Automation and Robotics

Servo Robot System Model 5250

Printed in Canada

User Guide 34175-E0

|3034175E00511`~

AB

AUTOMATION AND ROBOTICS

SERVO ROBOT SYSTEM MODEL 5250

by the Staff of Lab-Volt Ltd.

Copyright 2004 Lab-Volt Ltd . All rights reserved. No part of this publication may be reproduced, in any form or by any means, without the prior written permission of Lab-Volt Ltd.

Legal Deposit Second Trimester 2004

ISBN 2-89289-712-2 SECOND EDITION, MAY 2004

Printed in Canada November 2005

Foreword
The Lab-Volt Servo Robot System, Models 5200 and 5250, provide complete and affordable training in the programming and operation of industrial style robots. Through the curriculum and hands-on experience gained in working with the Servo Robot System, you will learn to create automated work cells ideal for Flexible Manufacturing Systems (FMS) and Computer-Integrated Manufacturing (CIM). Safety is an important issue, especially in a real working environment. Before you connect and use the training system, it is important for you to read this manual. We hope that your learning experience with the Servo Robot System will be the first step of a successful career in robotics.

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Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI Section 1 Overview of the Servo Robot System . . . . . . . . . . . . . . . . . . . . 1-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Servo Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Robot Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Hand-Held Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 Emergency Stop Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 External Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Section 2 Installation and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Space Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Section 3 Hand-Held Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wrist R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wrist P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Save Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TTL Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TTL Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CNC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CNC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Save Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x Clears all points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C Deletes the point beside the cursor . . . . . . . . . . . . . . 6 Moves the point beside the cursor over the preceding point . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Moves the point beside the cursor under the next point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2 3-2 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-4 3-4 3-4 3-4 3-4 3-4 3-4 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-6 3-6

Table of Contents (contd)

Task Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Run Once . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Run Forever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Trace Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Clear Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 File Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Save to Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Load from Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Set Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Clr Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Hard Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Free Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Torque Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Hardware Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Soft Limits OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Soft Limits ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Ch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Ch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Key Click . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Save Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Teach Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Gripper Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Gripper Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Wrist CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Wrist CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Wrist Pitch Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Wrist Pitch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Elbow Pitch Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Elbow Pitch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Shldr Pitch Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Shldr Pitch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Base CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Base CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Ch 1 Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Ch 1 Backward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Ch 2 Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Ch 2 Backward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 TTL Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 TTL Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 CNC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 CNC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Save ABS Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Save REL Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Save Control (point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
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Table of Contents (contd)

Resuming the Servo Robot System after an Emergency Stop . . 3-15 Section 4 Robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Computer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Familiarization with Robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Menu Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Save As . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Revert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Print Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Undo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Redo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Duplicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Select All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Find Next . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Go to Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Go to Bookmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Set Bookmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Run Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Set Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Clear Soft Home . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Free Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Torque Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Hard Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Download From . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Task Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Point Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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Table of Contents (contd)

Upload to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . New Task Editor . . . . . . . . . . . . . . . . . . . . . . . . Point Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Release Emergency Stop . . . . . . . . . . . . . . . . . . . . Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . File Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CNC Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tile Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tile Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Close All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimize All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restore All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . Point Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Active Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Context-Sensitive Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . In the Robot Section of the Point Editor in Teach Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . In the Point list Section of the Point Editor and Task Editor Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . In the Left Column of the Task Editor Window . . . . . . . Programming Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point-to-Point Programming . . . . . . . . . . . . . . . . . . . . . Task Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copying Points from the Point Editor into the Task Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copying Points from the Robot Controller Memory into the Task Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Task Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Running a Task Program Editing a Task Program . . . . . . . . . . . . . . . . . . . . . . . . . Annotating a Task Program . . . . . . . . . . . . . . . . . . . . . . Deleting Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4-10 4-10 4-11 4-11 4-11 4-11 4-12 4-13 4-14 4-15 4-15 4-15 4-15 4-15 4-15 4-15 4-16 4-17 4-22 4-22 4-22 4-22 4-22 4-23 4-24 4-24 4-24 4-25 4-26 4-27 4-27 4-27 4-27 4-28 4-28 4-28 4-29 4-29 4-29

Section 5 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Section 6 Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
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Table of Contents (contd)

Appendices A B C D E F G H I Hand-Held Terminal Menus Robotics Menus Task Commands Rotary Carousel, Model 5208 Belt Conveyor, Model 5210 Gravity Feeders, Models 5119 and 5121 Pneumatic Feeders, Models 5122 and 5142 Linear Slide, Model 5209 Error Codes of Firmware 5250

IX

Introduction
This user guide is designed to provide all the information required to install and use the Lab-Volt Servo Robot System. It is intended for students, instructors, and the personnel in charge of the laboratory equipment. The user guide is divided into five sections. Section 1 is an overview of the Servo Robot System, Section 2 explains how to install and connect the equipment, Section 3 explains how to use the Hand-Held Terminal, Section 4 explains how to install and use Robotics to operate the training system, and Section 5 describes the care and maintenance required by the Servo Robot. The appendices show the various menus with their shortcuts, describe the task commands, and explain how to connect and use the optional devices.

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XII

Section Overview of the Servo Robot System

Description The Lab-Volt Servo Robot System consists of the Servo Robot, Robot Controller, Hand-Held Terminal, Grids, Work Surfaces, Emergency Stop module, Robotics to control the Servo Robot from a host computer, and all the accessories required to perform the hands-on exercises of the student manual. These components are shown in Figure 1-1.

Servo Robot The overall mechanical layout of the Servo Robot is shown in Figures 1-2 and 1-3. The base supports the arm mechanisms. It houses the motor that provides shoulder rotation. The shoulder rotates on the base. It houses the motors associated with the gears and belts that move the other sections of the arm. The lower end of the upper arm carries the gears and pulleys that drive the forearm, wrist, and gripper. One end of the forearm is attached to the upper arm and the other end is attached to the wrist. The upper arm and forearm have up and down motions. The wrist and gripper work together to pick up parts and move them to the required locations. The wrist moves up and down to control the two-finger gripper. It can also rotate in a 360-degrees clockwise or counterclockwise direction. The fingers of the gripper move in an open and close motion. A servo motor turns a shaft that is attached to a worm gear. The worm gear then drives two spur gears. The fingers are joined to the spur gears and as the gears rotate, the fingers open or close. The operation of the Servo Robot, also called manipulator or manipulator-arm robot, is controlled using the Hand-Held Terminal or the Robotics software via the Robot Controller. The term Servo Robot comes from the type of motors used by the robot: servo motors. The servo motors of the Servo Robot have a device called an Optical Encoder that provides feedback to the Robot Controller.

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Overview of the Servo Robot System

MOUNTING BASE SERVO ROBOT

ROBOT CONTROLLER

METALLIC CAN

FILM CANISTERS

WORK SUFACE p/n 6309

GRID SHEET

CABLE p/n 95028

EMERGENCY STOP MODULE

CABLE p/n 95921

HAND-HELD TERMINAL

CABLE p/n 93017

CABLE p/n 95922

CABLE p/n 93236

CABLE p/n 95451

Figure 1-1. Main components of the Servo Robot System.

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Overview of the Servo Robot System

GRIPPER

FOREARM

ELBOW WRIST

UPPER ARM

SHOULDER

BASE

Figure 1-2. Mechanical layout of the Servo Robot (View A).

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Overview of the Servo Robot System

MOTOR DRIVE INPUT

MOTOR FEEDBACK OUTPUT

Figure 1-3. Mechanical layout of the Servo Robot (View B).

The optical encoder consists of a LED (Light Emitting Diode) that sends light through a finely screened code wheel that is rigidly mounted onto the motor shaft as shown in Figure 1-4. A receiver (phototransistor) detects the light changes (light/dark). The light changes are converted into electrical pulses and sent back to the Robot Controller. The Robot Controller compares the control signal to the feedback signal to ensure that the position is correct at all times.
LED WHEEL PHOTOTRANSISTOR

MOTOR SHAFT

Figure 1-4. Optical encoder of a servo motor.

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Overview of the Servo Robot System

Robot Controller The Robot Controller is the brain of the Servo Robot System. It is a specialized computer with ports, switches, and programming capabilities that enable it to function as a controller. It contains the inputs and outputs required to send and receive TTL (Transistor-Transistor Logic) signals to/from the external devices and CNC (Computerized Numerical Control) machine tools. The Robot Controller is operated from the Hand-Held Terminal or from Robotics. As Figure 1-5 shows, the front panel of the Robot Controller includes the following: C Hand-Held Terminal connector to connect the Hand-Held Terminal. C Motor Disabled (LED) indicator. The LED lights when the servo motors of the Servo Robot are disabled (not torqued condition). C Motor Enable/Disable pushbutton is used to enable and disable the servo motors of the Servo Robot. They are enabled (torqued condition) when the button is pressed. This button must be pressed when powering up the system. C TTL inputs and status indicators (LED). The LED of a TTL input lights when the level is high. C TTL outputs and status indicators (LED). The LED of a TTL output lights when the level is high. C Relays. Each Relay includes a set of normally open (NO) and normally closed (NC) contacts, and status indicator (LED). The LED of a relay lights when it is activated. C A floppy disk drive to save and load programs.

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Overview of the Servo Robot System

HAND-HELD TERMINAL MOTOR DISABLED INDICATOR STATUS INDICATOR (LED) TTL INPUTS TTL OUTPUTS RELAYS

TTL M

TTL
[ 20 mA MAX.] [ 30 V 500 mA MAX.]

MOTOR ENABLE/DISABLE PUSH-BUTTON FLOPPY DISK DRIVE

Figure 1-5. Robot Controller - front view.

As Figure 1-6 shows, the rear panel of the Robot Controller includes the connectors required to connect the host computer (serial port), CNC machines (CNC 1 and CNC 2), external devices (CH 1 and CH 2), Servo Robot Motor Drive, Servo Robot Motor Feedback, and Emergency Stop module. It also includes the main power connector, power switch and fuse access panel.
MOTOR DRIVE OUTPUT EMERGENCY STOP SERIAL PORT MOTOR FEEDBACK INPUT

CNC 1

CNC 2

CH 1

CH 2

5250

5250

CNC 1

CNC 2

CHANNEL 1

CHANNEL 2

MAIN POWER CONNECTOR POWER SWITCH

FUSE ACCESS PANEL

Figure 1-6. Robot Controller - rear view.

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Overview of the Servo Robot System

Hand-Held Terminal The Hand-Held Terminal communicates with the Robot Controller to control the Servo Robot and external devices, and create programs. The Hand-Held Terminal is shown in Figure 1-7, it contains the keys which are used for entering alphanumeric characters and selecting special functions, and a LCD (Liquid Crystal Display) to view the instructions entered and the resulting executions. All keys are labeled for a specific task. The functions of the Hand-Held Terminal are explained in Section 3 of this guide.
LCD SCREEN

FUNCTION INDICATORS

RUN

TEACH

ERROR

SUSPD

FUNCTION KEYS

ESC

Teach Menu

Main Menu

Clear Error

Suspd Oper.

A F

B G

C H

D I

E J

K P

L Q

M R

N S

O T

U X

V Y

W Z

? /

( #

7
, .
ESC DEL

9
SPACE ENTER

SHIFT

Figure 1-7. Hand-Held Terminal.

Emergency Stop Module As Figure 1-8 shows, the Emergency Stop module contains a pushbutton and a LED indicator. When the pushbutton is pressed, all operations are halted, the LED indicator lights, the Suspd (suspend operation) indicator on the Hand-Held Terminal lights, and the Emergency Stop window in Robotics opens (if Robotics is used). A key is required to release the stop switch to resume operation. The procedures to resume operation are explained in Sections 3 and 4 of this guide.

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Overview of the Servo Robot System

KEY RELEASE PUSH-BUTTON LED INDICATOR

Figure 1-8. Emergency Stop module.

External Devices External devices such as a Rotary Carousel (Model 5208), Belt Conveyor (Model 5210), Gravity Feeders (Models 5119 and 5121), Pneumatic Feeders (Models 5122 and 5142), and Linear Slide (Model 5209) can be added to the Servo Robot System. The operation of these optional devices is described in the appendices of this guide.

1-8

Section Installation and Connections

Installation The Servo Robot System is supplied with two Grids and two Work Surfaces to help you to position the equipment at specific locations. As Figure 2-1 shows, the Grids and Work Surfaces have 12 rows and 12 columns. On the Grids, the rows and columns are numbered from R0 to R11 and from C0 to C11 respectively.
R0 R1 R2 R3 R4 R5

R7, C9
R6 R7 R8 R9 R10 R11 C11

R7, C9

35828-01

C10

C9

C8

C7

C6

C5

C4

C3

C2

C1

C0

GRID

WORK SURFACE

Figure 2-1. Layout of the Grid and Work Surface.

The row and column numbers are used to locate the equipment. As an example, when it is asked in a procedure to place a film canister at position (R7,C9), the center of the film canister must be placed at the intersection of the eighth row from the top of the Grid (or of the Work Surface), and the tenth column from the right. When using the Grids, the Servo Robot must be snapped to the mounting base (steel plate) supplied with the Servo Robot System. First, position the mounting base on the Grid by centering the small perforations on the base at the desired row and column intersections, then snap the Servo Robot to the mounting base. To do so, align the push-lock fasteners with the perforations of the mounting base then firmly push on the fasteners. When using the perforated Work Surfaces, do not use the mounting base. Simply position and snap the Servo Robot to the Work Surface.

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Installation and Connections

Although the Servo Robot is designed to be used with both the Grids and Work Surfaces, it is strongly recommended to use the Work Surfaces. They are simple to use and less subject to undesirable movements. The Work Surfaces are designed to be used on top of a table. Two Work Surfaces can be joined using the handles (p/n 30036) supplied with the Servo Robot System.

Space Required The path of points that can be reached by a robot is called the work envelope. The work envelope of an articulated-arm robot as the one of your training system is shown in Figure 2-2. To allow a secure operation, no wall or obstacle should be present in the work envelope, or within 750 mm (30 in) from the base of the Servo Robot in any direction.

TOP VIEW

SIDE VIEW

Figure 2-2 Work envelope of the Servo Robot.

Connections This section describes how to connect the components of the Servo Robot System. Position the Servo Robot and Robot Controller as shown in Figure 2-3.
Note: The position of the Servo Robot is determined relative to the position of the push-lock fasteners.

2-2

Installation and Connections

R0, C4

ROBOT CONTROLLER

R6, C7 R6, C4

Figure 2-3. Location of the equipment on the Work Surface.

Before making any connections, ensure that the power switch on the rear panel of the Robot Controller is at the off (O) position.
CAUTION! Do not make or remove any connections to/from the Robot Controller while the power is on. This could damage the module.

Perform the following steps: C Connect the Motor Feedback Output on the base of the Servo Robot to the Motor Feedback Input on the Robot Controller using the cable p/n 95922. Refer to Figure 2-4 if necessary.
Note: To ensure correct operation, make sure the connector is all the way in before it is screwed.

C Connect the Motor Drive Input on the base of the Servo Robot to the Motor Drive Output on the Robot Controller using the cable p/n 95921. C Connect the Emergency Stop module to the Emergency Stop connector on the Robot Controller. C Connect the serial port on the Robot Controller to the host computer serial port using the cable p/n 93017. C Connect the Robot Controller to an AC power outlet using the cable p/n 95451.

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Installation and Connections

C Connect the Hand-Held Terminal to the Hand-Held Terminal connector on the front panel of the Robot Controller using the cable p/n 95028. Refer to Figure 2-5 if necessary.

CNC 2 SERIAL PORT CNC 1 CHANNEL 1 CHANNEL 2

MOTOR DRIVE OUTPUT EMERGENCY STOP MOTOR FEEDBACK INPUT

MOTOR DRIVE INPUT MOTOR FEEDBACK OUTPUT

ROBOT CONTROLLER (REAR VIEW)

TO AN AC POWER SUPPLY

SERVO ROBOT

EMERGENCY STOP MODULE TO COMPUTER SERIAL PORT

Figure 2-4. Connections.

HAND-HELD TERMINAL ROBOT CONTROLLER (FRONT VIEW)

RUN TEACH ERROR SUSPD ESC

Teach Menu

Main Menu

Clear Error

Suspd Oper.

A F

B G

C H

D I

E J

K P

L Q

M R

N S

O T

TTL
U X V Y W Z ? / +

TTL
[ 20 mA MAX.] [ 30 V 500 mA MAX.]

( #

7
, .
ESC DEL

9
SPACE ENTER

SHIFT

Figure 2-5. Connection of the Hand-Held Terminal.

2-4

Installation and Connections

All cables are now connected and should be securely fastened. Refer to the appendices of this guide to learn how to connect external devices to the training system.

2-5

2-6

Section Hand-Held Terminal

Description The Hand-Held Terminal is used to control the operation of the Servo Robot and external devices, and create programs. It is a menu driven device that includes tactile touch keys, LEDs and a LCD screen, as shown in Figure 3-1. The menus appearing on the LCD screen are quite similar to the menus in Robotics (described in Section 4).
LCD SCREEN

FUNCTION INDICATORS

RUN

TEACH

ERROR

SUSPD

FUNCTION KEYS

ESC

Teach Menu

Main Menu

Clear Error

Suspd Oper.

A F

B G

C H

D I

E J

K P

L Q

M R

N S

O T

U X

V Y

W Z

? /

( #

7
, .
ESC DEL

9
SPACE ENTER

SHIFT

Figure 3-1. Hand-Held Terminal.

The name and function of the five white keys at the top of the Hand-Held Terminal keypad are as follows: C ESC: Backs up one step from the current position in the menu. C Teach Menu: Displays the Teach menu and activates the keys to manipulate the Servo Robot and external device(s) connected to CH 1 and CH 2, and sets the TTL inputs, TTL outputs, CNC inputs, CNC outputs, Relays, and Delay. This is also in the Teach menu where the position and control points are saved. C Main Menu: Displays the Main menu from where all support menus for the Servo Robot are accessed.
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Hand-Held Terminal

C Clear Error: Clears the Error indicator on the Hand-Held Terminal. The Error indicator lights when the system is halted by pressing the emergency stop button. Error must be cleared to resume operation. C Suspd Oper.: Suspends any operation being executed.

The arrow keys at the bottom of the Hand-Held Terminal are used to move through a list of menu options (when present). A table showing the structure of the HandHeld Terminal menus is shown in Appendix A. Refer to this table to facilitate your learning of the various menus of the Hand-Held Terminal. The description of each Hand-Held Terminal menu is as follows:

Main Menu The Main menu is the home base that can link you to all the support menus. The Main menu appears at the end of the start-up process. You can return to this menu by pressing the Esc key once or several times depending on your menu location, or by pressing the Main Menu key.
Note: To select an option in a menu, place the cursor beside the desired option using the arrow keys and press the Enter key. Alternatively, you can press the shortcut key (the character beside the option). MAIN MENU 1 POINT MANAGER 2 TASK MANAGER 3 FILE MANAGER 4 MOTION CONTROL 5 CONFIGURATION 9 SHUTDOWN

1 Point Manager: Displays the list of the points stored in the Robot Controller memory. A point list may contain two types of points: position and control points. Once a point list is displayed, you can edit and modify the settings of the point beside the cursor by pressing the E key. If the point is a position point, the Point Editor menu will open. If the point is a control point, the Control Editor menu will open.

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Hand-Held Terminal
Point Editor: Changes the settings of a position point. This menu is accessed by pressing the E key while the cursor is beside a position point in the point list. POINT EDITOR NAME:_____ FLAGS:ABSOLUTE/RELATIVE SPEED:0-99 GRIPPER:_ WRIST R:_ WRIST P:_ ELBOW:_ SHOULDER:_ BASE:_ CH 1:_ CH 2:_ SAVE CHANGES

N F S 1 2 3 4 5 6 7 8 0

Note: To modify the settings of a position point, place the cursor beside the parameter, then press the Enter key. Use the arrow keys to move the cursor, and the alphanumeric character keys to enter the new settings. Press the Enter key to confirm your changes then press the 0 key to save the new settings. It is also possible to save the new settings by placing the cursor beside the Save Changes option and pressing the Enter key.

N Name: Displays the name of the position point. Using the arrow keys to move the cursor, you can enter a different name (maximum 8 characters).
Note: Press the Shift key to access the characters in the dark blue section of the keys (where present).

F Flags: Indicates if the coordinates of the point are absolute or relative. Absolute means that the coordinates are determined relative to a predetermined position (hard home position). Relative means that the position coordinates are determined relative to the previous position. S Speed: Displays the speed setting. The speed can be set between 0 and 99. 1 Gripper: Shows the gripper coordinates. 2 Wrist R: Shows the wrist axis coordinates relative to the rotation. 3 Wrist P: Shows the wrist axis coordinates relative to the pitch (up and down motion). 4 Elbow: Shows the elbow axis coordinates. 5 Shoulder: Shows the shoulder axis coordinates.
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Hand-Held Terminal
6 Base: Shows the base axis coordinates. 7 CH 1: Shows the coordinates of the device connected to CH 1 on the Robot Controller. 8 CH 2: Shows the coordinates of the device connected to CH 2 on the Robot Controller. 0 Save Changes: Saves the current settings.

Control Editor: Changes the settings of a control point. This menu is accessed by pressing the E key while the cursor is beside a control point in the point list. CONTROL EDITOR NAME:_____ TTL OUTPUT TTL INPUT RELAY CNC 1 CNC 2 DELAY SAVE CHANGES

N 1 2 3 4 5 D 0

Note: To modify the settings of a control point, place the cursor beside the parameter, then press the Enter key. Use the arrow keys to move the cursor and the alphanumeric character keys to enter the new settings. Press the Enter key to confirm your changes then press the 0 key to save the new settings. It is also possible to save the new settings by placing the cursor beside the Save Changes option and pressing the Enter key.

N Name: Displays the name of the control point. Using the arrow keys to move the cursor, you can enter a different name (maximum 8 characters). 1 TTL Output: Displays the current level (L low or H high) of the TTL outputs in the OLD row, and sets the level at which the TTL outputs will be after this instruction line is executed. The level is set by pressing the TTL output number on the keypad. The setting is displayed in the NEW row. TTL OUTPUT KEY 1 2 3 4 5 6 7 8 OLD L L L L L L L L NEW X X X X X X X X

Note: The character X indicates that no level has been assigned.

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Hand-Held Terminal
2 TTL Input: Displays the current level (L or H) of the TTL inputs in the OLD row, and sets the level at which the TTL inputs must be before proceeding with the next instruction line in the program. The level is set by pressing the TTL input number on the keypad. The setting is displayed in the NEW row. TTL INPUT KEY 1 2 3 4 5 6 7 8 OLD L L L L L L L L NEW X X X X X X X X

3 Relay: Displays the current status (activated or deactivated) of the Relays in the OLD row, and sets the status at which the Relays will be after this instruction line is executed. The status is set [H (activated) or L (deactivated)] by pressing the Relay number on the keypad. The setting is displayed in the NEW row. RELAY KEY 1 2 3 4 OLD L L L L NEW X X X X

4 CNC 1: Displays the current level (L or H) of the CNC 1 inputs and outputs in the OLD row, and sets the level at which the CNC 1 inputs 1 to 4 must be before proceeding with the next instruction line in the program. Also sets the level at which the CNC 1 outputs A to D will be when this instruction line is executed. The level is set by pressing the CNC 1 input or output number on the keypad. The setting is displayed in the NEW row. CNC1 INPUT | OUTPUT KEY 1 2 3 4 A B C D OLD L L L L L L L L NEW X X X X X X X X

5 CNC 2: Displays the current level (L or H) of the CNC 2 inputs and outputs in the OLD row, and sets the level at which the CNC 2 inputs 1 to 4 must be before proceeding with the next instruction line in the program. Also sets the level at which the CNC 2 outputs A to D will be when this instruction line is executed. The level is set by pressing the CNC 2 input or output number on the keypad. The setting is displayed in the NEW row. CNC2 INPUT | OUTPUT KEY 1 2 3 4 A B C D OLD L L L L L L L L NEW X X X X X X X X
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Hand-Held Terminal

D Delay: Sets the amount of time in seconds the system will pause before proceeding with the next instruction line in the program. 0 Save Changes: Saves the current settings.

x: Clears all points stored in the Robot Controller memory.

CLEAR ALL POINTS ARE YOU SURE ENTER TO CONTINUE ESC TO ABORT

C: Deletes the point beside the cursor.

6: Moves the point (position or control) beside the cursor over the preceding
point.

7: Moves the point (position or control) beside the cursor under the next
point.

2 Task Manager: Runs point-to-point program or clear points. TASK MENU RUN ONCE RUN FOREVER TRACE POINTS CLEAR POINTS

1 2 3 4

1 Run Once: Executes the current program once. EXECUTE POINTS RUN ONCE _____ PRESS ESC TO ABORT

2 Run Forever: Executes the current program over and over. Press the Esc key to abort execution. EXECUTE POINTS RUN FOREVER:_ _____ PRESS ESC TO ABORT

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Hand-Held Terminal
3 Trace Points: Executes an instruction line of the current program each time the Enter key is pressed. When the last instruction line is executed, the Servo Robot returns to the home position. EXECUTE POINTS TRACE MODE _____ PRESS ESC TO ABORT

4 Clear Points: Delete all points stored in the Robot Controller memory. CLEAR ALL POINTS ARE YOU SURE? ENTER TO CONTINUE ESC TO ABORT

3 File Manager: Enables you to save the program in the Robot Controller memory to the floppy disk drive, or load a program from the floppy disk drive. FILE MENU 1 SAVE TO DISK 2 LOAD FROM DISK

1 Save to Disk: Saves the current program in the Robot Controller memory to the floppy disk. When the Save File window opens, the cursor is placed beside the default name SAMPLE suggesting to enter a number. Using the arrow keys to move the cursor, you can enter a different name for the program (maximum 8 characters). Press the Enter key to complete the process. SAVE FILE ENTER FILENAME >SAMPLE_

2 Load From Disk: Loads an existing program from the floppy disk into the Robot Controller memory. Press the Enter key then use the arrow keys to select a file. Press the Enter key to complete the process. OVERWRITE TASK ARE YOU SURE? ENTER TO CONTINUE ESC TO ABORT

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Hand-Held Terminal
4 Motion Control: Controls the home positioning, frees and torques the servo motors, reinitializes the motors, controls the operation of the soft limits. MOTION CONTROL SOFT HOME SET SOFT HOME CLR SOFT HOME HARD HOME FREE MOTORS TORQUE MOTORS HARDWARE RESET SOFT LIMITS OFF SOFT LIMITS ON

1 2 3 4 5 6 7 8 9

1 Soft Home: Moves the Servo Robot to the position that you assigned as soft home using the Set Soft Home instruction. It is the position the Servo Robot starts its movements from, and where it will come to rest when you tell it to go home after completing the assigned instruction lines. The soft home position is the same as the hard home position when no position has been assigned as soft home. 2 Set Soft Home: Sets the current Servo Robot position as the soft home position. The default Home point in the point list of the Point Manager changes to Soft Home point when a position is assigned as soft home position. 3 Clr Soft Home: Clears the current soft home position. 4 Hard Home: Moves the Servo Robot to a fixed reference point where the Servo Robot goes to reset all its settings. After you press the 4 key to select the Hard Home option, press the Enter key within 6 seconds to execute the Hard Home instruction. PERFORM HARD HOME ENTER TO CONTINUE ESC TO ABORT
Note: A program can be developed to be executed once and then deleted. However, it is usually developed to be used more than once. In order to repeat a program, the equipment must be in the same location and orientation as when you created the position points of the program and the Servo Robot must start in the same position. For this reason, a hard home positioning must be executed at the beginning of each session.

5 Free Motors: Removes power from the motors. This corresponds to the freed condition (not torqued).

3-8

Hand-Held Terminal
6 Torque Motors: Applies power to the motors so they will hold their positions. This corresponds to the torqued condition. 7 Hardware Reset: Reinitializes all motors connected to the Robot Controller. After performing a "Hard Reset" always perform a "Hard Home". HARDWARE RESET ARE YOU SURE? ENTER TO CONTINUE ESC TO ABORT

8 Soft Limits OFF: Disables the soft limits. Press the Enter key when the cursor is beside this option to disable the soft limits. The default setting is OFF.
Note: The soft limits are programmed positions that limit the movement of each articulation of the Servo Robot to prevent excessive movements.

9 Soft Limits ON: Enables the soft limits. Press the Enter key when the cursor is beside this option to enable the soft limits.

5 Configuration: Enables the configuration of the Servo Robot System. CONFIG MENU GRIP:_____ CH 1:_____ CH 2:_____ KEY CLICK:_____ SHIFT LOCK: OFF SAVE CONFIG

1 2 3 4 5 S

Note: To configure an element in the Config menu, place the cursor beside the element, then press the Enter key as required to obtain the desired parameter. To save the configuration entries, select Save Config then press the Enter key, or press the S key.

1 Grip: Selects the type of gripper used. The available choices are servo, pneu (pneumatic), elec (electric), and none.
Note: The gripper of your Servo Robot is driven by a servo motor. Select Servo.

2 CH 1: Selects the device connected to CH 1 on the Robot Controller. The available choices are Carousel, L Slide (Linear Slide), and none. 3 CH 2: Selects the device connected to CH 2 on the Robot Controller. The available choices are Carousel, L Slide (Linear Slide), and none. 4 Key Click: Activates or deactivates the beeper of the Hand-Held Terminal.
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Hand-Held Terminal
5 Shift Lock: Locks the Shift key in the activated mode. The default setting is unlock. Save Config: Saves the current configuration settings. To save the configuration entries, select Save Config then press the Enter key, or press the S key.
Note: The Robot Controller must be configured to detect the Gripper, Linear Slide, and Rotary Carousel if you have them. The other options in the Config menu can be configured whenever you want.

9 Shutdown: Exits the program (firmware) of the Robot Controller. When you select the Shutdown option, the Message Firmware Shutdown - Turn off Controller is displayed on the Hand-Held Terminal. The Robot Controller must be restarted to resume the system.

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Hand-Held Terminal
Teach Menu The Teach menu allows the control of the Servo Robot and external devices. It allows also the creation of point-to-point programs.
TEACH MENU 0 SPEED CONTROL 1 GRIPPER OPEN H GRIPPER CLOSE 2 WRIST CW I WRIST CCW 3 WRIST PITCH DOWN J WRIST PITCH UP 4 ELBOW PITCH DOWN R ELBOW PITCH UP 5 SHLDR PITCH DOWN S SHLDR PITCH UP 6 BASE CCW T BASE CW 7 CH 1 FORWARD Z CH 1 BACKWARD 8 CH 2 FORWARD / CH 2 BACKWARD F TTL OUTPUT G TTL INPUT P RELAY Q TIME DELAY X CNC 1 Y CNC 2 . SAVE ABS POINT # SAVE REL POINT * SAVE CONTROL Note: To move the Servo Robot, select the articulation you want to move in the Teach menu with the up and down arrow keys, or by pressing the shortcut keys, then press and hold the Enter key. Alternatively, you can press and hold the shortcut keys.

Figure 3-2 shows the characters (shortcut keys) associated with each articulation of the Servo Robot. This figure is also screened on the base of the Servo Robot.

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Hand-Held Terminal
R

FOREARM
J I 4 S 3

UPPER ARM

SHOULDER

WRIST
1 2 5 T 6

GRIPPER

BASE

Figure 3-2. Characters associated with each articulation of the Servo Robot.

0 Speed Control: Sets the speed between 0 and 99. The speed setting is used for all movements that follow the setting, or until a new speed setting is made. To set the speed, select the Speed Control option or press the 0 key. In the Set Speed window, use the numeric keys or the arrow keys to set the Speed value. To set the tens of units, use the numeric keys or the up (to increase) and down (to decrease) arrow keys. To increase or decrease the speed by one unit, press the right or left arrow keys. SET SPEED 1 >------------------+< 099 99

1 Gripper Open: Opens the gripper. H Gripper Close: Closes the gripper.
Note: To facilitate the use of the Hand-Held Terminal, the movements associated with the keys of the second row are in the opposite direction to those of the fifth row. This relation repeats for the third and sixth row.

2 Wrist CW: Rotates the wrist in the clockwise direction. I Wrist CCW: Rotates the wrist in the counterclockwise direction.

3 Wrist Pitch Down: Lowers the wrist. J Wrist Pitch Up: Raises the wrist. 4 Elbow Pitch Down: Lowers the forearm.

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Hand-Held Terminal
R Elbow Pitch Up: Raises the forearm. 5 Shldr Pitch Down: Lowers the upper arm. S Shldr Pitch Up: Raises the upper arm. 6 Base CCW: Rotates the shoulder in the counterclockwise direction. T Base CW: Rotates the shoulder in the clockwise direction. 7 CH 1 Forward: Moves the device connected to CH 1 in the forward or clockwise direction. Z CH 1 Backward: Moves the device connected to CH 1 in the backward or counterclockwise direction. 8 CH 2 Forward: Moves the device connected to CH 2 in the forward or clockwise direction. / CH 2 Backward: Moves the device connected to CH 2 in the backward or counterclockwise direction. F TTL Output: Displays the current level (L or H) of the TTL outputs in the OLD row, and sets the level at which the TTL outputs will be after this instruction line is executed. The level is set by pressing the TTL output number on the keypad. The setting is displayed in the NEW row. TTL OUTPUT KEY 1 2 3 4 5 6 7 8 OLD L L L L L L L L NEW X X X X X X X X

G TTL Input: Displays the current level (L or H) of the TTL inputs in the OLD row, and sets the level at which the TTL inputs must be before proceeding with the next instruction line in the program. The level is set by pressing the TTL input number on the keypad. The setting is displayed in the NEW row. TTL INPUT KEY 1 2 3 4 5 6 7 8 OLD H H H H H H H H NEW X X X X X X X X

P Relay: Displays the current status (activated or deactivated) of the Relays in the OLD row, and sets the status at which the Relays will be after this instruction line is executed. The status [H (activated) or L (deactivated)] is set by pressing the Relay number on the keypad. The setting is displayed in the NEW row.

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RELAY KEY 1 2 3 4 OLD L L L L NEW X X X X

Q Time Delay: Sets the amount of time in seconds the system will pause before proceeding with the next instruction line in the program. SET DELAY VALUE IN SECONDS >_

X CNC 1: Displays the current level (L or H) of the CNC 1 inputs and outputs in the OLD row. Sets the level at which the inputs 1 to 4 must be before proceeding with the next instruction line in the program. Also sets the level at which the outputs A to D will be when this instruction line is executed. The level is set by pressing the CNC 1 input or output number on the keypad. The setting is displayed in the NEW row. CNC1 INPUT | OUTPUT KEY 1 2 3 4 A B C D OLD L L L L L L L L NEW X X X X X X X X

Y CNC 2: Displays the current level (L or H) of the CNC 2 inputs and outputs in the OLD row. Sets the level at which the inputs 1 to 4 must be before proceeding with the next instruction line in the program. Also sets the level at which the outputs A to D will be when this instruction line is executed. The level is set by pressing the CNC 2 input or output number on the keypad. The setting is displayed in the NEW row. CNC2 INPUT | OUTPUT KEY 1 2 3 4 A B C D OLD L L L L L L L L NEW X X X X X X X X

C Save ABS Point: Saves the absolute coordinates of the current position of the Servo Robot and external device(s) connected to CH 1 and CH 2. You can save the point with the default name shown on the display or enter a new name before pressing the Enter key (maximum 8 characters). The absolute coordinates are determined relative to a predetermined position (hard home position). SAVE POSITION ENTER POINT NAME >POINT1_

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# Save REL Point: Saves the relative coordinates of the current position of the Servo Robot and external device(s) connected to CH 1 and CH 2. You can save the point with the default name shown on the display or enter a new name before pressing the Enter key (maximum 8 characters). The character r is added beside the point name in the point list of the Point Manager to indicate that the coordinates of the point are relative. The relative coordinates are determined relative to previous position. SAVE POSITION ENTER POINT NAME >POINT1_

* Save Control: Save the current settings of the TTL inputs, TTL outputs, Relays, CNC inputs, CNC outputs and delay of the control point. You can save the point with the default name shown on the display or enter a new name before pressing the Enter key (maximum 8 characters). SAVE CONTROL ENTER POINT NAME >CTRL1_

Resuming the Servo Robot System after an Emergency Stop To resume the Servo Robot System after an emergency stop, perform the following steps: C Ask your instructor to check your setup to remove any dangerous condition, and to release the switch using the appropriate key. C On the Hand-Held Terminal: Press the Esc key. Press the Clear Error key. Press the Enter key. The system is now ready to operate.

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Section Robotics

Introduction Robotics is a software used to control the operation of the Servo Robot and external devices, and create programs. This section provides the information to install and use Robotics. The Computer Requirements subsection describes the computer requirements to operate Robotics. The Software Installation subsection deals with the installation of the software on the hard disk of your computer. The Familiarization with Robotics subsection explains how to use the application.

Computer Requirements The computer requirements are: C C C C C C 233 MHz, Pentium II processor 15 Mb of hard drive space 32 Mb RAM Serial port CD-ROM drive Windows 98 or higher

Software Installation Perform the following steps to install Robotics on the hard disk of your computer: C Close all programs on your computer. C Insert the Robotics CD-ROM in the CD-ROM drive. C Choose the Run command in the Start menu of Windows. C Type X:\Setup.exe in the command line, then click the OK button, or press the Enter key on the keyboard.
Note: Replace the X by the letter associated with your CD-ROM drive.

C The Welcome to the InstallShield Wizard for Robotics window appears. To start the installation, click the Next button.

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C The License Agreement window appears. Read the license agreement terms carefully. If you accept the terms, click the Yes button.

C The Choose Destination Location window appears. Setup will install Robotics in the folder shown. To accept the default folder (recommended), click the Next button. To select a different folder, click the Browse button, then select the desired folder.

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C The Select Program Folder window appears. Setup will add program icons to the program folder listed below. Type a folder name in the Program Folder field, or select one from the existing folder list, then click the Next button.

C The Start Copying Files window appears. If you are satisfied with the settings shown, click the Next button to start copying files.

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C The InstallShield Wizard Complete window appears when the installation is completed. Click the Finish button to exit the installation process.

Familiarization with Robotics Robotics is now ready to use. To launch the application, click the Robotics icon appearing on the desktop or choose the Run command in the Start menu of Windows, and type X:\Program Files\Lab-Volt\Robotics\Robotics.exe (if you did not accept the default folder, enter your folder path), and click the OK button or press the Enter key on the keyboard.
Note: Replace the X by the letter associated with your hard disk drive.

Robotics allows the manipulation of the Servo Robot through a visual interface. The Hand-Held Terminal is not required to operate the Servo Robot when using Robotics. However, large programs are often developed with Robotics in conjunction with the Hand-Held Terminal.

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The Hand-Held Terminal is used for the precise moves where you must be placed near the device to record the points, and Robotics for the moves that can be seen from the computer and for editing purposes. The Robot Controller must be turned on and connected to the computer to use Robotics.
Note: The Servo Robot System must be configured. Refer to the Options menu described in this section.

Main Window The Main window is the first window you see when Robotics is launched. It includes a menu bar, a tool bar and a status bar.

Main window.

Menu Bar The description of each option in the menu bar is as follows:
Note: A table showing the structure of the Robotics menus is shown in Appendix B.

File New: Opens the Program Information window to create a Robotics file (filename.A4).

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Program Information window.

The Program Information window is used to enter general information about the task program. This includes the name of the author, date, project name, revision number, and comments. Clicking the OK button saves the information, closes the Program Information window, and opens the Task Editor window.

Task Editor Window The Task Editor window is where task programs are created. The left column of the window is where instruction lines are written. The right column is where the points are copied from the Point Editor window (described in the Point Editor Window section), or from the Robot Controller before they are used in the task program. It is not required to use every points in the right column when designing the task program.

Task Editor window.

Open: Opens an existing Robotics file. Up to 10 files can be open simultaneously.

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Close: Closes the currently open Robotics file. If the current file has been modified, a dialog box opens asking if you wish to save the changes before closing the Robotics file. Save: Saves a file under the current name. If you save a file for the first time, the Save command will work as the Save As command, and a dialog box will open asking you to name the file.
Note: It is recommended to create a folder to save your programs before using Robotics. To create a folder in Windows Explorer, select Folder in the submenu New of the menu File.

Save as: Saves a file with a different name. A dialog box will open asking you to name the file. Revert: Deletes the change(s) made to a file by restoring the original version. Info: Opens the Program Information window that contains the information relative to the active task program. Print: Prints the instruction lines of the active task program. Print Setup: Opens the Printer Setup window. Shutdown: Opens the Shutdown window. If you click the Yes button, the message Shutdown Completed will appear during a few seconds and the program (firmware) in the Robot Controller will end. You must restart the Robot Controller to resume the system.

Shutdown window.

Exit: Closes Robotics. If a file has been modified, a dialog box appears asking you if you wish to save the changes before exiting Robotics.

Edit Undo: Reverses the last change. The Undo function can be repeated as necessary to reverse previous changes. Redo: Reverses the last Undo action. Cut: Cuts the selected text and stores it in the Clipboard. Copy: Copies the selected text and stores it in the Clipboard.
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Paste: Pastes the Clipboard content at the insertion point. Duplicate: Duplicates the selected text. Clear: Deletes the selected text. Select All: Selects all instruction lines in the Task Editor window.

Search Find: Searches for specific words and phrases in the Task Editor window and locates the first match. Find Next: Searches for the next occurrence of the specific words and phrases in the Task Editor window and locates the match. Replace: Searches for specific words and phrases in the Task Editor window and replaces them by new ones. Go to Line: Moves the cursor to a specific instruction line in the Task Editor window. Go to Bookmark: Moves the cursor to the instruction line where a bookmark was set using the Set Bookmark command. Set Bookmark: Sets a bookmark in an instruction line of a task program.

Robot Run Task: Compiles the active task program and opens the Run Task window.

Run Task window.

The available options in the Current Status and Task Control sections of the Run Task window are: Repeat Task check box: Repeats the task program over and over when enabled (checked). Click the Pause button to stop the execution.

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Repeat Count: Indicates the number of times the task program has repeated. Line Number: Indicates which instruction line is being executed. Command: Indicates which command is being executed. Status: Describes the status of the command which is being executed. Message field: Displays the messages associated with the execution of the task program or called by a task command. Run button: Executes the task program once. Step button: Executes an instruction line each time the Step button is pressed. Pause button: Pauses the task program once the execution of the instruction line is completed. Reset button: Returns to the first instruction line of the task program and waits. Close button: Closes the Run Task window.

Motion Control Soft Home: Moves the Servo Robot and external device(s) connected to CH 1 and CH 2 to the position assigned as the home position using the Set Soft Home command. It is the position the Servo Robot starts its movements from, and where it will come to rest when you tell it to go home after completing the assigned instruction lines. The soft home position is the same as the hard home position when no position has been assigned as soft home. Set Soft Home: Sets the current position of the Servo Robot and external devices as the soft home position. Clear Soft Home: Clears the current soft home position. Free Motors: Removes power from the motors. Torque Motors: Applies power to the motors so they will hold their positions. Hard Home: Moves the Servo Robot to a fixed reference point where the Servo Robot goes to reset all its settings.

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Note: A program can be developed to be executed once and then deleted. However, it is usually developed to be used more than once. In order to repeat a program, the equipment must be in the same location and orientation as when you created the position points of the program and the Servo Robot must start in the same position. For this reason, a hard home positioning must be executed at the beginning of each session.

Download from Task Editor: Opens a Warning window. Once the OK button is clicked, copies the active task program in the Task Editor window to the Robot Controller memory. All current points in the Robot Controller memory are deleted when the file is downloaded.

Warning window.

Point Editor: Opens a Warning window. Once the OK button is clicked, copies the content of the Point Editor window to the Robot Controller memory. All current points in the Robot Controller memory are deleted when the file is downloaded.

Upload to New Task Editor: Opens the Program Information window. Once the OK button is clicked, copies the content of the Robot Controller memory to a new Task Editor window. Point Editor: Opens a Warning window. Once the OK button is clicked, copies the content of the Robot Controller memory into the Point Editor window in Robotics. All current points in the Point Editor window are deleted when the file is uploaded.

Warning window.

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Release Emergency Stop: Releases the Emergency Stop status. When the Emergency Stop is activated, the Emergency Stop window appears, and a message appears in the Controller Status window.

Emergency Stop window.

To resume the Servo Robot System after an emergency stop, perform the following steps: C Ask your instructor to check your setup to remove any dangerous condition, and to release the switch using the appropriate key. C Close the Emergency Stop window by clicking on the OK button. C Close the Run Task window by clicking the Close button (if active). C Select Release Emergency Stop in the Robot menu. The system is now ready to operate.

Online: Allows communications between the host computer and the Robot Controller when enabled. The option must be enabled to operate the Servo Robot using Robotics.

Options Environment: Opens the Environment folder of the Program Options window.

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Environment folder in the Program Options window.

The options that can be set in the Environment folder are: Language: Selects the language. Data Directory: Selects the folder where the Robotics files are saved. Robotics will automatically access this folder when saving or opening a file. Line Numbers: Displays the instruction line numbers in the Task Editor when enabled. Force Uppercase: Forces upper case letters in the Task Editor when enabled. Editor Colors: Sets the foreground and background colors for the text and numbers.
Note: For each folder of the Program Options window, click the Save button once the settings and selections are completed to save and apply them. They will be used as default settings the next time Robotics is launched. Clicking the Cancel button closes the Program Options window without saving the settings.

Hardware: Opens the Hardware folder of the Program Options window.

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Hardware folder in the Program Options window.

The options that can be set in the Hardware folder are: Gripper: Selects the type of gripper. The available choices are Servo Motor Gripper, Pneumatic Gripper, Electric Gripper, and No Gripper Attached.
Note: The gripper of your Servo Robot is driven by a servo motor. Select Servo Motor Gripper.

Channel 1: Selects the device connected to CH 1. The available choices are Linear Slide, Rotary Carousel, and No External Device Connected. Channel 2: Selects the device connected to CH 2. The available choices are Linear Slide, Rotary Carousel, and No External Device Connected. Serial Port: Selects the serial port where the Robot Controller is connected (COM1 to COM6). Transit: Sets the transit speed between 0 and 99. The default value is 75. The transit speed is recommended for long distance when precision is not required. Approach: Sets the approach speed between 0 and 99. The default value is 40. The approach speed is recommended when the movement requires medium precision. Precision: Sets the precision speed between 0 and 99. The default value is 15. The precision speed is recommended when the movement requires precision.

File Server: Opens the File Server folder of the Program Options window.

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File Server folder in the Program Options window.

The options that can be set in the File Server folder are:
Note: The File Server software is used to save and load programs when using the Teach Pendant-Controlled Robot System, Model 5100.

Run File Server Software: Runs the File Server software when Robotics is launched, when enabled. File Server Program Location: Selects the folder where the File Server software is installed. Data File Directory: Selects the folder where the File Server saves files. Serial Port: Selects the serial port where the Teach Pendant Controller is connected (COM 2 to COM 7).

CNC Software: Opens the folder CNC Software of the Program Options window.

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CNC Software folder in the Program Options window.

The options that can be set in the CNC Software folder are: CNC Mill Program Location: Selects the folder where the Mill Software is installed. Serial Port: Selects the serial port where the CNC Mill is connected (COM 1 to COM 6). CNC Lathe Program Location: Selects the folder where the Lathe Software is installed. Serial Port: Selects the serial port where the CNC Lathe is connected (COM 1 to COM 6).

Window Cascade: Arranges all open Task Editor windows in a cascade so that each one is visible. This reduces and overlaps all currently open windows to create a look similar to that of a well-organized filing cabinet. The title bars of all windows are always visible, and the window closest to the front is active. Tile Horizontal: Arranges from top to bottom all open Task Editor windows as tiles so that each one is visible. Tile Vertical: Arranges side by side all open Task Editor windows as tiles so that each one is visible. Close All: Closes all Task Editor windows. Minimize All: Minimizes all Task Editor windows. Restore All: Restores all Task Editor windows.
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Controller Status: Opens the Controller Status window. This window displays the status of the inputs and outputs of the Robot Controller.
Note: The Controller Status window will not open if the Online option in the Robot menu is disabled, or if the Robot Controller is not configured.

Controller Status window.

The Controller Status window shows the following elements: Inputs: Shows the status of the TTL inputs.
Note: A green LED corresponds to a high level, and a red LED corresponds to a low level.

Outputs: Shows the status of the TTL outputs. The level of an output can be changed by clicking the corresponding LED. Relays: Shows the status of the Relays. The status of a relay can be changed by clicking the corresponding LED.
Note: A green LED corresponds to the activated status, and a red LED corresponds to a non activated status.

CNC 1 Inputs: Shows the status of the CNC 1 inputs. CNC 1 Outputs: Shows the status of the CNC 1 outputs. The level of an output can be changed by clicking the corresponding LED. CNC 2 Inputs: Shows the status of the CNC 2 inputs. CNC 2 Outputs: Shows the status of the CNC 2 outputs. The level of an output can be changed by clicking the corresponding LED. Warning Messages: The following warning messages are displayed when applicable.

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Robot has not been hard homed.: Indicates that the Servo Robot has not been hard homed. A hard home positioning must be executed at the beginning of each session. Emergency stop is Activated.: Indicates that the emergency stop button has been pressed. Ask your instructor to check your setup to remove any dangerous condition, and to release the switch using the appropriate key.

Point Editor: Opens the Point Editor window. The Point Editor window is an interface from where the Servo Robot is controlled and where position and control points are created, saved, and edited. The Point Editor window can be viewed in Teach mode and Edit mode. Teach Mode: In this mode, the Point Editor window is used to control the Servo Robot and external device(s) connected to CH 1 and CH 2, and to save position and control points.

Point Editor in Teach mode.

The description of each function in the window is as follows: Movement Arrows: Moves the articulated sections. To do so, place the cursor on the arrows representing the desired movement while pressing and holding the left button of the mouse. The articulated section will move as long as the left button is held pressed or until a limit switch is activated. The arrows named Open and Close control the gripper, and the CH 1 and CH 2 arrows control the devices connected to these ports. Speed: Sets the speed of the Servo Robot and external device(s) connected to CH 1 and CH 2 between 1 and 99.

Edit button: Switches the Point Editor window in Edit mode.

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Replace button: Replaces the point beside the cursor in the point list. Clicking the Replace button when the cursor is beside a position point opens the Save Position Point window. This window is described in this section. Clicking the Replace button when the cursor is beside a control point opens the Save Control Point window. This window is described in this section. Delete button: Deletes the selected point(s) in the point list. Drive button: Executes a group of points. To do so, select the group of points you want to execute, then click the Drive button. The Run Point window appears and the group of points is executed starting with the first selected point. The Run Point window shows the status of the instruction that is executed and the name of the current point.
Note: To select a group of points, highlight the points by clicking each point while holding the Ctrl key pressed, or by clicking the first and last point of the list while holding the Shift key pressed.

Run Point window.

Move button: Moves the Servo Robot from the current position to a point in the point list. To do so, click the point where you want the Servo Robot to move then click the Move button. The Run Point window appears, and the Servo Robot moves directly to the point without executing the intermediate points, if any. If an obstacle is present between the current position and the selected point, a collision will occur. Execute button: Executes all points in the point list. Clicking the Execute button opens the Run Point window, and all points are executed as shown in the list, from top to bottom. Move Up button: Moves the position or control point beside the cursor over the preceding point. Move Down button: Moves the position or control point beside the cursor under the next point. Save Position Point button: Opens the Save Position Point window to save the position coordinates of the current position. The elements that can be set in the Save Position Point window are:

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Name: Displays a default, also allows a new name to be entered. Robot check box: Saves the coordinates of the Servo Robot. External Device check box: Saves the coordinates of the external device(s) connected to CH 1 or CH 2. Save button: Saves the point with the name shown in the Name field.

Save Position Point window.

Note: The Robot and External Device check boxes allow independent operation of the Servo Robot and external device(s) connected to CH 1 and CH 2. Saving a point when both check boxes are enabled, will cause the Servo Robot and external device(s) to move simultaneously. The default setting of the check boxes is Robot enabled and External Device disabled.

Cancel button: Closes the window without saving any changes.

Set Control Point button: Opens the Save Control Point window. Sets the status of inputs and outputs.

Save Control Point window.

The elements that can be set in the Save Control Point window are: Name: Names the control point. Accept the default name or enter a new name in the Name field. Inputs: Sets the level at which the TTL inputs must be before proceeding with the next instruction line in the program.

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Note: The level is set by clicking the corresponding LED. A green LED corresponds to a high level, a red LED corresponds to a low level, and a blue LED indicates that no level is assigned.

Outputs: Sets the level at which the TTL outputs will be after this instruction is executed. CNC 1 Inputs: Sets the level at which the CNC 1 inputs must be before proceeding with the next instruction line in the program. CNC 1 Outputs: Sets the level at which the CNC 1 outputs will be after this instruction line is executed. CNC 2 Inputs: Sets the level at which the CNC 2 inputs must be before proceeding with the next instruction line in the program. CNC 2 Outputs: Sets the level at which the CNC 2 outputs will be after this instruction line is executed. Relays: Activates or deactivates the Relays. To activate a relay, click the corresponding LED. A green LED corresponds to activated, a red LED corresponds to deactivated, and a blue LED indicates that no status is assigned. Delay: Sets the amount of time in seconds the system will pause before proceeding with the next instruction line in the program. Save button: Saves the current settings with the name shown in the Name field. Cancel button: Closes the window without saving any changes.

Edit Mode: In Edit mode, the Point Editor is used to change the characteristics of a position or control point.

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Point Editor in Edit mode.

The elements that are editable are:

Speed Gripper Wrist Pitch Wrist Rotation Elbow Shoulder Base Channel 1 Channel 2 TTL inputs TTL outputs CNC 1 inputs CNC 1 outputs CNC 2 inputs CNC 2 outputs Relays Delay

To change the characteristics of a point, double click the point name in the point list to select it, then click the Edit button. In the Point Editor window in Edit mode, click the Edit button to enable the edition mode. If the selected point is a position point, the elements in the Robot and External Device sections are edited and can be modified. Enter the new settings in the field beside the parameter to change, then click the Teach button to save the settings and return the Point Editor window in Teach mode. If the selected point is a control point, the elements in the Control Point section are edited and can be modified by clicking the LEDs, and/or entering a new Delay value. Make the desired changes, then click the Teach button to save the settings and return the Point Editor window in Teach mode. The description of each function in this window is as follows: Teach button: Saves the current settings and switches the Point Editor window in Teach mode. Edit button: Edits the various settings to allow changes.

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Delete button: Refer to the description given in the Teach Mode section. Drive button: Refer to the description given in the Teach Mode section. Move button: Refer to the description given in the Teach Mode section. Execute button: Refer to the description given in the Teach Mode section. Reset button: Cancels the changes without closing the window. Move Up button: Refer to the description given in the Teach Mode section. Move Down button: Refer to the description given in the Teach Mode section. Robot check box: Refer to the description given in the Teach Mode section. External Device check box: Refer to the description given in the Teach Mode section. Absolute Position check box: When enabled, indicates that the point coordinates are absolute. This means that the coordinates are determined relative to a predetermined position (hard home position). When disabled (not checked), indicates that the point coordinates are relative. This means that the coordinates are determined relative to the previous position.

Active Tasks: Displays the files that are currently open (maximum 10).

Help Contents: Enters the Robotics Help. About: Opens a window which provides general information about Robotics.

Toolbar The description of each button of the toolbar is as follows: Exit: Refer to the description given in the File subsection of the Menu Bar section. Open: Refer to the description given in the File subsection of the Menu Bar section. Save: Refer to the description given in the File subsection of the Menu Bar section.

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Info: Refer to the description given in the File subsection of the Menu Bar section. Print: Refer to the description given in the File subsection of the Menu Bar section. Undo: Refer to the description given in the Edit subsection of the Menu Bar section. Cut: Refer to the description given in the Edit subsection of the Menu Bar section. Copy: Refer to the description given in the Edit subsection of the Menu Bar section. Paste: Refer to the description given in the Edit subsection of the Menu Bar section. Find: Refer to the description given in the Search subsection of the Menu Bar section. Find and Replace: Searches for specific words and phrases in the Task Editor window and replaces them by new ones. Find Next: Refer to the description given in the Search subsection of the Menu Bar section. Go to Line: Refer to the description given in the Search subsection of the Menu Bar section. Run Task: Refer to the description given in the Robot subsection of the Menu Bar section. Contents: Enters the Robotics Help.

Status Bar The Status bar is shown at the bottom of the Main window. It contains 5 fields showing information about the operation of Robotics.

From left to right, the content of each field is as follows: C The first field gives information about the operation of the system. It also describes the function of the buttons and options in the menus. C The second field indicates if the Robot Controller is Online or Offline.

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C The third field indicates the current position of the cursor in the Task Editor window (horizontally and vertically). C The fourth field indicates if the file was modified since the last save operation. C The last field shows the typing mode: Insert or Overwrite.

Context-Sensitive Menus Context-sensitive menus are available in Robotics. They are displayed by clicking the right button of the mouse. The commands available in the context-sensitive menus depend on the window sections on which the mouse pointer is placed when the button is clicked. The commands available in the context-sensitive menus are: In the Robot Section of the Point Editor in Teach Mode Speed: Maximum: Sets the speed at 99. Speed: Transit: Sets the speed at 75. The transit speed is used for long distance when precision is not required.
Note: The Transit, Approach and Precision Speed values can be changed. Refer to the description given in the Options subsection of the Menu Bar section.

Speed: Approach: Sets the speed at 40. The approach speed is used when the movement requires medium precision. Speed: Precision: Sets the speed at 15. The precision speed is used when the movement requires precision. Save Point: Saves the absolute coordinates of the point. Refer to the description of the Save Position Point button given in the Teach Mode subsection of the Point Editor Window section. Save Control Pt.: Refer to the description given in the Teach Mode subsection of the Point Editor Window section. Save Relative Pt.: Saves the relative coordinates of the point. Refer to the description of the Save Position Point button given in the Teach Mode subsection of the Point Editor Window section. Set Soft Home: Refer to the description given in the Motion Control subsection of the Robot section.

In the Point List Section of the Point Editor and Task Editor Windows Move Up: Refer to the description given in the Teach Mode subsection of the Point Editor Window section.

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Move Down: Refer to the description given in the Teach Mode subsection of the Point Editor Window section. Move to Top: Moves the point beside the cursor to the top of the point list (next to the home or soft home). Move to Bottom: Moves the point beside the cursor to the bottom of the point list. Rename: Opens the Save Position Point or Save Control Point window depending on if the cursor is beside a position or a control point to enter a new name for the point. Duplicate: Duplicates the selected point. Replace: Refer to the description given in the Teach Mode subsection of the Point Editor Window section. Delete: Refer to the description given in the Teach Mode subsection of the Point Editor Window section. Drive To: Refer to the description given in the Teach Mode subsection of the Point Editor Window section. Move To: Refer to the description given in the Teach Mode subsection of the Point Editor Window section. Move Home: Refer to the description given for the Soft Home option of the Motion Control subsection of the Robot section. Set Active: Moves the cursor beside the highlighted point. The active point is the point beside the cursor. Execute: Refer to the description given in the Teach Mode subsection of the Point Editor Window section.

In the Left Column of the Task Editor Window Edit Redo: Refer to the description given in the Edit subsection of the Menu Bar section. Cut: Refer to the description given in the Edit subsection of the Menu Bar section. Copy: Refer to the description given in the Edit subsection of the Menu Bar section. Paste: Refer to the description given in the Edit subsection of the Menu Bar section.

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Duplicate: Refer to the description given in the Edit subsection of the Menu Bar section. Clear: Refer to the description given in the Edit subsection of the Menu Bar section. Select All: Refer to the description given in the Edit subsection of the Menu Bar section. Search Find: Refer to the description given in the Search subsection of the Menu Bar section. Find Next: Refer to the description given in the Search subsection of the Menu Bar section. Replace: Refer to the description given in the Search subsection of the Menu Bar section. Go To Line: Refer to the description given in the Search subsection of the Menu Bar section. Go To Bookmark: Refer to the description given in the Search subsection of the Menu Bar section. Set Bookmark: Refer to the description given in the Search subsection of the Menu Bar section.

Tools Clear Undo Buffer: Deletes the content of the Clipboard. Clear All (without undo): Deletes the selected instruction line(s) but does not save to the Clipboard. It is not possible to recall the deleted line(s). Print: Refer to the description given in the File subsection of the Menu Bar section. Print Setup: Refer to the description given in the File subsection of the Menu Bar section.

Programming Principles Two types of programs can be developed with your Servo Robot System: Point-toPoint programs and Task programs.

4-26

Robotics
Point-to-Point Programming Point-to-point programming means moving the Servo Robot (or external device(s) connected to CH 1 and CH 2) through a series of positions (points) and recording the coordinates of each point. Once all points are recorded, the sequence of points is executed as listed in the point list. Note that once the execution is launched, the program executes all points. Pointto-point programs may consist in a list of position points and control points. They can be created with both the Hand-Held Terminal and Robotics.

Task Programming Task programs consist in a list of instruction lines. The instruction lines include task commands and points. Task programming is not possible when using the Hand-Held Terminal alone. To create a task program, the position points are first determined using Robotics or the Hand-Held Terminal. Then, they are copied into the Task Editor window where they are associated with task commands. All task commands are inserted in the Task Editor window.

Copying Points from the Point Editor into the Task Editor You can copy a single point or a group of points from the Point Editor to the Task Editor. To copy a single point, click the point and drag it to the right column of the Task Editor window.
Note: To open the Task Editor window, select New in the File menu. The Program Information window will appear. Enter the information and click the OK button. Then the Task Editor window will open.

To copy a group of points, use the Shift or Ctrl key to select the desired points. Click the last point while pressing the Shift or Ctrl key and drag the group to the right column of the Task Editor window. The same methods apply when you copy points in the opposite direction: from the Task Editor to the Point Editor.

Copying Points from the Robot Controller Memory into the Task Editor To copy points from the Robot Controller into the Task Editor, select New Task Editor in the Upload to submenu from the Robot menu and follow the instructions.
Note: Once the points are copied in the Task Editor, save the file. It is good practice to save the file as soon as the points are copied into the Task Editor.

4-27

Robotics
Task Commands Once the points are copied into the right column of the Task Editor window, they must be selected and copied into the left column where they will be associated with task commands to form a program. Robotics has a powerful set of task commands. The task commands are entered by placing the cursor beside a line number and by typing the task command, inserting a space, and typing the name of the point: MOVETO POINT3 as an example. The name of the point must be exactly the same as the spelling of the point in the right column. It is not necessary to use every point in the right column. The description of the task commands available in Robotics is shown in Appendix C.

Running a Task Program Run the task program by performing the following steps: C Select Run Task in the Robot menu. If syntax errors are present, the Compile Task window will appear identifying the line where the problem is, and an error message.

Compile Task window.

C Correct the error and select Run Task again. When the task program is free of errors, the Run Task window appears. Click the Step button in the Run Task... window if you desire to execute the instruction lines one-by-one. The Step button allows you to see how each instruction line is executed. When you are confident with each instruction line, click the Run button.

Editing a Task Program Like the Point Editor, the Task Editor has editing capabilities.
Note: For adding points, you must use the Point Editor to manipulate the Servo Robot to create and save new points. 4-28

Robotics

Using the Task Editor you can annotate instruction lines, delete and add instructions.

Annotating a Task Program A good practice is to annotate the purpose of the major instruction lines. If the annotation is well done, you will be able to make modifications and improvements more easily. You can make comments any place in your task program by preceding the comment with a backslash (\).

Deleting Code To delete characters, select the required character or group of characters then select Clear in the Edit menu, or press the Delete key on the keyboard or the Scissors icon. To delete a line space, place the cursor at the beginning of the open line then press the Delete key on the keyboard.

Adding Code You can add code to the task program by placing the cursor where required and typing the code.

4-29

4-30

Section Safety Procedures

Safety Procedures
Caution! Follow these recommendations scrupulously when using the training system.

C The equipment must be installed and connected as described in this guide. C The installation of heavy equipment such as the Servo Robot, Linear Slide and Rotary Carousel, should be made by two people. C No wall or obstacles should be present within 750 mm (30 in) from the base of the Servo Robot. C The power source must be in accordance with the applicable codes. C The instructor should visually check the Servo Robot and work area to identify hazardous conditions before using the system. C Safety glasses must be worn at all times while operating the equipment. C Make sure you are not wearing anything that might get caught, such as a tie or jewelry. If your hair is long, tie it out of the way. C The Emergency Stop module must be easily accessible by the operator at any time. C No food or drink is allowed in the laboratory. C If the equipment does not appear to be operating properly or malfunctions, stop using it immediately and report the problem to the instructor.

5-1

5-2

Section Care and Maintenance

The Servo Robot of the Servo Robot System requires little maintenance. However, it is important to maintain the gear and belt system clean to insure many hours of trouble-free operation. If a problem occurs, do not try to service it yourself as you may void your warranty. If you are uncertain about what may be wrong, call your sales representative or the Lab-Volt technical support department.

Lubrication Once a week, apply one drop of general-purpose lubricating oil at each location shown in Figure 6-1.
Note: Applying the correct amount of lubricating oil is important. Over lubrication does not help the operation.

6-1

Care and Maintenance

Figure 6-1. Lubrication points.

Belt Tension Proper tension on each belt is required to obtain precision. The arm on the robot moves as a result of pulleys and belts working together. Through normal use, belts may develop slack due to normal wear. If an articulation seems loose, one or more belts may need to be tightened. To do so, identify which belt(s) are slack, and loosen the screws of the belt tensioners on both sides of the arm. The belt tensioners are located in Figure 6-2. Move the tensioner until the belt slack is removed, then tighten the screws. The cover of the shoulder must be removed to access some of the belt tensioners.

6-2

Care and Maintenance

BELT TENSIONERS

BELT TENSIONER

Figure 6-2. Location of the belt tensioners.

6-3

6-4

Appendix Hand-Held Terminal Menus

Main Menu N Name:_ Absolute F Flags: Relative S Speed:_ 1 Gripper:_ 2 Wrist R:_ Point Editor 3 Wrist P:_ 4 Elbow:_ 5 Shoulder:_ 6 Base:_ 7 Ch 1:_ 8 Ch 2:_ 0 Save Changes N Name:_ TTL OUTPUT KEY 1 2 3 4 5 6 7 8 OLD X X X X X X X X NEW X X X X X X X X TTL INPUT KEY 1 2 3 4 5 6 7 8 OLD X X X X X X X X NEW X X X X X X X X RELAY KEY 1 2 3 4 OLD X X X X NEW X X X X CNC1 INPUT | OUTPUT KEY 1 2 3 4 A B C D OLD X X X X X X X X NEW X X X X X X X X CNC2 INPUT | OUTPUT KEY 1 2 3 4 A B C D OLD X X X X X X X X NEW X X X X X X X X

1 TTL Output 1 Point Manager 2 TTL Input

3 Relay Control Editor

4 CNC 1

5 CNC 2

D Delay:_ 0 Save Changes CLEAR ARE ENTER ESC ALL POINTS YOU SURE? TO CONTINUE TO ABORT

C 6 7

Deletes the point beside the cursor. Moves the point beside the cursor over the preceding point. Moves the point beside the cursor under the next point. EXECUTE POINTS RUN ONCE ____ PRESS ESC TO ABORT EXECUTE POINTS RUN FOREVER: _ ____ PRESS ESC TO ABORT EXECUTE POINTS TRACE MODE ____ PRESS ESC TO ABORT

2 Task Manager

1 Run Once

2 Run Forever

3 Trace Points

A-1

Hand-Held Terminal Menus

CLEAR ARE ENTER ESC ALL POINTS YOU SURE? TO CONTINUE TO ABORT

4 Clear Points

1 Save to Disk _ 3 File Manager 2 Load From Disk

SAVE FILE ENTER FILENAME

OVERWRITE TASK ARE YOU SURE? ENTER TO CONTINUE ESC TO ABORT

1 Soft Home 2 Set Soft Home 3 CLR Soft Home PERFORM HARD HOME 4 Hard Home ENTER TO CONTINUE ESC TO ABORT

4 Motion Control

5 Free Motors 6 Torque Motors HARDWARE RESET ARE YOU SURE? ENTER TO CONTINUE ESC TO ABORT

7 Hardware Reset

8 Soft Limits OFF 9 Soft Limits ON Servo Pneu 1 Grip Elec None L Slide 2 Ch 1 Carousel None 5 Configuration 3 Ch 2 L Slide Carousel None ON 4 Key Click OFF ON 5 Shift Lock OFF S Save Config 9 Shutdown Teach Menu 0 Speed Control SET SPEED >------------------+< 1 099 99

1 Gripper Open H Gripper Close 2 Wrist CW I Wrist CCW 3 Wrist Pitch Down J Wrist Pitch Up 4 Elbow Pitch Down R Elbow Pitch Up 5 Shldr Pitch Down

A-2

Hand-Held Terminal Menus

S Shldr Pitch Up 6 Base CCW T Base CW 7 Ch 1 Forward Z Ch 1 Backward 8 Ch 2 Forward / Ch 2 Backward TTL OUTPUT KEY 1 2 3 4 5 6 7 8 OLD L L L L L L L L NEW X X X X X X X X TTL INPUT KEY 1 2 3 4 5 6 7 8 OLD H H H H H H H H NEW X X X X X X X X RELAY KEY 1 2 3 4 OLD L L L L NEW X X X X SET DELAY VALUE IN SECONDS >_ CNC1 INPUT | OUTPUT KEY 1 2 3 4 A B C D OLD L L L L L L L L NEW X X X X X X X X CNC2 INPUT | OUTPUT KEY 1 2 3 4 A B C D OLD L L L L L L L L NEW X X X X X X X X SAVE POSITION ENTER POINT NAME >POINT1_ SAVE POSITION ENTER POINT NAME >POINT1_ SAVE CONTROL ENTER POINT NAME >CTRL1_

F TTL Output

G TTL Input

P Relay

Q Time Delay

X CNC 1

Y CNC 2

C Save Abs Point

# Save Rel Point

* Save Control

A-3

A-4

Appendix Robotics Menus

New Open Close Save Save As File Revert Info Print Print Setup Shutdown Exit Undo Redo Cut Edit Copy Paste Duplicate Clear Select All Find Find Next Search Replace Go To Line Go To Bookmark Set Bookmark Run Task Soft Home Set Soft Home Motion Control Clear Soft Home Free Motors Torque Motors Robot Download from... Upload to... Release Emergency Stop Online Hard Home Task Editor Point Editor New Task Editor Point Editor

B-1

Robotics Menus
Environment Options Hardware File Server CNC Software Cascade Tile Horizontal Tile Vertical Window Close All Minimize All Restore All Controller Status Point Editor Help Contents About

B-2

Appendix Task Commands

TASK COMMANDS - QUICK REFERENCE TABLE Command Parameters Function

CAROUSEL
CNCINPUT(x,y) CNCOUTPUT(x,y) DELAY DO DRIVETO ELSE END ENDIF ERROR GOSUB HOME IF INPUT(x) LATHE MESSAGE MILL MOVETO OUTPUT(x) RELAY(x) REPEAT RESTART RETURN RUNTO SPEED SUB UNTIL WHILE

<[0|1]> <[0|1]> <[0|1]> <0-999> <1-9999> <point> none none none <msg> <name> none <expr> <[0|1]> <filename> <msg> <filename> <point> <[0|1]> <[0|1]> none none none <point> <0-99> <name> none <expr>

Starts carousel on CH 1 or CH 2, waits for TTL input x high(1) or low(0) then stops the carousel Waits for CNC x (1 or 2), line y high (1) or low (0) Sets the CNC x (1 or 2), line y to high (1) or low (0) Delays the execution for xxx seconds Repeats a series of line instructions for a set count Executes all points in sequence from active to named point Branch point for false condition in IF statement Ends the task Ends of IF conditional Halts task execution and display a custom error msg Transfers execution to the named subroutine Moves to the soft home position Branch execution on conditional expression Waits for TTL input x high(1) or low(0) Download via the CNC Lathe Software Displays a custom message on the task window Download via the CNC Mill Software Executes a specified point Sets TTL output x to high(1) or low (0) Activates or deactivate Relay x Ends the WHILE loop statement list Restarts the task program at the first command Ends of the current subroutine Executes a specified point at max speed Sets an override speed for all subsequent point Defines the start of a subroutine Ends the DO loop statement list Begins a loop of statements when <expr> is true

C-1

Task Commands
COMMAND DESCRIPTION CAROUSEL Syntax: Parameters: Description: CAROUSEL(<integer 1-2>,<integer 1-8>) <[HIGH | LOW]> The Carousel command is used to control the operation of the Rotary Carousel. It causes the Rotary Carousel to rotate one turn or less if the status of a specified TTL input corresponds to a desired level. The values in parentheses indicate the channel (1 or 2) where the Rotary Carousel is connected and the TTL input (18) to read. The parameter that follows indicates the desired level of the TTL input. This command will suspend the rotation of the Rotary Carousel if the level matches the command parameter. <[HIGH | LOW]> can be interchanged with <[ON | OFF]>, <[CLOSE | OPEN]>, or <[1 | 0]>. 0001: 0002: 0003: CAROUSEL(1,1) HIGH MOVETO POINT1 END

Note:

Example:

Line 1 causes the Rotary Carousel to rotate one turn or less if the level detected at TTL input 1 is high. Then the program executes POINT1 and ends.

CNCINPUT Syntax: Parameters: Description: CNCINPUT(<integer 1-2>,<integer 1-4>) <[HIGH | LOW]> This command reads the specified input on CNC 1 or CNC 2. Usually a channel is used to directly interface with other automation or CNC equipment. The value in parentheses indicates the channel (1 or 2) and the input (1-4) to read. This command will block and suspend task execution until the read value matches the command parameter. <[HIGH | LOW]> can be interchanged with <[ON | OFF]>, <[CLOSE | OPEN]>, or <[1 | 0]>. 0001: 0002: 0003: 0004: CNCINPUT(1,2) HIGH GOSUB LOAD_PART CNCOUTPUT(1,2) HIGH RESTART

Note:

Example:

This program shows a simple control loop that might be used with CNC equipment. First, line 1 waits for CNC 1, input 2 to be high,

C-2

Task Commands
then a subroutine that loads a piece of stock into the machine executes. Once the stock is loaded, CNC 1, output 2 (or B) is set at high. Finally, the process is restarted.

CNCOUTPUT Syntax: Parameters: Description: CNCOUTPUT(<integer 1-2>,<integer 1-4>) <[HIGH | LOW]> This command controls the specified output on CNC 1 and CNC 2. Usually a channel is used to interface with other automation or CNC equipment. The value in parentheses indicates the channel (1 or 2) and the output (1-4 or A to D) to change. The parameter that follows indicates the desired status of the output. <[HIGH | LOW]> can be interchanged with <[ON | OFF]>, <[CLOSE | OPEN]>, or <[1 | 0]>. 0001: 0002: 0003: 0004: CNCINPUT(1,2) HIGH GOSUB LOAD_PART CNCOUTPUT(1,2) HIGH RESTART

Note:

Example:

This program shows a simple control loop that might be used with CNC equipment. First, line 1 waits for CNC 1, input 2 to be high, then a subroutine that loads a piece of stock into the machine executes. Once the stock is loaded, CNC 1, output 2 is set at high. Finally, the process is restarted.

DELAY Syntax: Parameters: Description: DELAY <integer 0-999> Delay task execution for the value expressed in seconds. If the parameter value is 0, then the task execution is paused until the user clicks the Run button in the Run Task window. 0001: 0002: 0003: 0004: 0005: 0006: MOVETO POINT1 DELAY 10 MOVETO POINT2 DELAY 0 HOME END

Example:

This program executes POINT1 then delays the execution for 10 seconds. Line 3 executes POINT2 and then the delay stops execution. The user then clicks the Run button and the HOME

C-3

Task Commands
command executes. Finally the program terminates at the END command.

DO Syntax: Parameters: Description: DO <integer 1-999> This command indicates the start of a series of commands that are to be executed repeatedly. The parameter indicates the number of repetitions that the instruction lines between the DO and UNTIL commands are run. 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: 0009: DO 5 IF INPUT(3) = LOW END ELSE MOVETO POINT1 MOVETO POINT2 MOVETO POINT3 ENDIF UNTIL

Example:

Note: As shown in this example, formatting the instruction lines of the program makes it easier to read.

This program executes POINT1, POINT2 and then POINT3 in order, 5 times in a row unless TTL input 3 goes low, and then the END command is executed. This demonstrates that the only way to stop the execution of the DO loop is by user abort or by inserting an END, RESTART or ERROR command into the loop. See also: UNTIL

DRIVETO Syntax: Parameters: Description: DRIVETO <string point name> This command operates as a shortcut instead of repeating multiple MOVETO commands. To execute a series of points from the associated point list, this command will execute every point between the current active point and the point named in the command parameter. The points will be executed in the order that they exist in the point list. Normally, you would start the execution of a long sequence of points by first calling the MOVETO command with the first point in sequence and then follow that command with a DRIVETO
C-4

Task Commands
command that indicates the last point in the sequence. This can simplify the task program when a large number of movements must be executed in order. Warning: The points execute in the order they exist in the point list. Changing the point list will modify how this command executes. 0001: 0002: 0003: MOVETO POINT1 DRIVETO POINT4 END

Example:

Assuming that POINT1, POINT2, POINT3, and POINT4 are defined in the point list in that order, this program will first execute POINT1. The DRIVETO command will then execute every point between POINT1 up to and including POINT4.

ELSE Syntax: Parameters: Description: ELSE None This command indicates the end of the instruction lines that are executed when a TRUE condition is evaluated by a previous IF command. The instruction lines that follow the ELSE command are executed in the event that the associated IF command evaluated a FALSE value. 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: 0009: 0010: MOVETO POINT1 MOVETO POINT2 IF INPUT(1) = HIGH IF OUTPUT(2) = LOW MESSAGE Turn on the conveyor! ELSE GOSUB LOAD_FROM_CONVEYOR ENDIF ENDIF END

Example:

This program shows how to use the IF command and also shows that you can nest IF commands within each other. Line 3 checks if TTL input 1 is high and if so, executes the next instruction line. Line 4 then checks if TTL output 2 is low. If the IF command detects that the external device on TTL output 2 is low, then the message on line 5 is displayed. Conversely, If the IF command detects that the external device on TTL output 2 is high, then the execution will jump to the instruction line that follows the ELSE command, which calls a GOSUB to actually run the loading routine. See also: IF, ENDIF

C-5

Task Commands

END Syntax: Parameters: Description: END None This command ends the execution of the current task. If the Repeat Task check box is checked in the Run Task window, the program will restart execution at the beginning of the program. This command can be placed anywhere in the task program but unless you are defining subroutines, all instruction lines past the END command will never be executed. 0001: 0002: 0003: MOVETO POINT1 MOVETO POINT2 END

Example:

See also:

MOVETO

ENDIF Syntax: Parameters: Description: ENDIF None This command indicates the end of an IF-ELSE-ENDIF block of codes and the execution continues with the next instruction line. For each IF command there must be exactly one matching ENDIF command. If there are multiple nested IF commands, each one must have a matching ENDIF command. 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: 0009: 0010: MOVETO POINT1 MOVETO POINT2 IF INPUT(1) = HIGH IF OUTPUT(2) = LOW MESSAGE Turn on the conveyor! ELSE GOSUB LOAD_FROM_CONVEYOR ENDIF ENDIF END

Example:

This program shows how to use the IF command and also that you can nest IF commands within each other. Line 3 checks if TTL input 1 is high and if so, executes the next instruction line. Line 4 then checks if TTL output 2 is low. If the IF command detects that the external device on TTL output 2 is low, then the message on line 5 is displayed. Conversely, If the IF command detects that the external device on TTL output 2 is high, then the

C-6

Task Commands
execution will jump to the instruction line that follows the ELSE command, which calls a GOSUB to actually run the loading routine. See also: IF, ELSE

ERROR Syntax: Parameters: Description: ERROR <string message> This command will halt the execution of the current task program and the string message provided as a parameter will be displayed in the message area of the Run Task window. The status will be set to display ERROR. Use this command if you want to generate an error in your program if an unexpected condition occurs. 0001: 0002: 0003: 0004: 0005: IF INPUT(1) = LOW ERROR No stock is available ELSE GOSUB LOAD_STOCK ENDIF

Example:

This program checks if TTL input 1 is low and if the condition tests true, the error message appears in the Message field of the Run Task window and the program execution is suspended.

GOSUB Syntax: Parameters: Description: GOSUB <string name> This command calls the named subroutine. Execution will return to the instruction line that follows the GOSUB command when the subroutine completes execution. You can call subroutines from within other subroutines. 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: 0009: 0010: IF INPUT(1) = HIGH MESSAGE Loading stock from conveyor. GOSUB LOAD_STOCK ENDIF END SUB LOAD_STOCK MOVETO POINT1 MOVETO POINT2 MOVETO POINT3 RETURN

Example:

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Task Commands
This program shows how to define and call subroutines. If TTL input 1 is high, then the GOSUB routine transfers execution to the instruction line that follows the SUB command. Lines 7 through 9 are then executed and the RETURN command in line 10 will return execution back to the instruction line that follows the GOSUB command that called this subroutine.

See also:

SUB, RETURN

HOME Syntax: Parameters: Description: HOME None Tells the Servo Robot to move to the assigned soft home position. This is the position that is defined by the point named HOME in the point list associated with this task. It is the position the Servo Robot starts its movements from, and where it will come to rest when you tell it to go home. You can modify the point coordinates using the Set Soft Home and Clear Soft Home functions. This command is functionally equivalent to calling MOVETO HOME. 0001: 0002: 0003: MOVETO POINT1 HOME END

Example:

This program executes POINT1 and then returns to the HOME position. HOME is defined as the first point in the point list.

IF Syntax: Parameters: Description: IF <expression> If the expression evaluates to TRUE, the execution continues normally with the next instruction line. If the expression is FALSE, the execution continues after the next ELSE command (if used) or ENDIF command. 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: MOVETO POINT1 MOVETO POINT2 IF INPUT(1) = HIGH IF OUTPUT(2) = LOW MESSAGE Turn on the conveyor! ELSE GOSUB LOAD_FROM_CONVEYOR ENDIF

Example:

C-8

Task Commands
0009: 0010: ENDIF END

This program shows how to use the IF command and also shows that you can nest IF commands within each other. Line 3 checks if TTL input 1 is high and if so, executes the next instruction line. Line 4 then checks if TTL output 2 is low. If the IF command detects that the external device on TTL output 2 is low, then the message on line 5 is displayed. Conversely, If the IF command detects that the external device on TTL output 2 is high, then the execution will jump to the instruction line that follows the ELSE command, which calls a GOSUB to actually run the loading routine. See also: ELSE, ENDIF

INPUT Syntax: Parameters: Description: INPUT(<integer 1-8>) <[HIGH | LOW]> This command reads the TTL inputs. The value in parentheses indicates the input to read and the parameter that follows the command indicates the desired status. This command will block and suspend task execution until the read value matches the command parameter. <[HIGH | LOW]> can be interchanged with <[ON | OFF]>, <[CLOSE | OPEN]>, or <[1 | 0]>. 0001: 0002: 0003: 0004: MOVETO POINT1 INPUT(4) LOW MOVETO POINT2 END

Note:

Example:

This program executes POINT1 and then waits until TTL input 4 is low then POINT2 is executed and the program ends.

LATHE Syntax: Parameters: Description: LATHE <string filenamepath> This command executes the external program associated with the LATHE command set in the Options window. The filename parameter is passed as a parameter to this program so that the CNC Lathe software will automatically download the file to a CNC Lathe.

C-9

Task Commands
Example: 0001: 0002: 0003: 0004: GOSUB LOAD_STOCK \Load stock into CNC Lathe LATHE sample_part.l4 \Download the part program to the Lathe CNCINPUT(1,1) HIGH \Wait for the CNC Lathe to signal completion END

This program shows how to use the LATHE command to download a CNC Lathe program. This command is used when integrating the Servo Robot System with CNC Lathe machinery.

MESSAGE Syntax: Parameters: Description: MESSAGE <string message> This command will display the string parameter data in the Message field of the Run Task window. This command does not stop the execution of the program so if you need the user to respond to your message, follow this command with a DELAY 0 command. 0001: 0002: 0003: 0004: IF INPUT(1) = HIGH MESSAGE Loading stock from conveyor. GOSUB LOAD_STOCK ENDIF

Example:

This program checks if TTL input 1 is high. If the condition tests true, a message is sent to the user in the Message field of the Run Task window, and the LOAD_STOCK subroutine is executed.

MILL Syntax: Parameters: Description: MILL <string filenamepath> This command executes the external program associated with the MILL command set in the Options window. The filename parameter is passed as a parameter to this program so that the CNC Mill Software will automatically download the file to a CNC Mill. 0001: 0002: 0003: 0004: GOSUB LOAD_STOCK \Load stock into CNC Mill. MILL sample_part.m4 \Download the part program to the Mill. CNCINPUT(1,1) HIGH \Wait for the Mill to signal completion. END

Example:

C-10

Task Commands
This program shows how to use the MILL command to download a CNC Mill program. This command is used when integrating the Servo Robot System with CNC Mill machinery. MOVETO Syntax: Parameters: Description: MOVETO <string point name> This command causes the execution of either a position point or a control point. 0001: 0002: MOVETO POINT1 END

Example:

This program executes POINT1 and then terminates.

OUTPUT Syntax: Parameters: Description: OUTPUT(<integer 1-8>) <[HIGH | LOW]> This command controls the status of the TTL outputs. The value in parentheses indicates the output to change and the parameter that follows indicates the new status of the output. <[HIGH | LOW]> can be interchanged with <[ON | OFF]>, <[CLOSE | OPEN]>, or <[1 | 0]>. 0001: 0002: 0003: 0004: OUTPUT(1) HIGH DELAY 5 OUTPUT(1) LOW END

Note:

Example:

This program sets TTL output 1 at high, delays for 5 seconds and then sets the output at low.

RELAY Syntax: Parameters: Description: RELAY(<integer 1-4>) <[CLOSE | OPEN]> This command controls the status of the relays. The value in parentheses indicates which relay is being controlled and the parameter that follows indicates the desired status: activated (close) or deactivated (open).

C-11

Task Commands
Note: <[CLOSE | OPEN]> can be interchanged with <[ON | OFF]>, <[HIGH | LOW ]>, or <[1 | 0]>. 0001: 0002: 0003: 0004: RELAY(1) CLOSE DELAY 5 RELAY(1) OPEN END

Example:

This program activates Relay 1, delays for 5 seconds and then deactivates the relay.

REPEAT Syntax: Parameters: Description: REPEAT None Indicates the end of a WHILE loop. When the loop reaches this command, execution will jump back to the associated WHILE command for reevaluation of the original WHILE expression. 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: MOVETO POINT1 WHILE INPUT(4) = HIGH \ Stock is available from feeder. GOSUB LOAD_STOCK OUTPUT(2) LOW GOSUB MOVE_STOCK OUTPUT(2) HIGH REPEAT END

Example:

This program shows how you might load stock from a feeder, move it somewhere, and repeat the operation until the stock feeder sets TTL input 4 at low. As long as TTL input 4 remains high, the instruction lines between the WHILE and REPEAT commands will be executed repeatedly. See also: WHILE

RESTART Syntax: Parameters: Description: RESTART None This command instructs the software to abort the current execution of the task and to restart from the beginning of the program. Unlike the END command, RESTART ignores the status of the Repeat Task check box in the Run Task... window.

C-12

Task Commands
Example: 0001: 0002: 0003: 0004: 0005: MOVETO POINT1 MOVETO POINT2 RESTART MOVETO POINT3 END

In this program, instruction lines 4 and 5 will never be executed.

RETURN Syntax: Parameters: Description: RETURN None This command defines the end of a subroutine. When this command is executed, the subroutine being executed exits and the execution will resume at the instruction line that follows the GOSUB command. Only one RETURN command is allowed in a subroutine and it must be the last command in the subroutine. 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: 0009: 0010: IF INPUT(1) = HIGH MESSAGE Loading stock from the conveyor. GOSUB LOAD_STOCK ENDIF END SUB LOAD_STOCK MOVETO POINT1 MOVETO POINT2 MOVETO POINT3 RETURN

Example:

This program shows how to define and call subroutines. If TTL input 1 is high, then the GOSUB routine transfers the execution to the instruction line that follows the SUB command. Lines 7 through 9 are then executed and the RETURN command in line 10 will return execution back to the instruction line that follows the original GOSUB command that called this subroutine. See also: GOSUB

RUNTO Syntax: Parameters: Description: RUNTO <string point name> This command tells the Servo Robot to execute either a position or control point. If the point is a position point, the movement will be executed at maximum speed. The Speed value that was defined for the point is ignored.

C-13

Task Commands
Example: 0001: 0002: 0002: MOVETO POINT1 RUNTO POINT2 END

This program will execute POINT1 and POINT2. If POINT2 is not a control point, the speed will be set at 99 (maximum value), overriding the Speed value saved in the position point. See also: MOVETO, END

SPEED Syntax: Parameters: Description: SPEED <integer 0-99> This command allows you to set an override Speed value for the instruction lines that follow the line containing this command. All position point moves will be executed at this new speed. The position points that follow a SPEED command set at 0 will be at their own defined speeds. 0001: 0002: 0003: 0004: 0005: 0006: 0007: MOVETO POINT1 MOVETO POINT2 SPEED 20 MOVETO POINT1 SPEED 0 MOVETO POINT2 END

Example:

In this program, the first two instruction lines move the Servo Robot to POINT1 and POINT2 normally. The speed override in line 3 means that the MOVETO command in line 4 will move at a speed of 20 instead of the previously defined speed of the point. Line 5 will disable the speed override and so the MOVETO on line 6 will move at the speed set in POINT2. This example assumes that POINT1 and POINT2 are not control points. The override Speed value has no effect on control points. See also: MOVETO, END

SUB Syntax: Parameters: Description: SUB <string name> This command defines the name and the starting location of a subroutine. All instruction lines that follow this command belong to the named subroutine until the RETURN command indicates the

C-14

Task Commands
end of the subroutine. Subroutines should always be defined after the END command and separate from each other. Subroutines can call other subroutines, but be warned that an infinite loop can occur when a subroutine calls itself. Example: 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: 0009: 0010: IF INPUT(1) = HIGH MESSAGE Loading stock from conveyor. GOSUB LOAD_STOCK ENDIF END SUB LOAD_STOCK MOVETO POINT1 MOVETO POINT2 MOVETO POINT3 RETURN

This program shows how to define and call subroutines. If TTL input 1 is high, then the GOSUB routine transfers execution to the instruction line that follows the SUB command. Lines 7 through 9 are then executed and the RETURN command in line 10 will return execution back to the instruction line that follows the original GOSUB command that called this subroutine. See also: GOSUB, RETURN

UNTIL Syntax: Parameters: Description: UNTIL None This command indicates the end of a DO loop sequence and if the number of passes through the DO loop is less than the DO command parameter, execution jumps to the original DO command. If the number of passes is greater than the number in the DO command, the execution continues with the instruction line that follows the UNTIL command. Example: 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: 0009: DO 5 IF INPUT(3) = LOW END ELSE MOVETO POINT1 MOVETO POINT2 MOVETO POINT3 ENDIF UNTIL

C-15

Task Commands
This program executes POINT1, POINT2 and then POINT3 in order, 5 times in a row unless TTL input 3 goes LOW, and then the END command is executed. This demonstrates that the only way to stop the execution of the DO loop is by user abort or by inserting an END, RESTART or ERROR command into the loop. See also: DO

WHILE Syntax: Parameters: Description: WHILE <expression> This command evaluates the expression. If it is true, it executes the instruction lines that follow, up to the REPEAT command. When the REPEAT command is reached, execution will return to the WHILE command in which the expression will be evaluated repeatedly until the expression fails. The expression value is only evaluated by the WHILE command. Changing the status of the inputs/outputs inside this command will not cause the loop to exit immediately. 0001: 0002: 0003: 0004: 0005: 0006: 0007: 0008: MOVETO POINT1 WHILE INPUT(4) = HIGH \Stock is available from feeder GOSUB LOAD_STOCK OUTPUT(2) LOW GOSUB MOVE_STOCK OUTPUT(2) HIGH REPEAT END

Notes:

Example:

This program shows how you might load stock from a feeder, move it somewhere, and repeat the operation until the stock feeder sets TTL input 4 at low. As long as TTL input 4 is high when the WHILE command on line 2 executes, the instruction lines between the WHILE and REPEAT commands will be executed repeatedly. See also: REPEAT

Conditional Statements The IF and WHILE commands use a parameter called an expression, which is a statement that when evaluated will produce a Boolean TRUE or FALSE value. A simple expression might look like this: IF ... TRUE (IF the expression INPUT(1) = HIGH is TRUE as an example) ... instruction lines ...

C-16

Task Commands
ELSE ... instruction lines ... ENDIF If the evaluated expression is true, the program will execute the instruction lines following it up to the ELSE command, where the execution would jump to the instruction line following the ENDIF command. In this example you can see that the instruction lines that fall between the ELSE and ENDIF are not executed because the evaluated expression is true. In all Robotics expressions, a general form is followed. This form is CMD <left expression> <conditional> <right expression>. CMD is either the IF or WHILE command. These are the only two commands that support expressions. The <left expression> and <right expression> are both values. These can be a direct value of 1 or 0 (or any of the legitimate replacements for these values: HIGH/LOW, ON/OFF, CLOSE/OPEN). Additionally, the expressions can be the value returned by any of the following commands: INPUT(x), OUTPUT(x), RELAY(x), CNCINPUT(x,y) or CNCOUTPUT(x,y). All of these commands will return either a 0 or 1 to indicate the current status of the input/output line. The <conditional> defines how to compare the two expressions. The following values are available:
CONDITIONAL STATEMENTS

=, == or EQ <>, != or NEQ <= or LEQ >= or GEQ < or LT > or GT && or AND || or OR XOR NAND

Equivalent Not equivalent Less than or equal Greater than or equal Less than Greater than Boolean AND (True if <left> = 1 and <right> = 1) Boolean OR (True if <left> = 1 or <right> = 1) Boolean XOR (Exclusive Or) True only if <left> is not equal to <right> Boolean NAND (Not And) True only if <left> = 0 and <right> = 0

C-17

C-18

Appendix Rotary Carousel, Model 5208

Description The Rotary Carousel of the Servo Robot System is shown in Figure D-1. It consists of a rotating platter mounted on a base. The Rotary Carousel is provided with a limit switch to detect the presence of objets on the platter.
CURSOR DISK PLATTER

NORMALLY OPEN TERMINAL NORMALLY CLOSED TERMINAL

LIMIT SWITCH

COMMON TERMINAL LOCATION PINS

[12 V

60 mA]

Figure D-1. Rotary Carousel, Model 5208.

The Rotary Carousel is also provided with a "cursor" disk. The cursor disk is located over the center of the platter. It is used to locate a reference position. To do so, rotate the cursor disk to align the line on the cursor disk with one of the lines on the platter. The Rotary Carousel is designed to be used with the Grids and the perforated Work Surfaces. When used with the Work Surfaces, the Rotary Carousel is located using two location pins under the base.

Connection The Rotary Carousel connects to CH 1 or CH 2 on the Robot Controller as shown in Figure D-2.
Note: Do not make or modify any connection while the Robot Controller is on.

D-1

Rotary Carousel, Model 5208

TO THE TTL INPUTS

ROBOT CONTROLLER REAR VIEW

CNC 1

CNC 2

CH 1

CH 2

5250

5250

Figure D-2. Connection of the Rotary Carousel.

The limit switch contacts connect to the TTL inputs on the Robot Controller. The blue terminal corresponds to the normally closed (NC) terminal of the limit switch, the yellow terminal corresponds to the normally open (NO) terminal, and the black terminals correspond to the common terminal.

Configuration Once the connection is made, the Robot Controller must be configured to detect the Rotary Carousel. To configure the Robot Controller when using Robotics, select the Hardware option in the Options menu. Select Rotary Carousel in the selection field of the channel where the Rotary Carousel is connected. Click the Save button to save the configuration. To configure the Robot Controller when using the Hand-Held terminal, press the 5 key in the Main menu to select Configuration. In the Configuration menu, place the cursor beside the channel number where the Rotary Carousel is connected, press the Enter key as required to select Carousel. Press the S key to save the configuration.

Operation The Rotary Carousel is driven by a servo motor mounted in the base. The platter can rotate either in the clockwise or counterclockwise direction. Its operation is controlled by clicking the CH 1 or CH 2 arrow in Robotics, or by pressing the 7 or Z key if the Rotary Carousel is connected to CH 1, or the 8 or / keys if it is connected to CH 2 when using the Hand-Held Terminal. The Carousel command can also be used to control the operation of the Rotary Carousel. Refer to Appendix C to obtain more information on how to use this command.
D-2

Rotary Carousel, Model 5208

Like the Servo Robot, the Rotary Carousel must be hard homed at the beginning of each session. Make sure that the parts are removed from the platter when executing a hard home positioning. The speed is controllable the same way as the motors of the Servo Robot. The position of the platter of the Rotary Carousel is saved as for the Servo Robot. Clicking the Save Position Point button in the Point Editor window of Robotics, opens the Save Position Point window. There are two check boxes in this window: Robot and External Device. Enable the External Device check box if you are saving the coordinates of the Rotary Carousel.

Save Position Point window.

The Robot and External Device check boxes allow independent operation of the Servo Robot and external device(s) connected to CH 1 and CH 2. When both check boxes are enabled, the Servo Robot and external devices are controlled simultaneously. It is not possible to save the coordinates of the Servo Robot and Rotary Carousel independently using the Hand-Held Terminal alone. The points created using the Hand-Held Terminal must be transferred in the Point Editor of Robotics. Each point must be edited and the check boxes enabled or disabled as required.

D-3

D-4

Appendix Belt Conveyor, Model 5210

Description The Belt Conveyor of the Servo Robot System is shown in Figure E-1. It consists of a belt which is driven by a servo motor. The Belt Conveyor is provided with a limit switch to detect the presence of parts on the belt. It is movable; there are several sets of mounting positions found along both sides of the conveyor chassis.

LIMIT SWITCH

LOCATION PIN

CONTROL PANEL

Figure E-1. Belt Conveyor, Model 5210

The Belt Conveyor is designed to be used with the Grids and the perforated Work Surfaces. When used with the Work Surfaces, the location guide must be installed on the Belt Conveyor. The guide is also movable, and it uses the same mounting holes as the limit switch.

Connection The Belt Conveyor connects to an AC power outlet. The STOP, MOTOR, and DIRECTION external inputs connect to the TTL outputs of the Robot Controller. The limit switch contacts connect to the TTL inputs of the Robot Controller. The blue terminal corresponds to the normally closed (NC) terminal of the limit switch, the yellow terminal corresponds to the normally open (NO) terminal, and the black terminals correspond to the common terminal.

E-1

Belt Conveyor, Model 5210

Operation The Belt Conveyor can be operated either by switches mounted on the control panel, or by control signals applied to its TTL inputs. The control signals are provided by the TTL outputs of the Robot Controller. The control panel of the Belt Conveyor is shown in Figure E-2. As the figure shows, the operating parameters that can be controlled on the control panel are the speed (SPEED), the logic level of the TTL input (STOP) at which the conveyor stops, motor engage/disengage (MOTOR), and belt direction (DIRECTION).

BELT CONVEYOR
MOTOR
EXT. INPUT

SPEED

ENGAGE EXT.

SLOW

FAST

DISENGAGE
[ TTL ]

STOP
INPUT LOGIC HIGH FORWARD

DIRECTION
EXT. INPUT

EXT. LOW
[ TTL ]

REVERSE
[ TTL ]

5210

Figure E-2. Control panel of the Belt Conveyor.

Speed The SPEED potentiometer controls the speed of the belt from Slow to Fast. At the Slow position, the belt of the conveyor is stopped.

Stop The Logic switch is used to select the TTL level required at the input Stop to remotely stop the conveyor. When the Logic switch is set at High, the conveyor stops on a high level. Conversely, when the Logic switch is set at Low, it stops on a low level.

E-2

Belt Conveyor, Model 5210

Motor The Motor switch is used to select between three operating modes: C Engage: In this mode, the motor of the Belt Conveyor is torqued and the conveyor runs if the settings of the Stop section correspond to a run condition. If the settings of the Stop section correspond to a stop condition the motor is stopped but remains torqued. Disengage: In this mode, the motor is stopped and freed (not torqued). Ext.: The operation is controlled remotely by a signal applied to the Ext. Input. When the level at the Ext. Input is high, the conveyor operates as in the Engage mode. Conversely, when the level is low, it operates as in the Disengage mode.

C C

Direction The Direction switch is used to select between three operating modes: C C C Forward: In this mode, the belt of the conveyor goes from right to left (when facing the control panel). Reverse: In this mode, the belt of the conveyor goes from left to right. Ext.: The operation is remotely controlled by a signal applied to the Ext. Input. When the level of the Ext. Input is high, the direction of the belt is in the Forward mode. Conversely, when the level is low, it is in the Reverse mode.

E-3

E-4

Appendix Gravity Feeders, Models 5119 and 5121

Description The Gravity Feeders of the Servo Robot System are shown in Figure F-1. The Model 5119 is designed to feed square parts having 50 x 50 x 25 or 37. 5 mm (2 x 2 x 1 or 1.5 in), and the Model 5121 is designed to feed cylindrical parts similar in form and dimensions to film canisters.

LOCATION PIN

MODEL 5119

MODEL 5121

Figure F-1. Gravity Feeders, Models 5119 and 5121

The Gravity Feeders are designed to be used with the Grid and the perforated Work Surfaces. When used with the Work Surfaces, the Gravity Feeders are located using the location pins at the back of the modules.

Connection The limit switch contacts connect to the TTL inputs on the base of the Servo Robot. The blue terminal corresponds to the normally closed (NC) terminal of the limit switch, the yellow terminal corresponds to the normally open (NO) terminal, and the black terminals correspond to the common terminal.

F-1

Gravity Feeders, Models 5119 and 5121

Operation The Gravity Feeders work on the principle that when a part is removed from the feeder, the force of gravity will bring the next piece down to where the Servo Robot can grasp it. The limit switch sends a signal when the feeder is empty. Usually, the Servo Robot will stop and wait until the feeder is filled before continuing on. When using the Gravity Feeder, Model 5121, it is suggested to add coins in the film canisters to improve stability.

F-2

Appendix Pneumatic Feeders, Models 5122 and 5142

Description The Pneumatic Feeders of the Servo Robot System are shown in Figure G-1.They work very much on the same principle as the gravity feeders but have the advantage of the force of air to propel the parts. Their operation is controlled by the Pneumatic Feeder Controller, Model 5149 (one controller is required for each feeder).
STORAGE SECTION

FEEDER SECTION

SLIDER

PNEUMATIC FEEDER MODEL 5122

PNEUMATIC FEEDER CONTROLLER MODEL 5149

Figure G-1. Pneumatic Feeder and Controller, Models 5122 and 5149.

The Pneumatic Feeder, Model 5122, is designed to feed square parts having 50 x 50 x 12.5 mm (2 x 2 x 0.5 in) and the Model 5142 is designed to feed cylindrical parts having a diameter of 19 mm (0.75 in) and a length of 50 mm (2 in). The Pneumatic Feeders are designed to be used with the Grids and the perforated Work Surfaces. When used with the Work Surfaces, the Pneumatic Feeders are located using the location pins under the modules.

G-1

Pneumatic Feeders, Models 5122 and 5142

Connection To connect a Pneumatic Feeder, perform the following steps:
Note: Do not place any parts in the storage section of the Pneumatic Feeder now.

Connect S1 on the Pneumatic Feeder to input 1 on the Pneumatic Feeder Controller as shown in Figure G-2.

PORT A PORT A PORT B INPUT 2 INPUT 1

A S1
S1 S2

PORT B

PNEUMATIC FEEDER CONTROLLER

SLIDER INPUTS EXTEND
PORT A
1 2

RETRACT
PORT B SPEED

B S2-A S2-B

SPEED

MAX.

MIN.

MAX.

MIN.

[12 V

60 mA]

5149

SLIDER SPEED CONTROLS

PNEUMATIC TUBES

Figure G-2. Connection of the Pneumatic Feeders.

C C

Connect S2-A on the Pneumatic Feeder to input 2 on the Pneumatic Feeder Controller as shown in Figure G-2. Connect port A on the Pneumatic Feeder to port A on the Pneumatic Feeder Controller with a pneumatic tube as shown in Figure G-2. Tighten the connectors. Connect port B on the Pneumatic Feeder to port B on the Pneumatic Feeder Controller with a pneumatic tube as shown in Figure G-2. Tighten the connectors. Connect the Air Supply Inlet on the Pneumatic Feeder Controller to an Air Supply Source as shown in Figure G-3. Note that the Air Supplied Source is not included with the Pneumatic Feeders.
Note: Do not apply compressed air to the Pneumatic Feeder now.

G-2

Pneumatic Feeders, Models 5122 and 5142

PNEUMATIC FEEDER CONTROLLER (REAR VIEW) AIR SUPPLY INLET DC POWER INPUT

AIR SUPPLY

POWER INPUT

TO AN AIR SUPPLY SOURCE (NOT INCLUDED)

275 kPa MAX. 40 PSI MAX.

[12 V

60 mA]

TO AN AC POWER SUPPLY

AC-TO-DC ADAPTOR

Figure G-3. Connection of the Pneumatic Feeder Controller (rear view).

Connect the AC-to-DC adaptor to an AC power outlet and the other extremity of the lead to the DC Power Input on the Pneumatic Feeder Controller, as shown in Figure G-3.

Limit switch S2-B connects to the TTL inputs on the Teach Pendant.

Operation Pneumatic Feeders The Pneumatic Feeders, Models 5122 and 5142, have three limit switches to detect the presence of parts: S1, S2-A, and S2-B. Switch S1 detects the presence of parts in the storage section, it is located at the bottom of the storage section. The contact of switch S1 is normally open (NO), meaning that it is open when the storage section is empty. Switch S2-A detects the presence of parts in the feeder section, it is located at the bottom of the feeder section. The contact of switch S2-A is normally closed (NC), meaning that it is closed when the feeder section is empty. Switches S1 and S2-A are used to control the operation of the Pneumatic Feeder Controller. Switch S2-B is located at the bottom of the feeder section. The contact of switch S2B is normally open (NO), meaning that it is open when the feeder section is empty. Switch S2-B is used to control the level of a TTL input.

G-3

Pneumatic Feeders, Models 5122 and 5142

Pneumatic Feeder Controller The Pneumatic Feeder Controller, Model 5149, includes a solenoid operated pneumatic valve. When the solenoid of the valve is energized, air flows through the valve to port A of the Pneumatic Feeder. This causes the slider to extend to push a new part as shown in Figure G-4a. When the solenoid of the valve is not energized, air flows through the valve to port B of the Pneumatic Feeder. This causes the slider to retract as shown in Figure G-4b.
STORAGE SECTION STORED PARTS SLIDER IN THE EXTENDED POSITION AVAILABLE PART FEEDER SECTION

S1

S2

PNEUMATIC CYLINDER

(a)

SLIDER IN THE RETRACTED POSITION

CYLINDER ROD

S1

S2

(b)

Figure G-4. Schematic diagram of the Pneumatic Feeder, Model 5122.

The solenoid of the pneumatic valve is energized only when the contacts of both switches S1 and S2-A are closed as shown in Figure G-5. The only way to obtain this condition is when the feeder section is empty but not the storage section.
G-4

Pneumatic Feeders, Models 5122 and 5142

INPUTS 1 S1 + 2 S2-A PNEUMATIC VALVE SOLENOID

Figure G-5. Electrical diagram of the Pneumatic Feeder Controller, Model 5149.

The operation is summarized in Table G-1.

AIR IS SUPPLIED TO PORT

SWITCH S1

SWITCH S2-A

SLIDER

closed (parts in the storage section) closed (parts in the storage section) open (storage section empty) open (storage section empty) Switch S1 is normally open (NO)

open (parts in the feeder section) closed (feeder section empty) open (parts in the feeder section) closed (feeder section empty)

retracts

extends

retracts

retracts

Switch S2-A is normally closed (NC)

Table G-1. Slider movement versus the status of switches S1 and S2-A.

Speed Setting The extension and retraction speeds of the slider can be set via the SPEED control knobs on the Pneumatic Feeder Controller. The SPEED control consists in a flow control valve that controls the air flow which is directed to the cylinder ports. The speed increases with air flow. To set the extension and retraction speed, perform the following steps: C C C C Ensure that the Pneumatic Feeder is connected as described in the Connection section of this appendix. Place five parts in the storage section and one in the feeder section. Set the Extend and Retract Speed control knobs at MIN. Apply compressed air to the Pneumatic Feeder Controller.
G-5

Pneumatic Feeders, Models 5122 and 5142

Note: The air pressure applied to the Pneumatic Feeder Controller should not exceed 275 kPa (40 psi).

Manually remove the available part from the feeder section.

Note: With the Speed control knobs at the MIN. position, the slider will not move or very little.

C C C

Slowly turn the Extend Speed control knob in the counterclockwise direction to increase the extension speed of the slider. Once the part is in the feeder section, turn slowly the Retract Speed control knob in the counterclockwise direction to increase the retraction speed. Remove the new part in the feeder section and repeat the last two steps until you obtain a smooth movement in both directions.
Note: For the Pneumatic Feeder, Model 5142, make sure the part will not be thrown out of the feeder.

G-6

Appendix Linear Slide, Model 5209

Description The Linear Slide of the Servo Robot System is shown in Figure H-1. It consists of a mobile metallic base on which the Servo Robot is mounted (screwed). The mobile base slides on two transverse shafts via four linear ball bearings. The base is driven by a servo motor via a lead screw.

MOBILE METALLIC BASE

LINEAR BEARING

LOCATION PINS

Figure H-1. Linear Slide.

The servo motor is similar to the ones that drive the Servo Robot and its control is also quite similar. The Linear Slide is designed to be used with the Grid and the perforated Work Surfaces. When used with the Work Surfaces, the Linear Slide is located using the location pins under the extremity sections of the module.

H-1

Linear Slide, Model 5209

Connection The Linear Slide connects to CH 1 or CH 2 on the Robot Controller as shown in Figure H-2.
Note: Do not make or modify any connection while the Robot Controller is on.
ROBOT CONTROLLER REAR VIEW

LINEAR SLIDE

CNC 1

CNC 2

CH 1

CH 2

5250

5250

Figure H-2. Connection of the Linear Slide.

Configuration Once the connection is made, the Robot Controller must be configured to detect the Linear Slide. To configure the Robot Controller when using Robotics, select the Hardware option in the Options menu. Select Linear Slide in the selection field of the channel where the Linear Slide is connected. Click the Save button to save the configuration. To configure the Robot Controller when using the Hand-Held terminal, press the 5 key in the Main menu to select Configuration. In the Configuration menu, place the cursor beside the channel where the Linear Slide is connected, and press the Enter key as required to select L Slide. Press the S key to save the configuration.

Operation The Linear Slide is controlled by clicking the CH 1 or CH 2 arrow in Robotics or by pressing the 7 or Z keys if it is connected to CH 1, or the 8 or / keys if it is connected to CH 2 if you are using the Hand-Held Terminal. As the Servo Robot and Rotary Carousel, the Linear Slide must be hard homed at the beginning of each session.
CAUTION! Make sure the Servo Robot has sufficient free space to execute a hard home positioning in all positions of the Linear Slide.

The speed is controllable the same way as the motors of the Servo Robot.

H-2

Linear Slide, Model 5209

Since the position of the Servo Robot depends on the position of the mounting base of the Linear Slide, their positions must be saved simultaneously. The Robot and External Device check boxes of the Point Editor in Robotics must always be enabled when saving a position point.

H-3

H-4

Appendix Error codes of Firmware 5250

*EMERGENCY STOP*: Emergency Stop is pushed. Turn the key to deactivate it and press "Clear Error" on the Teach Pendant to clear the error. *LIMIT ERROR*: G=Gripper, R=Wrist Rotation, P=Wrist Pitch, E=Elbow, S=Shoulder, B=Base, 1=External motor #1, 2=External motor #2. This problem happens when a limit switch is activated. It is normally self-correcting (the robot moves in the opposite direction to clear the limit switch). If the limit switch is not cleared automatically, use the teach pendant to safely move the axis away from the limit switch. *SYSTEM ERROR*: An illegal instruction has occurred. To correct this problem, the controller must be turned off. Then turn it on to reboot it. *CONTROL ERROR*: One of the motor controllers has failed to execute a command. This is probably due to a faulty component inside the controller. MOTORS APPEAR TO BE FREED. CHECK MOTOR RELEASE SWITCH: This problem happens when then motor drives cannot send signals to the motors. To correct this problem, verify the "MOTORS" button on the front panel of the controller. Make sure that the button is pushed on the "Enabled" position and that the red LED marked "Disabled" is turned off. *MOTOR ERROR* MOTOR STALL: G=Gripper, R=Wrist Rotation, P=Wrist Pitch, E=Elbow, S=Shoulder, B=Base, 1=External motor #1, 2=External motor #2. One of the motors has reached a position error causing it to stall. This happens when the robot has tried to move an object but has not been able to move it because the object is too heavy. *FILE ERROR*: The teach pendant has not been able to open or save a file. ROBOT ERROR USER ABORT: The user aborted during a programmed task movement by using the ESC button of the teach pendant. ROBOT ERROR RUN POINT REFUSED: The programmed point cannot be reached because its information is corrupted (bad speed, bad positions, etc...) or the robot is already executing a task

I-1