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MRMC Bolt X Quick Start Manual

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Bolt X
Quick Start Guide
QSG Product Code: MRMC-2253-00
Products Covered: MRMC-2023-00, MRMC-2080-00

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Summary of Contents for MRMC Bolt X

  • Page 1 Bolt X Quick Start Guide QSG Product Code: MRMC-2253-00 Products Covered: MRMC-2023-00, MRMC-2080-00...
  • Page 2 Bolt X Quick Start Guide QSG Product Code: MRMC-2253-00 Products Covered: MRMC-2023-00, MRMC-2080-00 Document version: BOLTX-QSG-20012021 © 2021 Mark Roberts Motion Control Ltd. All rights reserved. No part of this publication may be reproduced, transmitted, or translated by any means — graphical, electronic, or mechanical — including...

  • Page 3: Table Of Contents

    Operational safety............6 Mounting the Yaskawa arm ..........8 Mounting the weight wings ..........9 Anchoring Bolt X On Pedestal to the floor ......10 Attaching the track motor pinch wheel to Bolt (Family of Robots) On Track ........14 Connecting the cables — Bolt X On Pedestal ....16 Connecting the cables —...
  • Page 4 Bolt X Quick Start Guide Ulti-box connector pin-out information ......48 Servo motor connector ..........48 Program serial connector ..........48 Power connector ............49 Camera Accessory connector........49 Data In connector............50 Brake 24V connector..........50 Brake 24V connector..........51 CAN connector............51 Appendix 3 Specifications............... 53 Physical Specification..........53 Range of Travel............54...

  • Page 5: Quick Start

    Bolt X Quick Start Guide Overview Thank you for using the Bolt X High-speed Cine-bot from Mark Roberts Motion Control (MRMC). Bolt X is designed for reliable day-in, day-out use in professional studio and Outside Broadcast environments. There are two versions of Bolt X:...

  • Page 6: Safety Procedures For Using Industrial Robots, Including High Speed Track

     If you are using Bolt X On Track then you need to take extra steps during installation and use due to the additional risks involved in using track. See the separate Precision Track Quick Start Guide for information on laying the track, securing it to the floor, and mounting Bolt X onto it.

  • Page 7: Assessing A Site

    Bolt X itself (630 kg for Bolt X On Pedestal, 830 for Bolt X On Track) plus the weight of the track (95 kg per section). The track must either be secured to the ground or to the weight plates supplied (2 plates per section=2x80 kg).

  • Page 8: Installation Safety

    Use the recommended minimum thickness steel plates. Check with MRMC if you are unsure of the exact requirements for your robot. ...
  • Page 9 Bolt X Quick Start Guide  Keep stands, lights and accessories out of the No Go Zone, if possible. If not possible then try to take as much care with their positioning and the motion of the rig, as if they were a person.

  • Page 10: Software Setup

    Bolt X Quick Start Guide Software setup  Always ensure you have the right configuration for the robot you are using, such as maximum axis speeds and accelerations.  Also check the Cartesian speed and acceleration limits are set to reasonable values.
  • Page 11 Bolt X Quick Start Guide  Keep the software in “slow mode” unless the move has been tested and is now specifically doing a high speed pass.  In the event that a person or Actor has to be within the no-go zone during a move (hand model etc.) ensure that they fully...

  • Page 12: Mounting The Yaskawa Arm

    Bolt X Quick Start Guide Mounting the Yaskawa arm Remove all packaging from the Bolt X arm and the pedestal. If not already added, attach the two mounting plates on the arm using 4 x M12 screws on each side. Ensure that each plate is mounted on the correct side.

  • Page 13: Mounting The Weight Wings

    Mounting the weight wings If you want to use Bolt X in a stationary position that is temporary (or if you don’t want to damage the floor by installing anchors in it), you must weigh down the Bolt X base to keep it stable during high-speed moves.

  • Page 14: Anchoring Bolt X On Pedestal To The Floor

    Hint You can move Bolt X using a pallet jack without removing the wings if you want, as long as you take the weight plates off first. Anchoring Bolt X On Pedestal to the floor If you are setting up Bolt X On Pedestal in a permanent (or semi-permanent) location, it is recommended that you anchor the pedestal to the floor.
  • Page 15 × 4 corners × 4 corners Temporarily put the Bolt X On Pedestal into place where you want. At one corner of the pedestal, use one of the two holes to draw a circle on the concrete with a pencil, to mark the position of the hole.
  • Page 16 11. Repeat steps 7 to 10 for the other Drop-in three corners. anchor insert 12. Put Bolt X On Pedestal in place over the holes. 13. Insert the four retaining bolts (M16) × 4 corners through the corners of the base and into the drop-in anchor inserts, and tighten.
  • Page 17 Bolt X Quick Start Guide Notes...

  • Page 18: Attaching The Track Motor Pinch Wheel To Bolt (Family Of Robots) On Track

    Bolt X Quick Start Guide Attaching the track motor pinch wheel to Bolt (Family of Robots) On Track Mounting bar Socket On the separately supplied pinch wheel assembly, remove the brass retaining pin by pulling on the ring. Mount the pinch wheel assembly onto the track motor on the rig underside, by sliding the track motor gear against the rack and putting the pinch wheel Socket onto the track motor Mounting bar.
  • Page 19 Bolt X Quick Start Guide Insert the small side of an allen key in the cavity on the block of the pinch wheel assembly and using the allen key pull the block towards the racking. Plug the pinch wheel cable to the socket on the rig underside, and...

  • Page 20: Connecting The Cables - Bolt X On Pedestal

    Bolt X Quick Start Guide Connecting the cables — Bolt X On Pedestal Bolt X Arm Power for Camera Power for Ulti box VIDEO 1 VIDEO 2 Yaskawa Robot cable E-Stop (Safety PLC) Power Supply: ideally 415 Volt, YRC1000 3-phase, 5 pin including Ground...
  • Page 21 Bolt X Quick Start Guide Power Supply: 120-240 Volts INtime dongle cable in USB port Ethernet Hub ROBOT ONLY ETHERNET for Camera ETHERNET for Ulti Bypass jumper* Bypass jumper Hand Held RT-14 Bypass jumper [15843]...

  • Page 22: Connecting The Cables - Bolt X On Track

    Bolt X Quick Start Guide Connecting the cables — Bolt X On Track Power for Camera Power for Ulti box 48V OUT VIDEO 2 VIDEO 1 Cable wrap ETHERNET for camera YRC1000 Robot VIDEO 1 Controller VIDEO 2 ULTI ETH...
  • Page 23 Bolt X Quick Start Guide E-stop Bypass jumper* RT-14 Bypass jumper* Bypass 24V IN jumper [15843] ETHERNET Power Supply: 120-240 Volts Ethernet Wifi ROBOT ONLY Dongle ETHERNET INtime dongle cable in USB port Power Supply: 415 Volt, 3-phase, 5-wire including...
  • Page 24 Bolt X Quick Start Guide Important The Jumper* in the Safety PLC applies when using this robot as a single robot operation. For more information on using the Universal Robot system with multiple robots, refer to the Universal E-stop System Quick Start Guide.

  • Page 25: Bolt X Arm Connectors For Ulti-Box And Camera

    Bolt X Quick Start Guide Bolt X arm connectors for Ulti-box and camera The connections that go through the Bolt X arm are shown below. These are for the Ulti-box mounted on the arm, and for the camera that you mount in the cage at the end of the arm.

  • Page 26: Starting Up The Bolt X System

    Bolt X Quick Start Guide Starting up the Bolt X system Once you have attached all the cables, you power up the Bolt X rig by switching on the components in the order described below. Make sure you have secured the area around Bolt X.
  • Page 27 Bolt X Quick Start Guide Power switch on YRC1000 For Bolt X On Track, turn controller unit on the power switch on the side of the Bolt X Base. The pendant shows the boot up sequence which normally takes about 1 minute.

  • Page 28: Bolt X Start-Up Summary

    Bolt X Quick Start Guide Bolt X start-up summary Secure the area Release the E-stop on the rig Switch on all the equipment on the system Switch on the Flair PC Start Flair Release the E-stop on the computer stack...

  • Page 29: Shutting Down The Bolt X System

    Bolt X On Track). or... If you are going to transport Bolt X to a new location, put the Bolt X arm into its transport position. You can do this either by using Flair (although you might have to reset the soft limits to reach the transport position).

  • Page 30: Troubleshooting

    The YRC1000 teach pendant should only be used for troubleshooting purposes and should not be used for normal operation of the rig. The teach pendant is not related to Flair/RTL in any way and is not an interlace to MRMC Bolt system. Symptoms Cause and/or action Flair fails to establish a Try a different cable.

  • Page 31: Checking When Yrc1000 Is Ready

    34. Checking when YRC1000 is ready The robot teach pendant is housed inside the Bolt X on Track base. To access it, undo screwsx11 and remove the cover. Remember to replace the pendant and the cover after you have used it.

  • Page 32: Switching Bolt X To Manual Mode

    Job menu Blank Function buttons Switching Bolt X to Manual Mode You can run the Bolt X in manual mode without using Flair. Ensure that YRC1000 is powered up and booted. Switch the key on the pendant to ‘Teach’ position.

  • Page 33: Moving The Robot In Manual Mode

    Press the Servo On Ready button on the pendant again. Moving the Robot in Manual Mode Use the axes buttons X to Z, shown, to move the joints on Bolt X. Rotate/ Track...

  • Page 34: Bolt X Recalibration

    Bolt X Quick Start Guide Bolt X Recalibration The robot should never lose calibration. However, the following are the examples of situations that the robot might lose calibration:  After a hardware crash.  The batteries inside the encoder keep the encoder position saved at all times even when the power to the robot is off.
  • Page 35 Bolt X Quick Start Guide Use the pendant to check if the axes zero properly (the Current Position of all axes should be less than 1000 pulse indicating they are close to zero.) To do this: Align the arrows on the arm by eye to bring it to zero position as accurately as possible (this can be done either with the software or the pendant in Manual Mode).
  • Page 36 Bolt X Quick Start Guide appear instead of absolute encoder position indicating that there is a problem with the calibration. (In this example, we are using Pan.) A message appears when you press Select. Select Yes. The values in the ABSOLUTE DATA column will not change as they...

  • Page 37: Changing User Profile

    Bolt X Quick Start Guide Select MAIN MENU → ROBOT → CURRENT POSITION. The axis is changed to 0. Changing User Profile Select MAIN MENU → SYSTEM INFO → SECURITY.

  • Page 38: Second Home Position Check And Reset

    Bolt X Quick Start Guide You will be presented with a list of user profiles. Select the desired user profile. Enter the password for the user:  Management Mode Password: 999999999  Safety Mode Password: 555555555 Press the Enter key on the keypad.
  • Page 39 Bolt X Quick Start Guide 1.4 Alternatively, if the safety PLC is not available, you can use Bypass Estop box [20529] and connect it directly to the umbilical. 1.5 Ensure that the E-stop on the pendant is released and there are no error messages on the pendant.
  • Page 40 Bolt X Quick Start Guide column and the Difference will be 0. Sometimes, you might need to move each axis individually. Press DATA. Click on Confirm Position. You might need to do this twice. The error should now clear. Switch the key back to ‘Remote’ and engage Flair in usual way.

  • Page 41: Setting Joint Limits

    Bolt X Quick Start Guide Setting Joint Limits Switch user profile to Safety Mode. Select MAIN MENU → ROBOT → SOFT LIMIT SETTING. Select the limit setting and enter a new setting. (Values are in pulses) Joint T (Roll) is 100000, which is approximately 180...

  • Page 42: Checking If Yaskawa Yrc1000 Output File Is Set To Flair

    Turn on the robot (YRC1000). In the Pendant, select MAIN MENU → JOBS → JOB. The Job name should be FLAIR. If the Job name is RTOS then the system needs to configured for Flair. Contact MRMC if this is the case.
  • Page 43 Bolt X Quick Start Guide Notes...

  • Page 44: Bolt X Panels

    Bolt X Quick Start Guide Bolt X Quick Start Guide Bolt X On Track base panel connector summary 240V AC output, for general use by additional devices that you want to mount on the base. VIDEO 1 IN input connector for the video 1 signal from the camera.
  • Page 45 Bolt X Quick Start Guide ROBOT connector. You use this to connect the robot Controller YRC1000 inside the Bolt X base, via the umbilical cable, to the hub in where the Flair PC is connected 10. E-STOP connector. You connect this to the PLC via the umbilical...

  • Page 46: Bolt X Arm Panels Connector Summary

    VID 1 output connector for the video 1 signal from the camera. This can be connected to the VIDEO 1 IN connector on the Bolt X base. VID 2 output connector for the video 1 signal from the camera. This can be connected to the VIDEO 2 IN connector on the Bolt X base.
  • Page 47 Bolt X Quick Start Guide YRC1000 power and controller connector. This is for the encoder and power cable that runs between the Bolt X arm and the YRC1000 controller unit, which supplies control to the arm.

  • Page 48: 12Vdc Connector

    Bolt X Quick Start Guide Bolt X arm connector pinout information 12VDC connector This type of connector is used to power the camera through the robot arm. Not used +12V 48VDC connector This type of connector is used to power the camera through the robot arm.

  • Page 49: Ulti-Box Connector Summary

    Bolt X Quick Start Guide Ulti-box connector summary The Ulti-box that is mounted on the Bolt X arm is a multi-purpose interface box that is used to control servo motors on many MRMC heads and Lens Control Motor (LCM) units. The Ulti-box offers versatile...
  • Page 50 Bolt X Quick Start Guide PAN connector for the Pan servo motor on a head. For pin-out information see Servo motor connector on page 48. PROG serial connector for connection to a controller using a Serial RS232 connection (as an alternative to an Ethernet or DataLink connection), and for updating the firmware in the Ulti-box.
  • Page 51 Bolt X Quick Start Guide connected to the external E-Stop box, but if no external E-Stop is needed, a bypass jumper may be used. CAN connector is used to communicate with external CAN capable motor drives. 10,11. ZOOM, FOCUS connectors for external servo Lens Control Motors (LCMs) mounted on the camera platform.

  • Page 52: Ulti-Box Connector Pin-Out Information

    Bolt X Quick Start Guide Ulti-box connector pin-out information Servo motor connector This type of connector is used for six servo motor connectors on the Ulti-box: Pan, Zoom, Focus, Tilt, Aux-1, Aux-2. DATUM MOTOR_B MOTOR_A LIMIT 10. GND Program serial connector Serial connector for connection to a controller using a Serial RS232 connection, and for updating the firmware in the Ulti-box.

  • Page 53: Power Connector

    Bolt X Quick Start Guide Power connector The power input connector for the Ulti-box. For usage see page 46. +35V +35V Camera Accessory connector This is a multi-purpose camera accessory connector with connections for three stepper motors, two serial lens controls, two trigger in controls, and two trigger out controls.

  • Page 54: Data In Connector

    Bolt X Quick Start Guide Data In connector This is a DataLink In connector for connection to a controller using a DataLink connection. DataLink In (Up Link) connector for connection to a DataLink device higher up in the DataLink daisy-chain. For usage see.

  • Page 55: Brake 24V Connector

    Bolt X Quick Start Guide Brake 24V connector This is a Lemo Size 1 2-way connector; external circuitry should keep the pins closed. E-STOP- E-STOP+ CAN connector This is a Lemo Size 0 3-way connector; is used to communicate with external CAN capable motor drives.
  • Page 56 Bolt X Quick Start Guide Notes...

  • Page 57: Appendix 3 Specifications

    Bolt X Quick Start Guide Appendix 3 Specifications Bolt X Quick Start Guide Bolt X Quick Start Guide Physical Specification Dimensions Bolt X On Bolt X On Track Pedestal Weight - Arm [kg] Weight - Base [kg] Weight - YRC1000 controller unit...

  • Page 58: Range Of Travel

    Tilt: - 210˚ to +10˚ range of travel @ 430˚/s Roll: ±450˚ range of travel @ 655˚/s Power requirements Bolt X on Track requires three-phase power line with Neutral in Wye connection plus Earth (Ground), 50-60 Hz. Phase 1 (Brown)

  • Page 59: Cable Colours

    Bolt X Quick Start Guide Cable Colours Brown Phase 1 Black Phase 2 Grey Phase 3 Green/Yellow Ground Note: No NEUTRAL is used General Electric Data Earth Earth must have good connection (less than 10 ohm) to the closest grounding point of the location.

  • Page 60: Power Data By Country - United States Of America

    Delta input to three phase 415 WYE output. The earth connection must be included. The transformer therefore is required to transform the three phase voltage and transform 3+E (Delta) to 3+N+E (WYE) as required by the Bolt X on Track.
  • Page 61 Bolt X Quick Start Guide Notes...
  • Page 62 Bolt X Quick Start Guide Notes...

  • Page 63: Appendix 4 Cleaning And Maintenance

    Do not spry cleaning fluids into these plugs and sockets. Cleaning The Bolt X on tracks should be turned off and unplugged for cleaning. Main Body and Arm The Bolt X on Track requires little maintenance, but should be cleaned frequently depending upon where it is used.

  • Page 64: Track Gearbox

    Bolt X Quick Start Guide Track Gearbox After approximately five years of use the track gearbox oil will need changing, this is just a gear oil available from motor factors, grade EP90. Track and Track Bearings The Track Bearings should be frequently greased using a good quality grease gun, again from a motor factor;...
  • Page 65 Bolt X Quick Start Guide Notes...
  • Page 66 Bolt X Quick Start Guide Notes...
  • Page 67 Bolt X Quick Start Guide Notes...
  • Page 68 Mark Roberts Motion Control Ltd. Unit 3, South East Studios, Blindley Heath, Surrey RH7 6JP United Kingdom Telephone: +44 (0) 1342 838000 info@mrmoco.com www.mrmoco.com...

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