READY FORGE Station General Application Manual

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General Application Guide

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Page 1 General Application Guide ...
Page 3 The documentation, best practices, and recommendations provided by READY Robotics do NOT constitute safety advice. Products sold through READY Robotics are not by themselves a fully integrated workcell. As required in ISO 10218-2, READY Robotics strongly recommends performing a complete risk assessment of the integrated workcell per ISO 12100. You may wish to use the methodology found in the ANSI/RIA TR R15.306 Task-...
Page 4: Table Of Contents
Connecting the READY pendant ........
Page 7: Uncrating Procedure
Uncrating procedure The Forge/Station 2.0 ships in a crate that you will return to READY. The design of the crate is sophisticated enough to keep the system secure during transport but simple enough that uncrating the system is quick and easy.
Page 8 Have one person hold the door shut (the door is hinged at the bottom). Lift each latch and turn it a full rotation counterclockwise to unlock it. Follow the order in the picture in the image from Step 1. Opening the butterfly latch © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 9 Lower the door of the crate so that it rests on the floor. This will act as a ramp for removing your Forge/ Station. Flip down the hinged steel plate at the end of the ramp. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 10: Removing Your Forge/Station From The Crate
Do not throw it away, as all wood blocks and components of this crate must be sent back to READY. Release the ratchet strap by pressing in on the release lever and then unfolding it. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 11 Unhook both ends of the strap from the base of the stand. Set the ratchet strap aside somewhere where it will not create a trip hazard. Do not throw it away, as it must be sent back to READY. Repeat steps 2 and 3 for the strap on the other side of the Forge/Station.
Page 12 Remove the wood board that sits on top of the Forge/Station's steel tabletop. Rotating the board 90 degrees counterclockwise may help you get it out. Set it aside somewhere where it will not create a trip hazard. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 14 PINCH POINT WARNING: Take caution whenever raising or lowering the leveling feet. Ensure that your hands are never between the Station and the jam nut or between the floor and the bottom of a leveling foot. These areas form pinch points. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 15 TWO PEOPLE REQUIRED: The Forge/Station is heavy and requires two people to lower it down the ramp and onto your floor. IMPORTANT: Do not pull on the arm or READY pendant to remove the Forge/Station from its crate. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 16 Station that can be used to help move it. Lock the wheels of your Forge/Station so that it won't move easily. For added stability, you can deploy the leveling feet by following these steps. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 17 Above each foot is a gray jam nut. Turn the nut counterclockwise so that it moves up towards the stand. Use an adjustable wrench to tighten it. Repeat this process with the other two leveling feet. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 18: Uncrating Documentation And Peripherals
To retrieve them, follow these steps. Locate the butterfly latch on the underside of the storage compartment. Lift the latch and turn it a full rotation counterclockwise to unlock it. Opening the butterfly latch © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 19: Preparing The Crate To Ship Back
Preparing the crate to ship back Follow these steps to prepare your crate for shipment back to READY. Close the door to the storage compartment and secure it shut with the butterfly latch. Follow these directions to secure the butterfly latch here and in subsequent steps Close the latch.
Page 20 Neatly place the ratchet straps and wooden boards that held your stand in the crate back into the crate. Neatly place the foam blocks that helped to protect your Forge/Station back into the crate. Close any trap doors that you opened and secure their respective butterfly latches. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 21 With the help of another individual, lift the door of the crate and shut the box. Make sure that one person is holding the door shut while the other secures the butterfly latches. TWO PEOPLE REQUIRED: Lifting the crate door and securing its latches requires the help of another person. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 23: Startup The Forge/Station
▪ Edit initial configuration details SAFETY WARNING: Use proper technique when supplying power to the Forge/Station. Improper usage can lead to an electric shock which has the potential to cause severe injury. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 24: Overview Of The System
The hardware which has an industrial computer with the necessary interfaces to automate a workcell. Forge/OS The operating system designed by READY which runs applications that assist in automating the workcell. READY Pendant The Human-Machine Interface (HMI) for Forge/OS and Task Canvas.
Page 25 50W Idle, 300W Max (Does not include external AC Load) Power Output NEMA 5-15r 120VAC, 10A (READY Pendant or Universal Robot Power Only) Short Circuit and Overcurrent Protection: 10A Circuit Breaker 4-Pole M12 Connector 12VDC, 4A (READY Pendant Power Only)
Page 26: Forge/Station 2.0 Specifications
19 kg (41.8 lbs) Dimensions (enclosure only) 400 x 400 x 210 mm (15.75 x 15.75 x 8.25 in) Connectivity Ethernet 2x LAN Ports 1x WAN Port 2x USB Type A Ports Forge/Station 2.0 Specifications © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 28: Forge/Ctrl Components
NEMA 5-15 Plug to supply power to the Forge/Ctrl and its connected peripherals. Air Input Industrial Quick Disconnect Plug to supply air to the Forge/Ctrl. Exhaust Push-to-Connect Fitting for the internal solenoids of the Forge/Ctrl. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 29 USB Type A Ports. HDMI HDMI Port to connect to the READY Pendant. PLC Module 26-Pin Amphenol Connector to connect to READY's PLC Breakout Box. Air Out 4mm Push-to-Connect Fitting for 4mm air hose. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 30: Connecting The Forge/Ctrl To Power
Ethernet port to connect the Forge/Ctrl to the internet. Module 1, 2, 3 M12 Connectors customizable by READY. Connecting the Forge/Ctrl to power There is a NEMA 5-15 Power Cable connected to the left side of the Forge/Ctrl. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 31: Connecting The Forge/Ctrl To Air
Plug the Power Cable into a 120VAC Outlet. Connecting the Forge/Ctrl to air There is a Quick Disconnect Plug on the left side of the Forge/Ctrl that is connected to the internal solenoids. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 32 To connect shop air to the system, pull back on the outer cylinder of the socket. Connect the quick disconnects together and then release the outer cylinder to secure the connection. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 33: Connecting The Ready Pendant
Connect the READY Pendant HDMI cable to the port on the Forge/Ctrl labeled "HDMI". Connect the READY Pendant M12 4-Pos Power Cable to the port on the Forge/Ctrl labeled "12V Power". The connection of the remaining M12 Connector is dependent on the robot controller and its safety circuit.
Page 34: Startup Procedure
Startup procedure The Forge/Ctrl will be used in tandem with the robot controller to automate your robot and workcell. READY is working towards being Robot Agnostic however, connecting to multiple robots is not as simple. Work with READY to have the correct instructions to connect your robot and robot controller to the Forge/Ctrl.
Page 35: Turning Off The Forge/Ctrl
On the right side of the Forge/Ctrl, press the Power Button. Turning OFF the Forge/Ctrl On the right side of the Forge/Ctrl, press the Power Button. On the READY Pendant, select SHUTDOWN. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 36: Forge/Os
Wait until the READY Pendant is powered down and the green light on the Power Button is OFF. On the left side of the Forge/Ctrl, turn the Power Disconnect Switch counterclockwise. Forge/OS Forge/OS Forge/OS is the READY operating system on which you can program and execute applications for a variety of robot and automation systems.
Page 37 The Control Suite across the bottom of the screen gives you access to System Settings and manual controls for the robot and attached devices. System Modes The current mode of the Forge system is indicated by the status bars on the left and right edges of the screen. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 38 ▪ (Universal Robots arms only) Guide mode allows you to move the robot arm by hand. When the arm is in Guide mode, you will have the same motion control as when holding the Teach button on the back of the UR pendant. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 39: Initial Configuration
WAN Ethernet port on the Forge/Ctrl. Note: The importance of connecting to the network is to be able to send notifications during the automation process. Also, it helps with communicating any issues to READY that you might encounter. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 40 IMPORTANT: If you set up an Admin PIN right now, then your system will start in the limited Operator role each time the system is reset. To switch to Admin mode, you must tap the menu labeled READY ROBOTICS in the bottom left corner of the screen and then tap USER ROLES and select Administrator.
Page 41 Enter the pin. Tap SAVE PIN. The pin is saved in the system. IMPORTANT: Do not lose or forget the pin that has been created for the Forge/Station. Otherwise you will have to contact READY to reset it. The READY support number is 1(833)732-3977...
Page 42 Stations have one. If your robot is an e-Series UR, it will be integrated into the robot itself. If your robot is a CB3 series, we provide a Robotiq force torque sensor attached to wrist 3 of the UR arm. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 44 Tap YES if the TeachMate is inline with your end effector and NO if the TeachMate is mounted on the robot arm. The last system to configure is the Robot I/O Configuration. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 45 The materials you will need for this step are the UR Teach Pendant and the READY Robotics Flash Drive that was included with your Forge/Station. READY Robotics Flash Drive Locate the flash drive and insert it into the USB slot located on the right side of the UR Teach Pendant.
Page 46 Once this is completed, the software has configured the Robot I/O. Tap Next. Last step, double check your configuration settings. Tap COMPLETE SETUP once the correct settings are recorded. This results in a loading screen, WELCOME TO FORGE/OS. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 47: Edit Initial Configuration Details
Edit initial configuration details In order to edit the steps which were skipped in the initial configuration, tap on the READY Robotics icon on the bottom left of the READY Pendant. This opens the READY menu. From there, you can make edits to: ▪...
Page 48 Issue: Main Power Switch is on, the power button is not illuminated, and the READY Pendant will not turn Check if the Station's power cable is properly attached to the station and outlet. Issue: Main Power Switch is on, the power button is illuminated, but the READY Pendant will not turn on.
Page 49: Steps For Moving A Forge/Station
Follow these steps to move your Forge/Station. TWO PEOPLE NEEDED: Moving the Forge/Station requires two people. The Forge/ Station is very heavy and it is important to have another person present to help prevent collisions and injury. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 50 Deactivate Guide mode by pressing the Guide button in the Control Suite. This will lock the robot's joints in this position. Adjust the position of the READY pendant so that it rests close to the Station and won't hit anything during transportation.
Page 51 Take a moment to ensure that nothing is dangling or protruding unnecessarily from your Station. Ensure that your Station has nothing plugged into it. If your Station's leveling feet are deployed down holding the machine in place, follow these steps to raise them. Otherwise move onto Step © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 53 Use the handles on your Forge/Station to move it. Once you have your Forge/Station where you want it, plug in your air and power. Turn the power switch on your robot to the On position. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 54: Positioning Your Forge/Station
Testing the position of your Forge/Station with a part: Place one of the parts that is supposed to go into your lathe into your gripper and test to see if it can orient the part into the lathe collet using these steps. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 55 Position the robot arm so that it is in a position where it can feed the part straight into the lathe collet. In addition to adjusting the joints, you may need to adjust the Forge/Station's position. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 56 Avoiding collisions: Make sure that the joints of the robot are not too close to any part of the lathe that they might collide with. Sometimes the robot may take different paths to reach the lathe collet, and it could cause a collision. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 57 This could trigger a warning state in Forge/OS. See the image below for an example. Other relevant destinations: Ensure that your robot arm can reach all other destinations that it needs to go to (part presentations, feeders, etc.). © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 58: Using Your Forge/Station's Leveling Feet
Ensure that your hands are never between the station and the jam nut or between the floor and the bottom of a leveling foot. These areas form pinch points. Lock the wheels on your Forge/Station by flipping the plastic tabs on the wheels down. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 59 Above each foot is a gray jam nut. Turn the nut counterclockwise so that it moves up towards the stand. Use an adjustable wrench to tighten it. Repeat this process with the other two leveling feet. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 60: Anchoring Your Forge/Station
If you would like to have a method to realign/fix all your waypoints at once, this can be accomplished with READY's optional R-Align peripheral. IMPORTANT: Your task should be fully completed and tested before mounting your robot into the floor.
Page 61: Mounting Procedure
This can be done easily by sliding one of your rods through each mounting hole and tracing its outline on the floor. We will be making additional, more exact markings in the next step. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 62 PINCH POINT WARNING: Take caution whenever raising or lowering the leveling feet. Ensure that your hands are never between the Station and the jam nut or between the floor and the bottom of a leveling foot. These areas form pinch points. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 63 Turn the handles counterclockwise until it lifts off of the ground. Repeat this process for the other two leveling feet. With the help of one other person, move your Forge/Station out of the way. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 64 Next, lower the leveling feet again by following these steps again. Turn the handles on your leveling feet clockwise to lower the feet. Once it contacts the floor and you feel resistance continue turning it for about ¾ of a full rotation. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 65: Robot Movement
This section provides information on how to: ▪ Move the robot in Guide mode ▪ Recover from a joint limit error ▪ Jog the robot in the RCP ▪ Jump the robot in the RCP © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 66: Ur Degrees Of Freedom
UR degrees of freedom The UR robot arm has six axes, which are labeled in the image below. UR Robot arm - joints labeled © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 67: Ur Technical Specifications
A robot mode in which the robot's joints unlock so that its position can be moved by hand. Note: Guide mode is mainly used for large, gross movements. For small, precise movements, we recommend using the jog controls in the Robot Control Panel, which will be covered later. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 68: Joint Limits
Rotate wrist 3 until the robot arm locks up and cannot be rotated any further. Check the READY pendant to see the error message stating that the joint limit was reached. Click on the FIX button from the joint limit warning notification. This will rotate the joint slightly away from the joint limit and exit the robot's warning state.
Page 70: Moving The Robot Arm Using The Robot Control Panel
The Control Suite is located at the bottom of the screen and can be used to access the various functions of the Forge/Station and its peripherals. Robot Control Panel The Robot Control Panel (RCP) can be used to move the robot from the READY (RCP) Pendant.
Page 71: Jogging Your Robot
Press and hold one of the directional arrows to move the gripper in the direction corresponding to the same colored arrow in the Render section. Next, try pressing and holding one of the arched arrows to rotate the gripper along its corresponding axis. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 72: Jumping Your Robot
Ensure that the Cartesian controls are selected and choose the Reference Frame and direction that you wish the robot to jump in. Specify the distance in the column titled Move By. Tap EXECUTE JUMP in the Jump Controls. © 2020 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

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