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CRS A255 User Manual

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A255 Robot Arm
User Guide
For use with C500C Controller
UMI-33-255-A

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  • Page 1 A255 Robot Arm User Guide For use with C500C Controller UMI-33-255-A...
  • Page 2 Copyright © 1999 CRS Robotics Corporation RAPL-3 is a trademark of CRS Robotics Corporation and may be used to describe only CRS Robotics products. Any brand names and product names used in this guide are trademarks, registered trademarks, or trade names of their respective holders.
  • Page 3 Preface This user guide accompanies the A255 robot arm used with the C500C controller. This Guide This user guide contains general information, arm specifications, safety precautions, installation instructions, startup procedures, and basic operation instructions for the CRS Robotics A255 robot arm.
  • Page 4 If you are installing the robot yourself, read the Installation and Commissioning chapter. • If the robot was installed by CRS or a distributor, read the chapters on Commissioning and Operation Basics. Before attempting to follow a procedure or examples, read the entire section first.

  • Page 5: Table Of Contents

    Contents Chapter 1 Introduction ................1 Optional Equipment ............2 Chapter 2 Specifications ................3 Range of Motion, Dimensions, and Weight......4 Reach ................. 6 Torque Ratings ..............8 Joint Speeds and Acceleration Rates ........8 Payload ................9 Resolution ................. 11 Brakes ................
  • Page 6 Moving by Limping One Joint at a Time ......54 Chapter 7 Gripper Installation ..............56 Installing the Gripper ............57 Connecting the Cable or Hose ..........58 Chapter 8 Calibration ................61 Restoring Factory Calibration Values ......... 62 Recalibrating the Robot Arm ..........63 Calibrating an Extra Axis ...........

  • Page 7: Chapter 1 Introduction

    C H A P T E R 1 Introduction The A255 arm is articulated with five joints or axes, providing it with five degrees of freedom. This allows the arm to move a gripper or other tool to cartesian spatial coordinates and orientation defined by X, Y, Z, Z-rotation, Y-rotation, and X- rotation.

  • Page 8: Optional Equipment

    A255 Robot Arm User Guide Optional Equipment The following options are available from CRS or an authorized CRS distributor. End Effectors • Servo Gripper and Adapter • Pneumatic Gripper and Adapter • Microplate Fingers for Servo Gripper Hardware and Equipment •...

  • Page 9: Chapter 2 Specifications

    C H A P T E R 2 Specifications This chapter describes the A255 arm: • Range of Motion, Dimensions, and Weight • Reach • Torque Ratings • Joint Speed and Acceleration Rates • Payload • Resolution • Brakes •...

  • Page 10: Range Of Motion, Dimensions, And Weight

    A255 Robot Arm User Guide Range of Motion, Dimensions, and Weight The arm’s range of motion depends on the dimensions of each arm section (base, links, tool flange) and the extent of travel of each joint. These measurements determine the shape of the arm’s workspace. See the following figures and tables.
  • Page 11 Chapter 2: Specifications The range of motion of the joints and the dimensions of the sections of the robot arm. The 350° range of motion of the waist joint of the robot arm. 99-04-23...

  • Page 12: Reach

    A255 Robot Arm User Guide Reach The maximum reach of the arm is calculated horizontally outward from the shoulder joint (axis 2) and vertically upward from the bottom of the base. The arm can reach points below the level of the bottom of the base.
  • Page 13 Chapter 2: Specifications 99-04-23...

  • Page 14: Torque Ratings

    A255 Robot Arm User Guide Torque Ratings This table shows the torque rating for each arm joint. Continuous Torque Rating Joint Axis Torque in-lb Waist 57.0 Shoulder 57.0 Elbow 57.0 Wrist pitch 13.0 Tool roll 0.71 Joint Speeds and Acceleration Rates The standard pick and place cycle is 1.8 seconds.

  • Page 15: Payload

    Chapter 2: Specifications Payload Payload is the amount of mass (weight) carried by the arm and/or the amount of force the arm can exert on an object. This includes the gripper and any load that it carries. The maximum and nominal payloads are determined for speed and acceleration that maintain rated precision.
  • Page 16 A255 Robot Arm User Guide Imperial: Payload decreases with the distance to its center of gravity. Metric: Payload decreases with the distance to its center of gravity. 99-04-23...

  • Page 17: Resolution

    Chapter 2: Specifications Resolution Resolution is the smallest increment of motion or distance that can be detected or controlled. Resolution depends on the distance between the center of the tool flange surface and the center of gravity of the payload, as shown in the resolution derating tables and curves.

  • Page 18: Brakes

    A255 Robot Arm User Guide Imperial: Resolution decreases with the distance to the payload’s center of gravity Metric: Resolution decreases with the distance to the payload's center of gravity. Brakes Fail-safe brakes prevent the robot from moving under the influence of gravity or inertia when power is removed.

  • Page 19: Gripper

    Chapter 2: Specifications Gripper An A255 robot requires the attachment of a gripper (or other end effector) to perform its intended task. Custom-designed grippers and other end effectors are available from CRS. Refer to page 57 for gripper installation instructions.
  • Page 20 A255 Robot Arm User Guide 99-04-23...

  • Page 21: Chapter 3 Safety Precautions

    C H A P T E R 3 Safety Precautions This chapter describes the design of safeguards and other precautions for the safe use of the robot system and its workcell. Danger! Design your robot workcell for safety. The robot is a potentially hazardous machine.
  • Page 22 A255 Robot Arm User Guide Install barriers outside the total reach of the robot arm, gripper, and payload. Radius = 22 in [559 mm] + Length + Length minimum gripper payload Height = 32 in [813 mm] + Length + Length...

  • Page 23: Emergency Stops (E-Stops)

    Chapter 3: Safety Precautions Emergency Stops (E-stops) An emergency stop (e-stop) button is a large, red, mushroom-shaped button that removes arm power when struck. It must be manually reset to restore arm power. The controller e-stop circuit removes arm power. When arm power is removed, fail- safe brakes engage to prevent the robot from moving due to gravity or inertia.

  • Page 24: Presence Sensors

    A255 Robot Arm User Guide Presence Sensors Install a presence-sensing safety interlock at any point of access through a barrier into the arm workspace. Design the interlock as part of the robot’s e-stop circuit. For example, a door-mounted contact switch connected to the e-stop circuit stops the arm when the door is opened and the contact broken, and it permits arm operation when the door is closed and contact is restored.

  • Page 25: Other Safeguards

    Chapter 3: Safety Precautions Example of barriers and light curtain. Example of barriers and pressure-sensitive mats. Other Safeguards In addition to physical barriers, e-stops, and presence-sensing devices, safeguards can include, but are not limited to: • Awareness signals An awareness signal is an audio or visual alarm, such as a buzzer or light, activated by a sensor in a larger envelope outside the inner, e-stop connected envelope.

  • Page 26: Power

    A255 Robot Arm User Guide • Awareness barriers An awareness barrier, such as a length of yellow chain, alerts personnel to their nearness to the workspace, but is not sufficient to prohibit access into the workspace. • Passive warnings Passive warnings include markings on the floor or table top.

  • Page 27: Environment

    Humidity Maintain the relative humidity below 50%, non-condensing. Corrosive Fumes Do not expose the robot to an environment of corrosive fumes without a CRS- certified protective cover. Contamination Use a protective cover to protect the arm from contaminated environments.

  • Page 28: Operator Safety

    A255 Robot Arm User Guide • Do not carry the arm any distance. Use a cart when transporting the arm. Grasp the robot under the base or arm link, not under the motor covers or wrist. Wiring and Encoders •...

  • Page 29: Safety And Operation Checks

    Operator Training Ensure that personnel who program, operate, maintain, or repair the robot are adequately trained and demonstrate competence to perform their jobs safely. Attend a CRS training course for proper training. Ensure that operators: • Are familiar with the applicable safety precautions as stated in this chapter.

  • Page 30: Working Within The Robot's Workspace

    A255 Robot Arm User Guide Working Within the Robot’s Workspace Before entering within the robot’s workspace, perform the following checks and safety precautions. • Visually inspect the robot to determine if any conditions exist that can cause malfunctions or injury to persons.

  • Page 31: Chapter 4 Installation

    C H A P T E R 4 Installation This chapter describes how to: • Design a Workcell • Unpack the Arm • Prepare a Mounting Platform • Mount the Arm on the Platform • Ground the Arm • Connect the Umbilical Cables to the Arm Arm or Controller First? You can install the arm first or the controller first.

  • Page 32: Required Tools And Supplies

    A255 Robot Arm User Guide Required Tools and Supplies You need the following tools and supplies to install the robot arm. Procedure Tools Supplies Designing a — — Workcell • Utility knife Unpacking the Arm — • Hex key ( in.),...

  • Page 33: Designing A Work Cell

    Chapter 4: Installation OPTIONS Container Contents • Arm labeled "DESCRIPTION: ARM" • Controller labeled "DESCRIPTION: CTRL" • Feedback cable labeled "OPTIONS" • Motor power cable • Fuse kit with AC power cable • Override plug • Options Designing a Work Cell When designing your work cell, consider: •...

  • Page 34: Unpacking The Arm

    A255 Robot Arm User Guide Upright Position You can install the arm upright on a table top. A portion of the workspace is occupied by the arm. Upright on a table top. Inverted Position When the arm is inverted, a greater portion of the table surface is available as workspace, but joint 2 and 3 limits must be considered.
  • Page 35 Chapter 4: Installation • Two or three persons As you unpack the arm, keep all packaging materials. To avoid damaging the arm or the shipping foam, remove the arm from the shipping container as follows: Getting Ready 1. Position the shipping container on the floor with shipping labels facing up. Position the container so that, when facing the container, the address label is at your far left and the description label is at the near right corner.
  • Page 36 A255 Robot Arm User Guide 6. Tilt up the arm’s back (on your right side). With the back higher, slide the arm out to your right, and then lift it up. Lifting the arm straight up from the bottom of the box is not possible, and will cause the shipping platform on the bottom of the arm to damage the foam packaging.

  • Page 37: Preparing The Mounting Platform

    Chapter 4: Installation Before you begin: • Clear any debris from the surface where you will place the base. 1. Using a hex key, unscrew the socket head cap screws fastening the base to the wooden shipping platform. 2. Remove the shipping platform. The encoder is now exposed on the open underside of the base.
  • Page 38 A255 Robot Arm User Guide 4. If you prepared a plate, firmly fasten the plate to your bench, bracket, or similar supporting structure. English (Imperial) units 99-04-23...
  • Page 39 Chapter 4: Installation Metric units 99-04-23...

  • Page 40: Mounting The Arm On The Platform

    1. Lift the arm onto the mounting platform. 2. Fasten the arm to the platform with the following fasteners. A mounting kit composed of these fasteners, imperial or metric, is available from CRS. Imperial: •...

  • Page 41: Connecting The Umbilical Cables

    Chapter 4: Installation • Electrical wire, minimum #12 gauge, from arm to grounding point. Procedure: 1. Connect the wire to the grounding stud with the nut. The stud is located on the left side of the rear of the robot arm base, beside the umbilical cable connectors.

  • Page 42: Next Steps

    A255 Robot Arm User Guide 3. Secure the cable grounding strap to the grounding point beside the connector, with the grounding screw, using a Phillips(+) screwdriver. Warning! Secure the cable grounding strap to the grounding point. Improper cable grounding can su the loss of arm position.

  • Page 43: Chapter 5 Commissioning

    C H A P T E R 5 Commissioning Commissioning is a set of procedures for starting up the robot system and testing it to ensure that it is functioning properly. Before commissioning, you must finish installing the arm and the controller. Commissioning involves five procedures that must be performed in sequence: 1.

  • Page 44: Check The Installation Of Arm And Controller

    A255 Robot Arm User Guide Check the Installation of Arm and Controller To check for proper functioning of the arm and to move the arm out of the shipping position, the arm and controller components must be installed and ready to operate.

  • Page 45: Check Encoder Feedback

    Chapter 5: Commissioning • Installed CROSnt on the computer, started CROSnt, and have the CROSnt Command Prompt window active. • Powered up the controller. • Have communication over the SimSockD connection. (Have \sbin\simsockd in -send mode running on CROSnt and \sbin\simsockd in -rcv mode running on CROS-500 with compatible configuration from each simsockd.cfg file.) Teach Pendant To use the teach pendant, ensure that you have:...

  • Page 46: Check All E-Stops

    A255 Robot Arm User Guide 2. Turn on the controller. The controller front panel display indicates “C500C CROS OK” and the terminal displays a $ prompt. 3. Start the application shell by typing ash test. 4. If the teach pendant is connected and obtains control, transfer control from the teach pendant to the terminal.

  • Page 47: Move Out Of The Shipping Position

    The arm is shipped with the wrist positioned at the bottom of the base and the tool flange turned towards the base. A255 arm shipping position. This is not a safe starting position. The recommended safe starting position. Once mounted, you can use the teach pendant or other tool to carefully move the arm out of the shipping position and into a safe starting position.
  • Page 48 A255 Robot Arm User Guide Using the Teach Pendant To use the teach pendant, follow these steps. Before you begin, ensure that you: • Connected the teach pendant. • Have the teach pendant (stpv3) process running and have control at the teach pendant.
  • Page 49 Chapter 5: Commissioning 6. When you are finished moving joints 2, 3, and 4 with the axis keys, the arm should be in a safe starting position, such as in the drawings on page 41. Using the Terminal To use the terminal, follow these steps. Before you begin, ensure that you: •...

  • Page 50: Check The Live-Man Switch

    A255 Robot Arm User Guide Check the Live-man Switch This procedure checks the teach pendant live-man switch to verify that it works. Note: You must hold the live-man switch with reasonable but not excessive force while you press an axis key for the duration of a robot move. Too little or too much force on the live-man switch breaks the e-stop circuit and removes arm power.

  • Page 51: Chapter 6 Basic Operation

    • Move the Arm by Limping One Joint at a Time The A255 is designed for stand-alone operation after homing. Stand-alone operation does not require operator intervention. RAPL-3 programs specially written for your particular application move the robot to predefined locations.

  • Page 52: Homing The Arm

    A255 Robot Arm User Guide Homing the Arm The A255 robot arm must be homed before you can teach locations or run any robot application. Why Home the Arm When power to the controller is off, the arm position data in the controller’s memory is lost.
  • Page 53 Chapter 6: Basic Operation 2. The bottom line of the screen indicates the selections. Press F1 (edit). This opens the Editing screen. Application test 1var 3motn 3. Press F3 (motion). This opens the Manual Motion screen. Manual Menu JOINT 3motn 4mode 4.
  • Page 54 A255 Robot Arm User Guide 4. Move each joint until its pointer sits within its starting zone. The location of pointer and zone labels are shown in the diagram. 5. When you are finished positioning the joints, the arm should be in the homing starting position.
  • Page 55 If the arm did not home correctly, repeat the procedure. • If the arm refuses to correctly home for three consecutive attempts, contact you distributor or CRS Robotics. Using the Terminal To use the terminal, follow these steps. Before you begin, ensure that you: •...
  • Page 56 +1000 motor –1000 and then home the arm. If this solves the problem, you may need to adjust your calibration. Contact your distributor or CRS Robotics. 99-04-23...

  • Page 57: Moving With The Teach Pendant

    Chapter 6: Basic Operation • If the arm refuses to home correctly for three consecutive attempts, contact your distributor or CRS Robotics. Moving with the Teach Pendant It is safer to use the teach pendant instead of terminal commands, since motion stops as soon as a pendant key is released, for most pendant keys.

  • Page 58: Moving With Terminal Commands

    A255 Robot Arm User Guide Joint mode directions are shown in the drawing on page 1 and described in the table below. Joint Axis Negative Positive – Waist Rotates arm Rotates arm (right-hand rule, vertical axis upward) Shoulder Lowers arm...
  • Page 59 Chapter 6: Basic Operation —A terminal emulator or the terminal window of Robcomm3 communicating through the front panel console port and having control of the robot at the application shell. (If not, at the teach pendant, press Shift + ESC to transfer control), or •...

  • Page 60: Moving By Limping One Joint At A Time

    A255 Robot Arm User Guide Moving by Limping One Joint at a Time In limp mode, a positive (+) key limps a joint and the negative (–) axis key unlimps the joint. “Ax 1” for axis 1 (the waist joint), “Ax2” for axis 2 (the shoulder joint), etc.
  • Page 61 Chapter 6: Basic Operation Warning! Support the link. Limping will release the joint. The link will fall due to gravity. Failure to support the link can result in damage to the arm, tooling, or work pieces. b. Press F2 for Yes. The joint limps. 039:Confirm: 039:Confirm: Limp robot axis?

  • Page 62: Gripper Installation

    C H A P T E R 7 Gripper Installation This chapter describes how to install the gripper. To install a gripper, the arm must be moved out of the shipping position and the tool flange made accessible. The gripper attaches onto the arm’s tool flange. If you are installing a homing bracket (for custom homing of the arm), you will need to install a tool adapter plate with ½...

  • Page 63: Installing The Gripper

    Chapter 7: Gripper Installation Installing the Gripper Installing a gripper requires the sequence of two procedures: 1) Limp the wrist 2) Attach the gripper to the wrist tool flange You need: • inch ball-head hex key Before you begin: • For best access to the tool flange, use the teach pendant or issue joint commands to place the arm in the Ready position and rotate joint 1 so the flange is towards you.

  • Page 64: Connecting The Cable Or Hose

    A255 Robot Arm User Guide 2) Attach the Gripper 1. Align the tool flange homing pointer anywhere near its homing zone, and position the gripper on the flange in your preferred position, either vertical or horizontal. 2. Position the gripper on the robot tool flange. Avoid straining the gripper cable, connector, hoses, and fittings.
  • Page 65 Chapter 7: Gripper Installation Pneumatic Gripper The pneumatic gripper is supplied with two inch [1.6 mm] barbed fittings. Caution! Design your pneumatic tooling so that, during a power failure, safe gripping is maintained. To connect the pneumatic gripper: The two air ports for the pneumatic gripper. 1.
  • Page 66 A255 Robot Arm User Guide Use the /diag/setup command to choose the type of gripper (air, servo, or magnetic), refer to the RAPL-3 Language Reference Guide. 99-04-23...

  • Page 67: Chapter 8 Calibration

    C H A P T E R 8 Calibration This chapter describes the circumstances and procedures for restoring factory calibration values or recalibrating the robot with new values. You can: • Reload factory calibration parameters when the calibration memory fails. •...

  • Page 68: Restoring Factory Calibration Values

    • A computer with Robcomm3 software • Your A255 Robot Arm distribution software disk or your own backup calibration disk if your system was previously recalibrated. The distribution disk contains calibration information stored in the following file. cal\srs_(robot arm serial number).cal The .cal file contains factory defined calibration values for the robot arm.

  • Page 69: Recalibrating The Robot Arm

    • Computer with Robcomm3 software • Your A255 distribution disk, or your own backup, if your system was previously recalibrated. If the distribution disk is lost, you can obtain a copy from your nearest distributor or CRS Robotics. Before you begin: •...
  • Page 70 A255 Robot Arm User Guide 3. Use the teach pendant to move the arm into an approximate Zero position, refer to the drawing below. Arm posed in the Zero (calrdy) position 4. Transfer control of the robot from the teach pendant to the terminal.
  • Page 71 Chapter 8: Calibration 8. Type nolimp and press Enter. Joint 1 unlimps. 9. Note the displayed motor pulse position and divide the travel value by two. This determines the value of the half-way position. Note: The sign (±) must be opposite of the displayed value. 10.
  • Page 72 3. Type /diag/cal and press Enter. At the prompt, type Y (yes). This resets the controller’s calibration data and homes the arm. 4. If required, pull off and re-apply the homing markers. Note: New markers can be purchased from CRS Robotics. 5. Type speed 10 and press Enter. 6. Type ready and press Enter.

  • Page 73: Calibrating An Extra Axis

    Chapter 8: Calibration 4. If you are using a homing bracket, ensure that all steps required for recalibration with the homing bracket are performed before you run your application. See the Homing Bracket User Guide. 5. Before running your application, perform the following check. a.
  • Page 74 A255 Robot Arm User Guide 99-04-23...

  • Page 75: Glossary

    The types of independent motions in which the arm can move its end effector (gripper, tool), as defined by the axes of motion. For example, the A255 has five degrees of freedom and can move to coordinates specified by X, Y, Z, Pitch, and Roll.
  • Page 76 A255 Robot Arm User Guide on a slightly smaller pitch diameter than the circular spline. The wave generator is a thin raced ball bearing assembly fitted onto an elliptical plug serving as a high efficiency torque converter. Interlock A safety device connected to a machine which prevents the machine from doing anything unless the device’s integrity is maintained or restored.
  • Page 77 Glossary Workspace The space or volume consisting of all points that the robot arm can reach. The outer boundary of the workspace is the work envelope. Yaw, Pitch, Roll The orientation of the wrist is defined by three angles: yaw (orientation about the Z axis), pitch (orientation about the Y axis), and roll (orientation about the X axis).
  • Page 78 A255 Robot Arm User Guide 99-04-23...

  • Page 79: Index

    Index acceleration rates, joint, 8 motion, axes of, 1 air supply, 59 motor power cable, 35 arm power, 39 mounting, 31 axes, 4 operator safety, 22 axes of motion, 1 Options, 2 barriers, 15 packaging materials, 31 brakes, 12 pick and place cycle, 8 cables, umbilical, 35 pneumatic gripper installation, 59 corrosive fumes, 21...
  • Page 80 Index 99-04-23...

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