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SCORBOT,ERIX

1. 1 2 RepackingforShipment 1 3 Specifications ________________ Structure 2 2 Work llle 2 3 Safety ooo PrecautloriS 5 guis ata mem FERE E s 3 1 MEDIIS ease eve ten fo fe yee ete Em e RIS 3 2 Installation amp 5 4 1 Controller and Computer Terminal Setup 4 1 Robot Setup oe 4 1 SCORBOT ER IX Installation 4 3 Controller Installation 4 3 Robot Installation 4 3 Homing the Robot a 4 4 5 4 5 Pneumatic 4 5 DC 4 7 Activating the Gripper 4 8 Operating Methods SoftWare BE EUR G 5 1 ACL ape DPF E be 5 1 ATS oth Ete we a Ba Ge 5 1 ouo eee ES bleed 5 2 SCORBASE 5 2 Teach Pendant a a 5 2 Drive System Motors mE S ita ud eerie eR BAAS 6 2 DC Motor Structure 6 3 SCORBOT ER IX Motors 6 4 Harmonic Drive Gears 6 5 Harmonic Drive 6 6 Axis
2. 6 7 vii SCORBOT ER IX CHAPTER 7 Position and Limit Devices Ns Wit eek dale ged Pese VEN 7 1 Encoder Resolution 7 3 End of Travel Limit Switches 7 4 Hard SODS nec Roe a 0 7 5 Home Switches 7 6 CHAPTER 8 Wiring Robot Power Cable and Connector 8 2 Encoder Cable and Connector 8 3 CHAPTER 9 Maintenance Daily 9 1 Periodic lt 9 2 Troubleshooting 9 2 Messages 9 6 User s Manual yiii SCORBOT ER IX 9603 CHAPTER 1 Unpacking and Handling This chapter contains important instructions for unpacking and inspecting the SCORBOT ER IX robot arm 8 Read this chapter carefully before you unpack the SCORBOT ER IX robot and controller Unpacking the Robot The robot is packed in expanded foam as shown in Figure 1 1 To protect the robot during shipment a metal plate holds the gripper mounting flange to the robot base The plate is fixed to the flange with three bolts and to the base with two bolts Use a 3mm hex socket wrench to detach these bolts Save these bolts and the plate You will need them should you repack the robot for shipment Save the original packing materials and shipping carton You may need them later
3. 4 blue M3 B D Motor 5 grey M4 A J Motor 5 pink M4 B F Motor 6 white M5 A G Motor 6 green M5 B SCORBOT ER IX 8 2 User s Manual 9603 Encoder Cable and Connector The encoder cable which connects the controller to the motor encoders and optical home switches contains 36 leads Figure 8 3 shows the D37 female connector that joins the encoder cable to the controller s back panel The following table details the connector pin functions and describes the cable wiring Figure 8 3 D37 Connector Encoder Cable and D37 Connector Pin Pin Description AXIS Telephone Pin Description ID Robot Side J1 Cable Color Controller Side J2 1 5V red 5V 8 COMMON yellow COMMON 0 5 Encoder Pulse A 1 green CHA 0 6 CHB 1 Encoder Pulse B white CHB 0 7 1 Encoder Index Pulse black CHC 0 31 MSWITCH Home Switch blue MSWITCH 1 5V red 5V 12 COMMON yellow COMMON 1 9 CHA2 Encoder Pulse A 2 green CHA 1 10 CHB2 Encoder Pulse B white CHB 1 11 CHC2 Encoder Index Pulse black CHC 1 32 MSWITCH Home Switch blue MSWITCH 1 5 45V 16 COMMON yellow COMMON 2 13 Encoder Pulse A 3 green CHA 2 14 CHB3 Encoder Pulse B white CHB 2 15 CHC3 Encoder Index Pul
4. ER IX 7 4 User s Manual 9603 As shown in Figure 7 7A when limit switch 1 is activated that 1s when the button is depressed the relay contact opens and the relay is deenergized The motor cannot move the joint beyond this point The diode allows the motor to reverse DRIVER direction thus permitting the joint to move away from the limit switch When the limit switch is activated it causes a control error resulting in the activation of COFF control off mode and an impact protection message CON control on mode must be activated and the robot arm must be manually moved using keyboard or teach pendant away from the impact condition Figure 7 7 Axis Limit Circuit As long as the axis has not reached one of its limits the relay contact remains closed and the diode has no effect on the circuit as shown in Figure 7 7B Current can flow in either direction the motor is thus able to rotate in either direction Hard Stops When the software limits and or the end of travel switches fail to halt the movement of the robot arm it is possible that the momentum of the robot arm will drive it until it reaches its mechanical limit When the joint reaches this hard stop the impact protection and thermic protection processes detect an error thus activating COFF CON must be activated and the robot arm must b
5. for shipment or for storage of the robot Figure 1 1 SCORBOT ER IX in Packing User s Manual 1 1 SCORBOT ER IX 9603 Handling Instructions The robot arm weighs 38 kilos 83 pounds Two people are needed to lift or move it Lift and carry the robot arm by grasping its body and or base Do not lift or carry the robot arm by its upper arm or forearm Acceptance Inspection After removing the robot arm from the shipping carton examine it for signs of shipping damage If any damage is evident do not install or operate the robot Notify your freight carrier and begin appropriate claims procedures The following items are standard components in the SCORBOT ER IX package Make sure you have received all the items listed on the shipment s packing list If anything is missing contact your supplier Item Description SCORBOT ER IX Includes Cabling with air hoses Hardware for mounting robot 3 Robot Arm 8 60 bolts 3 M8 washers 3 M8 nuts Gripper 2 options Pneumatic Gripper includes pneumatic solenoid valve Hardware for mounting gripper 6 4Mx8 screws Electric DC Servo Gripper with encoder includes Hardware for mounting gripper 4 4 10 screws ACL Controller B Includes Power Cable 100 110 220 240V AC RS232 Cable 3 driver cards for 6 axes Optional Emergency By Pass Plug required when TP not connected Additional driver cards for control of up to 12 axes Auxiliary mul
6. help you perform this test prepare and continuously run a simple ACL program as follows 9 3 SCORBOT ER IX LABEL 1 PRINTLN HS n DELAY 20 GOTO 1 If the value of HS does not change possible causes Faulty arm circuitry Faulty optical switch optical switch not properly mounted Faulty driver circuitry Problem in controller power supply unit 5 1 4 One of the axes does not function Check the driver card LED for this axis at the back of the controller If the LED is not lit check the corresponding fuse Check the motor drive circuitry Check the encoder Enter the command SHOW ENCO to display the encoder readings Enter the command COFF to disable servo control and then pAysically move the axis in question in both directions The encoder reading should rise for rotation in one direction and fall for rotation in the opposite direction If this does not occur there is a problem in the encoder or its circuitry If the encoder readings do not change check whether the encoder connector is properly connected to the rear controller panel The problem may be caused by faulty encoder connectors on the robot s internal PCB s 5 Motors suddenly stop No message on screen No response to keyboard entries Check the power source Make sure the MOTORS power switch is on make sure the Emergency button is not depressed Turn off the controller and open up the cover Turn on the controller Check the ye
7. is elliptical the flexspline is pushed out in two places As the motor rotates the input shaft the wave generator rotates and the location of meshing teeth rotates with it However because there are two less teeth on the flexspline it has to rotate backwards slightly as the wave generator rotates forwards For each complete rotation of the input shaft the flexspline moves backwards by two teeth Figures 6 7 and 6 8 show the different steps in this process FLEXSPLINE WAVE GENERATOR DYNAMIC SPLINE CIRCULAR SPLINE Figure 6 6 Harmonic Drive Structure User s Manual 6 5 SCORBOT ER IX 9603 Harmonic Drive Gear Ratios As in all gears the gear ratio of the Harmonic Drive is the ratio of the input speed to the output speed If the number of teeth on the flexspline is then for every revolution of the input shaft the output shaft rotates by 2 N of a revolution that is two teeth out of Ny teeth Hence 1 HD gear ratio s The Harmonic Drive gear ratios for each of the SCORBOT ER IX axes are as follows Axis 1 161 1 Circular Axis 2 160 1 Axis 3 160 1 Axis 4 100 1 Axis 5 100 1 Flexspline Figure 6 7 Operation of the Harmonic Drive Dynamic Spline ircular Spline Flexspline E 1 Wave Generator Starting After several position input revolutions Figure 6 8 Operation of the Harmonic Drive SCORBOT ER IX 6 6 User s Manual 96
8. 03 Axis Gear Ratios Referring again to Figure 6 1 the transmission of axes 1 through 4 consists of two stages the timing belt drive and the Harmonic Drive The overall gear ratio of the output shaft which moves the axis is therefore expressed as Nr X Nap Naxis Where Nr is the belt drive ratio that is the radii ratio NHD is the Harmonic drive ratio as described above NAXIS is the overall gear ratio of the axis SCORBOT ER IX Gear Ratios Nr Naxis Axis 1 ites ss geome 161 1 214 13 1 Axis 2 160 1 243 8 1 Axis 3 1 33 1 160 1 213 33 1 Axis 4 1 8 1 100 1 180 1 Axis 5 100 1 LOO 1 Thus one rotation 360 of axis 3 for example requires 213 33 rotations of the motor shaft The actual movement of the axis however is limited by the arm s mechanical structure User s Manual 6 7 SCORBOT ER IX 9603 This page intentionally left blank SCORBOT ER IX 6 8 User s Manual 9603 CHAPTER F Position and Limit Devices This chapter describes the various elements in the SCORBOT ER IX which play a part in the positioning of the robot arm and the limiting of its motion Encoders End of Travel Switches Hard Stops Home Switches Encoders The location and movement of each SCORBOT ER IX axis is measured by an electro optical encoder attached to the motor which drives the axis The encoder translates the rotary motion of th
9. During movement the robot arm reached its envelope limits and the system aborted the movement This may occur when executing the following types of movements linear MOVEL circular MOVEC MOVES and SPLINE Since the trajectory is not computed prior to motion the movement may exceed the limits of the working envelope Modify the coordinate values of the positions which define the trajectory UPPER LIMIT AXIS n During keyboard or TP manual movement of the specified axis its encoder attained its maximum allowed value Move the axis in the opposite direction 9 9 SCORBOT ER IX
10. R IX The SCORBOT ER IX robot arm is driven by DC electric motors These actuators converts signals from the controller electric power into rotations of the motor shaft mechanical power A robot arm such as the SCORBOT ER IX imposes severe requirements on the actuators such as the following The robot motor must rotate at different speeds and with a high degree of accuracy For example if the robot is to be used for a spray painting application it must be able to accurately follow the defined path at the specified speed The robot motor must allow fine speed regulation so that the robot will accelerate and decelerate as required by the application The robot motor must supply large torques throughout its speed range and also when the joint is stationary The robot motor must be able to stop extremely quickly without overshooting the target position and perform rapid changes in direction Since mounting motors on the robot arm adds to the robot s weight and inertia the robot motors must be light and compact yet powerful As shown in Figure 6 2 the motors of the SCORBOT ER IX are located on the axes they drive with a two stage axes 1 4 or one stage axis 5 transmission MOTOR 5 Our Figure 6 2 Motor Locations in SCORBOT ER IX 6 2 User s Manual 9603 DC Motor Structure The principles of operation of electrical motors in general and DC motors in particular are based on an ele
11. SCORBOT ER IX User s Manual 2nd Edition ESED gt WARNING The SCORBOT ROBOT is DANGEROUS and can cause severe injury USE WITH EXTREME CAUTION Set up a protective screen or guardrail around the robot to KEEP PEOPLE AWAY from its working range Copyright 1996 1999 Eshed Robotec Catalog 100066 Rev B ISBN 965 291 068 6 March 1996 March 1999 Reprinted PDF version Every effort has been made to make this book as complete and accurate as possible However no warranty of suitability purpose or fitness is made or implied Eshed Robotec is not liable or responsible to any person or entity for loss or damage in connection with or stemming from the use of the software hardware and or the information contained in this publication Eshed Robotec bears no responsibility for errors which may appear in this publication and retains the right to make changes to the software hardware and manual without prior notice ESHED ROBOTEC INC 444 East Industrial Park Drive Manchester NH 03109 USA Tel 1 800 777 6268 Tel 603 625 8600 Fax 603 625 2137 User s Manual y SCORBOT ER IX 9603 User s Manual yi SCORBOT ER IX 9603 Table of Contents CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 5 CHAPTER 6 User s Manual 9603 Unpacking and Handling Unpacking the 1 1 Handling 1 2 Acceptance Inspection
12. SH 1f it exists has been executed Possible causes 1 The arm attempted to reach a position which could not be reached due to an obstacle for example a position defined as being above a table but actually slightly below the table s surface The impact protection is not activated because the obstacle is close to the target position However integral feedback will increase the motor current and the motor will overheat subsequently causing the Thermic Protection to be activated 2 An axis driver is faulty or its fuse has blown 3 The robot arm is near to the target position but does not succeed in reaching it due to a driver fault The software will then detect an abnormal situation 4 The Thermic Protection parameters are improperly set or have been corrupted by improper loading of parameters Check the positions the axis driver card and parameters Reenable servo control of the motors CON LARGE SPEED axis n Possible causes 1 The controller has detected a movement which is too fast that is the required displacement of the encoder as calculated from the speed limit parameter PAR 180 axis is too great 2 Since the trajectory is not calculated prior to a linear or circular movement the linear or circular movement may cause one of the joints to move too fast Lower the value of speed for that movement SCORBOT ER IX 9 8 User s Manual 9603 User s Manual 9603 TRAJECTORY ERROR
13. ailed descriptions and examples of the ACL commands and functions ATS Advanced Terminal Software is the user interface to the ACL controller ATS is supplied on diskette and operates on any PC The software is a terminal emulator which enables access to the ACL environment from a PC host computer 5 1 SCORBOT ER IX ATS features include the following Short form controller configuration Definition of peripheral devices Short cut keys for command entry Program editor Backup manager Print manager The ATS Reference Guide for Controller B is a complete guide to ATS ACLoff line ACLoff line is a preprocessor software utility which lets you access and use your own text editor to create and edit ACL programs even when the controller is not connected or not communicating with your computer After communication is established the Downloader utility lets you transfer your program to the controller The Downloader detects the preprocessor directives and replaces them with a string or block of ACL program code ACLoff line also enables activation of ATS Advanced Terminal Software for on line programming and system operation ACLoff line is described fully in the ACLoff line User s Manual SCORBASE Software SCORBASE Level 5 is a robot control software package which is supplied on diskette with the controller Its menu driven structure and off line capabilities facilitate robotic programming and operation SCORBASE runs
14. arm Make sure the connector is oriented as shown in Figure 4 10 Make sure the gripper cable is positioned as shown in Figure 4 11 Carefully execute the robot HOME command Stay close to the teach pendant or controller If the gripper cable becomes entangled or excessively stretched during the homing abort the procedure immediately The gripper has a rotation of 270 Do not attempt to move the gripper beyond this limit At the end of each work session before turning off the controller or before homing the robot make sure the gripper s position is as shown in Figure 4 11 Axis 6 is reserved by default controller configuration for a servo gripper To connect a different device as axis 6 you must change the system configuration by means of the ACL command CONFIG User s Manual 9603 Figure 4 10 Connecting Gripper to SCORBOT ER IX 4 7 SCORBOT ER IX Figure 4 11 Connecting Gripper to SCORBOT ER IX Activating the Gripper 1 2 Activate ATS Press lt Ctrl gt F3 to activate the Peripheral Setup screen Change the robot gripper defini
15. connector screws are fastened The gripper is properly connected The air supply for a pneumatic gripper is functioning properly Any peripheral devices or accesssories which will be used such as the teach pendant or a remote emergency button are properly connected to the controller 2 After you have powered on the system check the following items No unusual noises are heard No unusual vibrations are observed in any of the robot axes There are no obstacles in the robot s working range 3 Bring the robot to a position near home and activate the Home procedure Check the following items Robot movement is normal No unusual noise is heard when robot arm moves Robot reaches home position in every axis User s Manual 9 SCORBOT ER IX 9603 Periodic Inspection The following inspections should be performed regularly Check robot mounting bolts for looseness using a wrench Retighten as needed Check all visible bolts and screws for looseness using a wrench and screwdriver Retighten as needed Check cables Replace if any damage is evident The following robot components may require replacing after prolonged use of the robotic arm causes them to wear or fail DC Servo Motors Motor Brushes Timing Belts V Rings Harmonic Drives Cross Roller Bearings Troubleshooting Whenever you encounter a problem with your system try to pinpoint its source by exchanging the suspected faulty component for example
16. control on has not been issued the motors have not been activated 3 A previous error such as Impact Protection Thermic Overload or Trajectory Error activated COFF thereby disabling the arm HOME FAILURE AXIS n The homing procedure failed for the specified axis Possible causes 1 The home microswitch was not found 2 The motor power supply is switched off 3 Hardware fault on this axis Home on group axis not done You attempted to move the arm to a recorded positions or to record a position before homing was performed on the group or axis SCORBOT ER IX 9 6 User s Manual 9603 User s Manual 9603 IMPACT PROTECTION axis n The controller has detected a position error which is too large The system aborted all movements of that axis group and disabled all axes of that group The user routine CRASH if it exists has been executed Possible causes 1 An obstacle prevented the movement of the arm 2 An axis driver fuse has blown 3 The motor power switch is turned off 4 An encoder fault 5 A mechanical fault 6 The axis is not connected Determine and correct the cause of the position error Then reenable servo control of the motors CON and restart the program INDEX pulse not found axis n The index pulse of the encoder was not found during the homing of the specified axis Possible causes 1 The distance between the index pulse and the home switch transition position has changed
17. ctrical current flowing through a conductor situated within a magnetic field This situation creates a force which acts on the conductor Figure 6 3 shows the basic structure and components of a DC motor comparable to the structure of the motors used in the SCORBOT ER IX This motors has three main components Stator This is a static component which creates the magnetic field The stator may be a permanent magnet or an electromagnet consisting of a coil wound around thin iron plates Rotor This is the component which rotates within the magnetic field The external load is connected to the rotor shaft The rotor is generally composed of perforated iron plates and a conducting wire is wound several times around the plates and through the perforations The two ends of the conductor are connected to the two halves of the commutator which are connected to the electric current via the brushes Brushes These connect the rotating commutator to the electric current source Electrical Connections Housing STATOR Permanent Magnet Bearing BRUSHES Commutator Shaft Winding Commutator Plate Figure 6 3 Basic Structure of a DC Motor User s Manual 6 3 SCORBOT ER IX 9603 SCORBOT ER IX Motors The SCORBOT ER IX uses permanent magnet DC motors to drive the axes Axes 1 2 and 3 of the SCORBOT ER IX are powered by the motor shown in Figure 6 4 Axes 4 and 5 are powered by the motor shown in Figure 6 5 These motors a
18. d circuit board PCB The motors encoders limit switches and home switches for each axis are directly connected to one of these three internal PCBs Two wire braids connect the PCBs Each PCB transfers power to the motors to which it is directly connected and receives signals from the corresponding limit and home switches When a limit switch is triggered the PCB automatically cuts off power to the motor that drives the axis In addition each PCB transfers power to the next PCB and sends encoder and home switch signals to the previous PCB The robot and encoder cable are directly connected to PCB 18100 The robot cable supplies power to the PCB and the encoder cable carries information from the encoders and the home switches for all six axes to the controller 8 1 SCORBOT ER IX Robot Power Cable and Connector Figure 8 2 shows the Burndy 19 pin male connector that joins the power cable to the controller s back panel The robot cable contains 12 leads The following table details the connector pin functions and cable wiring Figure 8 2 Burndy 19 Pin Connector Robot Power Cable Wiring and Connector Pin Pin Description Beldan Pin Description ID Robot Side J1 Color Controller Side P1 A Motor 1 black MO A M Motor 1 red MO B C Motor 2 brown L Motor 2 orange MI B E Motor 3 yellow M2 A H Motor 3 purple M2 B B Motor 4 light blue M3 A K Motor
19. due to a mechanical fault on the axis or a maintenance procedure such as replacement of the motor motor belt encoder or gear Enter the command ZSET Then retry homing 2 Index pulse faulty Check the encoder and wiring LOWER LIMIT AXIS n During keyboard or TP manual movement of the specified axis its encoder attained its minimum allowed value Move the axis in the opposite direction Motor power switch is OFF Be sure the controller s MOTORS switch is on Activate CON Then repeat the motor or movement command No hard homing axis n The specified axis has not been configured for hard homing Use the HOME command instead of HHOME OR Check the type of homing suitable for that axis If necessary change the system parameters to allow hard homing of the axis No homing The homing parameters for the axis PAR 460 axis and PAR 600 axis are set to 0 as a result the homing procedure will not be performed on the axis 9 7 SCORBOT ER IX OUT OF RANGE axis n An attempt was made to record a position HERE HEREC etc while the robot arm was out of its working envelope Manually move the arm to a location within its working envelope Then repeat the command THERMIC OVERLOAD axis n Through a software simulation of motor temperature the system has detected a dangerous condition for that motor The system aborted all movements of that axis group and disabled all axes of that group The user routine CRA
20. e manually moved away from the impact condition User s Manual 7 5 SCORBOT ER IX 9603 Home Switches The SCORBOT ER IX uses an optical home switch on each axis to identify the fixed reference or home position The home switch is mounted on the same disk as the end of travel switches and a flag is attached to the Harmonic Drive output shaft as shown in Figure 7 8 During the homing procedure the robot joints are moved one at a time Each axis is moved until the flag cuts the beam of light When that occurs the optical detector on each joint sends a specific signal to the controller Once the home switch location has been detected the axis motor continues to rotate until its encoder produces an index pulse The point at which that occurs is the axis home position UMT _ 4 HARMONIC DRIVE SWITCH O SWITCH DISK OPTICAL OPTICAL HOME HOME AXIS NOT AT HOME AXIS AT HOME Figure 7 8 Home Switch Activation SCORBOT ER IX 7 6 User s Manual 9603 User s Manual 9603 CHAPTER 8 Wiring Figure 9 1 is a schematic diagram of the SCORBOT ER IX cable connections PCB 18300 18100 18200 POWER CROBOT 1 CONTROLLER B ENCODERS Figure 8 1 SCORBOT ER IX Cabling The wire braid which connects the robot to the controller contains a power robot cable and an encoder cable The body upper arm and forearm links each contain a printe
21. e motor shaft into a digital signal understood by the controller Figure 7 1 shows the encoder mounted on a SCORBOT ER IX motor The encoder used on the SCORBOT ER IX contains a single light emitting diode LED as its light source Opposite the LED is a light detector integrated circuit This IC contains several sets of photodetectors and the circuitry for producing a digital signal A perforated rotating disk is located between the emitter and detector IC Figure 7 1 SCORBOT ER IX Encoder User s Manual 7 1 SCORBOT ER IX 9603 As the encoder disk rotates between the emitter and detectors the light beam is interrupted by the pattern of bars and windows on the disk resulting in a series of pulses received by the detectors The SCORBOT ER IX encoders have 512 slots as shown in Figure 7 2 An additional slot on the encoder disk is used to generate an index pulse C pulse once for each full rotation of the disk This index pulse serves to determine the home position of the axis Figure 7 2 SCORBOT ER IX Encoder Disk The photodetectors are arranged so that alternately some detect light while others do not The photodiode outputs are then fed through the signal processing circuitry resulting in the signals A A B B I and I as shown in Figure 7 3 Comparators receive these signals and produce the final digital outputs for channels A B and I The output of channel A is in quadrature with that of chan
22. e work space Figures 2 1 and 2 2 identify the joints and links of the mechanical arm Each joint is driven by a permanent magnet DC motor via a Harmonic Drive gear transmission and timing belt The movements of the joints are described in the following table Axis No Joint Name Motion Motor No 1 Rotates the body 1 2 Shoulder Raises and lowers the upper arm 2 3 Elbow Raises and lowers the forearm 3 4 Wrist Pitch Raises and lowers the end effector 4 5 Wrist Roll Rotates the end effector 5 Figure 2 1 SCORBOT ER IX Joints Figure 2 2 SCORBOT ER IX Links SCORBOT ER IX 2 2 User s Manual 9603 Work Envelope The length of the links and the degree of rotation of the joints determine the robot s work envelope Figure 2 3 shows the dimensions and reach of the SCORBOT ER IX while Figure 2 4 gives a top view of the robot s work envelope The base of the robot is normally fixed to a stationary work surface It may however be attached to a slidebase resulting in an extended working range 4 37in RE d Lr 152mm 6in Figure 2 3 Operating Range Side View User s Manual 2 3 SCORBOT ER IX 9603 Figure 2 4 Operating Range Top View User s Manual 2 4 SCORBOT ER IX 9603 CHAPTER 3 Safety The SCORBOT ER IX is a potentially dangerous machine Safety during operation is of the utmost importance Use extreme caution when work
23. ecision with which it is positioned is affected by such factors as backlash mechanical flexibility and control variations User s Manual 7 3 SCORBOT ER IX 9603 End of Travel Limit Switches The SCORBOT ER IX uses limit switches to prevent the joints from moving beyond their functional limits When a control error fails to stop the axis at the end of its working range the limit switch serves to halt its movement The switch is part of an electric circuit within the robot arm independent of the robot controller The limit switches used in the SCORBOT ER IX are shown in Figure 7 5 Each of axes 1 through 4 has two limit switches one at each end of the axis working range Axis 5 roll has no travel limit switches it can rotate endlessly When a gripper is attached to axis 5 its movements are controlled and limited by means of software only encoder The limit switches are mounted on a disk which is attached to the robot s frame The disk for axis 3 is shown in Figure 7 6 Figure 7 5 The output shaft of the Harmonic Drive moves SCORBOT ER IX relative to the microswitch disk Limit Switch As the joint moves a cam 8 ACTUATING on the Harmonic Drive BUTTON output shaft reaches a point LIMIT F at which it forces the SWITCH actuating button of the limit switch into a position which activates the switch HARMONIC LIMIT SWITCH _ DRIVE OUTPUT Figure 7 6 Limit Switch Activation SCORBOT
24. ed for both the robot and the controller 2 Do not install or operate the SCORBOT ER IX under any of the following conditions Where the ambient temperature drops below or exceeds the specified limits Where exposed to large amounts of dust dirt salt iron powder or similar substances Where subject to vibrations or shocks Where exposed to direct sunlight Where subject to chemical oil or water splashes Where corrosive or flammable gas is present Where the power line contains voltage spikes or near any equipment which generates large electrical noises 3 Donotabuse the robot arm SCORBOT ER IX Do not operate the robot arm if the encoder cable is not connected to the controller Do not overload the robot arm The combined weight of the workload and gripper may not exceed 2kg 4 4 Ib It is recommended that the workload be grasped at its center of gravity Do not use physical force to move or stop any part of the robot arm Do not drive the robot arm into any object or physical obstacle Do not leave a loaded arm extended for more than a few minutes Do not leave any of the axes under mechanical strain for any length of time Especially do not leave the gripper grasping an object indefinitely 3 2 User s Manual 9603 CHAPTER 4 Installation Preparations Before you make any cable connections set up the system components according to the following Preparation instructions Controller and Computer Te
25. he controller is in the control off COFF state Then activate the control on CON state from PC or TP Make sure all robot and encoder cables are properly connected Check driver card fuses Each driver card has a pair of LEDs and a pair of fuses accessible from controller back panel The upper LED and fuse correspond to the axis number at the top of the card the lower LED and fuse correspond to the axis number at the bottom of the card Both LEDs on each card in use should be lit indicating that power is being supplied to the axis driver If one of the LEDs is not lit remove the fuse for the corresponding axis and examine it To remove the fuse press it in and rotate counter clockwise Robot does not find Home position in one or all of the axes Make sure the homing command was properly issued Make sure all robot and encoder cables are properly connected If the robot has just undergone maintenance or repair use the command ZSET Then issue the home command Make sure system homing parameters have not been erased Make sure system homing parameters are properly set Refer to the ACL Reference Guide Check whether the optical home switch for this axis is functioning Manually move the faulty axis from teach pendant or keyboard and check the value of system variable HS n where n is the index of the axis The value of HS will change to either 1 or 0 defined by parameter 560 axis when the home switch is detected To
26. ing with the robot Precautions User s Manual 9603 The following chapters of this manual provide complete details for proper installation and operation of the SCORBOT ER IX The list below summarizes the most important safety measures Make sure the robot base is properly and securely bolted in place Make sure the cable from the body to the base can move freely during all movements of the robot s base axis Make sure both the encoder cable and the robot power cable are properly connected to the controller before it is turned on Make sure the robot arm has ample space in which to operate freely Make sure a guardrail or rope has been set up around the SCORBOT ER IX operating area to protect both the operator and bystanders Do not enter the robot s safety range or touch the robot when the system is in operation Press the controllers EMERGENCY switch before you enter the robot s operating area Turn off the controller s POWER switch before you connect any inputs or outputs to the controller To immediately abort all running programs and stop all axes of motion do any of the following press the teach pendant s EMERGENCY button use the ACL command A Enter press the controller s red EMERGENCY button 3 1 SCORBOT ER IX Warnings 1 Do not operate the SCORBOT ER IX until you have thoroughly studied both this User s Manual and the ACL Controller B User s Manual Be sure you follow the safety guidelines outlin
27. llow watchdog LED on the main board If it is lit it indicates that that one of the following fuses on the power supply unit has blown out 12VA 12VA 12VDR 12VDR Turn off the controller and disconnect it from the power source Check each of these four fuses Replace the blown fuse SCORBOT ER IX 9 4 User s Manual 9603 6 Errors the repeatability of the robot Try to identify the faulty axis If many or all axes are faulty look for an electrical noise source in your environment Check the controller s ground and the robot s ground connection to the safety ground terminal at the back of the controller Check the encoder Bring the robot to a starting position Using a pencil draw a fine continuous line on the robot which crosses from the cover of one link to the cover of the adjacent link at the joint in question Enter the command SHOW ENCO to display the encoder readings Enter the command COFF to disable servo control and then physically move the axis to another position Then return to the starting position marked by the line you drew Check the encoder reading for the axis again It should be within 5 counts of the previous reading if not the encoder needs to be replaced 7 Unusual noise Loose screws Poor lubrication Ratcheting Worn motor brushes Worn timing belt Damaged harmonic drive 8 Unusual smell A motor has burnt out and needs to be replaced 9 Axis axes vibrating too weak t
28. masking tape 1 3 SCORBOT ER IX This page intentionally left blank SCORBOT ER IX 1 4 User s Manual 9603 CHAPTER 2 Specifications The following table gives the specifications of the SCORBOT ER IX robot arm Robot Arm Specifications Mechanical Structure Vertical articulated enclosed casting Number of Axes 5 plus gripper Axis Movement Axis Range Effective Speed Axis 1 Base rotation 2770 79 sec 112 sec Axis 2 Shoulder rotation 145 68 sec 99 sec Axis 3 Elbow rotation 210 76 sec 112 sec Axis 4 Wrist pitch 196 87 sec 133 sec Axis 5 Wrist roll 737 166 sec Maximum Operating Radius 691mm 27 2 without gripper End Effector options Pneumatic Gripper Electric DC Servo Gripper Hard Home Fixed position on all axes Feedback Incremental optical encoders with index pulse Actuators DC servo motors Transmission Harmonic Drive gears and timing belts Maximum Payload 2 kg 4 4 Ib including gripper Position Repeatability 0 09mm 0 0035 Weight 38 kg 83 Ib Ambient Operating Temperature 2 40 36 104 User s Manual SCORBOT ER IX 9603 Structure The SCORBOT ER IX is a vertical articulated robot with five revolute joints With gripper attached the robot has six degrees of freedom This design permits the end effector to be positioned and oriented arbitrarily within a larg
29. matic valve Connect a 5 bar 90 PSI air supply to the IN port on the valve Refer to Figure 4 9 Figure 4 6 Pneumatic Gripper Connect the valve to the controller s User Power Supply as follows Connect the black wire to a common terminal Connect the red wire to the normally open NO terminal of any unused relay output Connect 12VDC or 24VDC in accordance with your valve s specification to the common C terminal of the same relay output as shown in Figure 4 9 4 5 SCORBOT ER IX 6 Attach the valve to the controller or any other metalic surface by means of the valve s magnetic base WIRES TO CONTROLLER et AIR HOSES TO ROBOT Figure 4 8 Pneumatic Solenoid Valve GUICK COUPLER FOR PNEUMATIC GRIPPER CONNECTOR FOR SERVO GRIPPER USER POWER SUPPLY RELAY OUTPUTS 4 0020000000000 24 VOC GRIPPER MOUNTING FLANGE to Solenoid Valve Figure 4 7 Figure 4 9 Valve Controller Connections Gripper Connectors SCORBOT ER IX 4 6 User s Manual 9603 DC Servo Gripper The electric DC servo gripper is shown in the inset in Figure 4 10 The robot must be homed before you mount the gripper Refer to Figures 4 10 and 4 11 Using 3 mm hex wrench and four M4x10 socket screws attach the gripper to the gripper mounting flange at the end of the robot arm Connect the gripper cable to the electrical connector on the robot
30. nel B 90 out of phase as shown in Figure 7 4 The final output of channel I is an index pulse When the disk rotation is counterclockwise as viewed from the encoder end of the motor channel A will lead channel B When the disk rotation is clockwise channel B will lead channel A COMPARATORS DETECTOR Figure 7 3 Encoder Circuitry Figure 7 4 Encoder Output Signals SCORBOT ER IX 7 2 User s Manual 9603 Encoder Resolution From the quadrature signal the SCORBOT ER IX controller measures four counts for each encoder slot thus quadrupling the effective resolution of the encoder The resolution of the encoder is expressed as 360 n Se Where SE is the resolution of the encoder n is the number of counts per encoder revolution The encoders used in the SCORBOT ER IX have 512 slots generating 2048 counts per motor revolution The encoder resolution is therefore Soe 176 When the encoder resolution is divided by the overall gear ratio of the axis the resolution of the joint is obtained Since the encoder is mounted on the motor shaft and turns along with it the resolution of the joint is expressed as SE SJOINT PETS Thus for example the resolution of joint 3 of the SCORBOT ER IX is therefore as follows S73 SE 0 000825 The resolution is the smallest possible increment which the control system can identify and theoretically control The accuracy of the axis that is the pr
31. nnector into the Robot Power port ee 9 6 o 6 6 o e be AIR HOSES for pneumatic gripper only F FL 9 06 06 oy Den 9 9 es roar rower Figure 4 4 Robot Controller Cable Connections User s Manual 4 3 SCORBOT ER IX 9603 Note When disconnecting the robot from the controller do it in the reverse order that 1s Disconnect the 19 pin round Robot Power connector Disconnect the 37 pin Encoders connector Disconnect the ground wires Homing the Robot After you have completed the robot installation execute the robot s Home routine as described below 9 The robot must be homed before you mount the gripper 9 Before you begin the homing procedure make sure the robot has ample space which to move freely and extend its arm 1 Turnon the controller Turn on the computer 2 From the ATS diskette or directory activate the ATS software Type ats Enter If the controller is connected to computer port COMO type ats c2 3 When the ATS screen and prompt appear you may proceed 4 Give the ACL command to home the robot Type home Enter The monitor will display WAIT HOMING During the Home procedure the robot joints move and search for their home positions in the foll
32. o carry load motion not smooth or jerks during or at end of motion System parameters are not properly adjusted Refer to the ACL Reference Guide Problem in axis driver card s in the controller Refer to the Controller B User s Manual User s Manual 9 5 SCORBOT ER IX 9603 10 Pneumatic gripper does not respond Check that all air hoses are connected properly Make sure the gripper is connected to the proper controller output Check the relay output to which the gripper is connected Check whether the relays have been switched LED is lit In output OFF NC is shorted to COM NO is disconnected from COM In output ON NO is shorted to COM NC is disconnected from COM If outputs have not been switched check the flat cable in the controller connecting the main board J17 and the I O card Messages Following is a alphabetical listing of system messages which indicate a problem or error in the operation of the robot arm Refer to the ACL Reference Guide for additional error messages Axis disabled 1 A movement command could not be executed because servo control of the arm has been disabled COFF 2 A previous movement of the arm resulted in an Impact or Trajectory error thereby activating COFF and disabling the arm Check the movements of the robot and correct the command s CONTROL DISABLED Motors have been disconnected from servo control Possible causes 1 COFF control off command was issued 2 CON
33. on any PC system and communicates with ACL the controller s internal language by means of an RS232 channel The SCORBASE Level 5 for Controller B Reference Guide provides detailed descriptions and examples of the SCORBASE commands Teach Pendant The teach pendant is a hand held terminal which is used for controlling the SCORBOT ER IX robot and peripheral equipment The teach pendant is most practical for moving the axes recording positions sending the axes to recorded positions and activating programs Other functions can also be executed from the teach pendant The Teach Pendant for Controller B User s Manual fully describes the various elements and functions of the teach pendant SCORBOT ER IX 5 2 User s Manual 9603 CHAPTER 6 Drive System The three main elements of the SCORBOT ER IX drive system are shown in Figure 6 1 DC electrical motor Harmonic Drive gear Timing belt and pulleys Figure 6 1 shows the drive system for axes 1 through 4 of the SCORBOT ER IX The roll axis axis 5 transmission does not contain the pulleys and timing belt only a Harmonic Drive is used 87 Note that the illustrations of components shown in this chapter are for descriptive purposes and may not be the actual components used in the SCORBOT ER IX TIMING BELT PULLEY PULLEY H D OUTPUT SHAFT ERU 5 Figure 6 1 The SCORBOT ER Drive System User s Manual 6 1 SCORBOT ER IX 9603 Motors SCORBOT E
34. owing sequence shoulder elbow pitch roll base If home is found a message is displayed HOMING COMPLETE ROBOT If the HOME process is not completed an error message identifying the failure is displayed For example HOME FAILURE AXIS 3 If the home switch is found but not the encoder s index pulse the following message is displayed INDEX PULSE NOT FOUND AXIS 2 SCORBOT ER IX 4 4 User s Manual 9603 Gripper Installation Pneumatic Gripper User s Manual 9603 The gripper is attached to the flange at the end of the robot arm whose layout is shown in Figure 4 5 M4 8mm DEEP X6 The pneumatic gripper shown in Figure 4 6 is controlled by a 5 2 solenoid pneumatic valve which is activated by one of the controller s relay outputs The valve may be 12VDC or 24VDC and can draw its power from the controller s User Power Supply Figure 4 5 Gripper Mounting Flange Layout The robot must be homed before you mount the gripper Using a hex wrench and six 4 8 socket screws attach the gripper to the robot arm flange Connect the coiled double hose from the gripper to the quick coupling on the robot s forearm as indicated in Figure 4 7 Refer to Figure 4 8 Connect the two transparent 1 4 O D hoses from the robot cable to the CYL ports on the pneu
35. re able to move at extremely high rates of revolution to move loads with high torques and with encoder attached to achieve a very high resolution Motor Specifications Motor Axes 1 2 3 Motor Axes 4 5 Peak Rated Torque 143 oz in 27 8 ozin Rated Torque 32 oz in 12 5 ozin Maximum Operating Speed 4000 rpm 4500 rpm Weight 1 29 k 2 84 lb 0 28 k 0 62 16 Figure 6 4 Motor on Axes 1 2 and 3 Figure 6 5 Motor on Axes 4 and 5 SCORBOT ER IX 6 4 User s Manual 9603 Harmonic Drive Gears The Harmonic Drive transmission used in the SCORBOT ER IX shown in Figure 6 6 offers a very high gear ratio The Harmonic Drive gears used in the SCORBOT ER IX have four main components Circular spline a solid steel ring with internal gear teeth usually fixed to the robot link Wave generator a slightly elliptical rigid disk which is connected to the input shaft with a ball bearing mounted on the outer side of the disk Flexspline a flexible thin walled cylinder with external gear teeth usually connected to the output shaft Dynamic spline a solid steel cylinder with internal gear teeth The external gear teeth on the flexspline are almost the same size as the internal gear teeth on the circular spline except there are two more teeth on the circular spline and the teeth only mesh when the wave generator pushes the flexspline outwards Because the wave generator
36. rminal Setup Place the controller and computer at a safe distance from the robot well outside the robot s safety range Make sure the setup complies with the guidelines defined in the chapter Safety in the ACL Controller B User s Manual Robot Setup User s Manual 9603 Refer to Figures 4 1 4 2 and 4 3 Set up the SCORBOT ER IX on a sturdy surface with at least one meter of free space all around the robot Note that the robot cable clamp is located at the midpoint of the robot s horizontal range Using this midpoint as a reference set up the robot so that it faces in the proper direction towards the application or machine it will serve Fasten the base of the robot to the work surface with three sets of M8 bolt washer and nut Figure 4 1 Robot Safety Range 4 1 SCORBOT ER IX Make sure the robot is securely bolted in place Otherwise the robot could become unbalanced and topple over while in motion gt Grasp the robot body and turn the robot to each extreme of its base axis 9 Make sure the segment of cable from the body to the base is not obstructed and or cannot become NN 4 caught under a corner of the robot s platform or work surface during all movements of the base axis Make sure the robot is mounted on a surface large enough to provide support for this segment of the robot cable d
37. robot controller teach pendant cable with one from a functioning system In general when trying to determine the source of a malfunction first check the power source and external hardware such as controller switches LEDs and cable connections Then check fuses you may also open the controller to check components according to the procedures and instructions detailed in the Controller B User s Manual In addition make sure the controller is properly configured for the robot and gripper the software commands have been correctly issued and system parameters are properly set All troubleshooting procedures described in the section can be performed by the user Do not attempt to open the robot arm There are no user serviceable parts inside If you are unable to determine and or correct the problem contact your service representative Only qualified technicians may remove and or replace robot components SCORBOT ER IX 9 2 User s Manual 9603 1 2 3 User s Manual 9603 Controller s MOTORS switch does not turn on the green LED does not light Make sure the Emergency button is released Turn off the controller disconnect it from the power source and open the cover Check the 0 5A SB fuse marked FAN POWER RELAYS Controller functioning but the robot cannot be activated Make sure an obstacle is not blocking the robot Make sure the controllers MOTORS switch is on and the green LED is lit Make sure t
38. se black CHC 2 33 MSWITCH Home Switch blue MSWITCH User s Manual 6 3 SCORBOT ER IX 9603 Encoder Cable and 037 Connector Pin Pin Description Asie Telephone Pin Description ID Robot Side J1 Cable Color Controller Side J2 2 5V red 5V 20 COMMON yellow COMMON 3 17 CHA4 Encoder Pulse A 4 green CHA 3 18 CHB4 Encoder Pulse B white CHB 3 19 CHC4 Encoder Index Pulse black CHC 3 34 MSWITCH Home Switch blue MSWITCH 2 5V red 5V 24 COMMON yellow COMMON 4 21 CHAS Encoder Pulse A 5 green CHA 4 22 CHBS Encoder Pulse B white CHB 4 23 CHCS Encoder Index Pulse black CHC 4 35 MSWITCH Home Switch blue MSWITCH 2 45V red 45V 28 COMMON yellow COMMON 5 25 CHA6 Encoder Pulse A 6 green CHA 5 26 CHB6 Encoder Pulse B white CHB 5 27 CHC6 Encoder Index Pulse black CHC 5 36 MSWITCH Home Switch blue MSWITCH SCORBOT ER IX 6 4 User s Manual 9603 CHAPTER 9 Maintenance The maintenance and inspection procedures recommended below will ensure the best possible performance of the robot over an extended period Daily Operation At the start of each working session check the robot and controller in the following order 1 Before you power on the system check the following items The installation meets all safety standards cables are properly and securely connected Cable
39. tion according to the gripper you have installed Refer to the section Peripheral Devices and Equipment Robot Gripper in Chapter 2 of the ACL Controller B User s Manual Open and close it in order to verify that it is functioning The following commands work for both the electric and the pneumatic gripper Type open lt Enter gt The gripper opens Type close lt Enter gt The gripper closes Key in Open Close The Open Close key toggles the gripper between its open and closed states programs you have just written SCORBOT ER IX 4 8 User s Manual 9603 CHAPTER 5 Operating Methods The SCORBOT ER IX robot can be programmed and operated in a number of Ways The Controller B User s Manual includes two chapters which guide you through the basic commands for operating and programming the robot Software ACL ATS User s Manual 9603 ACL Advanced Control Language is an advanced multi tasking robotic programming language developed by Eshed Robotec ACL is programmed onto a set of EPROMs within Controller B and can be accessed from any standard terminal or PC by means of an RS232 communication channel ACL features include the following Direct user control of robotic axes User programming of robotic system Input output data control Simultaneous and synchronized program execution full multi tasking support Simple file management The ACL Reference Guide for Controller B provides det
40. tiport RS232 board cable and connectors Teach Pendant optional Includes mounting fixture connector adapter plug Teach Pendant for Controller B User s Manual ATS Advanced Terminal Software diskette Software includes ACLoff line software SCORBASE Level 5 Software diskette SCORBOT ER IX User s Manual ACL Controller B User s Manual Docuinentation ACL for Controller B Reference Guide ATS for Controller B Reference Guide ACLoff line User s Manual SCORBASE Level 5 for Controller B Reference Guide SCORBOT ER IX 1 2 User s Manual 9603 Repacking for Shipment User s Manual 9603 Be sure all parts are back in place before packing the robot When repacking the robot for shipping bolt the flange and base to the metal plate Failure to do so may result in irreversible damage to the arm particularly to the Harmonic Drive transmissions Also be sure to secure the cables around the foam spool The robot should be repacked in its original packaging for transport If the original carton is not available wrap the robot in plastic or heavy paper Put the wrapped robot in a strong cardboard box at least 15 cm about 6 inches longer in all three dimensions than the robot Fill the box equally around the unit with resilient packing material shredded paper bubble pack expanded foam chunks Seal the carton with sealing or strapping tape Do not use cellophane or
41. uring all movements of the base axis 5 Setup a guardrail or rope around the SCORBOT ER IX operating area to protect both the operator and bystanders ROBOT CABLE TO CONTROLLER CABLE SEGMENT BODY TO BASE VPEBEEEEEEENNS Figure 4 3 Robot Setup SCORBOT ER IX 4 2 User s Manual 9603 SCORBOT ER IX Installation Controller Installation Perform the installation procedures detailed in the following sections of Chapter 2 Installation in the Controller B User s Manual Computer Terminal Controller Installation Power On Controller Configuration lt When the Peripheral Setup screen appears at the end of the controller configuration select Gripper Connection None You will change this setting after the gripper is installed Refer to the section Peripheral Devices and Equipment Robot Gripper in the Controller B User s Manual Robot Installation Before you begin make sure the controller POWER switch is turned off The robot cable has a number of connectors Connect them to the controller according to following three steps Refer to Figure 4 4 1 Connect the green yellow wire to the Safety Ground Unscrew and remove the ground nut and washer from the Safety Ground stud Place the ground wire terminal onto the stud then replace and tighten the washer and nut 2 Plug the the D37 connector into the Robot Encoders port Tighten the retaining screws on the connector 3 Plugthe 19 pin round co

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