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ready robotics Forge/CTRL User Manual

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Summary of Contents for ready robotics Forge/CTRL

  • Page 2: Safety And Risk Assessment

    With this system, your business has the tools to enter a world of more efficient and more precise manufacturing processes. This user manual, along with the included “Quick Reference Guide” and “Risk Assessment Procedure,” will get you on the path to setting up your Forge/CTRL as soon as possible.
  • Page 3 Forge/CTRL User Manual Table of Contents Safety and Precautions Overview General safety Robot safety Electrical safety Pneumatic safety Introduction to the Forge/CTRL Overview Choosing the right task Overview of your system TeachMate Primary axes Hardware Set Up Overview Connecting power and air...

  • Page 4: Safety And Precautions

    Safety and Precautions Overview The Forge/CTRL system connects to a variety of robotic arms and devices. Although some robot arms are collaborative and designed to be used in proximity to people, there are still safety considerations that come with working with any system that uses electric and air power for high-speed handling of parts.

  • Page 5: Robot Safety

    A risk assessment must be performed for all collaborative applications. • The Forge/CTRL system is designed to connect to a variety of robot arms. Some robot arms are human-safe and designed to enter a protective stop when they contact any object, including a person. Whether the arm is collaborative or not, there are some guidelines that should be considered when working with a robot arm.
  • Page 6 Forge/CTRL User Manual Safety modes - continued Emergency stop The robot arm enters an emergency stop when either an emergency stop button is pressed or when a high-speed collision occurs. When in an emergency stop: The robot arm applies internal brakes to ensure rigidity.
  • Page 7 Forge/CTRL User Manual Safety modes – continued Safeguard stop The robot arm enters a safeguard stop when a connected safety device detects a condition that that causes the robot arm to stop to prevent harm or injury and maintain a safe work environment. Safeguard stops can be triggered by a person or object entering the work area or coming within a defined distance of the system.

  • Page 8: Electrical Safety

    Do not open the Forge system’s enclosure to attempt maintenance on any electrical system within. • • Only use cables provided by READY Robotics that are in good condition and do not show signs of wear. • Unplug the Forge/CTRL system in these situations: During electrical storms or power outages.

  • Page 9: Introduction To The Forge/Ctrl

    Choosing the right task The best way to learn the capabilities of your Forge/CTRL system is to work with it yourself! Try various tasks at different machines and with different end effectors, parts, and devices. If there’s a task you believe your system can handle but you don’t have the tools for it, reach out to READY Robotics to discuss expanding the capability of...

  • Page 10: Overview Of Your System

    Forge/CTRL User Manual Overview of your system Your system is comprised of three major pieces of the Forge/CTRL system. Each piece plays an important role in helping you create a task for your system to complete. Piece Description Forge/CTRL The system that connects Forge/OS and you to the robot arm. Forge/CTRL also acts as the hub to provide power and air to the TeachMate and attached devices.

  • Page 11: Forge/Ctrl Left Side

    Overview of your system – continued Forge/CTRL left side The following labels the main interaction points of the left side of the Forge/CTRL system. Forge/CTRL right side The following labels the main interaction points of the left side of the Forge/CTRL system.

  • Page 12: Teachmate Mode Indicator

    See the “TeachMate button control” section of this chapter for more information on the TeachMate’s button functionality. TeachMate mode indicator The TeachMate LEDs indicate the current operating mode of the Forge/CTRL system. Use this table for information on the status: Color...
  • Page 13 Safeguard stop can be triggered by a person or object entering the work area or coming within a defined distance of the system. When the system encounters a safeguard stop, clear the condition to return the system to active mode. Introduction to the Forge/CTRL Version 2.0...
  • Page 14 When a warning happens, follow the instructions in Forge/OS to resolve the condition and return the Forge/CTRL system to active mode. Error The robot arm is rigid, and tasks cannot be executed. The margins in Forge/OS are white and display “Robot Error”.

  • Page 15: Teachmate Button Control

    Toggle the end effector state. On the first press, the TeachMate LED effector will blink yellow; on the second press, the end effector state changes. Press any other button after the first press to cancel the gripper state change. Introduction to the Forge/CTRL Version 2.0...

  • Page 16: Rapid Teach

    Open Gripper block is placed. For more information on Blend, Pattern, waypoints, and Tool blocks, see sections “Robot Moves” and “Tools” of the “Blocks” chapter for more information. Introduction to the Forge/CTRL Version 2.0...

  • Page 17: Hardware Setup

    The power and compressed air inlets are located on the left side of the system. Power The main power cable for the Forge/CTRL system must be attached to AC power for the system to turn on and operate. Compressed air The compressed air connection takes a standard 1/4-inch industrial quick coupler.

  • Page 18: Starting The System

    Power on the Forge/CTRL The Power Disconnect switch, on the left side of the Forge/CTRL provides the system with power. It does not start up the system. Once the Power Disconnect is on and power is available, pressing the Power button starts up the system.

  • Page 19: Startup The System

    End effectors attach to the robot arm by securing the end effector’s tool flange to the wrist flange. The wrist flange at the end of the robot arm is designed to interface with a variety of end effectors provided by READY Robotics.

  • Page 20: Attach An End Effector To The Arm

    Forge/CTRL User Manual Attach an end effector to the arm Follow these steps to attach an end effector to the end of the robot arm. Step Action Release the locking bolt. Pulling button out on the end of the locking lever.

  • Page 21: Attaching Devices To The Air And Plc Modules

    Attaching devices to the air and PLC modules The air and programmable logic controller (PLC) modules are located on the right side of the Forge/CTRL system. Your Forge/CTRL system comes preconfigured with modules depending on your task needs. The air modules take a standard 1/4-inch industrial quick coupler.

  • Page 22: Connect To A Camera

    Forge/CTRL User Manual Connect to a Camera Overview Integrating a camera into your task can increase the flexibility of your system. The camera acts as the eyes of the robot arm. Without the camera, you program the location of each workpiece the robot arm interacts with. The result is manually programming several blocks and waypoints.

  • Page 23: Network Settings

    Forge/CTRL User Manual Network settings Use these network settings when setting up the camera. These settings will allow the camera to send information to Forge/OS. In the camera’s software settings: Network Setting Value Communication TCP/IP DHCP Disabled Static IP 172.16.255.254 Server Host 172.16.255.250...

  • Page 24: Setup The Camera In Forge/Os

    Forge/CTRL User Manual Setup the camera in Forge/OS Follow these steps to begin the camera setup process in Forge/OS. Step Action Access System Loadout in Forge/OS. Select Devices => Camera. If your camera requires a calibration grid, place the calibration grid on the work surface.

  • Page 25: Define The Frame

    Forge/CTRL User Manual Define the frame To define the frame, establish two axes from three points, the origin point and two points extending out from the origin point. Things to consider while defining the frame: • Begin the process by snapping the end effector to the Z axis of the stand frame.

  • Page 26: Troubleshooting And Technical Support

    Nobody’s perfect, and the Forge system is no exception. If you’re having issues getting the system to work as expected, this section should provide some guidance on troubleshooting. If there isn’t a fix for your issue in the manual, please contact READY Robotics via email or phone. Issue...
  • Page 27 Forge/CTRL User Manual Troubleshooting - continued Issue Cause Solution Air not attached to Check that the air hose is attached to the stand and that air is Forge system flowing. Verify that the lockout valve is pulled up and air is not leaving through the valve.
  • Page 28 Forge/CTRL User Manual Troubleshooting - continued Issue Cause Solution Force sensor is not Verify that the force sensor is firmly and fully attached to the plugged in TeachMate. If needed, use pliers or a small wrench to tighten the wire cap against the TeachMate.

  • Page 29: Technical Support

    If the troubleshooting information doesn’t address your Forge system’s bug, reach out to us with the Report Issue feature via the READY menu in the lower left corner. READY Robotics recommends using the Report Issue feature before contacting technical support, as the issue report will help us pinpoint the problem in your system and significantly reduce the time to troubleshoot.
  • Page 30 Forge/CTRL User Manual Technical Specifications for the Forge/CTRL System technical specifications The follow section includes any technical specifications that may help setup your Forge system. If you have questions that aren’t answered by the information in this section, please reach out to us right away.

  • Page 31: Force Sensor Threshold Values

    +Z in a jog block with an end effector that is calibrated from the Setup Tool screen. Solid line values are tested, dotted line are extrapolated. Applied Force in +Z (lbs) by Threshold y = 1.4344x + 2.8864 Force Threshold Technical Specifications for the Forge/CTRL Version 2.0...

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