Robot System Components

Robot System Objectives

• Understand robot components
• Learn about major and minor axes, joints, and links
• Know about servo motors and serial pulse coders
• Know what software/ operating system is
• Know the different controller types
• Become familiar with standard operating panels

Robot System Overview

• Key robot components: the mechanical unit, software, controller, and peripheral equipment

Mechanical Unit

• A robot is a sequence of mechanical links driven by servomotors
• Each junction between the links either forms a joint or axis
• First three axes are known as major axes
• The major and minor axes move tooling on the end of a robot arm
• Movements are twisting up-and-down and side-to-side motions
• Range of motion depends on the End Of Arm Tooling (EOAT)
• Major axes are 1, 2, and 3
• Minor axes are 4, 5, and 6

Robot Axis Description

• J1: Base or waist
• J2: Shoulder
• J3: Elbow
• J4: Rotation of the arm
• J5: Pitch of the wrist
• J6: Rotation of the hand or face plate
• J7: Optional (X-Rail, Gantry, Turn Table, EOAT motion, Spot Welding)

Mechanical Unit Motors

• Each axis has an electric servomotor
• Serial Pulse Coder is used for positioning
• Motors are not customer serviceable
• Most motors have an internal brake which is applied mechanically and released electrically via a signal from a servo amplifier
• Improper lubrication of the robot can damage the motors
• The brake failure is usually due to a lack of current at the brake, and not failure of the brake itself
• If the brake fails, the motor is replaced

Serial Pulse Encoder (SPC)

• Each motor contains a rotary pulse encoder
• An encoder senses the angle of the motor shaft and converts the angle to a digital code
• Encoders send speed and position to a controller
• Encoder pulse counts are stored in robot memory when the robot is powered
• Batteries retain pulse encoder counts

Fanuc Controllers

• Different controller sizes are available (A-size and B-size)
• Controllers contain a power supply, operator controls, control circuitry, and memory
• Controllers convert program data to servo drive signals
• Main board and servo amplifier are included
• Contains communication hardware and I/O hardware

Controller Interface

• Communication ports
• Emergency stop connections

Standard Operator Panel (SOP)

• Panels vary based on software version, including V8.0, V7.0 and V6.0
• Controls basic robot functions
• Facilitates the loading and saving of files
• Provides indication concerning robot operation
• Includes a mode switch, reset button, fault light, hour meter and cycle start/power light

SOP Status Indicators

• Battery: Indicates low backup battery voltage
• Fault: Indicates a fault condition
• Remote: Indicates operator panel lacks motion control
• Remote/Local: Set control to either remote (PLC) or local (controller)
• On/Off: Indicates whether the controller is ON or OFF
• Cycle Start: When lit, indicates program is running
• Users #1/2: User-definable, assigns macros to run when buttons are pushed
• Hold: Pauses program without dropping servo motors
• E-Stop: Immediately stops the robot
  • Caution: under certain load/speed conditions it could damage the robot
  • The hold button's use is preferred in non-emergencies.
• Fault Reset: Clears a fault message from the teach pendant screen after it has been corrected.

Software

• Defines the function of the robot
• Contains the core operating program
• Performs fault isolation and diagnostics
• Uses communication protocols

Peripheral Equipment

• Any item that is not part of the mechanical unit, controller, or software
• Programmable Logic Controller (PLC)
• End-of-Arm Tooling (EOAT)
• Proximity Switches
• Limit Switches
• Photo Eyes
• Vision Systems
• Force Sensing Unit
• Panel View
• Human Machine Interface (HMI)
• Ethernet IP and communication interfaces

Application Software for Material Handling Robots

• Handling Tool is the application software installed on material handling robots
• There are two versions of material handling software
  • LR Handling Tool (lighter version and installed on all LR Mate robots only)
  • Handling Tool for all other material handling robots
• Handling Tool software working in conjunctions with the robot and controller allows you to:
  • Set up information required for the application
  • Program your application
  • Test your Program
  • Run Production
  • Display and monitor process information

Mode Select Switch

• The mode select switch has 2 and 3 mode switch options
• Note that in Canada, most controllers may not come equipped with the T2 selection

Teach Pendant

• A device that gives motion control solely to the operator
• Moves the robot
• Creates and edits programs
• Tests programs
• Sets up production runs
• Checks status
• Performs manual functions
• Configures the application

iPendant

• Provides a color graphics interface and pop-up menus
• Has multiple windows
• Provides Internet/ Intranet access
• Built-in help and diagnostics
• Customized displays
• May be touch screen capable
• Has R-30iA iPendant Hardware and iPendant Firmware
  • Benefits of iPendant Firmware: Higher performance, New rear grip and a new browser
• USB port enables faster controller
• Includes built-in error code diagnostics

R-30iB iPendant

• R 30iB +Pendant Hardware
  • Includes Bright light weight LED Backlight
  • New + Key (shortcut key)
  • 4 additional Jog Keys with Axis 7 & 8
  • New Lighter Weight, Faster Internal Processor, New Rear Grip
• Features new +Pendant Firmware:
  • Higher performance and New Browser with current WEB tools
• Unique 3D Graphics Capability
• NOT compatible with R-30iA

Teach Pendant Key Components

• Deadman switch
• ON/OFF Switch (Enable/Disable Switch)
• Emergency Stop (E-Stop)
• Navigation and Data entry keys
• Robot Motion keys
• Execution & Editing Keys
• Application-Specific keys
• Help/Diagnostic Keys (iPendant only)

Teach Pendant Key Components cont’d

• On/Off switch
• Status/System indicators
• Navigation arrows-menu keys
• Alphanumeric keypad
• Axis jog keys
• Coordinate selector
• E-Stop
• Screen: can be split in 2 or 3 screens
• Flying menus, the black arrow indicates sub-menu
• Jog keys will move the robot as "shift’ is held down
• Override Speed

R-30iB iPendant I Key Functions

• i + MENU - Displays the Top Menu.
• i + FCTN - Displays the Related View Menu if i is displayed on the right side of the title line.
• i + SELECT - Displays the Select menu in the left pane and 3D node map in the right pane for the program that is highlighted by the cursor.
• i + EDIT - Displays the TPP editor in the left pane and 3D node map in the right pane.
• i + DATA - Displays the position register data in the left pane and a 3D display of position registers in the right pane.
• i + POSN - Presents a 3D display of the robot using the last selected scene.
• i + COORD - Toggle jog preview off and on.
• i JOG KEY - Shows the direction that the robot will move when the jog key is pressed when the 3D screen is displayed.
• i DISP - Switches the display to the next window if one is available.

R-30iB iPendant -Menu Favorites

• Allows you to generate and store a list of menus that you display most often

Teach Pendant Status Indicators

• Busy: Indicates that the controller is processing information
• Run: Indicates that a program is being executed
• I/O: Indicates that the I/O is ENABLED
• Prod: Indicates that the robot is in PRODUCTION MODE
• T Cyc: Indicates that the robot is in the TEST CYCLE
• Step
• Hold
• Fault

Pendant Key Functions

• SELECT key is used to display the program selection screen
• EDIT key used to display the program edit screen
• DATA key used to display the program data screen
• DISP key is available only on the Pendant and is used to activate DISPLAY menu/ change the focus
• FCTN key is used to display the function menu.

Robot Motion Key Functions

• The GROUP switch switches groups; holding down the GROUP switch and pressing a number key switches to a specified group
• The SHIFT switch jogs the robot, teaches position data, and starts a program
• The Jog keys jog the robot while a SHIFT switch is pressed
• COORD selects a jog coordinate system each time the switch is pressed, selecting: JOINT, JGFRM, World frame, TOOL, and USER in the correct order
• Override adjusts a machine's feedrate

Execution Key Functions

• The FWD or BWD switch with SHIFT starts a program
• HOLD switch causes a program to halt
• STEP switch selects step or continuous test operation
• RESET switch is used to clear an alarm

Editing Key Functions

• The ENTER key is used to process and activate the current information set.
• The BACK SPACE key deletes the character or numeral immediately before the cursor.
• The arrow keys are used to highlight or select an item on the screen.
• The ITEM key moves the cursor to a line whose number is specified.

HandlingTool Specific Key Functions

• TOOL 1/2 key displays related screen
• MOVE MENU switch is not supported
• SETUP, STATUS and POSM keys are used to display respective screens
• I/O key displays I/O screen
• DIAG/HELP keys display associated info.