c4g Motion Programming

Comau Roboticsstruction Handbook

C4G SW ManualsC4GMOTION PROGRSystem Softwar

Robot movements in progmotion, cooperative motiosmartmove4, kinematic copositioners and portals, T

CR00757558_en-00/0708InAMMINGe Rel. 3.2x

ramming mode, motion control, optional features (synchronous n, sensor tracking, conveyor tracking, weaving, path governor, mpensation, collision detection), moving through singularities, O_SET program.

The information contained in this manual is the property of COMAU S.p.A.

Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.

COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.

Copyright 2003 by COMAU - Date of publication 07/2008

Summary

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IXSymbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IX

Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

Modification History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XI

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.1Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

2. SYSTEM OPERATING MODES AND STATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.1Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

System operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

System states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3HOLD status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4AUTO status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4PROGR status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5AUTO-T status (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5ALARM status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Stand-by function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

3. TURN-SET AND CALIBRATION - BASIC CONCEPTS . . . . . . . . . . . . . . . . . . . . . . ..3.1Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

Turn-set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Turn-set on system calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Turn-set on user calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3Turn-set for robot axes with multi-turn stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4System calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5User calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

4. ROBOT MOTION IN PROGRAMMING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4.1Ilb-rc-c4e-motionTOC.fm

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Summary

Reference frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

System reference frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

Manual motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

Manual motion in WRIST_JNT mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

Manual motion of a single arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

Manual motion of auxiliary axes, slides and rotating columns . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

Manual motion with Controller multi-arm configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

Motion instruction in programming status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

5. MOTION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Frames of Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1System Frame of Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Base System of Reference definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3Flange Tooling definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

TCP Offset definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4Calculating the Rotation Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5

FIRST METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6SECOND METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

User System of Reference definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

Trajectory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9Joint Interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9Linear Interpolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9Circular Interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9Orientation Evolution during Linear or Circular movements. . . . . . . . . . . . . . . . . . . . . . . . . 5.10Attitude Flags During Linear and Circular Movements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10Turn Flag and minimum path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

Position Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12On Trajectory Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12On Position (ON POS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

Example of On Pos and On Trajectory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14

Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14Speed Overrides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15Cartesian Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16

Cartesian Speed Control Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17Run-Time modifying the Linear Speed Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18

Joint Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19Manual Motion Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19

Acceleration and Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20Acceleration/Deceleration Overrides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21Joint Interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22Cartesian Interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22Manual Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23

Motion termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23COARSE and FINE Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23IIlb-rc-c4e-motionTOC.fm

Summary

JNT_COARSE and JNT_FINE Termination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24NOSETTLE Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24

Trajectory Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24Recovery Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24

Pending Motion Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25Recovery Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25Execution Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25

Process Resume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26Automatic Process Resume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28

Continuous Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29Trajectory Shape During Continuous Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30Continuous Motion Modes (FLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30

FLY_NORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30FLY_CART (Controller Aided Resolved Trajectory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31

Dynamic Machine Stress Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31Constant Speed Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32Control of Trajectory During FLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32Debug of Fly Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34Variables used with FLY Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36

Remote Tool System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36

Integrated Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37Integrated Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38

Jogging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39Reference Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40

6. SYNCHRONOUS MOTION (OPTIONAL FEATURE) . . . . . . . . . . . . . . . . . . . . . . . . ..6.1Synchronization with Auxiliary Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

Synchronized Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

Motion limitation of the two Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

Jogging Synchronized Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

Teaching and Modifying Positions (REC/MOD) with Synchronized Arms . . . . . . . . . . . . . . . . . 6.3

Loss of Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

Run-time modifying the Linear Speed Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

7. COOPERATIVE MOTION (OPTIONAL FEATURE) . . . . . . . . . . . . . . . . . . . . . . . . . ..7.1Cooperative Motion with Auxiliary Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

Cooperative Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

8. SENSOR TRACKING (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8.1IIIlb-rc-c4e-motionTOC.fm

Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

Summary

Configuration on several arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Sensor interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3Integrated Sensors ( MCP-ST board (Seam Track)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4External sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

Sensor reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5Sensor integral with the tool (TOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5Sensor integral with the user reference system (USER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6Sensor integral with the world reference system (WORLD). . . . . . . . . . . . . . . . . . . . . . . . . . 8.7Sensor integral with the weaving reference system (WEAVE). . . . . . . . . . . . . . . . . . . . . . . . 8.7

Type of information acquired by the sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7

Correction actuation criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8Relative and absolute deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8Actuation of deviation in time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9Overall deviations control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12

Sensor tracking enable mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12

Sensor malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14Robot stop in the case of sensor malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14Redefinition of overall deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14

Accumulative overall deviations management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16Interrupted sensor tracking session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16Suspended sensor tracking session. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17Resetting in spread condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17Limitations in parameter changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18

Programming example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19

9. CONVEYOR TRACKING(OPTIONAL FEATURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

Process Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

Tracking Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

Motion Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

Teaching Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

Tracking Interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

Limitations during Conveyor Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

Use of the Roto-translating Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8Configuration parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9

10. INTEGRATED CONVEYOR TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1IVlb-rc-c4e-motionTOC.fm

Summary

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2Conveyor configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2Motion programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

11. MOTION WITH WEAVING (OPTIONAL FEATURE). . . . . . . . . . . . . . . . . . . . . . . . ..11.1Weaving Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

Weaving Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

Weaving Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2Wave Shape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3Weave Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6Weave Amplification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8

Stopping Motions with Weaving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10

Programming Weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11

Weaving without Arm motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13Example - Using the weaving without Arm motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13

12. PATH GOVERNOR (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..12.1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

Enable Path Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

Disable Path Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3

13. SMARTMOVE4 (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..13.1Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1

Jerk Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2

Cartesian Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2

14. FLOW MODULATEALGORITHM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..14.1

15. PRESUPPOSITIONS FOR SMART ROBOT PROGRAMMING . . . . . . . . . . . . . . . ..15.1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1

Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2

Offset algorithm with Dynamic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3

Kinematic offset algorithm (optional feature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Vlb-rc-c4e-motionTOC.fm

Moving through axis 5 singularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3

Summary

Using WRIST_JNT modality to go through singularities . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Jogging through wrist singularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5

Robots without compensation (effect of the inverse kinematics) . . . . . . . . . . . . . . . . . . . . . . . 15.6Inverse conversion of SMART NH4 (non-spherical wrist) model . . . . . . . . . . . . . . . . . . . . . 15.6

Approximation in the orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6Move to a taught POSITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6Fly between MOVE LINEAR/CIRCULAR and MOVE JOINT . . . . . . . . . . . . . . . . . . . . . . 15.7Axis 5 singularity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7Cartesian position out of range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9TCP in the back of the robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10TCP behind axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12WCP close to axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13

Inverse conversion of SMART NH, NS and NM (spherical wrist models only) . . . . . . . . . 15.15Axis 5 singularity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15TCP close to axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16

Programming rules for non-spherical wrist robots (SMART NH4) . . . . . . . . . . . . . . . . . . . . . 15.17How to stay away from a singularity zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18

Changing the orientation of the points along the path . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18Properly designing the work-cell layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20Modifying tool inserting a small angle between robot flange and tool flange . . . . . . . . . 15.23

Using WRIST_JNT modality to go through singularities . . . . . . . . . . . . . . . . . . . . . . . . . . 15.25Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28Exact working range for SMART NH4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28

16. COLLISION DETECTION(OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1

Basic concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1

Activation/deactivation of Collision Detection function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2

Collision Detection sensitivity type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3$COLL_TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3$ARM_SENSITIVITY (sensitivity threshold of the axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4$COLL_SOFT_PER (axes compliance thresholds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6

Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6

Notes about the collision detection use procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6

CollMngr Program to activate/deactivate the sensitivity thresholds calculation. . . . . . . . . . . 16.11CollisionStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11CollisionEnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12How to use the Collision Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12

Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13Enabling the Collision Detection functionality for a single MOVE statement . . . . . . . . . . . 16.13Enabling Collision Detection again from within a Program. . . . . . . . . . . . . . . . . . . . . . . . . 16.14Automatic calculation of the sensitivity thresholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.15Updating of thresholds in cold robot/warmed robot mode . . . . . . . . . . . . . . . . . . . . . . . . . 16.16VIlb-rc-c4e-motionTOC.fm

Managing "collision detected" event. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.28

Summary

17. USE OF POSITIONERS MANAGED BY C4G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..17.1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2

General Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2Axis rotation directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2Convention for the mechanical positioning of points P1, P2 and P3 . . . . . . . . . . . . . . . . . . 17.3

Programming override value calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4

Positioners with 1 rotating axis type MP, PTDO, PTDV, TR3000/6000. . . . . . . . . . . . . . . . . . 17.4Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5

PTORB - Positioner with 2 perpendicular axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6Positioner with two tilting-rotating axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6

Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8

Positioner with two axes in "L" arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9

Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10

Positioners with 2 non perpendicular axes, type PTORB-alfa . . . . . . . . . . . . . . . . . . . . . . . . 17.12Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13

Integrated robot positioning axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15Integrated slide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15

Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.16Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.16Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17

Integrated rotating column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19

Three linear axes portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.22Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.22

Two linear axes Portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.24Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.24Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25

Integrated trans-rotational Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.26Definition of the reference system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.26Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.27Kinematic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.27

18. TO_SET PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..18.1VIIlb-rc-c4e-motionTOC.fm

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1

Summary

Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2From TP4i/WiTP Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2From WinC4G on Personal Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3

First screen page of TO_SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4

TOOL automatic calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5Tools needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5

Calibrated tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5Reference point (or master cube). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6

General characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6Tool orientation calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6How to identify the "dummy reference system" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7Tool calculation with standard method- Complete procedure . . . . . . . . . . . . . . . . . . . . . . 18.10Tool verification with standard method - Partial procedure . . . . . . . . . . . . . . . . . . . . . . . . 18.11Tool Calculation with "4 points method" - Complete procedure . . . . . . . . . . . . . . . . . . . 18.17

Local Tool verification with "4 points method" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.20Payload identification (optional function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.21

Basic concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.22Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.23

Requirements to modify Payload identification programs . . . . . . . . . . . . . . . . . . . . . 18.23Activation and execution of the Payload identification procedure . . . . . . . . . . . . . . . 18.24

Software to validate the payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.33

REMOTE TOOL Automatic Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.34Tools needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.34

Tool with known dimensions mounted on Robot Flange . . . . . . . . . . . . . . . . . . . . . . . . 18.34General characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.34

UFRAME automatic calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35Tools needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35

Tool with known dimensions mounted on Robot Flange . . . . . . . . . . . . . . . . . . . . . . . . 18.353 Reference Points (ORIGIN, Xpos and XYpos) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35

General characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.36

REMOTE UFRAME automatic calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.41Tools needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.41

Tool with known dimensions mounted on the Robot Flange . . . . . . . . . . . . . . . . . . . . . 18.413 reference points (ORIGIN, Xpos and XYpos). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.41

General characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.42Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.42

BASE automatic calculation for POSITIONERS (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 18.47Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.47

Tool of known dimensions mounted on the robot flange . . . . . . . . . . . . . . . . . . . . . . . . 18.473 reference points (P1, P2, P3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.47

General characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.48

CONVEYOR TRACKING installation and configuration (optional service) . . . . . . . . . . . . . . 18.57Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.57

Tool of known dimensions mounted on the robot flange . . . . . . . . . . . . . . . . . . . . . . . . 18.573 Reference points (P1, P2, P3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.57VIIIlb-rc-c4e-motionTOC.fm

Preface

PREFACE

Symbols used in the manual

Reference documents

Modification History.

Symbols used in the manualThe symbols for WARNING, CAUTION and NOTES are indicated below together withtheir significance.

This symbol indicates operating procedures, technical information andprecautions that if ignored and/or are not performed correctly could causeinjuries.

This symbol indicates operating procedures, technical information andprecautions that if ignored and/or are not performed correctly could causedamage to the equipment.

This symbol indicates operating procedures, technical information andprecautions that it are important to highlight.IXHS-0-0-0-mot_01.fm00/0000

Preface

Reference documentsThis document refers to the C4G Control Unit.

The complete set of manuals for the C4G consists of:

These manuals are to be integrated with the following documents:

Comau C4G Control Unit Technical Specifications Transport and installation Guide to integration, safeties, I/O and

communications C4G Control Unit Use.

Comau Robot Technical Specifications Transport and installation Maintenance

Programming PDL2 Programming Language Manual VP2 - Visual PDL2 Motion programming

Applications According to the required type of application.

Altersys PLC programming ISaGRAF Workbench XHS-0-0-0-mot_01.fm

00/0000

Preface

Modification History System Software version 3.01 - the description of how to Use of the

Roto-translating Conveyor has been added

System Software version 3.1x - the following paragraphs have been added: Weaving without Arm motion, Manual motion of auxiliary axes, slides and rotating columns, Run-Time modifying the Linear Speed Override for Single Arms Systems, Run-time modifying the Linear Speed Override for multiarm Systems.

System Software version 3.12 - the following paragraph has been added: CollMngrProgram to activate/deactivate the sensitivity thresholds calculation.

System Software version 3.2x - in par. 17.8 Integrated robot positioning axes on page 17-15, the following

sections have been added: par. 17.8.3 Three linear axes portal on page 17-21, par. 17.8.4 Two linear axes Portal on page 17-24, par. 17.8.5 Integrated trans-rotational Column on page 17-26.

several modifications in par. 5.5.2.1 Cartesian Speed Control Options onpage 5-17.XIHS-0-0-0-mot_01.fm00/0000

PrefaceXIIHS-0-0-0-mot_01.fm

00/0000

General Safety Precautions

1. GENERAL SAFETY PRECAUTIONS

1.1 Responsibilities

The system integrator is responsible for ensuring that the Robot and ControlSystem are installed and handled in accordance with the Safety Standards in forcein the country where the installation takes place. The application and use of theprotection and safety devices necessary, the issuing of declarations of conformityand any CE markings of the system are the responsibility of the Integrator.

COMAU Robotics & Service shall in no way be held liable for any accidents causedby incorrect or improper use of the Robot and Control System, by tampering withcircuits, components or software, or the use of spare parts that are not originals orthat have not been defined as equivalent by COMAU Robotics & Service

The application of these Safety Precautions is the responsibility of thepersons assigned to direct / supervise the activities indicated in the Applicabilitysection,They are to make sure that the Authorised Personnel is aware of andscrupulously follow the precautions contained in this document as well as theSafety Standards in addition to the Safety Standards in force in the country in whichit is installed.

The non-observance of the Safety Standards could cause injuries to the operatorsand damage the Robot and Control System.

The installation shall be made by qualified installation Personnel and shouldconform to all national and local codes.1-1ge-0-0-0_01.FM07/1007


1.2 Safety Precautions

1.2.1 Purpose

These safety precautions are aimed to define the behaviour and rules to be observedwhen performing the activities listed in the Applicability section.

1.2.2 Definitions

Robot and Control SystemThe Robot and Control System consists of all the functions that cover: Control Unit,robot, hand held programming unit and any options.

Protected AreaThe protected area is the zone confined by the safety barriers and to be used for theinstallation and operation of the robot

Authorised PersonnelAuthorised personnel defines the group of persons who have been trained and assignedto carry out the activities listed in the Applicability section.

Assigned Personnel The persons assigned to direct or supervise the activities of the workers referred to inthe paragraph above.

Installation and Putting into ServiceThe installation is intended as the mechanical, electrical and software integration of theRobot and Control System in any environment that requires controlled movement ofrobot axes, in compliance with the safety requirements of the country where the systemis installed.

Programming ModeOperating mode under the control of the operator, that excludes automatic operationand allows the following activities: manual handling of robot axes and programming ofwork cycles at low speed, programmed cycle testing at low speed and, when allowed,at the working speed.

Auto / Remote Automatic ModeOperating mode in which the robot autonomously executes the programmed cycle at thework speed, with the operators outside the protected area, with the safety barriersclosed and the safety circuit activated, with local (located outside the protected area) orremote start/stop.

Maintenance and RepairsMaintenance and repairs are activities that involve periodical checking and / orreplacement (mechanical, electrical, software) of Robot and Control System parts orcomponents, and trouble shooting, that terminates when the Robot and Control Systemhas been reset to its original project functional condition.1-2ge-0-0-0_01.FM

07/1007


Putting Out of Service and DismantlingPutting out of service defines the activities involved in the mechanical and electricalremoval of the Robot and Control System from a production unit or from an environmentin which it was under study.Dismantling consists of the demolition and dismantling of the components that make upthe Robot and Control System.

IntegratorThe integrator is the professional expert responsible for the installation and putting intoservice of the Robot and Control System.

Incorrect UseIncorrect use is when the system is used in a manner other than that specified in theTechnical Documentation.

Range of Action The robot range of action is the enveloping volume of the area occupied by the robotand its fixtures during movement in space.

1.2.3 Applicability

These Specifications are to be applied when executing the following activities:

Installation and Putting into Service;

Programming Mode;

Auto / Remote Automatic Mode;

Robot axes release;

Stop distances (threshold values)

Maintenance and Repairs;

Putting Out of Service and Dismantling1-3ge-0-0-0_01.FM07/1007


1.2.4 Operating Modes

Installation and Putting into Service

Putting into service is only possible when the Robot and Control System has beencorrectly and completely installed.

The system installation and putting into service is exclusively the task of theauthorised personnel.

The system installation and putting into service is only permitted inside a protectedarea of an adequate size to house the robot and the fixtures it is outfitted with,without passing beyond the safety barriers. It is also necessary to check that undernormal robot movement conditions there is no collision with parts inside theprotected area (structural columns, power supply lines, etc.) or with the barriers. Ifnecessary, limit the robot working areas with mechanical hard stop (see optionalassemblies).

Any fixed robot control protections are to be located outside the protected area andin a point where there is a full view of the robot movements.

The robot installation area is to be as free as possible from materials that couldimpede or limit visibility.

During installation the robot and the Control Unit are to be handled as described inthe product Technical Documentation; if lifting is necessary, check that the eye-bolts are fixed securely and use only adequate slings and equipment.

Secure the robot to the support, with all the bolts and pins foreseen, tightened tothe torque indicated in the product Technical Documentation.

If present, remove the fastening brackets from the axes and check that the fixingof the robot fixture is secured correctly.

Check that the robot guards are correctly secured and that there are no moving orloose parts. Check that the Control Unit components are intact.

If applicable, connect the robot pneumatic system to the air distribution line payingattention to set the system to the specified pressure value: a wrong setting of thepressure system influences correct robot movement.

Install filters on the pneumatic system to collect any condensation.

Install the Control Unit outside the protected area: the Control Unit is not to be usedto form part of the fencing.

Check that the voltage value of the mains is consistent with that indicated on theplate of the Control Unit.

Before electrically connecting the Control Unit, check that the circuit breaker on themains is locked in open position.

Connection between the Control Unit and the three-phase supply mains at theworks, is to be with a four-pole (3 phases + earth) armoured cable dimensionedappropriately for the power installed on the Control Unit. See the productTechnical Documentation.

The power supply cable is to enter the Control Unit through the specific fairlead andbe properly clamped.

Connect the earth conductor (PE) then connect the power conductors to the mainswitch. 1-4ge-0-0-0_01.FM

07/1007


Connect the power supply cable, first connecting the earth conductor to the circuitbreaker on the mains line, after checking with a tester that the circuit breakerterminals are not powered. Connect the cable armouring to the earth.

Connect the signals and power cables between the Control Unit and the robot.

Connect the robot to earth or to the Control Unit or to a nearby earth socket.

Check that the Control Unit door (or doors) is/are locked with the key.

A wrong connection of the connectors could cause permanent damage to theControl Unit components.

The C4G Control Unit manages internally the main safety interlocks (gates,enabling pushbuttons, etc.). Connect the C4G Control Unit safety interlocks to theline safety circuits, taking care to connect them as required by the Safetystandards. The safety of the interlock signals coming from the transfer line(emrgency stop, gates safey devices etc) i.e. the realisation of correct and safecircuits, is the responsibility of the Robot and Control System integrator.

The safety of the system cannot be guaranteed if these interlocks are wronglyexecuted, incomplete or missing.

The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for thesafety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop isonly active in Automatic states; in Programming the power is cut out (powercontactors open) immediately. The procedure for the selection of the controlledstop time (that can be set on ESK board) is contained in the Installation manual .

When preparing protection barriers, especially light barriers and access doors,bear in mind that the robot stop times and distances are according to the stopcategory (0 or 1) and the weight of the robot..

Check that the environment and working conditions are within the range specifiedin the specific product Technical Documentation.

The calibration operations are to be carried out with great care, as indicated in theTechnical Documentation of the specific product, and are to be concludedchecking the correct position of the machine.

To load or update the system software (for example after replacing boards), useonly the original software handed over by COMAU Robotics & Service.Scrupulously follow the system software uploading procedure described in theTechnical Documentation supplied with the specific product. After uploading,always make some tests moving the robot at slow speed and remaining outside theprotected area.

Check that the barriers of the protected area are correctly positioned.

In the cell/line emergency stop circuit the contacts must be included of the controlunit emergency stop buttons, which are on X30. The push buttons are notinterlocked in the emergency stop circuit of the Control Unit.

Check that the controlled stop time is consistent with the type of Robot connectedto the Control Unit. The stop time is selected using selector switches SW1 andSW2 on the ESK board.1-5ge-0-0-0_01.FM07/1007


Programming Mode

The robot is only to be programmed by the authorised personnel.

Before starting to program, the operator must check the Robot and Control Systemto make sure that there are no potentially hazardous irregular conditions, and thatthere is nobody inside the protected area.

When possible the programming should be controlled from outside the protectedarea.

Before operating inside the Protected Area, the operator must make sure fromoutside that all the necessary protections and safety devices are present and inworking order, and especially that the hand-held programming unit functionscorrectly (slow speed, emergency stop, enabling device, etc.).

During the programming session, only the operator with the hand-held terminal isallowed inside the Protected Area.

If the presence of a second operator in the working area is necessary whenchecking the program, this person must have an enabling device interlocked withthe safety devices.

Activation of the motors (Drive On) is always to be controlled from a positionoutside the range of the robot, after checking that there is nobody in the areainvolved. The Drive On operation is concluded when the relevant machine statusindication is shown.

When programming, the operator is to keep at a distance from the robot to be ableto avoid any irregular machine movements, and in any case in a position to avoidthe risk of being trapped between the robot and structural parts (columns, barriers,etc.), or between movable parts of the actual robot.

When programming, the operator is to avoid remaining in a position where parts ofthe robot, pulled by gravity, could execute downward movements, or moveupwards or sideways (when installed on a sloped plane).

Testing a programmed cycle at working speed with the operator inside theprotected area, in some situations where a close visual check is necessary, is onlyto be carried out after a complete test cycle at slow speed has been executed. Thetest is to be controlled from a safe distance.

Special attention is to be paid when programming using the hand-held terminal: inthis situation, although all the hardware and software safety devices are active, therobot movement depends on the operator.

During the first running of a new program, the robot may move along a path that isnot the one expected.

The modification of program steps (such as moving by a step from one point toanother of the flow, wrong recording of a step, modification of the robot position outof the path that links two steps of the program), could give rise to movements notenvisaged by the operator when testing the program.

In both cases operate cautiously, always remaining out of the robots range ofaction and test the cycle at slow speed.1-6ge-0-0-0_01.FM

07/1007


Auto / Remote Automatic Mode

The activation of the automatic operation (AUTO and REMOTE states) is only tobe executed with the Robot and Control System integrated inside an area withsafety barriers properly interlocked, as specified by Safety Standards currently inforce in the Country where the installation takes place.

Before starting the automatic mode the operator is to check the Robot and ControlSystem and the protected area to make sure there are no potentially hazardousirregular conditions.

The operator can only activate automatic operation after having checked: that the Robot and Control System is not in maintenance or being repaired; the safety barriers are correctly positioned; that there is nobody inside the protected area; that the Control Unit doors are closed and locked; that the safety devices (emergency stop, safety barrier devices) are

functioning;

Special attention is to be paid when selecting the automatic-remote mode, wherethe line PLC can perform automatic operations to switch on motors and start theprogram.

Robot axes release

In the absence of motive power, the robot axes movement is possible by means ofoptional release devices and suitable lifting devices. Such devices only enable thebrake deactivation of each axis. In this case, all the system safety devices(including the emergency stop and the enable button) are cut out; also the robotaxes can move upwards or downwards because of the force generated by thebalancing system, or the force of gravity.

Stop distances (threshold values)

As for the stop distance threshold values for each robot type, please turn to theCOMAU Robotics & Service Dept.

Example: Considering the robot in automatic mode, in conditions of maximumextension, maximum load and maximum speed, when the stop pushbutton ispressed (red mushroom head pushbutton on WiTP) an NJ 370-2.7 Robot will stopcompletely in approx. 85 of motion, equivalent to approx. 3000 mm displacementmeasured on the TCP flange. Under these conditions indicated, the stoppage timeof the NJ 370-2.7 Robot is 1.5 seconds.

Considering the robot in programming mode (T1), when the stop pushbutton ispressed (red mushroom head pushbutton on WiTP) an NJ 370-2.7 Robot will stopcompletely in approx. 0.5 seconds.

Maintenance and Repairs

When assembled in COMAU Robotics & Service, the robot is supplied withlubricant that does not contain substances harmful to health, however, in somecases, repeated and prolonged exposure to the product could cause skin irritation,or if swallowed, indisposition.First Aid. Contact with the eyes or the skin: wash the contaminated zones with

Before using the manual release devices, it is strongly recommended to sling therobot, or hook to an overhead travelling crane.1-7ge-0-0-0_01.FM07/1007

abundant water; if the irritation persists, consult a doctor.


If swallowed, do not provoke vomiting or take anything by mouth, see a doctor assoon as possible.

Maintenance, trouble-shooting and repairs are only to be carried out by authorisedpersonnel.

When carrying out maintenance and repairs, the specific warning sign is to beplaced on the control panel of the Control Unit, stating that maintenance is inprogress and it is only to be removed after the operation has been completelyfinished - even if it should be temporarily suspended.

Maintenance operations and replacement of components or the Control Unit are tobe carried out with the main switch in open position and locked with a padlock.

Even if the Control Unit is not powered (main switch open), there may beinterconnected voltages coming from connections to peripheral units or externalpower sources (e.g. 24 Vdc inputs/outputs). Cut out external sources whenoperating on parts of the system that are involved.

Removal of panels, protection shields, grids, etc. is only allowed with the mainswitch open and padlocked.

Faulty components are to be replaced with others having the same code, orequivalent components defined by COMAU Robotics & Service.

Trouble-shooting and maintenance activities are to be executed, when possible,outside the protected area.

Trouble-shooting executed on the control is to be carried out, when possiblewithout power supply.

Should it be necessary, during trouble-shooting, to intervene with the Control Unitpowered, all the precautions specified by Safety Standards are to be observedwhen operating with hazardous voltages present.

Trouble-shooting on the robot is to be carried out with the power supply cut out(Drive off).

At the end of the maintenance and trouble-shooting operations, all deactivatedsafety devices are to be reset (panels, protection shields, interlocks, etc.).

Maintenance, repairs and trouble-shooting operations are to be concludedchecking the correct operation of the Robot and Control System and all the safetydevices, executed from outside the protected area.

When loading the software (for example after replacing electronic boards) theoriginal software handed over by COMAU Robotics & Service is to be used.Scrupulously follow the system software loading procedure described in thespecific product Technical Documentation; after loading always run a test cycle tomake sure, remaining outside the protected area

Disassembly of robot components (motors, balancing cylinders, etc.) may causeuncontrolled movements of the axes in any direction: before starting a disassemblyprocedure, consult the warning plates applied to the robot and the TechnicalDocumentation supplied.

It is strictly forbidden to remove the protective covering of the robot springs.

After replacement of the ESK module, check on the new module that the settingof the stop time on selector switches SW1 and SW2 is consistent with the type ofRobot connected to the Control Unit.1-8ge-0-0-0_01.FM

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Putting Out of Service and Dismantling

Putting out of service and dismantling the Robot and Control System is only to becarried out by Authorised Personnel.

Bring the robot to transport position and fit the axis clamping brackets (whereapplicable) consulting the plate applied on the robot and the robot TechnicalDocumentation.

Before stating to put out of service, the mains voltage to the Control Unit must becut out (switch off the circuit breaker on the mains distribution line and lock it inopen position).

After using the specific instrument to check there is no voltage on the terminals,disconnect the power supply cable from the circuit breaker on the distribution line,first disconnecting the power conductors, then the earth. Disconnect the powersupply cable from the Control Unit and remove it.

First disconnect the connection cables between the robot and the Control Unit,then the earth cable.

If present, disconnect the robot pneumatic system from the air distribution line.

Check that the robot is properly balanced and if necessary sling it correctly, thenremove the robot securing bolts from the support.

Remove the robot and the Control Unit from the work area, applying the rulesindicated in the products Technical Documentation; if lifting is necessary, check thecorrect fastening of the eye-bolts and use appropriate slings and equipment only.

Before starting dismantling operations (disassembly, demolition and disposal) ofthe Robot and Control System components, contact COMAU Robotics & Service,or one of its branches, who will indicate, according to the type of robot and ControlUnit, the operating methods in accordance with safety principles and safeguardingthe environment.

The waste disposal operations are to be carried out complying with the legislationof the country where the Robot and Control System is installed.1-9ge-0-0-0_01.FM07/1007

General Safety Precautions1-10ge-0-0-0_01.FM

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General Safety Precautions1-11ge-0-0-0_01.FM07/1007

System operating modes and states

2. SYSTEM OPERATING MODES AND STATES

2.1 ForewordThis chapter describes the following:

System operating modes

System states

Stand-by function

2.2 System operating modesThe C4G Robot Control Unit can operate in four different modes that can be selectedthrough the status selector switch on the Robot Controller Cabinet (RCC):

Auto T (status selector switch in position T2 - optional feature)

programming (T1),

local automatic (AUTO) and

remote automatic (REMOTE).

AUTO mode is used to execute production programs; as they contain instructions for the2-1HS-0-C4E-USO_32.fm

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robot movement, to be able to start it is necessary to press the START key on the Teach


Pendant. The status selector switch must be set on AUTO.Active TOOL, BASE and FRAME, cannot be changed when working in AUTO mode.

The Automatic remote mode (REMOTE) is the same as Automatic local mode(LOCAL), but the commands (for example the start) are sent from a remote device (forexample a PLC).The state selector switch must be set to the REMOTE position. Active TOOL, BASE andFRAME, cannot be changed when working in AUTO mode.

The Programming mode (T1) is used to create and verify programs The robot moves,for safety reasons, are run at a lower speed than in automatic mode (maximum robotspeed allowed in programming is 250 mm/s on the flange centre).

In Auto T mode (T2 - optional feature) the system runs as in Programming mode (T1),except that the program testing can be executed at working speed.

If, in T2, the jog keys are used, the system will automatically reduce the speed to lessthan 250 mm/s.

When the status selector switch is set to T1 or T2 (optional feature), programs can bedeveloped using editor environment and positions can be learnt by the Teach Pendant,jogging the robot by means of the motion keyst; the programs can be set up using thedebug tools of the system. In programming mode, the execution of a move instructionrequires that the operator presses the START key and the enable device on the TeachPendant.

When the status selector switch has been set on T1, or T2 or AUTO, the system is underthe control of the operator. When the selector is set on REMOTE, the system is underremote control (for example from PLC).Active TOOL, BASE and FRAME, cannot be changed when working in REMOTE mode.

Before any operation can be executed that requires movement, the drives must bepowered:

if the state selector switch is in either T1 or T2 (optional) position, press in theintermediate position the Teach Pendant Enabling Device, to power ON the drives;tho switch them OFF and activate brakes on all axes controlled by the Control Unit,just release the Teach Pendant Enabling Device,

if the state selector switch is in AUTO position, press the R5 softkey (TeachPendant right menu - it means DRIVE ON when in AUTO state), to power ON thedrives; to switch them OFF and activate brakes on all axes controlled by theControl Unit, press the R5 softkey again (Teach Pendant right menu - now it means

NoteWhen the status selector switch is set to T2, the system generates a latched alarmthat prevents the entry to the actual T2 status, even if allowing to switch the driveson. No movements are allowed (nor the manual one) until the latched alarm is notacknowledged. To enable this optional mode, the user has then to confirm the message.The latched alarm described above is automatically reset if the selector switch ismoved to another state, but it resumes as soon as there is a return to T2.T2 status is only enabled when the user confirms the latched alarm. At this point the user is free to run motion programs keeping either the START keyor the enabling device pressed. The speed can be increased at will up to 100%,hence bringing the robot to its maximum speed (the same speed that can bereached in automatic mode).2-2HS-0-C4E-USO_32.fm01/0208

DRIVE OFF).


Active TOOL, BASE and FRAME, cannot be changed when working in AUTOmode.

if the state selector switch is in REMOTE position, DRIVEs ON and OFF areremote controlled.

A detailed description follows of all the possible system states.

2.3 System statesThe system status depends mainly on:

the status selector switch on the Robot Controller Cabinet (RCC)

the DRIVE ON, DRIVE OFF and HOLD keys on the Teach Pendant

system alarm

The transition from one system status to another is also influenced by the enablingdevice on the Teach Pendant.

The Control Unit may be in one of these four states:

HOLD status: the robot is gradually decelerated until the stopping point is reached;movement is suspended and also the execution of the movement program(holdable). When there are all the necessary conditions to exit from the HOLDstatus, the system returns to the previous state (programming or automatic), but tocontinue to execute the movement program it is necessary to press START.AUTO status: this is usually used to execute production programs that control therobot movements (status selector switch positioned on AUTO or REMOTE or T2).Active TOOL, BASE and FRAME, cannot be changed when working either inAUTO or REMOTE mode.

PROGR status: the robot can be moved manually using the jog keys or executingprogram instructions (from editor environment or by EXECUTE). In the latter case,in order that the movement be executed, the START key and the enabling buttonhave to be kept pressed.

A special sub-status is AUTO-T status (optional) that, besides having all thecharacteristics of the PROGR status, allows the program to be run at workingspeed. This is an OPTIONAL status.

If the controlled stop function class 1 (EN 60204-1) is active, the power cut-out (openingof the power contactor) may take place with a delay that ranges from a minimum of 1second to a maximum of 2 seconds.

With the status selector switch positioned on T1 or T2, the power cut-out is immediate(EN 60204-1, class 0 stop).

ALARM status: this status is entered when there is a system alarm. According tohow serious the error is, the system takes different actions, such as suspending theprogram execution, deactivation of the drives, etc. A situation may occur where thealarm cannot be reset, therefore the drives cannot be switched on.

The current system status is displayed on the first status line of the Teach Pendant (orin the Terminal window of tool WINC4G on PC).

The figure shows a simplified diagram of the actions that determine the systemchange-over from one state to another.2-3HS-0-C4E-USO_32.fm

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Fig. 2.1 - Simplified diagram of the system states

1. Status selector switch on T1 + HOLD released 2. HOLD or DRIVES OFF or selector switch change3. HOLD or DRIVES OFF or selector switch change4. Status selector switch on AUTO or REMOTE or T2 + HOLD released

Note: To perform transient 4 also the enabling device key has to be pressed

2.3.1 HOLD status

The safety rules to be complied to when operating with the Control Unit have beenstudied so that the system enters the HOLD status every time a change is made in theoperating mode, passing for instance from LOCAL to PROGR mode.

To exit from the HOLD status to enable a certain operating mode, there must be all therequired safety conditions. A typical example is when the operator brings the statusselector switch to PROGR to work near the robot, holding the Teach Pendant to carryout learning operations for the points.

In PROGR or AUTO-T, exiting from HOLD can be obtained by pressing START, this iscontrolled by the system and therefore is active when an instruction or a movementprogram is executed. When the START key is released again the system returns toHOLD status.

When entering the HOLD status, the corresponding HOLD key on the Teach Pendantis considered as pressed. Further pressure on the key causes the system to exit fromHOLD status.

If the HOLD status has been caused by pressing the DRIVE OFF key on the TeachPendant, the DRIVE OFF and HOLD keys must be pressed again to exit from HOLDstatus. and then the DRIVE ON key to re-power the drives.

2.3.2 AUTO status

To have the system in AUTO status, the status selector switch on the Robot ControlCabinet must be set on AUTO or REMOTE. Active TOOL, BASE and FRAME, cannotbe changed when working either in AUTO or REMOTE mode.2-4HS-0-C4E-USO_32.fm01/0208


In AUTO status, to start programs ready for execution, press the START key on theTeach Pendant or activate the START input from remote device.

Conditions that change the system status from AUTO to HOLD are:

status selector switch changed to another position;

DRIVE OFF or HOLD pressed;

system alarm.

To return to AUTO, bring the selector switch back to the required position, and pressagain the previous buttons (DRIVE OFF and/or HOLD). To continue the movementprogram execution, press START after making sure that the drives are powered (DRIVE

2.3.3 PROGR status

PROGR status is active when:

the status selector switch is set to T1.

In this state the robot can be moved manually, using the jog keys on the Teach Pendant.It is also possible to run programs from IDE environment (see IDE Page in Use of C4GControl Unit manual) to check that they are correct and if necessary makechanges. Movements are at slow speed.

2.3.4 AUTO-T status (optional)

This status is active when:

status selector switch is set to (T2) and latched alarm confirmed(see Note).

In this status the movements can be run, at full speed, from the Teach Pendant,requiring that the START key, together with the enabling device, is kept pressed by theoperator to execute the move.

The system passes from AUTO_T status to HOLD status when:

the Enabling Device is released by the operator. This also causes the stop of themove, that can be resumed by pressing the Enabling Device again. The secondline of the status window will ask for this pushbutton to be pressed.

the status selector switch is changed to any other position

the HOLD key is pressed, or the START key is released.

2.3.5 ALARM status

The system enters ALARM status when an alarm is generated. An error message isdisplayed on the second status line of the system screen and the associated LED, nextto the ALARM key on the Teach Pendant, lights up.

There are different conditions that can generate an alarm and the action to be taken toexit from ALARM status and bring the system back to the previous state vary accordingto how serious the error is.2-5HS-0-C4E-USO_32.fm

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2.4 Stand-by functionThe purpose of the Stand-by function is to cut down the current consumption when therobot is stationary.

The function is automatically activated when the Control Unit is in local automatic orremote automatic mode and after the robot has remained stationary for a time definedby variable $TUNE [27];this function activates the motor brakes to keep the staticposition of the robot. The value of variable $TUNE [27], set by COMAU, is 120 seconds;if this variable is set to 0 the function is deactivated.

The Stand-by function is automatically deactivated at the first request to start movementagain (START, RESUME) from the system.

The system Stand-by status is displayed in the status bar of the Teach Pendant. Todisplay the state of a single arm, read this status on the Status sub-page, the Motionpage on TP4i/WiTP or send the DisplayArmStatus (DAS) command.

The safety precautions are to be scrupulously observed regarding this operatingcondition of the Controller.2-6HS-0-C4E-USO_32.fm01/0208

System operating modes and states2-7HS-0-C4E-USO_32.fm

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Turn-Set and Calibration - basic concepts

3. TURN-SET AND CALIBRATION - BASIC CONCEPTS

3.1 ForewordThe purpose of this chapter is to describe the basic concepts and the terminology for themanagement of robot axes position information. The description of the operatingprocedures is contained in the chapter TURN-SET AND CALIBRATION -

OPERATING PROCEDURES, that specifically regards the robot used.

This chapter contains the basic information on the following topics:

Terminology used

Turn-set

Calibration

3.2 Terminology TRANSDUCER: There are two types of position transducers: encoder and

resolver.

NUMBER OF TRANSDUCER TURNS: during the robot axis movement, thetransducer may make several turns; the number of turns is initialised through thecalibration or the turn-set.

AXIS VALUE: the value of an axis contains all the information needed to determinethe exact position of an axis in space;

VALUE RECONSTRUCTION: when the Control Unit is powered on, the systemsoftware, among the various initialisations, reconstructs the value of the robotaxes.The system software checks this value; in fact, it checks that the differencebetween the reconstructed position and the position before shut-down is below acertain threshold. If the threshold is exceeded, the Control Unit displays the error59411 SAX: movement after shut-down and leaves it to the operator to checkthat the physical position of the robot corresponds to the new value.

CALIBRATION POSITION: a pre-set position that has been checked usingspecific equipment (dial gauges, supports, calibration fixtures). The calibrationposition is a reference position in the robot working space that serves to initialisethe value of each axis.

CALIBRATION CONSTANTS: the calibration constant is the difference betweenthe datum read by the transducer and the nominal position of the robot axis thatthe transducer should assume in that particular position of the robot axis. In fact,since the positioning of the transducer as to the robot joint is casual, (because itdepends on how the transducer has been mounted), it is necessary to correct the3-1HS-0-C4E-USO_35.fm01/0906


actual position of the transducer according to the nominal position required by therobot axis. The calibration constant is defined inside a transducer turn and is stored in variable$CAL_DATA. It is represented in motor turns and is a value between -0.5(excluded) and +0.5 (included). The calibration constant described in variable$CAL_DATA can be read through the CAV (Configure, Arm, View_cal) instruction.

CALIBRATION ASCII FILE: the calibration fileUD:\SYS\_CAL.PDL (where $SYS_ID indicates thesystem identification, for example NH4_001) is an ASCII file with syntax of a PDL2file, where the calibration constants ($CAL_DATA[n]) and other typical data of therobot are stored.

NVRAM - MCP: the memory used to save the characteristic information of the robotassociated to the Control Unit, the calibration constants and the length of thelevers. If the SMP+, NVRAM-MCP board is installed, it is the partition, on the actualboard, for the motion process (Motion Control Process); if the MCP board isinstalled, it refers to the MCP board memory.

3.3 Turn-setThe purpose of the turn-set is to update the number of transducer turns only,should it occur that the when switched on again, the Control Unit has lost thisvalue.

The operation consists in bringing the axis involved to the calibration position, using thelocating notches, and giving the required command. No special equipment is needed,because the only value initialised is the number of turns of the transducer.

The turn-set operation is required when

there has been axis movement with the control off (for example when the error59411 SAX - movement after shut-down) is displayed.

events take place that cause the loss of the number of turns only, and therefore donot require the execution of the calibration procedure. On the Teach Pendantstatus window or on the PV video the text Ar:TURN is displayed.

According to whether the turn-set is executed with the robot in system calibrationposition or in user calibration position, we shall have:

Turn-set on system calibration position

Turn-set on user calibration position

Turn-set for robot axes with multi-turn stroke

3.3.1 Turn-set on system calibration position

Enables the initialising of the number of transducer turns of the individual robot axes, inthe system calibration position (calibration position pre-defined by COMAURobotics).

For further information see System calibration ($CAL_SYS).3-2HS-0-C4E-USO_35.fm

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3.3.2 Turn-set on user calibration position

Enables the initialising of the number of transducer turns of the individual robot axes, inthe user calibration position (out of range position defined by the user).

For further information see User calibration ($CAL_USER).

3.3.3 Turn-set for robot axes with multi-turn stroke

With robot axes that are able to execute the multi-turn stroke, it may happen that whencarrying out the TURN SET procedure, the mechanical calibration notches aremisaligned (this condition can occur when the robot axis, having made one or morecomplete rotations, positions in a mechanical turn that is different to that of the originalcalibration).

Fig. 3.1 - Axis Positioning Error in TURN SET

If the conditions described above occur, do not send the TURN SET command (the axiswould be calibrated in a wrong position), but restore the correct position by performingone of these procedures:

1. Turn the axis and make attempts to find the axis turn position where the originalcalibration was executed. Align the notches and run the TURN SET command.When the correct position has been resumed, the message Command Completedwill appear on the terminal

In the condition indicated above, when moving the axis to align the notches, apositioning error message is shown on the terminal.

Fig. 3.2 - Axis Positioning Correction and Error Message3-3HS-0-C4E-USO_35.fm01/0906

otherwise, as an alternative


2. Make the complete axis calibration (see the Chapter - Turn-set and Calibration -Operating Procedures)

Fig. 3.3 - Correct Axis Positioning Message

3.4 CalibrationThe purpose of the calibration procedure is to establish the position of a robot axisreferring it to an ideal robot. This makes it possible to initialise the values of the robotaxes and to make the position variables used in the robot programs universal.

During the calibration procedure, when the desired axis is in the calibration position, twovalues are stored:

the deviation, inside a transducer turn, between the value of the actual position andthat of the axis nominal position,

the number of transducer turns.

The notches on the individual axes make it possible to execute future turn-set operationson a robot that has already been installed.

The recovery of the calibration (executed by COMAU), if necessary, is to be executedwhen first putting the robot into operation.

The basic concepts are described below for:

System calibration

User calibration

Remember that executing the calibration operation (Configure Arm Calibrate -CAC) having simply positioned the robot axes on the locating notches withoutusing the opportune equipment, is an operation that does not guarantee thenecessary robot positioning precision.

Subsequently, the calibration does not need to be executed again, unless there isa mechanical failure that involves the replacement of a component of thekinematic chain, or in the case of impacts that damage the robot structure.3-4HS-0-C4E-USO_35.fm

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3.4.1 System calibration

To initialise the robot axis values in the system calibration position (calibrationposition predefined by COMAU Robotics - $CAL_SYS).

3.4.2 User calibration

User calibration defines a new calibration position that is different to that of thesystem.

This type of calibration (commonly called out-of-range calibration) can be used whenthe system position is difficult to reach once the robot is inserted in the final application,and therefore it becomes necessary to define a different calibration position, called usercalibration position ($CAL_USER).

To determine the correct calibration position, special equipment has to be used(dial gauges, supports, etc.) to determine with the necessary precision theposition of each individual axis.

It is the responsibility of the user to provide the appropriate instruments and tocheck the correct positioning of the robot in any user re-calibrations, especiallyregarding the arrangemen

c4g Motion Programming

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