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User`s Manual

1. If you will be using a teach pendant connect it to the Teach Pendant port D25 connector on the controller If you will be operating additional axes by means of the controller connect them at this time Refer to the following section Peripheral Axes When you have completed all cable connections tighten all retaining screws on all the connectors SCORBOT ER VII 4 3 10 Make sure the controller s power switch is off Then plug the controller s power cable into AC power supply outlet You may now perform the Power On Configuration and Homing procedures according to the instructions which appear later in this chapter Peripheral Axes I Do not connect peripheral devices to the axis driver connectors labeled 1 2 3 4 5 and 6 which are reserved for the SCORBOT ER VII robot axes and electric gripper Doing so will cause irreversible damage Use only axis driver connectors 7 and 8 and 9 through 11 where available for connecting peripheral devices For information on installing additional driver cards refer to the section Adjustments and Repairs in Chapter 8 For instructions on configuring Controller A for use with peripheral devices refer to the ATS Reference Guide I Do not connect accessories which require high current to axis 8 or 10 Accessories which require high current such as the linear slidebase must be connected to axis 7 9 or 11 Power On 1 Once you have
2. Enter the command SHOW ENCO to display the encoder readings Enter the command COFF to disable servo control and then physically 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 the encoder readings do not change the problem is caused by a faulty encoder a break in the encoder wiring or a faulty connection on a PCB within the robot Follow the procedures in Item 9 and Item 10 9 Errors in the accuracy of the robot Controller does not read the encoder fails to respond to command SHOW ENCO Using an oscilloscope check the signals Po and P1 received from the encoder s two phototransistors Figure 8 4 shows the wave diagrams which emanate from the two channels of the encoder Po and P1 with respect to the time axis The top two signals should be clean square waves VL low value should be 0 4V or less VH high value should exceed 4 V In addition check the third wave which shows the sum of the two waves The diagram reflects a time shift of a quarter cycle between the two waves If the waves are distorted with an incorrect shift between them the encoder is faulty and should be adjusted or replaced Vutt VL2 Figure 8 4 Encoder Signals 10 Errors in the repeatability of the robot Try to identify the faulty axis If many or all axes are faulty look for an electrical noise source i
3. If you accidently record coordinates for position 0 execute the Home program The homing routine records the proper coordinates for position 0 The teach pendant allows you to simultaneously define and record a position To record a robot position first be sure the Group A is selected Then use the axis movement keys to bring the robot to any location Record this as position 12 2 Record i Ent Position Axis 7 Axis 8 4 ae DONE Move the robot to another location and record it as position 13 The Record Position key records the position of the currently active axis control group A B or an independent axis in joint coordinates If you want to define the location of both the robot and the peripheral axes you must record two positions one for each group SCORBOT ER VII 6 13 Type Type Type Type To define and record positions from the keyboard you must first exit Manual mode Use the ACL command DEFP to define a robot position For example defp Al lt Enter gt Defines position Al for the robot When a position is defined it is assigned to a specific axis control group By default it is assigned to the robot Group A axes To define a position for Group B or an independent axis the command format determines the group to which the position is dedicated defpb B24 lt Enter gt Defines position B24 for Group B defpc C3 10 lt Enter gt Defines position C3 for axis 10 Define three rob
4. Refer also to Figure 2 14 SCORBOT ER VII Cables and Connector Pin Assignments Axis D9 Connector Wire ee Funct Robot Cable Pin Color une PCB 3 Red 5V 4 Blue Home switch 5 Black Telephone Common 1 6 Green Encoder channel B 8 White Encoder channel B 9 Red Motor 1 Molex 1 Black Motor 1 3 Red 5V 4 Blue Home switch 5 Black Telephone Common 2 6 Green Encoder channel B 8 White Encoder channel B 9 Orange Motor 2 Molex 1 Brown Motor 2 3 Red 5V 4 Blue Home switch 5 Black Telephone Common 3 6 Green Encoder channel B 8 White Encoder channel B 9 Violet Motor 3 Molex 1 Yellow Motor 3 3 Red 5V 4 Blue Home switch 5 Black Telephone Common 4 6 Green Encoder channel B 8 White Encoder channel B 9 Blue Motor 4 Molex 1 Light Blue Motor 4 SCORBOT ER VII SCORBOT ER VII Cables and Connector Pin Assignments Axis D9 Connector Wire ao SPEE Robot Cable Pin Color uneton PCB 3 Red 5V 4 Blue Home switch 5 Black Telephone Common 3 6 Green Encoder channel B 8 White Encoder channel B 9 Pink Motor 5 Molex 1 Gray Motor 5 3 Red 5V 4 Blue Home switch 5 Black Telephone Common 6 6 Green Encoder channel B 8 White Enco
5. Simultaneous Execution The RUN command can be included in a program in order to start execution of another program When a running program encounters a RUN prog command both program are executed concurrently When several programs are running those with a higher priority have precedence those with the same priority share controller CPU time by means of an equal distribution algorithm User s Manual SCORBOT ER VII 7 15 9206 Program Interrupt Since two programs may conflict with one other it may be preferable to use the GOSUB command rather than RUN Like RUN the GOSUB command is used to start execution of another program Unlike RUN however when a program encounters a GOSUB prog command the program is suspended until the called program has completed execution At that point the first program resumes execution from the line which follows the GOSUB command The TRIGGER command can be used to execute another program when a specified input or output is turned off or on However it will activate the program only once regardless of subsequent changes in the I O state Saving a Program Backup to Disk The programs positions and variables used in programs will remain stored in the controller s BBRAM However the controller s battery backed RAM is limited and can be accidently erased Program files should be saved to disk They can be downloaded to the controller as needed ATS has a Backup Manager which serves this pu
6. 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 shut off 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 TRAJECTORY ERROR During movement the robot arm reached its envelope limits and the system aborted the movement 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 SCORBOT ER VII User s Manual 9602 Adjustments and Repairs I These procedures are to be performed only by a qualified technician who has received proper training and certification from the manufacturer Opening the Controller Cover 1 Turn off the controller s power switch 2 Unscrew t
7. The proportional parameter is the gain of the control system Its value determines the reaction time to position errors When a position error exists that is the actual motor position is off by a certain amount of encoder counts the processor multiplies the error by the proportional parameter and adds the product to the DAC value thereby reducing the error The proportional parameter is the parameter in the PID control system which acts most quickly in reducing the position error especially during motion It is also the first parameter to respond to position errors when the robot has stopped at a target position The greater the proportional parameter the faster the sytem responds and reduces the error But using too great a value for the proportional parameter will cause the axis to oscillate The main disadvantage of proportional control is that it cannot completely cancel the error because once it has reduced the error it cannot generate enough power to overcome friction in the system and propel the axis to its target position Even in steady state under load the controlled value output signal will always be different from the desired value input signal The steady state error can be reduced by increasing the gain but this will increase the oscillation and reduce stability User s Manual SCORBOT ER VII A 9 9602 Differential Control In differential control the controller output C is a function of the rate at whic
8. When all joints are at home the robot is at home This is the point of reference for robot operation Whenever the system is turned on the robot should be sent to this position by means of a software homing routine When the software limits and or the limit 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 The SCORBOT ER VII has a stopping screw on the Harmonic drive output shaft for this purpose If the stopping screw hits the microswitch disk the impact protection processes detect an error thus activating COFF CON must be activated and the robot arm must be manually moved away from the impact condition The SCORBOT ER VII can be equipped with either a pneumatic gripper driven by output signals or by an electric servo gripper driven by a DC motor and controlled as axis number 6 shown in Figure 2 13 These grippers have parallel finger motion The non servo DC gripper cat 608 is no longer available for the SCORBOT ER VII Figure 2 13 DC Servo Gripper SCORBOT ER VII User s Manual 9602 Cables and Pin Assignments User s Manual 9602 The robot cable contains six cables with D9 connectors for connecting to axis driver card ports at the back of the controller Each cable is labeled for a specific axis The robot cable wiring and pin assignments are given in the table below
9. 9602 3 Make sure a guardrail rope or safety screen has been set up around the SCORBOT ER VII operating area to protect both the operator and bystanders 4 Do not enter the robot s safety range or touch the robot when the system is in operation Before approaching the robot make sure the motor switch on the controller front panel has been shut off 5 Make sure loose hair and clothing is tied back when you work with the robot Controller 1 The power cable must have a ground connection If your power outlet does not have a safety ground do not connect the controller Failure to connect the power cable to a grounded outlet could result in electrical shock 1 Turn off the controller s motor switch before you enter the robots operating area 2 Turn off the controller s power switch before you connect any inputs or outputs to the controller 3 Turn off the controller s power switch and disconnect the controller power cable from the AC power outlet before you open the controller cover or remove any fuses The power cable must be disconnected to remove possible shock hazard 4 Never open the controller cover during robot operation I Be sure you know how to immediately abort all running programs and stop all axes of motion press the Abort key on the teach pendant or use the ACL command A lt Enter gt or press the controller s red EMERGENCY button Warnings User s Manual 9602 Do not install or operate the
10. If successful reconnect the RS232 cable Check for a blown logic power supply fuse Using an ohmeter measure the resistance of the fuses If resistance is close to 0Q the fuse is functioning SCORBOT ER VII amp 3 2 Controller s motors switch does not turn on Motors green LED does not light up Check for a blown power transformer fuse Using an ohmeter measure the resistance of the fuses If resistance is close to 0Q the fuse is functioning 3 No communication between the controller and the computer terminal Message appears on screen Controller Not Responding Make sure the controller s power switch is turned on Make sure the RS232 cable between the controller RS232 port and the computer COM port is properly connected Make sure you have loaded ATS with the proper C switch If teach pendant also does not function make sure the flat cable is properly connected between the communication card PC700 and connector J8 on the main board Refer to Figure 8 5 Make sure there is no break in the wires If problem persists continue to Item 4 4 Controller is totally inoperative although all power supplies are working Make sure the Emergency switch is not pressed Turn the controller power switch off and on again If switching off and on does not solve problem turn off the controller again and open up the cover Turn on the controller Check the red LED on the main board as shown in Figure 8 1 If it remain
11. Replacing or Adding a Driver Card 8 19 Adjusting Driver Card Current Limit 8 20 Driver Card Jumper Configuration 8 20 Installing the Auxiliary RS232 Communication Card 8 21 APPENDIX A Theory of Control A 1 Servo Control s sos roeas a es A 1 Open Loop Control oaoa aa a A 1 Closed Loop Control a a a aa a A 1 Digital Control oaoa a a A 2 Transient and Steady State Responses A 4 Controller A Control Process A 6 Trajectory Control 2 2 ee a A 7 Paraboloid o o e e A 7 Trapezoid o A 7 Pal Control dica a Ee eee ea Sh A 7 Point to Point Control A 7 Continuous Path Control A 8 The Control Parameters o 20004 A 9 Proportional Control 0 A 9 Differential Control A 10 Integral Control o o A 10 Proportional Integral Differential Control A 11 OMSOL 002 dat eae der io RA ed A 11 Changing Parameter Values A 12 x SCORBOT ER VII User s Manual 9602 CHAPTER 1 General Information I Read this chapter carefully before you unpack the robot and controller This chapter contains instructions for unpacking and handling the SCORBOT ER VII and Controller A This chapter also includes important safety guidelines and warnings Unpacking Instructions The robot ar
12. causes the actual value to oscillate around the desired value Further increase of the controller gain may lead to instability of the entire system that is uncontrollable oscillation A control system is damped when it reaches steady state without overshoot A critically damped response is the fastest approach to steady state without overshooting an overdamped response is a slow approach to steady state Figure A 4 shows different transient responses SCORBOT ER VII User s Manual 9602 UNSTABLE OSCILLATORY STEADY STATE ERROR OUTPUT SIGNAL C ds CRITICALLY DAMPED Figure A 4 Transient State Responses Encoder Figure A 5 Controller A Control Loop User s Manual SCORBOT ER VII A 5 9602 Controller A Control Process The basic steps of the Controller A control loop are described below Refer to Figure A 5 The entire control cycle takes 10ms The processor calculates the command position and speed once per cycle It outputs a digital value to the DAC unit in the range of 5000 The analog unit creates a series of pulses resulting in an average voltage value proportional to the DAC input The power unit drives the motor by switching 24V to it at 20KHz according to the input pulse The motor cannot react to this high frequency of switching and is therefore affected by only the average value of the voltage This method of controlling the time during which current flows through the m
13. function The controller recognizes the keys from the order in which they are pressed Thus the numeric function will be active only if a function such as SPEED RUN or MOVE has been keyed in first otherwise the axis drive command will be active Following are descriptions of the teach pendant s keys and instructions for activating them Bulleted items indicate the different functions of multi functional keys User s Manual SCORBOT ER VII 5 3 9602 Accepts and or executes the command which has been entered Enter Starts execution of a program following a Run command A toggle key Switches the command mode between Joints and Cartesian XYZ quam Group When used following a numeric function this key acts as a backspace function it Select cancels the last numeric entry and moves the cursor one position to the left Enables TP control of a specific axis group Successively press for group A group B group C and again for group A and so on When group C is displayed enter the axis number on the numerical keys Then press Enter The Record Position and Speed functions apply only to the currently selected group a A toggle key Enables CON and disables COFF control of the selected group Control On Off The Axis keys move axes 7 through 11 in two directions 3 5 0 1 2 4 6 7 8 9 Axis 7 PAxis8 EP Axis 9 B Axis 101 The numeric keys are operative if one of the fol
14. 4 5 and 4 6 Pneumatic Gripper The pneumatic gripper shown in Figure 4 7 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 To install the pneumatic gripper do the following Make sure the robot has been succesfully homed Using a hex wrench and six M3 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 8 Refer to Figure 4 9 Connect the two transparent 1 4 O D hoses from the robot cable to the CYL ports on the pneumatic valve Connect a 5 bar 90 PSI air supply to the IN port on the valve Connect the valve to the controller s User Power Supply as follows Connect one wire to a ground terminal Connect the other wire to the normally open NO terminal of any relay output Connect 12VDC to the common C terminal of the same relay output Figure 4 7 Pneumatic Gripper SCORBOT ER VII User s Manual 9602 User s Manual 9602 Attach the valve to the controller or any other metalic surface by means of the valve s magnetic base Open and close the gripper to verify that it is functioning Refer to
15. 7 Controller A Components 3 8 SCORBOT ER VII User s Manual 9602 Controller Components User s Manual 9602 Dwg 12 13 10 19 15 17 18 11 14 5 6 20 Cat 110715 110717 113002 110719 110723 102501 110725 107204 110721 35008 35006 35003 35001 450541 45018 45019 45011 45013 45023 45009 45003 40004 40018 40007 40005 411807 411806 411808 411805 40017 40010 40009 40006 408102 404501 45024 45012 Controller Parts List Description Metal case lower part Metal case upper part Controller front panel Metal case rear panel Coil fastener Lexan tags for front panel Long bracket driver card support Blank brackets Transformer cover Logic power supply 220 110VAC 24V 12V Transformer 100V AC Gripper coil assembly Fan plus cabling and connector Main board Driver cards for robot Driver cards for accessories Display card VO card User power supply card Communication card Power LED card plus motors switch plus cabling Emergency switch plus cabling 24VDC feed cable from J12 to capacitor J12 Diode bridge cabling Switching cable from J20 to user power supply Flat cable from J10 to I O card Flat cable from J13 to communicationcard Flat cable from J11 to display card Flat cable from J8 to communication card Gripper cable jumper Grounding cable for capacitor Grounding cable for transformer metal cover Resistors cable for capacitor Diode br
16. ER VII Robot Arm Includes power cable 100 110 220VAC RS232 cable 4 driver cards for 8 axes bolts for mounting robot ACL Controller A set of hex wrenches Gripper Options Pneumatic or Electric DC Servo ATS Advanced Terminal Software 2 diskettes one Software is write protected includes ACLoff line software SCORBASE Level 5 Software 1 diskette SCORBOT ER VII User s Manual ACL Reference Guide Documentation ATS Reference Guide SCORBASE Level 5 ACL Version Reference Guide ACLoff line User s Manual The following table is a sampling of the optional accessories which are compatible for use with the SCORBOT ER VII system For a complete list of the accessories devices software and documentation for integration and use with the SCORBOT ER VII sytem contact your agent Optional Components for SCORBOT ER VII System Item Cat Notes Teach Pendant for Controller A 1703 Driver Card for Peripheral Axes Card with two 2A fuses 45018 Each card drives 2 axes Card with one 2A fuse and one 4A fuse 45019 If ordered with controller Card with two 4A fuses 45020 card is factory installed Auxiliary RS232 Communication Card 45012 If ordered with controller Cable with 8 connectors for auxiliary card 40024 card is factory installed SCORBASE Levels 1 3 software 9004 SCORBOT ER VII 1 3 Optional Components for SCORB
17. Enter gt lt Enter gt lt Enter gt goto 1 lt Enter gt exit lt Enter gt AAA IS VALID SCORBOT ER VII 7 3 Displaying Program Lines Type To view the program you have edited use the command LIST followed by the name of the program list aaa lt Enter gt PROGRAM AAA KKKKKKKKKKKKK KKK KKK KK 293 LABEL 1 26 MOVED 31 27 OVED 32 28 OVED 33 29 GOTO 1 30 END END END marks the end of a program END marks the end of a listing They are written by the controller they are not entered by the user Halting Program Execution Bring the robot to its home position and then run program AAA The robot moves to positions A31 A32 and A33 in a continuous loop without stopping Since you have now created and executed a program which will run in an endless loop this section describes the ACL commands which are used to halt a program during its execution Suspend the Program Type Type The companion commands SUSPEND and CONTINUE respectively suspend execution of a program and then restart it from the point of interruption by executing the next program command line suspend aaa lt Enter gt The robot completes the current movement command and then stops Program AAA is now suspended continue aaa lt Enter gt The CONTINUE command causes the robot to continue moving from the point where it was halted by a SUSPEND command SCORBOT ER VII User s Manual 9206 Abo
18. Manual movement of the axes will be executed according to the currently active coordinate system To select a coordinate system from the keyboard you must first activate Manual mode To activate the Joint coordinate system Press j JOINT MODE To activate the XYZ coordinate system Press x XYZ MOD GI 6 6 SCORBOT ER VII User s Manual 9602 Servo Control Press Press again Press Press User s Manual 9602 The controller must be in the servo control CON state for the axes to execute movement commands Activating the Home routine will activate CON Certain events such as impact overheating thermic error or activation of the Emergency switch will automatically switch off the servo control state COFF CON must be activated to resume motion and servo control While the controller is in the COFF state you cannot operate the axes To toggle servo control on and off Control On Off CONTROL ENABLED Control On Off CONTROL DISABLED When Control On Off is activated from the teach pendant the CONTROL ENABLED CONTROL DISABLED message also appears on the computer screen If Manual mode is active you can enable and disable control from the keyboard c CONTROL ENABLED f CONTROL DISABLED The commands C and F enable and disable control of all axes which are connected to the controller SCORBOT ER VII 6 7 If Manual mode is not active you can use
19. SCORBOT ER VII or Controller A under any of the following conditions Where the ambient temperature or humidity 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 SCORBOT ER VII 1 5 Robot Controller Where corrosive or flammable gas is present Where the power line contains voltage spikes or near any equipment which generates large electrical noises Do not overload the robot arm The combined weight of the workload and gripper may not exceed 2kg 4 4 1b 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 Since the SCORBOT ER VII motors are rated 12VDC nominal while the controller motor drivers supply 24VDC do not drive axes continuously in one direction at maximum speeds Specifically when using the ACL command SET ANOUT n DAC make sure the DAC value is in the range 2500 Before you plug the controller into the AC outlet make sure its voltage requir
20. controller output and the longer the duration of the error the greater the controller output The main advantage of integral control is that the steady state error is always reduced to zero since its value increases each cycle thus strengthening the control system s ability to react and reduce the error However using too great a value for the integral parameter may cause overshoots while too small a value may prevent the cancellation of a steady state error Unlike the proportional parameter the integral parameter takes effect more slowly and is less noticeable during motion However when the axis comes to a complete stop and the proportional parameter can no longer reduce the steady state error the integral parameter takes over and can cancel the error completely A 10 SCORBOT ER VII User s Manual 9602 Proportional Integral Differential Control Offset User s Manual 9602 The PID control method enables optimal exploitation of all three types of control proportion integral and differential In this manner it creates an output response which follows the input signal closely without gaps or lags in both slow and rapid processes including those in which the load is in a constant state of change In summary the PID control parameters serve the following functions Proportional Parameter Enables fast and powerful reactions of the arm to movement commands Responsible for the repeatability of the motion Integral P
21. electrical connector on the robot arm Make sure the connector is oriented as shown in Figure 4 5 Make sure the gripper cable is positioned as shown in Figure 4 6 Again execute the ACL 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 SCORBOT ER VII User s Manual 9602 I The gripper has a rotation of 270 Do not attempt to move the gripper beyond this limit 7 Open and close the gripper to verify that it is functioning At the gt prompt in the ATS main screen enter the ACL commands Type open lt Enter gt The gripper opens Figure 4 5 Connecting DC Servo Gripper top view Figure 4 6 Connecting DC Servo Gripper side view User s Manual SCORBOT ER VII 4 9 9602 Type close lt Enter gt The gripper closes Or from the teach pendant key in Open Close The Open Close key toggles the gripper between its open and closed states I 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 Figures
22. gripper How many axes are installed 8 This defines the number of axes which can be driven by the controller Press lt Enter gt to accept 8 axes default or Type any other valid number and press lt Enter gt Is expanded memory installed Y N Y Press Y or lt Enter gt if controller has 128K RAM default or Press N if controller has 32K RAM Does the controller have an auxiliary RS232 board Y N N Press Y if the auxiliary multiport RS232 board is installed in your controller or Press N or lt Enter gt if the board is not installed default Working directory is c ATS Is this correct Y N Y The first time this prompt appears it shows the DOS directory from which the ATS software was activated The Working directory must be the directory which contains the parameter files and the SCORBASE program file CBU files If you change the directory definition it is written to a file named SETUP DIR Thereafter whenever ATS is loaded the Working directory is set according to SCORBOT ER VII User s Manual 9602 Homing Type User s Manual 9602 the definition in the SETUP DIR file Similarly the SETUP DIR file determines the definition of the Backup directory shown in the Backup Manager screen SETUP DIR is updated when either the Working directory or Backup directory definition is changed Press N if you want to change the directory The cursor moves to the directory line prompting
23. herer A99 A33 lt Enter gt The coordinates of position A99 are actually offset values that is the difference in the encoder count at position A31 and at position A99 If the coordinates of position A31 change position A99 will remain relative to position A31 by the same number of encoder counts To record a position relative to the current location of the robot by joint coordinates you are prompted to enter values encoder counts for each of the axes If offset values have already been recorded for this position they will appear in the brackets otherwise the brackets are empty For example Type here A99 lt Enter gt 1 gt 0 lt Enter gt Base no offset 2 gt 500 lt Enter gt Shoulder 500 counts offset 3 gt 250 lt Enter gt Elbow 250 counts offset 4 gt 0 lt Enter gt Pitch no offset 5 gt 0 lt Enter gt Roll no offset The command TEACHR allows you to record a position which is relative to another position or relative to the current position of the robot in Cartesian coordinates TEACHR can be easily used to maintain a vertical offset along the Z axis between two positions for example Type gt teachr over Relative position OVER will always Xx gt 0 be 50mm above the current position Y gt 0 of the robot Z gt 500 P gt 0 R gt 0 ACL has a number of commands for recording position coordinates they are detailed in the ACL Reference Guide and will not be discusse
24. is active the screen shows the current program line number and a prompt such as this 143 _ The controller assigns the line numbers they are not user definable Quick on line help is available while you are working with ACL Simply enter the command HELP A list of DIRECT mode commands are displayed when in DIRECT mode a list of EDIT mode commands are displayed when in EDIT Enter the command DO HELP when in DIRECT mode in order to display the EDIT mode commands SCORBOT ER VII 7 1 Creating a Program Type Type To create a program activate the EDIT mode by using the command EDIT followed by the name you want to call the program Program names are limited to five characters for example edit aaa lt Enter gt AAA NEW PROGRAM DO YOU WANT TO CREATE THAT PROGRAM Y N gt y lt Enter gt PROGRAM AAA KKEKKKKKKKKKKK KKK KKK kK ZOU At the _ prompt you can begin entering program command lines Writing a Program Type To write a program which will send the robot to each of the positions recorded earlier enter the following command lines moved A31 lt Enter gt moved A32 lt Enter gt moved A33 lt Enter gt exit AAA IS VALID Although the command MOVE may be used in EDIT mode the command MOVED is preferable MOVED ensures that the robot will accurately reach the target position before continuing to the next command The commands MOVEL and MOVEC are also available
25. made all the required hardware connections you can power on the controller Turn on the controller s power switch Turn on the controller s motors power switch The green power and motor LEDs light up Turn on your computer and boot using your own DOS If your computer does not wake up disconnect the RS232 cable then power on the computer and then reconnect the RS232 cable If your computer has a hard drive make a directory for ATS and copy the files from the ATS distribution disk to that directory If your computer does not have a hard drive make a backup copy of the ATS disk Keep the original disk in a safe place and use the copy for operation Make the ATS directory or disk drive the default SCORBOT ER VII User s Manual 9602 At the DOS prompt activate ATS If the controller is connected to computer port COM1 default type ats lt Enter gt If the controller is connected to computer port COM2 type ats c2 lt Enter gt Once the software has loaded the ATS main screen will appear on your monitor Advanced Terminal Software version 1 9 C ESHED ROBOTEC lt Shift F10 gt Backup lt Shift F8 gt Print lt Shift F9 gt Exit lt ALt H gt Help icon 2coff Shomel Yrun 5move Emovel teach Shere 9diry Dedit Press lt Enter gt to receive the gt prompt if it is not already displayed If you have connected a teach pendant the TP display will show A JOINTS You can now comm
26. robot s frame and are normally depressed Figure 2 12 shows the microswitches on axis 3 The Harmonic drive output shaft moves relative to the microswitch disk As the joint moves the limit switch reaches a notch on the Harmonic drive output shaft which releases the activating button and thus activates the switch When the limit switch is activated it causes a control error resulting in the activation of COFF and an impact MICROSWITCH ARRON ORE OUTPUT SHAFT protection message CON must be activated and the robot arm must be KA manually moved using keyboard or 5 O oe teach pendant away from the impact condition STOPPING O A Axis 5 roll has no limit switches it a S o can rotate endlessly When a gripper is VA o attached to axis 5 its movements are controlled and limited by means of SO Y DSK software encoder only Figure 2 12 Microswitches on Axis User s Manual SCORBOT ER VII 2 7 9602 Home Switches Hard Stops Gripper The SCORBOT ER VII also has a microswitch on each axis to identify the fixed reference or home position The home switch is mounted on the same disk as the limit switches and is activated by the stopping screw on the Harmonic drive output shaft During the homing procedure the robot joints are moved one at a time Each axis is moved until its home switch is activated The axis is then moved slightly until the switch shuts off at that point the joint is at home
27. the ACL commands CON and COFF Type con lt Enter gt Enables control of all axes Type coff lt Enter gt Disables control of all axes The format can be altered to enable and disable control of specific groups of axes for example cona Enables control of robot axes Group A coffb Disables control of peripheral axes Group B con 9 Enables control of axis 9 Group C Axis Control Groups By default the controller assumes the five robot axes Group A are under servo control The Group Select key allows you to switch control to peripheral axes Group B or to an independent axis Group C To select the axis control group Press q Group Select Press again Group Select AXIS When selecting an independent Group C axis you must also key in the axis number followed by Enter wl JOINTS Continue pressing this key until the desired axis group is displayed ACL does not have a command for selecting the axis control group The specific format of each command indicates the axis control group 6 8 SCORBOT ER VII User s Manual 9602 Moving the Axes XYZ and Joint Movements Press Press Press Press Press User s Manual 9602 When the coordinate system is set to the XYZ mode Movement commands to the X Y or Z axis result in a linear motion of the TCP tip of gripper along the respective axis while maintaining a constant orientation of the gripper or tool Movement com
28. the controller s front panel lights up when the power switch is turned on It indicates that power is being supplied to the controller Motors and User Power Supply Switch and LED This switch connects and and disconnects DC voltage to all the connected motors and to the user power supply A green LED embedded in the switch lights up when the switch is on The motors switch is turned off in the following circumstances To disconnect power to the motors user power supply and inputs without turning off the controller To prevent possible motion of axes 3 4 SCORBOT ER VII User s Manual 9602 When the motors switch is turned off the robot motors and all connected axes are unable to move In addition it disconnects the user power supply making the controller inputs and open collector outputs inoperative Emergency Switch and Lamp This switch halts all controller operations A red lamp embedded in the switch lights up with the switch is on When the switch is depressed the following occurs The red emergency lamp lights up All running programs are aborted Motor power is disconnected all motor movement stops the green motors LED shuts off All the green LEDs on the rear panel shut off The user power supply is shut off The inputs and outputs are shut off When the switch is pressed again the following occurs The red emergency lamp shuts off The green LED on the motors switch lights up The green LEDs on the rear pan
29. the level of the current limit Watch the voltmeter reading the voltmeter reading reflects the amperage of the current limit level Adjust the current limit as follows Current Robot Axes Driver Cards Limit SCORBOT ER VII Upper Axis Axes 1 2 3 6 3 V SCORBOT ER VII Lower Axis Axes 4 5 6 4 0 V Peripheral Axes Driver Cards Peripheral Device Upper Axis Axes 7 9 11 40 V Peripheral Device Lower Axis Axes 8 10 2 25 V Driver Card Jumper Configuration Note the configuration of the two jumpers W2 and W3 on the driver card shown in Figure 8 8 The jumpers must be mounted in the upper position when connecting the SCORBOT ER VII Conversely the jumpers must be in the lower position when connecting a SCORBOT ER Vplus robot and peripheral axes to the controller SCORBOT ER VII User s Manual 9602 Installing the Auxiliary RS232 Communication Card User s Manual 9602 An auxiliary multiport RS232 communication card may be installed in the controller to provide additional RS232 communication channels The cable leading from the card may have either two or eight D25 connectors Refer to Figures 4 3 and 8 9 12 6 booooocooooocooooooooo CIB yya C25 u19 X1 o CEALL ch RNC C189 wis C26 9600006000 i 9000000 i 9009900 e Tele x HED ule ES ui ROBOTEC cg us C1 o0oo0vecoo fal ovooocoo ASS e c2 c7 G0000500 CERCO ui 2000000 U2 nosco000000000000000
30. them later for shipment Table of Contents CHAPTER 1 General Information 1 1 Unpacking Instructions 1 1 Handling Instructions 2 000 1 2 Repacking for Shipment 1 2 Acceptance Inspection a 1 3 Safety Precautions 0002 eee 1 4 Robot ne add SRS 1 4 Controller y Se warna e Aa e ee 0 1 5 Warning s pie a a o e 1 5 RODO v 26 tte A oe a BS E BR AN 1 6 Controller 33 sie aie ia a ee as E 1 6 CHAPTER 2 The Robot Arm 2 1 Specifications 0 o 2s 2 2 SUCE a Ai Re e Bi 2 3 Work Envelope o e e 2 4 Drive Syst m a sai abi goa e a A de 2 5 Position and Limit Devices 2 6 Encoders cas a a ak bob he he 2 6 Microswitches o e e 2 7 Limit SwitGhe s a tauo cai ge ae gah ee es ag ay ad 2 7 Home Switches o 2 8 Hard Stops ien ar a A ad 2 8 GiIPDOG at oe tet yen oles puntas oe Eco asin a 2 8 Cables and Pin Assignments 2 9 CHAPTER 3 The Controller 3 1 Specifications o 2200002 3 2 Controller Functions 0 o 3 4 Power On Off Switch and LED 3 4 Motors and User Power Supply Switch and LED 3 4 Emergency Switch and Lamp 3 5 User Power Supply Terminals 3 5 Input and Output Terminals andLEDs 3 6 PORE 2 MS ae ete A A 3 6 Outputs i a irod ae
31. top of each driver card bracket to detach the driver card from the connector slot 5 Holding the card with two hands lift it out very carefully CONNECTO LOWER AX CONNECTC CURRENT LIMIT ADJUSTMENT UPPER AXIS LOWER AXIS Zo f LOWER AXIS S N JUMPER CURRENT LIMIT MEASUREMENT 4 S Gece Jumper Setting UPPER AXIS GND SCORBOT ER VII LOWER AXIS SCORBOT ER Vplus and ACCESSORIES El Figure 8 8 Axis Driver Card User s Manual SCORBOT ER VII 8 19 9602 Before inserting the new driver card make sure none of the 64 pins in the male DIN connector is bent Then make sure the driver card is directly above the female DIN connector on the main board and that the metal bracket fits the rear panel Firmly but gently press the driver card into the driver card slot Reattach the long bracket to the transformer housing and the controller frame Reattach each driver card to the long bracket and its connector slot Retighten all the screws Check and adjust the current limit according to the instructions in the following section Adjusting Driver Card Current Limit Refer to Figure 8 8 Turn off the controller Connect the common probe of the voltmeter to the middle point in TP marked GND in Figure 8 8 Turn on the controller Using a small screwdriver rotate POT 1 for upper axis or POT 2 for lower axis Rotating clockwise reduces the level of the current limit Rotating counterclockwise increases
32. you to type and lt Enter gt a different directory Press Y if the directory is correct Press lt Esc gt if you are not sure whether the displayed directory is correct This will cancel the configuration procedure Press F10 to access the ATS Backup Manager menu to verify the proper directory definition Or exit to DOS to verify the location of the CBU files WARNING USER RAM WILL BE ERASED ARE YOU SURE Y N N Press Y to proceed with the configuration Press N or lt Enter gt to cancel the configuration After you confirm ATS compares your selections with the controller s current configuration You are warned of any differences and again prompted to confirm the configuration After you again confirm ATS performs the configuration and loads the proper parameter files in accordance with your selections For complete instructions on the short form controller configuration including configuration for use with the SCORBASE software refer to the ATS Reference Guide For definitions not included in the short form configuration procedure such as axes in control group C a robot of another make and memory allocation you will need to use the ACL command CONFIG Refer to the ACL Reference Guide the Robot The robot is homed from the ATS main screen At the gt prompt enter the ACL command HOME home lt Enter gt WAIT HOMING If all axes reach their home postion a
33. 0 CZO WHE C27 y2t C3 u3 RNN Geesoegses di TNE eoo00009 O 9DO0D00000O SEARS P 8 0 i NN4 C34 BD c34 D c21 u7 CEEI Bonao im 0600060000 o00o0ooco i de C2 2 00000009 459000000 cIg o a TA e Grr 63 DO0G00G00000000000000 O EXARAL AAA AR AAA nopocoo nocoocoo 20 6D CEXELLE RRE CEE RA LO Dp 0o000 yy 0000000000 00 0 us C8 ug 9 2000000000 cis u0ocosooco 13Ge000000000000000000 OSCE TSSORNN y9 o e TOOOT OOOO US c2 u fp ococoooooo 20000000C16 ib A O CBr Ba A 5000000000 q 09000000 cS us COOTCHSCDOOHSGOCSCDACSCDSOSOCOCSOOOGOH v000000000000009000000000 eo090900900000000000 0000000000000000000 0000000000005600000 O 37 Rig R y2 4 PC7200 Rev 02 ml c0000006 Figure 8 9 Auxiliary RS232 Communication Card First make sure Pins 1 and 2 are shorted on the card s Jumper JP1 1 Jumper JP1 allows the software to determine whether or not the communication card has been installed in the controller Default factory setting Pin 1 and pin 2 shorted Turn off the controller Remove the cover of the controller Remove the blank bracket at the back of the controller on the slot J7 for the auxiliary RS232 card Before inserting the auxiliary RS232 card first check that none of the 64 pins in the male DIN connector is bent Then make sure the card is directly above the fem
34. 2 o a 6 7 Axis Control Groups o e 2005 6 8 Moving the Axes 2 2 0 0000 4 6 9 XYZ and Joint Movements 6 9 Activating the Gripper 6 11 Setting the Speed 000004 6 12 Defining and Recording Positions 6 13 Relative Positions 044 6 15 Listing Positions 0000 6 16 Deleting Positions 0 o 6 16 Moving to Recorded Position 6 17 Linear Movement o 6 18 Circular Movement o 6 18 User s Manual 9602 CHAPTER 7 Programming with ACL 7 1 EDIT Mode ia a ra de awl aed Pay el 7 1 Fel p lt E a PO he Bee Se 7 1 Creating a Program o 7 2 Writing a Program 0 o e ee 7 2 Running a Programi aooe sa o o E ee 7 3 Program KOOp 20 iio e e E G 7 3 Displaying Program Lines 7 4 Halting Program Execution 2 7 4 Suspend the Program 22 7 4 Abort the Program o o 7 5 Stop the Program 0 7 5 Delaying Program Execution 7 6 Variable Programming o o 7 6 Mathematical and Logical Functions 7 7 Iteration Functions o o 7 8 Conditional Functions 7 9 Input and Output Programming 7 10 Displaying Input O
35. 2 and 3 of the SCORBASE software can be ordered separately and are recommended for those who wish to learn robotic programming from the most basic stages SCORBASE is described fully in the SCORBASE Level 5 Reference Guide 5 2 SCORBOT ER VII User s Manual 9602 Teach Pendant The teach pendant is an optional device The teach pendant TP is a hand held terminal used for controlling the robot and axis connected to Controller A 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 A JOINTS The teach pendant s display panel is a 2 line 32 character liquid crystal display LCD It shows the current status of the controller the current user command and system ae Control J messages a id A The teach pendant has 30 function E i p Pitch keys These functions are described lt Base shoulder bos Pie in this chapter Many of the El command keys on the teach pendant Base gor Yy are ACL commands these 1 2 3 4 5 commands are described fully in the ACL Reference Guide 6 7 8 9 0 Keypad Functions Open Record quit E Position Position f G Enter The teach pendant s keypad has 30 Close eeu color coded keys Most of the keys are multi functional for example some keys include both an axis Figure 5 1 Teach Pendant drive command and a numeric
36. ER VII 2 3 9602 Work Envelope The length of the links and the degree of rotation of the joints determine the robot s work envelope Figure 2 4 shows the dimensions and reach of the SCORBOT ER VII 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 Figure 2 4 Operating Range With Gripper Attached 2 4 SCORBOT ER VII User s Manual 9602 Drive System The main elements of the SCORBOT ER VII drive system are motors Harmonic drive gears and pulleys and timing belts as PULLEY shown in Figures 2 5 and 2 6 j TIMING BELT PULLEY A Brush commutated DC permanent magnet motors drive the five axes Figure 2 7 shows the location of the motors The direction of motor revolution is determined by the polarity of the HARMONIC DRIVE GEAR he MICROSWITCH operating voltage positive DC H D OUTPUT SHAFT ENCODER voltage turns the motor in one direction while negative DC Figure 2 5 Drive System voltage turns it in the opposite direction Each motor is fitted with an encoder for closed loop control Motor Specifications Motor Axes 1 2 3 Motor Axes 4 5 Motor Constant 3 01 ozin VW 1 94 oz in VW Peak Torque Stall 41 3 oz in 15 6 oz in No Load Speed 6151 rpm 5592 rpm Motor Friction Torque 0 60 oz in 0 50 oz in Mot
37. Enter to begin program execution The controller automatically assigns an ID number to each user program The ACL command DIR lists the programs and their assigned IDENTITY number Aborts execution of all running programs Stops movement of the robot and all peripheral axes The Display Panel The LCD panel shows the current status of the controller the current user command and system messages A resident note shows the coordinates system currently active JOINTS or XYZ Another resident note shows the currently active group A B or the number of one of the independent axes in control group C User s Manual SCORBOT ER VII 5 7 9602 This page intentionally left blank SCORBOT ER VII User s Manual 9602 CHAPTER 6 Operating the Robot This chapter introduces you to the basic commands for operating the SCORBOT ER VII robot by means of both the ACL software and the teach pendant DIRECT Mode This chapter describes the operation of the robotic system when it is functioning in the DIRECT mode When the system is in DIRECT mode the user has direct control of the axes and the controller executes commands as soon as they are entered by the user When in DIRECT mode the screen prompt appears like this gt _ When the system is operating in EDIT mode commands are entered into a user program which can be saved and executed at a later time Program editing procedures are described in Chapter 7 Manual Mode Us
38. G The system is not case sensitive You may use either uppercase and lowercase characters to enter commands and data Descriptions of TP operation show the teach pendant keys which the user must press System responses are shown in boxed capital letters For example Control On Off CONTROL ENABLED A JOINTS Activating the Sytem Activate the system and load the ATS software as described in the section Power On in Chapter 4 6 2 SCORBOT ER VII User s Manual 9602 Homing the Robot and Peripheral Axes The location of the robot axes is monitored by encoders which track the amount of movement relative to an initial home position To obtain repeatable robot performance this reference position must be identical each time the robot is used Thus whenever the system is activated the homing program which is internally programmed into the controller must be executed During the homing procedure the robot joints move and search for their home positions one at a time Each axis is moved until the microswitch which is mounted on the joint sends a specific signal to the controller indicating the axis is at home Before you begin the homing procedure make sure the robot has ample space in which to move freely and extend its arm Press 0 Enter Axis 11 7 Type User s Manual 9602 This instructs the controller to execute Program 0 the robot homing routine The display panel on the teach pe
39. II User s Manual 9206 The command DEFINE is used to define a private variable Up to twelve variables can be defined in one command For example Type define pv lt Enter gt Defines PV as a private variable define va vb vc lt Enter gt Defines VA VB and VC as private variables The command GLOBAL is used to define a global variable Up to twelve variables can be defined in one command For example global gv lt Enter gt Defines GV as a global variable global gva gvb gvc lt Enter gt Defines GVA GVB and GVC as global variables Variable names must begin with an alphabetical character and may have up to 5 characters The commands DIM n and DIMG n are used to define arrays of private and global variable arrays respectively n defines the dimension number of elements in the array Mathematical and Logical Functions The SET command performs mathematical and logical operations on variables The command format may be one of the following set varl var2 set varl oper var2 set varl var2 oper var3 Where var is a variable var2 and var3 can be either a variable or a constant oper is Arithmetic operator Algebraic operator ABS EXP LOG MOD Trigonometrical operator COS SIN TAN ATAN Logical Boolean operator AND OR NOT The simplest format assigns a variable the value of a constant or another variable For example set var 1 set varl var2 The value of a variable can be the resul
40. OT ER VII System Item Cat Notes DC Motor Kits Motor with 5 9 1gear ratio 1210 Motor with 19 5 1 gear ratio DORE eS encoderand connector cable Motor with 65 5 1 gear ratio 1211 Motor with 127 1 gear ratio 1206 Rotary Table black 1005 12VDC 350mm plate Proximity Sensor for Rotary Table 1209 Conveyor Belt gray 1006 12VDC 20 slot encoder Proximity Sensor for Conveyor 1203 Experiment Table 1201 72 Linear Slidebas ion2_ 12vDC 1SM Linear Slidebas 1007 4VDC Gripper attachment for round square parts 616 For 613 DC Servo Gripper 613 Pneumatic Gripper 614 Vacuum Gripper 1 suction cup 601 Vacuum Gripper 3 suction cups 602 Air Brush Paint Gun 603 Requires 1204 and 1208 Syringe Dispenser 604 Includes solenoid value air Utilities Control Box 1204 regulator fittings power supply Air Supply Adapter Kit 1208 eee oe ee VO Interface Box for Controller A 1215 Safety Precautions Robot This manual provides complete details for proper installation and operation of the SCORBOT ER VII and Controller A Do not install or operate the robot or controller until you have thoroughly studied this User s Manual Be sure you fheed the safety guidelines for both the robot and the controller Make sure the robot base is properly and securely bolted in place Make sure the robot arm has ample space in which to operate freely SCORBOT ER VII User s Manual
41. SCORBOT ER VII User s Manual 2nd Edition Catalog 100017 Rev C ESED O Bl WARNING The SCORBOT ER VII is dangerous and can cause severe injury USE WITH EXTREME CAUTION Set up a protective screen or guard rail around the robot to KEEP PEOPLE AWAY from its working range Copyright 1996 1998 by Eshed Robotec 1982 Limited February 1996 reprinted December 1998 PDF Catalog 100017 Rev C ISBN 965 291 033 3 All rights reserved This book is designed to provide information about the SCORBOT ER VII 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 1982 Ltd is not liable or responsible to any person or entity for loss or damage in connection with or stemming from the use of Controller A ACL ATS the SCORBOT ER VII robot and or the information contained in this publication Eshed Robotec 1982 Ltd bears no responsibility for errors which may appear in this publication and retains the right to make changes to the hardware software and manual without prior notice SCORBOT is a registered trademark and ACL is a trademark of Eshed Robotec 1982 Ltd Read this manual thoroughly before attempting to install or operate the robot If you have any problems during installation or operation call your agent for assistance Save the original carton and all packing material You may need
42. 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 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 Possible causes 1 An obstacle prevented the movement of the arm 2 An axis driver fuse has shut off 3 An encoder fault 4 A mechanical fault 5 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 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 User s Manual SCORBOT ER VII 8 13 9602 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 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
43. U99 U100 U101 U102 U88 U93 U98 for outputs U76 U77 U78 U79 USO U81 U103 U108 PC7000 POWER SUPPLY J6 J5 J4 J3 J2 J1 ES ROBOT MOTORS J7 J12 PC7600 Communication Card ROBOT to J4 PC7600 Communication Card COMPUTER TEACH PENDANT to J1 POWER SUPPLY USER POWER SUPPLY I O Card PC7400 Display Card PC7300 FRONT LEDS amp LAMPS EMERGENCY SWITCH FRONT FAN Figure 8 5 Main Board Connectors User s Manual SCORBOT ER VII 8 11 9602 19 Controller does not give output signal Relay Outputs For Outputs 1 4 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 Refer to Figure 8 6 If outputs have not been switched check the flat cable connection between the I O card and the main board J10 Open Collector Outputs For Outputs 5 16 check whether the load and voltage source have been properly connected If the supply has been connected directly to the output terminal the output transistor will blow out immediately Refer to Figure 8 5 Check the flat cable connection between the I O card and the main board J10 Alternately check the ICs which drive the open collector outputs signals U76 U77 U78 20 Pneumatic gripper or end effector does not respond Make sure all air hoses are connected properly Make sure the gripper device is connected to the p
44. W Move axis 2 shoulder 3 E Move axis 3 elbow 4 R Move axis 4 wrist pitch 5 T Move axis 5 wrist roll 6 Y Closes Opens electrical gripper axis 6 In XYZ mode the following changes in manual movement occur Press 1 Q TCP moves along X and X axes 2 W TCP moves along Y and Y axes 3 E TCP moves along Z and Z axes 4 R Pitch moves TCP maintains position All other movements are the same as in Joint mode In XYZ mode moving the robot to positions at the maximum range of reach may result in jerky movements Use Joint mode to reach these positions While moving the arm you may alternate between XYZ and Joint modes as often as required If peripheral axes are connected the following keys are also used Press 7 U Move axis 7 Move axis 8 Move axis 9 Move axis 10 Move axis 11 8 9 0 m U O H 6 10 SCORBOT ER VII User s Manual 9602 Activating the Gripper Press Press Press Type Type User s Manual 9602 In response to the commands to open and close the electrical gripper goes completely from one state to the other Open Close The Open Close key toggles the gripper between its open and closed states If the gripper was open it will now close and vice versa Repeat the command When Manual mode is active the following keys activate the gripper Y Opens the gripper 6 Closes the gripper When Manual mode is not active the ACL commands OPEN and CLOSE are used open
45. Y 3 ENDFOR IF IN 16 1 IF INPUT 16 IS ON EXIT FROM PROGRAM SET OUT 16 0 PRINTLN program inout stopped SCORBOT ER VII User s Manual 9206 PRINTLN GOTO 2 ENDIF GOTO 1 LABEL 2 END PRINTLN comments will be displayed on the screen during program execution PRINTLN without a comment or argument simply enters a carriage return and brings the screen cursor to the beginning of the next line The variable I is used as the counter for 16 loops FOR starts a program loop which checks state of all 16 inputs The first IF command starts a conditional routine with instructions for responding to the state of an input if an input is turned on the output of the same index is also turned on if the input is turned off the output is turned off The asterisk precedes a user comment within a program the comment is not displayed during program execution ENDIF ends the IF conditional routine ENDFOR ends the FOR loop The second IF command starts a routine which checks and responds to the the state of input 16 If input 16 is on output 16 will not light the program will go to label 2 and terminate If input 16 is off the program will go to label 1 and repeat When running this program you can simulate an external input by shorting the input terminals Be sure you do so according the instructions for shorting inputs detailed in Chapter 3 Run the program and prepare to short the inpu
46. ale DIN connector J7 on the main board and that the metal bracket fits the rear panel Firmly but gently press the card into the slot Tighten the bracket screw Make the cable connections Connect the D37 connector from the multiport connector cable to the auxiliary RS232 port on the controller Connect the D25 connectors on the multiport connector cable to the corresponding COM ports on the other controllers or computers The controller must be reconfigured for the auxiliary RS232 card SCORBOT ER VII 10 Before you perform the configuration you must backup to disk the entire contents of the controller including all parameters Power on the system From the ATS Backup Manager menu select the options Backup ALL and BACKUP to disk F3 Perform the configuration using either of the following methods Use the command lt Ctrl gt F1 as described in the section Controller Configuration in Chapter 4 or Use the ACL command CONFIG as described in the ACL Reference Manual Reload the contents of the controller including all parameters which you backed up to disk From the ATS Backup Manager menu select the options Restore ALL and RESTORE from disk F5 SCORBOT ER VII User s Manual 9602 APPENDIX A Theory of Control The function of the controller is to instruct the movements of the robot arm or other devices in the robotic system to monitor these movements and to make a
47. arameter Assists the proportional parameter in eliminating steady State errors Differential Parameter Provides the required damping Control theories often assume complete linearity that is the speed is proportional to the power supplied to the motor However at low levels of power the motor will not move mainly due to friction that is the static friction is higher than the dynamic friction This is a non linearity Figure A 8 shows linearity and non linearity The offset is a threshold level of the DAC Above this DAC value the control system acts as a linear system Below this value the control system acts as an on off system Figure A 9 shows the offset y _DAC 5000 value DAC 5000 value Figure A 8 Figure A 9 Linearity and Non Linearity Control System Offset SCORBOT ER VII A 11 Changing Parameter Values The control system parameters of Controller A are factory set and are suitable for most robotic applications Although parameter values can be manipulated by user commands only experienced users should attempt to do so For more details refer to the ACL Reference Guide SCORBOT ER VII User s Manual 9602
48. ate position velocity etc error e for each motor and the control signal U which is sent to the motors to correct the error The control signal is converted to an analog signal by a DAC and then amplified before driving the motor SCORBOT ER VII User s Manual 9602 ANALOG SIGNAL DIGITAL SIGNAL Figure A 2 Analog and Digital Signals The feedback device measures the actual state and produces an analog signal The feedback signal is converted by a ADC so that the processor can read it to compute e A digital control system can be programmed to compute any number of control equations The processor s control program is a continuous loop whose basic steps are as follows 1 Read desired state from memory 2 Read actual state from feedback device 3 Calculate the state error e 4 Calculate control signal from control equation 5 Go back to step 1 The main difference between digital and analog controllers is the time delay caused by the processor s computations This time delay is in effect the sampling time of the DAC and of the output control signal it produces If the processor can complete a loop within a few milliseconds the sampling time will be rapid and the digital controller will produce an output similar to the equivalent analog controller On the other hand if the processor is slow to make the computations the controller will be unaware of fast changes in the feedback signal and the control signal
49. coordinate system is a geometric system used to specify the position of the robot s TCP tool center point tip of gripper by defining its distance in linear units from the point of origin the center bottom of its base along three linear axes as shown in Figure 6 1 PITCH To complete the position definition the pitch and roll are specified in angular units When robot motion is executed in XYZ mode all or some of the axes move in order to move the TCP along an X Y or Z axis Figure 6 1 Cartesian Coordinates Joint Coordinates User s Manual 9602 Joint coordinates specify the location of each axis in encoder counts When the axes move the optical encoders generate a series of alternating high and low electrical signals The number of signals is proportional to the amount of axis motion the controller counts the signals and determines how far an axis has moved Similarly a robot movement or position can be defined as a specific number of encoder counts for each axis relative to the home position or another coordinate When robot motion is executed in Joint mode individual axes move according to the command If any peripheral devices are connected to the robotic system the position of their axes is always stated in encoder counts SCORBOT ER VII 6 5 To toggle between the two coordinate systems Press A JOINTS Press again A XYZ The display reflects the currently active coordinate system
50. d in either of two modes Negative logic mode NPN default mode ON is defined as low voltage less than 1 5VDC or ground OFF is defined as high voltage 5VDC to 24VDC Positive logic mode PNP ON is defined as high voltage 5 VDC to 24VDC OFF is defined as low voltage less than 1 5VDC or ground When the motors switch is turned off it disconnects the user power supply making the controller inputs and open collector outputs inoperative To simulate the operation of an input when no device is connected short the input manually use a wire or an unraveled paper clip for example When the input is operating in NPN mode short the input by connecting it to a ground connector When the input is operating in PNP mode short the input by connecting it to the user power supply SCORBOT ER VII User s Manual 9602 Outputs The controller s outputs allow the robotic system to transmit signals to external devices in the robot s environment The controller has 4 relay outputs and 12 open collector outputs Relay Outputs 1 4 Outputs 1 to 4 shown in Figure 3 4 include relays in their final stage Each relay includes three contact points Common Tab COM Normally Closed Tab NC Normally Open Tab NO Nc OUTPUT OFF c Maximum voltage allowed 24VDC Maximum current allowed 4A Figure 3 5 shows the ON and OFF states of a relay output 4 NC NO Figure 3 5 Relay Output States Open Coll
51. d in this manual User s Manual SCORBOT ER VII 6 15 9602 Listing Positions To see a list of the defined positions use the ACL command LISTP Type listp lt Enter gt The list of defined positions is displayed on the screen Positions 12 13 A31 A32 A33 and A99 should now appear in the list To view the coordinates of position A31 use the ACL command LISTPV Type listpv A31 lt Enter gt Position coordinates are displayed on the screen in the following manner 1 0 2 1791 3 2746 4 0 Dl x 1690 Y 0 Z 6011 P3636 Rect Two sets of values are displayed for robot positions The first line shows the joint coordinates defined in encoder counts The second line shows the Cartesian X YZ coordinates X Y and Z are defined in tenths of millimeters P Pitch and R Roll are defined in tenths of degrees For example Z 6011 Z 601 1mm P 636 P 63 6 Deleting Positions To delete positions use the ACL command DELP Type delp A99 lt Enter gt DO YOU REALLY WANT TO DELETE THAT POINT YES NO gt _ Type yes lt Enter gt A99 DELETED To prevent accidental deletion of a position you are required to respond by entering the entire word yes followed by lt Enter gt Entering any other other character including Y is regarded as no 6 16 SCORBOT ER VII User s Manual 9602 Moving to Recorded Position User s Manual 9602 Press Type Type T
52. der channel B 9 Green Motor 6 Molex 1 White Motor 6 to CONTROLLER to HARD LIMIT SW and HOME SW to MOTOR 2 ENCODER 2 PC8400 HOME SW 1 MOTOR 1 HARD LIMIT SW 1 ENCODER 1 SEAM tee eh IO Figure 2 14 Robot Wiring 2 10 SCORBOT ER VII User s Manual 9602 CHAPTER 3 The Controller This chapter details the specifications and functions of Controller A which controls the SCORBOT ER VII robotic system ry Weure UU AER Figure 3 1 Controller A User s Manual SCORBOT ER VII 3 1 9602 Specifications Item Controller A Specification Notes Stand alone Real time Terminal or PC required Type of Control Multi tasking only for programming PID proportional integral differential stage PWM pulse width modulation Number of Standard 8 Servo Axes Maximum 11 Groups of Control 11 axes can be divided into 3 groups Group A Group B Group C independent axes Each group has independent control Axis interpolation in groups A and B Axis Drivers PWM pulse width modulation 20 KHz PTP point to point CP continuous path Joint Path Control Linear Circular User defined path Paraboloid Trajectory Control Trapezoid Open Loop not for user 10 ms control cycle Software c
53. djustments automatically in order to correct any errors Servo Control Open Loop Control In open loop non servo control the system does not check whether the actual output position or velocity equals the desired output In open loop control systems the controller output signal U is determined only by the input signal r If the system response is incorrectly predicted or if the output signal is affected by other factors deviations from the desired state will occur Since no feedback exists the system is unable to correct output errors In open loop robotic control power is applied to the motors according to a predefined program The path and speed cannot be precisely predicted since they are determined by the torque and load on the motors and other environmental factors Closed Loop Control User s Manual 9602 In closed loop control the control system measures the output signal C compares it with the input desired signal r and corrects any errors Figure A 1 compares schematic diagrams of open loop and closed loop control systems In servo control systems a feedback device commonly an optical encoder measures the output C the amount speed and direction of motor rotation converts it to an output signal Up and transmits it to the comparator A comparator connects the input and feedback signals produces an error signal equal to the algebraic difference of its two input signals The comparato
54. ector Outputs 5 16 Outputs 5 to 16 shown in Figure 3 6 include a transistor with an open collector in their final stage These outputs must be connected to a load 5 6 78 9 10 1112 13 1415 16 Never connect open collector outputs directly to a power supply or ground Figure 3 6 Open Collector Output Terminals When using an inductive load such as a solenoid or relay connect a protection diode across the load You may connect an open collector output directly to an input Open collector outputs can be operated in either of two modes Negative logic mode NPN default mode ON is defined as low voltage 0 3VDC or less OFF is defined as V refer to Figure 3 7 Positive logic mode PNP ON is defined as 12VDC OFF is defined as 0 volts refer to Figure 3 8 Maximum voltage allowed 24VDC Maximum current allowed 0 5A User s Manual SCORBOT ER VII 3 7 9602 PNP Protection A Diode Output ON OFF commands SOURCE SINK d dr Output Output NPN Terminal Terminal Output ON OFF gt commands gt 4 Output Output Terminal Terminal User GND User GND Figure 3 8 Open Collector Output PNP Mode Figure 3 9 Open Collector Output NPN Mode Input and Output LEDs 16 yellow LEDs corresponding to outputs 1 16 light up when the outputs are ON 16 orange LEDs corresponding to inputs 1 16 light up when the inputs are ON Figure 9
55. ed and topple over while in motion SCORBOT ER VII 4 1 Set up a guardrail rope or safety screen around the robot s operating area to protect both the operator and bystanders Place the controller and computer on a sturdy surface at a safe distance from the robot well outside the robot s safety range Do not yet mount the robot gripper First complete the installation procedures according to the instructions in this chapter in the following order Figure 4 2 Robot Base Plate Layout Cable connections e Peripheral axis connections Activate and configure the controller Home the robot Mount the gripper The robot must be homed before the gripper is mounted Cable Connections Be sure to verify that the controller s voltage setting matches your voltage supply before you connect the controller to the AC power outlet Install and configure your computer terminal and monitor according to the manufacturer s instructions Connect the computer power cable to an AC power source It is recommended though not imperative that you connect the computer to an AC power source other than the one used by the controller Make sure the controller s power switch and computer s power switch are in the off position before you continue to the next step For the following steps refer to Figure 4 3 Connect each of the D9 connectors on the robot cable to driver ports 1 through 6 Note the n
56. een 1 100 and press lt Enter gt When Manual mode is not active the ACL command SPEED is used to define the speed at which movements are executed For example speed 50 Sets speed movements of Group A axes to 50 of maximum speed speedb 20 Sets speed of movements of peripheral axes Group B to 20 of maximum speed SCORBOT ER VII User s Manual 9602 Defining and Recording Positions Press User s Manual 9602 Defining a position reserves space in controller memory and assigns it a name Recording a position writes coordinate values to the allocated space in controller memory Two types of position names are possible Numerical names such as 3 22 101 of up to five digits Positions with this type of name do not need to be defined before they are recorded by means of the teach pendant the position recording command automatically defines and records positions with numerical names Alphanumeric names such as P POS10 A2 The name may be a combination of up to five characters and should begin with a letter These positions cannot be accessed from the teach pendant Positions may belong to a vector that is an array of positions identified by a specific name and an index for example PVEC 1 and PVEC S are positions in a vector named PVEC When a vector is attached to the teach pendant by means of the ACL command ATTACH vector positions can be accessed from the teach pendant by means of their index number
57. el light up again The controller s CPU is reset and the following appears on the screen RAM TEST COMPLETE ROM TEST COMPLETE SYSTEM READY Pz I The robot must be homed before work can resume following an Emergency User Power Supply Terminals The user power supply allows external devices in the users applications to receive power from the controller The controller user power supply has four terminals Two 12VDC 2A regulated power supply Two safety ground When the motors switch is turned off it also disconnects the user power supply User s Manual SCORBOT ER VII 3 5 9602 Input and Output Terminals and LEDs Inputs Controller A is equipped with an I O board which allows you to individually configure the inputs and open collector outputs to operate in either negative NPN or positive PNP logic The controller is factory configured for operation in NPN mode Refer to the section Adjustments and Repairs in Chapter 8 for instructions on altering the I O logic mode The controller s inputs allow the robotic system to receive signals from external devices in the robot s environment The controller has 16 input terminals and four ground connection points as shown in Figure 3 3 All inputs are coupled to the controller system with opto couplers 9999999999999 999OOOOD 23475 6 7 8 9 101112 131415 16 gt Figure 3 3 Input Terminals Inputs can be operate
58. ement as seen on the tag at the back of the controller matches your voltage supply If the voltage setting does not match your supply do not connect the controller contact your agent Do not connect accessories to the driver cards for axes 1 through 6 cards with black brackets Irreversible damage will occur Do not connect any voltage in excess of 24 VDC to the input terminals Do not connect any voltage in excess of 24VDC to the output terminals Never connect voltage from a power supply directly to any open collector outputs terminals 5 16 The open collector ouputs must always be connected to a load Never connect a load to voltage exceeding 24VDC Never drive a current of more than 4A through the relay outputs terminals 1 4 Never drive a current of more than 0 5A through the open collector outputs terminals 5 16 SCORBOT ER VII User s Manual 9602 CHAPTER The Robot Arm This chapter details the specifications and components of the SCORBOT ER VII robot arm Figure 2 1 SCORBOT ER VII Robot Arm User s Manual SCORBOT ER VII 2 1 9602 Specifications The following table details the robot arm specifications SCORBOT ER VII Specifications Mechanical Structure Vertical articulated Number of Axes 5 axes plus gripper Axis Movement Axis 1 Base rotation Axis 2 Shoulder rotation Axis 3 Elbow rotation Axis 4 Wrist pitch Axis 5 Wrist roll 250 310 user progra
59. er s Manual 9602 Manual mode is available when the system is in DIRECT mode The Manual mode enables direct control of the robot axes when a teach pendant is not connected When using the keyboard to perform some of the procedures described in this chapter the system must be in Manual mode To activate Manual mode hold the lt Alt gt key and press the character M lt Alt gt m The system will respond in one of the following ways MANUAL MODE MANUAL MODE gt _ gt _ JOINT MODE XYZ MODE The system s response indicates the currently active coordinate system SCORBOT ER VII 6 1 To exit Manual mode the same command is used Press lt Alt gt m EXIT MANUAL MODE gt Using this Manual To familiarize yourself with the system you should read through this chapter and the following ones and practice entering the commands described in each section All operations described in this chapter can be performed from the keyboard The steps for using the keyboard are indicated by the heading PC The teach pendant is optional The operations which can also be performed from the teach pendant are indicated by the heading TP This manual uses the following typographical conventions Descriptions of PC operation show user entries in bold lowercase text System responses are shown in capital letters The actual screen display may be different For example home lt Enter gt WAIT HOMIN
60. ess Enter to accept the displayed default speed Or use the numerical keys to enter a different speed and press Enter Record Position number Enter Defines and records a position Only numerical position names of up to five digits can be entered from the TP The position is defined for the currently active group and receives the current values of the axes in that group Press Record Position Then press up to five digits for the position name Then press Enter to record the position coordinates If you use a position name which has already been defined the new coordinates will overwrite the existing ones This command is also used to record positions in a vector The vector must first be attached to the teach pendant by means of the ACL command ATTACH Go Position number Moves the axes to a target position Press Go Position Then use the numeric keys to enter the position name Then press Enter to execute the move In Joint mode robot movement is by joints In XYZ mode robot movement is linear To send the axes to their home position enter the following commands Go Position 0 sends all the axes of group A to their HOME position Go Position 00 sends all the axes of group B to their HOME position 5 6 SCORBOT ER VII User s Manual 9602 puna e Executes a program Press Run Then press the program s identity number on the numerical keys The program name will be displayed in brackets Then press
61. executed before the next command is executed The command format includes a time parameter n which is expressed in hundreths of a second for example if n 200 the delay is 2 seconds Edit program AAA Insert delay commands following each MOVED command line Enter gt elay 200 lt Enter gt Enter gt lt lt Enter gt d lt delay 200 lt Enter gt lt d lt M Enter gt elay 200 lt Enter gt Enter gt exit lt Enter gt Another ACL command WAIT command causes program execution to pause until a certain condition is met Variable Programming Variables are locations in controller memory which are defined by name and hold values Variables simplify programming by allowing instructions to be executed conditionally and repeatedly ACL has a number of system defined variables whose values indicate the status of inputs outputs encoders and other control system elements Some of these variables can accept user defined values None of these variables can be deleted from the system User variables are defined and manipulated by the user and can be created or deleted as needed User variables may be either private local or global Private variables are defined and manipulated in the EDIT mode and recognized only by the specific program in which they are defined Global variables can be defined and manipulated in both the EDIT and DIRECT modes and can be used in any program SCORBOT ER V
62. faye ed eee ALA nee a 3 7 Relay Outputs 1 4 3 7 Open Collector Outputs 5 16 3 7 Input and Output LEDS 3 8 Controller Components o 3 9 Controller Computer RS232 Cable 3 10 User s Manual SCORBOT ER VII 9602 CHAPTER 4 CHAPTER 5 CHAPTER 6 viii SCORBOT ER VII Installation 4 1 Preparations aooaa a 4 1 Cable Connections o aooaa a 4 2 Peripheral Axes aoaaa a 4 4 Power On aoaaa es 4 4 Controller Configuration aoaaa a a 4 5 Homing the Robot o aa 4 7 Gripper Installation 4 8 DC Servo Electric Gripper 4 8 Pneumatic Gripper oo 4 10 Operating Methods 5 1 Softwatels age bt tun a hdd wa a ash hie 5 1 PC Leper A tat vad ee ene 5 1 ATS ced AG ica Bhs oe ae a 5 1 ACLoff line 2 2 a 5 2 SGORBASE sy of dics god cious AA ay Guat wea fs 5 2 Teach Pendant i o 2 eee 5 3 Keypad Functions 0 o 5 3 The Display Panel 5 7 Operating the Robot 6 1 DIRECT Mode o o e e 6 1 Manual Mode o e e ee 6 1 Using this Manual o 6 2 Activating the Sytem a 6 2 Homing the Robot and Peripheral Axes 6 3 Coordinate Systems aooaa a 6 5 Cartesian XYZ Coordinates 6 5 Joint Coordinates o 6 5 Servo Control 2
63. h the error U changes The faster the rate of change of the error the greater the controller output C In other words the controller is sensitive to the slope of the error signal The differential parameter is responsible for reducing the speed error The control system calculates the actual speed once per cycle and compares it to the desired value While the robot is accelerating during the first part of path the differential acts as a driving factor While the robot is decelerating during the second and last part of path the differential acts as a braking factor A good differential setting will result in a clean and smooth motion along the entire path Lack of the differential will cause overshoot at the end of path High differential values will cause small vibrations along the path In this control method the controller predicts the value of the error in accordance with the error signal slope and causes the correction to take place in advance However if the error is constant and unchanging differential control will not be able to reduce the error to zero Integral Control In integral control all the state errors which have been recorded each cycle are totalled and their sum is multiplied by the integral parameter value In integral control the controller output C reduces the error signal U to zero at a rate proportional to the size and duration of the error In other words the greater the error the greater the
64. he 4 Phillips screws which hold the cover Unscrewing just the two screws at the front of the controller and lifting up the cover is possible but not recommended as it prevents access to the rear connector panel of the controller 3 Carefully lift off the cover and set it aside Changing the Voltage Setting To change the controller s voltage setting you must change the controller s power transformer fuse and the voltage switches Refer to Figure 8 6 1 Open the controller cover and replace the power transformer fuse 1 100 110V requires 4A SB fuse 220V requires 2 5A SB fuse This fuse is accessed from the side of the transformer housing Using a screwdriver push down on the fuse holder cover while turning it counterclockwise Remove the fuse holder and replace the fuse Reinsert the fuse holder and retighten it clockwise until it is securely in place DRIVER CARD LOGIC BRACKET POWER SUPPLY TRANSFORMER HOUSING Figure 8 6 Controller Voltage Setting User s Manual SCORBOT ER VII 8 15 9602 2 Change the two switches inside the controller Using a small tool push the red switch 2 on the transformer housing to the opposite side Manually push the switch 3 on the logic power supply to the proper setting Replacing Fuses I Warning Before you begin to check or remove fuses turn off the controller s power switch and disconnect the power cable from the AC power source Logic Power Supply F
65. he user interface to the ACL controller ATS is supplied on diskette and operates on any PC host computer The software is a terminal emulator which enables access to ACL from a PC computer SCORBOT ER VII 5 1 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 ATS is described fully in the ATS Reference Guide 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 SCORBASE is a robotic control software package which can be used with Controller A Its menu driven structure and off line capabilities facilitate robotic programming and operation SCORBASE is supplied on diskette and operates on any PC system SCORBASE communicates with ACL the controller s internal language by means of an RS232 channel Levels 1
66. idge 10 000 uF 63V capacitor Teach pendant card inside teach pendant optional Auxiliary RS232 multiport card SCORBOT ER VII 3 9 Controller Computer RS232 Cable The computer and controller communicate on the RS232 channel at 9600 baud with 8 data bits 1 stop bit no parity and XON XOFF protocol The RS232 cable connections between the computer and controller are as follows Computer D25 female connector Controller D25 male connector Pin 2 Transmit Pin 3 Receive Pin 3 Receive Pin 2 Transmit Pin 7 Logic GND Pin 7 Logic GND Pin 4 to Pin 5 Pin 6 to Pin 8 and 20 SCORBOT ER VII User s Manual 9602 CHAPTER 4 Installation Before installing the SCORBOT ER VIL be sure you have read and understood the safety instructions and warnings detailed in Chapter 1 Preparations User s Manual 9602 Be sure you have ample space to set up the robotic system as shown in Figure 4 1 Set up the SCORBOT ER VII on a sturdy surface with a minimum 900mm of free space all around the robot SAFETY SCREEN ROBOT WORKING AREA CONTROL DESK Figure 4 1 SCORBOT ER VII Installation Fasten the base of the robot arm to the work surface with at least 3 bolts 120 apart as shown in Figure 4 2 Robot Base 330 mm Pitch Circle 226 mm Hole 6 off Z 8 mm Make sure the robot is securely bolted in place Otherwise the robot could become unbalanc
67. in EDIT mode As with the MOVE command it is preferable to use the command format with the D suffix that is MOVELD and MOVECD The EXIT command is used to end the current editing session and return the system to DIRECT mode SCORBOT ER VII User s Manual 9206 Running a Program Type When the gt prompt is displayed it indicates the system is in DIRECT mode To check the program you have just created do the following Make sure control is enabled CON and the robot is at its home position run aaa lt Enter gt DONE The robot moves to positions A31 A32 and A33 and then stops Program Loop User s Manual 9206 Type Type Press Press Press Type Type You will now edit the program and add command lines which will cause the program to run in a loop Program loops are created by using the companion commands LABEL and GOTO LABEL n marks the beginning of a routine GOTO n sends program execution to the line which follows the corresponding LABEL edit aaa lt Enter gt WELCOME TO ACL EDITOR TYPE HELP WHEN IN TROUBLE PROGRAM AAA KKEKKKKKKKKKKK KK KKK BOS The prompt shows the first line of the program Entering a new command inserts a command line at this point Pressing lt Enter gt without entering a new command simply displays and accepts the line as is and moves the editor to the next line label 1 lt Enter gt lt
68. in place before packing the robot controller When repacking the robot for shipment bolt the flange and base to the metal plate Failure to do so may cause irreversible damage to the arm particularly to the harmonic drive transmissions Also be sure to secure the cables around the foam spool The robot and controller should be repacked in their original packaging for transport If the original carton is not available wrap the robot controller in plastic or heavy paper Put the wrapped robot controller 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 masking tape SCORBOT ER VII User s Manual 9602 Acceptance Inspection User s Manual 9602 After removing the robot arm and controller from their shipping cartons examine them for signs of shipping damage If any damage is evident do not install or operate the system Notify your freight carrier and begin appropriate claims procedures The following is a list of the standard components in the SCORBOT ER VII package Make sure you have received all the items listed on the shipment s packing list If anything is missing contact your supplier SCORBOT ER VII Standard Package Catalog 404 Item Description SCORBOT
69. ks the movement of the robot axes and the input output functions of the controller During the test the following occurs In sequence each configured axis is moved briefly in both directions a message will display an axis failure All outputs are turned on and then off All inputs are scanned If an input is on the corresponding output is also turned on To simulate the activation of an input when no device is connected short the input manually by means of a wire or an unraveled paper clip When the input is operating in NPN mode short the input by connecting it to a ground connector When the input is operating in PNP mode short the input by connecting it to the user power supply If you want to check the homing microswitches use the command LSON before entering the TEST command Use command SHOW DIN to see the results Diagnostic Procedures 1 User s Manual 9602 Controller does not turn on The yellow power LED does not light up Fans do not rotate Make sure the AC power supply matches the controller s voltage requirement as seen on the tag at the back of the controller If the voltage supply and controller voltage setting do not match change the voltage setting as described later in this chapter Make sure AC power is being supplied to the power outlet Make sure the power cable is connected to both the proper power source and the controller If RS232 cable is connected disconnect it and and retry power on
70. line s until it reaches an ENDIF command which marks the end of the conditional routine if varl var2 goto 1 endif The IF statement may however be followed by another conditional statement The next line may be an alternative condition ORIF or an additional condition ANDIP if varl var2 At least one of the two conditions orif var3 gt 10 must be true in order for the goto 2 program to jump to label 2 endif if varl var2 Both conditions must be true in andif var3 gt 10 order for the program to jump to goto 2 label 2 endif The conditional routine may also contain a routine to be executed when the IF condition is false The beginning of such a routine begins with the command ELSE if varl var2 If the condition is not true the goto 2 program will jump to label 1 else goto ih endif User s Manual SCORBOT ER VII 7 9 9206 Input and Output Programming The state of the controller s 16 inputs and 16 outputs is determined by means of two system variables IN n and OUT n n specifies the I O index that is 1 16 The value of the variable indicates whether the input or output is on or off when the value of the variable is 1 the input or output is ON when the value is 0 the input or output is OFF Displaying Input Output Status Type Type Inputs The I O LEDs on the front panel of the controller turn on and off to reflect the status of the inputs and outputs If you are not close enough to
71. lowing functions has been activated Speed Run Record Position Go Position Group Select 5 4 SCORBOT ER VII User s Manual 9602 X X d Base Base gt In Joint mode the Base X keys move the base axis in two directions In XYZ mode the Base X keys move the TCP tip of gripper along the X axis Y and Z coordinates do not change Y Z A A Shoulder Elbow In Joint mode the Shoulder Y keys move the shoulder axis in two directions In XYZ mode the Shoulder Y keys move the the TCP tip of gripper along the Y axis X and Z coordinates do not change In Joint mode the Elbow Z keys move the elbow axis in two directions In XYZ mode the Elbow Z keys move the TCP tip of gripper along the Z axis X and Y coordinates do not change In Joint mode the Pitch keys move the TCP tip of gripper up or down without moving the other axes In XYZ mode the Pitch keys move three axes shoulder elbow and pitch in order to change the pitch angle without changing the position of the TCP tip of gripper In both Joint and XYZ modes the Roll keys move the roll axis in two directions Open A toggle key Opens and closes the electrical gripper User s Manual SCORBOT ER VII 5 5 9602 Speed number Sets the speed of manual axis movement of the current axis control group that is group A B or C The speed is defined as a percentage 1 100 of maximum speed Press Speed The current speed is displayed Pr
72. lt Enter gt close lt Enter gt Pneumatic grippers or devices are controlled by means of ACL output commands To activate a pneumatic gripper or end effector from the teach pendant ACL output commands must be written to two program one for opening the gripper and one for closing it Each program can then be called from the teach pendant resulting in activation of the pneumatic gripper or device For more information refer to the section on I O programming in Chapter 7 SCORBOT ER VII 6 11 Setting the Speed Press Press The speed of the robot during Go Position movements controlled from the teach pendant is defined as a percentage of maximum speed Speed defined as 100 gives the robot maximum speed while a speed of 1 is the minimum When the system is first turned on the default speed is set at 50 approximately half the robot s maximum speed The speed of the robot during manual movements controlled from the teach pendant is relative to the speed setting and much slower than Go Position movements Use the teach pendant to set the robot s speed to a speed of 30 for example 3 0 Speed pee Axis 9 H Axis 11 All Go Position movement commands will be executed at a speed of 30 until a different speed is entered When Manual mode is active use the key S to set the speed of manual movement s SPEED You are prompted for a speed value a percentage of the maximum speed Type a number betw
73. m and the controller are packed in two separate cartons Save the original packing materials and shipping carton You may need them later for shipment or storage 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 See Figure 1 1 Use the hex wrench supplied with the robot to detach these bolts Save these bolts and the plate You will need them should you repack the robot for shipment More important you will need three of these bolts to attach the gripper to the flange Figure 1 1 SCORBOT ER VII Packing User s Manual SCORBOT ER VII l 1 9602 The controller package contains two ATS diskettes Each diskette includes a parameter file named PAR7 CBU which is uniquely associated with the robot you have received One diskette is write protected Store the protected disk together with the computer print out of the robot s parameter file Handling Instructions Lift and carry the robot arm only by grasping the body or the base See Figure 1 2 Do not lift and or carry the robot arm by its upper arm or forearm Lift and carry the controller by grasping it on and under the left and right side panels Do not grasp the controller on either its front or back panel and avoid handling near the power switch Figure 1 2 Robot Arm Parts Repacking for Shipment Be sure all parts are back
74. mands to the pitch or roll axis will change the orientation of the gripper or tool while maintaining a constant TCP position When the coordinate system is set to the Joint mode movement commands cause the robot to move one joint Peripheral axes always move according to Joint coordinates When in XYZ mode the controller recognizes the Cartesian functions of the teach pendant keys When in Joint mode the controller recognizes the joint functions shaded in diagram of the teach pendant keys The teach pendant offers the easiest method for moving the robot arm You simply press an axis movement key and the robot moves When you release the key movement stops Before you press the keys shown below make sure JOINTS Group A and Control On are active Move the axes of the robot in both directions Shoulder Shoulder y A Elbow SCORBOT ER VII 6 9 Before you press the keys shown below make sure XYZ appears on the teach pendant display Watch how the keys now affect the movement of the TCP Ne To directly control movement of the robot axes from the keyboard Manual mode and Control On must first be activated The keys listed below are then used to move the robot The axes will move as long as the activating key is depressed until a fixed stop is reached The gripper will either open completely or close completely In Joint mode the keys produce the following movements Press 1 Q Move axis base 2
75. message is displayed HOMING COMPLETE ROBOT If the homing process is not completed an error message identifying the failure is displayed SCORBOT ER VII 4 7 or press HOME FAILURE AXIS 4 To stop the homing while the operation is in progress use the abort commands A lt Enter gt lt Ctrl gt A For instructions on homing the robot by means of the teach pendant and homing the peripheral axes refer to Chapter 6 Gripper Installation DC Servo Electric Gripper The gripper is attached to the flange at the end of the robot arm whose layout is shown in Figure 4 4 The controller supplied with the SCORBOT ER VII robot is equipped with a piggy back board with 68020 CPU and 68881 FPU floating point unit and ACL EPROM version F 44 or later The controller must be be properly equipped and or upgraded if you intend to Figure 4 4 Gripper Mounting Flange mount a DC servo electric gripper on an older model of Controller A or one which was supplied with a SCORBOT ER V or SCORBOT ER Vplus robots To install the DC servo electric gripper do the following Make sure the D9 connector for the gripper is connected to the axis 6 driver port at the rear of the controller Make sure the robot has been succesfully homed Using a hex wrench and six M3 socket screws attach the gripper to the gripper mounting flange at the end of the robot arm Connect the gripper cable to the
76. mmable 170 225 180 360 Maximum Operating Radius 690 27 2 at flange End Effector options Pneumatic and DCServo Fixed position on each axis Harc Pome found by means of microswitches Optical incremental encoder on each axis pee 96 slot disk Actuators 12VDC servo motors Transmission Harmonic drives timing belts and pulleys Maximum Payload 2 kg 4 4 1b including gripper Position Repeatability 0 2 mm 0 008 Weight 30 kg 66 Ibs Maximum Path Velocity 1000 mm sec 39 4 sec Ambient Operating Temperature 2 40 C 36 104 F SCORBOT ER VII User s Manual 9602 Structure The SCORBOT ER VIT 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 large work space Figures 2 2 and 2 3 identify the joints and links of the mechanical arm The movements of the joints are described in the following table Axis No Joint Name Motion Motor No 1 Base 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 2 Robot Arm Links Figure 2 3 Robot Arm Joints User s Manual SCORBOT
77. n the driver cards simply press E LOWER AXIS FUSE 1t Earlier models of Controller A CONNECTOR the switch on those fuses to Figure 8 3 Driver Card Fuse reset Check the motor drive circuitry Drive the motor in open loop for a few seconds only Use the command SET ANOUT n DAC nis the axis number DAC is the drive level 5000 lt DAC lt 5000 Note the following DAC values and their effect DAC value Motor Speed 5000 full speed 2500 half speed 0 motor stops 2500 half speed 5000 full speed DAC values of 1500 2000 are recommended for this test I Use extreme caution when applying the SET ANOUT command to robot axes or accessories whose movements are mechanically restricted High DAC values may cause unwanted mechanical impact and can damage the robot or accessory User s Manual 9602 To cancel the SET ANOUT command use an Abort command or enter the command SET ANOUT n 0 To help you perform the motor test you can also prepare and run a simple ACL program which contains the following routine S D S ET ANOUT n 1500 ELAY 200 ET ANOUT n 0 If the axis does not rotate the problem can be either in the arm motor transmission cabling or in the controller driver card main board communication card or flat cable connections Tf the axis rotates as expected in both directions proceed to check the encoder feedback readings SCORBOT ER VII 8 7 Check the encoder
78. n the warning light whenever the robot is in motion SCORBOT ER VII 7 11 The light is normally connected to relay output 1 Therefore the following commands are used in program ONOFF set out 1 1 When output 1 turns on the light turns on set out 1 0 When output 1 turns off the light turns off In order to download this program file for use refer to the downloading procedure described later in this chapter Sample Program INOUT Type A program named INOUT can be found in the file DEMO CBU which is factory loaded into the controller and included in the ATS diskette supplied with the system The program contains two loops one loop has instructions for checking the status and responding to the state of all the inputs the other loop has instructions for responding when input 16 is on This sample program demonstrates program loops and conditional routines In addition it shows how to include user comments within a program Use the LIST command to view the program shown below Explanatory notes are provided below list inout lt Enter gt PROGRAM INOUT KKKKKKKKKKKKK KKK KKK KK PRINTLN this program tests inputs amp sets outputs PRINTLN LABEL L FOR I 1 TO 16 TE IN I 1 TEST IF INPUT 1 S ON SET OUT I 1 SET OUTPUT I ON ELSE SET OUT I 0 SET OUTPUT I OFF ENDIF DELA
79. n your environment Check the encoder Follow the procedures in Item 8 and Item 9 If no problem found by means of Items 8 and 9 do the following Bring the robot to a starting position Using a pencil draw a fine continuous line on the robot which crosses from one link to the adjacent link at the joint in question SCORBOT ER VII User s Manual 9602 11 12 13 User s Manual 9602 Enter the command SHOW ENCO to display the encoder readings Enter the command COFF to disable servo control 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 several counts of the first reading Repeat this step a number of times If the error in the encoder reading accumulates the encoder needs to be replaced One axis turns constantly in one direction Reset the controller by pressing and releasing the Emergency button Then give the command to home the robot If problem persists replace the driver card Axis axes vibrating too weak to 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 If problem persists replace the driver card Electric gripper does not respond at all Make sure the gripper cable is securtely connected to the axis 6 port at the rear of the controller Check whether the gripper i
80. nd MOVEC use the ACL command MOVEC You must specify two positions for MOVEC Otherwise there are infinite possibilities for defining the curve For example send the robot from the home position to position A31 via position A32 Be careful when using this command For the first attempt set the speed to a low setting such as 20 Type move 0 lt Enter gt Type speed 20 lt Enter gt Type movec A31 A32 lt Enter gt Reset the speed to 50 when you have completed the movement 6 18 SCORBOT ER VII User s Manual 9602 CHAPTER F Programming with ACL This chapter serves as a tutorial to help you become familiar with program editing To learn how to write and edit a program you should follow in sequence the procedures described in this chapter This chapter introduces you to the basic commands for programming the SCORBOT ER VII Many more commands and formats are available in the ACL language Refer to the ACL Reference Guide for complete lists and descriptions of editing functions and ACL commands For additional instruction in the procedures introduced in this chapter the ACL Laboratory Manual catalog 100039 is recommended EDIT Mode Help User s Manual 9206 So far you have learned to operate the robot in the DIRECT mode in which all commands are executed the moment you press lt Enter gt To write programs which will be executed by the robotic system you will use the EDIT mode Whenever the EDIT mode
81. nd of the loop The PRINTLN command causes comments text within quotation marks to be displayed on the screen during program execution Thus when you run program LOOP the word LOOP will be displayed 10 times By altering the PRINTLN command line you can cause the system to report which loop has been completed Bring the cursor to the ENDFOR command line Enter the command DEL this will delete the preceding command line Then enter anew command line println LOOP var Make sure you have included a space following the text LOOP SCORBOT ER VII User s Manual 9206 The PRINTLN command causes the current value of a variable to be displayed on the screen during program execution Thus when you run program LOOP the following will now appear on the screen LOOP 1 LOOP 2 LOOP 3 and so on until LOOP 10 is displayed In the section on input output programming later in this chapter you will see additional examples of program loops which enable the system to check and respond to the state of the controller s 16 inputs Conditional Functions Many applications require the program to flow according to certain conditions The command format IF varl oper var2 checks the relation between var and var2 Varl must be a variable var2 may be either a variable or a constant Oper is one of the following comparison Operators gt lt gt lt lt gt When the IF statement is true the program executes the next
82. ndant will show HOMING When the Home search is successfully completed the display panel will show HOMING COMPLETE If the robot is unable to find a home position in one or more of the axes you will see a message such as HOME FAIL 4 To stop the homing while the operation is in progress press the Abort key The peripheral axes are homed by means of the TP command Run 00 To home the robot axes Group A use the ACL command HOME home lt Enter gt WAIT HOMING If all axes reach their home postion a message is displayed HOMING COMPLETE ROBOT SCORBOT ER VII 6 3 Type or press Type Type If the homing process is not completed an error message identifying the failure is displayed HOME FAILURE AXIS 4 To stop the homing while the operation is in progress use the abort commands A lt Enter gt lt Ctrl gt A To home peripheral axes each axis must be homed individually for example home 7 lt Enter gt home 8 lt Enter gt home 9 lt Enter gt To home an axis such as a slidebase which uses a hard stop rather than a microswitch use the ACL command HHOME hhome 8 lt Enter gt SCORBOT ER VII User s Manual 9602 Coordinate Systems The SCORBOT ER VII can be operated and programmed in two different coordinate systems Joint and Cartesian XYZ coordinates Cartesian XYZ Coordinates The Cartesian or XYZ
83. nually appear or even occasionally reoccur replace the main board 6 Controller functioning but the robot cannot be activated Make sure an obstacle is not blocking the robot Make sure the controller s motors switch is on and the green LED is lit Make sure the controller is in the control off COFF state Then activate the control on CON state from PC or TP Make sure the robot cable is properly connected to the controller Figure 8 2 Driver Card LEDs Check whether all driver card LEDs on the controller rear panel are lit See Figure 8 2 Each driver card has a pair of LEDs the upper LED corresponds to the axis number at the top of the card the lower LED 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 proceed to Item 8 User s Manual SCORBOT ER VII 8 5 9602 7 Robot does not find Home position in one or all of the axes Make sure the homing command was properly issued Make sure the robot cable is properly connected to the controller Make sure system homing parameters are properly set Make sure system homing parameters have not been erased Check the microswitch for this axis Manually move the faulty axis from teach pendant or keyboard and use the LSON and SHOW DIN commands to check the microswitch The value will change to either 1 or O when the microswitch i
84. o call from the teach pendant Priority By default the controller assigns each program a run time priority of 5 on a scale of 1 10 The user can define a program s priority by means of the PRIORITY or RUN command Multi Tasking Controller A is a multi tasking real time controller it can simultaneously execute and control 20 independent programs Use the DIR command and note the programs PICP IO IOA To run these three programs concurrently use three RUN commands to start execution in both DIRECT and EDIT mode SCORBOT ER VII User s Manual 9206 Type run picp lt Enter gt run io lt Enter gt run ioa lt Enter gt Program PICP takes the robot through a series of pick and place movements Programs IO and IOA both turn controller outputs on and off watch the LED display on the controller while these programs are being executed To abort all three programs use the Abort command Displaying Program Status While programs are running use the command STAT to view their status Type stat lt Enter gt JOB_NAME PRIORITY STATUS PICP 000005 PEND IO 000005 DELAY IOA 000005 SUSPEND PEND program is executing a movement command DELAY program execution is currently being delayed SUSPEND execution has been halted by SUSPEND command Activating a Program from Another Program As indicated throughout this chapter Controller A enables interaction and synchronization of programs
85. ontrolled acceleration deceleration PID parameters Speed Control Speed Travel time Speed programmed as a percentage of range Control Parameters Servo control Speed velocity profile smoothing Axis position error Gripper operation Thermic impact limit protection Homing Encoder interface Cartesian calculations Power Requirements 100 110 220V AC 50 60Hz 500W max 5 Internal Power Motors 24VDC 18A Supplies User 12VDC 2A Weight 19 kg 42 lbs 490mm 19 3 L Dimensions 445mm 17 5 W 150mm 5 9 H Ambient Operating 2 40 C 36 104 F Temperature CPU Motorola 68020 EPROM 384KB 3 2 SCORBOT ER VII User s Manual 9602 Item Controller A Specification Notes System 64KB KAM User 128KB Communication RS232 serial port Inputs 16 inputs with indicator LEDs NPN default and PNP logic modes 12 open collector outputs with indicator LEDs TTL 12V or 24V logic Outputs NPN default and PNP logic modes 4 relay outputs with indicator LEDs es ACL Advanced Control Language Ga ee SCORBASE Level 5 Software Using PC cutee We Using ACL Position Recording SCORBASE reed Teach Pendant No of program lines positions 12800 lines or 6375 positions or any combination No of programs in user RAM Hundreds depends on length of programs Multi tasking Maximum simul
86. or Weight 10 1 oz 8 98 oz Axes through 4 are driven by a two stage transmission as shown in Figure 2 5 The roll axis axis 5 is driven directly by a Harmonic drive gear MOTOR 5 Edo O MOTOR 4 NE dy MOTOR 3 MOTOR 2 Figure 2 6 Transmissions Figure 2 7 Motor Locations User s Manual SCORBOT ER VII 2 5 9602 Position and Limit Devices Encoders The SCORBOT ER VII uses encoders microswitches and hard stops to position the robot arm and limit its motion The location and movement of each SCORBOT ER VII axis is measured by an electro optical incremental encoder which is attached to the shaft of the motor which drives the axis as shown in Figure 2 8 When the robot axis moves the encoder generates a series of alternating high and low electrical digital signals which can be understood by the controller The controller reads these signals and determines the extent and direction of axis movement The encoder used on the SCORBOT ER VII 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 The SCORBOT ER VII encoders have 96 slots as shown in Figure 2 9 As the encoder disk rotates between the emitter and detectors
87. ot positions defp A31 defp A32 defp A33 The ACL command HERE records a position in joint coordinates according to the current location of the axes Remember to activate Manual mode before starting motion and to exit Manual mode when the motion is completed Also be sure the position is defined before you attempt to record it Move the robot to any location and record its coordinates for position A31 here A31 lt Enter gt Move the robot two more times and record coordinates for positions A32 and A33 If you attempt to record a position which has not been defined for example HERE A34 the system will display an error message If you specify a name of a position which has already been recorded for example HERE A31 the HERE command will will overwrite the existing coordinates with new coordinates The ACL command TEACH records a robot position in Cartesian coordinates according to user defined settings it does not record the coordinates of the robot s current location SCORBOT ER VII User s Manual 9602 Relative Positions Relative positions cannot be recorded by means of the teach pendant The ACL commands HERER and TEACHR allow you to record a position as relative to another position or as relative to the current position of the robot To record a position which is relative to another position by joint coordinates move the robot to the relative location and record the position For example Type
88. ot to touch or short it Driver Card Fuses User s Manual 9602 Each driver card has two slow blow SB fuses one fuse per axis See Figures 8 3 and 8 8 The first three driver cards for axes through 6 have a 4A fuse for each axis The fourth driver card for peripheral axes 7 and 8 has a 4A fuse for the top axis axes 7 and a 2A fuse for the lower axis axis 8 Additional driver cards for axes 9 through 11 are the same as the fourth driver card with a 4A fuse for the top axis and a 2A fuse for the lower axis Remove the driver card from the controller before you replace any of its fuses To replace a driver card fuse simply grasp it and extract it from its holder You may need to use a tweezers Insert the new fuse into the holder and make sure it is firmly in place Driver cards in earlier models of Controller A have two semi automatic fuses one fuse per axis These fuses should not need to be replaced only reset However if you do replace such a fuse solder it only when in the open state SCORBOT ER VII 8 17 Changing the I O Logic Mode The I O logic mode can be set individually for each input and open collector output terminal by means of jumpers on the I O card PC7400A as shown in Figure 8 7 The jumpers are marked I1 to 116 and O5 to O16 Note that the relay outputs do not require jumpers Use tweezers or a fine tip pliers to lift off the jumpers and reset them You do not need to remove the I O ca
89. otor rather than controlling the value of the current is known as PWM Pulse Width Modulation control Refer to Figure A 6 Once per cycle the processor reads the encoder s count and calculates the motor s position and speed rate of encoder counts The processor then compares the actual output position and speed values with the desired input ones determines the error values and takes the necessary action to cancel them DAC MOTOR VOLTAGE VOLTAGE FULL SPEED at 4 2 5V HALF SPEED CW HALF SPEED CCW FULL SPEED CCW Figure A 6 Controller A Control Signals A 6 SCORBOT ER VII User s Manual 9602 Trajectory Control For better path performance that is to accurately reach the desired state and avoid overshoots trajectory control profiles may be programmed into the control system Controller A offers two profiles paraboloid and trapezoid Refer to Figure A 7 Paraboloid The paraboloid profile causes the motors to accelerate slowly until maximum speed is reached then decelerate at the same rate Trapezoid The trapezoid profile causes the motors to accelerate and decelerate quickly at the start and end of movement with a constant speed along the path TRAPEZOID PARABOLOID Figure A 7 Trajectory Control Profiles Path Control It is desirable that the path and speed of a robot between taught points be predictable Ideally the path between consecutive points is traversed at a constant velocity
90. r output the error signal is generally denoted as U SCORBOT ER VII A 1 POWER SUPPLY r Ur Ue c INPUT SIGNAL AMPLIFIER ACTUATOR ACTUATOR INPUT TRANSDUCER OUTPUT A OPEN LOOP CONTROL POWER SUPPLY U U Ue p INPUT SIGNAL gt AMPLIFIER ener FEEDBACK DEVICE B CLOSED LOOP CONTROL Figure A 1 Open Loop and Closed Loop Control The error signal is the most important value in the closed loop system The system aims to reduce U to the smallest possible value When U 0 the output signal the actual state is equal to the input signal the desired state Digital Control Unlike analog control systems in which all signals within the controller are continous analog signals digital control systems are those in which some of the signals within the controller are discrete digital signals due to the presence of microprocessors In digital control systems the controller must be capable of converting between analog and digital signals For the microprocessor to read an analog signal the signal must first pass through an Analog to Digital Converter The ADC samples that is reads the signal at periodic intervals and stores the value for the processor to read For the microprocessor to transmit an analog signal it must send the discrete values of the signal to a Digital to Analog Converter The DAC holds the output continuously until given a new value Controllers use microprocessors to calculate the st
91. rd from the controller NPN Logic Shorting the two pins on the left sets the corresponding terminal to negative NPN logic All inputs and outputs area factory configured for operation in negative NPN logic mode ON low voltage or ground OFF high voltage PNP Logic Shorting the two pins on the right sets the corresponding terminal to positive PNP logic ON high voltage OFF low voltage or ground 00000000 00000000 00000000 00000000 1900000000 D D p 5ljO0000000 plooo00000 Bloooooooo ooooooo0ooBooooo0oo000 NPN 00000000 CM PNP 00000000 00000000 000000000000 00000000 ca 000000000000 00000000 POOODOODOO Figure 8 7 I O Card Logic Jumpers 8 18 SCORBOT ER VII User s Manual 9602 Replacing or Adding a Driver Card Refer to Figure 8 8 Skip Steps 4 and 5 when adding a driver card 1 Turn off the controller and disconnect the power cable from the power outlet 2 Remove the cover of the controller 3 Remove the long bracket which extends across the driver cards Remove the screw which holds the long bracket to the transformer cover see Figure 8 6 Using pliers to grip the self locking washer from inside the controller frame remove the screw that fastens the bracket to the side of the controller Remove the screws and washers which hold the long bracket to each driver card 4 Note the location of each driver cards you will replace them later in these same positions Remove the screw at the
92. roper controller output Check the relay output to which the gripper is connected according to the instructions in Item 19 21 User programs are not saved in the BBAM Response to ACL command DIR is Directory is Empty Check the voltage level of the backup battery on the main board See Figure 8 1 A good battery produces 3 4V 3 7V Battery should backup RAM as long as the Vcc supply to U4 U10 U16 and U21 is 2V or higher Replace battery if necessary Make sure the battery is properly and securely set in its socket If battery is all right replace the main board When battery is low backup the controller frequently to avoid loss of data SCORBOT ER VII User s Manual 9602 Error 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 control on has not been issued motors have not been activated 3 A previous error such as Impact Protection
93. rpose In order to save program files to disk perform the following steps 1 From the DIRECT mode press lt Alt gt 10 The Backup Manager menu will appear on your screen 2 Use the arrow keys to highlight Backup PROGRAMS and press lt Enter gt Backup directory type and lt Enter gt the name of the drive where you want the file to be saved it may be a floppy drive disk or a subdirectory on your hard disk File name type filename or any name of up to 8 characters and press lt Enter gt The CBU extension will automatically be written 3 Press F2 to save the file to disk When DONE appears press lt Esc gt to return to the main ATS screen Note that this procedure saves all programs positions and variables which are currently in the controller s BBRAM to the file filename CBU 7 16 SCORBOT ER VII User s Manual 9206 Downloading a Program Restore to Controller The following steps will download the contents of a file to the controller BBRAM 1 From the DIRECT mode press lt Alt gt 10 The Backup Manager menu will appear on your screen 2 Backup directory Type and lt Enter gt the name of the drive where the backup files are located it may be a floppy disk drive or a subdirectory on your hard disk You can press F9 CATALOG to make sure filename appears in the directory Use the arrow keys to highlight Restore PROGRAMS and ADD TO Controller Contents Press lt Enter gt
94. rt the Program Type Press To immediately abort running programs and stop all axis movement enter the abort command in either one of the following ways a lt Enter gt lt Ctrl gt A PROGRAM AAA ABORTED Program AAA can now be reactivated only by means of the RUN command which will start the program from the beginning If several programs are running and you want to abort only one of them following the command by the name of the specific program for example a aaa lt Enter gt This format aborts the specified program only after the command currently being executed has been completed Stop the Program Type Type User s Manual 9206 To include an abort command in a program you are editing use the command STOP The STOP command will abort a program only after all axis movement commands which have already been sent to the controller movement buffer have completed execution Use the STOP command in one of the following ways stop aaa lt Enter gt Aborts only program AAA stop lt Enter gt Aborts all running programs STOP is available in EDIT mode only STOP cannot be used to abort a running program when in DIRECT mode SCORBOT ER VII 7 5 Delaying Program Execution Press Press Type Press Type Press Type Press Type The DELAY command causes program execution to pause for a specified amount of time The DELAY command ensures that preceding commands have been properly
95. s defined as axis 6 by typing the ACL command CONFIG Check the value of PAR 75 It should be 4000 If problem persists proceed with corrective actions recommended for other axes Discconnect gripper cable from the robot forearm and check for voltage 1 5V 2 0V by connecting pins and 6 while entering CLOSE OPEN commands Pins 1 and 6 are respectively the pins immediately to the right and left of the notch on the connector If voltage exists the problem is in the gripper Check the cable and the motor Check for excessive friction Try raising the value of the current limit of the gripper driver axis as explained later in this chapter If raising the current limit above 0 5A enables gripper motion make adjustments to reduce friction Be sure to reset the current limit for the gripper axis to 0 5A SCORBOT ER VII amp 9 14 15 16 WA Electric servo gripper opens and closes but does not react properly to JAW command The problem is probably in the feedback Check the encoder the wiring and the driver card Follow the procedures in Item 8 and Item 9 Gripper opens and closes too freely weak gripping force or the gripper motor rotates endlessly Check the value of PAR 275 It should be 1000 Unusual noise Loose screws Poor lubrication Worn motor brushes Worn timing belt Controller does not receive an input signal Make sure motors switch is on and make sure user power supply is 12VDC If no
96. s detected Use the commands LSON and TEST Or prepare and continuously run a simple ACL program to test the microswitches as follows LSON LABEL 1 PRINTLN IN n DELAY 200 GOTO 1 If values do not change check the microswitch itself Use a small screwdriver to press down on the microswitch You should hear it click and see it pop back up If this does not happen the microswitch should be fixed or replaced If the microswitch has clicked depress it again and with an ohmeter check whether the microswitch shorts its two poles If there is a short depress the switch again and check the wires between the microswitch and D50 connector If there is a short depress the switch and check the two microswitch pins in the D50 connector Refer to Chapter 10 for wiring and pin information If there is a short replace the driver card for that specific axis If the problem persists replace the main board Alternately check ICs U88 U93 U98 U82 and U87 8 One of the axes does not function Make sure you have performed all steps in Item 5 and Item 6 If the driver card LED for this axis is not lit check the corresponding fuse on the axis driver card Refer to Figure 8 3 Turn off the controller and open the cover SCORBOT ER VII User s Manual 9602 Check the fuse on the top of the driver card for the faulty UPPER AXIS FUSE axis If the fuse has blown replace have semi automatic fuses o
97. s lit the CPU is in the HALT state Turn off the controller and remove all the driver cards For instructions on removing driver cards refer to the section Adjustments and Repairs later in this chapter Then turn the controller on Pc7000 again Backup If the red LED shuts off the problem Battery 1 f the driver cards Return the mi s one O y driver cards to the controller one at a time until you determine which one is faulty Replace the faulty driver card Figure 8 1 Main Board Memory SCORBOT ER VII User s Manual 9602 Make sure the hardware and software configuration are compatible with the user RAM ICs Hardware Refer to Figure 8 1 Make sure all four jumpers for configuring user RAM W1 W1A W2 W2A are set for 128K RAM The two lower pins must be shorted Software Make sure the controller is configured for 128K memory by entering the command CONFIG Remove the user RAM ICs U4 U10 U16 U21 and reinsert them If problem persists replace the main board 5 Controller is inoperative Message on PC screen reads bus error trap exception trap etc and data on PC screen reads Address error trap DO gt D7 00000000 A0 gt A7 00000C10 OOOAO3FC PC EB942404 SR 0008 SSP 0008796C USP 0 Turn the controller off and on If problem persists remove the driver cards and again turn the controller power switch off and on again If these messages conti
98. see the controller panel you may want another means to check the I O status In DIRECT mode use the following commands to display the status of all 16 inputs and outputs respectively show din lt Enter gt Shows status of the inputs show dout lt Enter gt Shows status of the outputs The display will indicate the I O status in the following manner 1 gt 163 0 1 0 1 0 00 01 Oy 11 0 Oud TO 0 O K When editing a program use the command PRINTLN to display the status of a specific input or output during program execution For example println in 5 When this command is encountered during program execution either 1 or 0 will be displayed that is the value of variable IN 5 depending on the state of input 5 Conditional commands such as IF and WAIT are used to read and respond to the state of the inputs For example you can use the following routine in a program if in 3 1 If input 3 is ON then move A31 Move to position A31 else If input 3 is NOT ON off then move A32 Move to position A32 endif End of conditional routine SCORBOT ER VII User s Manual 9206 Outputs As with inputs conditional commands can read and respond to the state of the outputs Commands can also be used to alter the state of outputs To change the state of an output in both DIRECT and EDIT modes use the SET command For example set out 6 1 lt Enter gt Turns ON input 6 set out 8 0 lt Enter gt Turns OFF input 8 Ac
99. t none of the inputs will be operative To determine whether the problem is in the controller or a user application enter the command SHOW DIN Zeros and ones appear on the screen corresponding to the status of the 16 inputs O OFF and 1 0N Short the specific input If the input is configured as NPN default Short the specific input to a ground connection If the input is configured as PNP Short the specific input to the 12V user power supply Again enter the command SHOW DIN Look for a status change If the status of the input changes the problem is in the user application If the status of the input does not change check the flat cable connections between Display card and main board J11 T O card and main board J10 If the input LED also does not light up refer to Item 18 If when checking the homeswitches LSON the input LED lights up and home is found only the input is not functioning replace the main board Alternately check U99 U100 U101 U102 U88 U93 U98 SCORBOT ER VII User s Manual 9602 18 VO display LEDs do not light up Refer to Figure 8 5 Check the flat cable connection between Display card and main board J11 T O card and main board J10 If the input or output functions but not the LED replace the LED or the display card PC7300 Replace the I O card PC7400A Alternately check U1 U2 U3 U4 US U6 U7 Replace the main board Alternatively check for inputs
100. t of an operation performed on another variable For example set varl abs var2 If the value of var2 is 1 varl is set to 1 User s Manual SCORBOT ER VII 7 7 9206 The value of a variable can be the result of a mathematical operation performed on either two other variables or another variable and a constant For example set varl var2 1 The value of var is greater by 1 than the value of var2 set vara varb varc The value of vara is the result of varb multiplied by varc set var var 100 The result of an operation can equal the same variable thereby changing its value The value of var now equals the previous value of var plus 1000 Iteration Functions Many applications require task iteration or repetition Variables can be used to produce program loops which repeat a command or commands thereby avoiding the need for redundant command lines within a program The command format FOR varl var2 TO var3 enables a program routine to be executed repeatedly Var must be a variable var2 and var3 may be either variables or constants For example enter the following commands to create program LOOP edit loop for var 1 to 10 println LOOP endfor exit The variable is a counter which is set initially to 1 and increased by one each time the loop is performed When the counter value reaches the final value 10 in this example the loop is performed for the last time The ENDFOR command is required to mark the e
101. taneous execution 20 user tasks Positioning System Incremental optical encoders Coordinate System XYZ coordinates Joint coordinates LED Indicators Main power Inputs Outputs On front panel Servo Power Emergency Axis power On rear panel Safety Features Emergency switch Motor power switch On front panel Adjustable current limit Automatic fuse On all axes Thermic impact and limit software protection Inputs Outputs User power supply Terminals on front panel Axis drivers On rear panel D9 connectors Connectors RS232 channel D25 connector Teach Pendant D25 connector Robot D50 connector Auxiliary RS232 channels optional D37 connector 30 multi function keys Teach Pendant 2 line LCD display 16 characters per line Full control features User s Manual 9602 SCORBOT ER VII Controller Functions The front panel of the controller contains switches LEDs and connection terminals for operator use Refer to Figure 3 2 MOTORS USER POWER INPUT amp SWITCH OUTPUT EMERGENCY SWITCH POWER 12VDC USER Y i Z ON OFF POWER SUPPLY af SWITCH GROUND 4 RELAY OUTPUTS 12 OPEN COLLECTOR OUTPUTS 16 INPUTS Figure 3 2 Controller Front Panel Power On Off Switch and LED The controller s power switch which is located on the side of the controller connects and disconnects AC power to the controller The yellow power LED on
102. the section Activating Output Driven Devices in Chapter 7 for instructions on how to program and operate the pneumatic gripper WIRES TO CONTROLLER PA AIR HOSES TO ROBOT Figure 4 9 Pneumatic Solenoid Valve SCORBOT ER VII QUICK COUPLER FOR PNEUMATIC GRIPPER 457 CONNECTOR FOR SERVO GRIPPER GRIPPER MOUNTING FLANGE Figure 4 8 Gripper Connectors This page intentionally left blank SCORBOT ER VII User s Manual 9602 CHAPTER 5 Operating Methods SCORBOT ER VII can be programmed and operated in a number of ways This chapter introduces the robotic software and the teach pendant functions Software and teach pendant operation is described in other chapters of this manual and in the other manuals supplied with the system Software ACL ATS User s Manual 9602 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 A and can be accessed from any standard terminal or PC computer 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 synchronized and interactive program execution full multi tasking support Simple file management ACL is described fully in the ACL Reference Guide ATS Advanced Terminal Software is t
103. the front panel rotates and draws air into the controller The fan in the rear panel within the supply unit extracts air from the controller All green LEDs on the controller rear panel light up 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 SCORBOT ER VII 8 1 Bring the robot to a position near home and activate the homing 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 Troubleshooting I The procedures in the section are intended only for technicians who have received proper training and certification from the manufacturer Do not attempt to perform procedures for which you are not qualified Whenever you encounter a malfunction try to pinpoint its source by exchanging the suspected faulty component for example robot controller teach pendant cable with an identical component from a working 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 Fuses should also be checked 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 Make sure the controller s power s
104. 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 Figure 2 8 Encoder The photodetectors are arranged so that alternately some detect light while others do not The photodiode outputs are then fed through the signal processing Figure 2 9 Encoder Disk Figure 2 10 Encoder Output Signals SCORBOT ER VII User s Manual 9602 circuitry resulting in the signals A A B and B Comparators receive these signals and produce the final digital outputs for channels A and B The output of channel A is in quadrature with that of channel B 90 out of phase as shown in Figure 2 10 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 Microswitches Microswitches shown in Figure 2 11 are used in the SCORBOT ER VII to limit robot motion limit switches and to home the robot home switches Limit Switches Limit switches prevent the joints from moving beyond their functional limits When the robot control software fails to stop the axis at the end of its working range the limit switch serves to halt its movement Each of axes 1 through 4 has two limit switches one at each end of the axis working range These Figure 2 11 Microswitch switches are mounted on a disk which is attached to the
105. tivating Output Driven Devices Pneumatic End Effectors or Devices Press As mentioned in Chapter 6 pneumatic end effectors or devices are connected to controller outputs and controlled by means of ACL output commands Assuming a pneumatic gripper is connected to controller relay output 2 use the following command format set out 2 1 lt Enter gt Turn on output 2 to open the gripper set out 2 0 lt Enter gt Turn off output 2 to close the gripper In order to activate the pneumatic gripper from the teach pendant you need to create two programs named OGRIP and CGRIP for example which can be called from the teach pendant by means of the Run key Each program contains one of the commands shown above Program OGRIP contains the command to turn on output 2 Program CGRIP contains the command to turn off output 2 Using the ACL command DIR note the identity number of programs OGRIP and CGRIP The command DIR is explained more fully later in this chapter Let s assume programs OGRIP and CGRIP are identified as program 8 and program 9 respectively Now whenever you want to open the pneumatic gripper by means of the teach pendant Run 9 Enter Warning Light User s Manual 9206 A flashing warning light can be integrated into the SCORBOT ER VII system A program named ONOFF is included in the ONOFF CBU file on the ATS diskette supplied with the system When the ONOFF program is activated it will automatically turn o
106. to accept these options File name Type filename and press lt Enter gt The CBU extension is not needed 3 Press F5 to load RESTORE the file from disk to the controller BBRAM When DONE appears press lt Esc gt to return to the main ATS screen I ACLoff line software which is included on the ATS diskette also provides a downloading utility Refer to the ACLoff line User s Manual for complete details User s Manual SCORBOT ER VII 7 17 9206 This page intentionally left blank SCORBOT ER VII User s Manual 9206 CHAPTER 8 Maintenance Maintenance 2 User s Manual 9602 The maintenance and inspection procedures detailed below will ensure continued optimum performance of the SCORBOT ER VII system At the start of each working session check the robot and controller in the following order Before you power on the system check the following items The installation meets all safety standards The robot is properly bolted to the work surface All cables are properly and securely connected Cable connector screws are fastened The teach pendant and any peripheral devices or accesssories which will be used are properly connected to the controller None of the open collector outputs is connected directly to a power supply No people are within the robot s working range After you have powered on the system check the following items The power and motors LEDs on the controller light up The fan in
107. ts When you short any of inputs 1 through 15 the output with the same index 1 15 will turn on When you short input 16 the program will stop Note the messages on the screen during program execution User s Manual SCORBOT ER VII 7 13 9206 Program Directory Type The ATS diskette supplied with the system contains a number of files with the extension CBU These files contain programs positions variables and parameters Some of these CBU files are factory loaded into the controller and stored in battery backed up RAM These files are not erased when the controller is turned off but their contents may be totally or partially erased during certain configuration and restore procedures To view the list of programs which are found in the controller s BBRAM use the DIR command in DIRECT mode For example dir lt Enter gt name validity identity priority AA E EL ES LOOP 2 5 DEMO 3 5 IO 4 5 IOA 5 5 and so on Validity If the program is valid no message appears Not valid will appear if the program contains a logic error such as a FOR command without an ENDFOR command Identity This is the controller assigned program identity number which is needed for executing a program from the teach pendant Since certain controller operations can cause program identity numbers to change use the DIR command at the beginning of each working session to verify the identity of program which you may want t
108. ts the robot motors to move accordingly When continuous path control is required the processor divides the path into short segments and interpolates the motion of the joints as frequently as possible Three type of CP control are possible Joint Control Each axis moves according to the trajectory profile The gripper path is not defined only the start and end points are defined All axes start and stop movement at same time Linear Path Control The axes are coordinated in order to move the TCP tool center point tip of the gripper in a straight line according to the trajectory profile Circular Path Control The axes are coordinated in order to move the TCP along a circular path according to the trajectory profile SCORBOT ER VII User s Manual 9602 The Control Parameters In the robotic system controller by Controller A as in common in closed loop systems the controlled value C is measured by an optical encoder The encoder signals serve as feedback to the controller enabling it to correct any deviations from the desired value Since control systems cannot react immediately to the input signal there will always be a lag between the generation of an error signal and the actual correction of the controlled value The PID proportional integral differential control parameters allow the controller to adapt to various conditions of operation such as overcoming nonlinear functions in the system Proportional Control
109. umber labeled on each cable and connect each cable to its proper port SCORBOT ER VII User s Manual 9602 TO TEACH TO AUXILIARY RS232 PENDANT COMPUTER MULTIPORT CARD OPTIONAL JUN ING E z lt a Z W a T a lt ul pes BEI J oo EF V POWER OUTLET TO AXES 4 5 DC SERVO User s Manual 9602 POWER SUPPLY GRIPPER Figure 4 3 Controller Rear Panel Connect the axis 6 reserved for electric gripper cable to port 6 even if you will be not be using an electric gripper Connect the RS232 cable D25 connector to the RS232 port on the controller and to the RS232 port on the computer You may use either COM1 or COM2 on the computer If your computer s COM port requires a D9 connector use a standard D25 D9 adapter to connect the RS232 cable to your computer If an auxiliary RS232 communication card is installed in the controller make the following cable connections Connect the cable s D37 connector to the auxiliary RS232 port on the controller The auxiliary card may have a cable with either two or eight D25 connectors Connect the cable s D25 connectors to the corresponding COM ports on the other controllers or computers If any of these COM ports requires a D9 connector use a standard D25 D9 adapter to connect the RS232 cable To install an auxiliary RS232 communication card in your controller follow the instructions described in the section Adjustments and Repairs in Chapter 8
110. unicate directly with the controller Perform the controller configuration as described in the following section Controller Configuration User s Manual 9602 This section describes the short form controller configuration which loads default parameter settings according to your responses to the prompts The procedure described below should be sufficient for you to begin operating the system If the controller has already been in operation be sure to back up all data before initiating this configuration procedure SCORBOT ER VII 4 5 The configuration procedure is initiated from the ATS main screen by pressing the hot key combination lt Ctrl gt lt F1 gt You are prompted Controller Configuration ARE YOU SURE Y N N Press Y to proceed with the configuration or Press N or lt Enter gt to cancel the configuration You are prompted by a short series of Controller Configuration options Make sure you select the proper options for your installation Incorrect selections may result in damage to your equipment Robot type ER V ER Vplus WII OTHER This defines the robot which is connected to the controller Use the left and right arrow keys to highlight ER VII which is the robot connected to the controller Then press lt Enter gt to accept When a robot not OTHER is selected the controller reserves axis 6 the first available axis after the robot axes for an electrical servo
111. use One 4A 220 110V fuse inside the logic power supply The logic power supply is an IBM PC type power supply It will not wake up if it is not loaded and it is protected against short load Therefore when searching for a blown fuse be sure you are trying to operate the logic power supply under loaded conditions To replace this fuse Disconnect the cable from the logic power supply to the main board J9 Remove the power supply from the controller by unscrewing the four screws on the rear panel of the controller Open the power supply and change the fuse which is mounted in a standard fuse holder Power Transformer Fuse One 2 5A SB fuse 220V or 4A SB fuse 110V on the side of the transformer housing Feeds AC power to the transformer from which the motors and user s power supplies are produced To replace this fuse Using a screwdriver push down on the fuse holder cover while turning it counterclockwise Remove the fuse holder and replace the fuse Reinsert the fuse holder and retighten it clockwise until it is securely in place 8 16 SCORBOT ER VII User s Manual 9602 User Power Supply Fuse One 2A 12VDC fuse on the power supply card PC7500 inside the transformer housing Protects the user s power supply To replace this fuse you must open the transformer housing Warning The large motors capacitor may be loaded with an electrical charge even after you have disconnected power Be careful n
112. utput Status 7 10 MPU ses tet Sh ath Blt Moka Md e Bh he 7 10 QUIPU S 3 wae i ed a ee ae we A 7 11 Activating Output Driven Devices 7 11 Pneumatic End Effectors or Devices 7 11 Warning Light 7 11 Sample Program INOUT 7 12 Program Directory 2 2 2 0 000002 7 14 Multi Tasking 2 2 2 eee ee eee 7 14 Displaying Program Status 7 15 Activating a Program from Another Program 7 15 Simultaneous Execution 7 15 Program Interrupt 0 o 7 16 Saving a Program Backup to Disk 7 16 Downloading a Program Restore to Controller 7 17 CHAPTER 8 Maintenance 8 1 Maintenance e o 8 1 Troubleshooting ca sa seata o 8 2 Robot Arm Calibration Parameters 8 2 General System Check 22 8 3 Diagnostic Procedures o 8 3 Error Messages o e e 8 13 Adjustments and Repairs 0 8 15 Opening the Controller Cover 8 15 Changing the Voltage Setting 8 15 Replacing Fuses 8 16 Logic Power Supply Fuse 8 16 Power Transformer Fuse 8 16 User Power Supply Fuse 8 17 Driver CardFuses 22 8 17 User s Manual SCORBOT ER VII 9602 Changing the I O Logic Mode 8 18
113. will be based on old measurements The greater the delay the more the response will oscillate eventually becoming unstable User s Manual SCORBOT ER VII A 3 9602 Transient and Steady State Responses When the desired input signal r changes suddenly the system will react in two phases as shown in Figure A 3 The initial reaction to a change in the input signal is called the transient response The second part of the reaction is known as the steady state response Once the input signal r has remained constant for some time and the error between the input and output signals has stabilized the system is said to be in steady state The transition from transient to steady state is not a cleanly defined break DYNAMIC ERROR STEADY STATE ERROR TRANSIENT STEADY STATE RESPONSE RESPONSE Figure A 3 Transient and Steady States This constant error known as the steady state error should be reduced as much as possible by the control system Increasing the amplitude of the controller output signal that is increasing the controller gain can reduce the steady state error and enable a more rapid approach to the steady state value The greater the controller gain the faster the system reacts However excessive gain may lead to a phenomenon called overshoot a rise in the controlled value to a point above the desired value followed by a drop below the desired value repeated several times before stabilization This in effect
114. witch is turned off before you open the controller cover Make sure the power cable is disconnected from the AC power source before you remove fuses Complete instructions for removing and replacing controller components are given in the section Adjustments and Repairs later in this chapter Robot Arm Calibration Parameters To obtain maximum accuracy in the movement of the robot XYZ axes each SCORBOT ER VII undergoes a calibration procedure during the manufacturing process and after it has been dismantled for repairs During the calibration the robot arm is sent to a position in which it is completely extended and parallel to a horizontal surface The axes are adjusted by teach pendant until they are all at the same height At this point the axes encoders are read and their values are assigned to parameters 52 56 The working range of each axis is also calibrated and the results are assigned to parameters 101 105 and 121 125 These specific parameters are stored in a file named PAR7 CBU on the two ATS SCORBOT ER VII User s Manual 9602 diskettes supplied with the robot system The contents of this file cannot be transferred from one robot to another Keep the diskettes together with the print out of the parameters and labeled for the specific robot General System Check When a problem occurs use the ACL command TEST as a first step in diagnosing the problem TEST activates an internal system procedure which chec
115. with defined acceleration and deceleration segments Along the path motion of all joints should be proportional so that all the joints start and finish moving at the same time The method of coordinating the movement of the joints so that all joints reach the desired location simultaneously is termed joint interpolation Point to Point Control Point to point control PTP involves the positioning of the robot s end effector at given points without defining the exact path of the end effector between any two points User s Manual SCORBOT ER VII A 7 9602 Point to point control is suitable for applications which require an exact and static position of the end effector at the points where operations will be performed In principle point to point control can be used to guide the robot through a large array of positions thus resulting in a complex path In order to obtain such a path points must be defined and recorded in a very close sequence The number of positions will be limited however by the capacity of the control system to maintain positions in memory Continuous Path Control Continuous path control CP involves the movement of the end effector between two points along a path defined by a mathematical formula This method of control is suitable for applications in which the end effector executes operations along a precise trajectory During program execution the control system calculates and plans the path and instruc
116. ype Once a position has been recorded you can easily send the robot or other devices connected to the controller to that position Depending on the currently active coordinate system the movement of the robot Group A will be either point to point in Joint mode or along a linear or curved path in XYZ mode Assuming the robot is at position 13 send the robot back to position 12 2 Record h Ent Position Axis 7 Axis 8 ot DONE Use the command Go Position 0 to send all the axes of group A to the home position Use the ACL command MOVE to send the robot to a position Assuming the robot is at home send the robot to position A31 move A31 lt Enter gt In this command the robot moves at the current speed setting The MOVE command may contain a duration parameter which is defined in hundredths of a second To send the robot to position A32 in 10 seconds move A32 1000 lt Enter gt You can use the PC to move to positions recorded by the TP Alternately you can use the TP to move to positions recorded by means of the PC providing the positions are defined by numerical names For example move 13 lt Enter gt SCORBOT ER VII 6 17 Linear Movement To move the TCP in a straight path use the ACL command MOVEL For example send the robot from the home position to position A33 Type move 0 lt Enter gt Type movel A33 lt Enter gt Circular Movement To move the TCP along a curved path use the ACL comma

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