Directechs PEAKROBOTICS KX-2, User Manual

Page 1: ...021 Author Patrick Moreland Modified By Patrick Moreland Approved By Patrick Moreland User s Manual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics co...

Page 2: ......

Page 3: ...n 2 2 0 Warnings 3 3 0 Safety Precautions 5 4 0 Compliance with Standards 7 5 0 Contents and Packaging Instructions 8 6 0 Product Description 11 7 0 Specifications 14 8 0 Gripper 20 9 0 Electrical Des...

Page 4: ...KX 2 Robot User s Manual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 1...

Page 5: ...ion and maintenance of the KX 2 Robot 1 3 Setup Guidelines This manual includes information on how to install the robot how to bring it online teach it and then diagnose and rectify any problems These...

Page 6: ...international symbols indicating that a potential hazard to personal safety exists from a high voltage source In this document the WARNING icon will accompany this symbol To reduce risk of electrical...

Page 7: ...ocument and other information from Peak Robotics Inc and authorized distributors provide product information for users having technical expertise The user is solely responsible for making the final se...

Page 8: ...of an unguarded robot shall wear safety glasses at all times that meet or exceed ANSI Z87 1 2015 3 3 Emergency Stop The robot is equipped with an emergency stop button which when pressed will decelera...

Page 9: ...tential can damage sensitive components inside the robot High voltage AC power 115 or 230VAC is present inside the robot power supply box 3 7 Collaborative Applications The KX 2 robot has been designe...

Page 10: ...application or a game controller can be used to teach the KX 2 robot These controls do not have an integrated emergency stop function Peak Robotics has made the determination that an integrated emerge...

Page 11: ...SB Cable Robot to User PC Connection Barcode Reader Cable Robot to User PC Connection USB Serial Adapter for Barcode Reader Cable Mounting Screws Dowel Pins Side Grip and Top Grip finger sets Gripper...

Page 12: ...two ends of the robot Step 4 With the help of an assistant lift the robot out of the box Lift via the two ends of the robot Rotate the robot so that the arm is pointing upward If the arm is positioned...

Page 13: ...ews Refer to the Installation Setup section for mounting hole dimensions Step 9 With the help of an assistant lift the robot and set it on top of the Robot Mount Plate Reinstall the three screws and f...

Page 14: ...ope The two rotary joints of the robot have unlimited travel allowing the robot to access all locations around it with no dead zones 6 4 Telescoping Arm The robot achieves extreme reach and is also hi...

Page 15: ...obot connects to the PC via a USB 2 0 port An RS232 serial port is required for the barcode reader a serial USB adapter is provided with the robot 6 10 Power The robot uses 57 VDC for motor power and...

Page 16: ...KX 2 Robot User s Manual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 13 Serial Number Tag...

Page 17: ...8 in lb Peak 7 3Nm 64 in lb Continuous Z 43 3N 9 7 lbs Peak 21 7N 4 9 lbs Continuous Elbow 11 3Nm 100 in lb Peak 5 7Nm 50 in lb Continuous Wrist 1 22Nm 10 8 in lb Peak 0 61Nm 5 4 in lb Continuous Grip...

Page 18: ...ith a microfiber cloth or paper towel partially saturated in isopropyl alcohol Power should be disconnected from the robot prior to cleaning and the robot should be left to dry for at least 15 minutes...

Page 19: ...KX 2 Robot User s Manual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 16 7 4 Robot Dimensions Top View...

Page 20: ...KX 2 Robot User s Manual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 17 7 5 Robot Dimensions Side View KX 2 500 shown...

Page 21: ...KX 2 Robot User s Manual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 18 7 6 Power Supply Dimensions...

Page 22: ...19 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 19 7 7 Axis Naming Definitions Name Designation Description Axis 1 S Shoulder Motor Shoulder Rotate Axis 2 Z Z Motor Vertical Axis Axis 3...

Page 23: ...d The gripper uses force feedback to verify a successful gripping operation The gripper jaws can be moved by hand when the motor is disabled 8 3 Microtiter Plate Handling The KX 2 is available with th...

Page 24: ...Due to location of this sensor it is not used for determining the presence absence of a plate in the gripper This is achieved by the servo gripper motor via force feedback 8 6 When using the sensor to...

Page 25: ...peakrobotics com Printed 3 3 2021 Page 22 8 7 Side Grip Side grip Universal 110mm Offset grips either portrait or landscape This gripper finger style is used typically with Side Grip Landscape FILO St...

Page 26: ...m Printed 3 3 2021 Page 23 8 8 Side Grip Portrait Jog Side grip Universal 116mm Offset grips either portrait or landscape This gripper finger style is used typically with Side Grip Portrait FILO Stack...

Page 27: ...stment The plate presence sensor for the Side Grip and Side Grip Portrait Jog grippers is located under the gripper housing as shown here Depending on the type of microplate being used the sensor may...

Page 28: ...3555 www peakrobotics com Printed 3 3 2021 Page 25 8 10 Gripping on Skirt All KX 2 grippers are designed to grip plates with or without lids however in some installations it may be advantageous to gri...

Page 29: ...ntains a 57VDC power supply and a 24VDC power supply A cable with a 13 pin mini DIN connector connects the power supply box to the robot and supplies the robot with DC power used by the motor drives s...

Page 30: ...robot but keeps the motor drive logic circuits powered Restarting the robot after an E Stop requires a deliberate input by the operator on the controlling computer Note Shutting off AC power to the ro...

Page 31: ...ped up power is applied to the robot and no Shoulder drive errors are present then the Drive Status LED located on the Shoulder connector panel should be green If the LED is red then either the E Stop...

Page 32: ...ed 3 3 2021 Page 29 9 6 Power LED If AC power is connected to the power supply box and the AC power switch is in the on position the blue LED powered by 24V should be on If this LED is not on then the...

Page 33: ...lectrical current to power the encoder circuits when main power is disconnected The zero position of each absolute encoder is calibrated at the factory If an axis is disassembled or replaced the zero...

Page 34: ...htened After a severe robot collision 10 2 Installing and Anchoring the Robot 10 2 1 Sub Frame Because of the high speed and center of mass of the robot the robot must be anchored to ensure stability...

Page 35: ...ned to a rigid metal frame underneath Braces should be positioned strategically directly under the robot and the devices so that flexing of the mounting surface is minimized 10 2 3 Attachment The robo...

Page 36: ...critical that the anchoring threaded holes be drilled and tapped accurately and perpendicular to the mounting surface If a milling machine is not available for this purpose it is recommended that the...

Page 37: ...locking nuts on the underside of the table Tighten the fasteners very firmly 8 Nm 2 If the cables are to be routed through a large hole in the table position the hole an adequate distance away from t...

Page 38: ...nting ears on the bottom of the robot and thread them into the Robot Mount Plate Tighten the mounting screws very firmly 8 Nm Removable strength thread locker such as Loctite 242 is recommended 10 3 R...

Page 39: ...sen the two M6x25 Hex Head screws securing the Arm to the Z Axis Loosen each screw about half a turn Raise the Z Axis to the top end of travel Support the Arm assembly securely with two hands Slide it...

Page 40: ...KX 2 Robot User s Manual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 37 Set the Arm assembly down on a soft surface...

Page 41: ...719 598 3555 www peakrobotics com Printed 3 3 2021 Page 38 Remove the six M3x6 SHCS screws from the large cover on the back of the Z Axis Remove the two top screws last This will help support the cov...

Page 42: ...d 3 3 2021 Page 39 Remove the two M5x16 FHCS screws from the smaller section of the counterweight on the right side Slide the smaller section of the counterweight upward and out of the Z Axis Remove t...

Page 43: ...CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 40 The weight of the robot is reduced significantly at this point and can be lifted onto a table by one person Assembly is the rever...

Page 44: ...nnector panel with the notches lined up 10 4 3 Plug the USB cable into the Type B square socket on the Shoulder connector panel Plug the other end Type A into an available USB 2 0 port on the PC 10 4...

Page 45: ...PC 10 4 7 Plug the AC power cord Volex 17661 into the power supply box 10 4 8 Plug the other end of the AC power cord into a standard grounded North American residential 110V outlet If this type of ou...

Page 46: ...ower to the power supply box by flipping the switch on the AC power entry module to the I position The blue power indicator LED on the box should light up The Shoulder drive status LED should also lig...

Page 47: ...be downloaded from https app box com v KX2 Software 10 5 3 Run the extracted file by double clicking it and follow the on screen instructions 10 5 4 USB CANOpen adapter Extract the file named Peak Sys...

Page 48: ...3 2021 Page 45 10 5 8 Open the Options window by clicking on the gear icon in the upper right corner of the window 10 5 9 Open the Communication Settings tab click the CAN Device list and verify the...

Page 49: ...Open the KX2 Teach Pendant from the Start All Programs PAA menu 10 6 6 Initialize the robot by clicking the Reset Robot icon on the Teach Pendant The following message box will be displayed 10 6 7 Cl...

Page 50: ...of systems 1 Simple and or non changing sequence 2 An application where a specific look and feel is desired for the interface 3 Multiple reproduced systems e g OEM system that will be built the same w...

Page 51: ...PC The TeachPoints ini file contains names and numerical data associated with Teach Points created by the user Important Note Most non repeatability problems with the installed robot can be traced to...

Page 52: ...t The positional data associated with this Teach Point if existing will be displayed in the Move Controls textboxes 12 6 1 2 Double click the Name field and enter the desired text name If the name is...

Page 53: ...ghlighted 12 6 1 9 By default there are 100 Teach Points in the list This can be adjusted by modifying the Settings Count value in the TeachPoints ini file Teach Points Right Click Context Menu 12 6 2...

Page 54: ...moves 12 6 3 3 The box labeled Maintenance Required indicates whether the robot requires periodic maintenance Double clicking this box will reset the status to False Do this only after actually perfo...

Page 55: ...12 7 1 1 Select the desired Motion type Continuous Clicking and holding a jog button will cause the axis to move continuously until the jog button is released or until the travel limit has been reache...

Page 56: ...then need to be re initialized by selecting the Reset Robot icon 12 7 1 6 Cartesian Settings If Cartesian Mode is selected the jog buttons will move the robot in the X Y Z or directions and the Cartes...

Page 57: ...k Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 54 World Reference Frame Cartesian Coordinates Top View Tool Reference Frame Ca...

Page 58: ...use of the teach button located on the front of the Elbow housing If each robot joint is positioned within three millimeters or degrees of a previously taught Teach Point that Teach Point will be ret...

Page 59: ...t Input pull down The High indicator will be marked with a dot if the input is high and blank if the input is low The gripper sensor teach button and the auxiliary inputs can all be monitored 12 8 1 2...

Page 60: ...the absence of an object in the gripper The gripper expects to encounter resistance while closing The Go button can be used to set the gripper in a desired position specified in Move box Do not use th...

Page 61: ...ined and the Enable box is checked motion between two teach points not in the Rules list will not be allowed when moving the robot using the controls under the Teach Points tab 12 9 2 Motion rules are...

Page 62: ...e that contains all of the settings that are stored in the Windows Registry by the KX 2 software These settings include items like the teach points file path and other items displayed in the Options w...

Page 63: ...seful when multiple Windows User accounts must be able to access shared robot settings Be sure to place the file in a location that is accessible with full read write privileges by all users The confi...

Page 64: ...User s Manual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 61 Shortcut Properties 12 10 1 4 Exit will close the Teach Pen...

Page 65: ...elements Two letter command e g PX for position MS for motion status EC for error code Array index which is in the form of a number surrounded by square brackets such as 1 Can be omitted for commands...

Page 66: ...s Teach Points cannot be renamed or deleted but they can be taught The robot can be moved manually The File menu is hidden Limited Access The robot can be moved and reset but no settings can be change...

Page 67: ...the Unlock icon at the top of the Teach Pendant to allow positioning of the arm by hand The motors will be disabled The encoders are still powered and will keep track of the robot position as it is m...

Page 68: ...Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 65 12 12 Sequence Editor Clicking the running man icon at the top of the Teach Pendant will open the following window which...

Page 69: ...on Variable values can be monitored using the Sequence Variables window The displayed value of the selected variable will update as the value changes due to variable manipulation by a running sequence...

Page 70: ...uence by clicking and dragging the operation to the desired new position The mouse button must be held down for a moment before dragging the operation Right clicking on an operation will display a qui...

Page 71: ...and the buzzer will emit a short beep The Teach button on the window can also be pressed 12 13 3 The joint positions will be read and a point named AutoTeach0 will be added to the list 12 13 4 Repeat...

Page 72: ...trol DLL directory The location of this file is specified in the Teach Point File textbox The location of the file can be modified if desired Sequence File When KX2 Robot Control DLL is installed a bl...

Page 73: ...control can be used with the robot not provided Select this option to enable the game controller Once this option is selected a new item will be added to the Tools menu titled Joystick Setup If the PC...

Page 74: ...Printed 3 3 2021 Page 71 Default Gripper State Check this option to have the gripper either open or close during initialization To leave the gripper in its current state uncheck this option Setting th...

Page 75: ...software to reinitialize automatically after a robot move error occurs If the Press Teach Button to Resume option is checked then a recovery attempt will occur only after the teach button on the arm...

Page 76: ...Address Enter the address that will show up as the sender of the email To Address Enter the address of the email recipient SMTP Server Enter the SMTP server being used to send the email SMTP Port Ente...

Page 77: ...Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 74 12 15 Help Menu About A window will open displaying the current version and release dat...

Page 78: ...gs tab Options Window Communication Settings Tab 12 16 3 Check the Joystick option Then press OK Plug the joystick into the PC and install drivers if requested by the operating system Click the Reset...

Page 79: ...5 www peakrobotics com Printed 3 3 2021 Page 76 12 16 5 The default mapping of robot functions to the joystick controls are as follows Shoulder X Shoulder X Elbow Y Elbow Y Z Z Wrist Wrist Continuous...

Page 80: ...ew control Joysticks and POV controls are analog devices so an analog value must be specified for each function that is controlled by an analog control To capture the desired value of an analog contro...

Page 81: ...irection 12 16 7 To monitor the states of the various joystick controls click on the Controls tab Joystick Settings Controls 12 10 1 1 As the joystick controls are manipulated their current values wil...

Page 82: ...wasted 13 3 An SBS footprint Teach Plate is included with the robot for use in place of a plastic microplate during the teaching process This setup standard is very precise and simplifies many of the...

Page 83: ...e name of the teach point as desired for example Instrument1Nest Renaming the teach points can be done at the end of the teaching process to eliminate the need to move back and forth between the robot...

Page 84: ...the inevitable non parallelism between the Z axis of the robot and the stack uprights 13 6 2 1 Teach the bottom position with no plates in the stack except for the Teach Plate in the gripper Ensure th...

Page 85: ...stack when moving in the stack 13 7 Teaching Plate Hotels 13 7 1 The KX 2 Robot is often used in conjunction with optional plate hotels This type of plate storage is a random access arrangement where...

Page 86: ...lt accommodating DLL functions PlacePlateInHotel and RemovePlateFromHotel which interpolate between the top and bottom teach points in a hotel when moving in the hotel Call the SetMovePathMode eMovePa...

Page 87: ...The rotary axis will move in the counterclockwise direction regardless of the distance to be traveled For example if the wrist is currently at 2 and the commanded position is 1 the wrist will move a r...

Page 88: ...e end Norcomp 180 015 103L001 or equivalent and into the Barcode Reader cable on the other end Norcomp 180 015 203L001 or equivalent This splitter cable will need to pass through the three lines speci...

Page 89: ...0218 1 2011 and defined by ISO 13849 1 2015 Category 3 specifies that a single fault will not lead to loss of safety function and the fault is detected No fault exclusions have been made 14 4 5 If mod...

Page 90: ...The emergency stop button contains two sets of normally closed contacts that open when the button is pressed The robot is permitted to operate when E Stop1 and E Stop2 are connected to fuse protected...

Page 91: ...O 13849 1 2015 to ensure that PL d and Category 3 ratings are preserved 14 4 18 If the Interlock Override is connected to a digital input as shown above then the Windows Registry settings for the KX 2...

Page 92: ...ogged and outputs can be actuated To check the functionality of individual sensors look for the light on the sensor to illuminate at the proper time 15 4 General Troubleshooting If an error condition...

Page 93: ...onent or wiring degradation Consult factory 15 6 6 In some cases it can be helpful to use a video camera to capture robot errors that happen during motion 15 7 For time critical applications Peak Robo...

Page 94: ...cating maintenance is required 16 1 3 If the controlling software does not monitor this event then the Teach Pendant should be checked every few months depending on use Check for Maintenance Required...

Page 95: ...nual Peak Robotics Inc 4747 Centennial Blvd Colorado Springs CO 80919 Ph 719 598 3555 www peakrobotics com Printed 3 3 2021 Page 92 16 1 8 Use Castrol Tribol GR 100 2 PD grease 14 oz cartridge is part...

Page 96: ...www peakrobotics com Printed 3 3 2021 Page 93 16 1 9 Grease the Z Axis arm support bearing as follows Raise the Z Axis to the top of its travel Pop the round black plastic cap out of the access hole...

Page 97: ...ort bearing needs 1 4 cubic centimeters 0 05oz of grease added to it at each maintenance interval The GreaseTek gun shown above pumps a volume of 0 025oz per pump so two full pumps of the handle will...

Page 98: ...Printed 3 3 2021 Page 95 16 1 10 Grease the Z Axis counterweight support bearing as follows Remove the six M3x6 SHCS screws from the large cover on the back of the Z Axis Remove the two top screws la...

Page 99: ...own above pumps a volume of 0 025oz per pump so approximately half a pump of the handle will deliver the correct volume Do not pump more grease than is required as excess grease will escape past the b...

Page 100: ...1 With the emergency stop button popped up in its normal position the Drive Status LED located on the Shoulder connector panel must be green 2 The emergency stop button should then be pressed down an...

Page 101: ...akrobotics com Printed 3 3 2021 Page 98 Revision History Revision Date Line Description 1 1 28 2020 All Initial Release 2 7 27 2020 5 1 Robot shipped with both Side Grip Top Grip fingers 8 5 6 Instruc...