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COSIMIR Educational, User's Guide

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1. You can name the selected view assign a dwell time and a zoom time and change the point of view manually 17 a 8 Creating an Animation You can create an animation of your simulation with the help of the camera cruise function The animation is saved as an AVI file Trainees can use this file for their own presentation purposes or can submit it as the result of their project To create an animation of your simulation 1 Configure a camera cruise sequence and test it in combination with your simulation 2 Inorderto create an animation start simulation and recording of the camera cruise sequence with the second toolbar button shown in the screenshot on the left Festo Didactic GmbH amp Co KG e COSIMIR Educational 61 3 Working with COSIMIR 3 Recording is stopped by clicking the last toolbar button shown in the screenshot on the left 4 The animation can then be played back with the third button and stopped with the last button It is advisable to configure the recording after completion in order to optimise the animation file 21x Video Recording Every Picture C Each 25 Picture Recording Period Exactly one Cycle C Until Camera Cruise Stop Recording Area C Workcell Window COSIMIR Frame Window including Window Frame Play Back slower faster Compression Details regarding configuration are included in the COSIMIR help function under Advanced gt Camera cruise
2. Sequence Plan The robot s gripper is open 10 HOPEN 1 The robot moves the gripper to the gripping position with a PTP movement 20 MOV P2 The gripper is closed 30 HCLOSE 1 The robot moves the gripper to the intermediate position with a PTP movement 40 MOV P3 The gripper is opened 50 HOPEN 1 The robot executes linear travel back to a point above the intermediate position 60 MVS P3 40 2 second waiting period 70 DLY 2 The robot moves the gripper to the intermediate position linear travel 80 MVS P3 The gripper is closed 90 HCLOSE 1 100 MOV P4 40 110 MVS P4 120 HOPEN 1 130 MOV P1 140 END 70 Festo Didactic GmbH amp Co KG e COSIMIR Educational 4 Programming Note Add an empty line at the end of the program For assistance during programming execute a right click inside the programming window You are then provided with a list of the most important function calls and the corresponding function commands are edited in the programming window via mouse click Comprehensive structured documentation of all Melfa Basic IV programming commands can be accessed in the Robotics Assistant under Programming robots gt Robot programs gt Basic course Save your program after it has been completed Melfa Basic IV Project Before compiling your program for the first time you ll have to create a project The project includes all of the associated programs and their respective position lists Select the Project manag
3. 5S i Open RV 2AJ SST Model PickAndPlaceABB Open FESTO 49 3 Working with COSIMIR 3 1 The COSIMIR help function is subdivided into three parts COSIMIR Help e Online help for working with COSIMIR e The COSIMIR Robotics Assistant e COSIMIR Educational which provides a comprehensive library of predefined robotic workcells The menu bar The menu bar provides access to functions like those of a standard Internet browser You can scroll forwards and backwards You can display or hide the navigation bar You can select a home page as well as other options for Internet connections You can print out any selected topics that serve your needs e c gt A amp E Hide Back Forward Home Print Options Figure 3 2 The menu bar Additional index cards You also have the option of conveniently navigating within the COSIMIR help function using additional index cards including contents index search and favourites e The Contents index card displays the entire contents of the COSIMIR help function in an explorer layout which can be navigated just like the Microsoft explorer e The Index displays all of the keywords used by the entire help function by means of which information can also be accessed e The Search function facilitates full text retrieval using all of the terms that occur within the entire COSIMIR help function e You can create your own explorer structure for the COSIMIR help f
4. Figure 4 2 Teach panel with world coordinates The robot can be moved along the world coordinate axes and the gripper can be rotated around these axes by clicking the corresponding arrow buttons Further details are included in the COSIMIR help function under Operating gt How to gt How to move and position the robot in COSIMIR Select the Tool coordinates mode in the teach in window in order to move the robot within the tool coordinate system The tool coordinate system is the robot s basic coordinate system but the zero point has been shifted to the robot s TCP Festo Didactic GmbH amp Co KG e COSIMIR Educational 65 4 Programming DIXI n Close Hand C XYZ Jog C JOINT Jog V TOOL Jog Set XYZ Position Position List Current Position Pos List Jog Override 3 HE Ki C gt 42 Figure 4 3 Teach panel with tool coordinates 4 2 Example Programming a Workcell 66 As described above the robot can be moved along the tool coordinate axes and the gripper can be rotated around these axes by clicking the corresponding arrow buttons Note that the TCP remains unchanged How can this be double checked This example necessitates the creation of a program for the Mitsubishi RV 2AJ robot that solves the sample task posed in section 2 3 for the First Steps workcell Open the First Steps RV 2AJ workcell with the help of
5. 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 digital digital digital digital digital digital digital digital digital digital digital digital digital digital digital ooooocoooooooo Erkannt DarkPart Erkannt Forced value DistanzSensor ColorSensorAteripper Sensor4HoleInBottom O Festo Didactic GmbH amp Co KG e COSIMIR Educational You can now see that the input in question is allocated to input bit no 8 This overview is also included in the documentation for the workcell You would also like to know which input bit is allocated to the symbolic Part_AV input at the robot controller in the MPS RobotStation mod workcell Open the folder for the RV 2AJ object and select the inputs subfolder All input bits are then displayed in the right hand window 89 6 Modelling 6 4 Example Modelling in a Workcell Illumination Robot selection 90 In chapter 6 3 you learned how to change object properties enabling you to easily modify the workcell layout There are numerous other possibilities of remodelling your workcell in a sensible fashion in COSIMIR Educational You wish to change the illumination in the graphic representation Illumination consists of ambient light and up to 7 additional light sources Open the Illumination folder and select the Ambient light object Open the properties dialogue box from the context menu The int
6. Festo Didactic GmbH amp Co KG e COSIMIR Educational 3 Working with COSIMIR After starting COSIMIR Educational you can directly access the COSIMIR Assistant Ausblenden zuriek Siete Cmicken Opionen inixi Inet ios Suchen Fev E U CoStar ioni ai 1 I Mons Frons Net COSIMIR Educational Kramhow i deception 2 Components 7 VO Comacione i Prager 2 Programming RV 2 Programming V2 m Vode Pick And Piece A i MadelPiccnd Paco i3 Vode FESTO Lepora t Vode FESTO Linspone i Modal Patetascomaiy 1 Vos Labasiameton m Mode Packecing 15 Model Disassembly Voss DekTest db Made Misure i3 Model PressAutomaton i Vode FME Mechinedss ti QD Modal EP 3 sow Hoe 2 Descigron 21 0 Cornectone i3 Components ti Programming m Wes FabotStaon is e ves Fbotes eese ti VPS RabaPuncring a m Modal MPS Pebot sser is Wade Pte tl Mode Raed i3 Model TablsPaning E Vise Coreen jb Modal POBMountng i3 Vode PentSmulston i Component Figure 3 1 Graphic navigation in the library of workcells Festo Didactic GmbH amp Co KG e COSIMIR Educational Models The models of COSIMIR Educational Click on the picture or the model title to get help for the model Click on on Open to open the model in COSIMIR Special Note Model FirstSteps Open RV M1 Open RY 2AJ Model r NextSteps G Open RV M1
7. 90 180 RA pal2pos1 i Bei 236 5 139 5 2 90 180 R A palzpos2 Right Above 176 5 138 5 2 30 1B0 R A pa12pos3 355 0 1 0 S 0 sona init ok corel ne The Position list entry dialogue box can be accessed with the menu function Edit gt Properties Alt Enter Edit the displayed position data as follows Positions X Y Z 167 00 185 00 240 00 Orientation roll A P pitch B R 90 0 180 0 Move the robot to the new P2 position by double clicking the position list entry Close the gripper by clicking the Close gripper button in the teach in window Use the world coordinate system in order to position the robot such that the blue workpiece is set into the middle section of the first pallet The coordinate axes can be displayed for improved orientation Extras gt Coordinate systems gt Show world coordinate system Festo Didactic GmbH amp Co KG e COSIMIR Educational 4 Programming Gripper settings Figure 4 6 Gripper settings Three dimensional navigation Video help function The gripper settings dialogue box can be opened with the menu function Extras gt Settings gt Gripper IV Wamings at Releasing m Gripper Control at Teach In HcLose1 Cancel Help All outputs are included in the Teach in gripper control drop down list which are assigned to objects capable of executing gripping tasks This output is activated whe
8. e With the mouse e Inthe teach In window Click in close proximity to the gripper end point with the left mouse key A voxel pixel in 3D space is marked at the clicked point If you double Click the voxel the robot moves to the selected point if it lies within its working range The robot can be advanced in a much more targeted way with the universal teach panel The teach panel can be accessed via the Teach in function in the Extras menu F8 Select the Joint coordinates mode from the teach in window Festo Didactic GmbH amp Co KG e COSIMIR Educational 63 4 Programming Figure 4 1 Teach panel with joint coordinates 64 Select one of the robots six joints and click one of the corresponding arrow buttons The robot moves around the selected joint in the corresponding direction Speed can be selected with the override slider After clicking the Set Joint coordinates button a dialogue box appears to which joint coordinate values can be explicitly entered The robot s current position can be transferred to the respective position list by clicking the Current Position gt Pos List button The gripper can be closed by clicking the Close gripper button after which the button is renamed as Open gripper Select the World coordinates mode in the teach in window in order to move the robot within the Cartesian coordinate system Festo Didactic GmbH amp Co KG e COSIMIR Educational 4 Programming
9. as single place version C change components Select the second option in order to license a single workstation Proceed with installation as described above Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction After installation has been completed additional COSIMIR program components can be installed with the help of the Change components option License server If you want to licence a workstation via a licenser server carefully read the included network installation instructions first 1 6 When you access a model for the first time from the help function a Special Notes dialogue box appears for downloading files Notes on working with this dialogue box can be displayed by clicking the Special Note link in the model help window 2lolx E Ausblenden Zk Seeete _ Cnckan _ Opionen rhet index Suchen Favoriten FESTU 5 ri COSIMIR Educational SE inve Foseps Ney t A Desciptien 3 Components VO Comocion di Poor Models TI Programming Riti 2 Programming Ri 2 i Model Pick And Piace A 11 Modell Pidin Pler The models of COSIMIR Educational E Model FESTO Lineporto m Modell FESTO Lineport Click on the picture or the model title to get help for the model 1 Modal Pallet ssombiy Click 0 t the model in COSIMIR ial Note m Model LabAuomatian lick on on Open to open model in AIR Special Note iiem m Mode Descr db ose Dette Model i8 Model
10. gt Configuring camera cruise gt Settings dialogue box Video Further helpful support is provided by the Camera cruise video in the COSIMIR help function under Examples gt Operating 62 Festo Didactic GmbH amp Co KG e COSIMIR Educational 4 Programming 4 1 Teach In The following programming languages can be used in COSIMIR9 Educational for programming robots e Mitsubishi MELFA Basic IV robot programming language e Mitsubishi MRL robot programming language e Standardised industrial robot language IRL DIN 66312 We have proceeded as follows in creating sample programs for the models All Mitsubishi robots have been programmed using MELFA Basic IV as long as this language is supported by the respective controller MRL has been used for all other Mitsubishi robots Other types of robots have been programmed using IRL The Robot Programming section of the Robotics Assistant includes comprehensive information regarding the programming of robots Details regarding the programming languages are contained in the chapter entitled Programming Languages in the COSIMIR help function In order to create a robot program certain positions must be defined to which the robot travels under certain conditions Generally speaking a robot can be advanced with the help of a manually operated control panel in order to teach such positions COSIMIR provides users with two different methods for advancing the robot manually
11. Agree and then click the Next button 25 COSIMIR Educational Please selectthe group for which COSIMIR Educational is to be installed Now you are provided with the option of installing the software for a single currently logged on user only Festo Didactic GmbH amp Co KG e COSIMIR Educational 13 1 Introduction Please enter your individual product ID This dialogue box prompts you to enter your product ID The product ID is a 12 place character string which is printed on the back of the CD sleeve If the product ID is entered incorrectly a message appears prompting you to enter a valid product ID 14 Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction The installation program copies COSIMIR Educational in the following folder You can select the folder to which COSIMIR Educational will be installed in the Directory path dialogue box C Programs didactic CosimirEducationalGB appears automatically as a default directory path If you would like to install the software to another folder click the Browse button Festo Didactic GmbH amp Co KG e COSIMIR Educational 15 16 1 Introduction Note In any case you should select a folder that does not contain any other versions of COSIMIR OSIMIR Educational Select Program Manager Group Selectthe program group under which the COSIMIR Educational symbols s
12. PC based operating systems including Windows 959 and 989 as well as Windows NT 2000 and XP9 COSIMIR facilitates the planning of robotic workcells testing the reach ability of all required positions the development of robotics and control programs and layout optimisation All motion sequences and handling operations can be simulated in order to rule out the possibility of collision and to optimise cycle times Work cells can be created using library components such as machines robots tools assembly lines loaders and more with the help of COSIMIR model expansion modules You can also create your own workcell components and import part models and workpieces from other CAD systems such as AutoCAD Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction 1 2 We ve integrated a host of new workcells into COSIMIR Educational What s new e A simple introductory workcell with Mitsubishi RV M1 and RV 2A robots e Robotic workcells from the Basic Robotics workbook BP70 furnished to our initial robot customers for taking advantage of existing learning scenarios in COSIMIR Educational e All robotic workcells from our new version C of MPS Robot station Robot station with assembly Robot station with assembly and hydraulic punch including comprehensive documentation of the sample programs Control panels are also made available as highly realistic 3D objects e Festo handling sys
13. RT Key 1 Key 2 A plus sign between the names of the two keys means that both keys are activated simultaneously Key 1 Key 2 A minus sign between the names of the two keys means that they are activated one after the other R U D A M n Hat Minimum Configuration a a ES Processor Pentium II 300 MHz or higher RAM 128 MB Hard disk space 850 MB Operating system Windows 959 989 NT 20009 or XP Graphic card 3D acceleration and support for OpenGL 32 MB RAM ws 2 n u Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction 1 5 Installation Installation with online activation Recommended Configuration a ss Processor Pentium IV 1 GHz RAM 256 MB Hard disk space 650 MB Operating system Windows NT 2000 or XP Graphic card 3D acceleration and support for OpenGL 64 MB RAM Monitor 17 screen with resolution of 1024 x 768 pixels ACD and this user s guide are supplied with COSIMIR Educational The software can be installed in two different ways e Network installation e Installation with online activation Getting started e Switch on your PC and start Microsoft Windows e Insert the COSIMIR Educational CD ROM into the CD disk drive e Click Run in the start menu e Enter d s
14. You ll receive your enable code in return which must be entered to the appropriate field Click the Finish button in order to enable your license Multiple License If you ve purchased a multiple license each installation must be enabled separately Each time an installation is enabled a message appears indicating how many licenses can still be issued with the specified product ID Festo Didactic GmbH amp Co KG e COSIMIR Educational 25 1 Introduction Network installation Single workstation 26 Most importantly the term network installation makes reference to software licensing which is executed via a network from a central license server A green license dongle is required for network installation Licensing of the individual installations is executed dynamically and licenses can be requested from any workstation within the network until the ordered number of licenses has been allocated The license server is a PC within the network that executes the licensing procedure The license dongle must be plugged into the parallel port of the license server and must be accessible to all licensed workstations at all times Single workstations can also be licensed locally Start installation as described above and the following initial window appears COSIMIR Educational x Licensing Will you use network licensing recommended or do you want to work locally with a single licence Licensing via license server
15. contains a robot program in high level language using the native language of the respective robot The name ofthe associated object is specified in the header MITSU_RV_E2 C COSIMIR 5 ith i Ni Posion inten Position List 301 83 0 347 0 1142 1 160 2 MENSE Click the menu function File gt Open and select the desired file type i e PEN E ET POS for Mitsubishi robot or PSL for industrial robot language Alternatively create a new position list with the menu function File gt New and select the desired window type i e MRL position list Mitsubishi robot or position list The screenshot shown on the left contains a position list for a robot The name of the associated object is specified in the header 3 The New function in the File menu can also be accessed with the button shown in the screenshot on the left or with the Ctrl N key combination User Input Output The User Input Output window appears automatically if the robot program contains commands with which data can be read in or read out for example via the serial interface at the robot controller Due to the fact that the robot controller is only replicated in the simulation data are not transmitted via the serial interface but rather via the User Input Output window Festo Didactic GmbH amp Co KG e COSIMIR Educational 59 3 Working with COSIMIR ee rag 60 Camera Cruise Camera cr
16. model library dialogue box and select the RV 1A from the Mitsubishi robots folder Add this robot to the process model A dialogue box appears indicating that the operation cannot be undone Acknowledge with Yes The old robot is now replaced with the new one and all I O connections are updated as well Note The name of the robot listed in the model explorer remains unchanged RV 2AJ Don t forget that all teach in points must be updated Festo Didactic GmbH amp Co KG e COSIMIR Educational 91 6 Modelling Importing new components Task Solution Gripping point Solution 92 You want to set up a partition between the two pallets in the First Steps workcell in order to demonstrate a collision problem The model library does not include a partition but the Next Steps workcell does Open the Next Steps workcell with COSIMIR Industrial or COSIMIR Professional and select the Wall component in the model explorer from the workcell s object folder Save the object as wall mod via the context menu This file can now be imported to any workcell in COSIMIR Educational with the help of the menu function File gt Import Create a rectangular workpiece with a side length of 45 mm in COSIMIR Industrial or COSIMIR Professional Open the First Steps workcell in COSIMIR Educational and import the new component named Box4 Position the component at the centre of the table Teach the robot to grasp the new
17. of the metal coatings on the disks This task can be expanded with a requirement for calculating the Cartesian coordinates of the disks and corresponding organisation of generated workcell data into data structures as part of the programming Mitsubishi S7 A Mitsubishi RH 5AH55 SCARA robot communicates with a PLC in this workcell The robot must execute simple handling tasks based upon PLC commands The robot and the PLC are connected to one another via digital inputs and outputs to this end The sample program is written in Melfa Basic IV FMS MachineAssembly The FMS MaschineAssembly mod workcell simulates a Festo Didactic FMS system Four different processes can be executed Depending upon the process a given workpiece holder is fed to the workcell ona conveyor belt The workpiece holder must be added to the model by clicking the appropriate button The following points outline the most important new learning content included in this workcell e Accurate teach in of difficult to access positions e Collision free path planning in very tight spaces e Control of the functional units included in an EMCO CNC milling machine e Complex I O communication e Initialisation of robot subprograms based upon sensor detection of the type of workpiece fed to the system Festo Didactic GmbH amp Co KG e COSIMIR Educational 45 2 The COSIMIR Educational Concept PressAutomation RobWeld TablePainting 46 Press linking is accomplishe
18. the robot s controller is unable to understand this text which must be translated step by step into for example the Melfa Basic IV programming language 10 HOPEN 1 20 MOV P1 30 P1 gripping position etc Festo Didactic GmbH amp Co KG e COSIMIR Educational 37 2 The COSIMIR Educational Concept Downloading to the robot controller Simulation Collision detection 38 The sequence plan should be laid out such that each step can be implemented by means of a command or a subprogram At the same time the sequence plan provides you with ideal documentation of your program Details regarding Mitsubishi programming languages can be found in the Programming chapter included in the COSIMIR help function The program has now been created and must be downloaded to the robot controller This procedure can be replicated in COSIMIR Educational because the simulation includes a fully fledged robot controller The downloading procedure is completed in two steps e Compile the program i e the syntax of the programming language is checked and is translated into universal IRDATA machine code e The machine code is downloaded to the robot controller i e the code is linked to the controller Any errors that might occur are displayed The details for this procedure are presented in chapter 4 2 The program has now been downloaded without error to the robot controller Start the program and observe the 3D mo
19. workpiece to the first pallet The task in this case is to specify that these two objects will be examined for possible collision Use the menu function Extras gt Settings gt Collision detection to this end Click the Selection index card Festo Didactic GmbH amp Co KG e COSIMIR Educational 5 Simulation Collision Detection p 2 x Display Messages Selection Check Select all Deselect all Pallette1 Pallette Pallette2 Pallette RV 2AJ Selected objects against each other Table Table MODO pu C Selected objects against all Abbrechen Hilfe Figure 5 1 Object selection for collision detection The index card displays a list of all of the objects included in the workcell Box3 is the blue workpiece Select Box3 and Pallet1 Pallet as you would in the Windows explorer Select the Selected objects against each other option in order to determine whether or not the selected objects collide with each other dal Click the button shown in the toolbar screenshot on the left in order to i activate collision detection or select the Collision detection function in the Execute menu Start the simulation once again Notice that the blue workpiece turns red during transfer before it is set down onto the first pallet This indicates that a collision has occurred This collision persists because the workpiece is set down onto the pallet How can we eliminate this collision before the workpiece is set down Recom
20. 1 provides you with direct access to all applications The descriptions of each of the respective workcells can be opened by clicking the image of the appropriate models in the graphic navigator Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept E aio e gt A 8 B VET drhal Jes Suchen Esvorten lp LUSIMAO E Operating r SE deine Model Pick And Place ABB 8 Prearammirg E Extensions a amie 3 LI COMINO Assan i8 COSIMA Robots Assiri E AL COSMRe Educational Q Mode TE Model Picked Pcs E Model Patessonty 18 Model Labaztonahon E Model Packeaina IE Model Disassembly i5 b Model DiskTest 18 Model scarings E Model Pressdutomaton IE Model NS Machines E Model MPS Robothese Click on the picture to stert the video E Mock NPS AicbotHen E Model TatiePaning Model CaPanino Note is Model PCBMounting E Model onSimzion i Conponenti gt Open ABB Open FANUC mu e IEEE Open KUKA This description is equally valid for the models Pick And Place FANUC and Pick And Place KUKA Contents show tion of the workcell ections E Programming OoOo em amp al IGN Stan WF Micosi Word Leiiaden GBOCSIMIN Educaional COSIMIR Heip Corel PHOTO PAINT 8 BA zz Figure 2 1 Model description An animation is started by clicking the model image and the respective w
21. 160 0 O Ig Pos2 3 5 d0 0 50 0 sti EE Rd geli iste i i Status Bar __ N 000s 154431 Festd Didactic GmbH Copyright 1992 2000 B IRE GERMANY Mitsu bishi Adept Position List Position List Mitsubishi Program Adept Program Position List Current Position gt Pos List j Hep SE Stststop Contioles Controller Handing RP 3AH Soldering RP 3AH Programme COSIMIR GB Mo_ Eila E3 Second Workcell Wind ow 54 Festo Didactic GmbH amp Co KG e COSIMIR Educational 3 Working with COSIMIR 3 4 The most important window types used in the COSIMIR user interface Window Types are described below The Toolbar Additional tools can be selected for inclusion in the toolbar with the menu function Extras gt Settings gt Adjust We recommend the following tools in any case e Collision detection ok eden ee e Model explorer e Project management e Renumber amp sort The Workcell Window A graphic representation of the currently selected workcell is displayed in the workcell window Additional views can be opened in the workcell window with the menu function View New allowing you to observe different perspectives simultaneously The three dimensional representation of the workcell is dependent upon the selected point of view cal Click the button shown in the toolbar screenshot on the left Ctrl shift The mouse po
22. 32 40 49 50 51 54 55 63 63 66 74 76 77 77 77 80 80 81 Contents 6 1 6 2 6 3 6 4 Modelling Model Hierarchy Model Libraries Model Explorer Modelling in a Workcell 83 83 84 85 90 Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction Welcome to the new 4 1 release of COSIMIR Educational COSIMIR Educational provides you with a virtual learning environment in the field of robotics Step by step you ll be able to advance independently from very simple robotics applications right through to highly complex workcells in a highly realistic simulated 3D work environment The virtual learning environment consists of e Programming and simulation environment for predefined robotic workcells that represent typical industrial applications e The Robotics Assistant online tutorial offering comprehensive robotics knowledge via multimedia presentations The Robotics Assistant is not a CBT computer based training but rather a multimedia information system that provides teachers with support in designing courses of study and that can be used by trainees for autodidactic learning You decide yourself how you ll proceed with your course of study With its integrated library of workcells COSIMIR Educational provides you with an introduction to robotics covering various degrees of complexity The library of workcells encompasses innumerable examples of typical ind
23. 6 2 Object properties Changing object properties Solution General Position Dimension Visualization Aix Position Mi c00mm amp J z 292 Coordinate system World bd Increment 100 00 mm a Rotation Boll 0 0 Pitch 00 Yaw D 0 ES Coordinate system World Increment 10 0 zi The Cartesian coordinates of the zero point from the object coordinate system are displayed here as well as the orientation of the object relative to the world coordinate system roll rotation around the Z axis pitch rotation around the Y axis yaw rotation around the X axis We want to expand our sample task by requiring that the cell is changed such that the green workpiece is approximately at the centre of the table turned 45 relative to the world coordinate system 1 The display of Cartesian coordinates and orientation values in the Object properties dialogue box can be directly overwritten or you can change the displayed values using the arrow buttons in steps according to the selected increment The workpiece is immediately moved to its new position 2 Change the Y coordinate and the roll angle accordingly Festo Didactic GmbH amp Co KG e COSIMIR Educational 87 6 Modelling Note Library elements Video help function 1 0 connections 88 The Object properties dialogue box includes additional parameters that are contained in the General D
24. F University Dortmund Layout 18 06 2003 Beatrice Huber Festo Didactic GmbH amp Co KG 73770 Denkendorf Germany 2003 Internet www festo com didactic e mail did festo com The copying distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited Offenders will be held liable for the payment of damages All rights reserved in particular the right to carry out patent utility model or ornamental design registration Contents 1 1 1 2 1 3 1 4 1 5 1 6 2 1 2 2 2 3 2 4 3 1 3 2 3 3 3 4 4 1 4 2 4 3 4 4 5 1 5 2 5 3 5 4 5 5 Introduction The COSIMIR 3D Simulation System What s new Notation ON WW System Requirements Installation Special Notes The COSIMIR Educational Concept Didactic Concept Approach and Learning Goals Learning via Virtual Workcells The Workcells Working with COSIMIR COSIMIR Help The COSIMIR Assistant The COSIMIR User Interface Window Types Programming Teach In Example Programming a Workcell Automatic Trajectory Generation Download to the Mitsubishi Robot Controller Simulation Settings Example Workcell Simulation Sensor Simulation PLC Simulation Process Simulation Festo Didactic GmbH amp Co KG e COSIMIR Educational 11 27 29 29 30
25. FESTO COSIMIR Educational User s Guide d AE Ele Edt View Execute Estas Window Help osma Senee S AAAA eela AB a at a e Fi fem e Close Hand XY dog C JOINT Jog TOOL Jog Set XYZ Position Postion List REN EIE REM Program for pick and place example REM PickAndPlaceKUKA MOD The robot takes REM the crankshaft at the storage position REM and moves it to the stacking REM rrranesseseaeeniaeeaieeeaneeneeeninetaneo REM position above storage PTP NOV POvStor IKUKA REM position at storage linear No MVS PStor REM grip crankshaft HCLOSE 1 PStor 1145 7 159 0 357 3 180 0 _0 R A N C Position to d 130 REN position above storage linear POvStor 1145 7 159 0 557 3 180 0 O R A N C Position aboy PovStack 754 5 449 2 557 3 180 0 _0 R A N C Position aboy AV aS PvE EOE REM position above stacking linear PStack 754 5 449 2 357 3 180 0 O R A N C Position to 3160 mvs Povstack REM position at stacking linear 0 00s 22 54 37 Festo Didactic GmbH Copyright 1992 2000 EFR IRF GERMANY AStant 197 Microsott Word eltaden glf COSIMIR Educational COSIMIR Help fb Corel PHOTO PAINT 8 OH 254 536501 EN 06 2003 Order no 526501 Description Manual Designation D HB COSIMIR EDUNET EN Revision level 06 2003 Authors Ulrich Karras IR
26. Messages window If error messages appear the corresponding program line can be highlighted in the program window by double clicking the respective error message As a result of cause and effect it is entirely possible that a different line will be highlighted which appears underneath the actually faulty program line Festo Didactic GmbH amp Co KG e COSIMIR Educational 73 4 Programming If program syntax is error free you can start analysing the program sequence with the help of the simulation function 4 3 This advanced COSIMIR function for automatic surface oriented Automatic Path trajectory generation provides programmers of robots used for coating Generation and deburring tasks with support by automatically generating robot paths and the corresponding robot programs Time involved in offline robot programming can thus be minimised and process results can be optimised at the same time Atable must be painted by a robot in the Table Painting sample workcell You can create the required trajectories by means of suitable teach in positions or you can use the trajectory generating tool In this example Table must be selected from the object folder in the model explorer see also 6 3 after which trajectory generation is started with the menu function Execute Surface trajectories 74 Festo Didactic GmbH amp Co KG e COSIMIR Educational 4 Programming Surface oriented trajectory generation Figu
27. Mitsubish 87 FirstSte im Model PressAulomaton Firstoteps E Model FMS MochineAss st yess ara Open RV M1 Kaw How i Descipion 22 1 0 Cunnectone Open RV 2AJ i3 Components ti Programmes m PEAS ET podel MPS Babot ssembvste i MPS Roba ure px NextSteps 11 Model MPS SobutAsser Mosa MPS Arata i Mov Roll Open RV M1 Vode TatlsPaning Made Catania 1 Open RV 2AJ n Model PCBMountng m Model PientSimulzion Gi Components Festo Didactic GmbH amp Co KG e COSIMIR Educational 27 1 Introduction Winamp 28 Known conflicts with other programs As a standard function Winamp registers file types with the mod extension in a protected mode This makes it impossible to open models from the help function If Winamp has already been installed on your PC it must first be deinstalled and then reinstalled with a different option setting Click the Special Note link to this end A display appears which includes a further link Known Conflicts Click the Known Conflicts link for a complete description of the correct option settings required for Winamp Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept 2 1 COSIMIR Educational software is based upon the concept of an open Didactic Concept learning environment Open learning environment means e An open approach to learning characterised by constru
28. able for Fanuc S700 and Kuka KR125Z robots Please note that it is very easy to replace the robot included in the workcell with any other robot from the robot library see also chapter 6 4 The sample programs are written in IRL Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept PickandPlaceFesto Festo linear gantry FESTO Linear gantry with conveyor belt BP70 A similar handling task is implemented with this workcell using a Festo 2 axis pneumatic linear system This modelis also available with sensors that detect the objects to be handled The sample program is written in IRL The linear gantry in this workcell is equipped with a double gripper system It is thus capable of simultaneously removing two crankshafts from different workpiece holders and transferring them to different destinations The sample program is written in IRL This workcell additionally includes two conveyor belts Two crankshafts are removed from a container However the container is closed and the gantry system must wait until it has been opened The two crankshafts are then removed and each is transferred to a conveyor belt by means of which they are taken away This workcell is available with the Mitsubishi RV M1 robot as well as the RV 2A It additionally includes two workpiece holders one tool holder with tool a pallet with workpieces and a simulation box with 8 inputs and outputs A large number of
29. all of the many aspects of this technology Problems associated with drive technology accuracy and dynamics are not taken into consideration in the simulations For this reason we also offer the respective hardware environments for several of the workcells e BP70 e MPS RobotStation e MPS RobotAssemblyStation e MPS PunchingStation e FMS MachineAssembly e RobWeld Festo Didactic GmbH amp Co KG e COSIMIR Educational 31 2 The COSIMIR Educational Concept 2 3 Learning via Virtual Workcells 32 An ideal learning environment can be created with these workcells by fulfilling the following basic requirements e Atleast one real robotic workcell e One workstation learning station with a COSIMIR Industrial or COSIMIR Professional license e Each trainee has their own COSIMIR Educational license In this way each trainee has the opportunity of downloading their program to the robot controller at the real workcell and can start up and run their own solution to the specified problem at the actual system The virtual workcells create an experimental environment for trainees allowing them to experience and grasp the required basic knowledge At the same time they are a point of departure for the examination of new questions and problems i e for building upon existing knowledge The educational portion supplies you with descriptions of all of the robotic workcells and the graphic navigator see figure 2
30. ctivism i e various tools including basic knowledge a lexicon and simulations are made available which can be combined and utilised as desired in accordance with your own learning objectives This open concept has also been implemented in organising the basic knowledge The central topic is robotics which is why we call it the Robotics Assistant It s not laid out as a CBT or a WBT but rather as an interactive multimedia knowledge and information system The contents of the program are presented as individual information modules including e Texts concepts explanations regulations examples etc e Graphics e Videos and animations The information modules are interconnected by means of hyperlinks The Robotics Assistant provides you with various options for accessing information in a targeted fashion e Searches for keywords or topics e Tree structure navigator e List of selected topics Selected information can also be printed out at any time Festo Didactic GmbH amp Co KG e COSIMIR Educational 29 2 The COSIMIR Educational Concept 2 2 Approach and Learning Goals Target groups and prerequisites 30 Why have we selected this open concept for imparting knowledge e We do not perceive the acquisition of knowledge and information as an end unto itself but rather as a necessity for solving problems e The project task or the problem to be solved are at the heart of our concept resulting in the ne
31. d by means of two type KUKA KR 125 industrial robots and a simulated S7 PLC in the PressAutomation mod workcell In addition to communication with the PLC via digital inputs and outputs the work procedures of two robots must be synchronised as an additional challenge in this case The sample program is written in IRL This workcell simulates the actual Festo Didactic FMS welding station Welding is performed by a Kawasaki FSO3N robot The gripper system consists of a pneumatic 3 finger gripper and a welding torch which is connected to the robot flange via a collision shutdown device for safety reasons The task is to weld three raw metal components together into a cylinder housing This can be accomplished by means of spot welding or path welding The sample program is written in IRL and executes a spot welding sequence A glass shield for the prevention of electro ophthalmia must be brought into position during welding for safety reasons The welding torch must be cleaned after welding A robot must paint the surface of a table with the help of a spray gun in the TablePainting mod workcell This painting sequence can also be simulated see also chapter 5 5 As an initial exercise you should first test the painting sequence in teach in mode in order to gain a bit of experience with painting quality The tool for automatic trajectory generation can also be used in order to calculate the robot s paths for execution of the painting sequence see a
32. different tasks can thus be executed with the workcell e Handling task e Machining task e Palletising task The tasks section in our Basic Robotics workbook includes concrete task suggestions This was the first robotic workcell offered by Festo as part of the MPS product range Festo Didactic GmbH amp Co KG e COSIMIR Educational 41 2 The COSIMIR Educational Concept MPS RobotStation MPS RobotHandling MPS RobotAssembly 42 This workcell is a simulation of the new MPS Robot Station and is equipped with the RV 2AJ robot Geometric data are based upon a CAD import of the associated design engineering data The station performs the following task sequence e Determine the material characteristics of a workpiece held by the robot s gripper with the help of a sensor e Remove workpieces from the seat in a chute after a signal has been generated e Detect the position of workpieces and set them down correctly orientated at an assembly point e Sort workpieces into magazines according to material characteristics This is the standard MPS robotic workcell The sample program is written in Melfa Basic IV The MPS RobotHandling mod workcell is a simulation of the MPS Robot Handling Station from Festo Didactic It was the predecessor of the above described station Different types of housings must be sorted into magazines using this workcell The housings are either on a pallet or in a sto
33. e S7 controllers and the installed S7 programs can be accessed with the S7 Program Manager function in the Execute menu Presented in a clear cut tree structure the S7 program administration window displays the name and elucidates the structure of the PLC programs that have been installed to each of the controllers within the selected workcell Programs may consist of the following elements e Organisational modules e Function modules e Data modules e Functions e System functions The contents of each type of element can be displayed by double clicking the respective element Festo Didactic GmbH amp Co KG e COSIMIR Educational 5 Simulation 5 5 Process Simulation Your S7 programs can be displayed in the STL programming language All modules organisational modules function modules and functions are displayed in tabular form Modules that cannot be represented in STL syntax are excluded for example system functions and system function modules Further details are included in the COSIMIR help function under Programming gt S7 simulator Process simulations for coating and deburring operations make it possible for robotics programmers to optimise the manufacturing sequence at an early stage during program creation and at the same time qualitatively evaluate processing results This eliminates the necessity for time consuming testing of motion sequences with test objects and the expense of offline programming is minimi
34. eate a position list First delete the contents of the predefined MRL position list and save it under the following new name FirstStepsTest pos e Add the robot s initial position as the first entry to the position list Click the Current Position gt Pos List button in the teach in window to this end e The second position P2 is the gripping position for the blue workpiece A line in the position list is highlighted after clicking underneath the first position Click the Current Position gt Pos List button in the teach in window once again As an exercise position P2 will be edited manually Select position entry P2 to this end Festo Didactic GmbH amp Co KG e COSIMIR Educational 67 4 Programming Figure 4 5 Position list entry Tip 68 rs Stopp xe B xo Heb jajemjaej 5 ssaa zie Della alal sigla vo P Gr rrogramms neu cosieduc er Mods Firsfps Rad BETES oq operation aay _lojx os Hand Eom C JONT eo TOOL ea Seba Pasion Carian Posion Pas Lit E Hes nm E DE Nome EE dza Noo Postion Diiematen Common PI 297 0 185 0 2 90 190 R 8 box1 pera v fam a pam am Rua Bm ru 177 0 195 0 2 90 180 2 boss 256 5 120 5 2 90 100 R A pallpoel i 236 5 120 5 2 90 180 m A psilposz Configurer 176 5 120 5 2 90 180 r R_ palipos3 panels 296 5 139 5 2
35. ed to acquire new knowledge in order to solve the problem at hand e Acquiring knowledge and information with modern methods based on software technology is one of the central learning tasks in today s technological society A further didactic concept is the provision of virtual work environments in the form of simulated robotic workcells These are represented in 3 dimensions in order to create as realistic an image as possible e Options for experimenting with the workcells effectively place the trainee in a close relationship to the object under study Knowledge is tested and reinforced e Realistic experience provided by the workcell gives rise to a new quality of knowledge theoretical knowledge is transformed into practical application and skills e The workcells promote learning by discovery at different levels of difficulty it works it doesn t work it works more efficiently etc Robotics is a fascinating but at the same time highly complex and intricate technology We restrict ourselves here to the field of industrial robotic systems and the area of mobile robotics will not be addressed at all Our approach is aligned to vocational training in the following areas e Mechatronics e Various technical qualifications for metalworking and electrical engineering e Information technology Our approach is aligned to technical colleges and universities We also assume that you the trainee are familiar with the Windows PC
36. ement function in the Execute menu or click the button shown in the toolbar screenshot on the left The following project management configuration window appears Project Management Eil x Project Setinge for Project IRDATA Files System Files alel amp x va 19 Fiestocompie oa x FirstSteps RV 2AJ Management 1 Project s Source Files Description 5 MELFA BASIC IV Projects s 2AJMB4 MainProgr FirstSteps RV 2AJ f FirstSteps RV 2AJPOS Position List Properties Compile Mode Mein Program X Path fi Figure 4 7 Project management Festo Didactic GmbH amp Co KG e COSIMIR Educational 71 4 Programming Figure 4 8 Project entry 72 In order to create a new project select the MELFA BASIC IV projects entry and click Add project in the context menu 121x Suchen in GPogems o emam lea FirstSteps RV 2AJ PRJ fa NextSteps RV 2AJ PRJ Dateiname FirstStepsTest Offnen Dateityp Project Files PRU Abbrechen 4 Enter a project name and acknowledge your entry with the Open button Select the Files register card and click the button shown in the screenshot on the left You are then prompted to open the program file The project name then appears in the right hand portion of the project management window Click the empty entry at the bottom and the corresponding line is selected Now add the associated position li
37. ensity and colour of the light can be changed You wish to find out which light sources are turned on in the sample workcell and what effect they have on the workcell Select for example light source 1 with a left click The orientation of the light source is graphically represented in the workcell window by means of alight beam and the associated object properties window is opened Light sources can be turned on and off and their orientation intensity and colour can be changed You want to replace the robot in a given workcell with a different robot for example you would like to replace the RV 2AJ robot in the MPS9 Robot Station with the 6 axis Mitsubishi RV 1A robot Open the model explorer and select the name of the respective workcell RobotStation Open the properties dialogue box via the context menu and select the libraries index card Festo Didactic GmbH amp Co KG e COSIMIR Educational 6 Modelling General Display Grid Libraries Print Sensor simulation Elemente A Options for model libraries RI Display L Show picture of model Y es E Automatic functions S Attach gripper to active robot Yes Pal Exchange active robot Y es dfh Change es C No Figure 6 4 Work cell properties Select the Exchange active robot option A line appears at the bottom prompting you to acknowledge the change Select Yes and then close the dialogue box Now open the
38. environment Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept Trainees must be equipped with certain basic knowledge in order to get started in the field of robotics The Robotics Assistant provides comprehensive basic knowledge on the subject of industrial robots see chapter 2 1 above The Robotics Assistant makes it possible for the trainee to e Acquire basic knowledge independently and in a targeted fashion e Prepare for problem solving tasks e Retrieve and if necessary print out additional information during the problem solving stage We also provide teachers with the opportunity of using the Robotics Assistant as a multimedia supplement to their own course Thus COSIMIR Educational assists you in organising the basics for your projected learning approach in a highly flexible way right from the beginning of the introductory phase We recommend covering at least the following subjects with the Robotics Assistant for introductory courses e Definition of robots including characteristic values e Robot design with subchapters covering hardware different types of robots and work safety e Robot programming languages That which has been read or heard can then be subjected to practical testing analysed and implemented by the trainee in his work with the numerous virtual robotic workcells Of course we are aware of the fact that a virtual workcell is not capable of imparting
39. etup exe to the entry field in the dialogue box which then appears Acknowledge your entry by clicking the OK button e If your CD ROM disk drive has a designation other than d the letter d must be replaced with the appropriate designation The installation program s initial window appears Festo Didactic GmbH amp Co KG e COSIMIR Educational 11 1 Introduction 12 JSIMIR Educational Welcome Press the Next button to start the installation of COSIMIR Educational You can press the Cancel button if you do not want to install COSIMIR Educational now ca Follow the instructions that appear at the screen If you are uncertain about how you should answer any given question click either Back or Next 25 COSIMIR Educational End User License Agreement Please acceptthe license agreement below Software End User Contract INOTICE TO USER THIS IS A CONTRACT BY INDICATING YOUR ACCEPTANCE BELOW YOU ACCEPT ALL THE TERMS AND CONDITIONS OF THIS AGREEMENT This Festo AG amp Co Festo End User License Agreement accompanies a Festo software product and related explanatory written materials 4 Agree Disagree Beck Next gt Cancel Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction The Festo Didactic license agreement is displayed first You must accept the license agreement in order to continue installing the software Click
40. h functions Which workcell should you start with If you have no previous robotics knowledge we recommend beginning with the First Steps and Next Steps models In the First Steps workcell simple rectangular workpieces can be picked up from a table moved to a pallet and finally positioned on a second pallet A glass plate is located between the two pallets in the Next Steps workcell and an alternate position must thus be added to the pick amp place sequence in order to avoid possible collision Work cells with either the Mitsubishi RV 2A robot or the RV M1 predecessor model can be selected The RV 2AJ can be programmed with the modern high level Melfa Basic IV robot language whereas the simple command language Movemaster Command MRL must be used with the older RV M1 We only recommend the model with the RV M1 robot if your hardware environment also includes RV M1 robots Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept Three dimensional navigation Robot motion Before writing a robot program you must first learn to move the robot and actuate its gripper The robot can be moved within various coordinate systems e Joint coordinates e World coordinates e Tool coordinates The various coordinate systems can be visualised in the workcell window Robots can be set into motion with a so called teach panel A universal control module is also replicated in the simulat
41. hall be saved fFestoDidectic 0 Adaptec Autostart Christiani Demos COSIMIR Control COSIMIR Educational COSIMIR Industrial COSIMIR Professional COSIMIR Professional Trial Version CULT2 OyberLink PowerDVD Divx You are also provided with the option of selecting a program group to which the COSIMIR Educational icons can be saved Festo Didactic appears automatically as a default program group which you can of course rename if you wish Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction MIR Educational Start Installation The installation of COSIMIR Educational is prepared Click on Next to start the installation process Click on Back to go back to the installation information dialog You can press the Cancel button if you do not wantto install COSIMIR Educational now COSIMIR Educational is now ready to be installed Click the Next button in order to start installation Installing COSIMIR Welcome xj Welcome to COSIMIR Educational Setup program E This program will install COSIMIR Educational on your computer Itis strongly recommended that you exit all Windows programs before running this Setup Program Click Cancel to quit Setup and close any programs you have running Click Next to continue with the Setup program WARNING This program is protected by copyright law and international treaties Unauthorized reproduc
42. hrough the use of various cylinder housings red black and silver it is possible to assemble various cylinders with different piston diameters identified by the colours black and silver This workcell is a virtual representation of a combination including the three MPS stations Robot Assembly and Hydraulic Punch As before the Assembly station is controlled by a simulated S7 PLC or the robot controller The hydraulic punch is controlled by a simulated S7 PLC The hydraulic punch produces the cylinder caps in this combination station Blank caps are fed to the punch from a cap magazine The hole for the piston rod is then punched into the cylinder cap and the cap is set into a tray Festo Didactic GmbH amp Co KG e COSIMIR Educational 43 2 The COSIMIR Educational Concept PalletAssembly LabAutomation Packaging Disassembly 44 The PalletAssembly mod workcell includes a Mitsubishi RV 2AJ robot that has the task of filling a pallet with workpieces This is also a handling task but robot movements take place to calculated positions as well as to predefined positions in this case For this task it is also useful to introduce the programming of loops Feeding workpieces from a magazine necessitates additional I O interrogations The sample program is written in Melfa Basic IV Gripper changeover systems must be taken into consideration with the LabAutomation mod workcell It must be determined
43. imension Visualisation index cards etc Except for display colour it is not possible to change these additional object properties with COSIMIR Educational Objects in a workcell can also be grouped together as library elements The goal is to assure that the included objects are always arranged ina fixed geometric constellation in relation to one another Library elements are recognised by means of their designation Library elements always have two part names Library_name Object_name Example First Steps workcell Pallet1 Pallet Only the properties of the corresponding library element can be changed For example if you want to change the position of the first pallet you must click the Pallet1 object in the Library folder included in the tree structure and open the Properties dialogue box from the context menu A video entitled Working with Objects is included in the COSIMIR help function under Examples gt Operating which explains how to work with objects in the model explorer After clicking I O connections in the tree structure an overview of all input output assignments is displayed and the designation of the associated object is shown for each input and output Festo Didactic GmbH amp Co KG e COSIMIR Educational 6 Modelling Figure 6 3 List of I O connections Solution Model Explorer E sf Objects Inp i gt AssemblySocket Inactive 000 gd Chute aft ColorSens
44. imulated controller 0 signals are displayed in red and 1 signals in green If the input signal is forced this is indicated by the fact that the input value appears in angle brackets e g lt 1 gt If the input is linked to an output the input value appears in brackets e g 1 the same applies to output displays Controller Selection Select the menu function Execute gt Controller selection COSIMIR Educational includes workcells with several controllers for example one PLC and two robot controllers which work together simultaneously in the simulation mode However if a procedure is to be taught into a robot the teach panel must be first allocated to the desired robot This task is executed by the controller selection window It is used to display and select a master and to activate and or deactivate individual controllers The display of robot positions the display of inputs and outputs and teach in are only possible for the robot that has been selected as a master Festo Didactic GmbH amp Co KG e COSIMIR Educational 3 Working with COSIMIR Robot Program EN Click the menu function File gt Open and select the desired file type i e MBA Melfa Basic IV MRL Movemaster Command or IRL industrial robot language Or create a new program with the menu function File New and select the desired window type i e IRL program Movemaster Command program or MELFA BASIC IV program The screenshot shown on the left
45. inter appears in the form of this button and can then be used to enlarge or reduce the display by moving the mouse t Click the button shown in the toolbar screenshot on the left shift The mouse pointer appears in the form of this button and can then be used to move the display by moving the pointer along the coordinate axis l The display can be rotated around the individual coordinate axes with the help of this button Ctrl Festo Didactic GmbH amp Co KG e COSIMIR Educational 55 3 Working with COSIMIR E Joint Coordinates E3 Joint 0 0 Deg Joint2 0 0 Deg Joint3 110 0 Deg Joint4 0 0 Deg Joint5 75 0 Deg Joint amp 0 0 Deg S8 World Coordinates Pija E3 X Pos 371 mm Y Pos 0 0 mm Z Pos 542 0 mm Folk 90 0 Deg Pitch Yaw Right Above No Flip 56 You can also select various predefined standard views Use the menu function View gt Standard to this end A dialogue box appears which includes various options e Preset 0 e Front view V e Rear view U e Top view A e Left hand side view L e Right hand side view R The desired view appears after clicking one of the above options as long as the workcell window is open This can also be accomplished by simply activating the corresponding keyboard keys Joint Coordinates Press the F7 key or select the menu function Extras Robot position gt Show joint coordinates The Joint coordinates window displays the individual positions
46. ion by means of the teach in window and can also be used to move the robot For example attempt to move the robot by simply changing the axis coordinates such that it is able to securely grasp a workpiece with its gripper Three dimensional navigation within the workcell presents you with an additional problem The representation of the workcell changes depending upon the point of view e From the top left or top right e From the front or the back e From up close or far away At least two different views are required for trouble free three dimensional orientation With COSIMIR Educational the number of views is only limited by the performance characteristics of your PC You ll discover that it s quite advantageous to make use of motion within the other coordinate systems in order to grasp a workpiece On the other hand each movement executed by the robot is the result of coordinated motion of the individual joints These can be viewed in the status window for example in order to observe the means by which axes must be moved in order to advance the gripper along the X axis in the world coordinate system In order to execute the gripping operation the gripper must be appropriately oriented Consider whether or not restrictions would result in this area through the use of a 5 axis articulated robot Festo Didactic GmbH amp Co KG e COSIMIR Educational 35 2 The COSIMIR Educational Concept The position list The first r
47. lar the MPS RobotStation for getting started with this subject matter In this workcell the positions of objects are detected by the robot in an elementary way and are evaluated for further processing You can make use of a simulation box with 8 inputs and outputs that are connected to the robot s controller in the BP70 workcell The sequence in which the workcells are laid out is organised such that as a rule knowledge gained in working with previous workcells is very helpful in solving the problems posed by subsequent workcells However if the trainee has prepared himself adequately the workcells can be processed in any other desired order In any case before you begin work with any given workcell you should carefully examine the respective video animation as well as instructions regarding programming and I O connections and included component descriptions These robotic workcells have already been described in detail in chapter 2 3 They are available with RV 2AJ and RV M1 robots The sample programs for the RV 2AJ have been created with Melfa Basic IV and for the RV M1 with MRL The PickandPlaceABB mod workcell includes a very simple handling task with a type 2400 16 ABB robot which serves as a basis for all further tasks Simple examination of the working space can be executed with this workcell by repositioning the robot and the pick amp place library component For the purpose of introduction this workcell is also avail
48. lso chapter 4 3 The effects of the parameter settings must be determined in this case Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept CarPainting PCBMounting PlantSimulation The goal of the CarPainting mod workcell is to paint a car hood Due to the fact that the hood is a freeform surface it is very difficult to create a painting sequence without the help of automatic trajectory generation Nevertheless an attempt should be made to complete some of the calculations with the help of teach in points in order to gain a better understanding of the problem The PCBMounting mod workcell is highly demanding and is well suited for project work It simulates a PCB production line which consists of 6 work stations e Station for inserting ICs e Station for soldering ICs e Station with three robots which position the PCB holder e Station for assembling the PCB to the holder e Station for screwing the PCB to the holder The individual robot programs must be created Finally master controls must be developed which coordinate the individual actions The PlantSimulation mod workcell simulates an entire production facility that consists of several manufacturing cells e The AGV workcell includes an automated guided vehicle system AGVS that interconnects the individual manufacturing cells within the entire production facility The AGVS receives picking orders which it fulfils autonom
49. lutions during installation the position list and the programming window are empty but they are set up such that you can begin work The basic procedures for working with COSIMIR are described in the following pages Festo Didactic GmbH amp Co KG e COSIMIR Educational 53 3 Working with COSIMIR 3 3 The COSIMIR User Interface Workcell Window Menu Bar Bled Ele Edi View recue Erias Window Help Joint Coordinates World Coordinates Teach In Window tekae e epo s e n Tool Bar Programme COSIMIA GB Models PCEMounting Mode BI EI Joint Joint Joini2 Joint Join Pos TOOL 0 DEFIO Read DEFIO Gripper BIT 1 RESET Ready 50 RESET Gripper 60 SPEED 2000 70 ACL 0 05 Joint Z Controller C APR GRAMMESCI Inputs Outputs Controller Selection B e E elseje eaea rss ee el oord B ml xt og Opera olle Bilal x d pes CeeHend Doba e H n D C JOINT Jog TOOL Jog Set vz Position d Coo E x 0 0 mm lel Ea FUNCTION CheckStation IN BOOL Startel 80 OVRD 200 Check station 50 JOVRD 200 BEGIN 100 MOV P1 E IF Started TRUE THEN Fi IF Ready TRUE THEN o mam ee Mixed ue mui ontrolle Progra R GBSModels PCBMou_ S94 f No Position Orientation ontralle Progia eX CD DE posi 128 0 0 0 dp o 180 0 EE peus mess POS2 335 0 0 0 5 0 180 0 O I Posi 115 0 0 50 0 POSI 175 0 10 0 40 0
50. mended solution Replace line 40 with the following 40 MVS P2 30 41 MOV P3 30 42 MVS P3 For a more detailed visualisation of collision detection use your sample program in the slightly modified NextSteps RV 2AJ mod workcell and test for collisions with the glass plate Festo Didactic GmbH amp Co KG e COSIMIR Educational 79 5 Simulation Video help function 5 3 Sensor Simulation 5 4 PLC simulation 80 A video that demonstrates how to set up the collision detection function is included in the COSIMIR help function under Examples gt Operating The sensor simulation functions expand the capabilities of COSIMIR such that complete robotic workcells can be simulated Many of the sensors utilised in manufacturing automation can be realistically configured and simulated Visualisation of sensor measuring ranges which is not possible in real applications provides additional help in avoiding design errors during the planning stages Sensors are utilised in numerous workcells for example in the MPS Robot Station for detecting objects and materials The characteristics of these sensors can be analysed with the model explorer see also chapter 6 3 The COSIMIR S7 simulator interprets executable S7 programs Each workcell may include several stored program controllers Each PLC is controlled by an S7 program It is not possible to change the S7 program furnished with COSIMIR Educational An overview of th
51. n using the example provided in the chapter on programming 6 1 The following types of elements are included in the COSIMIR model Model Hierarchy hierarchy Objects Objects are at the top of the model hierarchy e Example A robot is an object Groups d Groups are assigned to objects Each group may enjoy a given degree of freedom and can thus be moved relative to the previous group e Example A robot joint is a group Components Components are assigned to groups and determine the graphic representation e Example Surfaces cuboids and polyhedrons are components Festo Didactic GmbH amp Co KG e COSIMIR Educational 83 6 Modelling gi L 6 2 Model Libraries Ed 84 Gripper Points A gripper point is assigned to a group included in the gripping object so that one object can grip another e Example A gripper point is located on the flange of a robot s sixth axis Gripping Points A gripping point is assigned to a group included in the object to be gripped so that one object can be gripped by another e Example A workpiece that is gripped has a gripping point COSIMIR includes comprehensive model libraries some of which are optional Objects or model components can be added to a workcell from these libraries Click the menu function Execute gt Model Libraries or the button shown in the toolbar screenshot on the left The following model libraries are available e ABB robots e Fa
52. n the right hand side of the window displays the elements included in the folder that has been selected in the tree structure Elements can be accessed by clicking the desired element in the tree structure if it appears there or in the element list Festo Didactic GmbH amp Co KG e COSIMIR Educational 85 6 Modelling Example Solution 86 An element selection context menu containing the most important commands can be displayed by double clicking an element or an element folder The Objects folder contains all of the workcells components We make reference to this folder name in the workcells function descriptions You want to determine the exact position of the green workpiece in the First Steps workcell expressed in world coordinates 1 Activate the editing mode using the Edit mode function in the Execute menu Ctrl E and open the model explorer Click the green workpiece The object is then selected and the associated object coordinate system is displayed The Objects file is selected in the tree structure as well as the appropriate component i e Box2 in the display window The desired allocation has now been established 2 Click the Box2 object in the tree structure and select Properties from the context menu The Object properties dialog box appears from which the Position index card must now be selected Festo Didactic GmbH amp Co KG e COSIMIR Educational 6 Modelling Figure
53. never you click the Close gripper button in the teach in window You can also choose to have possible warnings displayed for gripper operations It is helpful to open a second workcell window to facilitate three dimensional navigation see also 3 4 e After moving to the desired position has been successfully completed add this position to the position list as point P3 e P4isthe final position in the second pallet Videos entitled Teach In Position list and Working with Positions are included in the COSIMIR help function under Examples gt Operating which address the subjects of robot teach in procedures and working with the position list in the simulation Festo Didactic GmbH amp Co KG e COSIMIR Educational 69 4 Programming Creating the program Click into the programming window in order to activate it Delete its contents and save it as a Melfa Basic IV program under the name of the position list FirstStepsTest mb4 The names of the program and the associated position list must be identical The MELFA Basic IV programming language is a dialect of Basic and each program line must thus be numbered However numbering has been automated First create the program lines without any numbering Now click the button shown in the toolbar screenshot on the left Extras gt Settings gt Renumber Implement the sequence plan from chapter 2 3 step by step in order to create the program
54. nuc robots e KUKA robots e Mitsubishi robots e Reis robots e Staubli robots e Siemens S5 S7 SPC e Various grippers e Various basic forms e Various LEDs e Various materials e Various mechanisms e Various robots e Various sensors e Various controllers e Various textures Festo Didactic GmbH amp Co KG e COSIMIR Educational 6 Modelling 6 3 The Model Explorer db Figure 6 1 Model Explorer All of the elements included in a workcell can be accessed via the model explorer In addition to objects and their subordinate elements this also applies to materials libraries illumination settings and all I O connections The model explorer is opened by clicking the menu function Execute Model Explorer Ctrl T or the button shown in the toolbar screenshot on the left Model Explorer x A FirstSteps RY 2AJ E f Objects a Alas Ob Folder gf Box1 Inputs Folder fg Box2 outputs Folder B Box3 Base Section gf Gripper s Waist Section gf Pallette1 Pallette mn Seok H Pallette2 Palette Pitch Section et J Roll Section gf Table Table Templates E f Materials Libraries E Pallette1 E Pallette2 amp Table zs 1 0 Connections H Lighting 1 object selected di The model explorer window is subdivided into two sections A tree structure used for navigation appears in the left hand section including folders for the individual workcell elements The element list included i
55. o exitthis installation lt Back Cancel 19 1 Introduction A message appears indicating that COSIMIR Educational has been installed successfully Click the Finish button COSIMIR Educational was successtully installed Click Finish to leave the installation program Software installation has now been completed Now you ll need to decide whether you want to activate your license immediately or later 20 Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction Online activation Various options are available for enabling your license We recommend using the direct online activation option Indirect online activation can be executed from a separate PC or you can request your activation code on the phone However this telephone service is only available from Monday through Friday from 8 a m to 10 p m central European time If you decide to use the direct online activation option Activation You are prompted to establish a connection with the Internet after which your license is enabled automatically Festo Didactic GmbH amp Co KG e COSIMIR Educational 21 1 Introduction The following dialogue box appears if your PC is equipped with a firewall that prevents incoming communication via the Internet COSIMIR Activation Your activation key appears in the display shown above Select this number and copy it to the clipboard with the key combination Ct
56. obot program 36 Now that you ve brought the robot into a position from which it can grasp the workpiece with its gripper you can save this point to the position list The position list contains all of the points to which the robot must move directly for a given program as well as important ancillary points for moving along a path mid point diverging point etc Why is a position list so important One could argue that as long as the cell is known any desired point can be calculated Why then should the robot first move to certain teaching points The answer is quite simple As a rule industrial robots demonstrate very good repetition accuracy but their absolute positioning accuracy is entirely inadequate for most applications Further details are included in the Robotics Assistant One of the main tasks during commissioning of a robotics application is testing the position list i e positions established in the simulation are tested via the real system and are modified if necessary It is thus extremely important for trainees to become well acquainted with the teach in procedure in the simulation Each workcell has its own position list which you can take advantage of in order to reduce the time required for teaching in all of the positions As is also the case with the teach in procedure two different types of motion commands are also used for programming robot motion e Movement from a starting point to an end point which i
57. of each ofthe robot s joints Position is specified in degrees for rotary axes and in millimetres for linear axes The Set joint coordinates dialogue box can be accessed by double clicking this window World Coordinates Activate the shift F7 key combination or select the menu function Extras gt Robot position gt Show world coordinates The World coordinates window displays the position and orientation of the TCP tool centre point in world coordinates In addition to position and orientation the robot s configuration appears in the bottommost line in the window The Set world coordinates dialogue box can be accessed by double clicking this window Festo Didactic GmbH amp Co KG e COSIMIR Educational 3 Working with COSIMIR Set World Coordinates xj p Pasition Orientation x Roll 180 0 v 00 Pitch 700 zu 579 Yaw 3800 r Configuration ignore C Left C Below C Flip Right Above No Flip Cancel Help m ae Teach In Joint eh AC CN m Ed Activate the F8 key or select the menu function Extras Teach in In D f ee addition to the designations of the robot s joints the window that now ae 21 Postion Lit i H m pecemm appears includes two small buttons which can be used to advance the te robot s individual joints The performance of a real robot is simulated when these buttons are activated The robot is accelerated to the preset speed override if one
58. of these buttons is pressed and held The preset speed is then held constant and braking to a speed of 0 ensues when the button is released controlled by means of a acceleration ramp By clicking the corresponding option teach in can be performed using world coordinates or tool coordinates Further details are included in chapter 4 1 Festo Didactic GmbH amp Co KG e COSIMIR Educational 57 3 Working with COSIMIR MixerOn b PHReady 0 Wait 0 Next 0 Pipette0K 0 Kim I Outputs 3 Grasp Attach Pipette Mixer PH_Measure Flush si oooccocolsl IET See Master Steuerung Aktivit t Start Stop x ager FANUC LR 100 Be mitsu Rv E2 Be ADEPT 550 x 58 Display Coordinate Systems Various types of coordinates systems can be displayed for support Select the menu Extras gt Coordinate systems to this end Ctrl K e Show tool centre point The path of the TCP is recorded when this option is selected e Show world coordinate system coordinate axes are displayed in colour e Show basic coordinate system robot coordinate system e Show object coordinate system e Show gripping points Inputs Outputs Press the F9 key activate the Ctrl F9 key combination or select the menu function Extras gt Inputs outputs gt Show inputs or Show outputs The Inputs window shows which signals are being applied to the inputs of the s
59. older in the LED 0 object for the SimuBox A display appears in the right window indicating that the On input is connected to the OUTO output Click the On input and select the function Edit 2 Remove Connection in the context menu Connect the On input at LED 0 to the OUTO output at the robot controller Position the mouse pointer at the On input for LED O in the display window Press and hold the left mouse key Move the mouse pointer to the OUTO output at the robot controller in the navigation window of the model explorer and then release the key connect by means of drag and drop The connection to the selected output appears in the display window Festo Didactic GmbH amp Co KG e COSIMIR Educational 93 94 Festo Didactic GmbH amp Co KG e COSIMIR Educational
60. onstant is utilised to control the relationship between simulation time and real time Open the First Steps RV 2AJ workcell with the First Steps Test project from the proceeding chapter Start the simulation with the Start function in the Execute menu or click the button shown in the toolbar screenshot on the left The program is simulated step by step Simulation time is displayed in the Status line The program line that is currently being simulated is highlighted in the program window At first you can execute each program step individually with the help of the button shown in the toolbar screenshot on the left Festo Didactic GmbH amp Co KG e COSIMIR Educational 77 5 Simulation Collision detection Example 78 If you want to start a new simulation cycle it is advisable to return the robotic workcell to its initial position Use the menu function Edit gt Reset Workcell to this end Simulation serves to check your program for two important criteria e Is the functional sequence correct e Can run time be further optimised We ll concentrate here on the first question i e e Is the logical sequence correct e Are there any collisions You should be able to answer the first question on your own As regards collision detection you should first decide which components are to be examined for possible collisions Consider our sample program to this end The first critical point is certainly the transfer of the blue
61. or tripe Hg Deposit BoxStack g Deposit2 BoxStack gf Mandrel 5 gf Multigrip amp gf PlateRobot Accessc isi af PlateRobot Plate od ity 8 gh ts s inactive 011 ea g Inactive 012 sh inactive 013 inactive 014 4 AP FI Ready gt RobotStation Output Value E Objects ERRV 2AJ HCLOSE1 0 AssemblySocket E hColorsensorAt DarkPart 1 fg Chute fSwitch4RedPart NewRedPat O sf ColorSensoratcripper tInternaswitch Pressed 2 fh Deposit BoxStack Switch4BlackPart NewBlackPart O ah Depostt2 BoxStack E internalSwitch_1 Pressed 0 E E hSwitch4MetalPart NewMetalPart 0 ft Mandrel InternalSwitch_2 Pressed o amp gf Multigrip S iMultigrip IsClosed o gf PlateR obot Accessorie 3 Multigrip IsClosed o x PlateRobot Plate Multigrip Isclosed 0 Bg RV 2A3 Muttigrip IsClosed o aft SwitchesForNewParts Multigrip IsClosed 0 f TroleyRobot Troley 3 Multigrip IsClosed 0 gh Templates Multigrip IsClosed 0 1 YA Materias 4 Multigrip Isclosed 1 Multigrip Isclosed 1 ei Libraries A Sensor4Holetm Erkannt o DistanzSensor Erkannt o gh Forced valu 1 00 Replicator4PartAtEnd Switch4RedPart Replicator4PartAtEnd Switch4BlackPart Replicator4PartAtEnd SwitchaMetalPart SmallGrip CenterGrip Verticalarip BigGrip CenterBoxGrip CenterBoxGripLOWA BigGripLOW Deposit1 BoxStack Deposit2 BoxStack RV 2AJ RV 2AJ RV 2AJ index Type vae connected output from Object 000 dgtd O
62. orkcell is demonstrated by means of a simulation sequence The trainee is thus provided with visual support in addition to the workcell s function description The following additional information can be displayed e Learning objectives know how Here we ve listed the typical learning objectives that can be realised with the respective workcell as examples Of course it is also possible to establish additional objectives with the selected robotic workcell depending upon the specified tasks e Description of the workcell This section provides a function description of the workcell creating the basis for the generation of one s own tasks e Components of the workcell This section contains a brief technical documentation of the most significant components included in the respective workcell Festo Didactic GmbH amp Co KG e COSIMIR Educational 33 2 The COSIMIR Educational Concept Introductory workcell 34 e l Oconnections Here you ll find a commentated list of I O assignments for the robot controller as well as for the PLC if included e Programming The structure of the sample program is explained and helpful hyperlinks and tips are provided for program writing In addition to and independent of the included hyperlinks you can also access any explanations of terminology and basic theory which you deem necessary for your problem solving task at any time with the help of the assistant explorer or the index and searc
63. ously The workcell consists of the AGVS a robot and various workpiece carrier trays with sensors e The Workshop workcell consists of two Mitsubishi robots one of which is mounted to an additional linear axis The robots must execute simple handling tasks in a work order related fashion e The Storage workcell controls automated warehousing It is linked to the AGVS by means of a conveyor belt Festo Didactic GmbH amp Co KG e COSIMIR Educational 47 2 The COSIMIR Educational Concept The Production workcell consists of a robot an injection moulding machine a press a laser labelling unit and a conveyor belt which links it to the AGVS A ventilator fan base is produced in this workcell The ventilator fan base must be painted in the Paintshop workcell which consists of a robot a rotary table a gripper changeover module for grippers with various paint spray guns for different colours and a conveyor belt which links it to the AGVS The individual parts of the ventilator are then assembled in the Assembly workcell This workcell consists of two robots and a conveyor system The ventilator is inspected and packaged in the CheckPack workcell It consists of a robot packaging materials and a conveyor belt which links it to the AGVS The individual workcells are available as separate cell models so that each workcell can initially be processed alone Integration can then be accomplished in the form of a large project 48
64. presentation of strictly specified PLC functionality in several of the sample workcells You re not only able to modify the layout with the new COSIMIR Educational release you can also import new designs which have been created using COSIMIR Industrial or COSIMIR9 Professional However the import function does not support I O connections which must be set up manually after import Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction 1 3 Certain types of notation are used for texts key combinations Notation shortcuts and key sequences making it easier to locate and identify different types of information Text formats The following text formats are used Text Format Used for Ter Cr Tri Et Bold Names of commands menus and dialogue boxes Cursive Place holder text must be specified for elements using cursive formatting CAPITALS Acronyms folder names and file names lower case letters can also be used when entering these names Quotation marks Command options quotation marks are also used to highlight chapter titles included as references within body text Co n _c_rcrrsc ee Festo Didactic GmbH amp Co KG e COSIMIR Educational 9 1 Introduction Notation for key combinations shortcuts and key sequences 1 4 System Requirements 10 Key combinations shortcuts and key sequences are written as follows Notation Meaning TI Tr DELULL IO NUL L
65. rage bin If the robot is to remove a housing from a storage bin the housing has to be added first by means of the import function The sample program is written in Melfa Basic IV The MPS RobotAssembly mod workcell is a simulation of the MPS Robot Assembly station from Festo Didactic It is available with the 6 axis Mitsubishi RV E2 robot as well as the new 5 axis Mitsubishi RV 2A It is the task of the robot to completely assemble various cylinders from individual parts The appropriate cylinder housing must be fed to the robot to this end by importing the respective model from the Import folder The sample programs are written in Melfa Basic IV for the RV 2AJ and in MRL for the RV E2 Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept MPS RobotAssemblyStation MPS RobotPunchingStation This workcell is a simulation of a combination including the new MPS Robot and Assembly stations The combination replaces the above described assembly station The Assembly station is controlled by a simulated S7 PLC or by the robot controller A comprehensively documented sample program is available for both variants The programs are identical to the respective programs for the real robotic workcells The task consists of assembling model cylinders from the following components e Cylinder housing e Piston e Spring piston return spring e Cylinder cap T
66. re 4 10 Surface trajectory generation The dialogue box shown above is opened before automatic generation ofthe paths intermediate positions Additional parameters can be entered here in order to optimise the generating process A comprehensive representation of this method is included in the COSIMIR help function under Extensions gt Surface oriented trajectory generation In addition to this a video dealing with actual use of this method can be found under Examples gt Operating Festo Didactic GmbH amp Co KG e COSIMIR Educational 75 4 Programming 4 4 Download to the Mitsubishi Robot Controller Caution 76 All ofthe programs you create in the Movemaster Command or MELFA Basic IV languages can be downloaded to a Mitsubishi controller via COSIMIR Industrial or COSIMIR Professional Open a new project in COSIMIR to this end with the New project function in the File menu select the appropriate robot and set up the communications link Open your program and your position list and resave the files to COSIMIR Industrial or COSIMIR Professional Establish communication with the robot and download the robot program and the position list Execute the following tests before starting the program after it has been successfully downloaded e Are all teach in points correct e Have all inputs and outputs been correctly wired e Has the TCP been set correctly Festo Didactic GmbH amp Co KG e COSIMIR Educa
67. rl C and then paste it to the COSIMIR activation dialogue box with the key combination Ctrl V Click the Finish button in order to complete license enabling 22 Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction Indirect activation The following dialogue box appears if you select the indirect online activation option for inquiring at a separate PC Access the website at the specified web address from a separate PC The following display appears Deutsch English COSIMIR Educational _ atona Activation License key LC173 AMIT9 KA787 PPTOT CL183 R __ Generate activation code Copy the license key into the appropriate entry field and click the Generate enable code button Festo Didactic GmbH amp Co KG e COSIMIR Educational 23 1 Introduction The activation code appears Copy this code and enter it in the appropriate field at the PC to which the software has been installed Telephone inquiry If you decide to request your enable code on the phone COSIMIR Activation Call the phone number shown in the above dialogue box You ll be asked for the license key You may save the license key Click the Print Copy button Following options will be offered 24 Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction COSIMIR Activation Send to standard printer amp Open as textfile E Copy to clipboard Cancel
68. robot in your laboratory environment you can use the ABB Pick amp Place FANUC Pick amp Place and KUKA Pick amp Place models as alternative introductory workcells Robot systems from various manufacturers use different programming languages although there is a standardised universal robot programming language known as IRL industrial robot language We have selected the following didactic solution for COSIMIR Educational e We offer the Melfa Basic IV high level programming language or the simple MRL command language for all robotic workcells with Mitsubishi robots e Ifthe workcell does not include any Mitsubishi robots we offer the standardised IRL language Please note that the robots in these cells can also be programmed with Melfa Basic IV but not all of the language s attributes will be supported in this case Keep in mind that IRL is a significantly more complex language than Melfa Basic IV Details regarding IRL are included in the COSIMIR help function under Programming Festo Didactic GmbH amp Co KG e COSIMIR Educational 39 2 The COSIMIR Educational Concept Sensor technology 2 4 The Workcells FirstSteps NextSteps PickandPlaceABB mod 40 A robot can only be used flexibly if it is capable of communicating with its work environment The analysis of sensor signals is utilised to this end We have provided numerous workcells for this purpose We recommend the BP70 model and in particu
69. s known as point to point movement abbreviated PTP The actual path to the robot s end point is not defined because all axes travel to their end positions independent of one another e Movement of the robot to the end point via a predefined path for example along a straight line Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept Sample task The blue workpiece in the First Steps model must first be set onto the middle section of the first pallet After a waiting period of 2 seconds it must then be sorted into the bottom section of the second pallet Sequence plan First a sequence plan is created for the program 1 The robot s gripper is open 2 The robot moves the gripper to the gripping position blue workpiece with a PTP movement 3 The gripper is closed 4 The robot moves the gripper to the middle section of the first pallet with a PTP movement The gripper is opened The robot moves linearly back to a point above the first pallet 2 second waiting period The robot moves the gripper back to the middle section of the first pallet linear movement 9 The gripper is closed 10 The robot moves the gripper to a point above the final position with a PTP movement for safety reasons 11 The robot moves the gripper to the final position linear movement 12 The gripper is opened 13 The robot returns to its initial position with a PTP movement 14 End 99 SON Of course
70. sed while improving process results Process simulation is used for example in the Table Painting sample workcell In order to activate process simulation select the desired object from the model explorer see also chapter 6 3 and start simulation with the Process simulation function in the Execute menu Process Simulation x Paintgun Paintgun Process Simi x 4um Paintgun Paintgun Coating Volume 2 um min max 0 um Current color Figure 5 2 Process simulation settings Festo Didactic GmbH amp Co KG e COSIMIR Educational 81 5 Simulation Video help function 82 You are provided with the opportunity of configuring additional parameters for simulating the painting process The program can then be started and you can observe the painting process at the same time A video entitled Process Simulation is included in the COSIMIR help function under Examples gt Operating which provides you with application support Festo Didactic GmbH amp Co KG e COSIMIR Educational 6 Modelling Although new workcells cannot be saved to COSIMIR Educational you are provided with numerous modelling functions within the workcells that allow you to change layouts and to analyse alternatively configured problems Various tools are made available by COSIMIR for modelling robot controlled workcells for example model libraries and the model explorer We ll help you get acquainted with the modelling functio
71. st by selecting the MELFA BASIC IV position list POS file type in the file selection window Due to the fact that a multitasking system is utilised you ll have to establish which program is the main program In this example your program is of course the main program Select your program entry in the project management window to this end and select Main program from the Compiler mode properties drop down list Festo Didactic GmbH amp Co KG e COSIMIR Educational 4 Programming Figure 4 9 Creating a new project Caution Project Management 3 21x Project Settings for Project IRDATA Files System Files Ajaj ae x Rv E Files to compile nlx 4 s FirstSteps RV 2AJ Management 2 Project s Source Files Des amp 3 MELFA BASIC IV Projects MB4 Mai E FirstSteps RV 2AJ FistStepsTestPOS Position List E FirstStepsTest p Properties Compile Mode Main Program Path P Now activate your project Select your project entry and click Set as Active Project in the context menu Acknowledge your project entry by clicking the OK button You can now download your project to the internal robot controller Activate the program window and click the Compile amp link function in the Execute menu Ctrl F9 or click the button shown in the screenshot on the left Utilised program and system modules as well as the number of errors and warnings appear in the
72. started Acknowledge your setting with the OK button You can also select another directory path by clicking the Browse button and display it immediately using the Open file button or select it as a start up information file Now it s time to finally get started with a robotic workcell in COSIMIR You need only click the button shown in the screenshot on the left and the corresponding workcell model is opened in COSIMIR i Open EEEIEE osma eser epe a Aae elea le AE di ioi ke amp xz JOINT Jog TOOL Jog 501312 Posto Postion List 3 Cunerk Postion Fos Lit Heb grip crankshaft 1145 7 159 0 557 3 159 PStor 1145 357 3 180 ition above storage linear FOvStack Con 57 3 100 ico REN ce lie mms Porstack 170 REM position at stacking linear ition above stacking linear Stack 754 5 IT rm 7 Stopped 0 00s 22 5497 Festo Didactic GmbH Copyright 1982 2000 EFR IRF GERMANY MStont 7 Micrsoft Word Leiter E COSIMIR Educational L COSINIR Hep Corel PHOTO PAINT 8 BA zu Figure 3 5 Work cell in COSIMIR Educational 52 Festo Didactic GmbH amp Co KG e COSIMIR Educational 3 Working with COSIMIR The opened workcell includes a display of all of the windows that are required for solving the assigned problem If you chose not to install the so
73. tems e Robotic welding station which is also offered as part of our CIM FMS system Manual feeding of workpieces is accomplished by means of simple supplementary buttons It s no longer necessary to import workpieces as new models The following methodology has been utilised for the workcell sample programs e All sample programs for Mitsubishi robots use the Melfa Basic IV programming language if supported by the utilised controller Otherwise MRL is used Movemaster Command e All programs for workcells that do not include any Mitsubishi robots have been written in universal IRL industrial robot language However Mitsubishi s Melfa Basic IV programming language can also be used with these workcells although not all of the special Mitsubishi functions can be used in this case Festo Didactic GmbH amp Co KG e COSIMIR Educational 7 1 Introduction A graphic representation of the I O assignment list for the workcell s sensors actuators and the inputs and outputs at the robot controller can be additionally selected in the model explorer New connections can be established by means of drag and drop within this display Input and output statuses are displayed online by mean of colour codes in the simulation mode The integrated S5 soft PLC has been replaced with an S7 soft PLC Program modules can be displayed online in the STL mode and can be run in single step operation This provides for a much more clear cut re
74. the graphic navigator or open the FirstSteps RV 2AJ mod file directory path Models FirstSteps Model with the menu function File gt Open Festo Didactic GmbH amp Co KG e COSIMIR Educational 4 Programming Figure 4 4 FirstSteps RV 2AJ mod Sample task Creating a position list Extras Window Hop Djema sf ae a efile ts ta on GE neuscosledu en vods SFIrsESTepstModeliFrstsk PROGRAMME NEUNGOSI VELHEHHTHTUTT 110 pick boxes amp place pall R20 77447A ILII PIHLA 130 MOV P1 40 pickeplace boxl 140 wvs PL 150 BCLOSE 1 160 ony 0 5 170 mvs r1 40 100 100 MOV 24 40 190 MVS pd gon HOPEN 1 bin oy 0 5 Ez MWS 24 a0 230 MOV P2 40 pickeplace box an mvs 22 sa CLOSE 1 ben DLY 0 5 E70 mvs 2 40 280 mvs p5 40 on mvs PS 00 soren 1 jig DLY 0 5 20 mvs p5 40 1320 mov 2 40 pickaplace box SEES es ae Coat 227 0 225 0 2 39 180 a poor ki 177 0 2195 0 2 90 18 8 fox ESTEE paizpast palzoosd Stopped 000s 21 87 02 Festo Didactic GmbH amp Co KG Copyright C 1992 2003 EFR IBF GERMANY As a reminder the blue workpiece must first be set onto the middle section of the first pallet After a waiting period of 2 seconds it must then be sorted into the bottom section of the second pallet We ve already created the sequence plan in chapter 2 3 Now we ll need to cr
75. tion or distribution of this program or any partion of it may resultin severe civil and criminal penalties and will be prosecuted to the maximum extent possible under law The initial window for the COSIMIR Educational installation program appears Festo Didactic GmbH amp Co KG e COSIMIR Educational 17 1 Introduction 18 COSIMIR Educational can be installed along with two supplementary options which can be selected in the following dialogue box COSIMIR Educational Installation We recommend to use the default settings Click the Option button of COSIMIR Kernel Following dialog box will appear The examples include predefined robotic workcells with comprehensively described tasks Click the OK button You will be asked to confirm following selection Festo Didactic GmbH amp Co KG e COSIMIR Educational 1 Introduction Festo Didactic GmbH amp Co KG e COSIMIR Educational COSIMIR Educational Installation x Select Components Choose which components to install by checking the boxes below Press the Options buttons to select sub components Iv Solutions 11138k Disk Space Required 787238 k Disk Space Remaining 6225258 k lt Back Cancel The corresponding solutions can also be installed Installation Complete xj COSIMIR Educational has been successfully installed I Display README TXT Press the Finish button t
76. tion sequence You can select either the automatic mode or the single step mode and you re able to determine whether or not the sequence is executed in a logically and functionally correct fashion Ifthe sequence is error free you should then check to see if any undesired collisions occur The Next Steps model is used to illustrate this procedure which includes an additional glass plate between the two pallets Start collision detection see chapter 5 2 and then start the above described program If a collision occurs the robot s path must be suitably changed Check to see whether or not any other collisions might occur during the sequence Why for example does the Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept Flexibility in designing tasks The IRL programming language robot move to a point above the final position for safety reasons in the above represented sequence plan Check the other movements and gripping positions with this in mind Various problems can be posed for each of the workcells The layout of any given workcell can be readily changed with the help of the model explorer see chapter 6 3 for example the pallets or the workpieces in the First Steps model can be repositioned Can the tasks still be completed after repositioning Additional components can also be imported to the workcell see also chapter 6 4 If you use a Kuka an ABB or a Fanuc
77. tional 5 Simulation 5 1 Settings Simulation Cycle 0 150000 Controller Cycle 0 010000 5 Maximum Simulation Cycle 93 Realtime Compensation Parameter p Graphic s Update IV Only Simulation Cycle I Show End Positions VV Skip Waiting Time Model Update Simulation Cycle C Controller Cycle cot ne 5 2 Example Workcell Simulation r E The simulation of programs that have been written offline using COSIMIR is described in the following pages Use the menu function Execute gt Simulation for configuration Simulation The simulation rate determines how frequently the graphic representation is refreshed The motion display becomes smoother but also slower as the selected value for the simulation rate is reduced The control rate is used to calculate intermediate positions for robot controllers and serves as a cycle time for stored program controllers The control rate determines the various possible simulation rate settings If you have selected the Real time option the simulation rate is adjusted automatically In the event of inadequate PC performance characteristics a real time link may not be possible resulting in a continuous increase of the simulation rate This effect can be limited by specifying a Maximum simulation rate The Control parameters option is only available if the Real time checkbox has been activated This parameter establishes which c
78. uise can be activated or deactivated with the menu function Execute Camera cruise The first toolbar button shown in the screenshot on the left can be used to access this function as well When a simulation is started movement is initialised to the stored points of view one after the other Linear interpolation is utilised between the views assuring smooth motion from one to the next After clicking the menu function Extras gt Settings gt Camera cruise a dialogue box appears which allows you to store various views of your workcell window Step Description Hold Zoom 001 Cell 400s 500s a 002 Housing amp Pist 25 00s 5 00s Spring 22 00 s 0 00 s e004 Cap Pick 25 00s 0 00 s 0005 Cap Place 8 00 s 4008 006 Slide 3000s 000s Add Remove Properties p ag Options Cancel Help Select the desired point of view for your workcell window and click the Add button in order to add the current view to the list Existing views can also be removed from the list If you want to change the settings for a view select the respective view and click the Properties button Festo Didactic GmbH amp Co KG e COSIMIR Educational 3 Working with COSIMIR Camera Cruise Step 3 zx Description Spring Hold 22 5 Zoom 0 s Viewpoint Reference Point Clipping Planes x 395 MESS 405 Near 5 YE 198 EEG 285 Far 10000 Z 1007 Z 761 Rotation 0 Deg Adopt View conce Hep
79. unction with the Favourites index card 50 Festo Didactic GmbH amp Co KG e COSIMIR Educational 3 Working with COSIMIR Contents index Search Favorites COSIMIR amp Operating Extended Operating Modeling Programming e Extensions e Examples E CQ cosiMRe Assistant COSIMIR Robotics Assistant E QQ cosimir Educational Models E Components Figure 3 3 Help function index cards 3 2 The COSIMIR Assistant The COSIMIR Assistant provides you with an online learning environment for robotics applications in the field of automation technology The assistant is subdivided into two parts e The COSIMIR Robotics Assistant e COSIMIR Educational The educational part provides you with a description of all of the robotic workcells All applications can be accessed directly via the graphic navigator see also chapter 2 3 Startup Info Workcell x Filename C Programme_neu cosiedu_en BIN COSIMIREducational chm W Display Startup Info Open File OK Cancel Figure 3 4 Start up information dialogue box Festo Didactic GmbH amp Co KG e COSIMIR Educational 51 3 Working with COSIMIR The dialogue box is opened by clicking the Start up info function in the Help menu The graphic display of the robot model appears here under the directory path used during installation You can activate or deactivate the display of this file each time COSIMIR Educational is
80. ustrial robotic workcells including appropriate function descriptions and technical documentation A sample application is included for each workcell and instructions are provided for implementing each respective application You can decide whether or not you d like to install the sample solutions while installing the software Of course you ll also have the opportunity of developing and solving a host of other tasks for any or all of the predefined robotic workcells Festo Didactic GmbH amp Co KG e COSIMIR Educational 5 1 Introduction 1 1 The COSIMIR 3D simulation system The COSIMIR Educational leaning environment provides you with user help in a number of ways The COSIMIR online help function is based on the standard HTML Windows help format The Microsoft Internet explorer version 3 0 or higher is required in order to use the help function This new release incorporates many of the comments and suggestions we have received from COSIMIR Educational users In order to continue improving COSIMIR Educational we invite all future users to send us their comments suggestions and criticism as well We would also be happy to answer any questions that might arise regarding COSIMIR Educational Just send us an e mail at dka festo com You can also contact us by calling our telephone hotline should you experience problems while installing or using COSIMIR Educational COSIMIR is an industrial 3D simulation system for
81. whether or not a new TCP needs to be calculated Various tasks must be executed with the various gripper systems which have to be organised via I O communication It is useful to elucidate the use of subprograms and counters for the programming of this workcell 6 axis Mitsubishi RV E2 robots are used The sample program is written in MRL A SCARA robot equipped with a vacuum gripper is utilised in the Packaging mod workcell Beyond this a conveyor belt and the creation of additional packages must also be controlled Removing packages from the conveyor belt is controlled by means of I O communication The sample program is written in the standardised IRL robotics language The integrated programming assistant can be exploited which provides considerable help in creating an initial program The bolts must be removed from an automobile wheel using a Reis RV 16 robot in the Disassembly mod workcell An inductive sensor is used to determine whether or not the robot is using the right socket wrench to remove the bolts Programming must be written in IRL Knowledge of procedural and modular programming must be acquired Sensor interrogations must also be incorporated into the communications sequence in this workcell Festo Didactic GmbH amp Co KG e COSIMIR Educational 2 The COSIMIR Educational Concept Disktest Hard disks are tested at four different stations with the Disktest mod workcell The test stations perform a surface inspection
82. workpiece What happens Select the menu function Extras gt Settings gt Grip for troubleshooting assistance Then select the Gripper warnings option in the configuration window A warning now appears when the gripper is closed No object Why does this warning appear Compare the structure of the Box3 and Box4 workpieces in the model explorer As you can see Box4 does not have a gripping point which means that the gripper does not recognise it as a graspable object Festo Didactic GmbH amp Co KG e COSIMIR Educational Creating I O connections Task Solution Proceed as follows in order to create a gripping point 1 Select the Basic subfolder for the Box4 object 2 Select New and Gripping point from the context menu 3 A gripping point appears in the right hand window 4 Select the gripping point and open the properties dialogue box from the context menu 5 Select the object coordinate system and position the gripping point at the centre of the workpiece 6 Agripping point range can then be created in the General index card In addition to this you can import any of the workcells and elements included in the model library However you must keep in mind that existing I O connections are not imported You ll have to set up the I O connections again after import This process can be easily elucidated Open the BP70 workcell and the model explorer Select the SimuBox object and the inputs subf

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