Intelitek SCORBOT-ER 9 User Manual

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SCORBOT-ER 9

User Manual

Catalog #100066 Rev. B

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Page 1 SCORBOT-ER 9 User Manual Catalog #100066 Rev. B...
Page 3 Every effort has been made to make this book as complete and accurate as possible. However, no warranty of suitability, purpose, or fitness is made or implied. Intelitek is not liable or responsible to any person or entity for loss or damage in connection with or stemming from the use of the software, hardware and/or the information contained in this publication.
Page 5 Table of Contents Unpacking and Handling CHAPTER 1 Unpacking the Robot ..... 1-1 Handling Instructions ..... 1-2 Acceptance Inspection .
Page 6 Position and Limit Devices CHAPTER 7 Encoders ......7-1 Encoder Resolution ....7-3 End of Travel (Limit) Switches .
Page 7: Unpacking The Robot
CHAPTER Unpacking and Handling This chapter contains important instructions for unpacking and inspecting the robot arm. SCORBOT-ER IX Read this chapter carefully before you unpack the robot and SCORBOT-ER IX controller. Unpacking the Robot The robot is packed in expanded foam, as shown in Figure 1-1. To protect the robot during shipment, a metal plate holds the gripper- mounting flange to the robot base.
Page 8: Handling Instructions
Handling Instructions The robot arm weighs 38 kilos (83 pounds). Two people are needed to lift or move it. Lift and carry the robot arm by grasping its body and/or base. Do not lift or carry the robot arm by its upper arm or forearm. Acceptance Inspection After removing the robot arm from the shipping carton, examine it for signs of shipping damage.
Page 9: Repacking For Shipment
Repacking for Shipment Be sure all parts are back in place before packing the robot. When repacking the robot for shipping, bolt the flange and base to the metal plate. Failure to do so may result in irreversible damage to the arm, particularly to the Harmonic Drive transmissions.
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Page 11: Structure
CHAPTER Specifications The following table gives the specifications of the robot arm. SCORBOT-ER IX Robot Arm Specifications Mechanical Structure Vertical articulated, enclosed casting Number of Axes 5 plus gripper Axis Movement Axis Range Effective Speed Axis 1: Base rotation 270° 79°/sec 112°/sec Axis 2: Shoulder rotation 145°...
Page 12 Structure is a vertical articulated robot, with five revolute joints. With SCORBOT-ER IX gripper attached, the robot has six degrees of freedom. This design permits the end effector to be positioned and oriented arbitrarily within a large work space. Figures 2-1 and 2-2 identify the joints and links of the mechanical arm. Each joint is driven by a permanent magnet DC motor via a Harmonic Drive gear transmission and timing belt.
Page 13: Work Envelope
Work Envelope The length of the links and the degree of rotation of the joints determine the robot’s work envelope. Figure 2-3 shows the dimensions and reach of the , while Figure 2-4 gives a top view of the robot’s work envelope. SCORBOT-ER IX The base of the robot is normally fixed to a stationary work surface.
Page 14 Figure 2-4: Operating Range (Top View) SCORBOT-ER IX 2 - 4 User’s Manual 9603...
Page 15: Precautions
CHAPTER Safety is a potentially dangerous machine. Safety during operation SCORBOT-ER IX is of the utmost importance. Use extreme caution when working with the robot. Precautions The following chapters of this manual provide complete details for proper installation and operation of the .
Page 16: Warnings
Warnings Do not operate the until you have thoroughly studied both this SCORBOT-ER IX User’s Manual and the Controller-B User’s Manual. Be sure you follow the safety guidelines outlined for both the robot and the controller. Do not install or operate the under any of the following conditions: SCORBOT-ER IX •...
Page 17: Preparations
CHAPTER Installation Preparations Before you make any cable connections, set up the system components according to the following “ Preparation” instructions. Controller and Computer/Terminal Setup Place the controller and computer at a safe distance from the robot—well outside the robot’s safety range. Make sure the setup complies with the guidelines defined in the chapter, “...
Page 18 Make sure the robot is securely bolted in place. Otherwise the robot could become unbalanced and topple over while in motion. Grasp the robot body and turn the robot to each extreme of its base axis. Make sure the segment of cable from the body to the base is not obstructed, and/or cannot become caught under a corner of the robot’s...
Page 19: Scorbot-Er Ix Installation
SCORBOT-ER IX Installation Controller Installation Perform the installation procedures detailed in the following sections of Chapter 2, “ Installation,” in the Controller-B User’s Manual: Computer/Terminal–Controller Installation • • Power On Controller Configuration • When the Peripheral Setup screen appears at the end of the controller configuration, select Gripper Connection: None.
Page 20: Homing The Robot
Note: When disconnecting the robot from the controller, do it in the reverse order; that • Disconnect the 19-pin round Robot Power connector. • Disconnect the 37-pin Encoders connector. • Disconnect the ground wires. Homing the Robot After you have completed the robot installation, execute the robot’s Home routine, as described below.
Page 21: Gripper Installation
Gripper Installation The gripper is attached to the flange at the end of the robot arm whose layout is shown in Figure 4-5. Pneumatic Gripper The pneumatic gripper, shown in Figure 4-6, is controlled by a 5/2 solenoid pneumatic valve which is activated by one of the controller’s relay outputs.
Page 22 Attach the valve to the controller or any other metalic surface by means of the valve’s magnetic base. Figure 4-8: Pneumatic Solenoid Valve Figure 4-7: Figure 4-9: Valve— Controller Connections Gripper Connectors SCORBOT-ER IX 4 - 6 User’s Manual 9603...
Page 23: Dc Servo Gripper
DC Servo Gripper The electric DC servo gripper is shown in the inset in Figure 4-10. The robot must be homed before you mount the gripper. Refer to Figures 4-10 and 4-11. Using a 3 mm hex wrench and four M4x10 socket screws, attach the gripper to the gripper mounting flange at the end of the robot arm.
Page 24: Activating The Gripper
Figure 4-11: Connecting Gripper to SCORBOT-ER IX Activating the Gripper Activate ATS. Press <Ctrl>+F3 to activate the Peripheral Setup screen. Change the robot gripper definition according to the gripper you have installed. Refer to the section, “ Peripheral Devices and Equipment--Robot Gripper,” in Chapter 2 of the Controller-B User’s Manual.
Page 25 CHAPTER Operating Methods The SCORBOT-ER IX robot can be programmed and operated in a number of ways. Controller-B User’s Manual includes two chapters which guide you through the basic commands for operating and programming the robot. Software ACL, Advanced Control Language, is an advanced, multi-tasking robotic programming language developed by Eshed Robotec.
Page 26: Acloff-Line
ATS features include the following: Short-form controller configuration. Definition of peripheral devices. Short-cut keys for command entry. Program editor. Backup manager. Print manager. The ATS Reference Guide for Controller-B is a complete guide to ATS. ACLoff-line ACLoff-line is a preprocessor software utility, which lets you access and use your own text editor to create and edit ACL programs even when the controller is not connected or not communicating with your computer.
Page 27 CHAPTER Drive System The three main elements of the drive system are shown in Figure SCORBOT-ER IX 6-1: • DC electrical motor • Harmonic Drive gear • Timing belt and pulleys Figure 6-1 shows the drive system for axes 1 through 4 of the SCORBOT ER-IX The roll axis (axis 5) transmission does not contain the pulleys and timing belt;...
Page 28: Motors
Motors robot arm is driven by DC electric motors. These actuators SCORBOT-ER IX converts signals from the controller (electric power) into rotations of the motor shaft (mechanical power). A robot arm such as the imposes severe requirements on the SCORBOT-ER IX actuators, such as the following: •...
Page 29: Dc Motor Structure
DC Motor Structure The principles of operation of electrical motors in general, and DC motors in particular, are based on an electrical current flowing through a conductor situated within a magnetic field. This situation creates a force which acts on the conductor. Figure 6-3 shows the basic structure and components of a DC motor comparable to the structure of the motors used in the .
Page 30: Scorbot-Er Ix Motors
SCORBOT-ER IX Motors uses permanent magnet DC motors to drive the axes. SCORBOT ER-IX Axes 1, 2 and 3 of the are powered by the motor shown in SCORBOT ER-IX Figure 6-4. Axes 4 and 5 are powered by the motor shown in Figure 6-5. These motors are able to move at extremely high rates of revolution, to move loads with high torques, and (with encoder attached) to achieve a very high resolution.
Page 31: Harmonic Drive Gears
Harmonic Drive Gears The Harmonic Drive transmission used in the , shown in Figure SCORBOT-ER IX 6-6, offers a very high gear ratio. The Harmonic Drive gears used in the have four main SCORBOT-ER IX components: • Circular spline: a solid steel ring, with internal gear teeth, usually fixed to the robot link. •...
Page 32: Harmonic Drive Gear Ratios
Harmonic Drive Gear Ratios As in all gears, the gear ratio of the Harmonic Drive is the ratio of the input speed to the output speed. If the number of teeth on the flexspline is N , then for every revolution of the input shaft, the output shaft rotates by 2/N of a revolution (that is, two teeth out of N...
Page 33: Axis Gear Ratios
Axis Gear Ratios Referring again to Figure 6-1, the transmission of axes 1 through 4 consists of two stages: the timing belt drive, and the Harmonic Drive. The overall gear ratio of the output shaft which moves the axis is therefore expressed as: ×...
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Page 35: Encoders
CHAPTER Position and Limit Devices This chapter describes the various elements in the which play a SCORBOT-ER IX part in the positioning of the robot arm and the limiting of its motion. • Encoders • End of Travel Switches • Hard Stops •...
Page 36 As the encoder disk rotates between the emitter and detectors, the light beam is interrupted by the pattern of “ bars” and “ windows” on the disk, resulting in a series of pulses received by the detectors. encoders have SCORBOT-ER IX 512 slots, as shown in Figure 7-2.
Page 37: Encoder Resolution
Encoder Resolution From the quadrature signal the controller measures four counts SCORBOT-ER IX for each encoder slot, thus quadrupling the effective resolution of the encoder. The resolution of the encoder is expressed as: 360° Where: is the resolution of the encoder. n is the number of counts per encoder revolution.
Page 38: End Of Travel (Limit) Switches
End of Travel (Limit) Switches uses limit switches to prevent the joints from moving SCORBOT-ER IX beyond their functional limits. When a control error fails to stop the axis at the end of its working range, the limit switch serves to halt its movement. The switch is part of an electric circuit within the robot arm, independent of the robot controller.
Page 39: Hard Stops
As shown in Figure 7-7A, when limit switch 1 is activated (that is, when the button is depressed), the relay contact opens and the relay is deenergized. The motor cannot move the joint beyond this point. The diode allows the motor to reverse direction, thus permitting the joint to move away from the limit switch.
Page 40: Home Switches
Home Switches uses an optical home switch on each axis to identify the SCORBOT-ER IX fixed reference, or home, position. The home switch is mounted on the same disk as the end of travel switches, and a “ flag” is attached to the Harmonic Drive output shaft, as shown in Figure 7-8. During the homing procedure, the robot joints are moved, one at a time.
Page 41 CHAPTER Wiring Figure 9-1 is a schematic diagram of the cable connections. SCORBOT-ER IX Figure 8-1: SCORBOT-ER IX Cabling The wire braid which connects the robot to the controller contains a power (robot) cable and an encoder cable. The body, upper arm and forearm links each contain a printed circuit board (PCB).
Page 42: Robot (Power) Cable And Connector
Robot (Power) Cable and Connector Figure 8-2 shows the Burndy 19 pin male connector that joins the power cable to the controller’s back panel. The robot cable contains 12 leads. The following table details the connector pin functions and cable wiring.
Page 43: Encoder Cable And Connector
Encoder Cable and Connector The encoder cable, which connects the controller to the motor encoders and optical home switches, contains 36 leads. Figure 8-3 shows the D37 female connector that joins the encoder cable to the controller’s back panel. The following table details the connector pin functions and describes the cable wiring.
Page 44 Encoder Cable and D37 Connector Pin Description Telephone Pin Description Axis Robot Side (J1) Cable Color Controller Side (J2) COMMON yellow COMMON 3 CHA4 (Encoder Pulse A) green CHA 3 CHB4 (Encoder Pulse B) white CHB 3 CHC4 (Encoder Index Pulse) black CHC 3 MSWITCH (Home Switch)
Page 45: Daily Operation
CHAPTER Maintenance The maintenance and inspection procedures recommended below will ensure the best possible performance of the robot over an extended period. Daily Operation At the start of each working session, check the robot and controller, in the following order: Before you power on the system, check the following items: •...
Page 46: Periodic Inspection
Periodic Inspection The following inspections should be performed regularly: • Check robot mounting bolts for looseness using a wrench. Retighten as needed. • Check all visible bolts and screws for looseness using a wrench and screwdriver. Retighten as needed. • Check cables.
Page 47 Controller’s MOTORS switch does not turn on; the green LED does not light. • Make sure the Emergency button is released. • Turn off the controller, disconnect it from the power source, and open the cover. Check the 0.5A (SB) fuse (marked FAN/POWER/RELAYS) Controller functioning, but the robot cannot be activated.
Page 48 LABEL 1 PRINTLN HS[ n ] DELAY 20 GOTO 1 If the value of HS does not change, possible causes: Faulty arm circuitry. Faulty optical switch; optical switch not properly mounted. Faulty driver circuitry Problem in controller power supply unit +5V1. One of the axes does not function.
Page 49 Errors in the repeatability of the robot. • Try to identify the faulty axis. If many or all axes are faulty, look for an electrical noise source in your environment. • Check the controller’s ground and the robot’s ground connection to the safety ground terminal at the back of the controller.
Page 50: Messages
Pneumatic gripper does not respond. • Check that all air hoses are connected properly. • Make sure the gripper is connected to the proper controller output. • Check the relay output to which the gripper is connected. Check whether the relays have been switched (LED is lit): In output OFF, NC is shorted to COM, NO is disconnected from COM.
Page 51 *** IMPACT PROTECTION axis n The controller has detected a position error which is too large. The system aborted all movements of that axis group, and disabled all axes of that group. The user routine CRASH, if it exists, has been executed. Possible causes: (1) An obstacle prevented the movement of the arm.
Page 52 *** OUT OF RANGE axis n An attempt was made to record a position (HERE, HEREC, etc. ) while the robot arm was out of its working envelope. Manually move the arm to a location within its working envelope. Then repeat the command.
Page 53 *** TRAJECTORY ERROR ! During movement, the robot arm reached its envelope limits, and the system aborted the movement. This may occur when executing the following types of movements: linear (MOVEL), circular (MOVEC) , MOVES, and SPLINE. Since the trajectory is not computed prior to motion, the movement may exceed the limits of the working envelope.