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Bosch WS502, Instruction Manual

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Bosch Rexroth AG 

Robotics Trainings System WS502 

Safety information 

  

2.10

 

User workstations 

Provide the following space for the WS502 training system to teach and learn the 

procedures on the WS502 training system:  

 

Abb. 1:

 

WS502 training system space requirements 

The following teaching stations are provided depending on the usage of the 

WS502 training system:  

Process step 

Number of persons 

Setup 

3 

Operation 

2 

Tabelle 4: 

Teaching stations in an WS502 training system 

 
During setup, a maximum of three people are allowed to work simultaneously on 

one WS502 training system. When operating, a maximum of two people plus the 

instructor are allowed to perform work. 

Teaching stations 

Summary of Contents for WS502

Page 1: ...Instruction manual Robotics Trainings System WS502 R901508696 Version 01 01 EN ...

Page 2: ...er from their obligation for their own assessments and tests Our products are subject to natural wear and tear as well as the ageing process All rights reserved by Bosch Rexroth AG also in case of registration of industrial property rights We retain all powers of disposition such as the right to copy and forward The title page shows an example of a configuration The delivered product may therefore...

Page 3: ...t 11 2 8 Obligations of the operating organisation 12 2 9 Safeguards 12 2 10 User workstations 14 3 General information on preventing property damage and damage to product15 4 Scope of supply 16 5 About this Product 17 5 1 General 17 5 2 General plan 18 5 3 Agilus industrial robot 19 5 3 1 Gripper on the Agilus robot 20 5 3 2 Connections on the Agilus robot 21 5 4 Cube rack 23 5 5 Cube chute 24 5 ...

Page 4: ...ement 43 10 9 Stop movement immediate stop 44 10 10 Perform home position run 44 10 11 Move the robot in jog mode 45 10 12 Saving the current robot position 46 10 13 Open close gripper 47 10 14 Restore operational readiness after gripper collision 48 10 15 Reset the set position points to the as delivered condition 49 10 16 Switch off the training system 49 11 Description of the user interface 50 ...

Page 5: ...s Trainings System WS502 Bosch Rexroth AG 5 64 Contents 14 2 1 Operating materials auxiliary materials tools measuring instruments 61 14 2 2 Replacing parts 62 15 Disposal 62 16 EC Declaration of Conformity 63 ...

Page 6: ...Information chapter before you work with the product 1 2 Required and supplementary documentation In addition to these operating instructions for the ready to use WS502 training system the following additional documentation is also available Teachware teacher and student manuals and software contains exercises in accordance with the recommendations Educational and information books on the topic of...

Page 7: ...in bodily injuries if it is not avoided CAUTION Indicates a hazardous situation which could result in minor or moderate bodily injuries if it is not avoided NOTE Indicates property damage The product or the environment can be damaged harmed Tabelle 1 Hazard classes according to ANSI Z535 6 2006 1 3 2 Symbols The following symbols indicate instructions that are not safety relevant but which enhance...

Page 8: ...e and skills in the sector of robotics as well as to control and feedback control systems technology For the development of complete systems and simulations use only devices and sets approved for the WS502 training system Operation is only permitted under the operating conditions stated in chapter 5 The product is intended for professional use only and not for private use Proper use also includes ...

Page 9: ...hing Apprentices and trainees may work on the WS502 training system only under the direct supervision and with the appropriate instruction of an instructor or by trained personnel The instructors for the WS502 training system must be trained specialists who are qualified in the field of mechatronics and robotics The instructor must give clear instructions if apprentices or participants work on the...

Page 10: ... pneumatic control circuit diagrams completely comprehend in particular the correlations of the built in safeguards and have knowledge of the function and construction of pneumatic components 2 5 General safety information Observe the valid regulations for the prevention of accidents and on the protection of the environment Observe the safety rules and regulations of the country in which the produ...

Page 11: ...before you do any electrical work Secure the plant system from reconnection Operate the WS502 training system only in a network with a functional RCD protective conductor or a protective ground Manipulated and or non functional safeguards and protection equipment Risk of serious injury Immediately stop the system The fault or manipulation must be immediately repaired by specialists Danger caused b...

Page 12: ...instructions by works security and the operating instructions of the operating organisation Behaviour in case of emergency 2 9 Safeguards For the protection of persons the WS502 training system is equipped with the following safeguards 3 EMERGENCY STOP buttons on the cell 1 EMERGENCY STOP button on the VH2110 hand control 1 EMERGENCY STOP button on the KUKA smartPAD if the smartPAD is connected to...

Page 13: ...viewed from the rear and mount the expansion module to the rear of the WS502 training system The existing EMERGENCY STOP door switch is then actuated by the mounted expansion module The training system must only be operated with a maximum pneumatic operating pressure of 5 6 bar The pressure of the system is adjustable The WS502 training system is equipped with a guard Makrolon panes which prevents...

Page 14: ...g system space requirements The following teaching stations are provided depending on the usage of the WS502 training system Process step Number of persons Setup 3 Operation 2 Tabelle 4 Teaching stations in an WS502 training system During setup a maximum of three people are allowed to work simultaneously on one WS502 training system When operating a maximum of two people plus the instructor are al...

Page 15: ...ug connectors as long as the system is energized Switch the system off on the main switch The robot controller is equipped with an uninterruptible power supply Voltage can still be present here approximately 5 minutes after switching off Incorrect setting of pressure relief valves and pressure switches of pneumatic components Property damage Operate the pneumatic components only with the recommend...

Page 16: ... the front by a cover The cover is fastened with nails or screws Designation Unit Value Dimensions Length mm 1580 Width mm 940 Height mm 2200 Tabelle 5 Dimension of the wooden crate 1 5 4 2 3 Abb 2 Crate with marking The following details are provided on the crate 1 Transport instructions or warnings as needed 2 Shipping number barcode 3 Delivery note in plastic bag 4 Label gross if applicable net...

Page 17: ...tachments mounted 1 Operating instructions DE EN ES 1 Circuit diagram DE EN ES 3 Mechanical expansion modules for attachments 1 Actuator assembly for the door switch for mounting on the Bosch Rexroth mMS 4 0 2 Mounting bracket for fastening the attachment 3 Cube demo objects 5 About this Product 5 1 General The following sections of these operating instructions show examples of a variant of the WS...

Page 18: ...gilus training system 1 EMERGENCY STOP door switch no contact 2 Signal tower 3 Aluminium profile frame with protective doors and Makrolon panes 4 Agilus robot 5 EMERGENCY STOP button 6 Control cabinet 7 KUKA robot controller 8 Adjustable machine mounts for fixed assembly 9 Controls and connectors on the control cabinet 10 Cube chute concealed 11 EMERGENCY STOP button 12 Cube racks with light barri...

Page 19: ...strial robot with six axes The robot is equipped with a pneumatic gripper with an occupied control which is protected against damage by a collision coupling system Abb 4 KR6R700 Agilus Sixx NOTE Agilus robot system manufacturer documentation You can find information about the Agilus robot system in the manufacturer documentation ...

Page 20: ...ith sensory position monitoring prevents the gripper from being damaged in case of accidental collisions In the event of a collision the collision clutch yields and releases out of the coupling mount The collision is detected by a position sensor and the system is stopped The signal tower flashes red and a message is displayed on the hand control Abb 5 Gripper Agilus robot 1 Sensor for Collision c...

Page 21: ...ripper function opening and closing The remaining connections can be used according to customer request Abb 6 Pneumatic connections on the Agilus robot The Agilus robot is equipped with a sensor system connection Abb 7 Sensor system connections on the Agilus robot The following signals are transmitted via the connection X41 Gripper End position open Gripper End position closed Gripper occupied sta...

Page 22: ...t are connected with the robot on the base Abb 8 Connections on the base of the Agilus robot 1 Grounding cable to the base 2 Pneumatic supply 3 Signal line 4 Connection of the robot motor cables Please refer to the manufacturer documentation for a complete description of the connections Connections on the base 1 2 3 4 ...

Page 23: ...ks on which the cube can be positioned are located on the base plate in the working area of the Agilus robot Abb 9 Cube rack 1 Rack opening to the cube chute 2 Fork light sensor with connection cable 3 Rack with guide pins 4 Base frame made of aluminium profile The storage positions assigned to the cube racks are each stated in the program The position names are also displayed on the hand control ...

Page 24: ...e available cube rack After 3 cubes are stored the remaining cubes are taken out of the mMS 4 0 unloaded through a hole in the base plate and collected on a chute Abb 10 Cube chute 1 Cube chute 2 Rack opening to the cube chute NOTE Cube chute The cube chute is not equipped with filling level detection The system does not report when the chute is fully occupied Remove the cubes from the chute from ...

Page 25: ...afety devices and switching elements Abb 11 Control cabinet 1 Power supply infeed 2 XM2200 controller with PROFINET extension module and I O assemblies 3 Fuses 4 Switch 5 Safety devices for protective door and EMERGENCY STOP 6 Series terminals 7 Power switch control 8 Power switch Agilus robot 9 Mains 230VAC for Agilus robot NOTE Agilus robot system mains connection The 230VAC socket outlet in the...

Page 26: ...he controller via cable The RESET blue illuminated pushbutton is used to execute various acknowledgements on the system Whenever a state has to be acknowledged by the user the illuminated RESET pushbutton flashes otherwise it is off The connection to the control cabinet internal XM2200 control or the robot can be made through the Ethernet interface RJ45 The main switch is used to switch the power ...

Page 27: ...sequent module XS2 Connection for EMERGENCY STOP and protective door circuit to the predecessor module NOTE EMERGENCY STOP and protective door circuit When operating the WS502 training system without predecessor module such as the Bosch Rexroth mMS module or without a subsequent module the jumper plugs included in the scope of supply must be installed To connect an expansion module Remove the jump...

Page 28: ...02 About this Product 5 7 Pneumatic maintenance unit Type key RD AS1 ACC G014 R480320321 Abb 13 Maintenance unit 1 Maintenance unit 2 Connection input side 3 Cut off valve 4 Connection output side Abb 14 Maintenance unit pneumatic circuit diagram 1 2 3 4 ...

Page 29: ...stallation site Closed room Ambient temperature C 10 to 25 Max relative humidity 90 at 20 C Max site altitude m 1000 above sea level Pneumatics Max operating pressure bar 8 Min operating pressure bar 6 Supply Connection and operating voltage V 230 AC Control voltage V 24 DC Frequency Hz 50 60 Rated power kW 2 5 Security A 16 Protective ground PE multiple protective earthing or RCD protective switc...

Page 30: ...f the WS502 training system is located on the control cabinet of the system In addition the specific characteristics of the WS502 training system are also stated here Abb 15 Type plate The following information is needed on the type plate to identify the WS502 training system e g for ordering spare parts MATERIAL NO R901443001 Type TS WS502 KUKA ...

Page 31: ...m by pressing one of these buttons Triggering the EMERGENCY STOP button stops the movement of the robot All processes are stopped immediately and hazardous currents are switched off Pressing the EMERGENCY stop button also stops any connected expansion modules However the mains voltage is still applied in the control cabinet Do not use the EMERGENCY STOP button for normal training system shutdown C...

Page 32: ...efer to the product documentation for a detailed description of the VH2110 hand control To use it the hand control must be connected through a VAC 31 connecting unit have had the correct VI composer installed be connected with the basic module Always connect the hand control to the WS502 training system Never remove the hand control during operation As long as not in use hang the hand control in i...

Page 33: ... a detailed description of the smartPAD 7 4 Signal tower The training system is equipped with a signal tower that displays the status of the system Display colours and their meaning Green System is ready for operation Yellow No function Red A component of the system is defective CAUTION EMERGENCY STOP button function on the hand controls The EMERGENCY STOP button on the hand controls is only effec...

Page 34: ...roperly Discard the pallet and the wooden crate properly or properly store them for later storage 8 1 1 Make the gripper ready for operation Secure the gripper against falling during transport Remove the packaging and transport locks from the gripper Make sure that the gripper with the clutch is correctly mounted in the coupler mechanism for assembly instructions see chapter 10 14 on page 48 Requi...

Page 35: ... operating height to the vertical frame construction of the cell Abb 19 Mounting the holder for the VH2110 manual control panel Hang the VH2110 manual control in the holder Unscrew the cap from the VAC31 connector module Connect the connection cable of the VH2110 manual operating panels to the connection module Abb 20 VAC31 connection module The WS502 training system can now be brought to its depl...

Page 36: ...wo buildings Note during transport Make sure the doors and entrances are sufficiently wide Remove attachments and sets that are not required beforehand Transport the training system only with a pallet truck or forklift Do not transport any other objects or persons together with the WS502 training system Perform the following steps Turn the main switch on the control cabinet to the OFF position Rem...

Page 37: ... straps 8 3 Storage Designation Unit Value Floor space of the WS502 training system M Approx 0 70 x 1 50 Quality of the floor space Level horizontal Min storage temperature C 10 Max storage temperature C 50 Relative humidity 25 70 non condensing Max site altitude m 1000 above sea level Tabelle 7 Storage conditions Requirements for the storage of the training system Make the training system is fit ...

Page 38: ...eAbb 1 WS502 training system Also take any possible supplementary attachments into consideration Check the flatness of the floor space and if necessary rework the surface or choose a different installation location Make sure that an electrical connection is available Ensure sufficient lighting conditions at the installation location During assembly please note the following Adjust the legs of the ...

Page 39: ...t the electrical installation The requirements for installing the WS502 training system are the WS502 training system is correctly assembled see chapter 9 1 Assembling the WS502 training system and is complete the mains voltage and fusing to the customer power supply is correct only trained electricians perform the work on the electrical equipment of the training system no cables are damaged the c...

Page 40: ...s plugged in If applicable unlock all EMERGENCY STOP buttons Turn the main switch of the training system to the ON position The control system starts The illuminated RESET blue pushbutton on the control cabinet flashes Press the illuminated RESET pushbutton A message is displayed on the robot system s hand control Press the Reset Abort button on the display The message Start Robot Auto External is...

Page 41: ...you want to run the WS502 training system with the mMS 4 0 check first to see whether the set positions for operating the rack match the end customer s existing system To check the conformity of the positions of the WS502 training system proceed as follows Install the mMS 4 0 on the WS502 training system see chapter 11 6 on page 56 Press the Automatic button Press the Rack button Set the speed ove...

Page 42: ...tton until the gripper reaches the desired X position if necessary correct in the reverse direction Select the Z axis in the desired direction Press and hold the Jog Enable button until the gripper reaches the desired Z position if necessary correct in the reverse direction 10 4 2 Save the new zero position Proceed as follows to save the position Tap in the Index section on the entered number Ente...

Page 43: ...at the same time The Automatic Start button flashes 10 6 Start the program Proceed as follows to start the selected program Check the set speed and reduce it if necessary Press the Automatic Start button The program starts After ensuring that during the program run no collisions or problems arise the speed of the robot can be increased step by step 10 7 Program stop stop cycle Proceed as follows t...

Page 44: ...e robot is typically not in the home position This message will appear on the display 10 10Perform home position run In the as delivered condition the home position of the robot home position is stored in the position coordinate with the index number 0 Proceed as follows to put the robot into home position Press the Manual button to switch to manual mode Press the MoveTypPos button Tap the number ...

Page 45: ... in the area of movement of the robot Risk of damage to components First move the robot gripper manually to a position from which the desired position can be safely approached Before you perform an automatic movement of the robot ensure that the range of movement is free of obstruction CAUTION Obstacles in the area of movement of the robot The robot has no range limit In manual mode there is the r...

Page 46: ...t Optionally you can also select the axis coordinate system Press the Axis button The further procedure is identical 10 12 Saving the current robot position The current position of the robot can be stored on a position index number Proceed as follows to save the current position of the robot Move the robot to the desired position Tap the number below the Index entry The input window opens Enter th...

Page 47: ...in manual mode To open the gripper of the robot manually proceed as follows In the main screen Press the Manual button in the OperationMode section Press the Open button in the Gripper section The gripper opens To manually close the gripper of the robot proceed as follows In the main screen Press the Close button in the Gripper section The gripper closes ...

Page 48: ...l tower flashes To restart the system after a gripper collision proceed as follows Check the set speed and reduce it if necessary Press and hold the illuminated RESET pushbutton on the control cabinet Move the gripper free in jog mode for jog mode description see above Install the gripper correctly again The control pin must point into the direction of the position sensor The 4 spring loaded ball ...

Page 49: ... button The data is displayed in the as delivered condition 10 16 Switch off the training system Proceed as follows to switch off the training system In the main screen Press the Automatic Stop button to stop the automatic program Wait until the robot is at a standstill Turn the main switch to the 0 Off position The Bosch Rexroth control is immediately switched off The robot system is shut down th...

Page 50: ...ipper in manual mode Button is grey limit switch not reached yet Button is green limit switch reached Part detected indicates if a part is detected in the gripper Robot Ready Green robot is ready for operation Red robot is not ready for operation Run Grey robot is not in Run mode Green robot is in Run mode StartAutoExternal button to start the robot in the AutoExternal operating mode to normal aut...

Page 51: ...KUKA manufacturer documentation Execute Button to start the movement MoveTypJog Selects the jog operating mode Here the axes selected by the operator are moved in the desired direction as long as the Jog Enable button is pressed Axis Button for selecting the axis coordinate system display of the rotary axes 1 to 6 with position data World Button for selection of the global coordinate system displa...

Page 52: ...r documentation T Turn for explanations see the KUKA manufacturer documentation LIN 1 The robot performs a linear movement 0 The robot moves as fast as possible to the specified target position Cont 1 The robot rounds the individual points of a movement that has multiple points 0 The robot approaches each point briefly stops and then continues Done Green Movement command to approach the position p...

Page 53: ...ist with all existing position records is shown in the position data screen Abb 24 Position data record excerpt To change individual pieces of data in a position data record proceed as follows Example You want to change the term Rack Position Y0 Z0 of position index 20 Tap the Rack Position Y0 Z0 text entry The following screen keyboard opens Abb 25 Screen keyboard Enter the desired name value in ...

Page 54: ...osition data Restore Resets the position data and offsets to the as delivered condition Rack Turn Overview The Rack Turn Overview section displays the storage locations of the Bosch Rexroth mMS 4 0 from 0 0 to 2 4 In order to service a location position gripper in front of storage position move into the storage position close gripper move out of the storage position Positions 23 24 25 and 26 were ...

Page 55: ...4 0 R901423235 which is not included in the scope of delivery can be attached Abb 27 mMS 4 0 training system NOTE Operation with mMS 4 0 The operation of the WS502 training system is possible either with an attached mMS 4 0 or with the sliding door closed The scope of delivery of the WS502 training system includes attachments for the detection and mounting of the mMS 4 0 to the training system Bef...

Page 56: ...he sliding door is closed or the mMS 4 0 must be installed The query of the protective door or the mMS 4 0 is via an electrosensitive EMERGENCY STOP switch To be able to use an existing mMS 4 0 the actuator with bracket 1 which is included in the scope of the WS502 training system must be retrofit to the mMS 4 0 This is done as follows Install the bracket using the bolts and slide blocks on the ri...

Page 57: ...MS system 4 0 and the training system together so that the frame parts on the left side are flush Abb 29 Locking of left side sliding door Connect the frame elements to the left rear below the worktop and on the vertical frame of the training system with a retaining bracket 1 Abb 30 Connection left side Connect the frame elements on upper rear right with a second retaining bracket Abb 31 Connectio...

Page 58: ...xroth AG Robotics Trainings System WS502 Description of the user interface Connect the frame elements on upper rear right with a second mounting bracket The WS502 training system can now be operated with the mMS 4 0 ...

Page 59: ...ystem Maintenance and inspection work that can only be performed by specifically trained and qualified personnel are described in chapter 14 13 1 General information Report any defects immediately to the competent supervisors so that they can be repaired quickly Please note that small defects can lead to major defects if they are not resolved in a timely manner Clean the plastic components exclusi...

Page 60: ...t are lying around Total training system Protective enclosure Check for completeness damage and correct assembly Weekly Total training system Check the electrical connection cables and lines for visible damage chafing cracks cuts Have the damages immediately repaired by the competent electrician Connection elements Check electrical devices switchboxes and switches buttons for visible damage Have t...

Page 61: ...als tools measuring instruments The following are required to work on the WS502 training system Protective work clothing according to regulations Cleaning and care products cleaning cloths Test and maintenance log writing device When What Where Comments Daily before each use EMERGENCY OFF button Check functioning Check effect when pressing no start up during unlocking In case of malfunction Put th...

Page 62: ...that is safe for the personnel and there is no risk to health falling down slippery due to moisture etc After you have repaired the wear and before starting up have a qualified specialist check that the job s was were properly executed and the WS502 training system is fully operational 15 Disposal The training system consists of materials which can be recycled and re used Specialized companies can...

Page 63: ...ety of machinery Safety related parts of control systems EN ISO 13849 2 Safety of machinery Safety related parts of control systems Validation DIN EN ISO 13850 2008 09 Safety of machinery Emergency stop Principles for design ISO 13850 2006 German version EN ISO 13850 2008 ISO 14120 2002 02 Safety of machinery Guards General requirements for the design and construction of fixed and movable guards D...

Page 64: ...tion of Conformity Bosch Rexroth AG Drive Control Academy Bahnhofplatz 2 97070 Würzburg Germany Phone 49 9352 18 1920 Fax 49 9352 18 1040 eMail training boschrexroth de www boschrexroth com training R901508696 Version 01 01 EN Bosch Rexroth AG 2019 Subject to change ...

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