Is the category for this document correct?
- Engineering & Technology
- Mechanical Engineering
Thank you for your participation!
No more boring flashcards learning!
Learn languages, math, history, economics, chemistry and more with free Studylib Extension!
- Distribute all flashcards reviewing into small sessions
- Get inspired with a daily photo
- Import sets from Anki, Quizlet, etc
- Add Active Recall to your learning and get higher grades!
Add to Chrome
It’s free
-
FANUC Robotics System R-J3, R-J3iB & R-30iA ArcTool eLearn
Student Manual MATELRNAT0511CE REV. AThis publication contains proprietary information of FANUC
Robotics America Corporation furnished for customer use only. No
other uses are authorized without the express written permission of
FANUC Robotics America Corporation FANUC Robotics America
Corporation 3900 W. Hamlin Road Rochester Hills, Michigan
48309-3253 -
i
Table of Contents
1 FRAMES
………………………………………………………………………………………………………
1 1.1 SLIDE 2-TYPES OF FRAMES
………………………………………………………………………………….1
1.2 SLIDE 3-FRAME
OVERVIEW…………………………………………………………………………………..1
1.3 SLIDE 4-TWO DIMENSIONAL CARTESIAN
COORDINATE……………………………………………….1
1.4 SLIDE 5-ONE QUADRANT
……………………………………………………………………………………..1
1.5 SLIDE 6-THREE DIMENSIONAL CARTESIAN
COORDINATE…………………………………………….1 1.6
SLIDE 7-9-ORIENTATION IN WORLD MODE-MINOR
AXES……………………………………………1 1.7 SLIDE
10-CARTESIAN COORDINATE SYSTEM
……………………………………………………………1
1.8 SLIDE 11-WORLD
FRAME……………………………………………………………………………………..1
1.9 SLIDE 12-RIGHT HAND RULE
………………………………………………………………………………..1
1.10 SLIDE 13-TOOL
FRAME………………………………………………………………………………………..1
1.11 SLIDE 14-TOOL FRAME
FEATURES…………………………………………………………………………1
1.12 SLIDE 15-ADJUSTING TOOL CENTER
POINT……………………………………………………………..1
1.13 SLIDE 16-ACTUAL TOOL CENTER
POINT………………………………………………………………….1
1.14 SLIDE 17-METHODS OF DEFINING THE TOOL
FRAME………………………………………………….1
1.15 SLIDE 18-TEACHING A TOOL CENTER POINT 6 POINT METHOD
……………………………………1 1.16 SLIDE 19-TOOL
CENTER POINT 6 POINT METHOD PROCEDURE
…………………………………..1 1.17 SLIDE 20-VERIFY
TCP…………………………………………………………………………………………1
1.18 SLIDE 21-SELECTING A TOOL FRAME FROM THE JOG
MENU………………………………………..1 1.19 SLIDE
22-HOW THE ROBOT FRAMES ARE
LINKED………………………………………………………1
1.20 SLIDE 23-USER
FRAME………………………………………………………………………………………..1
1.21 SLIDE 24- EXAMPLE OF USER & TOOL FRAME IN A TP
PROGRAM…………………………………1 1.22 SLIDE
25-SAMPLE PROGRAM UFRAME VS. WORLD FRAME
…………………………………………1 1.23 SLIDE
26-USER FRAME PROCEDURE
……………………………………………………………………..1
1.24 SLIDE 27-YOU TRY IT-USER
FRAME……………………………………………………………………….1
1.25 SLIDE 28-REMOTE TOOL CENTER
POINT…………………………………………………………………1
1.26 SLIDE 29-FUNCTION
KEY……………………………………………………………………………………..1
1.27 SLIDE 30-RTCP
INSTRUCTION………………………………………………………………………………1
1.28 SLIDE 31-NO RTCP INSTRUCTION
…………………………………………………………………………1
1.29 SLIDE 32-JOG
FRAME………………………………………………………………………………………….1
1.30 SLIDE 33-JOG FRAME
PROCEDURE………………………………………………………………………..1
1.31 SLIDE 34-FRAMES
SUMMARY………………………………………………………………………………..1
1.32 SLIDE 35-QUIZ
…………………………………………………………………………………………………..1 -
Table of Contents MATELRNAT0511CE REV. A
ii
2
INPUT/OUTPUT………………………………………………………………………………………………
1 2.1 SLIDE 2-ANALOG
………………………………………………………………………………………………..1
2.2 SLIDE 3-DIGITAL INPUT/OUTPUT
……………………………………………………………………………1
2.3 SLIDE
4-DIGITAL…………………………………………………………………………………………………1
2.4 SLIDE 5-ROBOT I/O
…………………………………………………………………………………………….1
2.5 SLIDE 6-ROBOT I/O
…………………………………………………………………………………………….1
2.6 SLIDE 7-MODEL A INPUT/OUTPUT
………………………………………………………………………….1
2.7 SLIDE 8-RACK ASSIGNMENT
…………………………………………………………………………………1
2.8 SLIDE 9-MODEL A RACK
……………………………………………………………………………………1
2.9 SLIDE 10-SLOT
ASSIGNMENT………………………………………………………………………………..1
2.10 SLIDE 11-MODEL A SLOT
ASSIGNMENT…………………………………………………………………..1
2.11 SLIDE 12-STARTING POINT/CHANNEL
ASSIGNMENT…………………………………………………..1
2.12 SLIDE 13-MODEL A-STARTING POINT ASSIGNMENT
…………………………………………………..1 2.13
SLIDE 14-CONFIGURING
I/O………………………………………………………………………………….1
2.14 SLIDE 15-CONFIGURIG I/O
STATUS………………………………………………………………………..1
2.15 SLIDE 16-COMPLEMENTARY SIGNALS
…………………………………………………………………….1
2.16 SLIDE 17-I/O DETAIL
…………………………………………………………………………………………..1
2.17 SLIDE 18-19-MONITORING/CONTROLLING I/O
………………………………………………………….1
2.18 SLIDE 20-SIMULATING
I/O…………………………………………………………………………………….1
2.19 SLIDE 21-CONFIGURING GROUP
I/O……………………………………………………………………….1
2.20 SLIDE 22-GROUP INPUT/OUTPUT
…………………………………………………………………………..1
2.21 SLIDE 23-INPUT/OUTPUT REVIEW
………………………………………………………………………….13 PROGRAM
INSTRUCTION………………………………………………………………………………….
1 3.1 SLIDE 2-MODULE CONTENT
………………………………………………………………………………….1
3.2 SLIDE 3-DATA REGISTER
……………………………………………………………………………………..1
3.3 SLIDE 4-POSITION REGISTER
INSTRUCTIONS……………………………………………………………1
3.4 SLIDE 5-POSITION REGISTER
ELEMENT…………………………………………………………………..1
3.5 SLIDE 6-PROGRAM
INSTRUCTIONS…………………………………………………………………………1
3.6 SLIDE 7-BRANCHING
INSTRUCTIONS……………………………………………………………………….1
3.7 SLIDE 8-LABEL DEFINITION INSTRUCTION LBL[X]
………………………………………………………1
3.8 SLIDE 9-UNCONDITIONAL BRANCH
CALL……………………………………………………………….1
3.9 SLIDE 10-CONDITIONAL BRANCHING INSTRUCTIONS
………………………………………………….1 3.10
SLIDE 11-IF REGISTER
………………………………………………………………………………………..1
3.11 SLIDE 12-EXAMPLE #1 IF REGISTER
……………………………………………………………………1 -
Table of Contents MATELRNAT0511CE REV. A
iii
3.12 SLIDE 13-EXAMPLE #2 IF REGISTER
……………………………………………………………………1
3.13 SLIDE 14-IF INPUT/OUTPUT
………………………………………………………………………………….1
3.14 SLIDE 15-EXAMPLE #3 IF /
OR……………………………………………………………………………1
3.15 SLIDE 16-IF PROCEDURE
…………………………………………………………………………………….1
3.16 SLIDE 17-YOU TRY IT IF REGISTER
……………………………………………………………………..1
3.17 SLIDE 18-SELECT
INSTRUCTIONS…………………………………………………………………………1
3.18 SLIDE 19-SELECT INSTRUCTION
PROCEDURE…………………………………………………………1
3.19 SLIDE 20-SELECT INSTRUCTIONS YOU TRY
IT………………………………………………………1
3.20 SLIDE 21-WAIT
INSTRUCTION……………………………………………………………………………….1
3.21 SLIDE 22-REMARK INSTRUCTION
…………………………………………………………………………1
3.22 SLIDE 23-OVERRIDE
INSTRUCTION………………………………………………………………………1
3.23 SLIDE 24-MESSAGE
INSTRUCTION……………………………………………………………………….1
3.24 SLIDE 25-TIMER INSTRUCTION
…………………………………………………………………………….1
3.25 SLIDE 26-MODULE COMPLETE
………………………………………………………………………………14 ARCTOOL PROGRAMMING
……………………………………………………………………………….
1 4.1 SLIDE 2-MODULE CONTENT
………………………………………………………………………………….1
4.2 SLIDE 3-ARCTOOL PROGRAM GUIDELINES
………………………………………………………………1
4.3 SLIDE 4-WELD
I/O………………………………………………………………………………………………1
4.4 SLIDE 5-CONTROLLED START R-J3 THRU R-3IB
……………………………………………………….1
4.5 SLIDE 6-CONTROLLED START FOR R-30IA
………………………………………………………………1
4.6 SLIDE [email protected] CONTROLLED START WELD I/O EQUIPMENT
SELECTION………………………………1 4.7 SLIDE 8-SETTING
UP THE WELDING SYSTEM
……………………………………………………………1
4.8 SLIDE 9-WELD
EQUIPMENT…………………………………………………………………………………..1
4.9 SLIDE 10-SETTING LINCOLN
EQUIPMENT…………………………………………………………………1
4.10 SLIDE 11-ARC DEFAULTS INSTRUCTION DEMO
…………………………………………………………1
4.11 SLIDE 12-ARC
PROGRAMMING………………………………………………………………………………1
4.12 SLIDE 13-WELD ENABLED KEY
……………………………………………………………………………..1
4.13 SLIDE 14-ARC START
………………………………………………………………………………………….1
4.14 SLIDE 15-ARC
END……………………………………………………………………………………………..1
4.15 SLIDE 19-ARC WELD
SCHEDULE……………………………………………………………………………1
4.16 SLIDE 20-DELAY TIME
…………………………………………………………………………………………1
4.17 SLIDE 21-ARC START SCHEDULE DEMO
………………………………………………………………….1
4.18 SLIDE 23-WEAVE INSTRUCTIONS
…………………………………………………………………………..1
4.19 SLIDE 24-ARC WEAVE
SETUP……………………………………………………………………………….1 -
Table of Contents MATELRNAT0511CE REV. A
iv
4.20 SLIDE 25-WEAVE SCHEDULE
………………………………………………………………………………..1
4.21 SLIDE 26-WEAVE INSTRUCTION
PROGRAM………………………………………………………………1
4.22 SLIDE 28-PATH
JOGGING……………………………………………………………………………………..1
4.23 SLIDE 29-TORCHMATE
………………………………………………………………………………………..1
4.24 SLIDE 30-TORCHMATE
VIDEO……………………………………………………………………………….1
4.25 SLIDE 31-INSTALLING & ALIGNING THE TOUCH BLOCK
……………………………………………….1 4.26 SLIDE
32-SETUP TORCHMATE
………………………………………………………………………………1
4.27 SLIDE 33-EXECUTE TM_ADJST
MACRO…………………………………………………………………1
4.28 SLIDE 34-VIEW THE TCP OFFSETS
………………………………………………………………………..1
4.29 SLIDE 35-COURSE OVERVIEW
………………………………………………………………………………15 MODIFYING A
PROGRAM………………………………………………………………………………….
1 5.1 SLIDE 2-MODIFYING PROGRAMS
……………………………………………………………………………1
5.2 SLIDE 3-INSERT
……………………………………………………………………………………………….1
5.3 SLIDE
4-DELETE……………………………………………………………………………………………….1
5.4 SLIDE 5-COPY
………………………………………………………………………………………………….1
5.5 SLIDE
6-PASTE…………………………………………………………………………………………………1
5.6 SLIDE 7-PASTE-F2 LOGIC
…………………………………………………………………………………..1
5.7 SLIDE 8-9 PASTE F3 POS-ID
……………………………………………………………………………1
5.8 SLIDE 10-11 PASTE F4 POSITION
……………………………………………………………………1
5.9 SLIDE 12-REVERSE
PASTE……………………………………………………………………………….1
5.10 SLIDE 13-PASTE — F1 R-LOGIC
…………………………………………………………………………..1
5.11 SLIDE 14-PASTE F1 R-LOGIC
………………………………………………………………………….1
5.12 SLIDE 15-PASTE F2 R-POS-ID
…………………………………………………………………………1
5.13 SLIDE 16-PASTE F2 R POS-ID
…………………………………………………………………………1
5.14 SLIDE 17-PASTE F4
R-POS……………………………………………………………………………..1
5.15 SLIDE 18-PASTE F4
R-POS……………………………………………………………………………..1
5.16 SLIDE 19-PASTE F3 RM-POS-ID
………………………………………………………………………1
5.17 SLIDE 20-PASTE F3 RM-POS-ID
………………………………………………………………………1
5.18 SLIDE 21-PASTE F5
RM-POS…………………………………………………………………………..1
5.19 SLIDE 22-PASTE F5
RM-POS…………………………………………………………………………..1
5.20 SLIDE 23-FIND
………………………………………………………………………………………………….1
5.21 SLIDE
24-REPLACE…………………………………………………………………………………………..1
5.22 SLIDE
25-RENUMBERING………………………………………………………………………………….1
5.23 SLIDE 26-COMMENT
…………………………………………………………………………………………1 -
Table of Contents MATELRNAT0511CE REV. A
v
5.24 SLIDE 27-UNDO
………………………………………………………………………………………………..1
5.25 SLIDE 28-YOU TRY IT
………………………………………………………………………………………….1
5.26 SLIDE 29-MODULE
REVIEW…………………………………………………………………………………..16 MACRO
COMMANDS……………………………………………………………………………………….
1 6.1 SLIDE 2-MODULE CONTENT
………………………………………………………………………………….1
6.2 SLIDE 3-OVERVIEW OF MACROS
……………………………………………………………………………1
6.3 SLIDE 4-TEACH PENDANT USER KEYS
……………………………………………………………………1
6.4 SLIDE 5-MACRO COMMAND
ASSIGNMENTS………………………………………………………………1
6.5 SLIDE 6-OPERATOR PANEL BUTTONS
…………………………………………………………………….1
6.6 SLIDE 7-MANUAL FUNCTIONS MACROS
…………………………………………………………………..1
6.7 SLIDE 8-SETTING UP MACRO
COMMANDS………………………………………………………………..1
6.8 SLIDE 9-YOU TRY IT
……………………………………………………………………………………………1
6.9 SLIDE 10-MACRO REVIEW
……………………………………………………………………………………17 PRODUCTION SETUP
………………………………………………………………………………………
1 7.1 SLIDE
2-AGENDA………………………………………………………………………………………………..1
7.2 SLIDE 3-REMOTE/LOCAL MODE
…………………………………………………………………………….1
7.3 SLIDE 4-PRODUCTION SETUP IN SYSTEM CONFIG
MENU…………………………………………….1 7.4 SLIDE
5-PRODUCTION SETUP
……………………………………………………………………………….1
7.5 SLIDE 6-PRODUCTION START CHECKS
……………………………………………………………………1
7.6 SLIDE 7-PRODUCTION SETUP GENERAL
CONTROLS………………………………………………..1
7.7 SLIDE 8-STYLE SELECT USING DIN START METHOD PROCEDURE
………………………………..1 7.8 SLIDE 9-SUMMARY
……………………………………………………………………………………………..18 FILE
MANAGEMENT………………………………………………………………………………………..
1 8.1 SLIDE 2-MODULE CONTENT
………………………………………………………………………………….1
8.2 SLIDE 3-DISPLAY PROGRAM
FILES…………………………………………………………………………1
8.3 SLIDE 4-COPY A
PROGRAM…………………………………………………………………………………..1
8.4 SLIDE 5-DELETE PROGRAM
FILES………………………………………………………………………….1
8.5 SLIDE 6-7-ABORTING A PROGRAM
…………………………………………………………………………1
8.6 SLIDE 8-YOU TRY IT
……………………………………………………………………………………………1
8.7 SLIDE 9-TYPES OF FILES
……………………………………………………………………………………..1
8.8 SLIDE 10-STORAGE
DEVICES………………………………………………………………………………..1
8.9 SLIDE 11-SET THE DEFAULT DEVICE & GENERATE A
DIRECTORY…………………………………1 8.10 SLIDE 12-YOU
TRY IT
………………………………………………………………………………………….1 -
Table of Contents MATELRNAT0511CE REV. A
vi
8.11 SLIDE 13-BACKUP UP FILES VS. CONTROLLER
BACKUP……………………………………………..1 8.12
SLIDE 14-BACKUP FILES USING THE FILE MENU
………………………………………………………1
8.13 SLIDE 15-LOADING FILES USING THE FILE
MENU……………………………………………………..1
8.14 SLIDE 16-BACKUP UP A CONTROLLER AS
IMAGES……………………………………………………..1
8.15 SLIDE 17-RESTORING CONTROLLER
IMAGES……………………………………………………………1 -
System R-J3, R-J3iB & R-30iA
1
Course Overview
Course Overview
1 Frames
2 Input/Output
3 Program Instruction
4 — ArcTool Programming
4 Modify a Program
5 Macro Commands
6 Robot Setup for Production
7 File Management
Module Contents Frames:
World Frame,
Tool Frame,
User Frame and within user frames, the Remote Tool Center Point
which is only available in some applications,Jog Frame
Input/Output:
After successfully completing this module, you should know the
different types of Inputs and Outputs and how to configure
them.There are several types of I/Os, but in this module, the
different types of Inputs and Outputs are:Robot
Digital;
Analog
Group
Inputs and Outputs are electrical signals that enable the robot
controller to communicate with End of Arm Tooling, process
equipment, other external sensors and other devices. -
Course Overview MATELRNAT0511CE REV. A
2
Program Instructions
Data Register
Position Register Instruction
Branching Instructions
Label
Unconditional
JMP LBL
CALL
Conditional
Wait Instructions
Miscellaneous Instructions
Remark
Override
Message
Timer
ArcTool Programming
ArcTool Program Guideline
Weld I/O
Setup and Select Weld Equipment
ArcTool Instructions
ArcTool Default Instructions
Arc Weld Schedule
Delay Time
Weld Enable
Weave Patterns
Weave Instructions
Weave Schedule
Torchmate
-
Course Overview MATELRNAT0511CE REV. A
3
Modifying a Program
Inserting blank lines into a Program.
Deleting lines from a Program
Copying and Pasting lines within a Program
Finding program instructions within a Program
Replacing Items
Renumbering Positional IDs
Turning ON and OFF Comments
And the UNDO function
Macro Commands
Overview of Macros
Setting Up Macro Commands
Assigning a Macro to a Teach Pendant User Key,Manual Functions
or Operator Panel ButtonsRobot Setup for Production
Learn how setup a robot for production using the teach
pendant.Cover various production modes, system and Cell I/O
configurations.A video to reinforce the step by step process needed to
configure the settingsFile Management
Copying and Deleting Programs,
Backup all or specific types of files to a specific device.
Learn how to load program from the backup device
Then wrap-up with how to do an image backup and Restore
-
Course Overview MATELRNAT0511CE REV. A
4
-
System R-J3, R-J3iB & R-30iA
5Frames 1 1 FRAMES
Frames
Frames
Audio:
Welcome to Frames. In this course we will investigate what type
of frames there are. We will see how to set them up and what they
are used for. -
Frames MATELRNAT0511CE REV. A
6
1.1 Slide 2-Types of Frames
Frames
Types of Frames
World frame — default frame of the robot Tool frame — user
defined frame User frame — user defined frameRTCP Remote Tool Center Point HandlingTool, DispenseTool,
andSpotTool+ only)
Jog frame — user defined frame
Audio:
This course will cover all the frames available within FANUC
software. The robot uses four kinds of frames which are World
Frame, Tool Frame, User Frame and within user frames, the Remote
Tool Center Point which is only available insome applications, and finally wrap up with Jog Frame
-
Frames MATELRNAT0511CE REV. A
7
1.2 Slide 3-Frame Overview
Audio:
1. But first, an overview of what a frame is. A frame is an
intersection of three planes at right angles to each other. The
point where all three planes intersect is called the origin point.
Where X,Y & Z values are all 0. Here are more examples of a
Frame with the Origin point in different positions.2. Any point can be located within a frame by providing three
positive or negative numbers to represent the X,Y & Z distances
from the origin. This kind of system is called a Cartesian
coordinate system.3. The frame itself is a set of numbers used to describe the
location, and orientation about the X,Y,Z axes of the reference
frame. -
Frames MATELRNAT0511CE REV. A
8
1.3 Slide 4-Two Dimensional Cartesian Coordinate
Frames
I
Two Dimensional Cartesian Coordinate y-axis
x-axis
Origin = 0
+
+
II
III IV
I
x values
yvalues
I >0 >0IIIIIIV
0
>0
-
Frames MATELRNAT0511CE REV. A
9
1.4 Slide 5-One Quadrant
Audio:
To determine the robots position in millimeters we use this
scale to figure this out. The result is positive 600 in the x
direction and positive 800 in the y direction -
Frames MATELRNAT0511CE REV. A
10
1.5 Slide 6-Three Dimensional Cartesian Coordinate
Audio:
In the three dimensional Cartesian Coordinate system we are
adding another axis to the plane. X axis becomes forward and
backward movement. Y axis becomes a side to side movement. Z is the
UP and DOWN movement.The values reflect the location for positional information, the
values shown in this slide reflectsDistance from the origin along the X axis which reflects in
example 600Distance from the origin along the Y axis which is 800
Distance from the origin from the Z axis which is negative
700 -
Frames MATELRNAT0511CE REV. A
11
1.6 Slide 7-9-Orientation in WORLD mode-Minor Axes
Frames
Orientation in WORLD mode Minor Axes
Major Axes
Minor Axes
Roll (R) Rotation around Z
OrientationYaw (W) Rotation around XPitch (P) Rotation around
YFrames
Orientation in WORLD mode Minor Axes
Major Axes
Minor Axes
Roll (R) Rotation around Z
OrientationYaw (W) Rotation around XPitch (P) Rotation around
YAudio:
The orientations of a position is expressed in three dimensions
also, but are measured in degrees of rotation about the x, y, and z
axes.Use the minor axes from the teach pendant when jogging about the
x, y and z axesWhen rotating Yaw it is Rotating around X
-
Frames MATELRNAT0511CE REV. A
12
1.7 Slide 10-Cartesian Coordinate System
Frames
Cartesian Coordinate System
+X=1800mm
+Y=1000mm
+Z=800mm
-BCKEDT- LINE 0 AUTO ABORTED
POSITION JOINT 100 %
World Tool: 1
Configuration: N U T, 0, 0, 0
x: 1800.000 y: 1000.000 z: 800.000
w: -146.360 p: -33.432 r: -22.691
[ TYPE ] JNT USER WORLD
Teach Pendant POSN menu
0
Audio:
Putting it all together this robots position in Cartesian is
positive 1800 millimeters in the x direction, positive 1000
millimeters in the y direction and positive 800 in the z direction
all from the origin.The robots orientation is negative 146 degrees about X which is
the yaw value and negative 33 degrees about Y which is the pitch
value and negative 22 degrees about Z which is the roll value.You can view the robots positional values from the Position menu
on the Teach Pendant. -
Frames MATELRNAT0511CE REV. A
13
1.8 Slide 11-World Frame
Frames
World Frame
J2
J2
ORIGIN OF WORLD FRAME
J1
J1
Audio:
Starting with World Frame.
1. The World Frame is the default frame of the robot. It cannot
be changed by the user.2. The origin of the world frame is located on the centerline of
the J1-axis and at the height of the centerline of the J2-axis.3. The location of this origin never changes.
4. And the orientation of the World frame never changes.
-
Frames MATELRNAT0511CE REV. A
14
1.9 Slide 12-Right Hand Rule
Frames
Right Hand Rule
+X
+X+Y
+Y
+Z
+Z
Audio:
The directions of the World frame can be represented by the
right hand rule. Also the World coordinates can be better
understood if you stand behind or by the side of the robot and then
use the right handed rule. -
Frames MATELRNAT0511CE REV. A
15
1.10 Slide 13-Tool Frame
Frames
Tool Frame
+X
+Y
+ZA Tool frame is
defined using the Cartesian
coordinate system
Default Tool Frame Origin
+X
+Y
+Z
Tool Center Point has moved from the faceplate to the tool
Audio:
Now we will discuss the Tool Frame.
Its origin is called the tool center point (TCP). By default,
the TCP is located at the center of the robots faceplate. When you
set up a Tool frame, also called a UTool, you move the TCP from the
robots faceplate to define the point on the applicator, gun, torch,
or other tool where the painting, welding, sealing, handling, or
other application work is to be done. -
Frames MATELRNAT0511CE REV. A
16
1.11 Slide 14-Tool Frame Features
Audio:
So why define a Tool Center Point.
An important reason to define a TCP is simply to jog the TCP to
the workpiece which makes programming easier. Some software
applications are based on a correctly defined TCP. For an Example,
in a SpotTool servo gun application, the TCP is tied to the tip
wear compensation.Another important reason to define a TCP is to have consistency
from robot to robot, especially in a plant that has many cells. -
Frames MATELRNAT0511CE REV. A
17
1.12 Slide 15-Adjusting Tool Center Point
Audio:
Here is another example of the default Tool Frame located on the
Face Plate. When the tool is mounted, it does not take into account
the actual position of the tooling where the work is to be done.
Therefore if you jog the robot using default tool coordinates you
will be unable to control the position of the robot relative to the
center of the attached tooling.In order for the Tool coordinates X,Y,& Z to refer to the
center of the tooling, you must adjust the Tool Frame offset as
shown here. -
Frames MATELRNAT0511CE REV. A
18
1.13 Slide 16-Actual Tool Center Point
Frames
Actual Tool Center Point
Audio:
Here are some examples of different toolings Tool Frame Offsets.
in PaintTool, the TCP is approximately 12 inches from the end of
the applicator, but this can vary depending on your particular
applicator; in ArcTool, the TCP is the tip of the wire; in
SpotTool+, the TCP is where the tips of the gun meet when they are
closed; in HandlingTool, the TCP is where the gripper closes to
pick the part up. -
Frames MATELRNAT0511CE REV. A
19
1.14 Slide 17-Methods of Defining the Tool Frame
Frames
Methods of Defining the Tool Frame
Three Point Method defines just the location of the tool frame
when the valuescannot be measured and directly entered
Six Point Method defines the location and orientation of the
tool frame when thevalues cannot be measured and directly entered.
Direct Entry Method used when tool dimensions are known and can
be entereddirectly into Tool Frame settings. Direct Entry must be used
with 4-axis robotsAudio:
There are three ways to define a tool Frame:
The Three Point Method, the Six Point Method, and the Direct
Entry Method. Use the three point method to define just the
location of the tool frame when the valuescannot be measured and directly entered Use the six point method
to define the location and orientation of the tool frame when
thevalues cannot be measured and directly entered. The direct entry
method provides for direct numerical entry of known tool
dimensions. DirectEntry is used when tool dimensions are known and can be entered
directly into Tool Frame settings. Direct Entry must be used with
4-axis robots, such as the M410iB and the A520iB.In this exercise you will set up the Tool Frame using the 6
point method. -
Frames MATELRNAT0511CE REV. A
20
1.15 Slide 18-Teaching a Tool Center Point 6 Point Method
Audio:
This video (which will repeat) is displaying the 6 point method
which requires you to teach 6 points. The first 3 approach points
are used to define the location of the Tool Center Point and are
the same approach points as in the 3 Point method. The three
additional points define the direction vector for the tool. These
three additional points define orientation, measured in degrees of
rotation about an axis. W stands for Yaw. Yaw rotates about the X
axis. P stands for Pitch, and rotates about the Y axis. R, for
Roll, rotates about the Z axis. All are measured in degrees.When recording the Orient origin point or to simplify teaching
points 4, 5, and 6, align the desired X, Y, and Z directions of the
tool with the X, Y, and Z of the World frame in any order that
avoids singularity. In this example it is convenient to align the
tool frame Z with the World frame Z and the Tool frame X with the
World frame X. This alignment is based on the shape of the tool and
the need to avoid singularity.When you teach the Orient Origin point it is often helpful to
start with all of the Zero position reference marks aligned. Then
you can move the minor axes until the tool is squared up with the
World Frame. Just be sure the robot is not in singularity. Then you
can record the Orient Origin point. -
Frames MATELRNAT0511CE REV. A
21
1.16 Slide 19-Tool Center Point 6 Point Method Procedure
Audio:
The following video will show how to define a Tool Center Point
using the 6 point method. You will teach 3 different approach
points, an Orient origin point and then define your Positive X and
Positive Z direction points. In the process of learning the 6 point
method, you will learn the 3 Point Method as well.1 The first thing you need to do is turn the Teach Pendant to
the ON position, then press the key. From the pop-up menu cursor
down to SETUP and press the key.2 Press the TYPE key and cursor down to FRAMES and press the
key. Upon selecting Frames, the Tool frame setup is the default
screen.3 Press the DETAIL key to select TOOL Frame #1.
4 To name this Tool Frame, press key. You will name this tool
frame POINTER, after you have typed the name PRESS the key.5 Select the 6 point method from the function key . 6 You begin
by teaching 3 points on a fixed reference, with the orientation of
the tool 90degrees different on each point. This is all that is required
when teaching a 3 point method.7 You will now jog the tool to the approach point #1 and HOLD
the key and PRESS RECORD to record it.MENUS
ENTER
ENTER
F5 SHIFT
F2
ENTERENTER
F2
F1
-
Frames MATELRNAT0511CE REV. A
22
8 Now cursor down to approach point #2 . Remember you need 3
different planes recorded. Now jog the tool to approach point #2,
and again hold the key and PRESS RECORD.9 Release the key and cursor down to APPROACH point 3. Jog the
tool to approach point 3 position then press and HOLD the key plus
the key to record this position.10 This completes the 3 point method. The 6 point method
continues to the next step of defining the Orient Origin point. Any
orientation of the tool will work as long as the tool is square to
the World Frame and the robot is not in Singularity.11 In the final 2 steps you define the Positive X and Positive Z
directions of the Tool Frame. First we will define the Positive X
direction by jogging the tool from the Orient Origin point at least
250 mm, then HOLD the key and PRESS the RECORD.12 Finally you need to define the Positive Z Direction. Start by
moving back to the Orient Origin point being careful that the tool
doesnt move the part.13 Now jog the tool at least 250mm in the direction that you
want to define as the Positive Z direction and HOLD the key and
PRESS the RECORD.The Tool Frame have now been defined.
F5SHIFT
F5SHIFT
SHIFT F5SHIFT
SHIFT F5
-
Frames MATELRNAT0511CE REV. A
23
1.17 Slide 20-Verify TCP
Frames
Verify TCP
Audio:
If the TCP was taught correctly, it will move in the direction
you want when you jog in X, Y, or Z.When you rotate the tool, it should rotate about the Tool center
point. The TCP should remain stationary. -
Frames MATELRNAT0511CE REV. A
24
1.18 Slide 21-Selecting a Tool Frame from the Jog Menu
Frames
Selecting a Tool Frame from the Jog Menu
Tool #1 Tool #2
+Tool ( .=10) 2Jog 0User 3Group 2
Audio:
When there are multiple tools and groups defined on a robot, you
can use the jog menu to verify and change the following jogging
information:TOOL, JOG, and USER frame number of each frame.
Additionally, you can change motion group number be aware that
before changing motion group number, the frame number that is
displayed is the frame number defined within that motion group.First press plus the coordinate key on the Teach Pendant. Select
TOOL and enter the number of the frame you want. Then press the
coordinate key without the shift key until desired coordinate
system is selected.After you have taught the Tool Center Point and that tool is
selected, you can test the tool by jogging in the Tool Frame you
have just taught.SHIFT
-
Frames MATELRNAT0511CE REV. A
25
1.19 Slide 22-How the Robot Frames are linked
Frames
How the Robot frames are linked
Robot
Tool Frame (TCP)
Positional data
User Frame origin
Taught PositionJ P[1] 100% FINE
Audio:
In Summary, the Tool Frame Offset tells the controller where the
Tool frame is relative to the center of the faceplatePositional data tells the controller where the Tool frame is,
relative to the User frame. In this example, there is a defined
User Frame that is not using the default world frame.User frame offset data (UFRAME) tells the controller where the
defined USER frame is relative to World frame. This is the next
subject. -
Frames MATELRNAT0511CE REV. A
26
1.20 Slide 23-User Frame
Frames
User Frame
+Z
-Z
+Y
-Y+X
-X+Z
-Z
+Y
-Y
+X-X
X PLANE
X PL
ANE
Y PLANE
Y PLANE
Z PLANE
Z PL
ANE
World Frame
You can define up to 9 user frames within R-J3 controllers
User Frame is this offset in
the X,Y,Z,W,P,R
User frame — user defined frame
User:
Now lets discuss the User Frame
User frame is a frame that you can set up in any location, with
any orientation. User frames are used so that positions in a
program can be recorded relative to the origin of the frame.If you do not set up the location and orientation of the user
frame before you create a program, then the user frame will be set,
by default, to the world frame origin point.When jogging the robot in User coordinates and you have not
defined a user frame, then the XYZ motion will be the same as XYZ
motion in world.If you jog the robot in User Coordinates, and a user frame has
been defined and that defined user frame is selected, you must
remember that the X, Y, & Z origin point is referenced from the
defined user frame, not the center of the robot, like World
Coordinates does.You can define up to nine user frames within the R-J3
controllersThere are three methods of setting the Uframe: The Three Point
Method, the Four Point Method and the Direct Entry Method. -
Frames MATELRNAT0511CE REV. A
27
1.21 Slide 24- Example of User & Tool Frame in a TP
ProgramFrames
Example of User & Tool Frame in a TP Program
Program Position Detail
Audio:
Each time a point is taught in a program, the recorded
positional data provides the location of the TCP, expressed as X,
Y, & Z, relative to the origin of the currently selected User
Frame. The orientation of the Tool Frame, expressed as W, P, &
R, for Yaw, Pitch and Roll, is also relative to the User Frame.Therefore, if no Tool Frame has been taught, the X, Y, & Z
positional data will reference from the center of the robot
faceplate and not the center of the attached tool. However, if a
Tool frame has been taught, and, that Tool Frame is selected, the
X, Y, Z, W, P, & R data will reference the actual Tool Center
Point. -
Frames MATELRNAT0511CE REV. A
28
1.22 Slide 25-Sample Program UFrame vs. World Frame
Frames
Sample Program UFrame vs. World Frame
Program is referenced from UFrame
Program Points
Audio:
One of the benefits of defining a user frame is when multiple
programs are based on a user frame which can be referenced from the
workpiece and when the workpiece moves, then editing the user frame
would adjust all programs based on that user frame. -
Frames MATELRNAT0511CE REV. A
29
1.23 Slide 26-User Frame Procedure
Audio:
This video will show you how to define a User Frame using the 3
point method.1 First turn the Teach Pendant to the ON position, then press
the key. From the pop-up menu cursor down to SETUP and press the
key.2 Now press the TYPE key and cursor down to FRAMES and press the
key. Upon selecting Frames, the Tool frame setup is the default
screen.3 Select User frame from the function key labeled OTHER and
press4 Press DETAIL function key to define and name the user frame. 5
You can name the user frame within the Comment line; however this
has already beendefined. To delete the existing name and rename it hold the
Shift key plus arrow right to delete one character at a time. We
will rename it to be called BOX. The Teach Pendant recognizes the
Frame number and not the comment name you provide.6 Press the softkey labeled method to select the method that you
will be using when defining the User Frame7 Jog the robot to the Orient origin point position and record
it using the and Record key8 Next, you define the Positive X direction by jogging the robot
from the Orient Origin point at least 250 mm, then HOLD the key and
PRESS the RECORD key.MENUS
F5SHIFT
ENTER F3
ENTER
ENTER
F2
F5SHIFT
F2
F1
-
Frames MATELRNAT0511CE REV. A
30
9 Now jog the tool at least 250mm in the direction that you want
to define as the Positive Y direction and HOLD the key and PRESS
the RECORD key.10 This completes the procedure on how to define a user frame
using the three point method 11 Now we will demonstrate using the
newly defined the User Frame. newly12 When you press the plus the key, you can verify the user
frame number that is selected.This completes the demonstration on how to create a three point
user frame.SHIFT
SHIFT COORD
F5
-
Frames MATELRNAT0511CE REV. A
31
1.24 Slide 27-You Try It-User Frame
Audio:
This is your opportunity to recall the steps needed to define a
User Frame using the 3 point method.You can name the user frame within the Comment line; however
this has already been defined. We will rename it to be called
BOX.We will Jog the robot to the Orient origin point position
We will jog the robot from the Orient Origin point 250 mm.
We will jog the tool at least 250mm in the direction that
defines the Positive Y direction. -
Frames MATELRNAT0511CE REV. A
32
1.25 Slide 28-Remote Tool Center Point
Frames
Remote Tool Center Point
+Y
+X
+ZTool
Frame
+Y-X
+ZUser Frame
(Remote Tool Center Point)
Audio:
In this section, we will cover the Remote Tool Center Point
A remote tool is an external tool within the robots working
envelope that performs work on a part that is delivered by the
robot. In situations where the robot carries the workpiece and the
tool is stationary, you can make use of the User Frame to provide
special movement of the workpiece about the tool. In these
situations the User Frame is called a Remote Tool Center Point.You can define a user frame whose origin is at the external tool
to allow moving the part relative to the external tool.When the user frame is employed this way, it is called a Remote
Tool Center Point.You must first define a user frame before you can use the Remote
Tool Center Point feature when jogging the robot. If you want to
include remote tool center point moves in a program, you must
include Remote Tool Center Point instructions in the program. -
Frames MATELRNAT0511CE REV. A
33
1.26 Slide 29-Function Key
Frames
Function Key
FCTN
Audio:
The controller must have the Remote Tool Center Point software
option installed.To jog the robot in Remote Tool Center Point, you must press the
Function key on the Teach Pendant, select Toggle Remote TCP and
press enter. Once you have selected the Remote TCP function and you
are using XYZ coordinates, the selected Remote Tool Center Point,
along with the coordinate system will be displayed in the teach
pendant window. In this example Remote TCP one and Tool Coordinate
is displayed in the Teach Pendant window.When this function is enabled and the remote tool center point
user frame has been defined, you can jog the robot with the part
around the remote tool. -
Frames MATELRNAT0511CE REV. A
34
1.27 Slide 30-RTCP Instruction
Audio:
if you want to use the Remote Tool Center Point option in your
Teach Pendant program, you must decide where it is needed and then
place it on the end of the program-line statement using the CHOICE
menu to display Motion Options to select RTCP. Notice in this
animation, which provides multiple views of the same motion, how
the robot with part will jog around the remote tool. When you are
done viewing this slide, press the next slide icon. -
Frames MATELRNAT0511CE REV. A
35
1.28 Slide 31-No RTCP Instruction
Audio:
Here is an example of the resulting path of a robot using a
Teach Pendant program without the Remote Tool Center Point option.
This example also shows multiple views of the same motion. Notice
how the robot with part is not accurate when rotating around the
tool. -
Frames MATELRNAT0511CE REV. A
36
1.29 Slide 32-Jog Frame
Frames
Jog Frame
Jog FrameWorld Frame
You can set up as many as 5 different jog frames for each
robotAudio:
We will wrap up with Jog Frame
The Jog Frame provides a convenient way to jog the robot
relative to a particular workpiece.In this example, A Jog frame was defined to move along a part
when the part is oriented differently from the world frame.This displays two examples: the world frame and the jog
frame.The benefits of defining a jog frame, are that it makes jogging
easier when teaching points, and it will remove the need to «tack
while jogging, if a part is skewed in relation to the world frame.
Remember that Jog frames can be taught anywhere inside the robots
workspace.You may like to think of a Jog Frame as another right hand rule
defined somewhere within the work envelope.NOTE that a Jog Frame has no effect on program data!
Before you can use a jog frame, you must set up its location and
orientation.You can set up as many as five different jog frames for each
robot. -
Frames MATELRNAT0511CE REV. A
37
You can select one jog frame to be active at a time per motion
group.Once the Jog Frame has been defined and is selected, the robot
can be jogged in that frame.There are two methods you can use to define a jog frame:
The Direct Entry method and the Three Point method
1. The direct entry method provides for direct recording and
numerical entry of the frame position.2. This method allows you to designate the origin with the
actual values for x, y, z, w, p, and r when they are already
known.Usually however, the frame data is unknown. In that case you can
use the three point method to teach a jog frame. -
Frames MATELRNAT0511CE REV. A
38
1.30 Slide 33-Jog Frame Procedure
Audio:
In this video you will learn how to define a jog frame.
1 First, turn on the Teach Pendant, then select Setup from the
key.2 Now press the function key labeled TYPE and cursor down to
FRAMES and press the key.3 Select Jog frame from the function key labeled OTHER and
press4 Press DETAIL function key to define and name the jog
frame.5 Press to name this frame BOX, then press again
6 Select the function key labeled METHOD and select 3 point. 7
Place the robot at the top left hand corner of the box and record
the origin point. When therobot is positioned at this point, press Shift plus to Record
this position. For the X direction, jog the robot in the direction
that you want the jog frame plus X directionto be. Any coordinates can be utilized to get to the directions.
Coordinates do not have any bearing on the final outcome in
defining the jog frame.8 Now jog the robot so that the pointer is half way down the box
to represent the +Y direction.MENU
+X
F5
ENTER
F2
F2
ENTER
ENTER F3
ENTER F1
-
Frames MATELRNAT0511CE REV. A
39
9 Press to record the direction 10 Now test the frame that was
just created. Change the coordinates to jog frame.11 When you bring up the jog menu with the plus the key, you
will see that jog frame number 1 is activeThis completes the Jog Frame setup procedure
1.31 Slide 34-Frames Summary
Frames
Frames Summary
World frame — default frame of the robot Tool frame — user
defined frame User frame — user defined frameRTCP Remote Tool Center Point HandlingTool, DispenseTool, and
SpotTool+ only)Jog frame — user defined frame
Audio:
You have completed the frames module. In this module
understanding the different types of frames has been the key topic.
We learned that world frame is always the default frame of the
robot. An important reason to define a tool frame is simply jog the
TCP to the work piece which makes programming easier. User frame is
a frame that you can setup in any location and any orientation.
User frames are used so that positions in a program can be recorded
relative to the origin of the frame.A remote tool is an external tool within the robots working
envelope that performs work on a part that is delivered by the
robot. And the course wrapped up with Jog frame which simply
provides a convenient way to jog the robot relative to a particular
work piece.+Y
SHIFT COORD
F5 SHIFT
-
Frames MATELRNAT0511CE REV. A
40
1.32 Slide 35-Quiz
Frames
Quiz
Now is your opportunity to test your knowledge
You must pass with an 80% or higher You may retake the questions
as many timesas necessary, but you must close out of the course before
retaking it again.Click here to begin the Quiz
Audio:
If you have any questions or would like to provide feedback,
please contact [email protected]And now in the next slides you will have the opportunity to test
your knowledge of the information that has been provided. -
System R-J3, R-J3iB & R-30iA
41Input/Output 2
2 INPUT/OUTPUT
Input/Output
Module ObjectivesAfter successfully completing this module you
should know the different types of I/O and how to configure
them:Audio:
Welcome to Input, Output
After successfully completing this module, you should know the
different types of Inputs and Outputs and how to configure
them.There are several types of I/Os, but in this module, the
different types of Inputs and Outputs are: Robot; Digital; Analog
and Group.Inputs and Outputs are electrical signals that enable the robot
controller to communicate with End of Arm Tooling, process
equipment, other external sensors and other devices. -
Input/Output MATELRNAT0511CE REV. A
42
2.1 Slide 2-Analog
Input/Output
Analog
Substance
Pressure Transducer — Analog
Typical Voltage Values
-10 volts to +10 volts
Audio:
First, what are Analog signals Analog Signals are created from
sensors, or transducers in the work cell, or sent from a Robot
controller via its control module to a transducer within the cell
to effect a change. This signal is normally an electrical voltage
within an accepted range of values that is transmitted to or from
an I/O circuit-board or module connected to a robot controller.Notice, in this example, that as the substance fills the tank,
the pressure transducer puts out an analog voltage that is used to
determine when to open the valve and release the substance.Analog input devices convert external analog signals into
numbers for use by the controller. Analog Output devices send
analog signals out to external devices. Typical voltages of analog
inputs and Outputs are from negative 10 to positive 10 volts -
Input/Output MATELRNAT0511CE REV. A
43
2.2 Slide 3-Digital Input/Output
Input/Output
Digital Input/Output
Light switch is OFFON
Audio:
A Digital Input and Output signal is a control signal sent to or
from the controller. Digital signals can have only one of two
possible states: ON or OFF. -
Input/Output MATELRNAT0511CE REV. A
44
2.3 Slide 4-Digital
Input/Output
Digital
Substance
Float with Switch Digital ONOFF
Audio:
Here is an example of a Digital signal. As a substance fills the
tank, a switch, connected to the float at the top of the tank will
disconnect to break a connection. This becomes a digital OFF
signal, and is used to stop the flow of substance. Then as the
substance drains out of the tank, the floats switch will make the
connection to turn the substance-flow on. -
Input/Output MATELRNAT0511CE REV. A
45
2.4 Slide 5-Robot I/O
Audio:
Robot Inputs and Outputs are digital signals usually used to
manipulate the End of Arm Tooling. These signals are sent through
theEnd Effector or the EE connector located on the robot. Although
all robot have it, not all robots use it. -
Input/Output MATELRNAT0511CE REV. A
46
2.5 Slide 6-Robot I/O
Audio:
This example shows how the programming instruction would be
written to manipulate the End of Arm Tooling utilizing Robot
Outputs. -
Input/Output MATELRNAT0511CE REV. A
47
2.6 Slide 7-Model A Input/Output
Audio:
Heres how to configure Digital AND ANALOG Inputs and
Outputs:When all appropriate I/O hardware has been installed and
connected, you must configure the I/O. Configuring I/O establishes
the correspondence between the signal number and the physical port.
Each signal, or signal-sequence must be configured to a rack, a
slot in the rack, and the channel number or starting point. You can
change this configuration depending on the kind of I/O you are
using. Model A I/O is unique, in the fact that some FANUC software
will be automatically configured, similar to the PC-worlds Plug and
Play. -
Input/Output MATELRNAT0511CE REV. A
48
2.7 Slide 8-Rack Assignment
Input/Output
Rack Assignment
The rack is the first part of the address for an I/O signal
The following ground rules apply to assigning I/O rack numbers
Racks are numbered sequentially Process I/O is always rack 0 Model
A or Model B I/0 Starts at rack 1 PLC I/O is always rack 16
DeviceNet is always rack 81-84 ControlNet is always Rack 85/86Audio:
The rack is the first part of the address for an I/O signal.
The following ground rules apply to assigning I/O rack numbers:
Racks are numbered sequentially Process I/O is always rack 0 Model
A or Model B I/0 Starts at rack 1 PLC I/O is always rack 16
DeviceNet is always rack 81-84 and ControlNet is always rack 85
& 86. -
Input/Output MATELRNAT0511CE REV. A
49
2.8 Slide 9-Model A Rack
Input/Output
Model A — RackRack
Audio:
The rack is the physical location on which the input or output
process I/O board or modular I/O is mounted. Your system can
contain multiple racks. -
Input/Output MATELRNAT0511CE REV. A
50
2.9 Slide 10-Slot Assignment
Input/Output
Slot Assignment
The slot is the second part of the address for an I/O signal
The slot number distinguishes individual I/O modules on a
rackThe following rules apply to slot assignment Slot numbers are
assigned sequentially Valid numbers are 1 through 9, no letters The
first process I/O board is always assigned slot 1 Slot numbers
cannot be used twice in the same rackAudio:
The slot is the second part of the address for an I/O signal.
The slot number distinguishes individual I/O modules on a rack.The following rules apply to slot assignment: Slot numbers are
assigned sequentially Valid numbers are 1 through 9, no letters The
first process I/O board is always assigned slot 1 And slot numbers
cannot be used twice in the same rack. -
Input/Output MATELRNAT0511CE REV. A
51
2.10 Slide 11-Model A Slot Assignment
Audio:
The first opening within the Rack is for the Interface card. The
remaining slots are for the Input and Output cards.Here is an example of a model A I/O inside a controller.
-
Input/Output MATELRNAT0511CE REV. A
52
2.11 Slide 12-Starting Point/Channel Assignment
Input/Output
Starting Point/Channel Assignment
Starting points-digital signals The physical position on the I/O
module orprocess I/O board that identifies the first port in a range
Channel-Analog Signals Physical position of the port on a
process I/O Terminal number for modular I/OAudio:
Starting points for digital signals are the physical position on
the I/O module or process I/O board that identifies the first point
in a range.Analog Signals use channels that are the physical position of
the port on a process I/O board or a terminal number for I/O
card. -
Input/Output MATELRNAT0511CE REV. A
53
2.12 Slide 13-Model A-Starting Point Assignment
Input/Output
Model A — Starting Point Assignment
I/O Signal Connections
Audio:
This is an example of a digital I/O card. It has 16 inputs or
outputs. The signal terminals are labeled A0 through A7 and B0
through B7. Digital input/output one is terminal A0. Digital input
2 is terminal A1, continuing through the first 8 input/outputs.
Digital input 9 is terminal B0, and the remaining input/outputs
continue on terminals B1 through B7. The schematic diagram
indicates the proper wiring for power, ground and connection for
each input/output signal. -
Input/Output MATELRNAT0511CE REV. A
54
2.13 Slide 14-Configuring I/O
-
Input/Output MATELRNAT0511CE REV. A
55
Audio: We are now ready to Configure Digital I/O:
1 Press the key and select I/O.
2 Then press the [TYPE] key and select Digital you will see the
following screen.3 The IN/OUT key will let you toggle between Inputs and
Outputs.4 Now press the CONFIG Key to get to the configuration screen. 5
First set your range or the number of ports you want to configure.
In this example we willchange the range from 1 thru 64 to 1 thru 16.
6 Then cursor over and assign the Rack, Slot and Starting
Point.It is important that once you have completed your I/O
configuration that you power down the controller and power it back
up to get the changes to take effect.MENU
F2
F3
F1
-
Input/Output MATELRNAT0511CE REV. A
56
2.14 Slide 15-Configurig I/O Status
Audio:
The Status line describes the current status of the I/O.
ACTIVE — the assignment is valid and active.
INVALID the assignment is invalid based on the I/O hardware
present when the controller was turned ON. Invalid will appear when
you choose incorrect values for that modulePENDING — the assignment is valid, but not active.
UNASSIGNED — An assignment has not been made.
-
Input/Output MATELRNAT0511CE REV. A
57
2.15 Slide 16-Complementary Signals
Input/Output
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
F1 F2 F3 F4 F5
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
F1 F2 F3 F4 F5F1 F2 F3 F4 F5
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
F1 F2 F3 F4 F5F1 F2 F3 F4 F5
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
Complementary Signals
Audio:
If Output signals are configured as a complementary pair, a
command to turn that signal ON will also turn its paired output
OFF.In this example Digital Outputs 1 and 2 are setup to be
complementary. By manipulating Digital Output 1, we can also
manipulate Digital output 2.In this example the cursor is on Digit Output 1, we have turned
it OFF then Digital Output 2 will automatically turn ON. Only
outputs can be set as complementary pairs. So Digital Output 1 and
2 can be a paired together, then 3 and 4 together, 5 and 6 are
together and so on. -
Input/Output MATELRNAT0511CE REV. A
58
2.16 Slide 17-I/O Detail
Input/Output
F1 F2 F3 F4 F5Next
I/O Detail
Audio:
The I/O Detail key lets you name, set the polarity of and
configure complementary pairs for each Input or Output.Complementary pairs are always defined on the odd output.
To access the detail screen, from the I/O screen press the next
key then press the DETAIL key. To name the I/O, with the cursor on
the Comment line, press the key. To set the output to be
complementary, cursor down to Complementary and press the TRUE key.
You must power down the controller and power it back up to get the
changes to take effect.F4 ENTER
F4
-
Input/Output MATELRNAT0511CE REV. A
59
2.17 Slide 18-19-Monitoring/Controlling I/O
Input/Output
Monitoring/Controlling I/O
WARNING:
BEFORE FORCING A SIGNAL BE SURE THATIT IS SAFE TO DO SO.
SIGNALS SHOULD BE FORCED FOR TESTINGAND TROUBLESHOOTING PURPOSES
ONLY.AFTER COMPLETION OF TESTING OR TROUBLESHOOTING BE SURE TO RETURN
ALLI/O SIGNALS TO THEIR NORMAL CONDITION.
Audio:
BEFORE FORCING A SIGNAL BE SURE THAT IT IS SAFE TO DO SO.
SIGNALS SHOULD BE FORCED FOR TESTING AND TROUBLESHOOTING
PURPOSES ONLY.AFTER COMPLETION OF TESTING OR TROUBLESHOOTING BE SURE TO RETURN
ALLI/O SIGNALS TO THEIR NORMAL CONDITION.
-
Input/Output MATELRNAT0511CE REV. A
60
Input/Output
DO [1]
DO [2]
DO [3]
DO [4]
DO [5]
DO [6]
DO [7]
DO [8]
DO [9]
DO [10]
DO [11]F1 F2 F3 F4 F5
Monitoring/Controlling I/O
Audio:
The Teach Pendant can be used to monitor and control Input and
Output signals. Monitoring I/O is using the teach pendant to see
the I/O being manipulated in a program. Controlling I/O is turning
the signals ON or OFF manually. As seen in this example Digital
Outputs can be manually forced ON or OFF without being
simulated. -
Input/Output MATELRNAT0511CE REV. A
61
2.18 Slide 20-Simulating I/O
Input/Output
OFF
ON
F1 F2 F3 F4 F5
Simulating I/O
Audio:
Simulating a Input allows us to change the bit for the signal
without a signal actually going into or out of the controller.
Digital Input signals must be Simulated first and then the signal
can be manually forced ON or OFF. -
Input/Output MATELRNAT0511CE REV. A
62
2.19 Slide 21-Configuring Group I/O
Input/Output
Configuring Group I/O
F1 F2 F3 F4 F5
Power OFF then ON to enable changes.
Audio:
Group I/O is made up of a sequence of digital I/O signals that
is interpreted as a binary integer.When configuring group I/O, you first need to look at the
configuration of the I/O you want to group. In this example we will
configure Digital Outputs (DO) 1-16 to Group Output #1. To view the
configuration, go into the I/O screen and press CONFIG. Digital
Outputs 1-16 are assigned to Rack 1, Slot 1 and our starting point
will be 1. Now press the TYPE key to view the Group Outputs. Press
the CONFIG key to configure the Group Output.Insert Rack information from the Digital Outputs configuration,
in example, we used Rack 1, Slot 1 and Starting Point 1 and the
range of digital output we used is 16.Once you have configured your Group Outputs you must power down
the controller and power it back up to gets the changes to take
effect.F2
F2 F1
-
Input/Output MATELRNAT0511CE REV. A
63
2.20 Slide 22-Group Input/Output
Input/Output
Group Input/Output
2 3 5
Binary Bits
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
1 2 4 8 16
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
41 2 3 5
DO[1] DO[2] DO[3] DO[4] DO[5]
1: GO [1] = 21: GO [1] = 101: GO [1] = 17
Audio:
Once the Group I/O are configured you can manipulate multiple
I/O with binary bits.When Group Output #1 is set to 2 the Binary bit 2 is switched
ON.When Group Output #1 is set to 10 both Binary bits 2 and 8 are
switched ON.And when Group Output #1 is set to 17, Binary bits 1 and 16 are
switched ON.An example of using Group I/O might to turn ON multiple colors
of paint or turn on several items simultaneously by using one
number. -
Input/Output MATELRNAT0511CE REV. A
64
2.21 Slide 23-Input/Output Review
Input/Output
Input/Output Review
Robot Inputs and Outputs are signals between the robot and the
controller.An analog signal is an input or output voltage that has a range
of values within the I/O board or module that is being used.Digital signals can have only one of two possible states: ON or
OFF.Group I/O is made up of a sequence of digital I/O signals that
is interpreted as a binary integer.Click here to begin the Quiz
Audio:
In Review Robot Inputs and Outputs are signals between the robot
and the controller. An analog signal is an input or output voltage
that has a range of values within the I/O boardor module that is being used. Digital signals can have only one
of two possible states: ON or OFF. Group I/O is made up of a
sequence of digital I/O signals that is interpreted as a binaryinteger. This concludes the Input/Output Module. The next four
slides will provide you theopportunity to test your knowledge and comprehension.
-
System R-J3, R-J3iB & R-30iA
65Program Instruction 3
3 PROGRAM INSTRUCTION
Program Instructions
Program Instructions
Audio:
Welcome to the Program Instructions Module
-
Program Instruction MATELRNAT0511CE REV. A
66
3.1 Slide 2-Module Content
Program Instructions
Module Content
Data Register Position Register Instruction Branching
InstructionsLabel Unconditional
JMP LBL CALL
Conditional Wait Instructions Miscellaneous Instructions
Remark Override Message Timer
Audio
This module will cover Data Registers, Position Register
Instruction, Unconditional and Conditional Branching,Wait Instructions and Miscellaneous Instructions which are
Remark, Override, Message and Timer -
Program Instruction MATELRNAT0511CE REV. A
67
3.2 Slide 3-Data Register
Program Instructions
Data Register
Registers are used to store numbers
Numbers can be used for arithmetic operations, track part count,
cycle count,May contain group I/O data Default number of registers is 32
Can be changed during initial setup or during control start
Direct vs Indirect
Direct R[3]= 2
Indirect R [R [3] ] = 5
Internal Register
External RegisterR[R[3]=2] or R[2]
Audio:
Registers are very powerful programming tools. When used
correctly, registers can be utilized as counter, to set program
flags, or to adjust program speed. A register stores one number.
The default number of registers is 32, however up to 999 registers
are available.Many instructions employ direct or indirect addressing
techniques. When direct addressing is used, the actual value is
entered into the instruction. For example, if the register
instruction R[3]= 2 is used, the current contents of register 3 is
replaced with the value 2.When indirect addressing is used, the instruction contains a
register within a register. This indicates that the actual value of
the internal register becomes the register number of the external
register. In the example shown Register 3 is the internal register
and statement shown (R[R[3]]) is the external register. Since in
the previous instruction value of the internal register 3 is 2, the
external register number addresses register 2 instead of register
3. Therefore, the result of the second instruction is that the
contents of the external register 2 is to be replaced with the
value 5.You can increase the number of registers during a controlled
start. -
Program Instruction MATELRNAT0511CE REV. A
68
3.3 Slide 4-Position Register Instructions
Program Instructions
POSITION REGISTER InstructionsPR[GRPn:x]=[value]
Audio:
Position registers can be used to store global positions, such
as a home or a maintenance position which contain x,y,z,w,p,r,
configuration.Position Registers allow positions to be predefined for shared
use by many programs.Position register instructions can manipulate the robot
positions. They include assignment, addition, and subtraction
instructions.The following is the instruction syntax
The Group number is needed if there is more than one group
defined. The x is the position register number direct or indirect.
For clarification of direct or indirect, refer to the slide
Register InstructionsThe value choices are LPOS which is the current Cartesian
coordinates in xyzwpr and configuration; JPOS which is Current
joint angles; UTOOL number is the Tool Frame; UFRAME number is the
User frame; PR number is the Position Register and P number is the
Position.The operator choices are addition, subtraction or carriage
return to terminate without adding an operatorThe maximum number of the same arithmetic operator you can have
in one instruction is 5. -
Program Instruction MATELRNAT0511CE REV. A
69
3.4 Slide 5-Position Register Element
Program Instructions
POSITION REGISTER Element PR [i, j]
Direct:Position Register element #
Indirect:Position register #= contents of R[x]
Indirect:Position register element #= contents of R[x]
Direct:Position Register element #For Cartesian Positions: For
Joint positions1=x 1=joint 12=y 2=joint 23=z 3=joint 34=w 4=joint
45=p 5=joint 56=r 6=joint 67=config n=joint n/PROG PREG_ELE 1: !POSITION REG VALUE 2:J P[1:ABOVE JOINT] 100%
FINE3:J P[2] 100% FINE 4: PR[1]=LPOS 5: PR[1,2]=600 6:L PR[1]
100.0inch/min FINE 7:J P[1:ABOVE JOINT] 100% FINE/ENDx, y, z, w, p, r, configx,600,z, w, p, r, config
Audio:
Position register element instructions manipulate a specific
position register element. A position register element is one
element of a specified position register. Where the designation for
i represents the position register number and the j represents the
position register element.The program example shown, line 4 is changing Position register
1 to equal the current Cartesian coordinates position in line 3
(x,y,z,w,p,r,config) as explained in the previous slide.Program line number 5 is using position register element 2 which
is y shown in the table, to equal 600.Program Line 6 will move the robot in a linear move to position
register 1 with 100 inches per minute travel speed and Fine
termination. -
Program Instruction MATELRNAT0511CE REV. A
70
3.5 Slide 6-Program Instructions
Program Instructions
Program Instructions
Instruction
1 Registers
2 I/O
3 IF/SELECT
4 WAIT
5 JMP/LBL
6 CALL
7 Miscellaneous
8 next page—
Instruction
1 Skip
2 Payload
3 Offset/Frames
4 Multiple control
5 Program control
6 MACRO
7 Tool Offset
8 next page—
Instruction
1 LOCK PREG
2 MONITOR/MON. END
3
4
5
6
7
8 next page—
Audio:
While creating or editing a program from the select menu, all
instructions can be displayed while the cursor is on the program
line number or at the END of the program. The function 1 key
labeled INSTRUCTION will provide a list as shown here. -
Program Instruction MATELRNAT0511CE REV. A
71
3.6 Slide 7-Branching Instructions
Program Instructions
Branching Instructions
1. Label Definition Instruction 2. Unconditional Branching
Instructions 3. Conditional Branching InstructionsAudio:
Starting with Branching instructions
Branching Instructions cause the program to branch, or jump,
from one place in a program to another. There are three kinds of
branching instructions:1. Label definition instruction
2. Unconditional branching instructions
3. Conditional branching instructions
-
Program Instruction MATELRNAT0511CE REV. A
72
3.7 Slide 8-Label Definition Instruction LBL[x]
Program Instructions
Label Definition Instruction LBL[x] LBL[x: comment]
Direct:Label number
Indirect:R[x] where label #= contents of R[x]
As many as 16 numbers, letters,
blank spaces, the punctuation ;, :, , , (, ), and the characters
* , _and @1: LBL [1]2: J P[2] 100% CNT803: L P[3] 2000mm/s CNT804: L P[4]
2000mm/s CNT805: L P[5] 2000mm/s CNT806: L P[2] 2000mm/s CNT807:
JMP LBL [1] ENDJMP LBL[x] Unconditional Branching Instruction
Audio:
A label marks the location in a program that is the destination
of a program branch. A label is defined using a label definition
instruction.A comment can be added to describe the label. After a label has
been defined, it can be used with conditional and unconditional
branching instructions.Use the Jump Label instruction to branch to the specified
label.Watch the program flow. When it reaches the Jump Label 1, the
program then looks for the label 1 to continue the program -
Program Instruction MATELRNAT0511CE REV. A
73
3.8 Slide 9-Unconditional Branch Call
Program Instructions
Unconditional Branch — CallCALL program
Name of Program
1: J P[2] 100% CNT802: J P[3] 2000mm/s CNT803: L P[4] 2000mm/s
CNT804: L P[5] 2000mm/s CNT805: L P[6] 2000mm/s CNT806: L P[2]
2000mm/s CNT807: CALL PROG2 8: L P[7] 2000mm/s CNT80ENDPROG1PROG1 JOINT 100%
1: J P[1] 100% CNT802: J P[2] 2000mm/s CNT803: L P[3] 2000mm/s
CNT804: L P[4] 2000mm/s CNT80ENDPROG2PROG2 JOINT 100%
Audio:
Another Branch instruction you could use is the CALL
instruction.The CALL program instruction causes the program to branch to
another program and execute it. When the called program finishes
executing, it returns automatically to the main program at the
first instruction after the call program instruction. It is not
necessary to add a call statement in the second program to return
back to the first program as it will automatically return when it
reaches the program END. -
Program Instruction MATELRNAT0511CE REV. A
74
3.9 Slide 10-Conditional Branching Instructions
Program Instructions
Conditional Branching Instructions
IF instructions — Branch to a specified label or program if
certain conditions are true. There are register IF instructions and
input/output IF instructions.SELECT instructions — Branch to one of several jump or call
instructions, depending on the value of a register.Audio:
Conditional branching instructions branch from one place to
another in a program, depending on whether certain conditions are
true. There are two kinds of conditional branching
instructions:IF instructions which branch to a specified label or program if
certain conditions are true. There are register IF instructions and
input/output IF instructions.And there is the SELECT instructions which branch to one of
several jump or call instructions, depending on the value of a
register. -
Program Instruction MATELRNAT0511CE REV. A
75
3.10 Slide 11-IF Register
Program Instructions
IF Register
IF R[x] [operator] [value] [action]Direct:
Register #
Indirect:R[x] where register #=
contents of R[x]
= equal
not equal
< less than
greater than or equal
constant value
R[x] where value = contents of R[x]
JMP LBL[x]
CALL program
Condition
IF R [1] = 1 AND R [2] = 2 AND DI [2] = ON, JMP LBL [2]
Audio:
Register IF instructions compare the value contained in a
register with another value and then take an action if the
comparison is true.For an IF instruction, conditions can be connecting using AND or
OR.Looking at the example shown, the IF is checking to see if
Register 1 is equal to 1 AND Register 2 is equal to 2 AND Digital
Input 2 is ON. When all three conditions are true, then the action
is to jump to label 2. -
Program Instruction MATELRNAT0511CE REV. A
76
3.11 Slide 12-Example #1 IF Register
Program Instructions
Example #1 IF Register
IF R[1] >= 3000 and R[2] = 5 and DI[2]=ON, JMP LBL [2]
R[1: Number of welds]R[2: Number of Tip Dresses]DI[2: Zone is
Clear]Audio:
In this example, Register 1 is tracking the number of welds
Register 2 is tracking the number of tip dresses
Digital Input 2 is used to determine if the Zone is clear
So If the number of welds in register 1 is greater than or equal
to 3000 and the caps have already been shaved or dressed more than
five times which is determined by the value in register 2 AND the
zone is clear which Digital Input [2] is equal to ON of other
equipment then jump to another part of the program to execute the
Cap Change program which means its time to change weld caps. -
Program Instruction MATELRNAT0511CE REV. A
77
3.12 Slide 13-Example #2 IF Register
Program Instructions
Example #2 IF Register
R[1: Number of parts on the pallet]R[2: Number pallets
stacked]DO[2: Request for Fork Truck]If R[1] >= 30 and R[2] = 5, JMP LBL [2]…LBL 2DO[2]=ON
Audio:
In example 2 IF the number of parts on the pallet is greater
than or equal to 30 which is determined by register 1 number value
indicates that the pallet is full AND the number of pallets stacked
in register 2 is equal to 5 then jump to another part of the
program to turn on the light beacon Digital Output [2] for the Fork
Truck indicating that these are ready to go. -
Program Instruction MATELRNAT0511CE REV. A
78
3.13 Slide 14-IF Input/Output
Program Instructions
IF Input/Output
IF [I/O] [operator] [value] [action]
DO[x]
DI[x]
RO[x]
RI[x]
SO[x]
SI[x]
UO[x]
UI[x]
= equal
not equalR[X]OnOffDO[x]DI[x]RO[x]RI[x]SO[x]SI[x]UO[x]UI[x]
JMP LBL[x]
CALL program
Condition
IF DI [10]=ON OR R [7]=R [8], JMP LBL [2]
Audio:
Input/output IF instructions compare an input or output value
with another value and take an action if the comparison is
true.You cannot mix the AND or OR operators in the same
operation.Here is an example of using an OR operator. The IF is checking
to see if Digital Input #10 is ON -OR- Register 7 has the same
value as Register 8. In the event one of the two conditions is
true, then the action will jump to label 2. -
Program Instruction MATELRNAT0511CE REV. A
79
3.14 Slide 15-Example #3 IF / OR
Program Instructions
Example #3 IF / OR
DO[10: Conveyor Running]R[7: Number of parts processed]R[8:
Maximum number of parts]LBL [1]…If DO[10] = OFF OR R[7] = R[8], JMP LBL [2]…JMP LBL
[1]LBL [2]ENDAudio:
In example 3, If the conveyor Digital Output [10] has been shut
off, or if the number of parts processed in register 7 equals the
number of parts needed in register 8, then the logic jumps to the
end of the program. Otherwise the program jumps back to the
beginning to continue to run until it processes all the parts
needed. -
Program Instruction MATELRNAT0511CE REV. A
80
3.15 Slide 16-IF Procedure
Audio:
This video will demonstration the steps to create an IF Register
program instructions.1 Select the program to be edited. 2 Arrow down to the End to
add the new Program Instruction or insert a new program line ifneeded.
3 Turn the Teach Pendant switch to the On position. 4 Press the
NEXT key to add the new Program Instruction5 Press key labeled INSTRUCTION 6 Arrow down to highlight the
IF/SELECT instruction7 Press to select the instruction 8 Select the appropriate
operator for the IF statement. This demonstration is using the
equaloperator, press to select it.
9 Press again to select Register statement 10 Select the
Register number for the IF instruction. This demonstration will use
a constantvalue to compare against Register 1
11 Enter in the constant value to compare with.
ENTER
ENTER
ENTER
F1
-
Program Instruction MATELRNAT0511CE REV. A
81
This completes a condition portion of the If statement. Arrow
down to select AND if you desire another condition3.16 Slide 17-You Try It IF Register
Audio:
Here you will need recall all the steps needed to create an IF
Register program instruction. -
Program Instruction MATELRNAT0511CE REV. A
82
3.17 Slide 18-SELECT Instructions
Program Instructions
SELECT Instructions
MAIN2:1:LBL[1]2: SELECT R[5:PRGSLCT]=1 CALL PROG13: =2 CALL
PROG24: =3 CALL PROG35: ELSE JMP LBL[1]L P[7] 2000mm/s CNT80ENDAudio:
A select instruction compares the value of a register with one
of several values and takes an action if the comparison is
true:If the value of the register equals one of the values, the jump
or call instruction associated with that value is executed.If the value of the register does not equal one of the values,
the jump or call instruction associated with the word ELSE is
executed.In the program example shown, once the program has captured a
valid number, it will execute this program once and then it will
move on to the next instruction. -
Program Instruction MATELRNAT0511CE REV. A
83
3.18 Slide 19-SELECT Instruction Procedure
Audio:
This video will demonstration all the steps that are needed to
call specific programs based on a Registers value utilizing the
SELECT branching instructions.1 Select and edit the program to add the instructions to. Tturn
on the teach pendant.2 Press the Next key to display the instruction choice.
3 Press Function 1 to select the instruction 4 Arrow down to
line 3 labeled IF/SELECT5 Press to select the instruction. All the IF and SELECT choices
will appear. You must press line 8 labeled next page to view the
SELECT instruction choices. We will use all three SELECT
instructions listed here to accomplish the task.6 Select the first item labeled SELECT Register equal to. 7
Enter register 5 8 Press Enter 9 Now select Constant 10 Within
Register 5, determine if the content contains the value 1. 11 If
the value is 1, then issue a CALL instruction to PROGRAM 1ENTER
SELECT
F1
-
Program Instruction MATELRNAT0511CE REV. A
84
12 To add additional branching instructions, we need to insert
two more select conditions.13 Arrow down to IF/SELECT and press 14 Once again, select NEXT
PAGE to view the SELECT instruction choices. 15 This time select
item 2 labeled equal 16 Now we will determine if Register 5,
contains the value 2. 17 Select the CALL instruction 18 If the
register 5 contains the value 2, select the program name PROG2 19
Now we will repeat the process to insert another CALL instruction
to Program namePROG 3
20 Now insert the ELSE JUMP LABEL
-
FANUC Robot series
R-30iB Mate CONTROLLER
MAINTENANCE MANUAL
MARETIBCN01121E REV. A 2013 FANUC Robotics America
CorporationAll Rights Reserved.
This publication contains proprietary information of FANUC
Robotics America Corporation furnished forcustomer use only. No other uses are authorized without the
express written permission ofFANUC Robotics America Corporation.
FANUC Robotics America Corporation 3900 W. Hamlin Road
Rochester Hills, Michigan 483093253
B-83525EN/01
-
Copyrights and Trademarks
This new publication contains proprietary information of FANUC
Robotics America Corporation furnished for customer use only. No
other uses are authorized without the express written permission of
FANUC Robotics America Corporation.The descriptions and specifications contained in this manual
were in effect at the time this manual was approved for printing.
FANUC Robotics America Corporation, hereinafter referred to as
FANUC Robotics, reserves the right to discontinue models at any
time or to change specifications or design without notice and
without incurring obligations.FANUC Robotics manuals present descriptions, specifications,
drawings, schematics, bills of material, parts, connections and/or
procedures for installing, disassembling, connecting, operating and
programming FANUC Robotics’ products and/or systems. Such systems
consist of robots, extended axes, robot controllers, application
software, the KAREL programming language, INSIGHT vision equipment,
and special tools.FANUC Robotics recommends that only persons who have been
trained in one or more approved FANUC Robotics Training Course(s)
be permitted to install, operate, use, perform procedures on,
repair, and/or maintain FANUC Robotics’ products and/or systems and
their respective components. Approved training necessitates that
the courses selected be relevant to the type of system installed
and application performed at the customer site.WARNING This equipment generates, uses, and can radiate
radiofrequency energy and if not installed and used in accordance
with the instruction manual, may cause interference to radio
communications. As temporarily permitted by regulation, it has not
been tested for compliance with the limits for Class A computing
devices pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference. Operation of the equipment in a residential area is
likely to cause interference, in which case the user, at his own
expense, will be required to take whatever measure may be required
to correct the interference. -
FANUC Robotics conducts courses on its systems and products on a
regularly scheduled basis at the company’s world headquarters in
Rochester Hills, Michigan. For additional information contactFANUC Robotics America Corporation Training Department 3900 W.
Hamlin Road Rochester Hills, Michigan 48309-3253www.fanucrobotics.com For customer assistance, including
Technical Support, Service, Parts & Part Repair, and Marketing
Requests, contact the Customer Resource Center, 24 hours a day, at
1-800-47-ROBOT (1-800-477-6268). International customers should
call 011-1-248-377-7159.Send your comments and suggestions about this manual to:
[email protected] Copyright 2013 by FANUC
Robotics America Corporation All Rights Reserved The information
illustrated or contained herein is not to be reproduced, copied,
downloaded, translated into another language, published in any
physical or electronic format, including internet, or transmitted
in whole or in part in any way without the prior written consent of
FANUC Robotics America Corporation. AccuStat, ArcTool, iRVision,
KAREL, PaintTool, PalletTool, SOCKETS, SpotTool, SpotWorks, and
TorchMate are Registered Trademarks of FANUC Robotics. FANUC
Robotics reserves all proprietary rights, including but not limited
to trademark and trade name rights, in the following names:
AccuAir, AccuCal, AccuChop, AccuFlow, AccuPath, AccuSeal, ARC Mate,
ARC Mate Sr., ARC Mate System 1, ARC Mate System 2, ARC Mate System
3, ARC Mate System 4, ARC Mate System 5, ARCWorks Pro, AssistTool,
AutoNormal, AutoTCP, BellTool, BODYWorks, Cal Mate, Cell Finder,
Center Finder, Clean Wall, DualARM, LR Tool, MIG Eye, MotionParts,
MultiARM, NoBots, Paint Stick, PaintPro, PaintTool 100, PAINTWorks,
PAINTWorks II, PAINTWorks III, PalletMate, PalletMate PC,
PalletTool PC, PayloadID, RecipTool, RemovalTool, Robo Chop, Robo
Spray, S-420i, S-430i, ShapeGen, SoftFloat, SOFT PARTS, SpotTool+,
SR Mate, SR ShotTool, SureWeld, SYSTEM R-J2 Controller, SYSTEM R-J3
Controller, SYSTEM R-J3iB Controller, SYSTEM R-J3iC Controller,
SYSTEM R-30iA Controller, SYSTEM R-30iB Controller, TCP Mate,
TorchMate, TripleARM, TurboMove, visLOC, visPRO-3D, visTRAC,
WebServer, WebTP, and YagTool. FANUC CORPORATION 2013No part of this manual may be reproduced in any form. All
specifications and designs are subject to change without
notice. -
Patents
One or more of the following U.S. patents might be related to
the FANUC Robotics products described in this manual. FANUC
Robotics America Corporation Patent List 4,630,567 4,639,878
4,707,647 4,708,175 4,708,580 4,942,539 4,984,745 5,238,029
5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944
5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687
5,737,218 5,823,389 5,853,027 5,887,800 5,941,679 5,959,425
5,987,726 6,059,092 6,064,168 6,070,109 6,086,294 6,122,062
6,147,323 6,204,620 6,243,621 6,253,799 6,285,920 6,313,595
6,325,302 6,345,818 6,356,807 6,360,143 6,378,190 6,385,508
6,425,177 6,477,913 6,490,369 6,518,980 6,540,104 6,541,757
6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773
6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978
7,266,422 7,399,363 FANUC CORPORATION Patent List 4,571,694
4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207
4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504
4,956,594 4,967,125 4,969,109 4,970,370 4,970,448 4,979,127
5,004,968 5,006,035 5,008,834 5,063,281 5,066,847 5,066,902
5,093,552 5,107,716 5,111,019 5,130,515 5,136,223 5,151,608
5,170,109 5,189,351 5,267,483 5,274,360 5,292,066 5,300,868
5,304,906 5,313,563 5,319,443 5,325,467 5,327,057 5,329,469
5,333,242 5,337,148 5,371,452 5,375,480 5,418,441 5,432,316
5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478
5,463,297 5,467,003 5,471,312 5,479,078 5,485,389 5,485,552
5,486,679 5,489,758 5,493,192 5,504,766 5,511,007 5,520,062
5,528,013 5,532,924 5,548,194 5,552,687 5,558,196 5,561,742
5,570,187 5,570,190 5,572,103 5,581,167 5,582,750 5,587,635
5,600,759 5,608,299 5,608,618 5,624,588 5,630,955 5,637,969
5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295
5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132
5,742,138 5,742,144 5,748,854 5,749,058 5,760,560 5,773,950
5,783,922 5,799,135 5,812,408 5,841,257 5,845,053 5,872,894
5,887,122 5,911,892 5,912,540 5,920,678 5,937,143 5,980,082
5,983,744 5,987,591 5,988,850 6,023,044 6,032,086 6,040,554
6,059,169 6,088,628 6,097,169 6,114,824 6,124,693 6,140,788
6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898
6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181
6,236,011 6,236,896 6,250,174 6,278,902 6,279,413 6,285,921
6,298,283 6,321,139 6,324,443 6,328,523 6,330,493 6,340,875
6,356,671 6,377,869 6,382,012 6,384,371 6,396,030 6,414,711
6,424,883 6,431,018 6,434,448 6,445,979 6,459,958 6,463,358
6,484,067 6,486,629 6,507,165 6,654,666 6,665,588 6,680,461
6,696,810 6,728,417 6,763,284 6,772,493 6,845,296 6,853,881
6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802
7,038,165 7,069,808 7,084,900 7,092,791 7,133,747 7,143,100
7,149,602 7,131,848 7,161,321 7,171,041 7,174,234 7,173,213
7,177,722 7,177,439 7,181,294 7,181,313 7,280,687 7,283,661
7,291,806 7,299,713 7,315,650 7,324,873 7,328,083 7,330,777
7,333,879 7,355,725 7,359,817 7,373,220 7,376,488 7,386,367
7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192
7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121 -
Conventions
WARNING Information appearing under the «WARNING» caption
concerns the protection of personnel. It is boxed and bolded to set
it apart from the surrounding text.CAUTION Information appearing under the «CAUTION» caption
concerns the protection of equipment, software, and data. It is
boxed and bolded to set it apart from the surrounding text.Note Information appearing next to NOTE concerns related
information or useful hints. -
Original Instructions
Before using the Robot, be sure to read the «FANUC Robot Safety
Manual (B-80687EN)» andunderstand the content.
x No part of this manual may be reproduced in any form. x All
specifications and designs are subject to change without
notice.The products in this manual are controlled based on Japans
Foreign Exchange andForeign Trade Law. The export from Japan may be subject to an
export license by thegovernment of Japan.
Further, re-export to another country may be subject to the
license of the government ofthe country from where the product is re-exported. Furthermore,
the product may also becontrolled by re-export regulations of the United States
government.Should you wish to export or re-export these products, please
contact FANUC for advice.The products in this manual are manufactured under strict
quality control. However, whenusing any of the products in a facility in which a serious
accident or loss is predicted due toa failure of the product, install a safety device.
In this manual we have tried as much as possible to describe all
the various matters.However, we cannot describe all the matters which must not be
done, or which cannot bedone, because there are so many possibilities.
Therefore, matters which are not especially described as
possible in this manual should beregarded as impossible.
-
Safety
i
FANUC Robotics is not and does not represent itself as an expert
in safety systems, safety equipment, or the specific safety aspects
of your company and/or its work force. It is the responsibility of
the owner, employer, or user to take all necessary steps to
guarantee the safety of all personnel in the workplace.The appropriate level of safety for your application and
installation can be best determined by safety system professionals.
FANUC Robotics therefore, recommends that each customer consult
with such professionals in order to provide a workplace that allows
for the safe application, use, and operation of FANUC Robotics
systems.According to the industry standard ANSI/RIA R15-06, the owner or
user is advised to consult the standards to ensure compliance with
its requests for Robotics System design, usability, operation,
maintenance, and service. Additionally, as the owner, employer, or
user of a robotic system, it is your responsibility to arrange for
the training of the operator of a robot system to recognize and
respond to known hazards associated with your robotic system and to
be aware of the recommended operating procedures for your
particular application and robot installation.Ensure that the robot being used is appropriate for the
application. Robots used in classified (hazardous) locations must
be certified for this use.FANUC Robotics therefore, recommends that all personnel who
intend to operate, program, repair, or otherwise use the robotics
system be trained in an approved FANUC Robotics training course and
become familiar with the proper operation of the system. Persons
responsible for programming the systemincluding the design,
implementation, and debugging of application programsmust be
familiar with the recommended programming procedures for your
application and robot installation.The following guidelines are provided to emphasize the
importance of safety in the workplace.CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION
Safety is essential whenever robots are used. Keep in mind the
following factors with regard to safety:The safety of people and equipment Use of safety enhancing
devices Techniques for safe teaching and manual operation of the
robot(s) Techniques for safe automatic operation of the robot(s)
Regular scheduled inspection of the robot and workcell Proper
maintenance of the robot -
Safety
ii
Keeping People Safe
The safety of people is always of primary importance in any
situation. When applying safety measures to your robotic system,
consider the following:External devices Robot(s) Tooling Workpiece
Using Safety Enhancing Devices
Always give appropriate attention to the work area that
surrounds the robot. The safety of the work area can be enhanced by
the installation of some or all of the following devices:Safety fences, barriers, or chains Light curtains Interlocks
Pressure mats Floor markings Warning lights Mechanical stops
EMERGENCY STOP buttons DEADMAN switchesSetting Up a Safe Workcell
A safe workcell is essential to protect people and equipment.
Observe the following guidelines to ensure that the workcell is set
up safely. These suggestions are intended to supplement and not
replace existing federal, state, and local laws, regulations, and
guidelines that pertain to safety.Sponsor your personnel for training in approved FANUC Robotics
training course(s) related to your application. Never permit
untrained personnel to operate the robots.Install a lockout device that uses an access code to prevent
unauthorized persons from operating the robot.Use antitiedown logic to prevent the operator from bypassing
safety measures. Arrange the workcell so the operator faces the
workcell and can see what is going oninside the cell.
Clearly identify the work envelope of each robot in the system
with floor markings, signs, and special barriers. The work envelope
is the area defined by the maximum motion range of the robot,
including any tooling attached to the wrist flange that extend this
range.Position all controllers outside the robot work envelope.
-
Safety
iii
Never rely on software or firmware based controllers as the
primary safety element unless they comply with applicable current
robot safety standards.Mount an adequate number of EMERGENCY STOP buttons or switches
within easy reach of the operator and at critical points inside and
around the outside of the workcell.Install flashing lights and/or audible warning devices that
activate whenever the robot is operating, that is, whenever power
is applied to the servo drive system. Audible warning devices shall
exceed the ambient noise level at the enduse application.Wherever possible, install safety fences to protect against
unauthorized entry by personnel into the work envelope.Install special guarding that prevents the operator from
reaching into restricted areas of the work envelope.Use interlocks. Use presence or proximity sensing devices such
as light curtains, mats, andcapacitance and vision systems to enhance safety.
Periodically check the safety joints or safety clutches that can
be optionally installed between the robot wrist flange and tooling.
If the tooling strikes an object, these devices dislodge, remove
power from the system, and help to minimize damage to the tooling
and robot.Make sure all external devices are properly filtered, grounded,
shielded, and suppressed to prevent hazardous motion due to the
effects of electromagnetic interference (EMI), radio frequency
interference (RFI), and electrostatic discharge (ESD).Make provisions for power lockout/tagout at the controller.
Eliminate pinch points. Pinch points are areas where personnel
could get trappedbetween a moving robot and other equipment.
Provide enough room inside the workcell to permit personnel to
teach the robot and perform maintenance safely.Program the robot to load and unload material safely. If high
voltage electrostatics are present, be sure to provide appropriate
interlocks,warning, and beacons.
If materials are being applied at dangerously high pressure,
provide electrical interlocks for lockout of material flow and
pressure.Staying Safe While Teaching or Manually Operating the Robot
Advise all personnel who must teach the robot or otherwise
manually operate the robot to observe the following rules:Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.Know whether or not you are using an intrinsically safe teach
pendant if you are working in a hazardous environment. -
Safety
iv
Before teaching, visually inspect the robot and work envelope to
make sure that no potentially hazardous conditions exist. The work
envelope is the area defined by the maximum motion range of the
robot. These include tooling attached to the wrist flange that
extends this range.The area near the robot must be clean and free of oil, water, or
debris. Immediately report unsafe working conditions to the
supervisor or safety department.FANUC Robotics recommends that no one enter the work envelope of
a robot that is on, except for robot teaching operations. However,
if you must enter the work envelope, be sure all safeguards are in
place, check the teach pendant DEADMAN switch for proper operation,
and place the robot in teach mode. Take the teach pendant with you,
turn it on, and be prepared to release the DEADMAN switch. Only the
person with the teach pendant should be in the work envelope.WARNING
Never bypass, strap, or otherwise deactivate a safety device,
such as a limit switch, for any operational convenience.
Deactivating a safety device is known to have resulted in serious
injury and death.Know the path that can be used to escape from a moving robot;
make sure the escape path is never blocked.Isolate the robot from all remote control signals that can cause
motion while data is being taught.Test any program being run for the first time in the following
manner:WARNING
Stay outside the robot work envelope whenever a program is being
run. Failure to do so can result in injury.— Using a low motion speed, single step the program for at least
one full cycle. — Using a low motion speed, test run the program
continuously for at least onefull cycle.
— Using the programmed speed, test run the program continuously
for at least one full cycle.Make sure all personnel are outside the work envelope before
running production. Staying Safe During Automatic OperationAdvise all personnel who operate the robot during production to
observe the following rules:Make sure all safety provisions are present and active.
-
Safety
v
Know the entire workcell area. The workcell includes the robot
and its work envelope, plus the area occupied by all external
devices and other equipment with which the robot interacts.Understand the complete task the robot is programmed to perform
before initiating automatic operation.Make sure all personnel are outside the work envelope before
operating the robot. Never enter or allow others to enter the work
envelope during automatic operation ofthe robot.
Know the location and status of all switches, sensors, and
control signals that could cause the robot to move.Know where the EMERGENCY STOP buttons are located on both the
robot control and external control devices. Be prepared to press
these buttons in an emergency.Never assume that a program is complete if the robot is not
moving. The robot could be waiting for an input signal that will
permit it to continue its activity.If the robot is running in a pattern, do not assume it will
continue to run in the same pattern.Never try to stop the robot, or break its motion, with your
body. The only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel, teach
pendant, or emergency stop stations around the workcell.Staying Safe During Inspection
When inspecting the robot, be sure to
Turn off power at the controller. Lock out and tag out the power
source at the controller according to the policies ofyour plant.
Turn off the compressed air source and relieve the air pressure.
If robot motion is not needed for inspecting the electrical
circuits, press theEMERGENCY STOP button on the operator panel.
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.If power is needed to check the robot motion or electrical
circuits, be prepared to press the EMERGENCY STOP button, in an
emergency.Be aware that when you remove a servomotor or brake, the
associated robot arm will fall if it is not supported or resting on
a hard stop. Support the arm on a solid support before you release
the brake.Staying Safe During Maintenance
When performing maintenance on your robot system, observe the
following rules:Never enter the work envelope while the robot or a program is in
operation. Before entering the work envelope, visually inspect the
workcell to make sure nopotentially hazardous conditions exist.
-
Safety
vi
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.Consider all or any overlapping work envelopes of adjoining
robots when standing in a work envelope.Test the teach pendant for proper operation before entering the
work envelope. If it is necessary for you to enter the robot work
envelope while power is turned on,you must be sure that you are in control of the robot. Be sure
to take the teach pendant with you, press the DEADMAN switch, and
turn the teach pendant on. Be prepared to release the DEADMAN
switch to turn off servo power to the robot immediately.Whenever possible, perform maintenance with the power turned
off. Before you open the controller front panel or enter the work
envelope, turn off and lock out the 3phase power source at the
controller.Be aware that when you remove a servomotor or brake, the
associated robot arm will fall if it is not supported or resting on
a hard stop. Support the arm on a solid support before you release
the brake.WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to avoid
electrical shock. HIGH VOLTAGE IS PRESENT at the input side
whenever the controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes power
from the output side of the device only.Release or block all stored energy. Before working on the
pneumatic system, shut off the system air supply and purge the air
lines.Isolate the robot from all remote control signals. If
maintenance must be done when the power is on, make sure the person
inside the work envelope has sole control of the robot. The teach
pendant must be held by this person.Make sure personnel cannot get trapped between the moving robot
and other equipment. Know the path that can be used to escape from
a moving robot. Make sure the escape route is never blocked.Use blocks, mechanical stops, and pins to prevent hazardous
movement by the robot. Make sure that such devices do not create
pinch points that could trap personnel.WARNING
Do not try to remove any mechanical component from the robot
before thoroughly reading and understanding the procedures in the
appropriate manual. Doing so can result in serious personal injury
and component destruction. -
Safety
vii
Be aware that when you remove a servomotor or brake, the
associated robot arm will fall if it is not supported or resting on
a hard stop. Support the arm on a solid support before you release
the brake.When replacing or installing components, make sure dirt and
debris do not enter the system.Use only specified parts for replacement. To avoid fires and
damage to parts in the controller, never use nonspecified
fuses.Before restarting a robot, make sure no one is inside the work
envelope; be sure that the robot and all external devices are
operating normally.KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE
Certain programming and mechanical measures are useful in
keeping the machine tools and other external devices safe. Some of
these measures are outlined below. Make sure you know all
associated measures for safe use of such devices.Programming Safety Precautions
Implement the following programming safety measures to prevent
damage to machine tools and other external devices.Backcheck limit switches in the workcell to make sure they do
not fail. Implement failure routines in programs that will provide
appropriate robot actionsif an external device or another robot in the workcell
fails.Use handshaking protocol to synchronize robot and external
device operations. Program the robot to check the condition of all
external devices during an operatingcycle.
Mechanical Safety Precautions
Implement the following mechanical safety measures to prevent
damage to machine tools and other external devices.Make sure the workcell is clean and free of oil, water, and
debris. Use DCS (Dual Check Safety), software limits, limit
switches, and mechanical hardstops to preventundesired movement of the robot into the work area of machine
tools and external devices. -
Safety
viii
KEEPING THE ROBOT SAFE
Observe the following operating and programming guidelines to
prevent damage to the robot.Operating Safety Precautions
The following measures are designed to prevent damage to the
robot during operation.Use a low override speed to increase your control over the robot
when jogging the robot.Visualize the movement the robot will make before you press the
jog keys on the teach pendant.Make sure the work envelope is clean and free of oil, water, or
debris. Use circuit breakers to guard against electrical
overload.Programming Safety Precautions
The following safety measures are designed to prevent damage to
the robot during programming:Establish interference zones to prevent collisions when two or
more robots share a work area.Make sure that the program ends with the robot near or at the
home position. Be aware of signals or other operations that could
trigger operation of toolingresulting in personal injury or equipment damage.
In dispensing applications, be aware of all safety guidelines
with respect to the dispensing materials.NOTE: Any deviation from the methods and safety practices
described in this manual must conform to the approved standards of
your company. If you have questions, see your supervisor.ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT
INSTALLATIONSProcess technicians are sometimes required to enter the paint
booth, for example, during daily or routine calibration or while
teaching new paths to a robot. Maintenance personnel also must work
inside the paint booth periodically.Whenever personnel are working inside the paint booth,
ventilation equipment must be used. Instruction on the proper use
of ventilating equipment usually is provided by the paint shop
supervisor. -
Safety
ix
Although paint booth hazards have been minimized, potential
dangers still exist. Therefore, todays highly automated paint booth
requires that process and maintenance personnel have full awareness
of the system and its capabilities. They must understand the
interaction that occurs between the vehicle moving along the
conveyor and the robot(s), hood/deck and door opening devices, and
highvoltage electrostatic tools.CAUTION Ensure that all ground cables remain connected. Never
operate the paint robot with ground provisions disconnected.
Otherwise, you could injure personnel or damage equipment.Paint robots are operated in three modes:
Teach or manual mode Automatic mode, including automatic and
exercise operation Diagnostic mode During both teach and automatic
modes, the robots in the paint booth will follow a predetermined
pattern of movements. In teach mode, the process technician teaches
(programs) paint paths using the teach pendant.In automatic mode, robot operation is initiated at the System
Operator Console (SOC) or Manual Control Panel (MCP), if available,
and can be monitored from outside the paint booth. All personnel
must remain outside of the booth or in a designated safe area
within the booth whenever automatic mode is initiated at the SOC or
MCP.In automatic mode, the robots will execute the path movements
they were taught during teach mode, but generally at production
speeds.When process and maintenance personnel run diagnostic routines
that require them to remain in the paint booth, they must stay in a
designated safe area.Paint System Safety Features
Process technicians and maintenance personnel must become
totally familiar with the equipment and its capabilities. To
minimize the risk of injury when working near robots and related
equipment, personnel must comply strictly with the procedures in
the manuals.This section provides information about the safety features that
are included in the paint system and also explains the way the
robot interacts with other equipment in the system.The paint system includes the following safety features:
Most paint booths have red warning beacons that illuminate when
the robots are armed and ready to paint. Your booth might have
other kinds of indicators. Learn what these are. -
Safety
x
Some paint booths have a blue beacon that, when illuminated,
indicates that the electrostatic devices are enabled. Your booth
might have other kinds of indicators. Learn what these are.EMERGENCY STOP buttons are located on the robot controller and
teach pendant. Become familiar with the locations of all ESTOP
buttons.An intrinsically safe teach pendant is used when teaching in
hazardous paint atmospheres.A DEADMAN switch is located on each teach pendant. When this
switch is held in, and the teach pendant is on, power is applied to
the robot servo system. If the engaged DEADMAN switch is released
or pressed harder during robot operation, power is removed from the
servo system, all axis brakes are applied, and the robot comes to
an EMERGENCY STOP. Safety interlocks within the system might also
ESTOP other robots.WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is released
on a bypassed robot.Overtravel by robot axes is prevented by software limits. All of
the major and minor axes are governed by software limits. DCS (Dual
Check Safety), limit switches and hardstops also limit travel by
the major axes.EMERGENCY STOP limit switches and photoelectric eyes might be
part of your system. Limit switches, located on the entrance/exit
doors of each booth, will EMERGENCY STOP all equipment in the booth
if a door is opened while the system is operating in automatic or
manual mode. For some systems, signals to these switches are
inactive when the switch on the SOC is in teach mode.When present, photoelectric eyes are sometimes used to monitor
unauthorized intrusion through the entrance/exit silhouette
openings.System status is monitored by computer. Severe conditions result
in automatic system shutdown.Staying Safe While Operating the Paint Robot
When you work in or near the paint booth, observe the following
rules, in addition to all rules for safe operation that apply to
all robot systems.WARNING
Observe all safety rules and guidelines to avoid injury.
-
Safety
xi
WARNING
Never bypass, strap, or otherwise deactivate a safety device,
such as a limit switch, for any operational convenience.
Deactivating a safety device is known to have resulted in serious
injury and death.WARNING Enclosures shall not be opened unless the area is known
to be nonhazardous or all power has been removed from devices
within the enclosure. Power shall not be restored after the
enclosure has been opened until all combustible dusts have been
removed from the interior of the enclosure and the enclosure
purged. Refer to the Purge chapter for the required purge time.Know the work area of the entire paint station (workcell). Know
the work envelope of the robot and hood/deck and door opening
devices. Be aware of overlapping work envelopes of adjacent robots.
Know where all red, mushroomshaped EMERGENCY STOP buttons are
located. Know the location and status of all switches, sensors,
and/or control signals thatmight cause the robot, conveyor, and opening devices to
move.Make sure that the work area near the robot is clean and free of
water, oil, and debris. Report unsafe conditions to your
supervisor.Become familiar with the complete task the robot will perform
BEFORE starting automatic mode.Make sure all personnel are outside the paint booth before you
turn on power to the robot servo system.Never enter the work envelope or paint booth before you turn off
power to the robot servo system.Never enter the work envelope during automatic operation unless
a safe area has been designated.Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.Remove all metallic objects, such as rings, watches, and belts,
before entering a booth when the electrostatic devices are
enabled.Stay out of areas where you might get trapped between a moving
robot, conveyor, or opening device and another object.Be aware of signals and/or operations that could result in the
triggering of guns or bells.Be aware of all safety precautions when dispensing of paint is
required. Follow the procedures described in this manual. -
Safety
xii
Special Precautions for Combustible Dusts (Powder Paint) When
the robot is used in a location where combustible dusts are found,
such as the application of powder paint, the following special
precautions are required to insure that there are no combustible
dusts inside the robot.Purge maintenance air should be maintained at all times, even
when the robot power is off. This will insure that dust can not
enter the robot.A purge cycle will not remove accumulated dusts. Therefore, if
the robot is exposed to dust when maintenance air is not present,
it will be necessary to remove the covers and clean out any
accumulated dust. Do not energize the robot until you have
performed the following steps.1. Before covers are removed, the exterior of the robot should
be cleaned to remove accumulated dust.2. When cleaning and removing accumulated dust, either on the
outside or inside of the robot, be sure to use methods appropriate
for the type of dust that exists. Usually lint free rags dampened
with water are acceptable. Do not use a vacuum cleaner to remove
dust as it can generate static electricity and cause an explosion
unless special precautions are taken.3. Thoroughly clean the interior of the robot with a lint free
rag to remove any accumulated dust.4. When the dust has been removed, the covers must be replaced
immediately. 5. Immediately after the covers are replaced, run a
complete purge cycle. The robot cannow be energized.
Staying Safe While Operating Paint Application Equipment When
you work with paint application equipment, observe the following
rules, in addition to all rules for safe operation that apply to
all robot systems.WARNING When working with electrostatic paint equipment, follow
all national and local codes as well as all safety guidelines
within your organization. Also reference the following standards:
NFPA 33 Standards for Spray Application Using Flammable or
Combustible Materials, and NFPA 70 National Electrical Code.Grounding: All electrically conductive objects in the spray area
must be grounded. This includes the spray booth, robots, conveyors,
workstations, part carriers, hooks, paint pressure pots, as well as
solvent containers. Grounding is defined as the object or objects
shall be electrically connected to ground with a resistance of not
more than 1 megohms.High Voltage: High voltage should only be on during actual spray
operations. Voltage should be off when the painting process is
completed. Never leave high voltage on during a cap cleaning
process.Avoid any accumulation of combustible vapors or coating matter.
Follow all manufacturer recommended cleaning procedures. Make sure
all interlocks are operational. -
Safety
xiii
No smoking. Post all warning signs regarding the electrostatic
equipment and operation ofelectrostatic equipment according to NFPA 33 Standard for Spray
Application Using Flammable or Combustible Material.Disable all air and paint pressure to bell. Verify that the
lines are not under pressure.Staying Safe During Maintenance
When you perform maintenance on the painter system, observe the
following rules, and all other maintenance safety rules that apply
to all robot installations. Only qualified, trained service or
maintenance personnel should perform repair work on a robot.Paint robots operate in a potentially explosive environment. Use
caution when working with electric tools.When a maintenance technician is repairing or adjusting a robot,
the work area is under the control of that technician. All
personnel not participating in the maintenance must stay out of the
area.For some maintenance procedures, station a second person at the
control panel within reach of the EMERGENCY STOP button. This
person must understand the robot and associated potential
hazards.Be sure all covers and inspection plates are in good repair and
in place. Always return the robot to the home position before you
disarm it. Never use machine power to aid in removing any component
from the robot. During robot operations, be aware of the robots
movements. Excess vibration,unusual sounds, and so forth, can alert you to potential
problems.Whenever possible, turn off the main electrical disconnect
before you clean the robot. When using vinyl resin observe the
following:— Wear eye protection and protective gloves during application
and removal. — Adequate ventilation is required. Overexposure could
cause drowsiness orskin and eye irritation.
— If there is contact with the skin, wash with water. — Follow
the Original Equipment Manufacturers Material Safety Data
Sheets.When using paint remover observe the following: — Eye
protection, protective rubber gloves, boots, and apron are
requiredduring booth cleaning.
— Adequate ventilation is required. Overexposure could cause
drowsiness. — If there is contact with the skin or eyes, rinse with
water for at least 15minutes. Then seek medical attention as soon as possible.
— Follow the Original Equipment Manufacturers Material Safety
Data Sheets. -
B-83525EN/01 SAFETY PRECAUTIONS
s-1
SAFETY PRECAUTIONS
Thank you for purchasing FANUC Robot. This chapter describes the
precautions which must be observed to ensure the safe use of the
robot. Before attempting to use the robot, be sure to read this
chapter thoroughly. Before using the functions related to robot
operation, read the relevant operator’s manual to become familiar
with those functions. If any description in this chapter differs
from that in the other part of this manual, the description given
in this chapter shall take precedence. For the safety of the
operator and the system, follow all safety precautions when
operating a robot and its peripheral devices installed in a work
cell. In addition, refer to the FANUC Robot SAFETY HANDBOOK
(B-80687EN).1 WORKING PERSON The personnel can be classified as follows.
Operator: x Turns robot controller power ON/OFF x Starts robot
program from operators panel Programmer or teaching operator: x
Operates the robot x Teaches robot inside the safety fence
Maintenance engineer: x Operates the robot x Teaches robot inside
the safety fence x Maintenance (adjustment, replacement)— An operator cannot work inside the safety fence. — A
programmer, teaching operator, and maintenance engineer can work
inside the safety fence. Theworking activities inside the safety fence include lifting,
setting, teaching, adjusting, maintenance, etc..— To work inside the fence, the person must be trained on proper
robot operation. During the operation, programming, and maintenance
of your robotic system, the programmer, teaching operator, and
maintenance engineer should take additional care of their safety by
using the following safety precautions. — Use adequate clothing or
uniforms during system operation — Wear safety shoes — Use
helmet -
SAFETY PRECAUTIONS B-83525EN/01
s-2
2 NOTATION OF WARNING, CAUTION and NOTE
This manual contains safety precautions against injury and
property damage. Those precautions are labeled Warning or Caution,
according to the degree of importance. Supplementary explanation is
given under Note. Before starting to use a robot, carefully read
the Warning, Caution, and Note.WARNING Failure to follow the instruction given under Warning
can cause fatal or seriousinjury to the user. This information is indicated in bold type
in a box so that it can be easily distinguished from the main body
of this manual.CAUTION Failure to follow the instruction given under Caution
can cause injury to theuser or property damage. This information is indicated in a box
so that it can be easily distinguished from the main body of this
manual.NOTE The information given under Note is a supplementary
explanation, which isneither a warning nor a caution. Carefully read and save this
manual.3 WORKING PERSON SAFETY Working person safety is the primary
safety consideration. Because it is very dangerous to enter the
operating space of the robot during automatic operation, adequate
safety precautions must be observed. The following lists the
general safety precautions. Careful consideration must be made to
ensure working person safety. (1) Have the robot system working
persons attend the training courses held by FANUC.FANUC provides various training courses. Contact our sales
office for details. (2) Even when the robot is stationary, it is
possible that the robot is still in a ready to move state, and
iswaiting for a signal. In this state, the robot is regarded as
still in motion. To ensure working person safety, provide the
system with an alarm to indicate visually or aurally that the robot
is in motion.(3) Install a safety fence with a gate so that no working person
can enter the work area without passing through the gate. Install
an interlocking device, a safety plug, and so forth in the safety
gate so that the robot is stopped as the safety gate is opened.The controller is designed to receive this interlocking signal
of the door switch. When the gate is opened and this signal
received, the controller stops the robot (Please refer to «STOP
TYPE OF ROBOT» in SAFETY PRECAUTIONS for detail of stop type). For
connection, see Fig.3 (b).(4) Provide the peripheral devices with appropriate grounding
(Class A, Class B, Class C, and Class D). -
B-83525EN/01 SAFETY PRECAUTIONS
s-3
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of
the robot motion, including the toolssuch as a hand. (7) Install a mat switch or photoelectric switch
on the floor with an interlock to a visual or aural alarmthat stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the
working person in charge can turn on thepower of the robot.
The circuit breaker installed in the controller is designed to
disable anyone from turning it on when it is locked with a
padlock.(9) When adjusting each peripheral device independently, be sure
to turn off the power of the robot (10) Operators should be
ungloved while manipulating the operators panel or teach pendant.
Operationwith gloved fingers could cause an operation error. (11)
Programs, system variables, and other information can be saved on
memory card or USB memories.Be sure to save the data periodically in case the data is lost
in an accident. (12) The robot should be transported and installed
by accurately following the procedures recommendedby FANUC. Wrong transportation or installation may cause the
robot to fall, resulting in severe injury to workers.(13) In the first operation of the robot after installation, the
operation should be restricted to low speeds. Then, the speed
should be gradually increased to check the operation of the
robot.(14) Before the robot is started, it should be checked that no
one is in the area of the safety fence. At the same time, a check
must be made to ensure that there is no risk of hazardous
situations. If detected, such a situation should be eliminated
before the operation.(15) When the robot is used, the following precautions should be
taken. Otherwise, the robot and peripheral equipment can be
adversely affected, or workers can be severely injured.— Avoid using the robot in a flammable environment. — Avoid
using the robot in an explosive environment. — Avoid using the
robot in an environment full of radiation. — Avoid using the robot
under water or at high humidities. — Avoid using the robot to carry
a person or animal. — Avoid using the robot as a stepladder. (Never
climb up on or hang from the robot.) (16) After connecting the
safety signals like external emergency stop signal and/or safety
fence signal,verify that,
All safety signals stop the robot as intended. There is no
mistake in connection of safety signals. -
SAFETY PRECAUTIONS B-83525EN/01
s-4
Fig.3 (a) Safety fence and safety gate
(Note) Connect EAS1 and EAS11, EAS2 and EAS21. Terminals
EAS1,EA11,EAS2,EAS21 are on the emergency stopboard.Fig.3 (b) Limit switch circuit diagram of the safety fence
3.1 OPERATOR SAFETY The operator is a person who operates the
robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply
to teach pendant operators. (1) If you do not have to operate the
robot, turn off the power of the robot controller or press theEMERGENCY STOP button, and then proceed with necessary work. (2)
Operate the robot system at a location outside of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker
other than the operator from enteringthe work area unexpectedly and to prevent the worker from
entering a dangerous area. (4) Install an EMERGENCY STOP button
within the operators reach. -
B-83525EN/01 SAFETY PRECAUTIONS
s-5
The robot controller is designed to be connected to an external
EMERGENCY STOP button. With this connection, the controller stops
the robot operation (Please refer to «STOP TYPE OF ROBOT» in SAFETY
PRECAUTIONS for detail of stop type), when the external EMERGENCY
STOP button is pressed. For connection, see Fir.3.1.(Note) Connect EES1 and EES11, EES2 and EES21. Terminals
EES1,EES11,EES2,EES21 are on the emergencystop board.Fig. 3.1 Connection Diagram for External Emergency Stop
Button3.2 SAFETY OF THE PROGRAMMER While teaching the robot, the
operator must enter the work area of the robot. The operator must
ensure the safety of the teach pendant operator especially. (1)
Unless it is specifically necessary to enter the robot work area,
carry out all tasks outside the area. (2) Before teaching the
robot, check that the robot and its peripheral devices are all in
the normaloperating condition. (3) If it is inevitable to enter the robot
work area to teach the robot, check the locations, settings,
andother conditions of the safety devices (such as the EMERGENCY
STOP button, the DEADMAN switch on the teach pendant) before
entering the area.(4) The programmer must be extremely careful not to let anyone
else enter the robot work area. (5) Programming should be done
outside the area of the safety fence as far as possible. If
programmingneeds to be done in the area of the safety fence, the programmer
should take the following precautions:— Before entering the area of the safety fence, ensure that
there is no risk of dangerous situations in the area.— Be prepared to press the emergency stop button whenever
necessary. — Robot motions should be made at low speeds. — Before
starting programming, check the entire system status to ensure that
no remote instruction tothe peripheral equipment or motion would be dangerous to the
user.The operator panel is provided with an emergency stop button and
a key switch (mode switch) for selecting theautomatic operation mode (AUTO) and the teach modes (T1 and T2).
Before entering the inside of the safetyfence for the purpose of teaching, set the switch to a teach
mode, remove the key from the mode switch to preventother people from changing the operation mode carelessly, then
open the safety gate. If the safety gate is openedwith the automatic operation mode set, the robot stops (Please
refer to «STOP TYPE OF ROBOT» in SAFETYPRECAUTIONS for detail of stop type). After the switch is set to
a teach mode, the safety gate is disabled. Theprogrammer should understand that the safety gate is disabled
and is responsible for keeping other people fromentering the inside of the safety fence.
-
SAFETY PRECAUTIONS B-83525EN/01
s-6
The teach pendant is provided with an enable/disable switch,
DEADMAN switch as well as an emergency stopbutton. These button and switch function as follows:
(1) Emergency stop button: Causes an emergency stop (Please
refer to «STOP TYPE OF ROBOT» in SAFETYPRECAUTIONS for detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the teach
pendant enable/disable switch settingstatus.
(a) Disable: The DEADMAN switch is disabled.
(b) Enable: Servo power is turned off when the operator releases
the DEADMAN switch or when theoperator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the
operator releases the teach pendant orpresses the pendant strongly in case of emergency. The R-30iB
Mate employs a 3-positionDEADMAN switch, which allows the robot to operate when the
3-position DEADMAN switch is pressedto its intermediate point. When the operator releases the
DEADMAN switch or presses the switchstrongly, the robot stops immediately.
Based on the risk assessment by FANUC, number of operation of
DEADMAN SW should not exceed about 10000times per year.
The operators intention of starting teaching is determined by
the controller through the dual operation of setting theteach pendant enable/disable switch to the enable position and
pressing the DEADMAN switch. The operatorshould make sure that the robot could operate in such conditions
and be responsible in carrying out tasks safely.The teach pendant, operator panel, and peripheral device
interface send each robot start signal. However thevalidity of each signal changes as follows depending on the mode
switch of the operator panel, the teach pendantenable/disable switch and the remote condition on the
software.Mode
Teach pendant
enable/disable
switch
Software
remote
condition
Teach pendant Operator panel Peripheral device
Local Not allowed Not allowed Not allowed On
Remote Not allowed Not allowed Not allowed
Local Not allowed Allowed to start Not allowed
AUTO
mode Off
Remote Not allowed Not allowed Allowed to start
Local Allowed to start Not allowed Not allowed On
Remote Allowed to start Not allowed Not allowed
Local Not allowed Not allowed Not allowed
T1, T2
mode Off
Remote Not allowed Not allowed Not allowed
T1,T2 mode: DEADMAN switch is effective.
(6) To start the system using the operators panel, make certain
that nobody is the robot work area and that there are no abnormal
conditions in the robot work area.(7) When a program is completed, be sure to carry out a test
operation according to the procedure below. (a) Run the program for
at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the
continuous operation mode at lowspeed. (c) Run the program for one operation cycle in the
continuous operation mode at the intermediatespeed and check that no abnormalities occur due to a delay in
timing. (d) Run the program for one operation cycle in the
continuous operation mode at the normaloperating speed and check that the system operates automatically
without trouble. (e) After checking the completeness of the program
through the test operation above, execute it inthe automatic operation mode. (8) While operating the system in
the automatic operation mode, the teach pendant operator shouldleave the robot work area.
-
B-83525EN/01 SAFETY PRECAUTIONS
s-7
3.3 SAFETY OF THE MAINTENANCE ENGINEER For the safety of
maintenance engineer personnel, pay utmost attention to the
following. (1) During operation, never enter the robot work area.
(2) A hazardous situation may arise when the robot or the system,
are kept with their power-on duringmaintenance operations. Therefore, for any maintenance
operation, the robot and the system should be put into the
power-off state. If necessary, a lock should be in place in order
to prevent any other person from turning on the robot and/or the
system. In case maintenance needs to be executed in the power-on
state, the emergency stop button must be pressed.(3) If it becomes necessary to enter the robot operation range
while the power is on, press the emergency stop button on the
operator panel, or the teach pendant before entering the range. The
maintenance personnel must indicate that maintenance work is in
progress and be careful not to allow other people to operate the
robot carelessly.(4) When entering the area enclosed by the safety fence, the
maintenance worker should check the entire system to make sure that
no dangerous situations are present. If the worker needs to enter
the area of the fence while a dangerous situation exists, the
worker should always take extreme care and check the current system
status.(5) Before the maintenance of the pneumatic system is started,
the supply pressure should be shut off and the pressure in the
piping should be reduced to zero.(6) Before the start of teaching, check that the robot and its
peripheral devices are all in the normal operating condition.(7) Do not operate the robot in the automatic mode while anybody
is in the robot work area. (8) When you maintain the robot
alongside a wall or instrument, or when multiple workers are
workingnearby, make certain that their escape path is not obstructed.
(9) When a tool is mounted on the robot, or when any moving device
other than the robot is installed,such as belt conveyor, pay careful attention to its motion. (10)
If necessary, have a worker who is familiar with the robot system
stand beside the operator paneland observe the work being performed. If any danger arises, the
worker should be ready to press the EMERGENCY STOP button at any
time.(11) When replacing a part, please contact FANUC service center.
If a wrong procedure is followed, an accident may occur, causing
damage to the robot and injury to the worker.(12) When replacing or reinstalling components, take care to
prevent foreign matter from entering the system.(13) When handling each unit or printed circuit board in the
controller during inspection, turn off the circuit breaker to
protect against electric shock.If there are two cabinets, turn off the both circuit breaker.
(14) A part should be replaced with a part recommended by FANUC. If
other parts are used, malfunctionor damage would occur. Especially, a fuse that is not
recommended by FANUC should not be used. Such a fuse may cause a
fire.(15) When restarting the robot system after completing
maintenance work, make sure in advance that there is no person in
the work area and that the robot and the peripheral devices are not
abnormal.(16) When a motor or brake is removed, the robot arm should be
supported with a crane or other equipment beforehand so that the
arm would not fall during the removal.(17) Whenever grease is spilled on the floor, it should be
removed as quickly as possible to prevent dangerous falls.(18) The following parts are heated. If a maintenance worker
needs to touch such a part in the heated state, the worker should
wear heat-resistant gloves or use other protective tools.— Servo motor — Inside the controller (19) Maintenance should be
done under suitable light. Care must be taken that the light would
not causeany danger.
-
SAFETY PRECAUTIONS B-83525EN/01
s-8
(20) When a motor, decelerator, or other heavy load is handled,
a crane or other equipment should be used to protect maintenance
workers from excessive load. Otherwise, the maintenance workers
would be severely injured.(21) The robot should not be stepped on or climbed up during
maintenance. If it is attempted, the robot would be adversely
affected. In addition, a misstep can cause injury to the
worker.(22) After the maintenance is completed, spilled oil or water
and metal chips should be removed from the floor around the robot
and within the safety fence.(23) When a part is replaced, all bolts and other related
components should put back into their original places. A careful
check must be given to ensure that no components are missing or
left unmounted.(24) In case robot motion is required during maintenance, the
following precautions should be taken : — Foresee an escape route.
And during the maintenance motion itself, monitor continuously
thewhole system so that your escape route will not become blocked
by the robot, or by peripheral equipment.— Always pay attention to potentially dangerous situations, and
be prepared to press the emergency stop button whenever
necessary.(25) The robot should be periodically inspected. (Refer to the
manual of the controller or mechanical unit.) A failure to do the
periodical inspection can adversely affect the performance or
service life of the robot and also may cause an accident.(26) After a part is replaced, a test operation should be given
for the robot according to a predetermined method. (See TESTING
section of Controller operators manual.) During the test operation,
the maintenance staff should work outside the safety fence.4 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
4.1 PRECAUTIONS IN PROGRAMMING (1) Use a limit switch or other
sensor to detect a dangerous condition and, if necessary, design
theprogram to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition
occurs in any other robots orperipheral devices, even though the robot itself is normal. (3)
For a system in which the robot and its peripheral devices are in
synchronous motion, particular caremust be taken in programming so that they do not interfere with
each other. (4) Provide a suitable interface between the robot and
its peripheral devices so that the robot can detectthe states of all devices in the system and can be stopped
according to the states.4.2 PRECAUTIONS FOR MECHANISM (1) Keep the component cells of
the robot system clean, and operate the robot in an environment
free ofgrease, water, and dust. (2) Dont use unconfirmed liquid for
cutting fluid and cleaning fluid. (3) Employ a limit switch or
mechanical stopper to limit the robot motion so that the robot or
cable doesnot strike against its peripheral devices or tools. (4) Observe
the following precautions about the mechanical unit cables. When
theses attentions are notkept, unexpected troubles might occur.
x Use mechanical unit cable that have required user interface. x
Dont add user cable or hose to inside of mechanical unit. x Please
do not obstruct the movement of the mechanical unit cable when
cables are added tooutside of mechanical unit.
-
B-83525EN/01 SAFETY PRECAUTIONS
s-9
x In the case of the model that a cable is exposed, Please do
not perform remodeling (Adding a protective cover and fix an
outside cable more) obstructing the behavior of the outcrop of the
cable.x Please do not interfere with the other parts of mechanical
unit when install equipments in the robot.(5) The frequent power-off stop for the robot during operation
causes the trouble of the robot. Please avoid the system
construction that power-off stop would be operated routinely.
(Refer to bad case example.) Please execute power-off stop after
reducing the speed of the robot and stopping it by hold stop or
cycle stop when it is not urgent. (Please refer to «STOP TYPE OF
ROBOT» in SAFETY PRECAUTIONS for detail of stop type.) (Bad case
example)x Whenever poor product is generated, a line stops by emergency
stop. x When alteration was necessary, safety switch is operated by
opening safety fence andpower-off stop is executed for the robot during operation.
x An operator pushes the emergency stop button frequently, and a
line stops. x An area sensor or a mat switch connected to safety
signal operate routinely and power-off stopis executed for the robot. (6) Robot stops urgently when
collision detection alarm (SRVO-050) etc. occurs. The frequent
urgentstop by alarm causes the trouble of the robot, too. So remove
the causes of the alarm.5 SAFETY OF THE ROBOT MECHANISM 5.1 PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an
appropriate speed so that the operator can manage the robot in any
eventuality.(2) Before pressing the jog key, be sure you know in advance
what motion the robot will perform in the jog mode.5.2 PRECAUTIONS IN PROGRAMMING (1) When the work areas of robots
overlap, make certain that the motions of the robots do not
interferewith each other. (2) Be sure to specify the predetermined work
origin in a motion program for the robot and program themotion so that it starts from the origin and terminates at the
origin. Make it possible for the operator to easily distinguish at
a glance that the robot motion hasterminated.
5.3 PRECAUTIONS FOR MECHANISMS (1) Keep the work areas of the
robot clean, and operate the robot in an environment free of
grease, water,and dust.
5.4 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN EMERGENCY OR
ABNORMAL SITUATIONSFor emergency or abnormal situations (e.g. persons trapped in or
by the robot), brake release unit can be used to move the robot
axes without drive power. Please refer to this manual and
mechanical unit operators manual for using method of brake release
unit and method of supporting robot. -
SAFETY PRECAUTIONS B-83525EN/01
s-10
6 SAFETY OF THE END EFFECTOR 6.1 PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators,
carefully consider the necessary time delay after issuing each
control command up to actual motion and ensure safe control.(2) Provide the end effector with a limit switch, and control
the robot system by monitoring the state of the end effector.7 STOP TYPE OF ROBOT The following three robot stop types
exist:Power-Off Stop (Category 0 following IEC 60204-1) Servo power is
turned off and the robot stops immediately. Servo power is turned
off when the robot is moving, and the motion path of the
deceleration is uncontrolled. The following processing is performed
at Power-Off stop. — An alarm is generated and servo power is
turned off. — The robot operation is stopped immediately. Execution
of the program is paused.Controlled stop (Category 1 following IEC 60204-1) The robot is
decelerated until it stops, and servo power is turned off. The
following processing is performed at Controlled stop. — The alarm
«SRVO-199 Controlled stop» occurs along with a decelerated stop.
Execution of theprogram is paused. — An alarm is generated and servo power is
turned off.Hold (Category 2 following IEC 60204-1) The robot is decelerated
until it stops, and servo power remains on. The following
processing is performed at Hold. — The robot operation is
decelerated until it stops. Execution of the program is paused.WARNING The stopping distance and stopping time of Controlled
stop are longer than thestopping distance and stopping time of Power-Off stop. A risk
assessment for the whole robot system, which takes into
consideration the increased stopping distance and stopping time, is
necessary when Controlled stop is used.When the E-Stop button is pressed or the FENCE is open, the stop
type of robot is Power-Off stop or Controlled stop. The
configuration of stop type for each situation is called stop
pattern. The stop pattern is different according to the controller
type or option configuration. -
B-83525EN/01 SAFETY PRECAUTIONS
s-11
There are the following 2 Stop patterns.
Stop
pattern Mode
E-Stop
button External E-Stop FENCE open SVOFF input
AUTO P-Stop P-Stop C-Stop C-Stop
T1 P-Stop P-Stop — C-Stop A
T2 P-Stop P-Stop — C-Stop
AUTO C-Stop C-Stop C-Stop C-Stop
T1 P-Stop P-Stop — C-Stop C
T2 P-Stop P-Stop — C-Stop
P-Stop: Power-Off stop C-Stop: Controlled stop -: Disable
WARNING In this manual, the term Emergency-stop is used for the
stop by above safetysignals. Please refer to above table for actual stop type. The
following table indicates the Stop pattern according to the
controller type or option configuration.Option Stop pattern
Standard A
Controlled stop by E-Stop
(A05B-2600-J570) C
The stop pattern of the controller is displayed in «Stop
pattern» line in software version screen. Please refer «Software
version» in operator’s manual of controller for the detail of
software version screen.«Controlled stop by E-Stop» option «Controlled stop by E-Stop»
option (A05B-2600-J570) is an optional function. When this option
is loaded, the stop type of the following alarms becomes Controlled
stop but only in AUTO mode. In T1 or T2 mode, the stop type is
Power-Off stop which is the normal operation of the system.Alarm Condition
SRVO-001 Operator panel E-stop Operator panel E-stop is
pressed.SRVO-002 Teach pendant E-stop Teach pendant E-stop is
pressed.SRVO-007 External emergency stops External emergency stop input
(EES1-EES11, EES2-EES21) isopen.
SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect
function, SSO[3] is OFF.SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect
function, SSO[4] is OFF.Controlled stop is different from Power-Off stop as follows: —
In Controlled stop, the robot is stopped on the program path. This
function is effective for a systemwhere the robot can interfere with other devices if it deviates
from the program path. — In Controlled stop, physical impact is
less than Power-Off stop. This function is effective forsystems where the physical impact to the mechanical unit or EOAT
(End Of Arm Tool) should be minimized.— The stopping distance and stopping time of Controlled stop is
longer than the stopping distance and stopping time of Power-Off
stop, depending on the robot model and axis. Please refer the
operator’s manual of a particular robot model for the data of
stopping distance and stopping time.When this option is loaded, this function can not be disabled.
The stop type of DCS Position and Speed Check functions is not
affected by the loading of this option. -
SAFETY PRECAUTIONS B-83525EN/01
s-12
WARNING The stopping distance and stopping time of Controlled
stop are longer than thestopping distance and stopping time of Power-Off stop. A risk
assessment for the whole robot system, which takes into
consideration the increased stopping distance and stopping time, is
necessary when this option is loaded.8 WARNING LABEL (1) Step-on prohibitive label
Fig.8 (a) Step-on prohibitive label
Description Do not step on or climb the robot or controller as
it may adversely affect the robot or controllerand you may get hurt if you lose your footing. (2)
High-temperature warning labelFig.8 (b) High-Temperature warning label
Description Be cautious about a section where this label is
affixed, as the section generates heat. If youmust touch such a section when it is hot, use a protective
provision such as heat-resistant gloves. -
B-83525EN/01 SAFETY PRECAUTIONS
s-13
(3) High-voltage warning label
Fig.8 (c) High-voltage warning label
Description A high voltage is applied to the places where this
label is attached. Before starting maintenance, turn the power to
the controller off, and turn the circuit breakeroff to avoid electric shock hazards. Take additional precautions
with the servo amplifier and other equipment, because high-voltage
remains in these units for a certain amounts of time -
B-83525EN/01 PREFACE
p-1
PREFACE
This manual describes the following models (R-30iB Mate
controller).Model Abbreviation
FANUC Robot LR Mate 200iD LR Mate 200iD LR Mate 200iD
-
B-83525EN/01 TABLE OF CONTENTS
c — 1
TABLE OF CONTENTS
SAFETY
PRECAUTIONS………………………………………………………………….s-1PREFACE……………………………………………………………………………………….p-1
1 OVERVIEW
…………………………………………………………………………………32 CONFIGURATION
……………………………………………………………………….4
2.1 EXTERNAL VIEW OF THE CONTROLLER
………………………………………….. 42.2 COMPONENT
FUNCTIONS………………………………………………………………..
82.3 PREVENTIVE
MAINTENANCE……………………………………………………………
93 TROUBLESHOOTING
………………………………………………………………..11
3.1 POWER CANNOT BE TURNED ON
………………………………………………….. 113.1.1 When the Teach Pendant Cannot be Powered
on……………………………………………11 3.1.2 When
the Teach Pendant Does not Change from the Initial
Screen…………………..123.2 ALARM OCCURRENCE
SCREEN……………………………………………………..
133.3 STOP SIGNALS
………………………………………………………………………………
163.4 MASTERING
…………………………………………………………………………………..
173.5 TROUBLESHOOTING USING THE ERROR CODE
…………………………….. 193.6 FUSE-BASED
TROUBLESHOOTING…………………………………………………
683.7 TROUBLESHOOTING BASED ON LED INDICATIONS
……………………….. 72 3.7.1 Troubleshooting Using the
LEDS On the Main Board ……………………………………73
3.7.2 Troubleshooting by LEDs on the 6-Axis Servo Amplifier
………………………………76 3.7.3 Troubleshooting by LED
on the Emergency Stop
Board…………………………………78 3.7.4
Troubleshooting by Alarm LEDs on the Process I/O Board
…………………………….803.8 MANUAL OPERATION IMPOSSIBLE
………………………………………………… 81 3.9
LEDS ON UNITS SUPPORTING I/O LINK i
……………………………………………… 823.9.1 Meanings of LEDs on Units Supporting I/O Link i
………………………………………..824 PRINTED CIRCUIT
BOARDS………………………………………………………84
4.1 MAIN
BOARD………………………………………………………………………………….
854.2 EMERGENCY STOP BOARD:A20B-2005-0150
………………………………….. 874.3 BACKPLANE
…………………………………………………………………………………..
874.4 PROCESS I/O BOARD MA (A20B-2004-0381)
……………………………………. 884.5 PROCESS I/O BOARD MB (A20B-2101-0731)
……………………………………. 894.6 I/O CONNECTOR CONVERTER BOARD (A20B-2004-0411)
……………….. 905 SERVO AMPLIFIERS
…………………………………………………………………91
5.1 LEDS OF SERVO
AMPLIFIER…………………………………………………………..
925.2 SETTING OF SERVO
AMPLIFIER……………………………………………………..
935.3 6-AXIS SERVO AMPLIFIER SPECIFICATIONS
………………………………….. 946 POWER
SUPPLY……………………………………………………………………….95
6.1 BLOCK DIAGRAM OF THE POWER SUPPLY
……………………………………. 957 REPLACING
UNITS……………………………………………………………………96 -
TABLE OF CONTENTS B-83525EN/01
c — 2
7.1 REPLACING THE PRINTED-CIRCUIT BOARDS
………………………………… 96 7.1.1 Replacing the
Backplane Board
(Unit)………………………………………………………….97
7.1.2 Replacing the Main
Board…………………………………………………………………………..987.2 REPLACING CARDS AND MODULES ON THE MAIN BOARD
…………….. 997.3 REPLACING THE E-STOP UNIT
……………………………………………………..
1047.4 REPLACING THE EMERGENCY STOP BOARD
………………………………. 1057.5 REPLACING THE POWER SUPPLY
UNIT……………………………………….. 1067.6 REPLACING THE REGENERATIVE RESISTOR UNIT
………………………. 1077.7 REPLACING THE 6-AXIS SERVO AMPLIFIER
…………………………………. 1087.8 REPLACING THE TEACH
PENDANT……………………………………………….
1107.9 REPLACING THE CONTROL SECTION FAN MOTOR
………………………. 1117.10 REPLACING THE AC FAN MOTOR
………………………………………………… 112
7.10.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet)
………………………1127.11 REPLACING THE BATTERY
…………………………………………………………..
113 7.11.1 Battery for Memory Backup (3
VDC)…………………………………………………………1131 GENERAL
……………………………………………………………………………….1172 BLOCK
DIAGRAM……………………………………………………………………1183 ELECTRICAL
CONNECTIONS…………………………………………………..119
3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS ………………
1193.2 FANUC I/O
LINK…………………………………………………………………………….
121 3.2.1 Connection of I/O Link
…………………………………………………………………………….121
3.2.2 Connection of the I/O Link Cable
………………………………………………………………1223.3 EXTERNAL CABLE WIRING DIAGRAM
…………………………………………… 125 3.3.1 Robot
Connection
Cables………………………………………………………………………….125
3.3.2 Teach Pendant Cable
………………………………………………………………………………..127
3.3.3 Connecting the Input Power
………………………………………………………………………1283.3.3.1 Connecting the input power cable
………………………………………………………….
1283.3.3.2 Leakage
breaker…………………………………………………………………………………..
1293.3.4 Connecting the External Emergency
Stop……………………………………………………129
3.3.5 Connecting the Auxiliary Axis Brake (CRR65 A/B)
…………………………………….136 3.3.6 Connecting the
Auxiliary Axis Over Travel (CRM68)
………………………………….1374 PERIPHERAL DEVICE, ARC WELDING, AND EE INTERFACES ….138 4.1
PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM……………………..
1404.1.1 In Case of Main Board (CRMA15, CRMA16)
…………………………………………….140 4.1.2 In
the Case of the Process I/O Board MA
……………………………………………………140
4.1.3 In the Case of the Process I/O Board MB
……………………………………………………141
4.1.4 In the Case of the Connector Conversion Board
…………………………………………..1424.2 I/O SIGNALS OF MAIN
BOARD……………………………………………………….
1434.3 INTERFACE FOR PERIPHERAL
DEVICES………………………………………. 145 4.3.1
Connection between the Main Board (CRMA15, CRMA16) and Peripheral
Devices……………………………………………………………………………………145
4.3.2 Connection between the Connector Conversion Board and
Peripheral Devices..151 4.3.3 Connection between the Process I/O
Board MA and Peripheral Devices…………1524.4 INTERFACE FOR WELDING MACHINES
………………………………………… 156 4.4.1
Connection between the Process I/O Board MB and Welding Machines
…………156 -
B-83525EN/01 TABLE OF CONTENTS
c — 3
4.5 INTERFACE FOR END EFFECTOR
………………………………………………… 158 4.5.1
Connection between the LR Mate 200iD and End
Effector……………………………1584.6 DIGITAL I/O SIGNAL SPECIFICATIONS
………………………………………….. 159 4.6.1
Peripheral Device Interface A
……………………………………………………………………159
4.6.2 EE
Interface…………………………………………………………………………………………….162
4.6.3 I/O Signal Specifications for ARC-Welding Interface
(A-cabinet/Process I/O Board MB)
……………………………………………………………1634.7 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES
AND WELDERS
…………………………………………………………………………….
166 4.7.1 Peripheral Device Interface A1 Cable(CRMA15: Tyco Electronics AMP, 40 pins)
……………………………………………….166 4.7.2
Peripheral Device Interface A2 Cable(CRMA16: Tyco Electronics AMP, 40 pins)
……………………………………………….166 4.7.3
Peripheral Device Interface B1 and B2 Cables(CRMA52; Tyco Electronics AMP, 30
pin)…………………………………………………167
4.7.4 ARC Weld Connection Cables(CRW11; Tyco Electronics AMP, 20 pin)
…………………………………………………..1674.8 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END
EFFECTORS, AND ARC WELDERS
……………………………………………….. 168 4.8.1
Peripheral Device Connection
Cable…………………………………………………………..168
4.8.2 Peripheral Device Cable Connector
……………………………………………………………169
4.8.3 Recommended Cables
………………………………………………………………………………1724.9 CONNECTION OF HDI
…………………………………………………………………..
173 4.9.1 Connecting HDI
………………………………………………………………………………………173
4.9.2 Input Signal Rules for the High-speed Skip (HDI)
……………………………………….1744.10 CONNECTING THE COMMUNICATION UNIT
………………………………….. 175 4.10.1 RS-232-C
Interface…………………………………………………………………………………..1754.10.1.1 Interface
……………………………………………………………………………………………..
1754.10.1.2 RS-232-C interface signals
……………………………………………………………………
1764.10.1.3 Connection between RS-232-C interface and I/O device
………………………….. 1764.10.2 Ethernet Interface
…………………………………………………………………………………….178
4.10.2.1 Connection to Ethernet
…………………………………………………………………………
1784.10.2.2 Routing of the Ethernet Cable
……………………………………………………………….
1794.10.2.3 100BASE-TX Connector (CD38A, CD38B) Pin
Assignments………………….. 1794.10.2.4 Twisted-pair Cable
Specification……………………………………………………………
1804.10.2.5 Electrical Noise Countermeasures
………………………………………………………….
1834.10.2.6 Check Items at Installation
……………………………………………………………………
1865 TRANSPORTATION AND INSTALLATION
…………………………………187 5.1
TRANSPORTATION……………………………………………………………………….
1875.2 INSTALLATION
……………………………………………………………………………..
188 5.2.1 Installation
Method…………………………………………………………………………………..188
5.2.2 Assemble at Installation
……………………………………………………………………………1895.3 INSTALLATION OF TEACH PENDANT HOOK
(Option)……………………… 1905.4 INSTALLATION CONDITION
…………………………………………………………..
1915.5 ADJUSTMENT AND CHECKS AT INSTALLATION
……………………………. 1935.6 RESETTING OVERTRAVEL AND EMERGENCY STOP
AT
INSTALLATION…………………………………………………………………………
193 5.6.1 Peripheral Device Interface
Processing……………………………………………………….193
5.6.2 Resetting
Overtravel…………………………………………………………………………………194
5.6.3 How to Disable/Enable HBK
…………………………………………………………………….194
5.6.4 How to Disable/Enable Pneumatic Pressure Alarm
(PPABN)………………………..194 -
TABLE OF CONTENTS B-83525EN/01
c — 4
A TOTAL CONNECTION
DIAGRAM………………………………………………197B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE………….213
B.1 SIGNAL
………………………………………………………………………………………..
213B.2 SETTING COMMON
VOLTAGE……………………………………………………….
215B.3 I/O SIGNALS
…………………………………………………………………………………
215 B.3.1 Input
Signals……………………………………………………………………………………………215
B.3.2 Output Signals
…………………………………………………………………………………………218B.4 SPECIFICATIONS OF DIGITAL
INPUT/OUTPUT………………………………. 221 B.4.1
Overview
………………………………………………………………………………………………..221
B.4.2 Input/Output Hardware Usable in the R-30iB Mate Controller
………………………221B.4.3 Software Specifications
…………………………………………………………………………….222C OPTICAL FIBER
CABLE…………………………………………………………..223D BRAKE RELEASE
UNIT……………………………………………………………226
D.1 SAFETY
PRECAUTIONS………………………………………………………………..
226D.2 CONFIRMATIONS BEFORE
OPERATION……………………………………….. 226D.3
OPERATION………………………………………………………………………………….
227 D.3.1 In case of operating to the robot
…………………………………………………………………227
D.3.2 In case of operating to the auxiliary
Axis…………………………………………………….229D.4 HOW TO CONNECT THE PLUG TO THE POWER CABLE (IN CASE OF
NOPOWER PLUG)
……………………………………………………………………………..
230D.5 DIMENSION
………………………………………………………………………………….
231D.6 FUSE
……………………………………………………………………………………………
232D.7
SPECIFICATIONS………………………………………………………………………….
233E TEACH PENDANT DISCONNECT FUNCTION (Option)
……………….234 E.1
CONFIGURATION………………………………………………………………………….
234E.2 PROCEDURE OF TEACH PENDANT DISCONNECT
………………………… 234 E.2.1 Teach Pendant Disconnect
………………………………………………………………………..234
E.2.2 Teach Pendant Connect
…………………………………………………………………………….235F INSTRUCTION FOR TERMINAL BLOCK
……………………………………236 -
I. MAINTENANCE
-
B-83525EN/01 MAINTENANCE 1.OVERVIEW
— 3 —
1 OVERVIEW This manual is applied to R-30iB Mate controller
(called R-30iB Mate). R-30iB Mate has three variations depending on
the required standards. Basic controller: To meet Safety Standard
and General electrical requirement CE controller: To meet Machinery
Directive, Low voltage Directive, EMC Directive to coverthe requirement of CE mark NRTL controller: To meet UL/CSA
standard This manual covers these three variations of R-30iB Mate.
The difference of NRTL and CE controller from Basic controller is
small as shown in Table 1 (ex. EMC parts, Breakers). And the
specific descriptions o
Более безопасное программное обеспечение
В отличие от контроллеров, работающих на базе компьютеров Windows, контроллеры R-30iB Plus используют собственное программное обеспечение FANUC, что обеспечивает надежную защиту от вирусов, хакерских атак и проблем со стабильностью.
Удобное управление
iPendant имеет интуитивно понятный и простой интерфейс, благодаря чему любой сотрудник производства может без каких-либо сложностей работать с контроллером R-30iB Plus.
Максимальная оптимизация энергопотребления
Интеллектуальная оптимизация электропитания и разнообразные функции энергосбережения способствуют тому, что энергоэффективность вносит значительный вклад в итоговую прибыльность предприятия заказчика.
Нестандартный искусственный интеллект
Все контроллеры R-30iB в стандартном исполнении способны реализовывать интеллектуальные функции, такие как работа с системой технического зрения, управление усилием и контроль на отсутствие столкновений.
Простая настройка
Благодаря улучшенным характеристикам движения новый пользовательский интерфейс (iHMI) позволяет установить робота в течение 30 минут с помощью руководства по начальной
Описание
Описание
Контроллер FANUC R-30iB – это разумная производительность.
Откройте для себя новый контроллер FANUC R-30iB, который имеет компактный дизайн и оборудован новым интеллектуальным пультом iPendant Touch для большего удобства, уменьшения энергопотребления и повышения производительности. R-30iB специально разрабатывался, объединяя в себе передовую технологию нового поколения встроенную систему технического зрения FANUC iRVision (2D и 3D), с повышением функциональных возможностей, надежности и удобства управления. Умные, Сильные, Желтые.
Конструктивные особенности
Контроллер FANUC 30iB — новый стандарт интеллектуальной производитель-ности. Передовые технологии нового поколения, включающие новую аппаратную часть и более 250-ти функций программного обеспечения, являются ключевыми для быстрой, точной и безопасной работы робота. Максимальное удобство использования, высокая производительность и минимизированное энергопотребление обеспечивают общую высокую функциональность, надежность и упрощают работу.Для предоставления гибких и низких по затратам решений контроллер 30iB поставляется с разными вариантами шкафов. Компактный модульный дизайн с возможностью установки контроллеров друг на друга оптимизирует рабочее пространство.
Пульт iPendant Touch
Облегченный эргономичный дизайн нового интеллектуального пульта iPendant Touch стал более удобным в использовании как для програм-мистов, так и для операторов на производстве.
- функция настройки экрана обеспечивает возможность создавать пользовательские интерфейсы с использованием HTML;
- клавиша i-key для быстрой справки;
- многооконный дисплей;
- клавиши управления движением для быстрого доступа к дополнительным;
- порт USB.
Прикладное программное обеспечение
Благодаря специальным инструкциям, интерфейсам и эксклюзивным функциям ПО, приклад-ные инструменты программного обеспечения FANUC упрощают и стандартизируют программи-рование, настройку и управление Вашего робота. В зависимости от конкретных задач контрол-лер FANUC R30iB может поставляться со следующим прикладным ПО:
- Handling Tool;
- Spot Tool+;
- Arc Tool;
- Paint Tool.
Более 250-ти функций программного обеспечения доступны в качестве дополнительных.
Дополнительные возможности
В зависимости от способа применения контроллер FANUC 30iB может поставляться с одним из следующих Дополнительные возможности:
- FANUC iRVision;
- FANUC iRVisual line tracking;
- Line Tracking;
- Позиционеры;
- Дополнительные оси;
- Force sensors.
Форматы шкафа
Open-Air Cabinet. Габаритные размеры: 370 x 200 x 350 мм. Эта мощная автономная установка идеально подходит для роботов M1, M2, M3 и LR Mate. Установка предназначена для использования в подсобных помещениях, загрязненных и влажных средах. Она может монтироваться на стойке в другом корпусе или устанавливаться над другими роботами в роботизированных модулях.
Mate Cabinet. Габаритные размеры: 470 x 400 x 322 мм. Данный мощный и автономный контроллер является идеальным решением для малых роботов. Он был специально разработан для изделий серий M и LR-Mate. В случае использования модулей с несколькими роботами контроллеры могут устанавливаться один над другим.
A-Cabinet. Габаритные размеры: 600 x 500 x 470 мм. Это компактный стандартный контроллер FANUC. Эти контроллеры можно устанавливать один над другим. Контроллер идеально подходит для работы в промышленных средах и разработан для ограниченного количества (2-х) вспомогательных осей.
B-Cabinet. Габаритные размеры: 740 x 1 100 x 550 мм. В этой модели используется та же технология, что и в A-Cabinet, однако в ней предусмотрено пространство для установки дополнительных усилителей или модулей ввода-вывода. Модель идеально подходит для работы в промышленных средах.