when handling or welding.

Tool software for application The tool software for application is a software package for all kinds of Robots manipulations installed on the Robot control unit. Any work can be performed by specifying menus and instructions from the teach pendant. The tool software for manipulating workpieces contains instructions for controlling the robot, hands, remote control units, and other peripheral devices. The I/O between an additional axis or control unit and another peripheral device can be controlled. Other peripheral devices include cell controllers or sensors.

Robot Robot has a hand or another end effector interface for control to do work. The FANUC robot is ideal for manipulating workpieces.

Controller The Robot control unit supplies power to drive the mechanical unit. The tool software for manipulating workpieces is installed on the Robot control unit to control the teach pendant, operators panel, and external peripheral devices. Peripheral devices, including remote control units, are required to configure a system for manipulating workpieces. The remote control units are used to control the Robot control unit. The hands, sensors, and other devices are operated using I/O and

serial communication units. Fig. 2 shows a typical robot system for manipulating workpieces. The system consists of a robot, the Robot control unit, and peripheral devices.

Fig. 2 Assembly system for car doors


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2.1 APPLICATION TOOL SOFTWARE The Application tool software has been specially designed to perform manipulating workpieces operations. The Application tool software is contained in the Robot and enables the following: Setting up the system for Robot applications Creating a program Performing the test operation of a program Performing the automatic operation Status display or monitoring When optional functions are incorporated, the system can be expanded and the management functions can be enhanced.

2.1.1 System Setting The Application tool software has an interface for specifying parameters of operation of the manipulation system. (For how to set the Robot system, see Chapter 3.) With the Application tool software, the Handling remote controller, and other external units can be controlled. Before the manipulation is started, the following must be specified: input from and output to the hand and other peripheral units, the coordinate system, communication, and automatic operation.

2.1.2 Jog Feed of the Robot Jog feed of the robot is the operation of moving the robot as desired by manually entering commands on the teach pendant. When a motion instruction of a program is executed, the robot is moved to the target position by jog feed, then the position is recorded. (For the jog feed of the robot, see Subsection 5.2.3.)

2.1.3 Program A program contains motion instructions, input/output instructions, register instructions, and branch instructions. (For the program structure, see Chapter 4.) Each instruction is assigned a statement number. The target work is accomplished by sequentially executing the instructions. The Spot teach pendant is used to create or correct a program. (For creation of a program, see Chapter 5.) The program contains the following instructions. Fig. 2.1.3 shows a basic program for manipulating workpieces. Motion instruction: Moves the tool to the target position within the operating range. Additional motion instruction: Performs an additional (special) operation during a motion. Register instruction: Places (loads) numerical data into a register.


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Position register instruction: Places (loads) position data into a register. Input/output instruction: Sends or receives a signal to or from a peripheral unit. Branch instruction: Changes the flow of a program. Wait instruction: Holds execution of the program until the specified conditions are

satisfied. Routine call instruction: Calls and executes a subprogram. Macro instruction: Calls a specified program and executes it. Palletizing instruction: Palletizes workpieces. Program end instruction: Terminates execution of a program. Comment instruction: Adds a comment to a program. Other instructions

Fig. 2.1.3 Robot Program

2.1.4 Test Operation (Test Execution)

After the system is set and a program is created, perform the test operation in the test execution mode to check the program for normal operation. (For the test operation, see Section 6.3.) The test execution of the program is one of the important steps in creating a good program. Before starting automatic operation, execute the test program.

2.1.5 Automatic Operation (Operation Execution) Automatic operation (operation execution) is the final step in executing programs. In automatic operation, the following processing is executed: Specified programs are started one after another. (For automatic

operation, see Sections 3.8 and 6.6.) During automatic operation, position data can be corrected (online

position correction Section 6.7). The processing is halted, then aborted or resumed. (For halting a

program, see Section 6.1.)


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2.2 ROBOT A robot is a mechanical unit consisting of axes and arms driven by servo motors. A place at which arms are connected is a joint, or an axis. J1, J2, and J3 are main axes. The basic configuration of the robot depends on whether each main axis functions as a linear axis or rotation axis. The wrist axes are used to move an end effecter (tool) mounted on the wrist flange. The wrist itself can be rotated about one wrist axis and the end effector rotated about the other wrist axis.

Fig. 2.2 (a) Main axes and wrist axes

Fig. 2.2 (b) Hand with Fingers

Fig. 2.2 (c) Hand with Suction Cups and No Fingers


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2.3 CONTROLLER Robot controller includes a power unit, user interface circuit, motion controlling circuit, memory circuit, and input/output circuit. The user should use a teach pendant and operator's box to operate the control unit. The operation control circuit controls the servo amplifier which moves all the robot axes, including any additional axes, via the main CPU printed circuit board. The memory circuit can store programs and data set by the user in the C-MOS RAM on the main CPU printed circu

Documents

R-30iA DispenseTool Operator Manual