CRS A255, User Manual

Page 1: ...A255 Robot Arm User Guide For use with C500C Controller UMI 33 255 A ...

Page 2: ...ut notice CRS Robotics Corporation makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose CRS Robotics Corporation assumes no responsibility for any errors that may appear in this document CRS Robotics Corporation makes no commitment to update nor to keep current the information containe...

Page 3: ...or the CRS Robotics Sales Department Training This installation guide is not intended as a self teaching tool It is intended as a guide for those who have attended a CRS Robotics robot training course and have a basic knowledge of CRS Robotics robots Training courses are offered at our facility in Burlington Ontario Canada or can be conducted at your facility For additional information contact the...

Page 4: ...cifications and Installation chapter If you are installing the robot yourself read the Installation and Commissioning chapter If the robot was installed by CRS or a distributor read the chapters on Commissioning and Operation Basics Before attempting to follow a procedure or examples read the entire section first Throughout this user guide warnings are marked by an icon in the left margin Failure ...

Page 5: ...king Within the Robot s Workspace 24 Chapter 4 25 Installation 25 Required Tools and Supplies 26 Component Parts 26 Designing a Work Cell 27 Unpacking the Arm 28 Preparing the Mounting Platform 31 Mounting the Arm on the Platform 34 Grounding the Arm 34 Connecting the Umbilical Cables 35 Next Steps 36 Chapter 5 37 Commissioning 37 Check the Installation of Arm and Controller 38 Check the Installat...

Page 6: ... Chapter 7 56 Gripper Installation 56 Installing the Gripper 57 Connecting the Cable or Hose 58 Chapter 8 61 Calibration 61 Restoring Factory Calibration Values 62 Recalibrating the Robot Arm 63 Calibrating an Extra Axis 67 Glossary 69 Index 73 ...

Page 7: ...n the RAPL 3 programming language You can operate the A255 by a teach pendant a terminal or a RAPL 3 program For standard applications you can edit programs move the arm teach locations and run programs from either the teach pendant or the terminal For advanced applications you can also edit and compile programs off line on a computer and use advanced tools through the terminal The A255 is designe...

Page 8: ...Adapter Pneumatic Gripper and Adapter Microplate Fingers for Servo Gripper Hardware and Equipment Teach Pendant Extra Length Umbilical Cables Linear Track Remote Operator Panel End Effector Custom Cabling Homing Bracket Force Sensor Pressurized Suit Software Robcomm3 RAPL 3 Program Development Environment and Interface to C500C POLARA Laboratory Automation Software ...

Page 9: ...99 04 23 C H A P T E R 2 Specifications This chapter describes the A255 arm Range of Motion Dimensions and Weight Reach Torque Ratings Joint Speed and Acceleration Rates Payload Resolution Brakes Gripper ...

Page 10: ...int is measured to the joint axis The arm weighs approximately 37 lb 17 kg Weight approx lb kg Arm 37 17 Joint Axis Range of Motion Waist 1 175 to 175 Shoulder 2 110 to 0 Elbow 3 0 to 125 Wrist pitch 4 110 to 110 Tool roll 5 180 to 180 Note The range of motion of the elbow joint 3 is dependent on the positions of the shoulder joint 2 and the wrist pitch joint 4 Section Dimensions inch mm Base moun...

Page 11: ...Chapter 2 Specifications 5 99 04 23 The range of motion of the joints and the dimensions of the sections of the robot arm The 350 range of motion of the waist joint of the robot arm ...

Page 12: ...the level of the bottom of the base A255 Maximum Arm Reach inch mm Horizontal to tool flange 22 00 558 8 outward from the shoulder axis in the X Y plane to finger platform of servo gripper 25 78 654 8 Vertical to tool flange 32 00 812 8 upwards along the Z axis to finger platform of servo gripper 35 78 908 8 Vertical to tool flange 2 00 50 8 downwards below the base level to finger platform of ser...

Page 13: ...Chapter 2 Specifications 7 99 04 23 ...

Page 14: ...ow the speed and acceleration rates for each arm joint Maximum speeds Motion m s Compounded joint interpolated motions 3 210 Linear and path motions 0 508 Joint Speeds at 100 Program Speed Joint Axis pulse ms Gear Maximum Speed Reduction rad s deg s Waist 1 42 72 1 3 67 210 Shoulder 2 42 72 1 3 67 210 Elbow 3 42 72 1 3 67 210 Wrist pitch 4 30 16 1 11 8 675 Tool roll 5 30 8 1 23 6 1350 Default Acce...

Page 15: ...aximum payload depends on the distance between the center of the tool flange surface and the center of gravity of the payload as shown in the payload derating tables and curves Payload Speed Mass Maximum 80 speed or acceleration 2 0 kilograms Nominal 100 speed or acceleration 1 0 kilograms Axial Distance From Tool Flange Surface Distance Mass inch mm lbs kg 0 00 0 0 4 40 2 00 2 00 50 8 4 40 2 00 4...

Page 16: ...10 A255 Robot Arm User Guide 99 04 23 Metric Payload decreases with the distance to its center of gravity Imperial Payload decreases with the distance to its center of gravity ...

Page 17: ...00 50 80 0 0036 0 0914 4 00 101 60 0 0044 0 1118 6 00 152 40 0 0051 0 1295 8 00 203 20 0 0059 0 1499 10 00 254 00 0 0067 0 1702 Radial Distance From Tool Flange Center Distance Resolution inch mm inch mm 0 00 0 00 0 0020 0 0508 2 00 50 80 0 0036 0 0914 4 00 101 60 0 0051 0 1295 6 00 152 40 0 0067 0 1702 8 00 203 20 0 0083 0 2108 10 00 254 00 0 0099 0 2515 Repeatability Repeatability is the ability...

Page 18: ...lamp on a rotating disk A 35 Volt DC signal energizes a magnetic solenoid which unloads the clamp Brakes are installed on all joints except joint 1 Do not move the joints by hand when brakes are engaged This may damage some components Imperial Resolution decreases with the distance to the payload s center of gravity Metric Resolution decreases with the distance to the payload s center of gravity ...

Page 19: ... servo controlled parallel motion two finger gripper with fingers specially designed for handling laboratory microplates Finger travel is 2 0 in 50 8 mm with programmable position and force Pneumatic Gripper PGR112 3 A two jaw double acting air gripper with 3 in 76 2 mm long angular motion re toolable fingers Fingers can be machined to meet specific needs Travel is 0 10 degrees per finger Grippers...

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Page 21: ...awareness signals Incorporate safety measures into your design to reduce the risk of hazards Ensure that you Use a diverse and redundant set of safety measures to provide an adequate level of safety Design measures so that the activation of an interlock installed to prevent against one hazard does not create a new hazard Correctly install and operate the robot Prevent Personal Injury Danger Never ...

Page 22: ... of the robot arm gripper and payload Radiusminimum 22 in 559 mm Lengthgripper Lengthpayload Install barriers outside the total reach of the robot arm gripper and payload Radiusminimum 22 in 559 mm Lengthgripper Lengthpayload Heightminimum 32 in 813 mm Lengthgripper Lengthpayload ...

Page 23: ... teach pendant Live man switch on the teach pendant To ensure safety you can install similar e stop buttons At or near the robot arm location Within human reach of any approachable side of the robot arm work cell Design your workcell so that All e stop buttons are unobstructed Personnel can reach and activate the e stop without difficulty All e stops are outside the total safeguarded space of the ...

Page 24: ...osed and contact is restored If connecting a device to the e stop circuit see Installing a Custom E Stop Circuit in the C500C Controller User Guide for connector pin identification and DIP switch positioning Presence sensing devices include Interlocks on doors Light curtains Pressure sensitive floor mats etc Design and construct any presence sensing device so that When any component fails the e st...

Page 25: ... not limited to Awareness signals An awareness signal is an audio or visual alarm such as a buzzer or light activated by a sensor in a larger envelope outside the inner e stop connected envelope The signal alerts the intruder to move away before tripping the e stop circuit Example of barriers and light curtain Example of barriers and pressure sensitive mats ...

Page 26: ...bot controller must be stable If your power supply is unstable has fluctuations in frequency or surges install a regulating system in the power supply Do not exceed voltage fluctuations 10 of the nominal voltage For variations in voltage only install a regulating transformer A more complete regulating system such as an Uninterruptible Power Supply UPS can be used for all robot systems Do not excee...

Page 27: ... below this range Humidity Maintain the relative humidity below 50 non condensing Corrosive Fumes Do not expose the robot to an environment of corrosive fumes without a CRS certified protective cover Contamination Use a protective cover to protect the arm from contaminated environments Protecting the arm and controller from contaminants will lead to extended use Note Purge the air in the controlle...

Page 28: ...ally live to come into contact with the arm or controller Operator Safety Operator Attitude of Robot Maintain an attitude of respect for the robot as a potentially dangerous machine Operator Awareness of Robot When working near the robot continue to be aware of the arm s position and motion For occasional close approach to the workspace have a second person observe the arm while prepared to activa...

Page 29: ...nted and is stable refer to Chapter 4 Installation for mounting and installation procedures The electrical connections are correct and that the power supplies voltage frequency and interference levels are within the specified ranges refer to page 20 for specified ranges If you have modified your system added hardware software or serviced your robot recheck all the changes or additions User memory ...

Page 30: ...trol of the programmer When possible program the robot with all personnel outside the safeguarded area When programming the robot and teaching locations within the safeguarded area ensure that robot motion is reduced to at least 25 speed While servicing the robot arm the robot system must be under the sole control of the service person Ensure that the robot is off line The arm must not be stopped ...

Page 31: ...cal Cables to the Arm Arm or Controller First You can install the arm first or the controller first This chapter covers installation of the arm A similar chapter in the controller user guide covers installation of the controller Gripper Gripper installation is covered separately in a later chapter Before attaching the gripper to the arm the arm and controller must be installed and commissioned ...

Page 32: ...approx 9 5 mm 12 gauge wire Connecting the Umbilical Cables Small Phillips screwdriver Component Parts Before installing the robot locate and check that you have received all the components If you did not order options the robot system is packaged in two containers If you ordered options the robot system is packaged in three or more containers Options may include gripper teach pendant arm user gui...

Page 33: ...obstructions If an obstruction cannot be removed avoid it by programming arm limits Before installation determine whether any permanent obstructions even with programming will prevent the arm from accomplishing its task Positioning the Arm Install the arm in either and upright position mounted on a table top or pillar or in an inverted position suspended from overhead brackets Warning Do not insta...

Page 34: ... portion of the table surface is available as workspace but joint 2 and 3 limits must be considered A base offset must be defined See the base command RAPL 3 For more information refer to the tables and drawings on page 4 Range of Motion and page 6 Reach Unpacking the Arm You need Utility knife 5 16 hex key Upright on a table top Inverted suspended from an overhead bracket A base offset must be de...

Page 35: ...nd open the flaps 3 Remove the page with the serial numbers of the arm and the controller and place it in the front of this arm user guide for safe keeping and future reference 4 Remove the top foam cushion Keep the anti static plastic on the arm 5 Place your left hand under the upper link of the arm which is near the left side of the box and place your right hand under the shoulder joint which is...

Page 36: ...astic Removing the Wooden Shipping Platform The encoder located at the base of the arm is a sensitive electronic component When the arm is removed from the shipping platform the encoder is exposed The encoder is black metal or plastic covered approximately two inches 50 mm in diameter and recessed approximately 3 16 inches 4 mm from the mounting surface Warning Carefully remove the shipping platfo...

Page 37: ...ng a mounting platform By fastening a metal plate to your supporting structure bench bracket etc and mounting the arm on that plate By fastening the arm directly on a supporting structure Tip Use dowel pins to align the robot in cases where the arm is regularly mounted and dismounted and precise relocation is necessary Dowel pins are also useful during installation after repair You need Machine to...

Page 38: ...32 A255 Robot Arm User Guide 99 04 23 4 If you prepared a plate firmly fasten the plate to your bench bracket or similar supporting structure English Imperial units ...

Page 39: ...Chapter 4 Installation 33 99 04 23 Metric units ...

Page 40: ...ter x 0 75 inch long hardened steel precision ground dowel pin Metric Quantity 2 M8 x 1 25 x 55 mm long stainless steel 18 8 A2 hex socket cap screw Quantity 2 M8 x 1 25 x 90 mm long stainless steel 18 8 A2 hex socket cap screw Quantity 4 8 mm stainless steel 18 8 A2 spring lockwasher to DIN 127 or British Standard Type B Quantity 2 6 mm diameter M6 limits x 18 mm long hardened steel precision gro...

Page 41: ...f the controller is installed ensure that the controller s main power switch is OFF 1 For each cable connect the end with the grounding strap to the controller This end is labeled controller end a When making a connection ensure that the connector keys and keyways are properly aligned If they are not you may damage the connector b Carefully turn the locking ring clockwise to draw the connectors to...

Page 42: ...er Disconnecting the 57 pin feedback cable while the other cable is connected and power is on can cause incomplete control of the arm or cause the arm to run out of control 1 At the controller disconnect the grounding strap from the grounding point on the rear panel of the controller a Turn the locking ring counter clockwise to release the connector b Pull the cable connector straight out from the...

Page 43: ... it to ensure that it is functioning properly Before commissioning you must finish installing the arm and the controller Commissioning involves five procedures that must be performed in sequence 1 Verify Installation 2 Check Encoder Feedback 3 Check All E stops 4 Move Out of the Shipping Position 5 Check the Live man Switch ...

Page 44: ...nents must be installed and operating To commission you need the following system tools Procedure Required or Preferred Tool Alternative Tool Check Encoder Feedback terminal Check E Stops Move Out of Shipping Position teach pendant terminal Check Live man Switch teach pendant Terminal CROS 500C To use a terminal from a computer ensure that you have Connected a straight through cable not a null mod...

Page 45: ... shell s siocfg command Connected the teach pendant to its connector on the front panel of the controller Have the teach pendant process stpv3 already running on CROS 500C or have started it by typing pendant at the C500C prompt Operation Follow the Safety Operation Checks on page 23 before operating the arm Check Encoder Feedback This procedure checks that the position signals from the arm are re...

Page 46: ...ast procedure then turn on arm power Note Striking an e stop does not remove power to the servo gripper As a safety feature motor power to the gripper is maintained so the gripper does not release its load 1 Ensure that the controller is powered on and displays C500C CROS OK 2 Re set all the e stops to complete the e stop circuit The e stop buttons on the controller and on the teach pendant are re...

Page 47: ...on and into a safe starting position A safe starting position is any position where the arm links and tool flange are safely away from the mounting surface base cabling and obstructions in the workcell The following pose is the recommended safe starting position You can move out of the shipping position by using the teach pendant or the application shell It is safer to use the teach pendant A255 a...

Page 48: ...t homed only joint mode is available Do NOT home the robot 4 Squeeze the live man switch Adequate pressure constantly applied permits arm operation No pressure or excessive pressure stops arm motion by shutting off arm power To restore arm power turn on arm power at the arm power switch 5 As you squeeze the live man switch press the following axis keys to move each joint to a safe starting positio...

Page 49: ... shipping position 1 Turn on arm power 2 Set the speed to a very slow value by typing speed 1 Warning Be prepared to strike an e stop When you use a command from the application shell the robot attempts to move to the commanded position without knowing if it is safe to do so Use the proper joint number and distance value to avoid a collision 3 Move joint 2 by 10 degrees by typing joint 2 10 Repeat...

Page 50: ...While holding the live man switch and pressing an axis key during a robot move release the live man switch a After releasing the live man switch you should hear a series of clicks as the arm brakes engage At the same time arm power is shut off Check that the LED in the arm power switch is not lit b Restore arm power by pressing the arm power switch on the front panel of the controller 2 While hold...

Page 51: ...t Axis Keys Move the Arm Using Terminal based Commands Move the Arm by Limping One Joint at a Time The A255 is designed for stand alone operation after homing Stand alone operation does not require operator intervention RAPL 3 programs specially written for your particular application move the robot to predefined locations ...

Page 52: ...arm from the teach pendant and from the terminal It does not describe homing the arm from a program or from the front panel s Home switch which is disabled when shipped from the factory To home the arm you must 1 Move to the homing starting position 2 Issue the home command Note If you ordered a homing bracket and are using it to home the arm follow the procedure in the Homing Bracket User Guide 1...

Page 53: ...low these steps Before you begin ensure that you Have a terminal running by having either A terminal emulator or the terminal window of Robcomm3 communicating through the front panel console port and having control of the robot If not at the teach pendant press Shift ESC to transfer control or The Command Prompt window of CROSnt communicating through the SimSockD cable in the teach pendant s port ...

Page 54: ...homed In the starting position each pointer is in its starting zone The positive and negative signs corresponds to the joint s directions of rotation 2 Issue the Home Command Once the arm is in the starting position you can home the arm You can home the arm by using the teach pendant or the terminal It is safer to use the teach pendant Systems with CROSnt may have to use the terminal Using the Tea...

Page 55: ...t panel of the controller is on 6 Press the READY key on the keypad Maintain light pressure on the live man switch for the duration of the READY sequence When the arm stops it is in the READY position 7 Visually inspect each homing marker The pointer should be toward the correct end of the zone for that joint as shown in the previous drawing If any pointer is outside the range of the homing mark r...

Page 56: ...s Enter The arm moves to the ready position 3 Visually inspect the arm The link between joints 1 and 2 should be vertical and the link between joints 3 and 4 should be horizontal Visually inspect each homing marker The pointer should be toward the correct end of the zone for that joint as shown in the previous drawing If any pointer is outside the range of the homing mark repeat the procedure maki...

Page 57: ...em F4 toggles mode options Mode Resulting Motion Coordinates joint rotates around a joint axis Axis 1 2 3 4 5 6 7 8 if track or carousels world moves along or around world cartesian axes X Y Z Zrotation Yrotation Xrotation tool moves along or around tool axes X Y Z Yaw Pitch Roll cylindrical moves along or around cylindrical axes θ R Z Zrotation perpendicular to R and Zrotation Rrotation Types The...

Page 58: ...ing at the type you want 3 If you selected velocity or jog type select a speed for velocity or increment for jog by pressing the SPEED UP or SPEED DOWN key 4 Squeeze the live man switch Adequate pressure constantly applied permits arm operation No pressure or excessive pressure stops arm motion by shutting off arm power To restore arm power turn on arm power at the arm power switch 5 Press an axis...

Page 59: ...empts to move to the commanded position without knowing if it is safe to do so Use the proper joint number and distance value to avoid a collision 3 Enter motion commands with parameters Command Example Motion joint joint 1 22 5 joint 3 45 rotates a joint by degrees wx wxs wy wys wz wzs zrot zrots yrot yrots xrot xrots wx 7 5 wzs 2 5 xrots 45 moves along or rotates around a world cartesian axis by...

Page 60: ...ll be working within the robot s workspace observe the safety and operation checks on page 24 Working Within the Robot s Workspace 1 Power ON at the main controller switch The teach pendant displays the Main Menu screen 2 Turn ON arm power The teach pendant displays the status message ON 3 Press F1 Manual to change to the Manual screen 4 Press F1 repeatedly until LIMP displays 5 Press the joint s ...

Page 61: ...p arm power is ON Hold the arm near the wrist to move the joint by hand Caution Do not move the joint too forcefully The harmonic drive is back drivable This allows you to rotate the joints and have that motion transferred back through the drives to the motors Excessive force when positioning the arm by hand may over stress the drives 6 Press the joint s negative axis key The servo engages and hol...

Page 62: ...per the arm must be moved out of the shipping position and the tool flange made accessible The gripper attaches onto the arm s tool flange If you are installing a homing bracket for custom homing of the arm you will need to install a tool adapter plate with inch hex socket cap screws see the Homing Bracket User Guide ...

Page 63: ...some components Caution When moving while limp do not move the joints too forcefully Excessive force may over stress the drives Warning Ensure the controller does not move the arm Ensure that commands are not entered at the teach pendant while you attach a gripper Be prepared to activate an e stop 1 Limp the Wrist When joints 4 and 5 are limped you can rotate and pitch the wrist and access the cap...

Page 64: ...t side of the arm The pneumatic connector is located on the right side of the arm approximately 2 in 60 mm behind the wrist axis Servo Gripper To connect the servo gripper cable 1 Line up the white dot marker on the gripper cable connector with the white dot marker on the arm connector 2 Push the cable connector onto the arm connector until it clicks The outer collar is spring loaded To disconnect...

Page 65: ...ase Use only dry clean filtered non lubricated air at a maximum of 100 psi 6 89 kPa 6 89 Bar 5 Test the operation of the gripper At the teach pendant press the GRIP key Press GRIP CLOSE and press GRIP OPEN Check that OPEN opens the gripper and CLOSE closes the gripper If the operation of the gripper is reversed OPEN closes the gripper and CLOSE opens the gripper reverse the connections of the two ...

Page 66: ...60 A255 Robot Arm User Guide 99 04 23 Use the diag setup command to choose the type of gripper air servo or magnetic refer to the RAPL 3 Language Reference Guide ...

Page 67: ...edures for restoring factory calibration values or recalibrating the robot with new values You can Reload factory calibration parameters when the calibration memory fails Recalibrate the robot with new parameters when you add an extra axis remove or replace a servo motor encoder or belt etc ...

Page 68: ...data can be obtained from your nearest distributor or CRS Robotics Before you begin Ensure that your computer is connected to the controller front panel communication port To restore the factory calibration values 1 Switch both the computer and the controller ON 2 Switch ON arm power 3 Transfer control of the robot from the teach pendant to your computer a At the teach pendant press ESC until the ...

Page 69: ...2 Adjust all the joints to the Zero calrdy position 3 Set and save the new calibration values 4 Check your locations Note These procedures do not calibrate extra axes If you are adding an extra axis refer to page 67 You need Precision 24 inch square with scale Computer with Robcomm3 software Your A255 distribution disk or your own backup if your system was previously recalibrated If the distributi...

Page 70: ... s work envelope refer to page 24 Warning Have someone else available to strike the e stop when working inside the robot envelope Working within the robot envelope when arm power is on represents a risk In the case of a controller or arm failure there is a danger of impact or trapping Joint 1 1 Type limp 1 and press Enter the waist joint limps 2 Type w1 and press Enter to display the position of t...

Page 71: ...bot s mounting surface to the joint 3 axle hole on the side of the arm refer to the drawing on the previous page 2 Use the motor command to adjust the joint so the measured distance is ten inches For example Type motor 2 motor pulse counts and press Enter Note Use small increments of motor pulses to move the arm 20 pulses Joint 3 1 Place the 24 inch square to measure the perpendicular distance fro...

Page 72: ...ion 3 Type diag cal and press Enter At the prompt type Y yes This resets the controller s calibration data and homes the arm 4 If required pull off and re apply the homing markers Note New markers can be purchased from CRS Robotics 5 Type speed 10 and press Enter 6 Type ready and press Enter 7 Exit the Terminal Emulator 8 Use Robcomm 3 to save the new calibration values on a backup disk Choose Cal...

Page 73: ...efined locations used in your application c Ensure that the arm moves to those locations as expected If not stop arm motion and recheck your calibration d If the problem persists after several tries you may have to re teach your locations Calibrating an Extra Axis If you are adding an extra axis such as a carousel use the following information to calibrate that axis If you are adding a track axis ...

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Page 75: ...s feedback from the arm During the running of an application the controller executes a robot software program Degree of Freedom DOF The types of independent motions in which the arm can move its end effector gripper tool as defined by the axes of motion For example the A255 has five degrees of freedom and can move to coordinates specified by X Y Z Pitch and Roll Emergency Stop E stop A method that...

Page 76: ...ink or an arm dependent on the limits of rotational motion of the joints and the lengths of the links Reach The maximum distance that the arm can extend the tool flange or gripper It defines the work envelope Resolution The smallest increment of motion or distance that can be detected or controlled RAPL Robot Automation Programming Language An automation oriented line structured language of comman...

Page 77: ...The outer boundary of the workspace is the work envelope Yaw Pitch Roll The orientation of the wrist is defined by three angles yaw orientation about the Z axis pitch orientation about the Y axis and roll orientation about the X axis The right hand rule applies in determining the direction of these angles ...

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Page 79: ...rtains 18 link length 4 locating components 26 markers for READY after homing 49 mass of arm 30 motion axes of 1 motor power cable 35 mounting 31 operator safety 22 Options 2 packaging materials 31 pick and place cycle 8 pneumatic gripper installation 59 power failure 20 power rating 20 power supply 20 precautions 15 pressure sensitive mats 18 range of motion elevation view 5 range of motion plan ...

Page 80: ...74 Index 99 04 23 ...