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99-05-31

C H A P T E R 1 0

Preventive Maintenance

This chapter covers the preventive maintenance necessary to keep the F3
system running trouble free.

All the procedures outlined in this chapter are of a non-invasive or minimally
invasive nature. In other words, there is no need to disassemble the robot
beyond removal of fasteners or covers. Service procedures requiring

disassembly are given in the F3 Service Guide.

The use of a maintenance log is strongly recommended. This is particularly
helpful when you call for CRS customer support. The following format is
suggested:

Date

Maintenance Activity

Personnel

Notes

The maintenance intervals recommended below have been set based on
normal operating conditions. For demanding applications (e.g. high payload,

high acceleration, high duty cycle, etc.), more regular maintenance is
necessary.

The maintenance schedule includes:

1.

regular inspection

2.

chain lubrication

3.

battery maintenance

4.

chain replacement

5.

harmonic drive lubrication

6.

wire harness replacement

7.

cleaning the robot.

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Summary of Contents for F3

Page 1: ...F3 Robot Arm for C500C Controller User Guide UMI F3 310 ...

Page 2: ...to change without notice CRS Robotics Corporation makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose CRS Robotics Corporation assumes no responsibility for any errors that may appear in this document CRS Robotics Corporation makes no commitment to update nor to keep current the infor...

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Page 5: ...of this guide installation guides in other languages or other CRS literature contact the Sales Department or the Customer Support Department of CRS or contact an authorized CRS distributor Other Guides For additional information refer to the following documentation Application Development Guide RAPL 3 Language Reference Guide F3t Track User Guide Training This user guide is not intended as an inde...

Page 6: ...A6 Canada Telephone 1 905 332 2000 Telephone toll free in Canada and United States 1 800 365 7587 Facsimile 1 905 332 1114 E Mail General info crsrobotics com E Mail Customer Support support crsrobotics com E Mail Sales sales crsrobotics com E Mail Training training crsrobotics com Web www crsrobotics com ...

Page 7: ...ng Basics Before attempting to follow any procedure or examples provided in this or any other manual on CRS products read the entire section first Throughout this user guide warnings are marked by an icon in the left margin Failure to comply with these warnings can result in injury to persons damage to the robot tooling work pieces loss in robot memory or system errors Failure to unpack install us...

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Page 9: ...s 14 Safeguards and Safety Measures in Workcell Design 15 Physical Barriers 15 Emergency Stops E Stops 16 Presence Sensing Interlocks 17 Other Safety Measures 20 Local Regulations 20 Environmental Requirements 21 Indoor Use 21 Temperature 21 Humidity 21 Atmospheric Contaminants 21 Ingress Protection 21 Vibration and Shock 21 Electromagnetic Interference 21 Power Requirements 22 AC Power Supply 22 ...

Page 10: ...em Features 45 Absolute Encoders 45 Arm Power Light 46 Brakes 46 Brake Release 46 Chain Tensioners 46 Embedded Control and Power Electronics 47 chapter 5 49 Installation 49 Unpacking the F3 System 50 Unpacking the Arm 50 Lifting the Arm 51 Collecting the Shipping Materials 52 Mounting the Arm 53 Positioning the Arm 53 Mounting Platform 54 Preparing a mounting platform 55 Mounting the arm on the pl...

Page 11: ...ke Release 76 Point of Control 76 Delay after Turning on Arm Power 77 Abnormal Process Termination 77 Chapter 9 79 Troubleshooting 79 Arm Power Failure 80 Amplifier Communications Failure 81 F3 Calibration Re Homing 82 F3 Calibration 82 Restoration of Calibration File 82 F3 Re Homing 82 chapter 10 85 Preventive Maintenance 85 Regular Inspection 86 Weekly Inspection 86 Monthly Inspection 86 After C...

Page 12: ...xii 99 05 31 Wire Harness Replacement 96 Cleaning the Robot System 97 APPENDIX A 99 Umbilical Cable Connector 99 APPENDIX B 101 System Fuses 101 Glossary 103 Index 113 ...

Page 13: ... robot Use only nickel metal hydride batteries Contact CRS Customer Support for more detailed specifications or purchase of replacement units Lift the Robot Carefully Do not lift the robot without assistance of a crane or other persons Design the Workcell Always design your workcell to be serviceable 1 Teach at least one robot location where it is easy to access the arm and the drawer at the base ...

Page 14: ...y functions when interfacing to the GPIO or SYSIO Use an external power supply Shut Down Properly To shut down the system 1 Turn off arm power by hitting an e stop 2 Properly shut down the operating system with the command shutdown now 3 Turn off the controller at the controller s main power switch ...

Page 15: ...ots in general and have received training with the F3 system For full instructions on installing and starting up the robot and for users inexperienced with the F3 system or robots in general read the entire user guide before proceeding with any action After completing quick installation and startup reading through the entire user guide is still necessary for users with any level of experience ...

Page 16: ...equate strain relief for the cable There should also be 45 cm or 18 inches of clearance at the back of the controller to provide adequate strain relief for the cable at that end The umbilical cable has a minimum bend radius of 23 cm 9 in Verify that the controller is properly configured for the local AC power supply Turning On the System Do not forget to observe guidelines listed here prior to pow...

Page 17: ...Power button at the top right hand corner of the front panel of the controller Verify that the light on the Arm Power button is lit Verify that the amber beacon on the robot arm is flashing If either of these indicators fails to turn on turn to Chapter 9 for instructions on troubleshooting You are almost ready to start moving and programming using the robot The following guidelines will be helpful...

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Page 19: ...e The cable conducts communications between the robot and controller as well as power for the electronics embedded in the robot An F3 system computer teach pendant controller and arm The F3 robot is run by a program that can be developed either on the controller with a terminal or teach pendant or off line on a computer using Robcomm 3 or equivalent tools From the teach pendant or a terminal you c...

Page 20: ...cable extensions spares etc Use the following table to check off the components which have been ordered and received Component Check if ordered Delivery date Serial number F3 arm hex key C500C controller umbilical cable fuse kit with AC power cable teach pendant override plug SYSIO override plug CROS diskettes 2 calibration diskette F3 User Guide Application Development Guide RAPL 3 Language Refer...

Page 21: ... it to move a gripper or any other tool of choice to the desired location defined by three coordinates for position in the workcell and three coordinates angles for orientation at that position Axes The F3 s six axes of motion joints are waist 1 shoulder 2 elbow 3 wrist rotate 4 wrist pitch 5 and tool roll 6 ...

Page 22: ...2VDC 2 x 24VDC 77VDC and two ground lines enclosed inside a black polyurethane jacket The umbilical cable has the following properties Properties Ratings abrasion resistance excellent heat resistance good flame retardancy good water resistance good dielectric strength 3000VDC operating rating 300 V operating temperature 0 C to 65 C weight 222 g m 0 15 lb ft plus weight of connectors minimum bend r...

Page 23: ...chment of different types of tools or grippers to the end of the tool flange a wide range of high speed high precision applications are possible Custom designed grippers and other tools are available from CRS Servo gripper This is an electric servo controlled parallel motion two fingered gripper capable of measuring objects between its fingers Finger travel is 50 8 mm 0 2 in with programmable posi...

Page 24: ...d up if air is not needed Early F3 robots are equipped with end of arm I O boards which control the solenoid but not the servo gripper Users with this version of the robot wishing to add a servo gripper should contact sales or customer support group at CRS To utilize the other I O channels of the SGIO board it is necessary to purchase the end of arm I O package which comprises an internal cable a ...

Page 25: ...ntegrator and the end user be aware of the robotic safety standards currently applicable They provide valuable considerations for the safe design of your workcell Two good references are UL1740 Safety Standard for Robotic Equipment ISO10218 Safety Standard for Manipulating Industrial robots Warning Injury to persons or damage to the robot tooling or other work cell components can occur from unsafe...

Page 26: ...robot systems is based on the following fundamental principles 1 A barrier or equivalent alternative should be set up to safeguard the workspace of the robot or the entire workcell 2 There should be no one in the safeguarded space during automatic operation 3 The design of the workcell should allow the maximum number of personnel tasks to be performed from outside the safeguarded space 4 Extra att...

Page 27: ...light mounted on the robot to indicate that the robot is powered and capable of motion see p 46 5 fail safe brakes on the main robot axes to prevent motion due to gravitational load see p 46 6 brake release switches located on the underside of the robot shoulder to permit the main robot joints to be manually moved with the motor power off see p 46 7 continuous fault detection during operation incl...

Page 28: ... While they can also provide some dynamic braking they do not have sufficient power to overpower the motors and instantaneously stop robot motion 4 No detection or safeguard exists for the loss of air pressure therefore any pneumatic tooling that can become hazardous as a result of loss of air pressure must be given special consideration 5 Ingress of liquids into the arm can result in short circui...

Page 29: ... safety Design the measures so that the activation of one safety measure against a hazard does not create a new hazard elsewhere Install barriers outside the total radius of the robot arm gripper and payload Danger Never enter or obstruct the workspace while the robot is in use The robot arm is capable of fast movement without warning Install safeguards to prohibit access to the workspace when the...

Page 30: ...is classed as an uncontrolled stop since power is immediately removed from the robot motors and brakes are engaged on the main drive axes As an added safety measure the control software is designed to decelerate the speed of the motors to zero at a rate so as to minimize any resultant jerk Resetting the e stop does not result in automatic actuation of arm power A separate action is required to re ...

Page 31: ...ther e stop buttons At or near the robot arm location Within human reach of any approachable side of the robot arm work cell Design your workcell so that All e stop buttons are unobstructed Personnel can reach and activate each e stop button without difficulty All e stop buttons are outside the total safeguarded space of the robot arm its gripper and any payload Presence Sensing Interlocks Install...

Page 32: ...ts Example of barriers and interlocked contacts on doors All presence sensing devices should be designed and constructed to fail safe in the event of a component failure Also the design should place the presence sensing envelope far enough from the arm so that arm motion stops before the intruder reaches the arm workspace ...

Page 33: ...Chapter 3 Safety Precautions 19 99 05 31 Example of barriers and interlocked pressure mats Example of barriers and interlocked light curtain ...

Page 34: ...rier such as a length of yellow chain alerts personnel of their proximity to the workspace but is not sufficient to prohibit access into the workspace Passive warnings Passive warnings include markings on the floor or tabletop An example is black and yellow stripe tape along a floor Beacon light A prominent light which lights up when the robot system has power on Training Ensure that personnel who...

Page 35: ...robot and controller to an environment of corrosive liquids or explosive fumes Neither is rated for exposure to these harsh environments and could result in hazardous situation The controller electronics are more sensitive to corrosion than the arm If the arm operates in a harsh environment place the controller in a separate and controlled environment Ingress Protection In general do not expose th...

Page 36: ... install a regulating transformer A more complete regulating system such as a non interruptible Power Supply UPS can be used for all robot systems Specification Value Nominal AC Input Voltage 100 115 230 VAC Input Current Fuse Rating 10 10 5 A Inrush Current 7 8 16 A Power System Grounded Single Phase Maximum Power 1000 VA Other Energy Sources The F3 robot has provision for actuating pneumatic too...

Page 37: ...levels in the case of a fault In addition the safety ground is required to reduce electromagnetic emissions The safety ground line of the controller is directly connected to the robot via the umbilical cable As a result it is important that the robot be mounted on a station that is at the same voltage potential as the ground of the controller Ground the station or equipment that the robot arm is m...

Page 38: ...people Damage to the fibre optics will occur if sufficient pressure is applied to the cable All cables and connectors should be shielded from exposure to extreme temperatures chemicals ultra violet light humidity and vibration Operational failure of the robot system will result if the prescribed bend radius for the umbilical cable is not followed ...

Page 39: ...ion Once the robot is in a tucked position turn off the controller power and disconnect the umbilical cable Attach the eyebolt provided into the socket located beside the amber light on the robot A crane or hoist with a lifting capacity of at least 100 kg is recommended to lift the robot An eyebolt is provided to assist in this process Lift the robot only as high as necessary to clear obstacles Th...

Page 40: ...ch pendant Wear an electrostatic discharge ESD wrist strap which contains a resistor connected to a ground when handling electronic components or working inside the controller For best results your electrostatic discharge ESD protection should be grounded to an industrial grounding rod dedicated to electrostatic discharge If a dedicated ground is not available you can connect your wrist strap to t...

Page 41: ...hile in the workcell avoid any location that confines you between the arm and another object For occasional close approach to the workspace have a second person observe the arm and prepare to activate an E Stop If continuous or frequent presence in the workspace is necessary install presence sensing devices interlocked with the E Stop circuit Operator Training Ensure that personnel who program ope...

Page 42: ...one if you have modified your system added hardware software or serviced your robot user memory is intact Errors should not appear in your programs or variable files the physical environment humidity atmospheric conditions and temperature is as specified For more information refer to page 21 AFTER applying arm power verify that the start stop and function keys on the teach pendant and controller f...

Page 43: ...ions program the robot with all personnel outside the safeguarded area whenever possible use the teach pendant whenever working within the safeguarded area when two programmers work together one teaching and one programming the teacher should always carry the teach pendant so that an E Stop is available use reduced robot speeds 25 and lower While servicing the robot arm the service person must hav...

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Page 45: ... the following characteristics about the F3 robot arm Physical Characteristics Dimensions System Control Robot Performance Workspace Reach Torque Ratings Joint Speeds and Acceleration Rates Resolution Load Location Characteristics Path Characteristics System Features ...

Page 46: ...oint 1 axis to tool flange Configuration Articulated Six degrees of freedom Motor DC brushless motors Transmission Harmonic drives on all joints Roller chains on joints 2 3 and 5 Gripper Controls Servo gripper connector optional Double actuation pneumatic solenoid standard Electrical Power Maximum Load 1000 Watts ...

Page 47: ...ach joint is measured from axis to axis Section Dimension mm in Base mounting surface to shoulder 350 13 8 Shoulder offset horziontal displacement from J1 axis to J2 axis 100 3 9 Shoulder to elbow 265 10 4 Elbow to wrist pivot 270 10 6 Wrist pivot to tool flange 75 3 0 ...

Page 48: ...ot Y rot X rot Variable tool transform Variable base offset compensation Motion Control 701 Hz PID servo loop rate 100 Hz command generation rate Motion Modes Joint interpolated point to point Cartesian interpolated straight line Continuous path Relative motion Blended motion ONLINE mode Circular interpolation Velocity Profile Types Trapezoidal Parabolic Teaching Off line Teach pendant ...

Page 49: ... to 45 Joint 3 135 Joint 4 180 Joint 3 135 Joint 6 51 turns or 18 432 Signal Performance 10 ms motion command update rate 20 ms I O scanning 701 Hz servo update 224 position range encoder counts per move serial encoder feedback Repeatability1 0 05 mm 0 002 1 Repeatability is the ability to return to a given location from a fixed starting location with all operating parameters fixed including speed...

Page 50: ...e center of the wrist joint plus the range of rotation or translation of each joint in the wrist ISO 9946 The following diagrams define the F3 workspace calculated from the wrist reference point The work envelope of the F3 arm plan view dimensions in mm The work envelope calculated from the wrist reference point dimensions in mm ...

Page 51: ...rd to tool flange 710 mm 27 9 in from the waist axis in the X Y plane to finger platform of servo gripper 810 mm 30 9 in Horizontal Backward to tool flange 357 mm 14 1 in from the waist axis in the X Y plane to finger platform of servo gripper 457 mm 18 0 in Vertical Upward to tool flange 960 mm 37 8 in along the Z axis to finger platform of servo gripper 1060 mm 41 7 in Vertical Downward to tool ...

Page 52: ...38 F3 Robot Arm User Guide 99 05 31 Reach of F3 with servo gripper dimensions in inches mm ...

Page 53: ... Torque Rating Joint Axis Torque N m in lb Waist 1 74 5 659 Shoulder 2 74 5 659 Elbow 3 74 5 659 Wrist rotate 4 16 6 147 Wrist pitch 5 16 6 147 Tool roll 6 16 6 147 Wrist Thrust and Torque Default tool axis Maximum Continuous Thrust Maximum Continuous Torque N lb Nm in lb Tool yaw 30 6 6 16 6 147 Tool pitch 30 6 6 16 6 147 Tool roll 30 6 6 16 6 147 ...

Page 54: ...0 1 210 Elbow 3 4000 100 1 240 Wrist rotate 4 5000 80 1 375 Wrist pitch 5 4000 80 1 300 Tool roll 6 5000 80 1 375 Joint Accelerations Acceleration Rates Joint Default s Maximum s Wrist 879 1 757 Shoulder 879 1 757 Elbow 879 2 636 Wrist Rotate 1 098 3 295 Wrist Pitch 1 098 3 295 Tool Roll 1 098 3 295 While the above table states the acceleration limits allowable by the system s Motion Engine the fo...

Page 55: ...1 2 3 payload kg acc deg s s Slew Time Slew time is defined as the rate at which the arm can be driven from limit to limit over a dynamic range Assuming that a joint is starting and stopping at rest and that the acceleration profile is parabolic slew time can be calculated as follows slew time Amax x Slew Angle Vmax 2 Amax x Vmax where Amax is maximum acceleration and Vmax is maximum joint speed T...

Page 56: ...m Slew Time For Each Joint Axis Slew Angle Max Acceleration Max Speed Slew Time Slew Speed s 2 s s s 1 360 1 757 240 1 7 212 2 180 1 757 210 184 3 270 2 636 240 1 3 208 4 360 3 295 375 1 1 327 5 270 3 295 300 1 0 270 6 eg 180 3 295 375 0 6 300 ...

Page 57: ...s Rotational Resolution Limits Joint Axis Resolution Wrist 1 0 0018 Shoulder 2 0 0018 Elbow 3 0 0018 Wrist Rotate 4 0 0022 Wrist Pitch 5 0 0022 Tool Roll 6 0 0022 Positioning Resolution The positioning resolution for the arm is based on the rotational resolution for each joint It is calculated at the tool flange with the arm in the ready position pointing down World Coordinate Positioning Resoluti...

Page 58: ...an object This includes the gripper and any payload that it carries The following de rating curves depict the variation of the payload capacity of the F3 robot with distance from the tool flange and axis Payload De rating 0 50 100 150 0 50 100 150 Distance from tool flange along tool axis mm Radial distance from tool axis mm 3 kg 2 kg 1 kg 0 5 kg ...

Page 59: ...ount Absolute position Typical active battery voltage controller on 4 5 V Typical resting battery voltage controller off 3 6 V Battery alarm on voltage 3 1 V to 3 4 V See below Battery alarm off voltage 3 2 V to 3 6 V See below Battery error voltage 3 0 V See below Low current consumption in battery mode 150 µA max A minimum of 6 continuous weeks in battery mode before encoders go into a state i e...

Page 60: ... robot from moving under the influence of gravity or inertia when power is removed Each brake consists of a spring loaded clamp on a rotating disk Brakes are installed on joints 1 2 and 3 A 24 Volt DC signal energizes a magnetic solenoid which unloads the clamp Warning Do not move the joints by hand when the brakes are engaged This may damage some components Brake Release While controller power is...

Page 61: ...e wrist is kept away from liquids and collision Entry of liquids into the wrist may lead to shorts in the wrist amplifier module and other embedded electronics The plastic wrist cover also cannot adequately protect the electronics from damage in case of collision The waist amplifier module is in the shoulder casting and is better protected but precautions are still necessary SGIO The servo gripper...

Page 62: ... Fibre Board The fibre board converts the optical signals from the umbilical cable to electrical serial signals conducted on two twisted pairs one for communications from the controller to the robot and the other in the opposite direction In addition it serves as the first junction for incoming power lines and also includes charging electronics for the encoder backup batteries ...

Page 63: ...e robot system 2 Mount the robot arm 3 Mount the controller 4 Connect the umbilical cable 5 Install the AC fuses and voltage selector 6 Ground the system Note Perform the above steps in sequence If you are customizing your installation refer to Chapter 6 on Customizing Installations ...

Page 64: ...ttached to the arm and to the controller The serial numbers are also listed on the sheet included in the shipping containers Keep this information in a secure and handy location as you will need it for calls to the CRS Customer Support department Unpacking the Arm The plywood crate consists of three parts one platform the base of the crate holding the arm with three 3 fixed side panels one removab...

Page 65: ...e using it for lifting The eyebolt may have come loose during shipping To avoid injury it is important that it is securely attached to the robot Warning Do not spin the robot while it is hoisted This may cause the eyebolt to loosen and result in the robot falling If manual lifting is unavoidable observe the following guidelines Robot can be easily damaged from being dropped Two or more persons are...

Page 66: ... cap screws used to ship the arm are 5 16 inch cap screws They are not adequate to fasten the arm in the workcell Workcell fastening requires four M12 x 1 75 x 50 mm long cap screws 1 Replace the foam pad four cap screws and hex key in the crate 2 Replace the cover of the crate on the platform of the crate aligning the A marks 3 Replace the black circled screws 4 Store the crate ...

Page 67: ...al forces during acceleration and deceleration Positioning the Arm Install the arm in either an upright position mounted on a table top or pillar or an inverted position suspended from overhead brackets Upright configuration Inverted configuration When the arm is in the upright position its base occupies a portion of a table surface limiting the available work area ...

Page 68: ...unting Platform There are two methods for preparing the mounting platform Fasten the arm directly on a supporting structure Fasten a metal plate to your supporting structure bench bracket etc and mount the arm on that plate Tip Use dowel pins to align the arm in case precise relocation is necessary after dismounting for service repair or other reasons Procedure To mount the arm on a platform 1 Pre...

Page 69: ... plate to your bench bracket or similar supporting structure Pin the plate if necessary Mounting the arm on the platform To mount the arm on the platform 1 Install the dowel pins if used Note The dowel pins must be in the holes of the platform before lifting the arm onto the platform 2 With a crane or at least two people lift the arm onto the mounting platform 3 Secure the arm to the platform with...

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Page 71: ...able To connect the umbilical cable to the controller 1 Align the connector with its receptacle on the controller 2 Push the connector into the receptacle on the controller 3 Secure the connector with the metal latch Apply necessary but not excessive force especially if the connector and receptacle are not properly aligned Disconnecting the Umbilical Cable 1 Ensure that the controller s main power...

Page 72: ...be mounted to to an industrial grounding rod that is common to the AC ground of the controller or to the same utility ground used for the controller Failure to do so may result in the risk of fire due to the high currents that may flow in the chassis ground line of the umbilical cable as a result of the difference in ground potential The C500C controller was designed to be used with a grounded AC ...

Page 73: ...59 99 05 31 C H A P T E R 6 Customizing Installations This chapter discusses how to add features to the F3 system including Installing a Tool on the Robot Connecting a Hose to the Pneumatic Port ...

Page 74: ... grippers and similar tooling The ports are configured with opposing actuation such that when one port is open the second is closed and vice versa When the controller power is off and air pressure is applied for the first time the ports will assume one of these states If controller power is lost the last state of the ports does not change upon restarting the system RAPL 3 commands support the enab...

Page 75: ...e of the port is maintained power to the appropriate valve is not removed Custom Designed Tools Custom tooling such as a gripper should be designed and constructed so that a power failure does not result in a hazardous condition such as dropping the payload this may be acceptable if the payload is not dangerous or the work cell is designed to contain a lost payload static and dynamic forces exerte...

Page 76: ...ttons to work correctly the controller must be configured for an air gripper default by using the ash command gtype air Verify that the Open key opens the gripper and the Close key closes the gripper The teach pendant s gripper close and open keys If the operation of the gripper is reversed Open closes the gripper and Close opens the gripper reverse the connections of the two hoses with the two ba...

Page 77: ...dure should be carried out in the following sequence 1 Verify Installation 2 Power up the Controller 3 Verify that the controller is connected to a Windows PC via a RS 232 serial cable 4 Start up Robcomm 3 or your choice of terminal emulator 5 Start the Application Shell 6 Check All E Stops 7 Move Out of the Shipping Position 8 Check the Operation of the Live man Switch ...

Page 78: ...ad engagement The umbilical cable is connected at both ends provided adequate clearance and otherwise protected from damage The fuses and voltage selector have been properly installed The system has been connected to a properly grounded AC outlet of correct electrical rating Robcomm 3 has been installed on a PC which is connected to the controller via the front panel console port Note If you do no...

Page 79: ...play it is likely AC power is not connected a fuse is either missing or blown or there is another power supply related problem Refer to Chapter 10 for troubleshooting instructions 3 Observe the messages displayed at the terminal window in Robcomm 3 If you are using Robcomm 3 and a small dialog box is displayed at the beginning when the controller first starts up just click OK The boot up sequence ...

Page 80: ... ash Initial operation is done from the application named test To start the application shell At the prompt enter ash test The name test can be replaced by that of another application Successful transfer to ash and the selected application is signaled by a change to the new prompt consisting of the name of the application plus the symbol for example test ...

Page 81: ...elays activate The LED in the arm power switch is now continuously lit and the arm power beacon on the robot is flashing 3 One at a time test each stop or equivalent safety mechanism Standard E Stops are front panel E Stop teach pendant E Stop and live man switch Additional E Stops or equivalent devices may be connected through the SYSIO connector a Trigger an emergency stop by striking the E Stop...

Page 82: ...itself the workbench or other objects in the workspace Damage and or failure may result from any collision Warning Use the application shell ash with caution When a command is entered from ash the arm continues to move until that command is completed If a collision is going to occur before the command is completed hit an E Stop Before you begin ensure that the controller is powered on the operatin...

Page 83: ...reen use F3 and F4 to scroll through types and modes of motion Select Velocity and Joint 5 Verify that arm power is on 6 While holding the live man switch press on the positive or negative button of any one of six pairs labeled Ax1 to Ax6 to move one of the six joints For example to move joint 2 up press on the button of the Ax2 pair shown below 7 Release the live man switch while the arm is still...

Page 84: ...t Arm User Guide 99 05 31 11 Without applying pressure to the live man switch press an axis key The arm should not move and there should be an audible beep indicating that the commanded motion cannot be executed ...

Page 85: ...te the robot Emphasis is placed on F3 specific topics namely units coordinate systems and reference frames motion modes system operation For complete instructions on development of robot applications refer to the Application Development Guide and the RAPL 3 Language Reference Guide ...

Page 86: ...t of distance is the millimeter mm To change units in a RAPL 3 system use the command diag setup For further information see the Application Development Guide and RAPL 3 Language Reference Guide The degree is the only unit available for describing joint and orientation angles ...

Page 87: ...al principles of robotics e g Craig J J Introduction to Robotics Mechanics and Control Addison and Wesley Publishing Company or contact the CRS Sales Department to inquire about training In general commanding the F3 robot to move is no different than with other CRS robots However one significant distinction is the definition of the tool frame which unlike other CRS systems follows the ISO conventi...

Page 88: ... positive joint command The following table summarizes this relationship joint relative direction of joint and motor commands 1 opposite 2 same 3 same 4 opposite 5 same 6 opposite In specifying the number of pulses for a motor command the speed reduction ratio of the joint should be taken into account along with the fact that there are 2 048 encoder pulses for every full turn of a F3 motor The fol...

Page 89: ...Chapter 8 Operating Basics 75 99 05 31 systems Programs written for the other systems may therefore not be immediately applied to a F3 robot ...

Page 90: ...tons A given joint can be released by depressing the corresponding button Warning Do not try to press these buttons while arm power is on Although there is no electrical or functional consequence from such an action it is not safe to be in the workspace of the robot when arm power is on Warning Support the arm as you release a brake Gravity may accelerate the descent of the wrist or outer link une...

Page 91: ... the robot and any other person or potential hazard in the vicinity Delay after Turning on Arm Power F3 robot motion should only be started 2 seconds after arm power is turned on In manual operation this is usually not an issue however in a RAPL 3 program the delay function should be used after automatic detection of arm power if robotispowered delay 2000 endif If the recommended delay is not adde...

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Page 93: ... F3 Robot System Only non invasive or minimally invasive procedures are described here Any inspection or remedial procedure requiring major disassembly is given in the F3 Service Guide The following classes of problems are discussed 1 Arm Power Failure 2 Amplifier Communications Failure 3 F3 Calibration Re Homing ...

Page 94: ...emote E Stop devices connected at the controller s SYSIO are not closed Action Reset all remote E Stop devices 4 The remote E Stop devices are not in use but the SYSIO part of the E Stop circuit is left open Action Open the controller and change DIP switch 2 from OFF to ON 5 The arm power watchdog is disabled by the Arm Off command in RAPL 3 Action Check the program logic Arm Off is a typical prog...

Page 95: ...are provided Replace the spare 2 High voltage is detected upon amplifier startup and before the user turns on the arm power switch This may be a result of the high power relays in the controller becoming welded One way to confirm this is to turn off the controller remove an arm power fuse and turn the controller back to verify whether the error state persists If it does not this confirms that one ...

Page 96: ...d calibration procedure Restoration of Calibration File In addition to calibration and re homing there may be situations which require restoration of calibration This need arises when neither structural change nor battery problems have occurred but the calibration file is lost from controller memory because of inadvertent erasure or change of firmware To restore calibration all that is required is...

Page 97: ...r arm encoders by entering the command diag encres When prompted enter module address 16 decimal or 0x10 hexadecimal for the lower three joints If there is an error message it indicates encoder error for one or more of the lower arm axes 7 For a track system reset the track encoder by entering the command diag encres When prompted enter module address 80 decimal or 0x50 hexadecimal 8 Turn off the ...

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Page 99: ... Guide The use of a maintenance log is strongly recommended This is particularly helpful when you call for CRS customer support The following format is suggested Date Maintenance Activity Personnel Notes The maintenance intervals recommended below have been set based on normal operating conditions For demanding applications e g high payload high acceleration high duty cycle etc more regular mainte...

Page 100: ...h speed to determine whether excessive stretch has occurred If joint 2 or 3 moves in a jerky way suggesting chain slack tighten the corresponding tensioner and verify whether the problem is either reduced or eliminated Contact our Customer Support Group if the problem persists In factory the plungers for the joint 2 and 3 tensioners are respectively set at 0 2 and 0 1 from the lip of the cup Drawi...

Page 101: ...ng to environmental conditions such as temperature fluctuations It is a good practice to set up a mechanism in your workcell to periodically verify the repeatability of the robot This can be based on machine vision dial gauges or other methods After Collision If you collide a robot against the workcell or any object carry out all of the above inspections to ensure the robot can continue to operate...

Page 102: ...le at slow speed Re lubricating Joint 2 Warning The re lubrication procedure requires robot motion Keep robot speed below 20 To re lubricate the joint 2 chain for an upright F3 robot 1 Remove the five stainless M4 machine screws from the shoulder chain cover The two top openings are for adding lubricant and the bottom three are drain holes Prepare to collect excess lubricant from these drain holes...

Page 103: ...penings 9 Rotate joint 3 through its range of motion back and forth at least five times at slow speed 10 Allow lubricant to drain for 5 minutes through the bottom opening at the small circular end of the link 11 Rotate joint 2 to 0 so that the lower link is vertically up 12 While the joint 5 chain is re lubricated allow lubricant to drain through the opening at the large circular end of the link R...

Page 104: ...all circular end of the wrist cover 16 Rotate joint 5 to 90 17 Add another 3 drops of lubricant through the opening on the small circular end of the wrist cover 18 Rotate joint 3 to 90 The remaining opening on the wrist cover is now on top 19 Repeat steps 5 to 10 20 Rotate joint 5 back and forth through its entire range of motion at least five times 21 Allow the wrist to drain for at least five mi...

Page 105: ...hut down the robot system under the following conditions The shutdown will be longer than five 5 days but less than six 6 weeks The robot system has not been connected to a live controller for at least 72 hours prior to the shutdown Verifying battery voltage of systems shipped in mid 1998 or later With the controller turned off remove the umbilical cable from the robot base Allow the batteries to ...

Page 106: ... the resting period If it is not possible to leave a live controller connected then the robot should be left in the calrdy configuration if possible to facilitate re homing when the robot is started up again Six Month Battery Check Even if you do not plan to shut down the F3 system you should verify the battery voltage six months after receiving the robot Turn off the controller for at least four ...

Page 107: ...nstall the new ones You have up to ten 10 minutes to carry out the above steps before the encoders are no longer active and calibration is lost Log Update After verifying or replacing the batteries in your F3 system record the maintenance activity in the maintenance log ...

Page 108: ...lacement Chains need to be replaced after 18 months of use or sooner if the load and duty cycle of the application are high Contact our Customer Support Group to determine the best schedule for chain inspection and replacement for your application ...

Page 109: ... x 107 on the wrist joints Consider as an example an application which moves the lower joints at an average speed of 20 rpm over three shifts per day Grease change should be scheduled after 520 days or roughly 17 months For applications with high load and duty cycle or operating at a higher temperature than 60 C more frequent grease changes may be necessary For example if the harmonic drives are o...

Page 110: ...ents copper conductors may fail after a high number of cycles of motion To prevent such a failure during operation it is recommended that the wire harnesses be replaced every 15 months or 107 cycles of joint motion whichever comes first In order to minimize down time replacement of chains and wire harnesses as well as changing of harmonic drive grease should take place at the same time e g once ev...

Page 111: ...low such products to seep into the robot interior through any seam Special attention is required when cleaning the wrist area near the wrist amplifier and the waist area near the waist amplifier In addition the use of some solvents or de greasers may damage printed surfaces Ensure that liquids do not enter inside the controller Do not immerse any part of the controller in liquid ...

Page 112: ...98 F3 Robot Arm User Guide 99 05 31 ...

Page 113: ...and Power Return GND A3 A3 Motor Power 77V 10A Power to motor Actuators B2 B2 Rx from Robot Fibre Fibre Optic communication line B3 B3 BRK_V 24V 1A Power to disengage robot brakes B4 B4 OPT_PWR 24V 1A Power supply for robot options gripper I O and brakes when using the robot brake release B5 B5 SYS_PWR 12V 3A Power supply for the robot amplifiers and support electronics C2 C2 Tx to Robot Fibre Fib...

Page 114: ...100 F3 Robot Arm User Guide 99 05 31 ...

Page 115: ... 4 110 VAC 10 A 250 V SLO BLO 5mm x 20mm 1 4 x 1 1 4 230 VAC 4 A 250 V SLO BLO 5mm x 20mm 1 4 x 1 1 4 DC fuses located behind front panel access cover Label Function Fuse Rating Type Size F5 Arm Power 77Vdc 10 A 250 VAC SLO BLO 5mm x 20mm 1 4 x 1 1 4 F4 24Vdc Power 1 A 250 VAC SLO BLO 5mm x 20mm 1 4 x 1 1 4 F3 12Vdc Power 3 A 250 VAC SLO BLO 5mm x 20mm 1 4 x 1 1 4 F2 Relay Common Terminals 1A 250 ...

Page 116: ...102 F3 Robot Arm User Guide 99 05 31 ...

Page 117: ...forms work The joints are powered and capable of moving the links and the tool to various positions and orientations articulated robot See robot ash See application shell awareness signal An audio or visual alarm device such as a buzzer or a light activated by a sensing device which makes aware the nearness of a person to the robot arm work cell or workspace axis X Y or Z A reference line of a coo...

Page 118: ...configuring configuration The action of entering parameters or specific settings to set up a component for use controller The computerized device that controls the arm It receives input processes data sends control signals to the arm and receives feedback from the arm During the running of a robot application the controller executes a robot software program coordinate system See frame of reference...

Page 119: ...s should wear an electrostatic discharge ESD wrist strap attached to an earth ground emergency stop E Stop A method that overrides robot controls removes arm power and stops movement of the robot arm encoder A precision device attached to each motor shaft which converts the movement of a joint to a signal for processing by the controller end effector A work performing device attached to the tool f...

Page 120: ...ints in place A limped joint can be moved by hand link A rigid part of a robot arm between two neighboring joints location A point in space known to the robot With a CRS robot a location can be one of two types of locations A cartesian location cloc stores information according to a cartesian straight line axes meeting at right angles coordinate system A precision location ploc stores information ...

Page 121: ... the application shell when it is executing on the system programmable logic controller See PLC programmer The person who programs or re programs the robot to do tasks See also operator system integrator RAPL robot automation programming language The language used to program CRS robots RAPL 3 has a completely different architecture from RAPL II RAPL 3 A high level block structured compiled languag...

Page 122: ...changed articulated robot A robot with an arm made up of rigid links connected by rotary joints which bend at the shoulder elbow and wrist This type of robot most closely resembles a human arm robot configuration file See rc file safeguard device A safeguard is a device designed to protect persons from a hazardous point or area Safeguard devices include but are not limited to fixed barriers interl...

Page 123: ...tting a tool transform which modifies the tool frame of reference from the origin at the centre of the tool flange to the position and orientation of the actual tool tool frame of reference The frame of reference with its origin at the centre of the tool flange This frame of reference moves with the tool F3 The tool axes are parallel to the world axes when the arm is at the calrdy straight up posi...

Page 124: ...vo gripper as well as power for the encoders servo gripper brake release and air solenoid control variable A variable is used in a program and holds a value RAPL 3 has five types of variables cloc cartesian location Holds data about a point in space based on cartesian coordinates distances along the X Y and Z axes and orientation around those axes ploc precision location Holds data about a point i...

Page 125: ...paratus integrated with the arm material handling reagents sensors etc and the arm workspace work envelope The outer boundary of the workspace The limit of the arm s reach Also known as the reach envelope workspace The space or volume consisting of all points that the robot arm can reach The outer boundary of the workspace is the work envelope world frame of reference The frame of reference with i...

Page 126: ...112 99 05 31 ...

Page 127: ...n 7 work envelope arm 36 workspace 15 workspace barriers 18 electrostatic discharge protection 26 E stops 16 e stops check 67 F3 options 9 gripper hose 62 gripper OPEN CLOSE 62 ground electrical 23 height arm 32 installation requirements 2 joint accelerations 40 joint speeds 40 lifting moving the arm 51 live man switch check 69 load capacity 44 lubrication harmonic drive 95 lubrication joint 89 ma...

Page 128: ...114 F3 Robot Arm User Guide 99 05 31 troubleshooting 79 umbilical cable connector 99 umbilical cable properties 8 unpacking 50 weight arm 32 wrist thrust and torque 39 ...

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