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BLUE DANUBE ROBOTICS AIRSKIN Operating Manual

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SAFETYFLANGE
OPERATING MANUAL
- 6-
(v . )
English
[Translation]

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Summary of Contents for BLUE DANUBE ROBOTICS AIRSKIN

  • Page 1 SAFETYFLANGE OPERATING MANUAL - 6- (v . ) English [Translation]...
  • Page 2 Blue Danube Robotics GmbH Donau-City-Strasse Vienna, Austria sales@bluedanuberobotics.com www.bluedanuberobotics.com...

  • Page 3: Table Of Contents

    AIRSKIN® Connection Box ........
  • Page 4 Stopping and switching off AIRSKIN® ........

  • Page 5: General

    The AIRSKIN® Safety ange is a safe ange adapter with an active sensor element for human-robot collaboration. The AIRSKIN® Safety ange monitors the displacement of a tool or workpiece in x, y and z directions as well as torsion around the z-axis. If a tool or workpiece that is attached to the AIRSKIN® Safety ange collides with an obstacle, the ange adapter is de ected against the sensor element and a safe stop signal is sent to the robot controller.

  • Page 6: Scope Of Delivery

    Scope of delivery Please check that the consignment you have received is complete and undamaged. The AIRSKIN® Safety ange comprises the following components: Fig. . : Exploded view of the AIRSKIN® Safety ange. When delivered, the AIRSKIN® Safety ange is precon gured with Spring (for 2.5 - 5 kg payload).
  • Page 7 AS-SF -TF_ - -M6 (assembly pattern as speci ed by ISO - -M6) countersunk screw DIN Each AIRSKIN® Safety ange is additionally supplied with the following components: • AIRSKIN® Connection Box (see Section . . • External cables • Manual Risk of suffocation for children! Keep packaging lms out of the reach of children.

  • Page 8: Safety Instructions

    Safety instructions The following essential safety instructions must in all circumstances be adhered to when the AIRSKIN® Safety ange is used. Please carefully read through the following safety instructions and information concerning safe operation. Familiarize yourself with all the functions of the AIRSKIN® Safety ange. You should only transfer the AIRSKIN®...

  • Page 9: Hazard Warnings

    • Endangering of persons due to improper commissioning of the AIRSKIN® Safety ange (the AIRSKIN® Safety ange has been attached to the robot, but has not been in- stalled as a safety system. This may engender a false sense of safety for other people.).

  • Page 10: Safety Instructions For Operators

    The AIRSKIN® Safety ange is conceived as collision and crushing protection for tools and workpieces on robots and machines. In order to guarantee the safety of the machine that is equipped with the AIRSKIN® Safety ange, one must comply with the Machinery Directive and ISO/TS 66 as well as the operating instructions.

  • Page 11: Speci C Life Cycles Of The Airskin® Safety Ange

    A visual inspection of the AIRSKIN® Safety ange should be conducted at least once a month in order to identify any early signs of damage, plastic deformation or other changes. In the case of plastic deformation (e.g. due to mechanical wear &...

  • Page 12: Description Of The Airskin® Safety Ange

    . Functionality The AIRSKIN® Safety ange is a collision sensor for end effectors such as grippers. If the end effector or the load that is being moved collides with a person or object, this leads to the machine being safely stopped.

  • Page 13: Example

    Fig. . : Auslenkungen und Nachgiebigkeit des AIRSKIN® Safety ange. Applications The main area in which the AIRSKIN® Safety ange can be used relates to pick-and-place applications: using the Safety ange can avoid crushing risks when putting down a workpiece. However, the Safety ange is also suitable for detecting collisions when moving a workpiece.

  • Page 14: Ec Type Examination

    (“actuated”, “not actuated”, “defective”). The AIRSKIN® Safety ange can be con- nected on its own or in series with other additional AIRSKIN® Pads. Besides the robot itself, it is also possible to encase the gripper with AIRSKIN® Pads. As soon as the Safety ange or any sort of Pad detects an actuation or fault, it opens the safety lines and duly signals this to the controller.
  • Page 15 AIRSKIN®-Pad Bias spring Cone Tool ange adapter Robot ange adapter Safety ange cover Plain bearing Sealing gasket Fig. . : Sectional view of the AIRSKIN® Safety ange.

  • Page 16: Airskin® Pad

    The purpose of the AIRSKIN® Connection Box is to connect the AIRSKIN® Safety ange to a robot or machine controller. The AIRSKIN® Connection Box connections are 24 V DC (‘+’), Ground (‘G’), ‘IN ’, ‘OUT ’, ‘IN ’, ‘OUT ’ on one side, and the connection cable to the rst AIRSKIN®...
  • Page 17 Fig. . : Dimensions of the AIRSKIN® Safety ange (in mm).
  • Page 18 Robot ange: - -M6 Robot ange: - - . - -M Robot ange: - -M6 Tool ange: - -M6 Tool ange: - - . - -M Tool ange: - -M6 Fig. . : AIRSKIN® Safety ange with corresponding ange adapters.
  • Page 19 31,5 h7 31,5 h7 6 H7 6 H7 1x45 1x45 31,5 h7 31,5 h7 6 H7 6 H7 50 mm Robot ange adapter 1x45 1x45 10,8 10,8 63 H8 63 H8 10,8 10,8 63 H8 63 H8 (b) 50 mm Robot ange adapter 63 H8 63 H8 63 H8...
  • Page 20 20 h7 20 h7 5 H7 5 H7 20 h7 20 h7 5 H7 5 H7 31.5 mm Robot ange adapter 63 H8 63 H8 63 H8 63 H8 (b) 31.5 mm Robot ange adapter 31.5 mm Tool ange adapter 40 h8 40 h8 20 H7...
  • Page 21 25 h7 25 h7 6 H7 6 H7 1x45 1x45 25 h7 25 h7 6 H7 6 H7 1x45 1x45 40 mm Robot ange adapter 10,8 10,8 10,8 10,8 63 H8 63 H8 63 H8 63 H8 (b) 40 mm Robot ange adapter 63 H8 63 H8 63 H8...

  • Page 22: Con Guration

    . Selection of the correct spring In order to con gure the AIRSKIN® Safety ange with the correct spring, one needs the total weight (consisting of the weight of the gripper plus the load). You can either nd the weight of the gripper on the manufacturer’s datasheet or simply use a commercially available set of scales to ascertain this.
  • Page 23 If different loads are manipulated, you should ensure that you base your calculations on the heavier load. Example: Variable load AIRSKIN® Safety ange Gripper: e.g. Schunk EGP with AIRSKIN®: 920 g Load : e.g. 4 kg Load : e.g. 6 kg Fig. .

  • Page 24: Exchanging The Spring

    . Detach the AIRSKIN® Safety ange from the robot. . In order to exchange the spring, place the AIRSKIN® Safety ange on a clean surface. Please note: Watch out for metal shavings or other sharp objects which might damage the AIRSKIN® Pad. . Untighten the countersunk screws and remove the cover of the Safety ange.
  • Page 25 Plain Bearing Washer Plain Bearing Washer Fig. . : Exchanging the spring.

  • Page 26: Forces And Torques

    Forces and torques The AIRSKIN® Safety ange has been developed so that it actuates in the case of a collision and once it has reached speci c breakaway force (<110 N in the quasi-static case). The breakaway force that is required for actuation can be produced in a variety of ways, and –...

  • Page 27: Actuation Due To Horizontally Acting Forces F

    (>2.5°) of the tilt angle. The actuation force indicated in Figure . is the required static force that must take effect in order to displace the AIRSKIN® Safety ange 3.5°. The actuation force changes as a function of the lever arm l , the center of gravity position l...
  • Page 28 In the case of a deviating center of gravity position l , the additional or reduced force that is required to cause actuation can be calculated by using the following formula: 0.6 m 0.2) ( . ) + 0.0364 is the payload, consisting of the weight of the gripper m and load m in [kg].
  • Page 29 Spring with 2.5 kg payload Spring with 5 kg payload Spring with 7.5 kg payload Without spring, with 10 kg payload Distance l [mm] Fig. . : Required horizontal actuation force F as a function of the vertical distance l (valid for center of gravity up to 200 mm).

  • Page 30: Actuation Due To Vertically Acting Forces F

    F is too small to produce tilting torque. The AIRSKIN® Safety ange actuates against the z-axis when confronted with only minor displacements (<2 mm). The maximum actuation force of 110 N takes effect if – with correct spring con guration and maximum payload –...
  • Page 31 Spring with 2.5 kg payload Spring with 5 kg payload Spring with 7.5 kg payload Without spring, with 10 kg payload Distance l [mm] Fig. .6: Required tilting force F as a function of the horizontal distance l Spring with 5 kg payload Spring with 2.5 kg payload Distance l...

  • Page 32: Actuation Due To Torque M

    F , and tilting will be actuated instead. If torque around the z-axis occurs, the AIRSKIN® Safety ange can give way around the z-axis by up to 10°. Rotation around the z-axis is coupled with a vertical displacement of 3 mm.
  • Page 33 The following actuation force F as a function of the lever arm l is required to produce torque M Spring with 2.5 kg payload Spring with 5 kg payload Spring with 7.5 kg payload Without spring, with 10 kg payload Distance l [mm] Fig.

  • Page 34: Actuation Due To Robot Accelerations A

    Excessive acceleration by the robot can actuate the AIRSKIN® Safety ange. Excessive accelerations lead to tilting (tilt angle 8.8°) of the AIRSKIN® Safety ange. When it comes to acceleration, the geometries of the gripper and the load that is to be manipulated have an important role to play because they are crucial for the center of gravity...
  • Page 35 Spring with 2.5 kg payload Spring with 5 kg payload Spring with 7.5 kg payload Without spring, with 10 kg payload Distance from centroid l [mm] Fig. . : Robot acceleration α required as a function of the centroidal distance l Spring with 5 kg payload Spring...

  • Page 36: Actuation Due To Tilts Θ On The Part Of The Robot

    Actuation due to tilts Θ on the part of the robot If at all possible, the AIRSKIN® Safety ange should always be used without a tilt angle Θ that is caused by the robot. Minor tilt angles Θ that are caused by the robot are indeed possible, but if this is the case one can no longer ensure that the maximum actuation force of 110 N is not exceeded.
  • Page 37 Spring with 3 kg payload Spring with 5.5 kg payload Spring with 8 kg payload Without spring, with 10.8 kg payload Distance from centroid l [mm] Fig. . 6: Tilt angle Θ required to actuate as a function of the distance from centroid l Spring with 5.5 kg payload Spring...

  • Page 38: Installation

    The robot on which an AIRSKIN® Safety ange is to be installed must be rmly xed in place. The robot must be switched off during installation,and all the brakes must be enabled. Prior to installation, ensure that the AIRSKIN®...

  • Page 39: Installation

    Please note: When changing the tool ange adapter plate, pay attention to the orientation. The orientation is de ned by a milled groove. When delivered, the AIRSKIN® Safety ange is precon gured with Spring (for 2.5 - 5 kg payload).
  • Page 40 Installation of the AIRSKIN® Safety ange on the robot: . Use an Allen key to x the AIRSKIN® Safety ange to the robot ange adapter . The cylinder screws...
  • Page 41 Allen key Allen key (a) Installation of the robot ange adapter (b) Installation of the AIRSKIN® Safety ange on the robot Fig. 6. : Installation of the AIRSKIN® Safety ange. Component is not included in the scope of delivery. The scope of delivery includes the robot adapter plate that is supplied for the speci c customer.

  • Page 42: Cable Connections

    6. . Electrical connection • Lay the supply cable from AIRSKIN® to the controller so there is no risk of anyone stumbling over it and the freedom of movement of the robot gets not limited. • Use the AIRSKIN® Connection Box to connect the supply cable to the PLC / the robot controller in accordance...
  • Page 43 It is possible to supply the AIRSKIN® Connection Box via an external power supply, rather than through the con- troller. This can be done via the clamp of the AIRSKIN® supply cable or via an integrated 5.5 mm DC socket on the AIRSKIN®...
  • Page 44 Power supply Spark button 24 V CONNECTION Safety channel RESTART safety pulses 24 V Safety channel safety pulses AIRSKIN® Connection Box 24 V to the pads Equipotential bonding Fig. 6. : Connecting AIRSKIN® to the PLC or the robot controller.
  • Page 45 (e) Operating an AIRSKIN® pad on a controller Fig. 6. : AIRSKIN® is connected to a controller via the AIRSKIN® Connection Box with a supply cable. AIRSKIN® pads connect to the AIRSKIN® Connection Box via LEMO or JST connectors.
  • Page 46 (c) Energizer slide switch and 5.5 mm DC jack (d) External power supply of the AIRSKIN® Connection Box via 5.5 mm plug (e) Energizer slide switch in normal position Fig. 6. : External power supply of the AIRSKIN® Connection Box via 5.5 mm DC connection.

  • Page 47: Commissioning

    Chapter Recon gure AIRSKIN® In order to use the AIRSKIN® Safety ange on a robot, the AIRSKIN® System must be recon gured before it is rst used and following any modi cation (e.g. exchange of a part). You should check the following items before recon guration: •...
  • Page 48 (c) Flashing status LEDs after releasing the (d) Release the Spark button on successful restart button recon guration (e) Restart the system by pressing the Restart (f) Actuate blue ashing pads button Fig. . : Illustration of an recon guration process using the AIRSKIN® Connection Box.

  • Page 49: Switching On Airskin

    • If the AIRSKIN® Connection Box is supplied with +24 V DC by the controller, this connection must be checked too. • If the AIRSKIN® Connection Box is supplied with +24 V DC by its own source of supply, this connection and potential equalization with the controller must also be checked.

  • Page 50: Switching On The Airskin® System

    . . Preparing to switch off Before switching off, ensure that no AIRSKIN® Pad is pressed and that the AIRSKIN® Safety ange is in a non- de ected rest position. You should only ever switch off AIRSKIN® and the robot/system if the AIRSKIN® System is not actuated! Stopping and switching off the AIRSKIN®...

  • Page 51: Operation

    Switching on the AIRSKIN® System The AIRSKIN® System is switched on as soon as it is supplied with +24 V DC, e.g. typically by switching on the robot controller. Immediately after switching on, each AIRSKIN® Pad undergoes an initialization phase which lasts to a maximum of seconds.

  • Page 52: Error States

    AIRSKIN® and directly connecting an termination part to the AIRSKIN® Connection Box. • If the two status LEDs on the AIRSKIN® Connection Box fail to light up, check the connection of the AIRSKIN® Connection Box to the robot controller in accordance with the robot-speci c installation manual.

  • Page 53: Status Codes Of The Airskin® Pads

    If only some of the Pads are active (but the remaining ones aren’t), check the connections of external cables and ensure that the active Pad is correctly connected to the nearest inactive Pad. Then restart the AIRSKIN® Connection Box. Detach the inactive Pad and wipe the magnetic contacts on the Pad and the support layer.
  • Page 54 To do this, the AIRSKIN® pad is pressed brie y ve times. Then the AIRSKIN® pad has to be actuated as soon as it lights up purple and released when it goes out. Finally, the AIRSKIN® pad must be pressed brie y three times, then the rmware restarts.

  • Page 55: Maintenance

    If AIRSKIN® is used as an active safety function for the system, straightforward maintenance jobs can also be carried out by regular personnel because this presents no danger to them. Switching off or bypassing AIRSKIN®...

  • Page 56: Maintenance Jobs

    (70 %). Also clean the gaps between the Pads, and in doing so check the connection hoses of any companion pads for kinks and bruises, as well as all the AIRSKIN® Pads for dents, scratches, paint defects, discoloration, and any other abnormalities. They must be recorded in the maintenance log.
  • Page 57 Plain Bearing Washer Plain Bearing Washer Fig.
  • Page 58 . Detach the AIRSKIN® Safety ange from the robot. . Prior to any maintenance, place the AIRSKIN® Safety ange on a clean surface. Please note: Watch out for metal shavings or other sharp objects that might damage the AIRSKIN® Pad. . Untighten the countersunk screws and remove the Safety ange cover .

  • Page 59: Jobs Following Maintenance/Servicing

    STEP ACTION Ensure at all times that the machine is switched off by another person, and identify AIRSKIN® as inactive and thus as a safety feature that is not available. Also pay attention to the safety instructions in the Manual for the machine to which AIRSKIN® is attached.

  • Page 60: Disposal

    . Shutdown and storage This is where you can nd information that you must pay attention to if you have to shut down the AIRSKIN® Safety ange for a lengthy period, and what you must watch out for when you put the AIRSKIN® Safety ange back into operation after this period.

  • Page 61: Detaching The Airskin® Safety Ange

    Unplug any external cables Disposal The AIRSKIN® Safety ange should be returned in its entirety to Blue Danube Robotics for disposal; some of the materials can be reused. By recycling parts or raw materials from used products you are making an important contribution to environmental protection.

  • Page 62: Technical Data

    Diameter of the AIRSKIN® Safety ange (135.1 1.0) mm Height of the AIRSKIN® Safety ange 0.5) mm (89.0 z-displacement of the end effector 82.5 mm Thickness of the pad on the AIRSKIN® 10 mm Safety ange Assembly type Screwed Installation time <0.5 h...

  • Page 63: Electrical

    Electrical Supply voltage +24 V DC ( 5 %) Current consumption of the AIRSKIN® 10 mA, max. 39 mA Safety ange Connection to robot controller x OSSD ( channels) + Power supply (+24 V DC, GND) AIRSKIN® topology Series/row Connection of AIRSKIN® to the Block terminal (min.

  • Page 64: Warranty

    Any warranty claim will be deemed invalid if AIRSKIN® has been repaired, altered or modi ed by the operator. Liability for damage to external systems is excluded. See General Terms & Conditions for more details. The General Terms & Conditions of Blue Danube Robotics at the time of purchase apply.

  • Page 65: Safety Characteristics

    Safety characteristics The AIRSKIN® Safety ange has been certi ed and EC type-examined by TÜV AUSTRIA in accordance with EN ISO in Performance Level e, Category and EN/IEC 6 6 in SIL as a safety component. . PFH The PFH...

  • Page 66: Declaration Of Conformity And Manufacturer

    Declaration of Conformity and manufacturer...

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