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User Manual - Sparkem Tech

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1. lt unnamed gt Command Graphics Structure Variables o tur tr uo ae Y oo Direction o FromPos Pattern 9 ToPos A pattern is a group of positions to be cycled through Patterns can be used for making much more palletizing etc S Wait 9 Waypoint Positions on a line Line i Wait 9 V Folder E gt Positions in a square Square E Halt esr mara Popup 9 V Loop T CAKE Tos 7 emp Positions in a box Box po d t Bl script i NS var_1 1 1 P call SubProgram 1 c 9 Vir A list of positions List E a c so Pallet eo Pattern 9 de PalletSequence 9 Approach 9 PatternPoint E Action lt poo simulation C E Speed J1eex Previous Next gt o Real Robot All Rights Reserved 83 URS UNIVERSAL ROBOTS 4 4 Programming The Pattern command can be used to cycle through positions in the robots program Ihe pattern command corresponds to one position at each execu tion A pattern can be given as one of four types The first three Line Square or Box can be used for positions in a regular pattern The regular patterns are defined by a number of characteristic points where the points define the edges of the pattern For Line this is the two end points for Square this is three of the four corner points where as for Box this is four of the eight corner points The programmer enters t
2. A waypoint with the position given relative to the robot s previous position such as two centimeters to the left The relative position is defined as the difference between the two given positions left to right Note that repeated relative positions can move the robot out of ifs workspace The distance here is the Cartesian distance between the tcp in the two po sitions The angle states how much the tcp orientation changes between the two positions More precisely the length of the rotation vector describing the change in orientation 4 4 8 Program Command Tab Variable Waypoint File Program Installation z lt unnamed gt Command Graphics Structure Variables Init Variables V hobo roga Variable position y V Move Variable Waypoint Move the robot to a variable position O Variable Action Use variable 9 ee Pallet eo Pattern 9 ee PalletSequence 9 Approach 9 PatternPoint Action E Wait 9 Exit 9 ee Destack 9 StartPos 9 ee Direction 9 FromPos 9 ToPos 9 de PickSequence 9 StackPos Action S Wait 9 Waypoint Wait l4 4 i 3 gt gt Remove this waypoint Add waypoint before Add waypoint after 9 Simulation e O Real Robot Med gt P E Speed 1JJiees Previous Next A waypoint with the position given by a variable in this case calculated pos Ihe variable has to be a pose
3. Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Y Robot Program in Insert program lines here In the Structure tab you will find various program statements that can be inserted Structure mE a simulation died gt b B Speed 1 100 da Previous Next gt o Real Robot Program commands need to be inserted here Press the Structure button to go to the structure tab where the various selectable program lines can be found A program cannot run before all lines are specified and defined All Rights Reserved 0 UR5 4 4 Programming UNIVERSAL ROBOTS 4 4 4 Program gt Command Tab Move File O Program Installation Move 1 0 l Log E lt unnamed gt Command Graphics Structure Variables Init Variables Y Robot Program Move MoveJ w 9 V MoveJ 9 Waypoint Here you specify how the robot should perform the movements between the 7 V Moved waypoints below Waypoint Pbi Use the menu in the upper right corner to switch between various movement y rca types The values set under Shared Parameters apply to all waypoints j D sie below and depend on the selected movement type oo PalletSequenc 9 Approach 9 PatternPoint E Actior Wait Il 9 Exit Yo tack 9 Start Y oo Direct o f 9 ToPos Y e
4. INITIALIZE Robot LANGUAGE Select Click Search for this robot to download a list of possible updates UPDATE Robot Description Set PASSWORD CALIBRATE Screen Setup NETWORK BACK 96 URS All Rights Reserved 4 5 Setup UNIVERSAL ROBOTS Provided the robot is attached to the Internet new software can be down loaded WARNING 1 Always check your programs after a software upgrade The upgrade might change trajectories in your program Ihe updated software specifications can be found by push ing the button located at the top right corner of the GUI Hardware specifications remain the same and can be found in the original manual 4 5 5 Setup Screen Password SETUP Robot O Please select Change Password INITIALIZE Robot Enter old password E LANGUAGE Select Enter new password Re enter new password UPDATE Robot Set password Set PASSWORD In order to protect users from being able to modify the CALIBRATE Screen program You should set a password to protect this area Setup NETWORK BACK Ihe programming part of the software can be locked using a password When locked programs can be loaded and run without the password but a password is required to create or change programs WARNING 1 Add a password to prevent non
5. I O Robot Health Readings Joint Load Controller Temp 0 0 C Base POWER OFF ird 0 0 V Main Voltage 0 0 V Shoulder POWER OFF BUE 0 0 V Avg Robot Power OW Elbow POWER OFF Nas 0 0 V Robot Current 0 0 A Wrist 1 POWER OFF ue 0 0 V IO Current 0 mA Wrist 2 POWER OFF iol 0 0 V Tool Current 0 mA Wrist 3 POWER OFF Ape 0 0 V T 0000d00h01m25 816s ive JLUpo LUIHIICLLOCU LU LUHLIVLLCI V 0000d00h00m00 000s URControl URControl 1 7 8872 Aug 31 2012 12 48 53 R 0000d00h00m00 000s URControl C102A0 Real Robot not connected Simulating Robot R 0000d00h00m00 008s URControl C100A0 Robot changed mode OK T 0000d00h00m32 760s RTHachine Program step forward stopped T 0000d00h00m35 008s RTHachine Program step forward stopped T 0000d00h00m35 296s RTHachine Program step forward stopped T 0000d00h00m36 160s RTHachine Program step forward stopped T 0000d00h00m38 000s RTHachine Program step forward stopped T 0000d00h00m39 832s RTHachine Program step forward stopped T 0000d00h00m40 064s RTHachine Program step forward stopped T 0000d00h00m40 488s RTHachine Program step forward stopped T 0000d00h00m44 336s RTHachine Program step forward stopped T 0000d00h00m46 864s RTHachine Program step forward stopped T 0000d00h00m47 216s RTHachine Program step forward stopped T 0000d00h00m47 384s RTHachine Program step forward stopped ww LAL Robot Health The top half of the screen displays the health of the robot The left part shows information relat
6. Register output A register output is a 16 bit quantity which can be set by the user Until the value of the register has been set the value of it is simply read This means that function code 0x03 Read Holding Registers is used until the signal is set either by a robot program or by specifying a signal value in the set signal value field and after that function code 0x06 Write Single Register is used onwards All Rights Reserved 60 UR5 4 3 Robot Control UNIVERSAL ROBOTS Set signal address This field shows the address of the signal Use the on screen keypad to choose a different address Valid addresses depends on the manufacturer and config uration of the modbus unit It is necessary to have a good understanding of the internal memory map of the Modbus controller in order to make sure the signal address actually corresponds to what is the intention of the signal Espe cially if might be worth verifying the meaning of a signal address when different function codes are used See 4 3 10 for a description of the function codes associated with the different signal types Set signal name Using the on screen keyboard the user may give the signal a meaningful name which will provide a more intuitive programming of the robot using The signal signal names are unique which means that two signals cannot be assigned the same name Signal names are restricted to be composed of no more than 10 characters Signal value Here the cur
7. This command gives access to the underlying real time script language that is executed by the robot controller It is intended for advanced users only If the File option in the top left corner is choosen it is possible to create and edit script programs files This way long and complex script programs can be used together with the operator friendly programming of PolyScope 4 4 20 Program Command Tab Event File Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Variables POTES Wait 9 Waypoi nt E Event 9 V Folder An Event is simmilar to an Interrupt however in an event the execution of the main program continues while the event code is Halt being executed While the event is being executed new events will Popup have no effect V Loop Depending on the state of the given sensor input or program ZH variable the following lines will be executed E script UB var_1 1 1 P call SubProgram 1 9 Vir eo Pallet 9 d Pattern Squar 9 ai1st Corner 9 a2nd Corner 9 a3rd rner 9 a4th rner alletSequence 9 Approach PatternPoin Action Wait Event 4 O Simulation o Real Robot All Rights Reserved Previous Next gt III 02 URS 4 4 Programming UNIVERSAL ROBOTS n event can be used to monitor an input signal and perform some action or set a variable when that input si
8. Universal Robots reserves the right to charge the customer for replacement or repair Ihe above provisions do not imply a change in the burden of proof to the detriment of the customer In case of a device exhibiting defects Universal Robots shall not cover any consequential damage or loss such as loss of production or damage to other production equipment 5 2 Disclaimer Universal Robots continues to improve reliability and performance of its prod ucts and therefore reserves the right to upgrade the right to upgrade the prod uct without prior warning Universal Robots takes every care that the contents of this manual are precise and correct but takes no responsibility for any errors or missing information 99 UNIVERSAL ROBOTS 5 2 Disclaimer All Rights Reserved 100 UR5 Chapter 6 Applied standards 6 1 List of used standards Below is a list of applied documents and standards 101 UNIVERSAL ROBOTS 6 1 List of used standards Applied EU directives 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2002 95 EC RoHS Directive 2002 96 EC WEEE Directive Applied harmonized standards ISO 13849 1 2006 Under applied EU directives ISO 13849 2 2003 ISO 10218 1 2006 Partly ISO 10218 1 2011 Partly ISO 10218 2 2011 Partly ISO 13850 2006 ISO 12100 2010 ISO 3745 2003 IEC 61000 6 2 ED 2 0 2005 IEC 61000 6 4 AMD ED 2 0 2010 IEC 61131 2 ED 3 0 2007 Partly EN ISO 13849 1 2008 EN ISO 13849 1 AC 2009 EN ISO 138
9. gt P P 2 Waits for a given amount of time or for an I O signal All Rights Reserved 70 URS 4 4 Programming UNIVERSAL ROBOTS 4 4 10 Program Command Tab Action File Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure V Robot Program 9 V MoveJ 9 Waypoint Action 9 V Moves i 9 Waypoint Select the action you wish the robot to perform at this point in the Action program You can also specify changes in the robot s payload 9 eo Pallet amp Pattern No Action 9 de PalletSequence 0 Approach O Set Digital Output Di Output v off 9 PatternPoint Action Set Analog Output lt An Output gt M 4 0 ES Wait 9 Exit ad set coutput gt foo BE 9 StartPos Y do Direction Set the total payload to 0 0 kg 9 FromPos 9 ToPos 9 oo PickSequence Perform action now 9 StackPos Action Wait 9 Waypoint Wait 9 V Folder I P lt gt depen al p ibe Speed 100 Previous Next gt sets either digital or analog outputs to a given value Can also be used to set the payload of the robot for example the weight that is picked up as a consequence of this action Adjusting the weight can be neccesary to prevent the robot from security stopping unexpectedly when the weight at the tool is different to that which is expected
10. 4 4 11 Program Command Tab Popup File Program Installation z lt unnamed gt Command Graphics Structure q V Move 9 Waypoint Action Popup oo Pallet eo Pattern Shows the message below on the screen and waits for the user to press OK eo PalletSequence 9 Approach 9 PatternPoint Action Popup type Preview Popup Wait 9 Exit o Message 9 oo Destack Warnin 9 StartPos G E Direction O Error 9 FromPo 0 ToP o Y oo PickSequence 9 StackPos Action S Wait 9 Waypoi nt S Wait 9 V Folder c t Halt mM Popup v T n io gt Halt program execution at this popup gt Meu Ma b b B8 speed 100 Previous Next E The popup is a message that appears on the screen when the program reaches this command The style of the message can be selected and the text itself can be given using the on screen keyboard Ihe robot waits for the user operator to press the OK button under the popup before continuing the All Rights Reserved 17 UR5 UNIVERSAL ROBOTS 4 4 Programming program If the Halt program execution item is selected the robot program halts at this popup 4 4 12 Program Command Tab Halt File Program Installation lt unnamed gt T TOTT 9 Waypoint 9 V MoveJ 9 Waypoint Command Graphics Structure Halt Program execution stops at this point Action eo
11. 9 Approach 9 PatternPoint Action S Wait 9 Exit 9 oo Destack 9 StartPos eo Direction 9 FromPos 9 ToPos 9 de PickSequence 9 StackPos Action Wait 9 Waypoint e A ES b NH Speed 100 Previous Next E The Variables tab shows the live values of the variables in the running pro gram and keeps a list of variables and values between program runs The vari ables tab appears only when it has information to display The variable names on this screen are shown with at most 50 characters and the values of the vari ables are shown with at most 500 characters 4 4 30 Program Command Tab Variables Initialization File Program Installation lt unnamed gt Command Graphics Structure Variables Init Variables Y Robot Program Initial Variable Values 9 V MoveJ 9 Waypoint 9 V Move 9 Waypoint Loop 1 has no specific initial value aypoi gt Action cnt 1 2 0 eo Pallet cnt 2 0 o y oo Pattern interpolate 1 0 0 pose 1 has no specific initial value Patternioint pose 2 has no specific initial value e Action pose 3 has no specific initial value Wait var_1 has no specific initial value 9 Exit 9 oo Destack 9 StartPos 9 n Y oe Direction 9 eo PalletSequence 9 Approach 9 FromPos 9 ToPos eS Variable Expression 9 StackPos ES Action Wait 9 Waypoint S Wait O i 9 V Folder ATA
12. Features Automatically Load Default Program Default Program File No Program Selected Select Default Program Automatically start default program when Di Input M is HI v The default program will be loaded when the control box is powered up 4 3 10 Modbus I O Setup Here the modbus O signals can be set up Modbus units on specific IP ad dresses can be added deleted and input output signals registers or digital on these units can be added deleted as well Each signal must be supplied with a unique name However several signals with different names may reference the same modbus signal but the user is advised to avoid this so as not to cause con fusion for the programmer Below the different buttons and fields are explained in detail File Program Installation Move 1 0 Log ITCP Position Modbus IO Setup Mounting 0 0 0 0 I O Setup 1P o o o o SER Modbus umm AA D __ Digital Output w 05 Modbus 1 prs LT Load Save D Please select v o i Modbus_2 SS E Features m ET D Please select v 0 Qe Modbus_3 A 0 0 0 0 1P 0 0 0 0 EN Show advanced options All Rights Reserved 99 UR5 UNIVERSAL ROBOTS 4 3 Robot Control Refresh Push this button to refresh the connectivity status of all modbus signals in the current in
13. The optional BeforeStart sequence is run just before the operation starts This can be used to walt for ready signals AfterEnd The optional AfterEnd sequence is run when the operation is finished This can be used to signal conveyor motion to start preparing for the next stack Pick Place Sequence Like for the Pallet operation 4 4 24 a special program sequence is performed at each stack position All Rights Reserved 20 UR5 4 4 Programming UNIVERSAL ROBOTS 4 4 26 Program Command Tab Suppress suppressed program lines are simply skipped when the program is run A sup pressed line can be unsuppressed again at a later time This is a quick way to make changes to a program without destroying the original contents All Rights Reserved 7 UR5 UNIVERSAL ROBOTS 4 4 Programming 4 4 27 Program gt Graphics Tab File Program Installation Move I O Log E lt unnamed gt Command Graphics Structure Variables Init Variables did amp G amp a gt 4 4 Y Robot Program Y MoveJ e O Waypo nt 3 9 V MoveJ Y 1yD t Variabl e tion I RA et Patte Y oo PalletSeq ia E 1 Yo kSequen 9 StackPo c tion Wait 0 Waypo nt t 4L i gt Vv gt TREER ded p be B Speed 100 Previous Next E eal Robo Graphical representation of the current robot program The path
14. authorized personnel from changing the robot installation All Rights Reserved 7 UR5 UNIVERSAL ROBOTS 4 5 Setup 4 5 6 Setup Screen gt Calibrate Touch Screen X Point very precisely in the center of the blue cross CANCEL Calibrating the touch screen Follow the on screen instructions to calibrate the touch screen Preferably use a pointed non metallic object such as a closed pen Patience and care help achieve a better result 4 5 7 Setup Screen Network SETUP Robot Please select Setup NETWORK Please select your DHCP INITIALIZE Robot network method O Static Address Disabled network LANGUAGE Select Network detailed settings IP address 0 0 0 0 UPDATE Robot Subnet mask 0 0 0 0 Default gateway 0 0 0 0 Set PASSWORD Preferred DNS server 0 0 0 0 Alternative DNS server 0 0 0 0 CALIBRATE Screen Apply settings Update Setup NETWORK BACK Panel for setting up the Ethernet network An Ethernet connection is not neces sary for the basic robot functions and is disabled by default All Rights Reserved 78 UR5 Chapter 5 Warranties 9 1 Product Warranty Without prejudice to any claim the user customer may have in relation to the dealer or retailer the customer shall be granted a manufacturer s Warranty un der the conditions set out below In the case of new devices and their components exhibiting defects re
15. auto buttons can be pressed individually for each joint or for the whole robot CAUTION 1 Great care should be taken if the robot is touching an obstacle or table since driving the robot into the obstacle might damage a joint gearbox Moving directly Move Buttons In the case where a joint is in a position where there is a major risk that un controlled motion would cause damage to the robot or its surroundings the operator can choose to home the robot manually for each joint section 4 1 2 4 2 On screen Editors 4 2 1 On screen Keypad Cancel simple number typing and editing facilities In many cases the unit of the typed value is displayed next to the number All Rights Reserved 49 UR5 UNIVERSAL ROBOTS 4 2 On screen Editors 4 2 2 On screen Keyboard X Cancel simple text typing and editing facilities The shift key can be used to gef some additional special characters 4 2 3 On screen Expression Editor and or xor not True HI s False Input w SOutput v lt Variable gt gt lt Pose gt ood ala lt Function gt x 0 SHIFT X Cancel While the expression itself is edited as text the expression editor has a num ber of buttons and functions for inserting the special expression symbols such as x for multiplication and l
16. be a simple answer to such relevant questions There are several complicated reasons for this being the case and in order to address these problems Universal Robots has developed unique and simple ways for a customer to specify the location of various objects relative to the robot Within a few steps it is therefore possible to do exactly what was asked for in the above questions File Program Installation Move 1 0 Log TCP Position Features Mounting I O Setup Modbus Def Program Load Save Features Tool a je Plane a New Point Line C Rename This button makes it possible fo rename a feature All Rights Reserved 62 UR5 4 3 Robot Control UNIVERSAL ROBOTS Delete This button deletes the selected feature and if any all sub features Show Axes Choose whether the coordinate axes of the selected feature shall be visible on the 3D graphics The choice applies on this screen and on the Move screen Joggable select whether the selected feature shall be joggable This determines whether the feature will appear in the feature menu on the Move screen Variable Select whether the selected feature can be used as a variable If this option is selected a variable named the name of the feature suceeded by var will then be available when editing robot programs and this variable can be as signed a new value in a program which can then be used to control
17. button is activated 9 Ihe teach function Impedance backarive shall only be used in installations where the risk assessment allows it Tools and obstacles shall not have sharp edges or pinch points Make sure that all personnel remain outside the reach of the robot File Program Installation Move 1 0 Log Robot Modbus Controller Input Tool Input Digital Digital 0 1 AR AO RN A EET mc J JL JL JE JL II Hos analog_in 0 analog in 1 analog in 2 EE 0 000 V ev 5v M 0 000 V ev 5v v 0 000 V lev Vw ev 5V ov 5V analog in 3 0 000 V lev 5V w Controller Output Tool Output Digital Digital 06 1 2 3 4 5 6 7 uo AAA On Off aor JOOS m j Voltage Current analog out 9 analog out 1 o o fewrrent e O ll SO nua 000 mA 0 12 24 4mA 20mA 4mA 20mA O Simulation o Real Robot On this screen you can always monitor and set the live I O signals from to the robot The screen displays the current state of the I O inluding during program execution If anything is changed during program execution the program will stop At program stop all output signals will retain their states The screen is updated at only 10Hz so a very fast signal might not display properly The electrical details of the signals are described in section 3 Analog Range Settings Ihe analog output can be set to either
18. contains some general warnings and cautions Some of which are repeated or explained in different parts of the manual Other warnings and cautions are present throughout the manual DANGER 1 Make sure fo install the robot and all electrical equipment according to the specifications and warnings found in the sections mounting instructions and electrical interface WARNING 1 Make sure the robot arm and tool are properly and securely bolted in place 2 Make sure the robot arm has ample space to oper ate freely 3 Make sure that safety measures e g guardrail rope or safety screen has been set up around the robot operating area to protect both the operator and bystandards A Do not enter the safety range of the robot or touch the robot when the system is in operation Before ap proaching the robot make sure the robot arm is powered off Do nof wear loose clothing or jewelry when working with the robot Make sure long hair is tied back when working with the robot All Rights Reserved 8 UR5 1 2 General warnings and cautions UNIVERSAL ROBOTS All Rights Reserved WARNING 6 Never use the robot if it is damaged If the software prompts a fatal error immediately activate emergenoy stop write down the conditions that lead to the error find the corresponding error codes on the log screen and contact your supplier 8 Do not connect any safety equipment to normal I O Use the emergency s
19. might cause unexpected movements of the robot 4 3 1 Move Tab On this screen you can always move jog the robot directly either by translat ing rotating the robot tool or by moving robot joints individually File Program Installation Move 1 0 Log Move Tool Robot Feature Qa iew Tool Position 179 93 H Y 606 87 mm Z 169 21 mm RX 0 0012 RY 3 1163 RZ 0 0389 Move Joints Shoulder 98 956 Em ERE i5 Em 126 223 03D Elbow Teach Wrist 1 Wrist 2 is o e ra G Simulation Speed pf 100 MX Cancel v OK o Real Robot tratta All Rights Reserved 9 UR5 UNIVERSAL ROBOTS 4 3 Robot Control Robot The current position of the robot is shown in 3D graphics Push the magnifying glass icons to zoom in out or drag a finger across to change the view lo get the best feel for controlling the robot select the View feature and rotate the viewing angle of the 3D drawing to match your view of the real robot Feature and tool position At the top right part of the screen the feature selector can be found The features selector defines which feature to control the robot relative to while below it the boxes display the full coordinate value for the tool relative to the selected feature Values can be edited manually by clicking on the co
20. name directly on the screen Open button Clicking on the Open button will open the currently selected file and return to fhe previous screen Cancel button Clicking on the Cancel button will abort the current loading process and cause the screen fo switch to the previous image Action buttons A series of buttons gives the user the ability to perform some of the actions that normally would be accessible by right clicking on a file name in a conventional file dialog Added to this is the ability to move up in the directory structure and directly to the program folder e Parent Move up in the directory structure The button will not be enabled in two cases when the current directory is the top directory or if the screen is in the limited mode and the current directory is the program folder e Goto program folder Go home e Actions Actions such as create directory delete file etc 4 3 14 Run Tab File O Run Move I O Log UNIVERSAL ROBOTS Program ABCDE Variables Status Stopped Time 0000d00h00m18 248s M na All Rights Reserved UR5 UNIVERSAL ROBOTS 4 4 Programming This tab provides a very simple way of operating the robot with as few but tons and options as possible This can be useful combined with password pro tecting the programming part of PolyScope see section 4 5 5 to make the robot into a tool that can run exclusively pre written programs 4 4 Programming All Rig
21. of the TCP is shown in the 3D view with motion segments in black and blend segments transitions between motion segments shown in green The green dots specify the positions of the ICP at each of the waypoints in the program The 3D draw ing of the robot shows the current position of the robot and the shadow of the robot shows how the robot intends to reach the waypoint selected in the left hand side of the screen The 3D view can be zoomed and rotated to get a better view of the robot The buttons in the top right side of the screen can disable the various graphical components in the 3D view The motion segments shown depends on the selected program node If a Move node is selected the displayed path is the motion defined by that move If A Waypoint node is selected the display shows the following 10 steps of movement All Rights Reserved 72 UR5 4 4 Programming File 4 4 28 Program Structure Tab Program Installation Move 1 0 Log UNIVERSAL ROBOTS O lt unnamed gt Command Graphics Y Robot Program C E hi n Insert Structure Basic Advanced Wizards Program Structure Editor Move Waypoint Wait I O Action After M selected Popup Halt Comment Folder Edit A Move Copy Paste After y selected Y M
22. only valid with a common mode voltage of OV To make it clear how easy it is to use analog outputs some simple examples are shown Using Analog Inputs Differential Voltage Input The simplest way to use analog inputs The equipment shown which could be a sensor has a differential voltage output Using Analog Inputs Non differential Voltage Input If it is not possible to achieve a differential signal from the equipment used a solution could look something like the setup above Unlike the non differential analog output example in subsection this solution would be almost as good as the differential solutions All Rights Reserved 39 UR5 UNIVERSAL ROBOTS 3 4 Tool I O Using Analog Inputs Differential Current Input When longer cables are used or if it is a very noisy environment current based signals are preferred Also some equipment comes only with a current output Io use current as inputs an external resistor is needed as shown above The value of the resistor would normally be around 200 ohms and the best result is accomplished when the resistor is close to the screw terminals of the controller box Note that the tolerance of the resistor and the ohmic change due to tempera ture must be added to the error specifications of the analog inputs Using Analog Inputs Non differential Current Input If the output of the equipment is a non differential current signal a resistor must be used as shown above The res
23. program commands Depending on the selection the underlying program commands are either looped infinitely a certain number of times or as long as the given condition is true When looping a certain number of times a dedicated loop variable called loop_1 in the screen shot above is created which can be used in expressions within the loop The loop variable counts from 0 to N 1 All Rights Reserved 19 UR5 UNIVERSAL ROBOTS 4 4 Programming When looping using an expression as end condition PolyScope provides an option for continuously evaluating that expression so that the loop can be interrupted anytime during its execution rather than just after each iteration 4 4 16 Program gt Command Tab SubProgram File Program Installation lt unnamed gt Command Graphics Structure Variables 9 de Direction A Renane FronPos SubProgram_1 9 ToPos 9 amp PickSequence A subprogram can either point to a file on disk or can be StackPos contained in this program Mein SubProgram file 9 Waypoint No File Selected Wait 9 V Folder Load File Halt Popup 9 V Loop Bl script var_1 1 1 P call SubProgram 1 9 Vir Event Save SubProgram Clear SubProgram V Thread 1 9 V Force O P subProgram 1 Show SubProgram Tree q TA Track program execution O Simulation n E Speed 100 Previous ji Next BP O Real Robo
24. that the tool trajectory thick black line moves in straight lines outside the blend areas dashed circles while the tool trajectory deviates from the straight line path inside the blend areas Also notice that the state of the digital input 1 sensor is read just as the robot is about fo enter the blend area around Waypoint 2 even though the if then command Is after Waypoint 2 in the program sequence This is somewhat counterintuitive but is necessary to allow the robot to select the right blend path All Rights Reserved 4 UR5 4 4 Programming UNIVERSAL ROBOTS 4 4 7 Program Command Tab Relative Waypoint File Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Variables Init Variables lative position w iw ia Waypoint Rename 9 V Move Relative Motion given by the difference between from and to positions Waypoint From point To point i Action Distance 0 0mm 9 so Pallet i i i i oo cee Set this point Set this point Angle 0 0 9 ee PalletSequence 9 Approach 9 PatternPoint Action Wait 9 Exit 9 ee Destack 9 StartPos 9 de Direction 9 FromPos 9 ToPos 9 de PickSequence 9 StackPos Action E Wait 9 Waypo nt Wait 9 V Folder 2 DE mm Remove this waypoint Add waypoint before Add waypoint after O Simulation Q Real Robot a CN E Speed 100 Previous Next E
25. the coordinate system axes the robot will use while it is operating in force mode Ihe features in the menu are those which have been defined in the installation see 4 3 1 1 All Rights Reserved 89 UR5 UNIVERSAL ROBOTS 4 4 Programming Force mode type The are four different types of force mode each determining the way in which the selected feature will be interpreted e Simple Only one axis will be compliant in force mode The force along this axis is adjustable The desired force will always be applied along the z axis of the selected feature However for Line features it is along their y axis e Frame Ihe Frame type allows for more advanced usage Here compli ance and forces in all six degrees of freedom can be independently se lected e Point When Point is selected the task frame has the y axis pointing from the robot tcp towards the origo of the selected feature Ihe distance be tween the robot tcp and the origo of the selected feature is required to be at least 10 mm Note that the task frame will change at runtime as the position of the robot tcp changes The x and z axis of the task frame are dependent on the original orientation of the selected feature e Motion Motion means that the task frame will change with the direction of the TCP motion The x axis of the task frame will be the projection of the tcp movement direction onto the plane soanned by the x and y axis of the selected feature Ihe y axis will be per
26. waypoints that depend on the value of a feature Set or Change Position Use this button to set or change the selected feature The Move screen will appear and a new position of the feature can be set Move Robot to Feature Pressing this button will move the robot towards the selected feature At the end of this movement the coordinate systems of the feature and the TCP will coincide except for a 180 degree rotation about the x axis Add Point Push this button to add a point feature to the installation The position of a point feature is defined as the position of the TCP at that point The orientation of the point feature is the same as the TCP orientation except that the feature coordinate system is rotated 180 degrees about its x axis This makes the z axis of the point feature directed opposite than that of the TCP at that point All Rights Reserved 63 UR5 UNIVERSAL ROBOTS 4 3 Robot Control File Program Installation Move 1 0 Log TCP Position Delet Point 1 Rename Mounting I O Setup Modbus Def Program Load Save Features v Show axes Move robot here Change this point v Joggable Variable Add Line Push this button to add a line feature to the installation A line is defined as an axis between two point features Ihis axis directed from the first point towards the second point will constitute the y axis of t
27. 0 V V JAIB SA 5B Input voltage 30 Guaranteed OFF if 30 SA SB Guaranteed ON if 10 SA SB Guaranteed OFF if 0 SA SB ON Current 10 30V 7 A RI Input voltage 30 A Rl Input guaranteed OFF if 30 AJ1 RI Input guaranteed ON if 10 A RJ Guaranteed OFF if 0 AJ RJ ON Current 10 30V 6 The safeguard stop input SA SB is a potential free input conforming to IEC 60664 1 and EN 60664 1 pollution degree 2 over voltage category Il Note that the yellow 24V connections is sourced by the same internal 24V power supply as the 24V connections of the normal O and that the maximum of 1 2 A is for both power sources together 3 3 Controller I O EF 24v zav zav sav sav sav sav ai ar ac sa 1 pl EFI EDZ EUS Eb n TH rr 12 o HE aa Boros Em Ern 2 En oor ay sspe Te ie e aS Rn Ew e Ewo oe Jou Jor po ew os Jos Jor Po pee pov euo sno suo sno uo cuo sno sue euo suo oro olololojolofojoajoja a Inside the controller box there is a panel of screw terminals with various O parts as shown above The rightmost part of this panel is general purpose l O 24V 24V supply connection DOx Digital output number x AOx Analog output number x plus Ax Analog input number x plus Ax Analog input number x minus The I O panel in the controller box has 8 digital and 2 analog inputs 8 digital and 2 analog outputs and a built in 24V power supply Digital in
28. 131 2 and EN 61131 2 and with all requirements for digital outputs of the same standards All digital outputs can be disabled automatically when a program is stopped by using the check box Always low at program stop on the I O Name screen see section 4 3 8 In this mode the output is always low when a program is not running CAUTION 1 The digital outputs are not current limited and overriding the specified data can cause permanent damage to them However it is not possible to damage the outputs if the in ternal 24V power supply is used due to its current protection 2 The controller box and the metal shields are con nected to GND Never send I O current through the shields or earth connections it might damage to the I Os The next subsections show some simple examples of how the digital outputs could be used Load Controlled by Digital Output f o alolololalalalo All Rights Reserved 96 UR5 3 3 Controller I O UNIVERSAL ROBOTS This example illustrates how to turn on a load Load Controlled by Digital Output External Power If the available current from the internal power supply is not enough simply use an external power supply as shown above 3 3 2 Digital Inputs Input voltage Input guaranteed OFF if Input guaranteed ON if Guaranteed OFF if ON Current 10 30V The digital inputs are implemented as pnp which means that they are ac tive when voltage is
29. 3 5 Installation 2 Load Save 0 4 3 6 Installation gt TCP Position 4 3 Installation 2 Mounfing 4 3 8 Installation gt l OSetup 0 4 3 9 Installation Default Program 4 3 10 Modbusl OSetfup 0 00 eee 43l FCOTICS 4 644 koh 3 XO ode O Row x 9 XX EES AA ere T AOA IUBE arroz ateo 4 4 Progranmrnmoing xx xo wu ko Ex x wok CX RU mox 3 0 X Rex 4 1 Program New Program 4 4 4 2 Program lab 4 6 Setting the waypoin A 7 Program gt Command Tab Relative Waypoint 4 4 8 Program gt Command lab Variable Waypoint 4 4 9 Program gt Command lab Wait ner RN 4 4 1 Program gt Command lab Popup 4 4 12 Program gt Command lab Halt 4 4 13 Program gt Command lab Commentl 4 4 14 Program gt Command lab Folder 4 4 15 Program gt Command lab Loop T 4 4 17 Program gt Command lab Assigamenft 4 4 18 Program gt Command lab If 4 4 19 Program Command lab Script 4 4 20 Program gt Command lab Event 4 4 2 Program gt Command lab Thread 4 4 22 Program Command lab Pattem 4 4 23 Program Command lab Force 4 4 24 Program gt Command lab Pallet 4 4 25 Program Command lab Seek 4 4 26 Program Command lab Supp
30. 49 2 2008 EN ISO 10218 1 2008 Partly EN ISO 10218 1 2011 Partly EN ISO 10218 2 2011 Partly EN ISO 13850 2008 EN ISO 12100 2010 EN ISO 3745 2009 EN 61000 6 2 2005 EN 61000 6 4 A1 201 1 EN 61131 2 2007 Partly EN 1037 2010 Applied general standards ANSI RIA R15 06 2012 Preliminary Nof all standards are listed ISO 9409 1 2004 Partly ISO 9283 1999 Partly ISO 9787 2000 Partly ISO 9946 2000 Partly ISO 8373 1996 Partly ISO TR 14121 2 2007 ISO 1101 2004 ISO 286 1 2010 ISO 286 2 2010 IEC 60664 1 ED 2 0 2007 IEC 60947 5 5 1997 IEC 60529 1989 A1 1999 IEC 60320 1 Ed 2 0 2001 IEC 60204 1 Ed 5 0 2005 Partly EN ISO 9409 1 2004 Partly EN ISO 9283 1999 Partly EN ISO 9787 2000 Partly EN ISO 9946 2000 Partly EN ISO 8373 1996 Partly EN ISO TR 14121 2 2007 EN ISO 1101 2005 EN ISO 286 1 2010 EN ISO 286 2 2010 EN 60664 1 2007 EN 60947 5 5 1998 EN 60947 5 5 A 1 2005 EN 50205 2003 EN 60529 1991 A1 2000 EN 60320 2003 EN 60204 2006 Partly All Rights Reserved 102 UR5 Appendix A Certifications 103 UNIVERSAL ROBOTS DANISH TECHNOLOGICAL INSTITUTE Universal Robots ApS m E Attn Lasse Kieffer DK 8000 rhus C Svendborgvej 102 Mic DK 5260 Odense S 16 March 2012 1302213 424098 TGR BBJ Test of UR5 Robot Danish Technological Institute Centre for Materials Testing has tested a URS robot for Universal Robots ApS see report 1302213 424098 The test is performed in accordance with the followi
31. Connecting Cables Use only the original robot cable to connect the robot to the controller box Ensure that the connectors are properly secured in place All electrical con nections to the tool or the interface inside the controller box shall conform to the specifications in section 8 T Never connect or disconnect any cables when the power is enabled or if any connector is wet All electrical equipment in the robot installation shall be connected to earth Use the screw connection marked with earth symbol inside the controller box when potential equalization with other machines is required The mains supply shall be equiped with the following as a minimum 1 A correct sized fuse 2 A residual current device RCD 3 A correct connection to earth Mains input specifications are shown below The shown power specifications are averages taken over one minute under normal conditions Power consump tion peaks during high accelerations at high speeds with high payloads Input voltage 240 M External fuse 16 Input frequency ed 63 stand by power 0 9 Nominal operating power 150 325 All Rights Reserved URS 1 Make sure that the controller box and cables do not come into contact with liquids A wet controller box could UNIVERSAL ROBOTS 2 9 Mounting Instructions gt z o E O LLI N 9 9y x Q so gt O 2 H7 0 015 6 0 E Lumberg RKMV 8 354 connector VX 06 Figure 2 4 The too
32. Cruise LI Deceleration Time Figure 4 1 Speed profile for a motion The curve is divided into three seg ments acceleration cruise and deceleration The level of the cruise phase is given by the speed setting of the motion while the steepness of the acceleration and deceleration phases is given by the acceleration parameter 4 4 5 Program Command Tab Fixed Waypoint File O Program Installation Move 1 0 Log z lt unnamed gt Command Graphics Structure Variables Init Variables Y Robot Program 9 V Move Waypoi nt Rename Fixed position Y Way V MoveJ 9 Waypoint Action 9 nay oo Palle eo Pattern pall oo PalletSe nce 9 Approach Set this waypoint Please specify the robot position for this waypoint Remove this waypoint Add waypoint before Add waypoint after O Simulation Q real Robot hed gt Li Speed 100 Previous ext gt A point on the robot path Waypoints are the most central part of a robot program telling the robot where to be A fixed position waypoint is given by physically moving the robot to the position 4 4 6 Setting the waypoint Press this button to enter the Move screen where you can specify the robot position for this waypoint If the waypoint is placed under a Move command in linear soace mo
33. Pallet eo Pattern 9 eo PalletSequence 9 Approach 9 PatternPoint Action E Wait 9 Exit 9 oo Destack 9 StartPos 9 de Direction 9 FromPos 9 ToPos 9 ee PickSequence 9 StackPos E Action Wait 9 Waypoint S Wait 9 V Folder e sag pad p lo Speed 1 00 Previous Next E The program execution stops at this point 4 4 13 Program Command Tab Comment File Program Installation lt unnamed gt Command Graphics Structure v TUD Tropo 9 V Moves 0 Waypoint b V Moves Comment 9 Waypoint Action eo Pallet E Please enter comment oo Pattern 9 ee PalletSequence 9 Approach 9 PatternPoint Action E Wait 9 Exit 9 eo Destack 9 StartPos 9 n Y oo Direction 9 FromPos 9 ToPos 9 oo PickSequence 9 StackPos Action Wait 9 Waypoint Wait 9 V Folder Comment Y e AREA E gt 54 NH Speed J100 Previous Next E Gives the programmer an option to add a line of text to the program This line of text does not do anything during program execution All Rights Reserved 78 UR5 4 4 Programming UNIVERSAL ROBOTS 4 4 14 Program Command Tab Folder File O Program Installation Move 1 0 Log unnamed Command Graphics Structure V Robot Program 9 V MoveJ 9 Waypoint Folder 9 V Move 9 Waypoint Action 9 oo Pallet o p oo Pattern A folder is simply a col
34. Rename SES Clear Expression f x HE lt gt are la b b B8 speed 100 Previous Next gt This screen allows setting variable values before the program and any threads start executing oelect a variable from the list of variables by clicking on it or by using the variable selector box For a selected variable an expression can be entered that will be used to set the variable value at program start All Rights Reserved 24 UR5 4 5 Setup UNIVERSAL ROBOTS If the Prefers to keep value from last run checkbox is selected the vari able will be initialized to the value found on the variables tab described in section 4 4 29 This permits variables to maintain their values between program executions Ihe variable will get its value from the expression if the program is run for the first time or if the value tab has been cleared A variable can be deleted from the program by setting its name to blank only spaces 4 5 4 5 1 Setup Setup Screen SETUP Robot O Please select INITIALIZE Robot LANGUAGE Select UPDATE Robot Set PASSWORD CALIBRATE Screen PolyScope 1 7 8872 Aug 31 2012 12 48 52 Setup NETWORK BACK Initialize Robot Goes to the initialization screen see section Update Upgrades the robot software to a newer version via the Internet see section Set Password Provides the facility to lock th
35. UNIVERSAL ROBOTS User Manual Version 1 6 FSIO UNIVERSAL ROBOTS The information contained herein is the property of Universal Robots A S and shall not be reproduced in whole or in part without prior written approval of Universal Robots A S The information herein is subject to change without notice and should not be construed as a commitment by Universal Robots A S This manual is periodically reviewed and revised Universal Robots A S assumes no responsibility for any errors or omissions in this document Copyright 2012 by Universal Robots A S The Universal Robots logo is a registered trademark of Universal Robots A S All Rights Reserved 2 UR5 Contents 1 Safety LETARGO dCUCION o rs roer rara AAA 1 2 General warnings and cautions 1 3 Statutory requirements 1 4 Risk assessment Lo EmergjencvV STOP s re esa 599949 593 4 5 X993 1 6 Emergency movement of the robot arm rss 2 Getting started Zal JOSEP esmas rocas 211 TDG RODO eva a Aa ae be EA e 2 152 PINs aa o ss ee eS eS 2 13 Riskassessment lle MEUSE 2 3 Turning On and Offf ons 2 3 1 Turning on the ControllerBOx 2 9 24 Turning on the Robot 7 eo su ow we ood we 9 a Rx we eS 2 3 8 Initializing the Robof lon 2 3 4 Shutting Down the Robot 2 3 9 Shutting Down the Controller Box 2 4 Quick start Step by Step 2 0 Mounting Instructions 1 e e 2 9 1 Ihe W
36. UR5 3 2 The Safety Interface UNIVERSAL ROBOTS All Rights Reserved Sl UR5 UNIVERSAL ROBOTS 3 2 The safety Interface An example where multiple UR robots share their emergency stop function is shown below Connect more robots as robot number 2 is connected This example uses 24V which works with many other machines Make sure to comply with all electrical specifications when UR robots share emergency stop with other machinery Electric Specifications A simplified internal schematic of circuitry is shown below It is important to no tice that any short circuit or lost connection will lead to a safe stop as long as only one error appears at a time Failure and abnormal behavior of relays and power supplies results in an error message in the robot log and prevents the robot from powering up Below Specifications of the Emergency Stop Interface V TA TB Voltage 105 12 12 5 TA TB Current Each output 120 mA Current protection ADO mA 30 EEA EEB Input voltage 30 V EEA EEB Guaranteed OFF if V EEA EEB Guaranteed ON if 30 V EEA EEB Guaranteed OFF if 3 mA EA EB EEA EEB ON Current 10 30V 14 EO1 E02 EO3 E04 Contact Current AC DC 0 6 EO1 E02 EO3 E04 Contact Voltage DC 90 EO1 E02 EO3 E04 Contact Voltage AC 250 DANGER l The robot installation shall conform to these specifica tions Failure to do so could result in serious injury or death as the safety
37. a jectory which is allowed before the robot security stops Units are mm and deg All Rights Reserved 86 UR5 4 4 Programming UNIVERSAL ROBOTS Test force settings The on off button Teach Iest toggles the behavior of the leach button on the back of the leach Pendant from normal teaching mode to testing the force command When the leach Test button is on and the Teach button on the back of the leach Pendant is pressed the robot will perform as if the program had reached this force command and this way the settings can be verified before actually running the complete program Especially this possibility is useful for verifying that compliant axes and forces have been selected correctly Simply hold the robot tcp using one hand and press the Teach button with the other and notice in which directions the robot can cannot be moved Upon leaving this screen the Teach lest button automatically switches off which means the Teach button on the back of the Teach Pendant button is again used for free teach mode Note The Teach button will only be effectual when a valid feature has been selected for the Force command 4 4 24 Program Command Tab Pallet File Program Installation Move 1 0 Log E lt unnamed gt Command Graphics Structure Variables 9 co Direction l 9 FromPos Pallet 9 amp PickSequence A pallet operation allows the robot to perform the same sequence of motions 0 StackPos and action
38. akes unlock After the robot has powereded up it needs to be initialized before it can begin to perform work 2 3 3 Initializing the Robot After the robot is powered up each of the robot s joints needs to find its ex act position by moving to a home position Each large joint has around 20 home positions evenly distributed over one joint revolution The small joints have around 10 The Initialization screen shown in figure 2 1 gives access to manual and semi automatic driving of the robot s joints to move them to a home po sition The robot cannot automatically avoid collision with itself or the surrounds during this process Therefore caution should be exercised Ihe Aufo button near the top of the screen drives all joints until they are ready When released and pressed again all joints change drive direction The Manual buttons permit manual driving of each joint A more detailed description of the initialization screen is found in section 4 1 2 2 3 4 Shutting Down the Robot The power to the robot can be turned off by touching the OFF button at the initialization screen Most users do not need fo use this feature since the robot is automatically turned off when the controller box is shutting down 2 3 5 Shutting Down the Controller Box shut down the system by pressing the green power button on the screen or by using the Shut Down button on the welcome screen shutting down by pulling the power cord out of the w
39. all socket may cause corruption of the robot s file system which may result in robot malfunction All Rights Reserved 18 UR5 2 4 Quick start Step by Step UNIVERSAL ROBOTS 2 4 Quick start Step by Step To quickly set up The robot perform the following steps l 2i CO N O Oo KR C 17 18 Unpack the robot and the controller box Mount the robot on a sturdy surface strong enough to withstand at least 10 times the full torque of the base joint and at least 5 times the weight of the robot arm Ihe surface shall be vibration free Place the controller box on its foot Plug on the robot cable between the robot and the controller box Plug in the mains plug of the controller box Press the Emergency Stop button on the front side of the teach pendant Press the power button on the teach pendant Wait a minute while the system is starting up displaying text on the touch screen When the system is ready a popup will be shown on the touch screen stating that the emergenoy stop button is pressed Touch the To Initialization Screen button at the popup Unlock the emergency stop buttons The robot state then changes from Emergency Stopped to Robot Power Off Step outside the reach workspace of the robot Touch the on button on the touch screen Wait a few seconds Touch the Start button on The touch screen Ihe robot now makes a noise and moves a little while unlocking the br
40. applied to them The inputs can be used to read buttons sensors or for communication with other PLC systems The inputs are compliant with all three types of digital inputs defined in IEC 61131 2 and EN 61131 2 which means that they will work together with all types of digital outputs defined in the same standaras Technical specifications of the digital inputs are shown below Digital Input Simple Button E ZEE EIE ET EC Ihe above example shows how to connect a simple button or switch Digital Input Simple Button External Power The above illustration shows how to connect a button using an external power SOUICE All Rights Reserved 3 UR5 UNIVERSAL ROBOTS 3 3 Controller I O Signal Communication with other Machinery or PLCs ag foo 502 003 voaf 005 nos oo zav zayf zav zav zav zav zav 2 l kpoo 001 202 os eos oo5 vosfpo7 zav zav zav zav 24v zav zav zav iu E A B H qjololololajale folololololola M ojojojo ojo o 0 OJo OJo o 0 If communication with other machinery or PLCs is needed they must use pnp technology Remember to create a common GND connection between the different interfaces An example where two UR robots A and B are communi cating with each other is illustrated above 3 3 3 Analog Outputs Valid output voltage in current mode O 10 V Valid output current in voltage mode 20 20 mA ohort circuit current in voltage mode mA Output resista
41. avior based on sensor inputs or variable values Use the expression editor to describe the condition under which the robot should proceed to the sub commandds of this If If the condition is evaluated to True The lines inside this r are executed Each r can have several ElseIf and one Else command These can be added using the buttons on the screen An ElseIf command can be removed from the screen for that command All Rights Reserved 5 UR5 UNIVERSAL ROBOTS The open Check 4 4 Programming Expression Continuously allow the conditions of the If and ElseIf statements to be evaluated while the contained lines are ex ecuted If a expression evaluates to False while inside the body of the 1 part the following ElseIf 4 4 19 Program File Or Else statement will be reached Command Tab Script O Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure 9 co Pallet eo Pattern 9 de PalletSequence 9 Approach 9 PatternPoint E Action Wait 9 Exit 9 oo Destack 9 StartPos 9 so Direction 9 FromPos 9 ToPos 9 de PickSequence 9 StackPos E Action Wait 9 Waypoint Wait 9 V Folder c Halt Popup A Script Code Line v Below you can enter text that will be executed as script code by the URController Lor Wem O Simulation o Real Robot Previous Next gt Ir
42. current 4 20m4A or voltage 0 10V output The analog input ranges adjusted to be from 10 10V to 0 5V The settings will be remembered for eventual later restarts of the robot controller when a program is saved 4 3 3 Modbus I O Here the digital modbus I O signals as set up in the installation are shown If the signal connection is lost the corresponding entry on this screen is disabled All Rights Reserved 93 UR5 UNIVERSAL ROBOTS 4 3 Robot Control File O Program Installation Move 1 0 Log Robot Modbus Inputs Outputs O Simulation o Real Robot Inputs View the state of digital modbus inputs Outputs View and toggle the state of digital modbus outputs A signal can only be toggled if the choice for I O tab control described in 4 3 8 allows if All Rights Reserved 94 UR5 4 3 Robot Control UNIVERSAL ROBOTS 4 3 4 AutoMove Tab Ihe AutoMove tab is used when the robot has to move to a specific position in its workspace Examples are when the robot has to move to the start position of a program before running it or when moving to a waypoint while modifying a program Rui ve I Of Automove Move Robot into Position Hold down Auto to perform the movement shown Release the button to abort Push Manual to move the robot into position manually Auto Manual Speed 00 X Cancel Animation The animat
43. d on this screen However if the robot is ceiling mounted All Rights Reserved 9 UR5 UNIVERSAL ROBOTS 4 3 Robot Control wall mounted or mounted at an angle this can be agjusted using the push buttons Ihe buttons on the right side of the screen are for setting the angle of the robot s mounting The three top right side buttons set the angle to ceiling 180 wall 90 floor 0 The Tilt buttons can be used fo set an arbitrary an gle Tne buttons on the lower part of the screen are used to rotate the mounting of the robot to match the actual mounting WARNING 1 Make sure to use the correct installation settings Save and load the installation files along with the program 4 3 8 Installation I O Setup File Program Installation Move 1 0 Log TCP Position Input Output Setup Output Names Mounting Input Names 1 0 Setup Modbus Def Program Load Save Features digital in 0 digital in 1 digital in 2 digital in 3 digital in 4 digital in 5 digital in 6 digital in 7 digital in 8 digital in 9 analog in 0 analog in 1 analog in 2 analog in 3 default default default default default default default default default default default default default default digital out 0 digital out 1 digital out 2 digital out 3 digital out 4 digital out 5 digital out 6 digita
44. de by the pro grammer can cause a voltage change to 24V which may damage the equipment and start a fire The internal control system will generate an error to the robot log if the current exceeds its limit The different I Os at the tool is described in the following three subsections 3 4 1 Digital Outputs Voltage when open 0 5 26 V Voltage when sinking IA 10058 0201 V Current when sinking 1 A Current through GND A Swichime ms The digital outputs are implemented so that they can only sink to GND OV and not source current When a digital output is activated the corresponding connection is driven to CND and when it is deactivated the corresponding connection is open open collector open drain Ihe primary difference be tween the digital outputs inside the controller box and those in the tool is the reduced current due to the small connector All Rights Reserved 4 UR5 UNIVERSAL ROBOTS 3 4 Tool I O WARNING 1 The digital outputs in the tool are not current limited and overriding the specified data can cause permanent dam age to them To illustrate clearly how easy it is to use digital outputs a simple example is shown Using Digital Outputs POWER GRAY DOS BLUE This example illustrates how to turn on a load when using the internal 12V or 24V power supply Remember that you have to define the output voltage at the I O tab see section 4 3 2 Keep in mind that the
45. different ways to force movements of the robot joints without powering the motors of the joints 1 Active backdriving If possible power on the robot by pushing the ON button on the initializing screen Instead of pushing the brake release button to power up the joint motors push the teach button on the back side of the teach pendant A special backdrive mode is entered and the robot will loosen its brakes automatically while the robot is hand guided Releasing the teach button re locks the brakes 2 Forced backariving Force a joint to move by pulling hard in the robot arm Each joint break has a friction clutch which enables movement during high forced torque Forced backariving is intended for urgent emergencies only and might damage the joint gears and other parts 3 Manual brake release Remove the joint cover by removing the few M3 screws that fix it Release the break by pushing the plunger on the small electromagnet as shown in the picture below WARNING 1 Beware of gravity and heavy payloads Ihe robot can collapse with full weight Do not turn any joints more than necessary All Rights Reserved 13 UR5 UNIVERSAL ROBOTS 1 6 Emergency movement of the robot arm A gt y y Lama se 10 2 All Rights Reserved 14 UR5 Chapter 2 Getting started 2 1 Introduction Congratulations on the purchase of your new Universal Robot URS The robot is a machine that can be programmed
46. e PickSequence Shared Parameters 90 StackPos Action Joint Speed 60 0 deg s pris t Joint Acceleration 80 0 deg s aypoin c2 Wait 9 V Folder zs Reset to defaults 4 li I Add Waypoint 4 yP 0 Simulation ir M4 o ob BH speed p 1 00 Previous Next gt o Real Robot The Move command controls the robot motion through the underlying way points Waypoints have to be under a Move command Ihe Move command defines the acceleration and the speed at which the robot will move between those waypoints Movement Types It is possible to select one of three types of movements MoveJ MoveL and MoveP each explained below e moveJ will make movements that are calculated in the joint space of the robot Each joint is controlled To reach the desired end location at the same time This movement type results in a curved path for the tool The shared parameters that apply to this movement type are the maximum joint speed and joint acceleration to use for the movement calculations specified in deg s and deg s respectively If it is desired to have the robot move fast between waypoints disregarding the path of the tool between those waypoints this movement type is the favorable choice e moveL will make the tool move linearly between waypoints This means that each joint performs a more complicated motion to keep the tool on a straight line path The shared parameters that can be set for this movement type are the de
47. e programming part of the robot to people without a password see section 4 5 5 Calibrate Screen Calibrates the Touch of the touch screen see sec tion 4 5 6 Setup Network Opens the interface for setting up the Ethernet network for the robot see section Back Returns to the Welcome Screen All Rights Reserved 29 UR5 UNIVERSAL ROBOTS 4 5 Setup 4 5 2 Setup Screen gt Initialize Initialize Robot O Push Auto until all lights turn green Rotate joints individually if necessary Robot Power 3 Robot Auto OK M Base lt a ES Auto POWER OFF a Shoulder lt A E gt Auto POWER OFF 3 Elbow da gt Auto POWER OFF 3 Wrist 1 au E gt Auto POWER OFF 3 Wrist 2 a E gt Auto POWER OFF a Wrist 3 E E gt Auto POWER OFF a Tool POWER OFF 3 ControlBox CONNECTING D e OK This screen is used when powering up the robot Before the robot can op erate normally each joint needs to move a little about 20 to finds its exact position The Auto button drives all joints until they are ok The joints change drive direction when the button is released and pressed again 4 5 3 Setup Screen Language Select Select the language to be used for the PolyScope software and for the help function The GUI needs to restart for changes to take effect 4 5 4 Setup Screen Update SETUP Robot Update robot software Search Please select
48. eaks Touch the blue arrows and move the joints around until every light at the right side of the screen turns green Be careful not to drive the robot into itself or anything else All joints are now OK Touch the exit button bringing you the Welcome screen Touch the PROGRAM Robot button and select Empty Program Touch the Next button bottom right so that the empty line is selected in the tree structure on the left side of the screen Go to fhe Structure tab 20 21 22 23 24 Touch the Move button Go to the Command tab Press the Next button to go fo the Waypoint settings Press the Set this waypoint button next to the picture On fhe Move screen move the robot by pressing the various blue arrows or move the robot by holding the Teach button while pulling the robot arm All Rights Reserved 19 UR5 UNIVERSAL ROBOTS 2 9 Mounting Instructions 29 Press OK 26 Press Add waypoint before 2 7 Press the Set this waypoint button next to the 2 picture 28 On the Move screen move the robot by pressing the various blue arrows or move the robot by holding the Teach button while pulling the robot arm 29 Press OK 30 Your program is ready The robot will move between the two points when you press the Play symbol Stand clear hold on to fhe emergency stop button and press Play 3l Congratulations You have now produced your first robot program that moves the robot between t
49. ed to the control box of the robot while the right part shows information about each robot joint Each robot joint shows informa tion for temperaure of the motor and electronics the load of the joint and the voltage at the joint All Rights Reserved 09 UR5 UNIVERSAL ROBOTS 4 3 Robot Control Robot Log On the bottom half of the screen log messages are shown The first column shows the time of arrival of the message Ihe next column shows the sender of the message The last column shows the message itself 4 3 13 Load Screen On this screen you choose which program to load There are two versions of this screen one that is to be used when you just want to load a program and execute it and one that is used when you want to actually select and edit a files program The main difference lies in which actions are available to the user In the basic load screen the user will only be able to access files not modify or delete them Furthermore the user is not allowed to leave the directory structure that descends from the programs folder Ihe user can descend to a sub directory but he cannot get any higher than the programs folder Therefore all programs should be placed in the programs folder and or sub folders under the programs folder Screen layout Load Program Current Directory home hudson programs x EU E ABCDE urp Filename Filter Universal Robots Program files Y Open Cance
50. et using the various screens under the Installation fab It is possible to have more than one installation file for the robot Programs created will use the active installation and will load this in stallation automatically when used Any changes to an installation needs to be saved to be preserved after power down Saving an installation can be done either by pressing the Save button or by saving a program using the installation 4 3 6 Installation TCP Position File 2 Program Installation Move 1 0 Log TCP Position Setup for the Tool Center Point Mounting Setting the Tool Center Point 1 0 Setup TCP Coordinates oo x 0 0 mm Bs Def Program Y 10 0 mm Y Load Save a A Features Z 0 0 mm Z So S The payload at the TCP is e 0 ks i Fit program to new TCP To Change motions gt gt p Change graphics The Tool Center Point 1CP is the point at the end of the robot arm that gives a characteristic point on the robot s tool When the robot moves linearly it is This All Rights Reserved 96 UR5 4 3 Robot Control UNIVERSAL ROBOTS point that moves in a straight line It is also the motion of the TCP that is visualized on the graphics tab The TCP is given relative to the center of the tool output flange as indicated on the on screen graphics WARNING 1 Make sure to use the correct installation settings Save and load the ins
51. for connecting to other machines All Rights Reserved 29 UR5 UNIVERSAL ROBOTS 3 2 The Safety Interface The Simplest Emergency Stop Configuration The simplest configuration is to use the internal emergency stop button as the only component to generate an emergency stop This is done with the configuration shown above This configuration is the default when the robot leaves the factory and thereby the robot is ready to operate However the emergenoy configuration shall be changed if required by the risk assessment see section 1 1 Connecting an External Emergency Stop Button In almost every robot installation the integrator is required according to the risk assessment conducted to connect one or more external emergency stop buttons Doing so Is simple and easy An example of how to connect one extra button is shown above Connecting Emergency Stop to Other Machinery When the robot is used together with other electro mechanical machinery it is often required to set up a common emergency stop circuit This ensures that if a dangerous situation arises the operator does not need to think about which buttons fo use It is also often preferable for every part of a sub function in a product line to be synchronized since a stop in only one part of the product line can lead to a dangerous situation An example with two UR robots emergency stopping each other is shown below All Rights Reserved 30
52. ge in the common CND connection can result in a disturbing signal in the analog inputs because there will be a voltage drop along the GND wires and inside connectors Note that a connection between the tool power supply and the analog inputs will permanently damage the I O functionality if the analog inputs are set in current mode To make it clear how easy it is to use digital inputs some simple examples are shown Using Analog Inputs Non differential POWER GRAY The simplest way to use analog inputs The output of the sensor can be either current or voltage as long as the input mode of that analog input is set to the same on the I O tab see section 4 3 2 Remember to check that a sensor with voltage output can drive the internal resistance of the tool or the measurement might be invalid Using Analog Inputs Differential POWER GRAY Using sensors with differential outputs is also straightforward Simply connect the negative output part to GND QV with a terminal strip and it will work in the same way as a non differential sensor All Rights Reserved 43 UR5 UNIVERSAL ROBOTS 3 4 Tool I O All Rights Reserved 44 UR5 Chapter 4 PolyScope Software UNIVERSAL ROBOTS 4 1 Introduction 4 1 Introduction PolyScope is the graphical user interface GUI which lets you operate the robot run existing robot programs or easily create new ones PolyScope runs on the touch sensitive screen attached to the contro
53. ght of the screen Commands can be inserted or removed using the All Rights Reserved 69 UR5 UNIVERSAL ROBOTS 4 4 Programming Structure fab described in section 4 4 28 The program name is shown directly above the command list with a small disk icon that can be clicked to quickly save the program The lowest part of the screen is the Dashboard Ihe Dashboard features a set of buttons similar to an old fashioned tape recorder from which programs can be started and stopped single stepped and restarted Ihe speed slider allow you to agjust the program speed at any time which directly affects the speed at which the robot moves To the left of the Dashboard the Simulation and Real Robot buttons toggle between running the program in a simulation or running it on the real robot When running in simulation the robot does not move and thus cannot damage itself or any nearby equipment in collisions Use simulation to test programs if unsure about what the robot will do While the program is being written the resulting motion of the robot is illus trated using a 3D drawing on the Graphics tab described in section 4 4 27 Next fo each program command is a small icon which is either red yellow or green A red icon means that there is an error in that command yellow means that the command is not finished and green means that all is OK A program can only be run when all commands are green 4 4 3 Program Command Tab lt Empty gt File
54. gnal goes high For example in the event that an output signal goes high the event program can wait for 100ms and then set it back to low again This can make the main program code a lot simpler in the case on an external machine triggering on a rising flank rather than a high input level 4 4 21 File Program Command Tab Thread Program Installation Move 1 0 Log lt unnamed gt S AAA A P Wait 9 V Folder ca 9 ee Pattern Squar 9 alst_Corner 9 a2nd Corner 9 a3rd Corner 9 a4th Corner 9 ee PalletSequence 9 Approach 9 PatternPoin Action Wait 9 Exit amp Event ca V Thread 1 4 Command Graphics Structure Variables Thread A thread is a parallel program that runs along with the main program A thread can perform 1 0 wait for signals and set variables Useful for controlling other machines while the robot is running v Loops Forever Track program execution O Simulation o Real Robot A thread is a paral III Previous Next gt lel process to the robot program A thread can be used to control an external machine independently of the robot arm A thread can communicate with the robot program with variables and output signals 4 4 22 Program Command Tab Pattern File Program Installation Move 1 0 Log o Y oo PickSequence 9 StackPos Action
55. he line coordinate system The Z Axis will be defined by the projection of the z axis of the first sub point onto the plane perpendicular to the line Ihe position of the line coordinate system is the same as the position for the first sub point File 2 Program Installation Move 1 0 Log TCP Position Line 1 Rename Mounting I O Setup Modbus Def Program Load Save Features Tool f Line_1 X Point_1 X Point_2 S o Show axes Move robot here s R Joggable Variable Add Plane Push This button to add a plane feature to the installation A plane is defined by three sub point features The position of the coordinate system is the same as the position for the first sub point Ihe z axis is the plane normal and the y axis All Rights Reserved 04 UR5 4 3 Robot Control UNIVERSAL ROBOTS is directed from the first point towards the second Ihe positive direction of the Z Axis is set so that the angle between the z axis of the plane and the z axis of the first point is less than 180 degrees File Program Installation Move 1 0 Log TCP Position Plane_1 Delete Mounting I O Setup Modbus Def Program Load Save Features Base Tool 9 Y Plane Xx Point 1 X Point 2 y X Point_3 1 4 lv Show axes Move robot here Joggable Variable 4 3 12 Log Tab File Program Installation Move
56. he number of positions along each of the edges of the pattern The robot controller then calculates the individual pattern positions by proportionally adding the edge vectors together If the positions to be traversed do not fall in a regular pattern the List option can be chosen where a list of all the positions is provided by the programmer This way any kind of arrangement of the positions can be realized Defining the Pattern When the Box pattern is selected the screen changes to what is shown below File Program Installation Move 1 0 Log El lt unnamed gt Command Graphics Structure Variables eae a8th Corner 1 Rename 9 Waypo nt wait Change this Position 9 V Folder gt Move robot here Halt El script var P call Sub 3 9 V If 9 ee Pallet eo tt din M t oe e umet 8 x Py E 6 x MO Fi tk SS C ti c 4 t nio i th Ca l LAM 8th Corner 1 a 3 4 gt lt gt P 2 2 a iT r gum E lat gt gt E Speed 1 00 Previous Next m o Real Robot A Box pattern uses three vectors to define the side of the box These three vectors are given as four points where the first vector goes from point one to point two the second vector goes from point two to point three and the third vector goes from point three to point four Each vector is divided by the interval count numbers A specific p
57. he tool is moving slowly causing the robot to work inefficiently and the conduction of the risk assessment to be difficult All Rights Reserved 20 UR5 2 5 Mounting Instructions UNIVERSAL ROBOTS Front Tilted Figure 2 2 Ihe workspace of the robot The robot can work in an approxi mate sphere 2170cm around the base except for a cylindrical volume directly above and directly below the robot base 2 5 2 Mounting the Robot The robot is mounted using 4 M8 bolts using the four 8 5mm holes on the robot s base If very accurate repositioning of the robot is desired two 28 holes are pro vided for use with a pin Also an accurate base counterpart can be purchased as accessory Figure 2 3 shows where to drill holes and mount the screws Mount the robot on a sturdy surface strong enough to withstand at least 10 times the full torque of the base joint and at least 5 times the waight of the robot arm Furthermore the surface shall be vibration free If the robot is mounted on a linary axis or a moving platform then the accelera tion of the moving mounting base shall be very low A high acceleration might cause the robot to stop thinking it bumped into something DANGER 1 Make sure the robot arm is properly and securely bolted in place The mounting surface shall be sturdy CAUTION 1 If the robot is bathed in water over an extended time period it might be damaged The robot should not be mounted in water or in a wet environmen
58. he two given positions WARNING 1 Tipping hazard If the robot is not securely placed on a sturdy surface the robot can fall over and cause an injury 2 Do not drive the robot into itself or anything else as this may cause damage fo the robot caught 3 Only stretch your arm inside the reach workspace of the robot Do not place fingers where they can be 4 his is only a quick start guide to show how easy it is to use a UR robot t assumes a harmless environment and a very careful user Do not increase the speed or acceleration above the default values Always conduct a risk assessment before placing the robot into operation 2 5 Mounting Instructions The robot consists essentially of six robot joints and two aluminum tubes con necting the robot s base with the robot s fool The robot is built so that the tool can be translated and rotated within the robot s workspace Ihe next subsec tions describes the basic things to know when mounting the different parts of the robot system 2 5 The Workspace of the Robot The workspace of the URS robot extends to 850 mm from the base joint The workspace of the robot is shown in figure 2 21 It is important to consider the cylindrical volume directly above and directly below the robot base when a mounting place for the robot is chosen Moving the tool close to the cylindrical volume should be avoided if possible because it causes the robot joints To move fast even though t
59. here the stack operation starts If the starting position is omitted the stack starts at the robots current position Direction File O Program Installation Move 1 0 Log E lt unnamed gt Command Graphics structure V Robot Program E Move E 3 9 Waypoint Di rect 10n Y Move J 9 t Acti A direction is given by the line between the TCP position of two gt amp Pallet waypoints eo Pattern r de PalletSequence y L Stop after 500 0 uds 9 Approach T 9 PatternPoint Stop when f x du Actior Wait 9 Exit tack 9 StartPos 9 ee Direction 9 FromPos rd O ToPo F ee PickSequer 9 Stack alos Shared Parameters Wait Waypoint Tool Speed 10 0 mm s Wait m 9 V Folder Tool Acceleration 1200 0 mm s 4 b Reset to defaults lt gt Simulation pd Speed J100 Previous Next gt O real Robot gt P The direction is given by two positions and is calculated as the position differ ence from the first positions TCP to the second positions TCP Note A direction does not consider the orientations of the points Next Stacking Position Expression The robot moves along the direction vector while continuously evaluating whether the next stack position has been reached When the expression is evaluated to True he special sequence is executed BeforeStart
60. hickness of the items in the stack On top of this one must define the condition for when the next stack position is reached and a special program sequence that will be performed at each of the stack positions Also speed and accelerations need to be given for the movement involved in the stack operation All Rights Reserved 88 UR5 4 4 Programming UNIVERSAL ROBOTS Stacking File O Program Installation lt unnamed gt Command Graphics Structure V Robot Program 9 V MoveJ 9 Waypoint Select Seek Type 9 V MoveJ 9 Waypoint Action A seek operation is given by a 9 ee Pallet starting position s and a direction d eo Pattern 9 eo PalletSequence 9 Approach p PatternPoint Please select between stacking and destacking Action S Wait 9 Exit eo Seek Wait Stacking Destacking 9 V Folder A c Halt B Popup 9 V Loop f 4 ay f iod EE ipii j D es l P cal m peer ume Q Vir li i 4 4 j e ARS E i E Speed 100 Previous Next E When stacking the robot moves to the starting position and then moves opposite the direction to search for the next stack position When found the robot remembers the position and performs the special sequence Ihe next time round the robot starts the search from the remembered position incremented by the item thickness along the direction The stacking is finished when the stack hight is more than some def
61. hts Reserved 08 UR5 4 4 Programming UNIVERSAL ROBOTS 4 4 1 Program New Program File O Program Installation Move 1 0 Log New Program Load From File Load Program Use Template m Pick and Place Empty Program A new robot program can start from either a template or from an existing saved robot program A template can provide the overall program structure so only the details of the program need to be filled in 4 4 2 Program Tab File Program Installation Move 1 0 Log unnamed Command Graphics Structure Y Robot Program c Program The window on the left shows the program tree Use the Next and Previous buttons to navigate through the program tree Use the Structure tab to modify the program tree Add BeforeStart Sequence 4 E Set Initial Variable Values 44 p lv Program Loops Forever O Simulation Q Real Robot ba b p a Speed J100 Previous Next gt The program tab shows the current program being edited The program tree on the left side of the screen displays the program as a list of Commands while the area on the right side of the screen displays infor mation relating to the current command The current command is selected by clicking the command list or by using the Previous and Next buttons on the bottom ri
62. ined number or when a sensor gives a signal Destacking File Program Installation lt unnamed gt Command Graphics Structure V Robot Program y V Move Destack 9 Waypoint 9 V Moves Destacking remove items one by one from a stack 9 Waypoint The stack is defined by the following of parameters 4 E Action 9 amp Pallet s The starting position d eo Pattern d The direction of the stack de PalletSequence i The item thickness i 9 Approach li 9 PatternPoint Action Wait 9 Exit oo Destack 9 StartPos 9 ee Direction e FromPos The next position is found when 9 ToPos meum 9 eo PickSequence L f x dud 9 StackPos c2 Action Wait Item thickness Shared Parameters 9 Waypoint TT ne 0 0 nn Tool Speed 250 0 mm s y y V Folder w Tool Acceleration 1200 0 mm s aa t aa T D Sequence BeforeStart Sequence AfterEnd Reset to defaults gt deni Ma b b B8 speed 100 Previous Next gt When destacking the robot moves from the starting position in the given direc tion to search for the next item When found the robot remembers the position and performs the special sequence The next time round the robot starts the All Rights Reserved 89 UR5 UNIVERSAL ROBOTS 4 4 Programming search from the remembered position incremented by the item thickness along the direction Starting position The starting position is w
63. intended for emergency situations The function is not intended to be a part of a normal routine Emergency stop shall be tested after installation and after any service Periodic All Rights Reserved 12 UR5 1 6 Emergency movement of the robot arm UNIVERSAL ROBOTS tests of emergency stop and other safety functions shall be scheduled accord ing fo regional and national recommendations Emergency stop shall be shared between all machines at a work station such that a push on a random emergenoy stop button stops all machines Extra emergenoy stop buttons shall be placed at the work station according to the risk assessment All emergency stop buttons shall be marked with the text Emergency Stop or E STOP All individuals in the facility shall be instructed on how to activate emergency stop Emergency stop and other safety equipment shall be connected redundantly All relays shall be monitored and the system shall enter a safe condition if a relay fails Ihe circuitry shall confirm to specifications in section DANGER 1 Make sure to install a sufficient number of emergency stop buttons and to place them carefully Failure to locate an emegency stop button in the event of an emergency could result in serious injury or death 1 6 Emergency movement of the robot arm In the unlikely event of an emergency situation where one or more robot joints needs to be moved and robot power is either nof possible or unwanted there are three
64. ion shows the movement the robot is about to perform Compare the animation with the position of the real robot and make sure that robot can safely perform the movement without hitting any obstacles CAUTION 1 Ihe automove function moves in joint space not in linear cartesian space Collision might damage robot or equip ment Auto Hold down the Auto button to move the robot as shown in the animation Note Release the button to stop the motion at any time Manual Pushing the Manual button will take you to the MoveTab where the robot can be moved manually Ihis is only needed if the movement in the animation is nof preferable All Rights Reserved 99 UR5 UNIVERSAL ROBOTS 4 3 Robot Control 4 3 5 Installation gt Load Save File 2 Program Installation Move 1 0 Log ITCP Position Load Save Robot Installation to File I O Setup The Robot Installation includes the options that can be set using the Modbus tabs to the left This includes I O names TCP setup and the robot s mounting The robot installation does not include a robot program Def Program Load Save Save the current installation default E Save Features Load a different installation file Load The installation covers aspects of how the robot is placed in its working envi ronment both mechanical mounting of the robot and electrical connections to other equipment These settings can be s
65. istor should be around 200 ohms and the relationship between the voltage at the controller inout and the output of the sensor Is given by Voltage Current x Resistance Note that the tolerance of the resistor and the ohmic change due to tempera ture must be added to the error specifications of the analog inputs 3 4 Tooll O At the tool end of the robot there is a small connector with eight connections All Rights Reserved 40 UR5 3 4 Tool I O UNIVERSAL ROBOTS Red OV GND Gray OV 12V 24V POWER Blue Digital output 8 DO8 Pink Digital output 9 DO9 Yellow Digital input 8 DIS Digital input 9 DIO White Analog input 2 AI2 Analog input 3 AI3 This connector provides power and control signals for basic grippers and sen sors which may be present on a specific robot tool This connector can be used to reduce wiring between the tool and the controller box Ihe connector is a standard Lumberg RSMEDG8 which mates with a cable named RKMV 8 354 Note that the tool flange is connected to GND same as the red wire Internal Power Supply Specifications supply voltage in 24V mode IBD 24 TBD V Supply current in both modes mA Shreicutcurenpotecton 650 mA Capacitive load TBD UF Inductive load TBD UH The available power supply can be set to either OV 12V or 24V at the I O tab in the graphical user interface see section 4 3 2 WARNING 1 Take care when using 12V An error ma
66. it 9 Exit Variable Expression Destack 9 StartPos 9 de Direction vari x E 1 1 9 FromPo Kidd Rename EN f x HE o p Y oo PickSequence 9 StackPos E Action Wait Wait 9 V Folder c Halt Popup 9 V Loop E Script HEN 9 Simulation b E Speed 100 Previous Next E o Real Robot Assigns values to variables An assignment puts the computed value of the right hand side into the variable on the left hand side This can be useful in complex programs 4 4 18 Program Command Tab If File Program Installation Move 1 0 Log eq lt unnamed gt Command Graphics Structure Variables de Y oo Direction 9 FromPos 9 ToPos If 9 co PickSequence StackPos Depending on the state of the given sensor input or program variable Action the following lines will be executed Wait 9 Waypoint If Wait beeen Check expression continuously f x mu c 2 Halt Popup El Script c var _1 21251 p Call SubProgram 1 V EE e Event Y Thread_1 9 V Force Add ElseIf Remove ElseIf P SubProgram_1 v al L Add Else ka Simulation M4 5H Speed 100 Previous Next gt o Real Robot An if fhen else construction can make the robot change its beh
67. l This image shows the actual load screen It consists of the following important areas and buttons Path history Ihe path history shows a list of the paths leading up to the present location This means that all parent directories up to the root of the computer are shown Here you will notice that you may not be able to access all the directories above the programs folder By selecting a folder name in the list the load dialog changes to that direc tory and displays it in the file selection area j4 3 13 File selection area In this area of the dialog the contents of the actual area is present It gives the user the option to select a file by single clicking on its name or to open the file by double clicking on its name All Rights Reserved 66 UR5 4 3 Robot Control UNIVERSAL ROBOTS In the case that the user double clicks on a directory the didlog descends into this folder and presents its contents File filter By using the file filter one can limit the files shown to include the type of files that one wishes By selecting Backup Files the file selection area will display the latest 10 saved versions of each program where o1d0 is the newest and o1d9 is the oldest File field Here the currently selected file is shown Ihe user has the option to manually enter the file name of a file by clicking on the keyboard icon to the right of the field This will cause an on screen keyboard to pop up where the user can enter the file
68. l box lo calibrate the touch screen read section 4 5 6 PolyScope Robot User Interface O Please select RUN Program UNIVERSAL ROBOTS SETUP Robot About SHUT DOWN Robot The picture above shows the Welcome Screen The bluish areas of the screen are buttons that can be pressed by pressing a finger or the backside of a pen against the screen PolyScope has a hierarchical structure of screens In the programming environment the screens are arranged in fabs for easy access on the screens File O Program Installation Move I O Log al lt unnamed gt Command Graphics Structure V Robot Program In this example the Program tab is selected at the top level and under that the Structure tab is selected he Program tab holds information related to the currently loaded program If the Move Tab is selected the screen changes to the Move screen from where the robot can be moved Similarly by selecting the I otab the current state of the electrical I O can be monitored and changed It is possible to connect a mouse and a keyboard to the controller box how ever this is not required Whenever a text or number input is needed an on screen keypad or keyboard is provided The on screen keypad keyboard and expression editor can be reached using the buttons shown above The various screens of PolyScope are described in the following sections All Right
69. l out 7 digital out 8 digital out 9 analog out 0 analog out 1 default default default default default default default default default default default default Please Select an Input or Output Rename to New Name t Input and output signals can be given names This can make it easier to remember what the signal does when working with the robot Select an I O by clicking on it and set the name using the on screen keyboard You can set the name back by setting it to only blank characters When an output is selected a few options are enabled Using the check box a default value for the output can set to either low or high This means that the output will be set to this value when a program is not running If the check box is not checked the output will preserve its current state after a program ends It is also possible to specify whether an output can be controlled on the I O tab by either programmers or both operators and programmers or if it is only robot programs that may alter the output value All Rights Reserved 98 UR5 4 3 Robot Control UNIVERSAL ROBOTS 4 3 9 Installation gt Default Program File 2 Program Installation Move I O Log ITCP Position Mounting Set Default Program rep The Default program is loaded automatically Modbus when the robot is turned on Def Program Load Save
70. l output flange ISO 9409 1 50 4 M6 This is where the tool is mounted at the tip of the robot All measures are in mm All Rights Reserved 24 UR5 2 5 Mounting Instructions UNIVERSAL ROBOTS NOTE The fuse shall not be higher than the lowest current rating of the spe cific country plug and socket All Rights Reserved DANGER 1 Lockout and tagout all power for the complete robot installation during service Other equipment shall not supply voltage to the robot I O when the system is locked out 2 Make sure that the robot is grounded correctly Electrical connection to earth Use the unused bolts associated with grounding symbols inside the controller box to create common grounding of all equipment in the system Ihe grounding conductor shall have at least the current rating of the highest current in the system 3 Make sure that the input power to the controller box is protected with a RCD Residual Current Device and a correct fuse 4 Make sure that all cables are connected correctly before the controller box is powered Always use an original and correct power cord o Use original cables supplied with the robot only Do not use the robot for applications where the cables will be subjected to flexing Contact your supplier if longer or flexible cables are needed 6 Make sure that all equipment not rated for water exposure remains dry If water comes inside the product lockout and tagout all power and then contact y
71. lection of program lines Please enter text to be displayed in the program tree F eo PalletSequence 9 Approach Folder Mou 9 PatternPoint Action Wait 9 de PickSequence 9 StackPos E Action E Wait 9 Waypoint Wait V Folder a Le Hide Folder Program Tree iss S Simulation Ma b b B Speed pc eex Previous Next E Real Robot P A folder is used to organize and label specific parts of a program to clean up the program tree and to make the program easier to read and navigate A folder does not in itself do anything 4 4 15 Program Command Tab Loop File Program Installation z lt unnamed gt Command Graphics Structure T U rrovcr 9 Waypoint Action Loop eo Pallet 9 p valli sapie Please select how many times the program in this loop should be executed Y oo PalletSequence 9 Approach Q Loop always 9 PatternPoint Action Wait G Loop times using variableLoo 1 9 Exit p 9 oo Destack 9 StartPos O Loop as long as the following expression is true o S n 9 FromPos o ro BE o9 p Y oo PickSequence 9 StackPos L Action Wait 9 Waypoint Wait 9 V Folder c m Halt Popup V Loop gt O Simulation O Real Robot C p b Speed 100 Previous Next gt Loops the underlying
72. n e Fixed feature If a fixed feature such as e g Base is selected this will not have any effect on Fixed and Relative waypoints The behavior for Vari able waypoints is described below e Variable feature If any of the features in the currently loaded installation are selected to be variable these corresponding variables will also be selectable in the feature selection menu If a feature variable named by the name of the feature and proceeded by var is selected the robot movements except to Relative waypoints will depend on the ac tual value of the variable when the program is running The initial value of a feature variable is the value of the actual feature This means that the movements will only change if the feature variable is actively changed by the robot program e Variable waypoint When the robot moves to a variable waypoint the tool target position will always be calculated as the coordinates of the variable in the space of the selected feature Therefore the robot movement for a variable waypoint will always change if another feature is selected The settings of the Shared Parameters of a Move command apply to the path from the robot s current position to the first waypoint under the command and from there to each of the following waypoints Ihe Move command set tings do not apply to the path going from the last waypoint under that Move command All Rights Reserved 12 UR5 4 4 Programming UNIVERSAL ROBOTS
73. nce command screen to define which of the waypoints in the sequence should correspond to the pattern positions All Rights Reserved 9 UR5 UNIVERSAL ROBOTS 4 4 Programming Pallet Sequence Anchorable Sequence In an Pallet Sequence node the motions of the robot are relative to the pallet position The behavior of a sequence is such that the robot will be at the po sition specified by the pattern at the Anchor Position Pattern Point Ihe remaining positions will all be moved to make this fit Do not use the Move Command inside a sequence as it will not be relative to the anchor position BeforeStart The optional BeforeStart sequence is run just before the operation starts This can be used to wait for ready signals AfterEnd The optional AfterEnd sequence Is run when the operation is finished This can be used to signal conveyor motion to start preparing for the next pallef 4 4 25 Program Command Tab Seek A seek function uses a sensor to determine when the correct position is reached to grab or drop an item The sensor can be a push button switch a pressure sensor or d capacitive sensor This function is made for working on stacks of items with varying item thickness or where the exact positions of the items are not known or foo hard to program Stacking Destacking ls ji i When programming a seek operation for working on a stack one must define s the starting point d the stack direction and i the t
74. nce in voltage mode 43 ohm The analog outputs can be set for both current mode and voltage mode in the range of 4 20mA and 0 10V respectively To illustrate clearly how easy it is to use analog outputs some simple exam ples are shown Using the Analog Outputs Analog controlled actuatar This is the normal and best way to use analog outputs The illustration shows a setup where the robot controller controls an actuator like a conveyor belt The best result is accomplished when using current mode because it is more Immune to disturbing signals Using the Analog Outputs Non Differential Signal All Rights Reserved 98 UR5 3 3 Controller I O UNIVERSAL ROBOTS If the controlled equipment does not take a differential input an alternative solution can be made as shown above This solution is not very good in terms of noise and can easily pick up disturbing signals from other machinery Care must be taken when the wiring is done and it must be kept in mind that disturbing signals induced into analog outputs may also be present on other analog I O 3 3 4 Analog Inputs Common mode input voltage 33 Differential mode input voltage 33 Differential input resistance 220 Common mode input resistance 99 The analog inputs can be set to four different voltage ranges which are implemented in different ways and therefore can have different offset and gain errors The specified differential mode input voltage is
75. nel are protected against all serious hazards OSHA Occupational Safety amp Health Administration is an agency of the United States Department of Labor and OSHA makes rules and standards for machine safety Two OSHA standards relevant for safety of robot installations are listed below 1 OSHA 29 CFR 1910 333 Selection and Use of Work Practices 2 OSHA 29 CFR 1910 147 The Control of Hazardous Energy Lockout Tagout All electrical installations shall be constructed to prevent electrical shock and the complete robot installation shall have a lockout tagout function Lock out tagout refers fo when all power to the machinery in the robot installation can be disconnected and that the disconnecting switch can be locked in the off position preventing other people from re powering the system Ihe integra tor is responsible for installing the lockout tagout function For more information go to http www osha gov Other safety standards exist besides the OSHA standards 1 ANSI RIA 15 06 2012 American national standard Safety requirements All Rights Reserved 10 UR5 1 4 Risk assessment UNIVERSAL ROBOTS 2 ISO 10218 1 2011 Robots and robotic devices Safety requirements for in dustrial robots Part 1 Robot 3 ISO 10218 2 2011 Robots and robotic devices Safety requirements for in dustrial robots Part 2 Robot systems and integration Note that these standards describe what is normally done to sufficiently re duce haza
76. ng standards EN ISO 10218 1 2011 5 10 item 5 10 5 EN ISO 10218 2 2011 5 11 item 5 11 5 5 EN ISO 10218 1 2006 5 10 item 5 10 5 ANSI RIA ISO 10218 1 2007 5 10 item 5 10 5 The robot is tested in a limited workspace and a force limit of 150N at the tool center point TCP of the robot is used during testing The following results are found during testing o po 1 Seecurity stop URcontrollerCli3A0 1 X 5 48 Security stop URcontollrCIl3A0 2 68 X Seecuritystoep CHAD Elbow 3 50 Secuitsop URcontrollrCil3A0 Ooa os Security stop URcontllerCli3A0 14 48 50 51 L6 50 Security stop URcontrllrCll3A0 8 28 pp Secwitystp URcontollrCIl3A0 o 5 Security stop URcontolerCIl3A0 io 65 Security stop URcontrolerCil3A0 u 68 Secwiysop CIIBAOBlbow 52 URcontroller C113A0 2 URcontroller C113A0 PS Security stop URcontroller C113A0 The test has verified that the robot is in compliance with the former mentioned items of the standards All the forces measured during testing are below the chosen force limit of 150N at the TCP Yours faithfully Centre for Materials Testing Thomas Greve M Sc Dir tel 45 72202321 E mail TGR teknologisk dk All Rights Reserved 104 UR5
77. ning All Rights Reserved l UR5 UNIVERSAL ROBOTS 4 3 Robot Control frames coordinate systems that relate the internal coordinate system of the robot the base coordinate system to the relevant object s coordinate system Reference can both be made to tool coordinates and to base coordinates of the robot A problem with such frames is that a certain level of mathematical knowl edge is required to be able to define such coordinate systems and also that it takes a considerable ammount of time to do this even for a person skilled in the art of robot programming and installation Often this task involves the cal culation of 4x4 matrices Particularly the representation of orientation is compli cated for a person that lacks the required experience to understand this prob lem Questions often asked by customers are for instance e Will if be possible to move the robot 4 cm away from the claw of my com puterised numerically controlled CNC machine e sit possible to rotate the tool of the robot 45 degrees relative to the table e Can we make the robot move vertically downwards with the object let the object loose and then move the robot vertically upward again The meaning of such and similar questions is very straight forward to an av erage customer that intends to use a robot for instance at various stations in a production plant and it may seem annoying and incomprehensible to the customer fo be told that there may not
78. ok up that module in the respective manual The module manual is usually attached as an appendix to This user manual 9 URS UNIVERSAL ROBOTS 1 3 Statutory requirements WARNING 1 Ihe robot and controller box generate heat during oper ation Do not handle or touch the robot while in operation or immediately after operation To cool the robot down power off the robot and wait one hour 2 Never stick fingers behind the internal cover of the controller box CAUTION 1 When the robot is combined with or working with ma chines capable of damaging the robot then it is highly recommended fo test all functions and the robot program separately It is recommended to test the robot program using temporary waypoints outside the workspace of other machines Universal Robots cannot be held responsible for any damages caused to the robot or to other equipment due to programming errors or malfunctioning of the robot 2 Do not expose the robot to permanent magnetic fields Very strong magnetic fields can damage the robot 1 3 Statutory requirements The robot is a component in a robot installation It cannot be considered a complete machine because it requires an installation including a tool When a specific robot installation is constructed it is very important to make a risk assess ment of the complete robot installation Guidance on risk assessment is given in the next sub chapter 1 4 The integrator shall ensure that all person
79. ordinate or the joint position Move Tool e Holding down A translate arrow top wil move the tool tip of the robot in the direction indicated e Holding down d rotate arrow button will change the orientation of the robot tool in the indicated direction The point of rotation is the TCP drawn as a small blue ball Note Release the button to stop the motion at any time Move Joints Allows the individual joints to be controlled directly Each joint can move from 360 to 360 which are the joint limits illustrated by the horizontal bar for each joint If a joint reaches its joint limit it cannot be driven any further away from 0 Teach While the Teach button is held down it is possible to physically grab the robot and pull it to where you want it to be If the gravity setting see in the Setup fab is wrong or the robot carries a heavy load the robot might start moving falling when the Teach button is pressed In that case just release the Teach button again All Rights Reserved 92 UR5 4 3 Robot Control UNIVERSAL ROBOTS WARNING 1 Make sure to use the correct installation settings e g Robot mounting angle weight in TCP TCP offset Save and load the installation files along with the program 2 Make sure that the TCP sittings and the robot mounting sittings are set correctly before operating the Teach button If these sittings are not correct the robot will move when the teach
80. orkspace of the RODO 00 ooo o 2 0 2 Mounting the Robot ns 2 0 3 Mounting the Tool nns 2 0 4 Mounting the Controller BOX 2 0 0 Mounting the Screen 2 0 0 Connecting Cables nn 3 Electrical Interface 3 1 INITOQUCHU N x xa ox X xGEOR X ok x Xo X amp oX 65 as 3 2 The Safety Interface ooo es 3 2 1 Ihe Emergency Stop Interface be Se pe Be ae oe paro vas 3 2 3 Automatic continue after safeguard stop FETTE 3 3 1 Digital Outputs aude E 6460828 o Roe ck EUR mos AAA 3 3 2 Digital Inputs nne 3 3 3 Analog Outputs a a ono M NUES oe ee OIE 3 3 4 Analog Inputs so ae sara AAA ANI o NIE E IA TEE 3 4 1 Digital Outputs 2864646028 o EA ck EUR mop AE A UNIVERSAL ROBOTS 3 4 2 Digitallnpufs 3 4 3 Analog IDnDUlS x sau sea eee KG aras 4 PolyScope Software AI introduction s o rr ns 4 1 1 Welcome screen oon 4 1 2 Initialization Screen oon 4 2 On screen Editors oos 4 2 1 On screen KeypQQl 4 2 2 On screen Keyboard 0 000 eee 4 2 3 On screen Expression Editor Z5 ODO COMO a xm ook eee ee ec x m ee eR eee 2 9 1 Move ICD e os ae ea o3 X obo Edo Pk Ow A box 432 WONG Ge x ook ee RE E bo Ee eee X x45 a e ae me 43 4 AutoMove lab 0 ooo 4
81. osition in the pattern is calculated by simply adding the interval vectors proportionally The Line and Square patterns work similarly A counter variable is used while traversing the positions of the pattern The name of the variable can be seen on the Pattern Command screen The vari able cycles through the numbers from 0 to X x Y x Z 1 the number of points in the pattern This variable can be manipulated using assignments and can be used in expressions All Rights Reserved 84 UR5 4 4 Programming UNIVERSAL ROBOTS 4 4 23 Program Command Tab Force Force mode allows for compliance and forces in selectable axis in the robots workspace All robot movements under a Force command will be in Force mode When the robot is moving in force mode it is possible to select one or more axes in which the robot is compliant Along around compliant axes the robot will comply with the environment which means it will automatically adjust its position in order to achieve the desired force It is also is possible to make the robot itself apply a force to Its environment e g a workpiece Force mode is suited for applications where the actual tcp position along a predefined axis is not important but in stead a desired force along that axis is required For example if the robot tcp should roll against a curved surface or when pushing or pulling a workpiece Force mode also supports applying certain torques around predefined axes Note
82. otective equipment to make sure the robots stops in certain situations The safety interface is comprised of two parts the emergency stop interface and the safeguard stop interface further described in the following sections The table below summarizes their differences Emergency Stop Safeguard Stop Robot stops moving Initiations Manual Manual or automatic Program execution Stops Pauses Brakes Active Not active Motor power Off Limited Reset Manual Automatic or manual Use frequency Infrequent Every cycle to infrequent Requires re initialization Brake release only No EN IEC 60204 and NFPA 79 Stop category I stop category 2 Performance level ISO 13849 1 PLd ISO 13849 1 PLd 3 2 1 The Emergency Stop Interface Test Output A Test Output B Emergency Stop Output Connection 1 Emergency Stop Output Connection 2 Emergency Stop Output Connection 3 Emergency Stop Output Connection 4 Robot Emergency Stop Input A Positive External Emergency Stop Input A Positive The Emergency Stop interface has two inputs the Robot Emergency Stop input and the External Emergency Stop input Each input is doubled for redundancy due to the safety performance level d The Robot Emergency Stop interface will stop the robot and will set the Emer gency Stop output intended for use by safety equipment near the robot The External Emergency Stop will also stop the robot but will not affect the Emer genoy Stop output and is only intended
83. our supplier Never stick fingers behind the internal cover of the controller box The cover protects against high voltages High voltage can stil be present inside the controller box even though it is locked out 8 Care must be taken when installing interface ca bles to the robot I O Ihe metal plate in the bottom is intended for interface cables and connectors Remove the plate before arilling any holes Make sure that all shavings are removed before reinstalling the plate Remember to use correct gland sizes 29 URS UNIVERSAL ROBOTS 2 9 Mounting Instructions All Rights Reserved 26 UR5 Chapter 3 Electrical Interface 3 1 Introduction The robot is a machine that can be programmed to move a tool around in the robots workspace Often it is desired To coordinate robot motion with nearby machines or equipment on the tool Ihe most straightforward way to achieve this is often by using the electrical interface There are electrical input and output signals I Os inside the controller box and at the robot tool flange This chapter explains how to connect equipment to the I Os Some of the I Os inside the controller box are dedicated to the robot safety functionality and some are general purpose l Os for connecting with other machines and equipment The general purpose I Os can be manipulated directly on the I O tab in the user interface see section or by the robot programs In this chapter all unspecified voltage and cur
84. ove Cut Delete Suppress 41 gt lt gt Simulation Hii P gt E Speed J1eex Previous Next gt o Real Robot The program structure tab gives an opportunity for inserting moving copy ing and removing the various types of commands To insert new commands perform the following steps 1 Select an existing program command 2 Select whether the new command should be inserted above or below the selected command 3 Press the button for the command type you wish to insert For adjusting the details for the new command go to the Command Tab Commands can be moved cloned deleted using the buttons in the edit frame If a command has sub commands a triangle next to the command all sub commands are also moved cloned deleted Not all commands fit at all places in a program Waypoints must be under a Move command not necessarily directly under E1serf and Else commands are required to be after an r In general moving E1serf commands around can be messy Variables must be assigned values before being used 93 URS All Rights Reserved UNIVERSAL ROBOTS 4 4 Programming 4 4 29 Program Variables Tab File Program Installation z lt unnamed gt Command Graphics Structure Variables Init Variables Variables V Robot Program 9 V move var 1 2 9 Waypoint 9 V MoveJ 9 Waypoint o Variable Action eo Pallet eo Pattern 9 ee PalletSequence
85. ow level software limits the torque generated by the joints permitting only a small deviation from the expected torque 5 The software prevents program execution when the robot is mounted dif ferently than specified in the setup 6 The weight of the robot is less than 18kg 7 The robot shape is smooth to reduce pressure N m per force N 8 It is possible to move the joints of an unpowered robot See section l The fact that the robot is very safe opens the possibility of either saving the safety guards or using safety guards with a low performance level depending on the robot installation As a help for the integrator when he is conducting the risk assessment the robot has been third party certified by the Danish Tech nological Institute II Tl is a Notified Body under the Machinery Directive in EU This means that Tl has the highest authority within EU to certifying machines This third party certification can also be used when conducting risk assessment for installations within US The Il certification concludes that the UR robots cannot exceed a force of more than 150N The certification is performed in accordance with the international ISO 10218 standards and thereby also in accordance with the R15 06 2012 Find the certificate in the chapter A 1 5 Emergency stop To immediately abort all running programs and stop all robot movement press the EMERGENCY STOP button The emergency stop function is a separate circuit only
86. pendicular to the robot motion and in the x y plane of the selected feature This can be usefull when deburring along a complex path where a force is needed perpendicular to the ICP motion Note when the robot is not moving If force mode is entered with the robot standing still there will no compliant axes until the tcp speed is above zero If later on while still in force mode the robot is again standing still the task frame has the same orientation as the last time the tcp speed was larger than zero For the last three types the actual task frame can be viewed at runtime on the graphics tab 4 4 27 when the robot is operating in force mode Force value selection A force can be set for both compliant and non compliant axes but the effects are different e Compliant The robot will adjust its position to achieve the selected force e Non compliant The robot will follow its trajectory set by the program while accounting for an external force of the value set here For translational parameters the force is specified in Newtons N and for rota tional the torque is specified in Newton meters Nm Limits selection For all axes a limit can be set but these have different meaning corresponding to the axes being complian or non compliant e Compliant Ihe limit is the maximum speed the tcp is allowed to attain along about the axis Units are mm s and deg s e Non compliant The limit is the maximum deviation from the program tr
87. puts and outputs are pnp technology and constructed in compliance with IEC 61131 2 and EN 61131 2 24V and GND can be used as input for the I O module or output as a 24V power supply When the controller box is booting it checks if voltage is applied to the 24V connection from an external power supply and if not it automatically connects the internal 24V power supply All Rights Reserved 99 UR5 UNIVERSAL ROBOTS 3 3 Controller I O Electrical specifications of the internal power supply Internal 24V voltage tolerance 15 20 Current from internal 24V supply 1 2x A Overload protection 1 4 A External power supply voltage 10 30 V Note that the safeguard yellow 24V connections are sourced by the same internal 24V power supply as the 24V connections of the normal I O and that the maximum of 1 2 A is for both power sources together If the current load of the internal 24V power supply is exceeded an error message is printed on the log screen Ihe power supply will automatically try to recover after a few seconds 3 3 1 Digital Outputs Parameter a Current per output source current all outputs together Voltage drop when ON 5 2 Leakage current when OFF O 0 1 aA The outputs can be used to drive equipment directly e g pneumatic relays or they can be used for communication with other PLC systems The outputs are constructed in compliance with all three types of digital inputs defined in IEC 61
88. ransportation UNIVERSAL ROBOTS Features Besides moving through waypoints the program can send I O signals to other machines at certain points in the robot s path and perform commands like if then and loop based on variables and I O signals 2 1 3 Risk assessment A complete robot installation Robot system robot application robot inte gration is a machine Since the robot cannot operate without being installed and without having a specific tool it is not considered as a complete machine A risk assessment shall be performed during each installation of the robot see chapter 2 2 Transportation Transport the robot in the original packaging Save the packaging material in a dry place you may need fo pack down and move the robot later on Liff both tubes of the robot arm at the same time when moving it from the pack aging to the installation place Hold the robot in place until all mounting bolts are securely tightened at the base of the robot The controller box shall be lifted by the hanale WARNING 1 Make sure not to overload your back or other bodyparts when the equipment is liffed Use proper lifting equipment All regional and national guidelines for lifting shall be fol lowed Universal Robots cannot be held responsible for any damage caused by transportation of the equipment 2 Make sure to mount the robot according to the mounting instructions in section 2 3 Turning On and Off How to turn the diffe
89. rds For hazardous and complex robot installations it is recommended to follow the relevant guidelines of R15 06 2012 The integrator is always responsible for the following 1 Making a risk assessment of the complete robot installation Installing a lockout tagout function for the complete robot installation Writing a user manual for the customer and or operators Providing a warning for any foreseeable imaginable dangers O BR Ww N Installing the robot in accordance with the recommendations of the man ufacturer Knowing and applying all relevant national and regional requirements 1 4 Risk assessment One of the most important things that an integrator needs to do is to conduct a risk assessment A risk assessment is explained as below 1 A risk assessment is The overall process comprising a risk analysis and a risk evaluation 2 A risk analysis is Ihe combination of the specification of the limits of the machine hazards identification and defining likely severity of harm and probability of it oc currence This includes foreseeable misuse 3 A risk evaluation is The judgment on the basis of risk analysis of whether the risk reduction objectives have been achieved More guidance on risk assessment is found in the international standard ISO 12100 2010 and at http www osha gov Ihe risk assessment shall be docu mented for future reference Universal Robots has identified the potential significant ha
90. re is voltage between the POWER connection and the shield ground even when the load is turned off 3 4 2 Digital Inputs Logical low voltage Logical high voltage 5 5 m The digital inputs are implemented with weak pull down resistors This means that a floating input will always read low The digital inputs at the tool are imple mented in the same way as the digital inputs inside the controller box Using Digital Inputs POWER GRAY The above example shows how to connect a simple button or switch 3 4 3 Analog Inputs The analog inputs at the tool are very different from those inside the controller box The first thing to notice is that they are non differential which is a draw back compared to the analog inputs at the controller I O The second thing to notice is that the tool analog inputs have current mode functionality which is an advantage compared with the controller I O The analog inputs can be set to different input ranges which are implemented in different ways and therefore can have different offset and gain errors All Rights Reserved 42 UR5 3 4 Tool I O UNIVERSAL ROBOTS Parameter Input voltage in voltage mode 0 5 26 V Input voltage in current mode 0 5 5 0 V Input current in current mode 2 9 25 MA Input resistance range OV to 5V 29 KO Input resistance range OV to 10V 15 KO Input resistance range 4mA to 20mA 200 An important thing to realize is that any current chan
91. rent data are in DC For additional I O Modbus units can be added via the extra Ethernet con nector in The controller box 2 UNIVERSAL ROBOTS All Rights Reserved 3 1 Introduction DANGER 1 Never connect a safety interface to a PLC which is not a safety PLC with the correct safety level Failure to follow this warning could result in serious injury or death as the safety stop function could be overridden It is important to keep safety interface signals seperated from the normal I O interface signals 2 Every minus connection OV is referred to as GND and is connected to the shield of the robot and the con troller box All mentioned GND connections are only for powering and signaling For PE Protective Earth use the M sized screw connections marked with earth symbols inside the controller box Ihe grounding conductor shall have at least the current rating of the highest current in the system If FE Functional Earth is needed use one of the M3 screws close to the screw terminals 3 Make sure that the mounting instructions are fol lowed see section 2 5 4 Use original cables supplied with the robot only Do not use the robot for applications where the cables will be subjected tfo flexing Contact your supplier if longer or flexible cables are needed o Make sure that all equipment not rated for water exposure remains dry If water comes inside the product lockout and tagout all power and then contact
92. rent parts of the robot system on and off is described in the following subsections 2 3 1 Turning on the Controller Box The controller box is turned on by pressing the power button at the front side of the teach pendant When the controller box is turned on a lot of text will appear on the screen After about 20 seconds the Universal Robot s Logo will appear with the text Loading After around 40 seconds a few buttons appear on the screen and a popup will force the user to go to the initialization screen 2 3 2 Turning on the Robot The robot can be turned on if the controller box is turned on and if all emer gency stop buttons are not activated Turning the robot on is done at the ini tialization screen by touching the ON button at the screen and then pressing All Rights Reserved n UR5 UNIVERSAL ROBOTS 2 3 Turning On and Off Initialize Robot O Push Auto until all lights turn green Rotate joints individually if necessary On Robot Power D Robot Auto OK D Base Auto POWER OFF E J o Shoulder n ES Auto POWER OFF Elbow lt a E Auto POWER OFF Wrist 1 a gt Auto POWER OFF D Wrist 2 a E gt Auto POWER OFF a Wrist 3 Auto POWER OFF L Tool POWER OFF D ControlBox CONNECTING D s OK Figure 2 1 The initialization screen Start When a robot is started a noise can be heard as the br
93. rent value of the signal is shown For register signals the value is expressed as an unsigned integer For output signals the desired signal value can be set using the button Again for a register output the value to write to the unit must be supplied as an unsigned integer Signal connectivity status This icon shows whether the signal can be properly read written green or if the unit responds unexpected or is not reachable gray Show Advanced Options This check box shows hides the advanced options for each signal Advanced Options e Update Frequency This menu can be used to change the update fre quency of the signal This means the frequency with which requests are sent to the Modbus controller for either reading or writing the signal value e Slave Address This text field can be used to set a specific slave address for the requests corresponding to a specific signal The value must be in the range 0 255 both included and the default is 255 If you change this value It is recommended that you consult the manual of your Modbus devices to verify their functionality with a changed slave adaress 4 3 11 Features Customers that buy industrial robots generally want to be able to control or manipulate a robot and to program the robot relative to various objects and boundaries in the surroundings of the robot such as machines objects or blanks fixtures conveyers pallets or vision systems Traditionally this is done by defi
94. ress All Rights Reserved 4 4 4 3 Program gt Command lab Empty 4 4 4 Program gt Command lab Move 4 4 5 Program gt Command lab Fixed Waypoint Contents T 42 E 78 Contents Esp D D gt 4 4 27 Program gt Graphics Tab 4 28 Program Structure Tab 4 29 Program gt Variables Tab 4 30 Program gt Command lab Variables Initialization 4 5 1 Setup Screen 4 5 2 Setup Screen gt Initialize 4 5 3 setup Screen gt Language Select 45 4 Setup Screen gt Update 0 rns 4 5 5 Setup screen gt Password UNIVERSAL ROBOTS 4 5 6 Setup Screen gt Calibrate Touch Screen 00 4 5 7 Setup Screen gt Network 0 0 5 Warranties 5 1 Product Warranty a a a 5 2 Disclaimer 6 Applied standards 6 1 List ofusedstandards ns A Certifications All Rights Reserved URS UNIVERSAL ROBOTS Contents All Rights Reserved UR5 Chapter 1 Safety 1 1 Introduction This chapter gives a short introduction to the statutory requirements and impor tant information about the risk assessment followed by a section concerning emergency stop and emergency movement of the robot arm All mounting instructions in section 2 5 shall be followed Technical specifications of the elec trical safety interface including performance level and safety categories are found in section opecial attention shall be paid to the
95. s Reserved 46 UR5 4 1 Introduction UNIVERSAL ROBOTS 4 1 1 Welcome Screen PolyScope Robot User Interface O Please select RUN Program UNIVERSAL ROBOTS SETUP Robot About iohannis SHUT DOWN Robot After booting up the controller PC the welcome screen is shown The screen offers the following options e Run Program Choose a program to run This is the simplest way to op erate the robot buf requires a suitable program to have already been produced e Program Robot Change a program or create a new program e Setup Set passwords upgrade software via the Internet request support calibrate the touch screen efc e Shut Down Robot Shuts down the Controller PC and powers off the robot All Rights Reserved 4 UR5 UNIVERSAL ROBOTS 4 1 Introduction 4 1 2 Initialization Screen Initialize Robot O Push Auto until all lights turn green Rotate joints individually if necessary 9 On Robot Power Robot Auto oK Base m gt Auto POWER OFF D Shoulder 2 m Auto POWER OFF D Elbow da ED Auto POWER OFF D Wrist 1 a E gt Auto POWER OFF D Wrist 2 4 I E gt Auto POWER OFF Wrist 3 a m Auto POWER OFF D Tool POWER OFF A ControlBox CONNECTING D On this screen you control the initialization of the robot When turned on the robot needs to find the position
96. s at several different positions This can be useful for Action palletizing or similar operations A pallet operation consist of the c3 Wait following features o w i P A Program Sequence to be performed at several positions 9 V Folder The Pattern either given as a list or as a lattice amp An optional before start sequence that will be performed before the first position Halt An optional after end sequence that will be performed after the last Popup position Y Loop E ca El script var_1 1 1 P call SubProgram 1 9 Vir c 9 eo Pallet eo Pattern 9 eo PalletSequence 9 Approach 9 PatternPoint e Action Optional program sequences 4 Special program sequence before the first point EA p la Special program sequence after the last point gt kg m b al B Speed 1 00 Previous Next BP Real Robot A pallet operation can perform a sequence of motions in a set of places given as a pattern as described in section 4 4 22 At each of the positions in the pattern the sequence of motions will be run relative to the pattern position Programming a Pallet Operation The steps to go through are as follows 1 Define the pattern 2 Make a Palletsequence for picking up placing at each single point The sequence describes what should be done at each pattern position 3 Use the selector on the seque
97. s of each joint To get the joint positions the robot needs to move each joint WARNING 1 The force protection during initialization can be higher than 150N The maximum force is only reduced by torque limits in the joints Stay outside the robot workspace when the robot arm is moving Status LEDs The status LEDs give an indication of the joints running state e A bright red LED tells that the robot is currently in a stopped state where the reasons can be several e A bright yellow LED indicates that the joint is running but dosn t know its presents position and needs homing e Finally a green LED indicates that the joint is running correctly and is ready to execute All the LEDs have to be green in order for the robot to operate normally Manual motion By hand When the joints are Ready and the Teach button on the back of the screen is pressed the joint modes change fo Backdrive In this mode the joints will release the brakes when motion is detected Ihis way the robot can be moved out of a machine manually before being started up Ihe brakes will reactive as soon as the button is released again All Rights Reserved 48 UR5 4 2 On screen Editors UNIVERSAL ROBOTS Auto movement Auto Buttons Normally it is always advisable to use the auto buttons to move the individual joints until they reach a known state In order to operate the button you have to press on the Auto button and keep it pressed The
98. sired tool speed and tool acceleration specified in mm s and mm s respectively and also a feature The selected feature will de termine in which feature space the tool positions of the waypoints are rep resented in Of specific interest concerning feature spaces are variable features and variable waypoints Variable features can be used when the tool position of a waypoint need to be determined by the actual value of the variable feature when the robot program runs e moveP will move the tool linearly with constant speed with circular blends and is intended for some process operations like gluing or dispensing The All Rights Reserved UR5 UNIVERSAL ROBOTS 4 4 Programming size of the blend radius is per default a shared value between all the way point A smaller value will make the path turn sharper whereas a higher value will make the path smoother While the robot is moving through the waypoints with constant speed the robot cannot wait for either an I O op eration or an operator action Doing so will might stop the robots motion or cause a security stop Feature selection For MoveL and MowveP it is possible to select in which feature space the way points under the Move command should be represented when specifying these waypoints Ihis means that when setting a waypoint the program will remem ber the tool coordinates in the feature space of the selected feature Ihere are a few circumstances that need detailed explanatio
99. stallation Add unit Push this button To add a new modbus unit to the robot installation Delete unit Push this button to delete the modbus unit and all signals added to the unit Set unit IP Here the IP address of the modbus unit is shown Press the button to change it Add signal Push this button to add a signal to the robot installation which can be found on the corresponding modbus unit Delete signal Push this button to delete the modbus signal from the installation Set signal type Use this drop down menu to choose the signal type Available types are Digital input A digital input is a one bit quantity which is read from the modbus unit on the coil specified in the adaress field of the signal Function code 0x02 Read Discrete Inputs is used Digital output A digital output is a one bit quantity which can be set to either high or low according to the configuration of the corresponding modbus terminal Until the value of this output has been set by the user the value is read from the unit This means that function code 0x01 Read Coils is used until the output has been set and then when either the out put has been set by a robot program or by pressing the set signal value button the function code 0x05 Write Single Coil is used onwards Register input A register input is a 16 bit quantity read from the address specified in the adaress field The function code 0x04 Read Input Regis ters is used
100. stop function could be overridden All Rights Reserved 92 UR5 3 2 The Safety Interface UNIVERSAL ROBOTS The two emergency stop inputs EA EB and EEA EEB are potential free inputs conforming to IEC 60664 1 and EN 60664 1 pollution degree 2 overvoltage cat egory ll The emergency stop outputs EO T EO2 EO3 EO A are relay contacts conforming to IEC 60664 1 and EN 60664 1 pollution degree 2 over voltage category III 3 2 2 The Safeguard Interface Automatic continue after safeguard stop Reset safeguard stop The Safeguard Interface is used to pause the robot movement in a safe way The Safeguard Interface can be used for light guards door switches safety PLCs etc Resuming from a safeguard stop can be automatic or can be controlled by a pushbutton depending on the safeguard configuration If the Safeguard Interface is not used then enable automatic reset functionality as described in section 3 2 3 Connecting a door switch Connecting a door switch or something comparable is done as shown above Remember to use a reset button configuration if the robot should not start au tomatically when the door is closed again Connecting a light guard How to connect a light guard is shown above It is also possible to use a category ISO 13849 1 and EN 954 1 light guard if the risk assessment allows it When connecting a category 1 light guard use TA and SA and then connect TB and SB
101. such as All Rights Reserved 9 UR5 UNIVERSAL ROBOTS 4 4 Programming var p 0 5 0 0 0 0 3 14 0 0 0 0 The first three are x y z and the last three are the orientation given as a rotation vector given by the vector rxryrz The length of the axis is the angle to be rotated in radians and the vector itself gives the axis about which to rotate Ihe position is always given in relation to a ref erence frame or coordinate system defined by the selected feature The robot always moves linearly to a variable waypoint For example to move the robot 20mm along the z axis of the tool var l159L0 0 0402540 0590 Movel Waypoint 1 varibale position Use variable var 1 Feature Tool 4 4 9 Program Command Tab Wait File O Program Installation Move 1 0 Log E lt unnamed gt Command Graphics Structure Y Robot Program 9 V Move 9 Waypoint Wait LT en Please select what should trigger the robot s next action Waypo tion H 9 amp Pallet O No Wait tterr Bana g aa i O Wait 0 01 seconds ae 9 Approact 9 Patter t O Wait for Digital Input Di Input gt 0 y SB Act S i Wait for lt An Input M gt v 0 0 Volts 9 tack 9 ee Directi 9 Fror 9 ToPo PickSequer 9 Stack Act Wait 9 Waypo t c3 Wait 9 V Folder 4 gt O Simulation proa Speed 100 Previous Next O Real Robot
102. sult ing from manufacturing and or material faults within 12 months of entry into service maximum of 15 months from shipment Universal Robots shall provide the necessary spare parts while the user customer shall provide working hours to replace the spare parts either replace the part with another part reflecting the current state of the art or repair the said part This Warranty shall be in valid if the device defect is attributable to improper treatment and or failure to comply with information contained in the user guides This Warranty shall not apply to or extend to services performed by the authorized dealer or the customer themselves e g installation configuration software downloads Ihe purchase receipt together with the date of purchase shall be required as evi dence for invoking the Warranty Claims under the Warranty must be submitted within two months of the Warranty default becoming evident Ownership of de vices or components replaced by and returned to Universal Robots shall vest in Universal Robots Any other claims resulting out of or in connection with the device shall be excluded from this Warranty Nothing in this Warranty shall at tempt to limit or exclude a Customer s Statutory Rights nor the manufacturer s liability for death or personal injury resulting from its negligence The duration of the Warranty shall not be extended by services rendered under the terms of the Warranty Insofar as no Warranty default exists
103. t 2 5 3 Mounting the Tool The robot tool flange has four holes for attaching a tool to the robot A drawing of the tool flange is shown in figure 2 4 All Rights Reserved 2 UR5 UNIVERSAL ROBOTS 2 9 Mounting Instructions Surface on which the robot is fitted It should be flat within 0 05mm N N E gt C m l l l i Y A N N N 7 N N iN m od NS N ar Y 7 7 7 7 7 7 7 gt Y N N d bs u P d NE P s AA So 27 ee D d Cable exit quee D132 0 5 D149 N N N N ZN 7 N 7 7 7 7 pa M N L_ Figure 2 3 Holes for mounting the robot scale 1 1 Use 4 M8 bolts All mea surements are In mm All Rights Reserved 22 UR5 2 5 Mounting Instructions UNIVERSAL ROBOTS DANGER 1 Make sure the tool is properly and securely bolted in place 2 Make sure that the tool is constructed such that it cannot create a hazardous situation by dropping a part unexpectedly 2 5 4 Mounting the Controller Box The controller box can be hung on a wall or it can be placed on the ground A clearance of 50mm on each side allows for sufficient airflow DANGER cause death 2 5 5 Mounting the Screen The screen can be hung on a wall or on the controller box Extra fittings can be bought Make sure that no one can trip over the cable 2 5 6
104. t for less than or equal to Ihe keyboard symbol button in the top right of the screen switches to text editing of the expression All de fined variables can be found in the variable selector while the names of the input and output ports can be found in the Input and output selectors Some special functions are found in Function All Rights Reserved 50 UR5 4 3 Robot Control UNIVERSAL ROBOTS The expression is checked for grammatical errors when the ok button is pressed The Cancel button leaves the screen discarding all changes An expression can look like this digital in 1 True and analog in 0 0 95 4 3 Robot Control Use the play Pause Stop and Step buttons found at the bottom of the screen fto start and stop robot programs Also there is a speed slider which can slow down the speed of the program during verification of the robot program and movement DANGER 1 Make sure to stay outside the robot workspace when the Play button is pressed The movement you programmed may be different than expected 2 Make sure to stay outside the robot workspace when the Step button is pressed The function of the Step button can be difficult to understand Only use it when it is absolutely necessary 3 Make sure to always test your program by reducing the speed with the speed slider Logic programming errors made by the integrator
105. t gt Pi B P A Sub Program can hold program parts that are needed several places A oub Program can be a seperate file on the disk and can also be hidden to protect against accidental changes to the SubProgram Program Command Tab Call SubProgram File Program Installation Move 1 0 Log z lt unnamed gt Command Graphics Structure Variables co Direction i 9 FromPos isa Call Subroutine F de PickSequence 9 StackPos Choose which subroutine to call at this point at the program execution Action Wait SubProgram 1 le 9 Waypoint Wait 9 V Folder c Halt Popup 9 V Loop Bl script yar 1 714 P Call SubProgram 1 9 Vi cm n amp Event i Y Thread_1 9 V Force c subProgram Simulation o gt H Speed 100 Previous n Next gt o Real Robot A call to a sub program will run the program lines in the sub program and then return to the following line All Rights Reserved 80 UR5 4 4 Programming UNIVERSAL ROBOTS 4 4 17 Program Command Tab Assignment File Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure O AS o se Pattam e Source Expression x 9 co PalletSequence Assignment 9 Approach 9 PatternPoint Action Assigns the selected variable with the value of the expression Wa
106. tallation files along with the program The two buttons on the bottom of the screen are relevant when the TCP is changed e Change Motions recalculates all positions in the robot program to fit the new ICP This is relevant when the shape or size of the tools has been changed e Change Graphics redraws the graphics of the program to fit the new TCP This is relevant when the ICP has been changed without any physical changes to the tool 4 3 7 Installation Mounting File Program Installation Move I O Log TCP Position Specify Robot Mount and Angle Mounting I O Setup Modbus p Def Program vl Load Save 4 Features Rotate Robot Base Mounting 45 4 0 0 BP 45 Ll Here the mounting of the robot can be specified This serves two purposes 1 Making the robot look right on the screen 2 Telling the controller about the direction of gravity The controller uses an advanced dynamics model to give the robot smooth and precise motions and to make the robot hold itself when backdriven For this reason it is important that the mounting of the robot is set correctly Warning Failure to set the robot mounting correctly might result in frequent security stops and or a possibility that the robot will move when the teach button is pressed The default is that the robot is mounted on a flat table or floor in which case no change is neede
107. texts marked with warning symbols The following symbols are used throughout the manual and can be found on the product PPP PEE DANGER This indicates an imminently hazardous electrical situation which if not avoided could result in death or serious injury DANGER This indicates an imminently hazardous situation which if not avoided could result in death or serious injury WARNING This indicates a potentially hazardous electrical situation which if not avoided could result in injury or major dam age to the equipment WARNING This indicates a potentially hazardous situation which if not avoided could result in injury or major damage to the equipment WARNING This indicates a potentially hazardous hot surface which if touched could result in injury CAUTION This indicates a situation which if not avoided could result in damage to the equipment 7 UNIVERSAL ROBOTS 1 2 General warnings and cautions This chapter is intended for integrators with a technical understanding of me chanics and electronics The guidance provided in the manual assumes that the integrator is based in United States of America US and that the robot is to be installed within the US Contact your supplier if guidance for other countries Is needed The robot and the documentation are designed for industrial applications Do not use the robot for medical or terror purposes 1 2 General warnings and cautions This section
108. that if no obstacles are met in an axis where a non zero force is set the robot will try to accelerate along about that axis Although an axis has been selected to be compliant the robot program will still try to move the robot along around that axis However the force control assures that the robot will still approach the specified force WARNING 1 If the force function is used incorrectly it can produce a force of more than 150N The programmed force shall be taken into consideration during risk assessment File O Program Installation Move 1 0 Log E lt unnamed gt Command Graphics Structure Variables 9 V Folder Force Se Feature Base v Type Simple v Popup WV LOOD E script The program part under this force command X CMM LESIN will be run in force mode P In force mode the robot vv P Sik will be free in the direction pieno RR h E of the selected feature ings in 7 1 to apply the specified force 9 a2nd C rner a AA Use the test button below a3rd_Corner 24th Corner Force 0 0 N in combination with the teach button oS PalletSequance to test the force mode 9 Appr i 9 Patter Acti Wait Teach test o f t E Event Y Thread_1 9 V Force l Tri 4 Simulation di Ira P E Speed J100 E Previous Next gt O real Robot P Feature selection The Feature menu is used to select
109. tirely using the touch panel without typing in any cryptic commandas since tool motion is such an important part of a robot program a way of teaching the robot how to move is essential In Polyscope the motions of the tool are given using a series of waypoints Each waypoint is a point in the robot s workspace Waypoints A waypoint is a point in the workspace of the robot A waypoint can be given by moving the robot to a certain position or can be calculated by software The robot performs a task by moving through a sequence of waypoints Various options regarding how the robot moves between the waypoints can be given in the program Defining Waypoints Moving the Robot Ihe easiest way to define a waypoint is to move the robot to the desired position This can be done in two ways 1 By simply pulling the robot while pressing the Teach button on the screen see 4 3 1 2 By using the touch screen to drive the tool linearly or to drive each joint individually Blends Per default the robot stops at each waypoint By giving the robot free dom to decide how to move near the waypoint it is possible to drive through the desired path faster without stopping This freedom is given by setting a blend radius for the waypoint which means that once the robot comes within a cer tain distance of the waypoint the robot can decide to deviate from the path A blend radius of 5 10 cm usually gives good results All Rights Reserved 16 UR5 2 2 T
110. to move a tool and com municate with other machines using electrical signals Using our patented pro gramming interface PolyScope it is easy to program the robot to move the tool along a desired trajectory PolyScope is described in section 4 The reader of this manual is expected to be technically minded to be fa miliar with the basic general concepts of programming be able to connect a wire to a screw terminal and be able fo drill holes in a metal plate No special knowledge about robots in general or Universal Robots in particular is required The rest of this chapter is an appetizer for getting started with the robot 19 UNIVERSAL ROBOTS 2 1 Introduction 2 1 1 The Robot The robot itself is an arm composed of extruded aluminum tubes and joints The joints are named A Base B Shoulder C Elbow and D E F Wrist 1 2 3 The Base is where the robot is mounted and at the other end Wrist 3 the tool of the robot is attached By coordinating the motion of each of the joints the robot can move its tool around freely with the exception of the area directly above and directly below the robot and of course limited by the reach of the robot 850mm from the center of the base 2 1 2 Programs A program is a list of commands telling the robot what to do The user inter face PolyScope described later in this manual allows people with only little programming experience to program the robot For most tasks programming is done en
111. top and safeguard stop interfaces only 9 Make sure to use the correct installation sittings e g Robot mounting angle weight in TCP TCP offset Save and load the installations file along with the program 10 The teach function Impedance backdrive shall only be used in installations where the risk assessment allows it Tools and obstacles shall not have sharp edges or pinch points Make sure that all people have their heads and faces kept outside the reach of the robot 11 Ihe robot force limitation does not give protection against momentum Any collision will release high portions of kinetic energy which are significantly higher at high speeds and with high payloads Kinetic Energy Mass Speed 12 Combining different machines might increase haz ards or create new hazards Always make an overall risk assessment for the complete installation When differ ent safety and emergenoy stop performance levels are needed always choose the highest performance level Always read and understand the manuals for all equipment used in the installation 13 Never modify the robot A modification might create hazards that are unforeseen by the integrator All autho rized reassembling shall be done according to the newest version of all relevant service manuals UNIVERSAL ROBOTS DISCLAIMS ANY LIABILITY IF THE PRODUCT IS CHANGED OR MODIFIED IN ANY WAY 14 f the robot is purchased with an extra module e g euromap interface then lo
112. veL Or moveP there need to be a valid feature selected at that Move command in order for this button to be pressable Waypoint names Waypoint names can be changed Iwo waypoints with the same name is al ways the same waypoint Waypoints are numbered as they are specified All Rights Reserved 13 UR5 UNIVERSAL ROBOTS 4 4 Programming Blend radius If a blend radius is set the robot trajectory blends around the waypoint allowing the robot not to stop at the point Blends cannot overlap so it is not possible to set a blend radius that overlaps a blend radius for a previous or following waypont A stop point is a waypoint with a blend radius of 0 0mm Note on I O Timing If a waypoint is a stop point with an I O command as the next command the I O command is executed when the robot stops at the waypoint However if the waypoint has a blend radius the following I O command is executed when the robof enters the blend Example Starting point Program move WaypointStart Straight line segment Waypoint Waypoint if digital input 1 then x Waypoint a WaypointEnd a V 5 cm blend else WaypointEndZ Straight line segment endif This 15 where the input port is read Waypoint 2 10cm blend Ending point 2 Ending point A small example in which a robot program moves the tool from a starting posi tion fo one of two ending positions depending on the state of digital_input 1 Notice
113. with a wire Remember to use a reset button configuration so that the safeguard stop is latched All Rights Reserved 33 UR5 UNIVERSAL ROBOTS 3 2 The safety Interface Connecting a reset button How to connect a reset button is shown above It is not allowed to have a permanently pushed reset button If the reset button is stuck a safeguard stop Is generated and an error message will appear on the log screen 3 2 3 Automatic continue after safeguard stop The safeguard interface can reset itself when a safeguard stop event is gone How to enable automatic reset functionality is shown above This is also the recommended configuration if the safeguard interface is not used However it is not recommended to use automatic reset if a reset button configuration is possible Automatic reset is intended for special installations and installations with other machinery Electric Specifications lo understand the safeguard functionality a simplified internal schematics of the circuitry is Shown below Any failure in the safety system will lead to a safe stop of the robot and an error message on the log screen All Rights Reserved URS 3 3 Controller I O UNIVERSAL ROBOTS 24V Voltage tolerance 15 1 20 Current available from 24V supply 1 2 A Overload protection 1 4 A TA TB AT RT Voltage 10 5 12 125 V TA TB AT RT Current 120 mA TA TB AT RT Current protection 400 mA 3
114. your supplier 6 Care must be taken when installing interface ca bles to the robot I O Ihe metal plate in the bottom is intended for interface cables and connectors Remove the plate before drilling the holes Make sure that all shavings are removed before reinstalling the plate Remember to use correct gland sizes CAUTION 1 The robot has been tested according to international IEC standards for EMC ElectroMagnetic Compatibility Dis turbing signals with levels higher than those defined in the specific IEC standards can cause unexpected behavior of the robot Very high signal levels or excessive exposure can damage the robot permanently EMC problems are found to happen usually in welding processes and are normally prompted by error messages in the log Universal Robots cannot be held responsible for any damages caused by EMC problems 2 According international IEC standards for EMC ca bles going from the controller box to other machinery and factory equipment may not be longer than 30m unless extended tests are performed 28 URS 3 2 The Safety Interface UNIVERSAL ROBOTS 3 2 The Safety Interface A 2442344000 DO Ie DOS DOS DOS DS DOT 2d A ee ee e dw o a o A Ale Al AD l l Inside the controller box there is a panel of screw terminals The leftmost part in black above is the safety interface Ihe safety interface can be used to connect the robot to other machinery or pr
115. zards listed below as hazards which shall be considered by the integrator Note that other significant hazards might be present in a specific robot installation 1 Fingers caught between robot mounting flange and base joint 0 2 Fingers caught between the robot arm and robot wrist joint 4 3 Penetration of skin by sharp edges and sharp points on tool or tool con nector 4 Penetration of skin by sharp edges and sharp points on obstacles near the robot track All Rights Reserved VW UR5 UNIVERSAL ROBOTS 1 5 Emergency stop 9 Bruising due to stroke from the robot Sprain or bone fracture due to strokes between a heavy payload and a hard surface Items falling out of tool E g due to a poor grip or power interruption 8 Electrical shock or fire due to malfunction of power supplies if the mains connection is not protected by a main fuse a residual current device and a proper connection to earth 9 Mistakes due to different emergency stop bottons for different machines Use common emergency stop function as described in section 3 2 However the URS is a very safe robot due to the following reasons 1 Control system conforms to ISO 13849 performance level d 2 Ihe control system of the robot is redundant so that all dangerous failures forces the robot to enter a safe condition 3 High level software generates a protective stop if the robot hits something This stop force limit is lower than 150N 4 L

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