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Comau RoboticsInstruction Handbook
Handling System
SmartHand
Application Software Rel. 115.xx
CR00757621-en_01/2012.07
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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 07/2012
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SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Implemented and respected essential health and safety requirements . . . . . . . . . . . . . . . . . . 7
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2. GENERAL DESCRIPTION OF SMARTHAND APPLICATION SOFTWARE . . . . . . ...17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Basic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Basic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. INSTALLING / ACTIVATING / UNINSTALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Preparation for SmartHand installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Use of WinApplicationCreator tool for C5G (WAC5G). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Uninstall procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. USER INTERFACE ON THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Process control keys (right menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Specific application environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Application Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Areas description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
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Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Softkeys description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Object Pages description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Integration of the application package with System environment . . . . . . . . . . . . . . . . . . . . . . . 36 Alarm page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Errors cause and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37I/O Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
User Help I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Integration with IDE environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Technological Instruction insertion in IDE environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Technological Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Process routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Gripper_sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Gripper_vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Gripper_vacuum_blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Gripper_chkpart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Grip_part_supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Grip_air_supervision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Advanced variables and routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hnvb_smarthand_in_fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Hnru_user_fault_abort_enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Hnru_user_fault_abort_ack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Hnrb_get_user_fault_abort. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Handling RESET key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47hnru_tp_reset_in_remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Using the System shared resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6. CUSTOMIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..50
I/O configuration towards PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7. OPTIONAL SOFTWARE FUNCTIONALITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..51
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SmartVisualProcess. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Functioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Part Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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PREFACE
Symbols used in the manual
The symbols used for WARNING, CAUTION and NOTES and their relevant meanings
are given below
This symbol indicates operating procedures, technical information and
precautions that if not observed and/or performed correctly could cause injuries
to the personnel.
This symbol indicates operating procedures, technical information and
precautions that if not observed and/or performed correctly cou ld cause damage
to the equipment.
This symbol indicates operating procedures, technical information and
precautions that are to be underlined.
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Reference documents
This document concerns the Handling System.
The complete set of Handling System manuals consists of:
Comau C5G Control Unit – Technical Specifications
– Transport and installation
– C5G Control Unit use.
Robot – Technical Specifications
– Transport and installation
– Maintenance
Programming – PDL2 Programming Language Manual
– Motion programming
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1. GENERAL SAFETY PRECAUTIONS
This specification deals with the following topics:
– Responsibilities
– Safety Precautions.
1.1 Responsibil it ies
– The system integrator is responsible for ensuring that the Robot System (Robot
and Control System) are installed and handled in accordance with the Safety
Standards in force in the country where the installation takes place. The application
and use of the protection and safety devices necessary, the issuing of declarations
of conformity and 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 caused
by incorrect or improper use of the Robot System (Robot and Control System), by
tampering with circuits, components or software, or the use of spare parts that are
not included in the spare parts list.
– The application of these Safety Precautions is the responsibility of the persons
assigned to direct / supervise the activities indicated in the Applicability sectionally
are to make sure that the Authorised Personnel is aware of and scrupulously follow
the precautions contained in this document as well as the Safety Standards in
addition to the Safety Standards in force in the country in which it is installed.
– The non-observance of the Safety Standards could cause injuries to the operators
and damage the Robot System (Robot and Control System).
1.1.1 Implemented and respected essential health and safetyrequirements
The robotic system composed of C5G Control Unit series SMART 5 considers as
implemented and respected the following Essential health and sefety requirements of
the 2006/42/CE Machinery Directive: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 – 1.2.4.3 –
1.2.5 – 1.2.6 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 – 1.5.9 –
1.5.10 – 1.5.11 – 1.5.13 – 1.6.3 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.
It deals with a general specification that apply to the whole Robot System. Due to ist
significance, this document is referred to unreservedly in any system instruction manual.
The installation shall be made by qualified installation Personnel and should conform to
all national and local codes.
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1.2 Safety Precautions
1.2.1 Purpose
These safety precautions are aimed to define the behaviour and rules to be observed
when performing the activities listed in the Applicability section.
1.2.2 Definit ions
Robot System (Robot and Control System)The Robot System is a functional unit consisting of Robot, Control Unit, Programming
terminal and possible options.
Protected AreaThe protected area is the zone confined by the safety barriers and to be used for the
installation and operation of the robot
Author ised Personnel Authorised personnel defines the group of persons who have been trained and assigned
to carry out the activities listed in the Applicability section.
Assigned PersonnelThe persons assigned to direct or supervise the activities of the workers referred to in
the paragraph above.
Installation and Putting into ServiceThe installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.
Programming ModeOperating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual handling of robot axes and programming of
work 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 the
work speed, with the operators outside the protected area, with the safety barriers
closed and the safety circuit activated, with local (located outside the protected area) or
remote start/stop.
Maintenance and RepairsMaintenance and repairs are activities that involve periodical checking and / or
replacement (mechanical, electrical, software) of Robot and Control System parts or
components, and trouble shooting, that terminates when the Robot and Control System
has been reset to its original project functional condition.
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Putting Out of Service and DismantlingPutting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.
Integrator The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.
Incorrect UseIncorrect use is when the system is used in a manner other than that specified in the
Technical 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 Applicabil ity
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;
– Maintenance and Repairs;
– Putting Out of Service and Dismantling
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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 the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area 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 under
normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in 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 could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the 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 to
the 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 or
loose parts. Check that the Control Unit components are intact.
– If applicable, connect the robot pneumatic system to the air distribution line paying
attention to set the system to the specified pressure value: a wrong setting of the
pressure 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 used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product
Technical Documentation.
– The power supply cable is to enter the Control Unit through the specific fairlead and
be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.
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– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals 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 the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the
line safety circuits, taking care to connect them as required by the Safety
standards. The safety of the interlock signals coming from the transfer line
(emrgency stop, gates safey devices etc) i.e. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.
– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic states; in Programming the power is cut out (power
contactors open) immediately. The procedure for the selection of the controlled
stop time (that can be set on SDM 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 stop
category (0 or 1) and the weight of the robot.
– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical 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), use
only the original software handed over by COMAU Robotics & Service.
Scrupulously follow the system software uploading procedure described in the
Technical Documentation supplied with the specific product. After uploading,
always make some tests moving the robot at slow speed and remaining outside the
protected 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 control unit
emergency stop buttons, which are on X30. The push buttons are not interlocked in the
emergency stop circuit of the Control Unit.
Check that the controlled stop time is consistent with the type of Robot connected to the
Control Unit. The stop time is selected using selector switches SW1 and SW2 on the
SDM board.
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Programming Mode
– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robot System (Robot and
Control System) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the hand-held terminal is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (Drive On) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the 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 of the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the hand-held terminal: in
this situation, although all the hardware and software safety devices are active, the
robot 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 to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
envisaged by the operator when testing the program.
– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.
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Auto / Remote Automatic Mode
– The activation of the automatic operation (AUTO and REMOTE states) is only to
be executed with the Robot System (Robot and Control System) integrated inside
an area with safety barriers properly interlocked, as specified by Safety Standards
currently in force in the Country where the installation takes place. – Before starting the automatic mode the operator is to check the Robot and Control
System and the protected area to make sure there are no potentially hazardous
irregular 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, where
the line PLC can perform automatic operations to switch on motors and start the
program.
Robot axes release
– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake 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 robot
axes can move upwards or downwards because of the force generated by the
balancing system, or the force of gravity.
– Enabling the brake releasing device may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the brake releasing
device (both for the integrated one and module one) is to be found in the
maintenance manuals.
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths thatmay imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.
Before using the manual release devices, it is strongly recommended to sling the robot,
or hook to an overhead travelling crane.
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Maintenance and Repairs
– When assembled in COMAU Robotics & Service, the robot is supplied with
lubricant that does not contain substances harmful to health, however, in some
cases, 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
abundant water; if the irritation persists, consult a doctor.
If swallowed, do not provoke vomiting or take anything by mouth, see a doctor as
soon as possible.
– Maintenance, trouble-shooting and repairs are only to be carried out by authorised
personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be 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 be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same code, or
equivalent 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 possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when 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 deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robot System (Robot and Control System)
and all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original 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 to
make sure, remaining outside the protected area
After replacement of the SDM module, check on the new module that the setting of the
stop time on selector switches SW1 and SW2 is consistent with the type of Robot
connected to the Control Unit.
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– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.
Putting Out of Service and Dismantling
– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Bring the robot to transport position and fit the axis clamping brackets (where
applicable) consulting the plate applied on the robot and the robot Technical
Documentation.
– Before stating to put out of service, the mains voltage to the Control Unit must be
cut out (switch off the circuit breaker on the mains distribution line and lock it in
open 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 power
supply 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, then
remove 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 the
correct fastening of the eye-bolts and use appropriate slings and equipment only.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.
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1.2.5 Performance
The performances below shall be considered before installing the robot system:
– Stop distances
– Mission time (typ. case).
Stop distances
– With Robot in programming modality (T1), if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 0 (according to the standard
EN60204-1), you will obtain:
– Considering the Robot in automatic modality, under full extension, full load and
maximum speed conditions, if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)
you will trigger the Robot complete stop with controlled deceleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.
Mission time (typ. case)
– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to
EN ISO 13849-1).
Tab. 1.1 - Stop spaces in programming modality (T1)
ModeExpected
speedCase
Stopping
time
Stopping
space
T1 250 mm/sNominal 120 ms 30 mm
Limit 500 ms 125 mm
Tab. 1.2 - Safety electronics reaction time in programming modality (T1)
ModeExpected
speedCase
Stopping
time
T1 250 mm/s
For the safety inputs of the SDM module (e.g.stop pushbutton of TP in wired version)
150 msFor the stop and enabling device inputs fromthe TP in wireless version, when the safetywire trasmission is active.
For the time-out of stop input and enablingdevice from TP in wireless version, when thesafety wire transmission is lost or interrupted.
350 ms
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2. GENERAL DESCRIPTION OFSMARTHAND APPLICATION
SOFTWARE
2.1 IntroductionThis chapter is the introduction to the COMAU Handling environment, with special
regard to SmartHand application software.
A Handling system can have different configurations according to the User’s specific
requirements. This manual only refers to:
– Basic System
– Basic Functions.
2.2 Basic SystemThis consists of the following basic components (see Fig. 2.1 - Basic System):
– Robot C5G Control Unit (1)
– SMART NJx, NS robots (2)
– One of the following Interface board
• Devicenet• Profibus-DP
– SmartHand application software
– Users manual.
Fig. 2.1 - Basic System
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2.3 Basic FunctionsThe basic functions, always available on a handling system, are as follows:
– Integrated Programming Environment (IDE)
– Set of Technological Instructions for the handling
– Special functions
– Alarms management ( Alarm page)
– A signals profile towards PLC, common to all the application Softwares provided
by Comau with standard signals (application inclusion, process activation, dry
cycle, anomaly reset, and corresponding status feedbacks towards PLC).
– A graphics environment composed by:
• main page ( Application Page): it includes general information about the
process status, configuration information and application software version,
and an informational area available to the User;
• Process control keys (right menu): the most common functionalities are
associated to the process keys, together with the corresponding icons;
• setup environment (Setup Page): functionalities to modify and save general
setup values (not included in the technological instructions as parameters)
which control the application working modalities.
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3. INSTALLING / ACTIVATING /UNINSTALLING
3.1 IntroductionThis chapter describes the installation procedure for the SmartHand application.
The following topics are dealt with:
– System requirements
– Preparation for SmartHand installation
– Use of WinApplicationCreator tool for C5G (WAC5G)
– Installation procedure
– Uninstall procedure
3.2 System requirements
3.2.1 Software
It is needed to enable the software option allowing to use the application itself.
Comau Code for SmartHand CR13612060
L'applicativo SmartHand può essere utilizzato con il Software di Sistema C5G la cuiversione corrisponde alle prime tre cifre presenti nella versione del software applicativo.
Ad esempio la versione 100.01 del software applicativo richiede una versione del
software di sistema che sia pari o superiore a 1.0x .
The SmartHand application software can be used in combination with the C5G System
Software, whose version is identified by the most significant three digits in the
application software version. For example version 100.01 of the application software,
requires a system software 1.0x or better.
3.2.2 Hardware
The following basic hardware components are necessary to use the SmartHand
application:
– C5G Robot Control Unit
– one of the following interface boards:
• C5G-Devicenet
• C5G-Profibus.
3.3 Preparation for SmartHand installation
Before starting the actual installation procedure, the C5G Control Unit has to be
prepared. The general installation preparations for the C5G Control Unit are contained
in the relevant C5G Control Unit- Transport and Installation manual.It may be necessary to install the SmartHand application in one of these situations:
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– C5G Controller with SmartHand application package not present.
– SmartHand updating - installation of a newer version with respect to the currently
installed on C5G; it is the situation in which either the SmartHand version must be
updated, keeping the existing configuration, or one or more SmartHand files have
been deleted from the User Directory, by fault.In both cases the procedure is the same (see Installation procedure)
3.4 Use of WinApplicationCreator tool for C5G(WAC5G)SmartHand application Software supplied by Comau is distributed in a single file
(version file) with extension .wac5g (SmartHandVxxx.xx.waC5G): it includes all the
available configurations, i.e. all the allowed devices. As far as SmartHand, just one
configuration is available.
The filename refers to the application type and the version number (e.g.SmartHandv10001.waC5G).
WAC5G is a PC application provided by Comau, to the User, in order to import files of
.wac5g type. It shows, in graphical form, all the allowed devices, grouped in columns,
depending on their type. The User can choose among the existing devices in his/her
own configuration and generate a specific installation file.
The installation file which is generated by WAC5G is an archive file (.zip extension)whose name is composed by
.zip
The configuration name is asked by WAC5G before generating the installation file.
The User can choose any meaningful string, which could help to better identify the
configuration. Such a string is the one displayed on the Teach Pendant in the application
About pages.
3.5 Installation procedureThe following operations are necessary to install the application:
a. Activate the SETUP page on the Teach Pendant
(see Fig. 3.1).
For a detailed description, about use and functionality of WAC5G tool, please
refer to the dedicated manual.
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Fig. 3.1 - SETUP
b. Select theInstall
icon and pressENTER
to confirm.
c. Press ENTER again, then down arrow to select the device (COMP:, XD:, UD:, TX:)
containing the being installed SmartHand application.
d. Confirm with ENTER. Down arrow to select the application to be installed, i.e.
SmartHand .
e. Confirm with ENTER (Fig. 3.2).
Fig. 3.2 - SETUP Application
f. Press the key for the Install command (F5) to carry out the installation.
g. If any error occurs while installing, messages and suggestions are issued.
h. In case of any error, the installation is stopped, the error is indicated with a
message and the C5G red alarm lamp lights up. The system remains in such a
condition until the RESET key is pressed.
The installation will continue from the point where it was interrupted, as soon as the
condition that caused the error is removed.
i. After the installation has been completed, re-start the system (Restart Cold).
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3.6 Uninstall procedureTo uninstall the application package it is needed to execute the following procedure:
a. Activate SETUP page (see Fig. 3.1) on the Teach Pendant
b. Select APPL icon and press ENTER
c. Select Uninstall icon and press ENTER (see Fig. 3.3)
Fig. 3.3 - SETUP - Uninstall
d. In the displayed combobox, select the wished application to be uninstalled and
press ENTER.
Fig. 3.4 - SETUP - Uninstall - 2
e. At the end of the procedure the User is requested to restart the System (Restart
Cold).
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4. USER INTERFACE ON THE TEACHPENDANT
4.1 IntroductionThis chapter describes the user interface on the Teach Pendant, for the SmartHand
application.
The following topics are dealt with:
– Process control keys (right menu)
– Specific application environments
– Integration of the application package with System environment
– Integration with IDE environment.
As fo r the Teach Pendant use, please refer to the pertain ing manual C5G Control
Unit use, chapter Teach Pendant.
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4.2 Process control keys (right menu)The Right Menu displays the softkeys and “software led” for the process control.
Commands associated to the softkeys could be either enabled or disabled as shown by
the following icons in Tab. 4.1.
The “software led” associated to each softkey indicates, depending on the displayed
colour, the status of the component represented by the icon. See the description in the
following Tab. 4.2.
In particular, descriptions for all the softkeys are provided, for all the allowed positions
of the modal selector switch on C5G Controller Unit:
– T1 position (System in Prog state)
– AUTO position (System in Local state)
– REMOTE position (System in Remote state)
Tab. 4.1 - Meaning of the sof tkeys
Icon enabled / disabled - description
When the corresponding softkey is enabled, the icon representing thefunctionality is displayed in colour .
When the corresponding softkey is disabled, the icon representing thefunctionality is displayed in grey.The software led always shows the component status.
Tab. 4.2 - Meaning of the software leds
LED colour - description
When the software led colour is yellow, it means that a command ($DOUT) hasbeen sent to the component, but the function performed confirmation ($DIN)hasn’t been received yet.
In the case shown on the left, the softkey functionality is disabled (e.g. becausethe command comes from remote) but the software LED still indicates thecomponent status: in this example, green means that the function has been
properly completed.
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(*) R4 and R5 keys are enabled only when the robot is in DRIVE ON for safety reasons.
(**) EXAMPLE 1: if R4 Seq 1 is used, the same key controls e ither opening the component when it is closed,
or closing the component when it is opened.
EXAMPLE 2: if R4 Vac 1 is used, the same key controls the intake of the suction devices unit if they are in
stop or vice-versa if they are operating. With the suction device in stop there is also a function of long pressure
to control the suction device blowing. When the key is released the suction device is locked.
Tab. 4.3 - Functionality and position of the modal selector switch
KEY ICON DESCRIPTION
R1
Select the wished gripper. It only works if SmartHand has been configured asa multigripper. Each pressure updates the icon depending on the total amountof configured grippers during the SETUP.The only colour of the software led is grey.The softkey is always enabled in all positions: T1, AUTO and REMOTE.
R2
Select the type of component to be displayed/commanded (Vac/Seq). Eachpressure updates the icon depending on the the type of the configuredcomponent of the gripper indicated by R1.The only colour of the software led is grey.The softkey is always enabled in all positions: T1, AUTO and REMOTE.
R3
Each pressure increases the R4 and R5 component number. The incrementvalue depends on the total amount of configured components.The only colour of the software led is grey.The softkey is always enabled in all positions: T1, AUTO and REMOTE.
R4 ed R5
These softkeys control the component which is represented by the displayedicon. Each softkey pressure causes the component to execute thecorresponding command (**).The allowed colours for the led are: – grey - after a Restart Cold it indicates the unknown state of the component
– yellow - a command ($DOUT) has been sent, but the confirmation ($DIN)
hasn’t been received yet.
– green - properly accomplished movement, thus each $DIN is in thewished condition.
The softkeys are enabled in T1(*) and disabled both in AUTO and REMOTE,but the corresponding icons still display the colour information in order to showthe component state.
R6
It handles the DRY CYCLE command.The allowed colours for the led are: – grey (with the prohibition sign) - dry cycle disabled
– green - dry cycle enabled
The key is enabled in either T1 or AUTO and disabled in REMOTE (because
the command comes from remote but the colour information is still provided).
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4.3 Specific application environmentsThe specific Application Pages are the following:
– Application Page
– Setup Page
A detailed description follows for each one of them, focused on their use for SmartHand
application.
4.3.1 Application Page
The Appl ication Page, on the Teach Pendant, is the Main Page of the installed
application; in this case the application is SmartHand.
On the Teach Pendant, when Appl (L6) key of the Left Menu is pressed, the Main Page
of the application is activated.
Such a page (see Fig. 4.1) is divided into four parts, also called areas, showing
differente information related to the installed application. If more than one applicationare installed on the Controller, there will be as many tabsheets as the total amount of
applications, in the Application Page: just move the focus to the different tabsheets
labelled with the names of the existing applications on the Controller, to display the
corresponding pages.
Fig. 4.1 - Applicat ion Page - star t page
A detailed description follows, about all the Application Page topics:
– Areas description
– About
– Object
4.3.1.1 Areas description
The four areas of the Application Page subdivision, are as follows (see Fig. 4.1):
– the first one (top left - (1)) identifies the selected application, specifying its
installation version
– the second one (top right - (2)), called Dynamic Data, includes the most important
process data, related to the selected application. They are dynamic data, so they
are updated as soon as their value changes
– the third one (bottom left - (3)), called Device Status, includes the hardware
configuration information, related to the selected application
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– Finally, the fourth one (bottom right - (4)) is the User dedicated area, so it is called
User Area. It is a table in which the User is allowed to display some wished
information (with a maximum o four), with string format.
The SmartHand application strings are:
hnxs_user_1 : ARRAY [ki_row] OF STRING [19] EXPORTED FROM sh_dd hnxs_user_2 : ARRAY [ki_row] OF STRING [19] EXPORTED FROM sh_dd
where:
– ki_row, is the maximum number of rows, i.e. 4
– hnxs_user_1 is the reference variable of the first column
– hnxs_user_2 is the reference variable of the second column
In the Application Page bottom menu, two softkeys are available, related to the following
functions:
– About (F5)
– Object (F1)
A detailed description for each of them, follows.
4.3.1.2 About
Displays a menu containing the following information related to the selected application:
– Configuration : this function displays the application name and the installation
version, the application configuration name which is the User assigned identifier (at
the .zip file generation time, by means of the WAC5G tool) and the application
hardware configuration.
Fig. 4.2 - Configuration
– Version: this function displays the application name and the installation version,
the application configuration name which is the User assigned identifier and the
existing software modules version.
For further information, please refer to the WAC5G tool manual.
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Fig. 4.3 - Version
– Version CL : it displays the Common Libraries version, used by the applications.
Fig. 4.4 - Version CL
4.3.1.3 Object
Object (F1) softkey, if present, allows accessing to further object pages related to the
selected application.
It also allows to go back to the Application Page environment if the currently displayed
page is different (e.g. About environment or Object Pages).
SmartHand application includes some more pages in addition to the Appl ication Page
4.3.2 Setup PageCurrent section describes the needed user procedures to modify global settings for
SmartHand application, by means of the Setup Page.
In particular, the following topics are described:
– General information
– Softkeys description
– Object Pages description
4.3.2.1 General information
When SETUP (L3) softkey of the Left Menu is pressed, the SETUP Home Page, usefulto act on the System settings, is activated (see Fig. 3.1).
To access the applications SETUP instead, select APPL : several icons are displayed,
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showing a monkey wrench, with the installed applications names (see Fig. 4.5).
Fig. 4.5 - Application Setup
Select the wished application icon and press ENTER. The application Setup Page isshown in Fig. 4.6.
Fig. 4.6 - Setup of SmartHand appl icat ion
It displays as many panes (Gripper_1, Gripper_2, Gripper_3, Config, Air) as the object
pages and sub-pages are, allowing to modify the application parameters.
The access to the Object Pages menus depends on the performed login; the default is
no menus available.
There are two login levels, enabling different levels of menu:
– Technology level 1 - only 'General' menus are enabled, in each Object Page
– Technology level 2 - all the menus are enabled in all Object Pages (e.g. Alarms
'Reset from TP/PLC')
The User can use the Setup environment Object Pages, to modify the application
configuration parameters, in Programming state only (modal selector switch in T1
position).To access any Object Page and their associated menus, perform the following steps:
It is therefore needed to create a suitable Technology Login , to be able to access
the wished environment.
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a. choose the wished page, by means of the left/right arrow keys;
b. press either ENTER or down arrow, to move the focus to the menus selection and
press ENTER to open the list;
c. select the wished menu and confirm with ENTER;
d. move focus onto the fields to be modified, using the arrow keys, perform the wished
modifications;
e. save the modifications, using the available softkeys in the bottom menu, as
explained in the following par. 4.3.2.2 Softkeys description on page 30.
4.3.2.2 Softkeys description
In each application SETUP Page, the following commands are available, which can be
activated by means of the four softkeys of the bottom menu (see Fig. 4.7):
– Save (F2) – Apply (F3)
– Reload (F4)
– Close (F6).
Fig. 4.7 - Softkeys description
Note that, Save, Apply, and Reload act on the performed modifications. During the
modifications, the being modified values are displayed in Italic style.
4.3.2.2.1 Save (F2)Saves the performed modifications, both in the execution memory and to a file. The
Object Page still remains open. The new value is displayed in the default style again. If
some values are saved which are different than the default ones, hn_conf.var (*) file,
containing the new configuration values, is saved in UD:\data\hand.
4.3.2.2.2 Apply (F3)
Saves the performed modifications, in the execution memory. The Object Page still
(*) This file is automatically generated by the application, only if User
modifi cations are performed in t he SETUP page. So, after the fi rst installation, it
can be not present yet. In case of sof tware updating, this file is preserved in order
not to lose the user configuration.
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remains open but the new values are NOT saved to a file. The new value is displayed
in the default style again.
4.3.2.2.3 Reload (F4)
Loads again, from the file, the application variables default values.
4.3.2.2.4 Close (F6)
Closes the SETUP Page.
4.3.2.3 Object Pages description
The SmartHand application Setup page makes available the following sub-pages:
– Gripper _X (from 1 to MAX_GRIPPER (3))
– Config
– Air .
4.3.2.3.1 Gripper
In this type of Object Page, the user has to enter all the devices to be used in the
process.
Each Object Page is similar to the others: the only difference is the gripper which it refers
to.
The possible choices (in the menu list) in the current Object Page are:
– Enable devices
– Sequence 1..6
– Vacuum 1..6
– Part_present 1..5.
GRIPPER : ENABLE DEVICES
It shows the list of the devices to be enabled/disabled, as in the following table
GRIPPER : Sequence 1….6
After the device has been enabled, it is allowed to access its subpage, by selectin the
wished component in the menu list.
In this environment $DIN inputs and $DOUT outputs can be inserted in order to handle
the componentne.
Each sequence can handle a maximum amount of
– 5 inputs for the open sequence – 5 inputs for the close sequence
PARAMETER DESCRIPTION RANGE
Sequence 1…..6 Allows enabling/disabling Sequences (1…6) to beused in the process
[ON/OFF]
Vacuum 1…6 Allows enabling Vacuum (1…6) to be used in theprocess
[ON/OFF]
Part_present 1…5 Allows enabling the control to handle the partpresence
[ON/OFF]
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– 5 outputs for the open sequence
– 5 outputs for the close sequence.
The parameters description and the corresponding range are shown in the following
table.
Examples of devices that can be used by the sequences group:
– Clamping / Centering w ith 2-input bi-stable valves
• Sequence_open_input_1 --> Enter $DIN open index
• Sequence_close_input_1 -> Enter $DIN close index
• Sequence_open_output_1 -> Enter $DOUT open index
• Sequence_close_output_1 ->Enter $DOUT close index
– Clamping / Centering with 1-input b istable valves• Sequence_open_input_1 -> enter the $DIN if it is an open input, otherwise
leave 0
• Sequence_close_input_1 -> enter the $DIN if it is a close input, otherwise
leave 0
• Sequence_open_output_1 ' enter the $DOUT opening index
• Sequence_close_output_1 ' enter the closing $DOUT index
– Clamping / Centering with 2-input monostable valves
• Sequence_open_input_1 -> enter the $DIN opening index
• Sequence_close_input_1 -> enter the $DIN closed index
• Sequence_open_output_1 -> enter the $DOUT if it is an opening output,
otherwise leave 0• Sequence_close_output_1 -> enter the $DOUT if it is a closing output,
otherwise leave 0
– Clamping / Centering with 1-input monostable valves
• Sequence_open_input_1 -> enter the $DIN if it is an open output, otherwise
leave 0
• Sequence_close_input_1 ->enter the $DIN if it is a close output, otherwise
leave 0
• Sequence_open_output_1 -> enter the $DOUT if it is an opening output,
otherwise leave 0
• Sequence_close_output_1 -> enter the $DOUT if it is a closing output,
otherwise leave 0 – Clamping / Centering without inputs
In this case no $DIN is to be entered and the process routine has to be called with
PARAMETER DESCRIPTION RANGE
Sequence_open_input_1....Sequence_open_input_5
Allows inserting the input signal ($DIN) for thereference sequence opening
$DIN[0…512]
Sequence_close_input_1....Sequence_close_input_5
Allows inserting the output signal ($DIN) for thereference sequence closing
$DIN[0…512]
Open_sequence_output_1....Open_sequence_output_5
Allows inserting the input signal ($DOUT) for thereference sequence opening
$DOUT[0…512]
Close_sequence_output_1....Close_sequence_output_5
Allows inserting the output signal ($DOUT) for thereference sequence closing
$DOUT[0…512]
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control flag at FALSE.
GRIPPER : Vacuum 1….6
Also for vacuums, as for Sequences, it is possible to insert Input and Output signals
($DIN, $DOUT), to handle the component just after enabling it.For each vacuum it is possible to enter a maximum of:
– 5 inputs for the vacuum meters
– 5 outputs for aspiration
– 5 outputs for clamping
– 5 outputs for blowing.
The parameters description and the corresponding range are shown in the following
table.
Examples of devices that can be used in the vacuum group:
– suction devices with bi-stable valves for aspiration and monostable for
blowing and a vacuum meter
• Vacuum_active_input_1 -> Enter the vacuum meter $DIN index
• Release_vacuum_output_1 -> Enter the $DOUT index to stop aspiration
• Active_vacuum_output_1 -> Enter the $DOUT index to activate aspiration
• Blow_vacuum_output_1 -> Enter the $DOUT index to activate blowing
– suction devices with mono-stable valves for aspiration and monostable for
blowing and a vacuum meter • Vacuum_active_input_1 -> Enter the vacuum meter $DIN index
• Release_vacuum_output_1 -> Leave 0
• Active_vacuum_output_1 -> Enter the $DOUT index to activate aspiration
• Blow_vacuum_output_1 -> Enter the $DOUT index to activate blowing
– suction devices only one mono-stable valve and a vacuum meter
• Vacuum_active_input_1 ->Enter the vacuum meter $DIN index
• Release_vacuum_output_1 -> Leave 0
• Active_vacuum_output_1 -> enter the $DOUT if the output activates
aspiration, otherwise leave 0
• Blow_vacuum_output_1 -> enter the $DOUT if the output enables blowing,
otherwise leave 0
– suction devices without information from vacuum meter
PARAMETER DESCRIPTION RANGEVacuum_active_input_1....Vacuum_active_input_5
Allows inserting the input signal ($DIN) to activatethe corresponding vacuum
$DIN[0…512]
Release_vacuum_output_1....Release_vacuum_output_5
Allows inserting the output signal ($DOUT) to stopaspiration
$DOUT[0…512]
Active_vacuum_output_1.... Active_vacuum_output_5
Allows inserting the output signal ($DOUT) toactivate aspiration
$DOUT[0…512]
Blow_vacuum_output_1
....Blow_vacuum_output_5
Allows inserting the output signal ($DOUT) toenable blowing $DOUT[0…512]
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In this case no $DIN is to be entered and the process routine is to be called with
the FALSE control flag.
GRIPPER : Part Present 1….5
To check the part presence on robot board – 3 inputs for presence microswitches
The parameters are the same for each device checking the part presence.
4.3.2.3.2 Config
In this sub-page the user can act on the GLOBAL Parameters settings, that operate in
real time on the handling process.
The corresponding menus are:
– Application program setting
– Reset alarms for TP/PLC.
The parameters corresponding to these two subpages are shown in the following tables
(Tab. 4.4 e Tab. 4.5), as well as their meaning and range of values.
Tab. 4.4 - Config - Applicat ion program settings
PARAMETER DESCRIPTION RANGE
Part_present_input_1....Part_present_input_3
Allows inserting the part input signal ($DIN) $DIN[0…512]
NOTE THAT to use $DIN and $DOUT signals, please refer to Tab. 5.1 showing theprovided User shared resources.
PARAMETRO DESCRIZIONE RANGE
Clear outputEnables the outputs reset after the motioncompletion
[ON/OFF]
Drive off fault Enables drive off during anomalies [ON/OFF]
Status Output faultIndicates the status of the anomaly output towards
PLC
[ON/OFF]
Timeout alarmTimeout after a movement before a fault isgenerated
[1000..5000] [ms]
Waiting TimeWaiting time used before exiting from a routine, ifthe process is called without inputs check
[500..3000] [ms]
Timeout supervision
Time used in the dynamic part present check to filterany vibrations of the part during the movement; ifthe part present input is missing for the timeincluded in the filter, the application will not signal alost part
[100…1000] [ms]
Time blowing
Time used for the blowing pulse. If the indicated
time is 0 the application will not use the PULSEmode, but will directly set the output [0…3000] [ms]
http://../Italiano/lb-hn-0-hnd_it.pdfhttp://../Italiano/lb-hn-0-hnd_it.pdf
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Tab. 4.5 - Config - Reset alarms from TP/ PLC
4.3.2.3.3 Air
This subpage allows enabling/disabling the pressure switches the User wishes to use in
the process, defining parameters needed to their handling.
The available menus in this Object page are:
– Enable pressure switches
– Air check 1..3
– Media Panel
Tab. 4.6 - Air - enable pressure switches
Air : Air check 1..3
It is allowed to access these subpages for defining each pressure switch
values/parameters, just after enabling such a device. Each subpage is similar to the
others: the only difference is the referenced device.
PARAMETER DESCRIPTION RANGE
Reset from TP in T1The Teach Pendant reset is enabled with the mode
selector switch on T1 (Prog mode)
$DIN[0…512]
Reset form TP in AUTOThe Teach Pendant reset is enabled with the modeselector switch on AUTO (Local mode)
[ON/OFF]
Reset from TP in REMOTEThe Teach Pendant reset is enabled with the modeselector switch on REMOTE (Remote mode)
[ON/OFF]
Reset form PLC in T1Reset from PLC is enabled with the mode selectorswitch on T1 (Prog mode)
[ON/OFF]
Reset from PLC in AUTOReset from PLC is enabled with the mode selectorswitch on AUTO (Local mode)
[ON/OFF]
Reset from PLC in REMOTEReset from PLC is enabled with the mode selectorswitch on REMOTE Remote mode)
[ON/OFF]
PARAMETER DESCRIPTION RANGE
Air check 1 Enable pressure switch 1 [ON/OFF]
Air check 2 Enable pressure switch 2 [ON/OFF]
Air check 3 Enable pressure switch 3 [ON/OFF]
PARAMETER DESCRIPTION RANGE
Input Number Enter the number of the $DIN port to be used tocontrol the pressure switch
$DIN[0…512]
Gripper Index
Choose the gripper where the pressure switch isinstalled. If the pressure switch is not mounted onthe gripper, but on a station, enter No Gripper. Thisis because if there is the tool changer application, ifthe pressure switch is mounted on the gripper,during the release procedure the applicationpackage will have to mask the air control so that it
does not become connected again
[No Gripper/Gripper 1/Gripper 2/ Gripper 3]
Timeout Air Enter the filter time in ms to mask any pressurefluctuations in the system
[100…1000] [ms]
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Air : Media Panel
This subpage is always visible, but it is just enabled at the application package
installation creation time.
When enabled, it allows enabling/disabling the air pressure switch control on the Media
Panel
4.4 Integration of the application package withSystem environmentThis section describes the System environment pages providing information about the
application.
Such pages are:
– Alarm page
– I/O Page
4.4.1 Alarm page
This User Page (which is the System Alarm Page) the issued application alarms are
displayed.
Fig. 4.8 - Alarm Page
The following information is displayed for each message i:
– alarm order number
– error code and severity
– message text
– date and time.
PARAMETER DESCRIPTION RANGE
PresentEnable/disable monitoring. Enabling this flag, thestate of a $DIN (previously configured by theapplication software), will be monitored
[ON/OFF]
Filter it is the Filter Time; insert the waiting time to be usedby the application software, before issuing an alarmmessage
[0..1000] [ms]
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An ALARM MESSAGE is displayed when SmartHand detects an anomalous condition
that requires the interruption of the process and the intervention of the operator. These
messages are only displayed following an operation performed by an instruction that
belongs to the Technological Instructions group. The message remains displayed until
SmartHand receives an alarm reset command.
The allowed Reset capabilities of the alarm can be:
– Retry (F1) - it is present depending on the alarm type; usually it is available when
an action is expected only. It repeats such an action
– Skip (F2) - it is present depending on the alarm type; it resets the alarm bypassing
its cause and goes ahead with the next operations.
– Reset (F3) - it has exactely the same functionality of the Teach Pendant RESET
key. The alarm is deleted and the event causing the alarm is checked again.
4.4.1.1 Errors cause and remedy
To know the cause of an application alarm and the corresponding available remedy, itis needed to type in the alarm number into the Cause and Remedy Window of WinC5G
interface, and issue Find command.
File hn_ms.crd, containing such information about SmartHand application, must be
added to the errors list, by means of the WinC5G Property Window, in the CRD File
field, byfirst pressing Edit key, and then Add key as shown in the following figures:
Fig. 4.9 - Property Window
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Fig. 4.10 - CRD f ile selection
File hn_ms.crd is present:
– on the PC, in the installation directory of WinC5G together with System alarms crd
files
– on the Controller in UD:\sys\msg\hn_ms.crd; it is copied in this directory duringSmartHand application installation.
If the alarm number typed in WinC5G Cause/Remedy Window is not found, the possible
reasons could be:
– file hn_ms.crd has not been added in WinC5G Property Window
– file hn_ms.crd is present but it could be not up to date; in this case the file stored
on the Controller must be added.
4.4.2 I/O Page
The I/Os handled by the application are grouped “by component” in a directory called
SMARTHAND.
Press I/O (L5) (left menu) to access it, moving focus on Ports subpage identified by the
tabsheet with this name, and selecting smarthand directory.
A list is displayed of all already configured (by means of the Setup Page) components.
Fig. 4.11 - I/O Ports
Fig. 4.12 shows an example of how I/Os are displayed.
For any further details about subpages and the use of the Alarm Page general
purpose softkeys, please refer to C5G Control Unit use manual, chap.Teach
Pendant - par. Alarm Page.
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Fig. 4.12 - Display ing I/Os
4.4.2.1 User Help I/Os
The I/Os comments, describing signals of each component configured on the GRIPPER
X ( where 'X' is the gripper number), are string variables included in hn_help_gripX.var
file.
The I/Os comments, describing inputs of the pressure switches which are NOT mounted
onto the gripper(s), are string variables included in hn_help_station_air.var file,
instead.
Such files, placed in UD:\\appl\\hio directory, are automatically generated by the
application only when the User modifies any values in the Setup Page. Depending on
the performed modification, the application will either generate a new var file or will
update the already existing one.
At the first installation, it is then possible that they are not present yet.The help strings aare never changed depending on the selected language; this allows
the User to directly customize them.
Let us suppose of modifying the configuration of sequence 1, input open 2, referred to
gripper 1, automatically generated by the application within hn_help_grip1.var file; it it
then:
hnvs_din_11_help STR Len: 128 Priv 'Grip 1 Seq 1 Input Open 2'
The item in Italic style is the string type variable name for the configured input: in this
case it is $DIN [11].
The item in bold style is the being modified string instead.
Example:
hnvs_din_11_help STR Len: 128 Priv 'Second input open of seq. 1, gripper 1'
To activate the new help string, it is necessary to perform a Restart Cold operation if
the string variable has been created for the first time; otherwise, if it was already exixting
and it has just been updated, issuing command 'ML/V'(Memory Load / Variables) of
the modified var file, is enough.
NOTE THAT such s trings are always and only generated in English language.
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Fig. 4.13 - Example of Help I/O
4.5 Integration with IDE environmentIn this section a detailed description is given on how to insert Technological Instructions
in the application program in IDE environment. A full analysis of such instructions is
given in par. 5.2 Technological Instructions on page 43.
4.5.1 Technological Instruction insertion in IDE environment
To insert Technological Instructions from within IDE environment, act as follows:
a. select the wished holdable program by pressing Prog (L3) key;
b. press ENTER to open the program in IDE environment, in order to edit it and insert
the required Technological Instructions
c. move the cursor to the line in which the required instruction is to be added, press
PDL2 (F3) key, choose Empty line and confirm with ENTER.
Fig. 4.14 - Inserting a Technological Instruction - example
NOTE THAT to con figure input and output signals ($DIN and $DOUT), it is neededto use IO_MAP program, available on the Teach Pendant in the SETUP age; please
refer to C5G Control Unit use manual, chap. SETUP Page, for further details.
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d. Press Statement (F1),
e. select SMARTHAND directory and confirm with ENTER; SmartHand application
Technological instructions are displayed and the User is requested to select the
wished one to be inserted in the program
Fig. 4.15 - Selecting the Technological instruction
f. In the shown above example (see Fig. 4.15), gripper_sequence instruction is
selected when pressing ENTER.
g. The System inserts the corresponding template (mask) for the required instruction
and the User must fill in all the fields and press ENTER to confirm.
Fig. 4.16 - Insertion complet ion
The above described insertion procedure is the same for each Technological
Instruction.
A functionality exists which makes inserting an application instruction faster, in IDE
environment.
Press SHIFT + '1' to activate such a functionality; a table is open, called Numeric
Keypad , which associates the numeric keys of the TP Alphanumeric Keypad, to the
application Technological Instructions (see Fig. 4.17).
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Fig. 4.17 - Use of the Numeric Keypad
By pressing any numeric key corresponding to an instruction, that same instruction will
be entered in the program.It is possible to enter instructions in an even quicker way: in the IDE environment, press
SHIFT + the numeric key associated to the desired instruction, at the same time,
without opening the numeric Keypad; the system will add the instruction to the program.
For example, (refer to Fig. 4.17) if the user presses SHIFT and 2 at the same time,
without opening the keypad, gripper_sequence technological instruction will be added
to the program.
Summarizing, the keys to control the numeric Keypad are the following ones:
– SHIFT + ‘1’ - opens the numeric Keypad
– ‘n’ - when the numeric Keypad IS OPEN, adds the instruction corresponding to ‘ n’
key and closes the numertic Keypad. – SHIFT + ‘n’ - when the numeric Keypad IS NOT OPEN, adds the instruction
corresponding to ‘n’ key, to the program.
– PAGE UP / PAGE DOWN - changes the numeric Keypad pages.
– up/down/right/left arrows - allows moving within the numeric Kaypad.
– ESC - closes the numeric Keypad without adding any instruction to the program.
– ENTER - adds the currently selected instruction (in the numeric keypad) to the
program and closes the numeric Keypad.
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5. PROGRAMMING
5.1 IntroductionThis chapter gives detailed information to the user who has to write programs for the
Handling application.
The following topics are dealt with in detail:
– Technological Instructions
– Handling RESET key
– Using the System shared resources.
5.2 Technological Instructions
The user has several technological instructions available, dedicated to the handling
process. They are grouped in the following classes:
– Process routines
– Advanced variables and routines.
5.2.1 Process routines
– Gripper_sequence
– Gripper_vacuum
– Gripper_vacuum_blow
– Gripper_chkpart
– Grip_part_supervision
– Grip_air_supervision.
Find below a detailed description of each Technological Instruction related to the
SmartHand application software.
5.2.1.1 Gripper_sequence
Name Gripper_sequence
Function/Usage Manages the clamps opening and closing command. Used to command a clamping.
Parameters
– ai_grip: gripper to be used - 1 .. 3 (INTEGER)
– ai_seq: sequence to be used - 1 .. 6 (INTEGER)
– ab_state: ON -> calls the sequence closure
OFF -> calls the sequence opening ON / OFF(BOOLEAN)
– ab_check (optional parameter): ON -> inputs checked
OFF -> inputs check excluded - ON / OFF(BOOLEAN)
Statementgripper_sequence (ai_grip, ai_seq:INTEGER; ab_state,
ab_check:BOOLEAN) EXPORTED FROM H_hand GLOBALEntering from IDE NO
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5.2.1.2 Gripper_vacuum
5.2.1.3 Gripper_vacuum_blow
Calling example
ROUTINE gripper_sequence (ai_grip, ai_seq:INTEGER; ab_state,
ab_check:BOOLEAN) EXPORTED FROM H_hand GLOBAL
BEGIN
Gripper_sequence( 1, 1, ON, ON)
...
END prog_1
Name Gripper_vacuum
Function/UsageManages the vacuum work and idle command. Used when a vacuum is to becontrolled.
Parameters
– ai_grip: gripper to be used - 1 .. 3 (INTEGER)
– ai_seq: suction device to be used - 1 .. 6 (INTEGER)
– ab_state: ON -> calls aspiration
OFF -> stops aspiration - ON / OFF(BOOLEAN) – ab_check (optional parameter): ON -> vacuum meter check
OFF -> vacuum meter check off - ON / OFF(BOOLEAN)
Statementgripper_vacuum (ai_grip, ai_vac : INTEGER; ab_state, ab_check :
BOOLEAN)EXPORTED FROM H_hand GLOBAL
Entering from IDE NO
Calling example
ROUTINE gripper_vacuum (ai_grip, ai_vac : INTEGER; ab_state,
ab_check : BOOLEAN)EXPORTED FROM H_hand GLOBAL
BEGIN
Gripper_vacuum( 1, 1, ON, ON)
...
END prog_1
Name Gripper_vacuum_blow
Function/Usage Manages the vacuum blowing. Used issue vacuum blowing.
Parameters
– ai_grip: gripper to be used - 1 .. 3 (INTEGER)
– ai_seq: suction device to be used - 1 .. 6 (INTEGER)
– ab_state: ON -> calls blowing
OFF -> stops blowing - ON / OFF(BOOLEAN) – ab_check (optional parameter): ON -> vacuum meter check
OFF -> vacuum meter check off - ON / OFF(BOOLEAN)
Statementgripper_vacuum_blow(ai_grip, ai_vac:INTEGER; ab_state,
ab_check:BOOLEAN)EXPORTED FROM H_hand GLOBAL
Entering from IDE NO
Calling example
ROUTINE gripper_vacuum_blow(ai_grip, ai_vac:INTEGER; ab_state,
ab_check:BOOLEAN)EXPORTED FROM H_hand GLOBAL
BEGIN
Gripper_vacuum_blow( 1, 1, ON, OFF)
...
END prog_1
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5.2.1.4 Gripper_chkpart
5.2.1.5 Grip_part_supervision
5.2.1.6 Grip_air_supervision
Name gripper_chkpart
Function/UsageManages the part presence or absence check. Used to check the presence or absenceof the part.
Parameters
– ai_grip: gripper to be used - 1 .. 3 (INTEGER)
– ai_part : part presence to be used - 1 .. 5 (INTEGER)
– ab_state: ON -> check presence
OFF -> check absence - ON / OFF(BOOLEAN)
Statementgripper_chkpart(ai_grip, ai_part : INTEGER; ab_state :
BOOLEAN)EXPORTED FROM H_hand GLOBAL
Entering from IDE NO
Calling example
ROUTINE gripper_chkpart(ai_grip, ai_part : INTEGER; ab_state :
BOOLEAN) EXPORTED FROM H_hand GLOBAL
BEGINgripper_chkpart( 1, 1, ON)
...
END prog_1
Name grip_part_supervision
Function/UsageManages the part presence or absence dynamic check. Used to activate or deactivatethe part presence dynamic check.
Parameters
– ai_grip: gripper to be used - 1 .. 3 (INTEGER) – ai_part : part presence to be used - 1 .. 5 (INTEGER)
– ab_state: ON -> enable dynamic check
OFF -> disable dynamic check - ON / OFF(BOOLEAN)
Statementgrip_part_supervision(ai_grip, ai_part : INTEGER; ab_state :
BOOLEAN)EXPORTED FROM H_hand GLOBAL
Entering from IDE NO
Calling example
ROUTINE grip_part_supervision(ai_grip, ai_part
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