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Comau RoboticsInstruction Handbook

Handling System

SmartHand

Application Software Rel. 115.xx

CR00757621-en_01/2012.07


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The information contained in this manual is the property of COMAU S.p.A.

Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.

COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.

Copyright © 2003 by COMAU - Date of publication 07/2012


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Summary

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SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Implemented and respected essential health and safety requirements . . . . . . . . . . . . . . . . . . 7

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. GENERAL DESCRIPTION OF SMARTHAND APPLICATION SOFTWARE . . . . . . ...17

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Basic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Basic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. INSTALLING / ACTIVATING / UNINSTALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Preparation for SmartHand installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Use of WinApplicationCreator tool for C5G (WAC5G). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Uninstall procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4. USER INTERFACE ON THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Process control keys (right menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Specific application environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Application Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Areas description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27


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Summary

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Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Softkeys description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Object Pages description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Integration of the application package with System environment . . . . . . . . . . . . . . . . . . . . . . . 36 Alarm page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Errors cause and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37I/O Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

User Help I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Integration with IDE environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Technological Instruction insertion in IDE environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Technological Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Process routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Gripper_sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Gripper_vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Gripper_vacuum_blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Gripper_chkpart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Grip_part_supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Grip_air_supervision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Advanced variables and routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Hnvb_smarthand_in_fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Hnru_user_fault_abort_enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Hnru_user_fault_abort_ack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Hnrb_get_user_fault_abort. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Handling RESET key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47hnru_tp_reset_in_remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Using the System shared resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6. CUSTOMIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..50

I/O configuration towards PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7. OPTIONAL SOFTWARE FUNCTIONALITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..51

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SmartVisualProcess. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Functioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Part Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52


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Preface

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PREFACE

Symbols used in the manual

The symbols used for WARNING, CAUTION and NOTES and their relevant meanings

are given below

This symbol indicates operating procedures, technical information and

precautions that if not observed and/or performed correctly could cause injuries

to the personnel.


precautions that if not observed and/or performed correctly cou ld cause damage

to the equipment.


precautions that are to be underlined.


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Reference documents

This document concerns the Handling System.

The complete set of Handling System manuals consists of:

Comau C5G Control Unit – Technical Specifications

– Transport and installation

– C5G Control Unit use.

Robot – Technical Specifications

– Transport and installation

– Maintenance

Programming – PDL2 Programming Language Manual

– Motion programming


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General Safety Precautions

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1. GENERAL SAFETY PRECAUTIONS

This specification deals with the following topics:

– Responsibilities

– Safety Precautions.

1.1 Responsibil it ies

– The system integrator is responsible for ensuring that the Robot System (Robot

and Control System) are installed and handled in accordance with the Safety

Standards in force in the country where the installation takes place. The application

and use of the protection and safety devices necessary, the issuing of declarations

of conformity and any CE markings of the system are the responsibility of the

Integrator.

– COMAU Robotics & Service shall in no way be held liable for any accidents caused

by incorrect or improper use of the Robot System (Robot and Control System), by

tampering with circuits, components or software, or the use of spare parts that are

not included in the spare parts list.

– The application of these Safety Precautions is the responsibility of the persons

assigned to direct / supervise the activities indicated in the Applicability sectionally

are to make sure that the Authorised Personnel is aware of and scrupulously follow

the precautions contained in this document as well as the Safety Standards in

addition to the Safety Standards in force in the country in which it is installed.

– The non-observance of the Safety Standards could cause injuries to the operators

and damage the Robot System (Robot and Control System).

1.1.1 Implemented and respected essential health and safetyrequirements

The robotic system composed of C5G Control Unit series SMART 5 considers as

implemented and respected the following Essential health and sefety requirements of

the 2006/42/CE Machinery Directive: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 – 1.2.4.3 –

1.2.5 – 1.2.6 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 – 1.5.9 –

1.5.10 – 1.5.11 – 1.5.13 – 1.6.3 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.

It deals with a general specification that apply to the whole Robot System. Due to ist

significance, this document is referred to unreservedly in any system instruction manual.

The installation shall be made by qualified installation Personnel and should conform to

all national and local codes.


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1.2 Safety Precautions

1.2.1 Purpose

These safety precautions are aimed to define the behaviour and rules to be observed

when performing the activities listed in the Applicability section.

1.2.2 Definit ions

Robot System (Robot and Control System)The Robot System is a functional unit consisting of Robot, Control Unit, Programming

terminal and possible options.

Protected AreaThe protected area is the zone confined by the safety barriers and to be used for the

installation and operation of the robot

Author ised Personnel Authorised personnel defines the group of persons who have been trained and assigned

to carry out the activities listed in the Applicability section.

Assigned PersonnelThe persons assigned to direct or supervise the activities of the workers referred to in

the paragraph above.

Installation and Putting into ServiceThe installation is intended as the mechanical, electrical and software integration of the

Robot and Control System in any environment that requires controlled movement of

robot axes, in compliance with the safety requirements of the country where the system

is installed.

Programming ModeOperating mode under the control of the operator, that excludes automatic operation

and allows the following activities: manual handling of robot axes and programming of

work cycles at low speed, programmed cycle testing at low speed and, when allowed,

at the working speed.

Auto / Remote Automatic ModeOperating mode in which the robot autonomously executes the programmed cycle at the

work speed, with the operators outside the protected area, with the safety barriers

closed and the safety circuit activated, with local (located outside the protected area) or

remote start/stop.

Maintenance and RepairsMaintenance and repairs are activities that involve periodical checking and / or

replacement (mechanical, electrical, software) of Robot and Control System parts or

components, and trouble shooting, that terminates when the Robot and Control System

has been reset to its original project functional condition.


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Putting Out of Service and DismantlingPutting out of service defines the activities involved in the mechanical and electrical

removal of the Robot and Control System from a production unit or from an environment

in which it was under study.

Dismantling consists of the demolition and dismantling of the components that make up

the Robot and Control System.

Integrator The integrator is the professional expert responsible for the installation and putting into

service of the Robot and Control System.

Incorrect UseIncorrect use is when the system is used in a manner other than that specified in the

Technical Documentation.

Range of Action

The robot range of action is the enveloping volume of the area occupied by the robotand its fixtures during movement in space.

1.2.3 Applicabil ity

These Specifications are to be applied when executing the following activities:

– Installation and Putting into Service;

– Programming Mode;

– Auto / Remote Automatic Mode;

– Robot axes release;

– Maintenance and Repairs;

– Putting Out of Service and Dismantling


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1.2.4 Operating Modes

Installation and Putting into Service

– Putting into service is only possible when the Robot and Control System has beencorrectly and completely installed.

– The system installation and putting into service is exclusively the task of the

authorised personnel.

– The system installation and putting into service is only permitted inside a protected

area of an adequate size to house the robot and the fixtures it is outfitted with,

without passing beyond the safety barriers. It is also necessary to check that under

normal robot movement conditions there is no collision with parts inside the

protected area (structural columns, power supply lines, etc.) or with the barriers. If

necessary, limit the robot working areas with mechanical hard stop (see optional

assemblies).

– Any fixed robot control protections are to be located outside the protected area and

in a point where there is a full view of the robot movements.

– The robot installation area is to be as free as possible from materials that could

impede or limit visibility.

– During installation the robot and the Control Unit are to be handled as described in

the product Technical Documentation; if lifting is necessary, check that the

eye-bolts are fixed securely and use only adequate slings and equipment.

– Secure the robot to the support, with all the bolts and pins foreseen, tightened to

the torque indicated in the product Technical Documentation.

– If present, remove the fastening brackets from the axes and check that the fixingof the robot fixture is secured correctly.

– Check that the robot guards are correctly secured and that there are no moving or

loose parts. Check that the Control Unit components are intact.

– If applicable, connect the robot pneumatic system to the air distribution line paying

attention to set the system to the specified pressure value: a wrong setting of the

pressure system influences correct robot movement.

– Install filters on the pneumatic system to collect any condensation.

– Install the Control Unit outside the protected area: the Control Unit is not to be used

to form part of the fencing.

– Check that the voltage value of the mains is consistent with that indicated on the

plate of the Control Unit.

– Before electrically connecting the Control Unit, check that the circuit breaker on the

mains is locked in open position.

– Connection between the Control Unit and the three-phase supply mains at the

works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned

appropriately for the power installed on the Control Unit. See the product

Technical Documentation.

– The power supply cable is to enter the Control Unit through the specific fairlead and

be properly clamped.

– Connect the earth conductor (PE) then connect the power conductors to the main

switch.


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– Connect the power supply cable, first connecting the earth conductor to the circuit

breaker on the mains line, after checking with a tester that the circuit breaker

terminals are not powered. Connect the cable armouring to the earth.

– Connect the signals and power cables between the Control Unit and the robot.

– Connect the robot to earth or to the Control Unit or to a nearby earth socket.

– Check that the Control Unit door (or doors) is/are locked with the key.

– A wrong connection of the connectors could cause permanent damage to the

Control Unit components.

– The C5G Control Unit manages internally the main safety interlocks (gates,

enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the

line safety circuits, taking care to connect them as required by the Safety

standards. The safety of the interlock signals coming from the transfer line

(emrgency stop, gates safey devices etc) i.e. the realisation of correct and safe

circuits, is the responsibility of the Robot and Control System integrator.

– The safety of the system cannot be guaranteed if these interlocks are wrongly

executed, incomplete or missing.

– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the

safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is

only active in Automatic states; in Programming the power is cut out (power

contactors open) immediately. The procedure for the selection of the controlled

stop time (that can be set on SDM board) is contained in the Installation manual .

– When preparing protection barriers, especially light barriers and access doors,

bear in mind that the robot stop times and distances are according to the stop

category (0 or 1) and the weight of the robot.

– Check that the environment and working conditions are within the range specified

in the specific product Technical Documentation.

– The calibration operations are to be carried out with great care, as indicated in the

Technical Documentation of the specific product, and are to be concludedchecking the correct position of the machine.

– To load or update the system software (for example after replacing boards), use

only the original software handed over by COMAU Robotics & Service.

Scrupulously follow the system software uploading procedure described in the

Technical Documentation supplied with the specific product. After uploading,

always make some tests moving the robot at slow speed and remaining outside the

protected area.

– Check that the barriers of the protected area are correctly positioned.

In the cell/line emergency stop circuit the contacts must be included of the control unit

emergency stop buttons, which are on X30. The push buttons are not interlocked in the

emergency stop circuit of the Control Unit.

Check that the controlled stop time is consistent with the type of Robot connected to the

Control Unit. The stop time is selected using selector switches SW1 and SW2 on the

SDM board.


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Programming Mode

– The robot is only to be programmed by the authorised personnel.

– Before starting to program, the operator must check the Robot System (Robot and

Control System) to make sure that there are no potentially hazardous irregular

conditions, and that there is nobody inside the protected area.

– When possible the programming should be controlled from outside the protected

area.

– Before operating inside the Protected Area, the operator must make sure from

outside that all the necessary protections and safety devices are present and in

working order, and especially that the hand-held programming unit functions

correctly (slow speed, emergency stop, enabling device, etc.).

– During the programming session, only the operator with the hand-held terminal is

allowed inside the Protected Area.

– If the presence of a second operator in the working area is necessary when

checking the program, this person must have an enabling device interlocked with

the safety devices.

– Activation of the motors (Drive On) is always to be controlled from a position

outside the range of the robot, after checking that there is nobody in the area

involved. The Drive On operation is concluded when the relevant machine status

indication is shown.

– When programming, the operator is to keep at a distance from the robot to be able

to avoid any irregular machine movements, and in any case in a position to avoid

the risk of being trapped between the robot and structural parts (columns, barriers,

etc.), or between movable parts of the actual robot.

– When programming, the operator is to avoid remaining in a position where parts of the robot, pulled by gravity, could execute downward movements, or move

upwards or sideways (when installed on a sloped plane).

– Testing a programmed cycle at working speed with the operator inside the

protected area, in some situations where a close visual check is necessary, is only

to be carried out after a complete test cycle at slow speed has been executed. The

test is to be controlled from a safe distance.

– Special attention is to be paid when programming using the hand-held terminal: in

this situation, although all the hardware and software safety devices are active, the

robot movement depends on the operator.

– During the first running of a new program, the robot may move along a path that isnot the one expected.

– The modification of program steps (such as moving by a step from one point to

another of the flow, wrong recording of a step, modification of the robot position out

of the path that links two steps of the program), could give rise to movements not

envisaged by the operator when testing the program.

– In both cases operate cautiously, always remaining out of the robot’s range of

action and test the cycle at slow speed.


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Auto / Remote Automatic Mode

– The activation of the automatic operation (AUTO and REMOTE states) is only to

be executed with the Robot System (Robot and Control System) integrated inside

an area with safety barriers properly interlocked, as specified by Safety Standards

currently in force in the Country where the installation takes place. – Before starting the automatic mode the operator is to check the Robot and Control

System and the protected area to make sure there are no potentially hazardous

irregular conditions.

– The operator can only activate automatic operation after having checked:

• that the Robot and Control System is not in maintenance or being repaired;

• the safety barriers are correctly positioned;

• that there is nobody inside the protected area;

• that the Control Unit doors are closed and locked;

• that the safety devices (emergency stop, safety barrier devices) are

functioning;

– Special attention is to be paid when selecting the automatic-remote mode, where

the line PLC can perform automatic operations to switch on motors and start the

program.

Robot axes release

– In the absence of motive power, the robot axes movement is possible by means of

optional release devices and suitable lifting devices. Such devices only enable the

brake deactivation of each axis. In this case, all the system safety devices

(including the emergency stop and the enable button) are cut out; also the robot

axes can move upwards or downwards because of the force generated by the

balancing system, or the force of gravity.

– Enabling the brake releasing device may cause the axes falling due to gravity as

well as possible impacts due to an incorrect restoration, after applying the brake

releasing module. The procedure for the correct usage of the brake releasing

device (both for the integrated one and module one) is to be found in the

maintenance manuals.

– When the motion is enabled again following the interruption of an unfinished

MOVE, the track recovery typical function may generate unpredictable paths thatmay imply the risk of impact. This same condition arises at the next automatic cycle

restarting. Avoid moving the Robot to positions that are far away from the ones

provided for the motion restart; alternatively disable the outstanding MOVE

programmes and/or instructions.

Before using the manual release devices, it is strongly recommended to sling the robot,

or hook to an overhead travelling crane.


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Maintenance and Repairs

– When assembled in COMAU Robotics & Service, the robot is supplied with

lubricant that does not contain substances harmful to health, however, in some

cases, repeated and prolonged exposure to the product could cause skin irritation,

or if swallowed, indisposition.First Aid. Contact with the eyes or the skin: wash the contaminated zones with

abundant water; if the irritation persists, consult a doctor.

If swallowed, do not provoke vomiting or take anything by mouth, see a doctor as

soon as possible.

– Maintenance, trouble-shooting and repairs are only to be carried out by authorised

personnel.

– When carrying out maintenance and repairs, the specific warning sign is to be

placed on the control panel of the Control Unit, stating that maintenance is in

progress and it is only to be removed after the operation has been completely

finished - even if it should be temporarily suspended.

– Maintenance operations and replacement of components or the Control Unit are to

be carried out with the main switch in open position and locked with a padlock.

– Even if the Control Unit is not powered (main switch open), there may be

interconnected voltages coming from connections to peripheral units or external

power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when

operating on parts of the system that are involved.

– Removal of panels, protection shields, grids, etc. is only allowed with the main

switch open and padlocked.

– Faulty components are to be replaced with others having the same code, or

equivalent components defined by COMAU Robotics & Service.

– Trouble-shooting and maintenance activities are to be executed, when possible,

outside the protected area.

– Trouble-shooting executed on the control is to be carried out, when possible

without power supply.

– Should it be necessary, during trouble-shooting, to intervene with the Control Unit

powered, all the precautions specified by Safety Standards are to be observed

when operating with hazardous voltages present.

– Trouble-shooting on the robot is to be carried out with the power supply cut out

(Drive off).

– At the end of the maintenance and trouble-shooting operations, all deactivated

safety devices are to be reset (panels, protection shields, interlocks, etc.).

– Maintenance, repairs and trouble-shooting operations are to be concluded

checking the correct operation of the Robot System (Robot and Control System)

and all the safety devices, executed from outside the protected area.

– When loading the software (for example after replacing electronic boards) the

original software handed over by COMAU Robotics & Service is to be used.

Scrupulously follow the system software loading procedure described in thespecific product Technical Documentation; after loading always run a test cycle to

make sure, remaining outside the protected area

After replacement of the SDM module, check on the new module that the setting of the

stop time on selector switches SW1 and SW2 is consistent with the type of Robot

connected to the Control Unit.


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– Disassembly of robot components (motors, balancing cylinders, etc.) may cause

uncontrolled movements of the axes in any direction: before starting a disassembly

procedure, consult the warning plates applied to the robot and the Technical

Documentation supplied.

– It is strictly forbidden to remove the protective covering of the robot springs.

Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to be

carried out by Authorised Personnel.

– Bring the robot to transport position and fit the axis clamping brackets (where

applicable) consulting the plate applied on the robot and the robot Technical

Documentation.

– Before stating to put out of service, the mains voltage to the Control Unit must be

cut out (switch off the circuit breaker on the mains distribution line and lock it in

open position).

– After using the specific instrument to check there is no voltage on the terminals,

disconnect the power supply cable from the circuit breaker on the distribution line,

first disconnecting the power conductors, then the earth. Disconnect the power

supply cable from the Control Unit and remove it.

– First disconnect the connection cables between the robot and the Control Unit,

then the earth cable.

– If present, disconnect the robot pneumatic system from the air distribution line.

– Check that the robot is properly balanced and if necessary sling it correctly, then

remove the robot securing bolts from the support.

– Remove the robot and the Control Unit from the work area, applying the rulesindicated in the products Technical Documentation; if lifting is necessary, check the

correct fastening of the eye-bolts and use appropriate slings and equipment only.

– Before starting dismantling operations (disassembly, demolition and disposal) of

the Robot and Control System components, contact COMAU Robotics & Service,

or one of its branches, who will indicate, according to the type of robot and Control

Unit, the operating methods in accordance with safety principles and safeguarding

the environment.

– The waste disposal operations are to be carried out complying with the legislation

of the country where the Robot and Control System is installed.


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1.2.5 Performance

The performances below shall be considered before installing the robot system:

– Stop distances

– Mission time (typ. case).

Stop distances

– With Robot in programming modality (T1), if you press the stop pushbutton (red

mushroom-shaped one on WiTP) in category 0 (according to the standard

EN60204-1), you will obtain:

– Considering the Robot in automatic modality, under full extension, full load and

maximum speed conditions, if you press the stop pushbutton (red

mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)

you will trigger the Robot complete stop with controlled deceleration ramp.

Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °

motion, that correspond to about 3000 mm movement measured on TCP flange.Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5

seconds.

Mission time (typ. case)

– We remind you that the safety system efficiency covering is equal to 20 years

(mission time of safety-related parts of control systems (SRP/CS), according to

EN ISO 13849-1).

Tab. 1.1 - Stop spaces in programming modality (T1)

ModeExpected

speedCase

Stopping

time

Stopping

space

T1 250 mm/sNominal 120 ms 30 mm

Limit 500 ms 125 mm

Tab. 1.2 - Safety electronics reaction time in programming modality (T1)

ModeExpected

speedCase

Stopping

time

T1 250 mm/s

For the safety inputs of the SDM module (e.g.stop pushbutton of TP in wired version)

150 msFor the stop and enabling device inputs fromthe TP in wireless version, when the safetywire trasmission is active.

For the time-out of stop input and enablingdevice from TP in wireless version, when thesafety wire transmission is lost or interrupted.

350 ms


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General Description of SmartHand Application Software

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2. GENERAL DESCRIPTION OFSMARTHAND APPLICATION

SOFTWARE

2.1 IntroductionThis chapter is the introduction to the COMAU Handling environment, with special

regard to SmartHand application software.

A Handling system can have different configurations according to the User’s specific

requirements. This manual only refers to:

– Basic System

– Basic Functions.

2.2 Basic SystemThis consists of the following basic components (see Fig. 2.1 - Basic System):

– Robot C5G Control Unit (1)

– SMART NJx, NS robots (2)

– One of the following Interface board

• Devicenet• Profibus-DP

– SmartHand application software

– Users manual.

Fig. 2.1 - Basic System


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2.3 Basic FunctionsThe basic functions, always available on a handling system, are as follows:

– Integrated Programming Environment (IDE)

– Set of Technological Instructions for the handling

– Special functions

– Alarms management ( Alarm page)

– A signals profile towards PLC, common to all the application Softwares provided

by Comau with standard signals (application inclusion, process activation, dry

cycle, anomaly reset, and corresponding status feedbacks towards PLC).

– A graphics environment composed by:

• main page ( Application Page): it includes general information about the

process status, configuration information and application software version,

and an informational area available to the User;

• Process control keys (right menu): the most common functionalities are

associated to the process keys, together with the corresponding icons;

• setup environment (Setup Page): functionalities to modify and save general

setup values (not included in the technological instructions as parameters)

which control the application working modalities.


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Installing / Activating / Uninstalling

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3. INSTALLING / ACTIVATING /UNINSTALLING

3.1 IntroductionThis chapter describes the installation procedure for the SmartHand application.

The following topics are dealt with:

– System requirements

– Preparation for SmartHand installation

– Use of WinApplicationCreator tool for C5G (WAC5G)

– Installation procedure

– Uninstall procedure

3.2 System requirements

3.2.1 Software

It is needed to enable the software option allowing to use the application itself.

Comau Code for SmartHand CR13612060

L'applicativo SmartHand può essere utilizzato con il Software di Sistema C5G la cuiversione corrisponde alle prime tre cifre presenti nella versione del software applicativo.

Ad esempio la versione 100.01 del software applicativo richiede una versione del

software di sistema che sia pari o superiore a 1.0x .

The SmartHand application software can be used in combination with the C5G System

Software, whose version is identified by the most significant three digits in the

application software version. For example version 100.01 of the application software,

requires a system software 1.0x or better.

3.2.2 Hardware

The following basic hardware components are necessary to use the SmartHand

application:

– C5G Robot Control Unit

– one of the following interface boards:

• C5G-Devicenet

• C5G-Profibus.

3.3 Preparation for SmartHand installation

Before starting the actual installation procedure, the C5G Control Unit has to be

prepared. The general installation preparations for the C5G Control Unit are contained

in the relevant C5G Control Unit- Transport and Installation manual.It may be necessary to install the SmartHand application in one of these situations:


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– C5G Controller with SmartHand application package not present.

– SmartHand updating - installation of a newer version with respect to the currently

installed on C5G; it is the situation in which either the SmartHand version must be

updated, keeping the existing configuration, or one or more SmartHand files have

been deleted from the User Directory, by fault.In both cases the procedure is the same (see Installation procedure)

3.4 Use of WinApplicationCreator tool for C5G(WAC5G)SmartHand application Software supplied by Comau is distributed in a single file

(version file) with extension .wac5g (SmartHandVxxx.xx.waC5G): it includes all the

available configurations, i.e. all the allowed devices. As far as SmartHand, just one

configuration is available.

The filename refers to the application type and the version number (e.g.SmartHandv10001.waC5G).

WAC5G is a PC application provided by Comau, to the User, in order to import files of

.wac5g type. It shows, in graphical form, all the allowed devices, grouped in columns,

depending on their type. The User can choose among the existing devices in his/her

own configuration and generate a specific installation file.

The installation file which is generated by WAC5G is an archive file (.zip extension)whose name is composed by

.zip

The configuration name is asked by WAC5G before generating the installation file.

The User can choose any meaningful string, which could help to better identify the

configuration. Such a string is the one displayed on the Teach Pendant in the application

About pages.

3.5 Installation procedureThe following operations are necessary to install the application:

a. Activate the SETUP page on the Teach Pendant

(see Fig. 3.1).

For a detailed description, about use and functionality of WAC5G tool, please

refer to the dedicated manual.

http://../Italiano/lb-hn-0-hnd_it.pdfhttp://../Italiano/lb-hn-0-hnd_it.pdf


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Fig. 3.1 - SETUP

b. Select theInstall

icon and pressENTER

to confirm.

c. Press ENTER again, then down arrow to select the device (COMP:, XD:, UD:, TX:)

containing the being installed SmartHand application.

d. Confirm with ENTER. Down arrow to select the application to be installed, i.e.

SmartHand .

e. Confirm with ENTER (Fig. 3.2).

Fig. 3.2 - SETUP Application

f. Press the key for the Install command (F5) to carry out the installation.

g. If any error occurs while installing, messages and suggestions are issued.

h. In case of any error, the installation is stopped, the error is indicated with a

message and the C5G red alarm lamp lights up. The system remains in such a

condition until the RESET key is pressed.

The installation will continue from the point where it was interrupted, as soon as the

condition that caused the error is removed.

i. After the installation has been completed, re-start the system (Restart Cold).


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3.6 Uninstall procedureTo uninstall the application package it is needed to execute the following procedure:

a. Activate SETUP page (see Fig. 3.1) on the Teach Pendant

b. Select APPL icon and press ENTER

c. Select Uninstall icon and press ENTER (see Fig. 3.3)

Fig. 3.3 - SETUP - Uninstall

d. In the displayed combobox, select the wished application to be uninstalled and

press ENTER.

Fig. 3.4 - SETUP - Uninstall - 2

e. At the end of the procedure the User is requested to restart the System (Restart

Cold).


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User interface on the Teach Pendant

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4. USER INTERFACE ON THE TEACHPENDANT

4.1 IntroductionThis chapter describes the user interface on the Teach Pendant, for the SmartHand

application.

The following topics are dealt with:

– Process control keys (right menu)

– Specific application environments

– Integration of the application package with System environment

– Integration with IDE environment.

As fo r the Teach Pendant use, please refer to the pertain ing manual C5G Control

Unit use, chapter Teach Pendant.


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4.2 Process control keys (right menu)The Right Menu displays the softkeys and “software led” for the process control.

Commands associated to the softkeys could be either enabled or disabled as shown by

the following icons in Tab. 4.1.

The “software led” associated to each softkey indicates, depending on the displayed

colour, the status of the component represented by the icon. See the description in the

following Tab. 4.2.

In particular, descriptions for all the softkeys are provided, for all the allowed positions

of the modal selector switch on C5G Controller Unit:

– T1 position (System in Prog state)

– AUTO position (System in Local state)

– REMOTE position (System in Remote state)

Tab. 4.1 - Meaning of the sof tkeys

Icon enabled / disabled - description

When the corresponding softkey is enabled, the icon representing thefunctionality is displayed in colour .

When the corresponding softkey is disabled, the icon representing thefunctionality is displayed in grey.The software led always shows the component status.

Tab. 4.2 - Meaning of the software leds

LED colour - description

When the software led colour is yellow, it means that a command ($DOUT) hasbeen sent to the component, but the function performed confirmation ($DIN)hasn’t been received yet.

In the case shown on the left, the softkey functionality is disabled (e.g. becausethe command comes from remote) but the software LED still indicates thecomponent status: in this example, green means that the function has been

properly completed.


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(*) R4 and R5 keys are enabled only when the robot is in DRIVE ON for safety reasons.

(**) EXAMPLE 1: if R4 Seq 1 is used, the same key controls e ither opening the component when it is closed,

or closing the component when it is opened.

EXAMPLE 2: if R4 Vac 1 is used, the same key controls the intake of the suction devices unit if they are in

stop or vice-versa if they are operating. With the suction device in stop there is also a function of long pressure

to control the suction device blowing. When the key is released the suction device is locked.

Tab. 4.3 - Functionality and position of the modal selector switch

KEY ICON DESCRIPTION

R1

Select the wished gripper. It only works if SmartHand has been configured asa multigripper. Each pressure updates the icon depending on the total amountof configured grippers during the SETUP.The only colour of the software led is grey.The softkey is always enabled in all positions: T1, AUTO and REMOTE.

R2

Select the type of component to be displayed/commanded (Vac/Seq). Eachpressure updates the icon depending on the the type of the configuredcomponent of the gripper indicated by R1.The only colour of the software led is grey.The softkey is always enabled in all positions: T1, AUTO and REMOTE.

R3

Each pressure increases the R4 and R5 component number. The incrementvalue depends on the total amount of configured components.The only colour of the software led is grey.The softkey is always enabled in all positions: T1, AUTO and REMOTE.

R4 ed R5

These softkeys control the component which is represented by the displayedicon. Each softkey pressure causes the component to execute thecorresponding command (**).The allowed colours for the led are: – grey - after a Restart Cold it indicates the unknown state of the component

– yellow - a command ($DOUT) has been sent, but the confirmation ($DIN)

hasn’t been received yet.

– green - properly accomplished movement, thus each $DIN is in thewished condition.

The softkeys are enabled in T1(*) and disabled both in AUTO and REMOTE,but the corresponding icons still display the colour information in order to showthe component state.

R6

It handles the DRY CYCLE command.The allowed colours for the led are: – grey (with the prohibition sign) - dry cycle disabled

– green - dry cycle enabled

The key is enabled in either T1 or AUTO and disabled in REMOTE (because

the command comes from remote but the colour information is still provided).


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4.3 Specific application environmentsThe specific Application Pages are the following:

– Application Page

– Setup Page

A detailed description follows for each one of them, focused on their use for SmartHand

application.

4.3.1 Application Page

The Appl ication Page, on the Teach Pendant, is the Main Page of the installed

application; in this case the application is SmartHand.

On the Teach Pendant, when Appl (L6) key of the Left Menu is pressed, the Main Page

of the application is activated.

Such a page (see Fig. 4.1) is divided into four parts, also called areas, showing

differente information related to the installed application. If more than one applicationare installed on the Controller, there will be as many tabsheets as the total amount of

applications, in the Application Page: just move the focus to the different tabsheets

labelled with the names of the existing applications on the Controller, to display the

corresponding pages.

Fig. 4.1 - Applicat ion Page - star t page

A detailed description follows, about all the Application Page topics:

– Areas description

– About

– Object

4.3.1.1 Areas description

The four areas of the Application Page subdivision, are as follows (see Fig. 4.1):

– the first one (top left - (1)) identifies the selected application, specifying its

installation version

– the second one (top right - (2)), called Dynamic Data, includes the most important

process data, related to the selected application. They are dynamic data, so they

are updated as soon as their value changes

– the third one (bottom left - (3)), called Device Status, includes the hardware

configuration information, related to the selected application


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– Finally, the fourth one (bottom right - (4)) is the User dedicated area, so it is called

User Area. It is a table in which the User is allowed to display some wished

information (with a maximum o four), with string format.

The SmartHand application strings are:

hnxs_user_1 : ARRAY [ki_row] OF STRING [19] EXPORTED FROM sh_dd hnxs_user_2 : ARRAY [ki_row] OF STRING [19] EXPORTED FROM sh_dd

where:

– ki_row, is the maximum number of rows, i.e. 4

– hnxs_user_1 is the reference variable of the first column

– hnxs_user_2 is the reference variable of the second column

In the Application Page bottom menu, two softkeys are available, related to the following

functions:

– About (F5)

– Object (F1)

A detailed description for each of them, follows.

4.3.1.2 About

Displays a menu containing the following information related to the selected application:

– Configuration : this function displays the application name and the installation

version, the application configuration name which is the User assigned identifier (at

the .zip file generation time, by means of the WAC5G tool) and the application

hardware configuration.

Fig. 4.2 - Configuration

– Version: this function displays the application name and the installation version,

the application configuration name which is the User assigned identifier and the

existing software modules version.

For further information, please refer to the WAC5G tool manual.


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Fig. 4.3 - Version

– Version CL : it displays the Common Libraries version, used by the applications.

Fig. 4.4 - Version CL

4.3.1.3 Object

Object (F1) softkey, if present, allows accessing to further object pages related to the

selected application.

It also allows to go back to the Application Page environment if the currently displayed

page is different (e.g. About environment or Object Pages).

SmartHand application includes some more pages in addition to the Appl ication Page

4.3.2 Setup PageCurrent section describes the needed user procedures to modify global settings for

SmartHand application, by means of the Setup Page.

In particular, the following topics are described:

– General information

– Softkeys description

– Object Pages description

4.3.2.1 General information

When SETUP (L3) softkey of the Left Menu is pressed, the SETUP Home Page, usefulto act on the System settings, is activated (see Fig. 3.1).

To access the applications SETUP instead, select APPL : several icons are displayed,



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showing a monkey wrench, with the installed applications names (see Fig. 4.5).

Fig. 4.5 - Application Setup

Select the wished application icon and press ENTER. The application Setup Page isshown in Fig. 4.6.

Fig. 4.6 - Setup of SmartHand appl icat ion

It displays as many panes (Gripper_1, Gripper_2, Gripper_3, Config, Air) as the object

pages and sub-pages are, allowing to modify the application parameters.

The access to the Object Pages menus depends on the performed login; the default is

no menus available.

There are two login levels, enabling different levels of menu:

– Technology level 1 - only 'General' menus are enabled, in each Object Page

– Technology level 2 - all the menus are enabled in all Object Pages (e.g. Alarms

'Reset from TP/PLC')

The User can use the Setup environment Object Pages, to modify the application

configuration parameters, in Programming state only (modal selector switch in T1

position).To access any Object Page and their associated menus, perform the following steps:

It is therefore needed to create a suitable Technology Login , to be able to access

the wished environment.


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a. choose the wished page, by means of the left/right arrow keys;

b. press either ENTER or down arrow, to move the focus to the menus selection and

press ENTER to open the list;

c. select the wished menu and confirm with ENTER;

d. move focus onto the fields to be modified, using the arrow keys, perform the wished

modifications;

e. save the modifications, using the available softkeys in the bottom menu, as

explained in the following par. 4.3.2.2 Softkeys description on page 30.

4.3.2.2 Softkeys description

In each application SETUP Page, the following commands are available, which can be

activated by means of the four softkeys of the bottom menu (see Fig. 4.7):

– Save (F2) – Apply (F3)

– Reload (F4)

– Close (F6).

Fig. 4.7 - Softkeys description

Note that, Save, Apply, and Reload act on the performed modifications. During the

modifications, the being modified values are displayed in Italic style.

4.3.2.2.1 Save (F2)Saves the performed modifications, both in the execution memory and to a file. The

Object Page still remains open. The new value is displayed in the default style again. If

some values are saved which are different than the default ones, hn_conf.var (*) file,

containing the new configuration values, is saved in UD:\data\hand.

4.3.2.2.2 Apply (F3)

Saves the performed modifications, in the execution memory. The Object Page still

(*) This file is automatically generated by the application, only if User

modifi cations are performed in t he SETUP page. So, after the fi rst installation, it

can be not present yet. In case of sof tware updating, this file is preserved in order

not to lose the user configuration.


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remains open but the new values are NOT saved to a file. The new value is displayed

in the default style again.

4.3.2.2.3 Reload (F4)

Loads again, from the file, the application variables default values.

4.3.2.2.4 Close (F6)

Closes the SETUP Page.

4.3.2.3 Object Pages description

The SmartHand application Setup page makes available the following sub-pages:

– Gripper _X (from 1 to MAX_GRIPPER (3))

– Config

– Air .

4.3.2.3.1 Gripper

In this type of Object Page, the user has to enter all the devices to be used in the

process.

Each Object Page is similar to the others: the only difference is the gripper which it refers

to.

The possible choices (in the menu list) in the current Object Page are:

– Enable devices

– Sequence 1..6

– Vacuum 1..6

– Part_present 1..5.

GRIPPER : ENABLE DEVICES

It shows the list of the devices to be enabled/disabled, as in the following table

GRIPPER : Sequence 1….6

After the device has been enabled, it is allowed to access its subpage, by selectin the

wished component in the menu list.

In this environment $DIN inputs and $DOUT outputs can be inserted in order to handle

the componentne.

Each sequence can handle a maximum amount of

– 5 inputs for the open sequence – 5 inputs for the close sequence

PARAMETER DESCRIPTION RANGE

Sequence 1…..6 Allows enabling/disabling Sequences (1…6) to beused in the process

[ON/OFF]

Vacuum 1…6 Allows enabling Vacuum (1…6) to be used in theprocess

[ON/OFF]

Part_present 1…5 Allows enabling the control to handle the partpresence

[ON/OFF]


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– 5 outputs for the open sequence

– 5 outputs for the close sequence.

The parameters description and the corresponding range are shown in the following

table.

Examples of devices that can be used by the sequences group:

– Clamping / Centering w ith 2-input bi-stable valves

• Sequence_open_input_1 --> Enter $DIN open index

• Sequence_close_input_1 -> Enter $DIN close index

• Sequence_open_output_1 -> Enter $DOUT open index

• Sequence_close_output_1 ->Enter $DOUT close index

– Clamping / Centering with 1-input b istable valves• Sequence_open_input_1 -> enter the $DIN if it is an open input, otherwise

leave 0

• Sequence_close_input_1 -> enter the $DIN if it is a close input, otherwise

leave 0

• Sequence_open_output_1 ' enter the $DOUT opening index

• Sequence_close_output_1 ' enter the closing $DOUT index

– Clamping / Centering with 2-input monostable valves

• Sequence_open_input_1 -> enter the $DIN opening index

• Sequence_close_input_1 -> enter the $DIN closed index

• Sequence_open_output_1 -> enter the $DOUT if it is an opening output,

otherwise leave 0• Sequence_close_output_1 -> enter the $DOUT if it is a closing output,

otherwise leave 0

– Clamping / Centering with 1-input monostable valves

• Sequence_open_input_1 -> enter the $DIN if it is an open output, otherwise

leave 0

• Sequence_close_input_1 ->enter the $DIN if it is a close output, otherwise

leave 0

• Sequence_open_output_1 -> enter the $DOUT if it is an opening output,

otherwise leave 0

• Sequence_close_output_1 -> enter the $DOUT if it is a closing output,

otherwise leave 0 – Clamping / Centering without inputs

In this case no $DIN is to be entered and the process routine has to be called with


Sequence_open_input_1....Sequence_open_input_5

Allows inserting the input signal ($DIN) for thereference sequence opening

$DIN[0…512]

Sequence_close_input_1....Sequence_close_input_5

Allows inserting the output signal ($DIN) for thereference sequence closing

$DIN[0…512]

Open_sequence_output_1....Open_sequence_output_5

Allows inserting the input signal ($DOUT) for thereference sequence opening

$DOUT[0…512]

Close_sequence_output_1....Close_sequence_output_5

Allows inserting the output signal ($DOUT) for thereference sequence closing

$DOUT[0…512]


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control flag at FALSE.

GRIPPER : Vacuum 1….6

Also for vacuums, as for Sequences, it is possible to insert Input and Output signals

($DIN, $DOUT), to handle the component just after enabling it.For each vacuum it is possible to enter a maximum of:

– 5 inputs for the vacuum meters

– 5 outputs for aspiration

– 5 outputs for clamping

– 5 outputs for blowing.

The parameters description and the corresponding range are shown in the following

table.

Examples of devices that can be used in the vacuum group:

– suction devices with bi-stable valves for aspiration and monostable for

blowing and a vacuum meter

• Vacuum_active_input_1 -> Enter the vacuum meter $DIN index

• Release_vacuum_output_1 -> Enter the $DOUT index to stop aspiration

• Active_vacuum_output_1 -> Enter the $DOUT index to activate aspiration

• Blow_vacuum_output_1 -> Enter the $DOUT index to activate blowing

– suction devices with mono-stable valves for aspiration and monostable for

blowing and a vacuum meter • Vacuum_active_input_1 -> Enter the vacuum meter $DIN index

• Release_vacuum_output_1 -> Leave 0

• Active_vacuum_output_1 -> Enter the $DOUT index to activate aspiration

• Blow_vacuum_output_1 -> Enter the $DOUT index to activate blowing

– suction devices only one mono-stable valve and a vacuum meter

• Vacuum_active_input_1 ->Enter the vacuum meter $DIN index

• Release_vacuum_output_1 -> Leave 0

• Active_vacuum_output_1 -> enter the $DOUT if the output activates

aspiration, otherwise leave 0

• Blow_vacuum_output_1 -> enter the $DOUT if the output enables blowing,

otherwise leave 0

– suction devices without information from vacuum meter

PARAMETER DESCRIPTION RANGEVacuum_active_input_1....Vacuum_active_input_5

Allows inserting the input signal ($DIN) to activatethe corresponding vacuum

$DIN[0…512]

Release_vacuum_output_1....Release_vacuum_output_5

Allows inserting the output signal ($DOUT) to stopaspiration

$DOUT[0…512]

Active_vacuum_output_1.... Active_vacuum_output_5

Allows inserting the output signal ($DOUT) toactivate aspiration

$DOUT[0…512]

Blow_vacuum_output_1

....Blow_vacuum_output_5

Allows inserting the output signal ($DOUT) toenable blowing $DOUT[0…512]


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In this case no $DIN is to be entered and the process routine is to be called with

the FALSE control flag.

GRIPPER : Part Present 1….5

To check the part presence on robot board – 3 inputs for presence microswitches

The parameters are the same for each device checking the part presence.

4.3.2.3.2 Config

In this sub-page the user can act on the GLOBAL Parameters settings, that operate in

real time on the handling process.

The corresponding menus are:

– Application program setting

– Reset alarms for TP/PLC.

The parameters corresponding to these two subpages are shown in the following tables

(Tab. 4.4 e Tab. 4.5), as well as their meaning and range of values.

Tab. 4.4 - Config - Applicat ion program settings


Part_present_input_1....Part_present_input_3

Allows inserting the part input signal ($DIN) $DIN[0…512]

NOTE THAT to use $DIN and $DOUT signals, please refer to Tab. 5.1 showing theprovided User shared resources.

PARAMETRO DESCRIZIONE RANGE

Clear outputEnables the outputs reset after the motioncompletion

[ON/OFF]

Drive off fault Enables drive off during anomalies [ON/OFF]

Status Output faultIndicates the status of the anomaly output towards

PLC

[ON/OFF]

Timeout alarmTimeout after a movement before a fault isgenerated

[1000..5000] [ms]

Waiting TimeWaiting time used before exiting from a routine, ifthe process is called without inputs check

[500..3000] [ms]

Timeout supervision

Time used in the dynamic part present check to filterany vibrations of the part during the movement; ifthe part present input is missing for the timeincluded in the filter, the application will not signal alost part

[100…1000] [ms]

Time blowing

Time used for the blowing pulse. If the indicated

time is 0 the application will not use the PULSEmode, but will directly set the output [0…3000] [ms]



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Tab. 4.5 - Config - Reset alarms from TP/ PLC

4.3.2.3.3 Air

This subpage allows enabling/disabling the pressure switches the User wishes to use in

the process, defining parameters needed to their handling.

The available menus in this Object page are:

– Enable pressure switches

– Air check 1..3

– Media Panel

Tab. 4.6 - Air - enable pressure switches

Air : Air check 1..3

It is allowed to access these subpages for defining each pressure switch

values/parameters, just after enabling such a device. Each subpage is similar to the

others: the only difference is the referenced device.


Reset from TP in T1The Teach Pendant reset is enabled with the mode

selector switch on T1 (Prog mode)

$DIN[0…512]

Reset form TP in AUTOThe Teach Pendant reset is enabled with the modeselector switch on AUTO (Local mode)

[ON/OFF]

Reset from TP in REMOTEThe Teach Pendant reset is enabled with the modeselector switch on REMOTE (Remote mode)

[ON/OFF]

Reset form PLC in T1Reset from PLC is enabled with the mode selectorswitch on T1 (Prog mode)

[ON/OFF]

Reset from PLC in AUTOReset from PLC is enabled with the mode selectorswitch on AUTO (Local mode)

[ON/OFF]

Reset from PLC in REMOTEReset from PLC is enabled with the mode selectorswitch on REMOTE Remote mode)

[ON/OFF]


Air check 1 Enable pressure switch 1 [ON/OFF]




Input Number Enter the number of the $DIN port to be used tocontrol the pressure switch

$DIN[0…512]

Gripper Index

Choose the gripper where the pressure switch isinstalled. If the pressure switch is not mounted onthe gripper, but on a station, enter No Gripper. Thisis because if there is the tool changer application, ifthe pressure switch is mounted on the gripper,during the release procedure the applicationpackage will have to mask the air control so that it

does not become connected again

[No Gripper/Gripper 1/Gripper 2/ Gripper 3]

Timeout Air Enter the filter time in ms to mask any pressurefluctuations in the system

[100…1000] [ms]


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Air : Media Panel

This subpage is always visible, but it is just enabled at the application package

installation creation time.

When enabled, it allows enabling/disabling the air pressure switch control on the Media

Panel

4.4 Integration of the application package withSystem environmentThis section describes the System environment pages providing information about the

application.

Such pages are:

– Alarm page

– I/O Page

4.4.1 Alarm page

This User Page (which is the System Alarm Page) the issued application alarms are

displayed.

Fig. 4.8 - Alarm Page

The following information is displayed for each message i:

– alarm order number

– error code and severity

– message text

– date and time.


PresentEnable/disable monitoring. Enabling this flag, thestate of a $DIN (previously configured by theapplication software), will be monitored

[ON/OFF]

Filter it is the Filter Time; insert the waiting time to be usedby the application software, before issuing an alarmmessage

[0..1000] [ms]


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An ALARM MESSAGE is displayed when SmartHand detects an anomalous condition

that requires the interruption of the process and the intervention of the operator. These

messages are only displayed following an operation performed by an instruction that

belongs to the Technological Instructions group. The message remains displayed until

SmartHand receives an alarm reset command.

The allowed Reset capabilities of the alarm can be:

– Retry (F1) - it is present depending on the alarm type; usually it is available when

an action is expected only. It repeats such an action

– Skip (F2) - it is present depending on the alarm type; it resets the alarm bypassing

its cause and goes ahead with the next operations.

– Reset (F3) - it has exactely the same functionality of the Teach Pendant RESET

key. The alarm is deleted and the event causing the alarm is checked again.

4.4.1.1 Errors cause and remedy

To know the cause of an application alarm and the corresponding available remedy, itis needed to type in the alarm number into the Cause and Remedy Window of WinC5G

interface, and issue Find command.

File hn_ms.crd, containing such information about SmartHand application, must be

added to the errors list, by means of the WinC5G Property Window, in the CRD File

field, byfirst pressing Edit key, and then Add key as shown in the following figures:

Fig. 4.9 - Property Window


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Fig. 4.10 - CRD f ile selection

File hn_ms.crd is present:

– on the PC, in the installation directory of WinC5G together with System alarms crd

files

– on the Controller in UD:\sys\msg\hn_ms.crd; it is copied in this directory duringSmartHand application installation.

If the alarm number typed in WinC5G Cause/Remedy Window is not found, the possible

reasons could be:

– file hn_ms.crd has not been added in WinC5G Property Window

– file hn_ms.crd is present but it could be not up to date; in this case the file stored

on the Controller must be added.

4.4.2 I/O Page

The I/Os handled by the application are grouped “by component” in a directory called

SMARTHAND.

Press I/O (L5) (left menu) to access it, moving focus on Ports subpage identified by the

tabsheet with this name, and selecting smarthand directory.

A list is displayed of all already configured (by means of the Setup Page) components.

Fig. 4.11 - I/O Ports

Fig. 4.12 shows an example of how I/Os are displayed.

For any further details about subpages and the use of the Alarm Page general

purpose softkeys, please refer to C5G Control Unit use manual, chap.Teach

Pendant - par. Alarm Page.


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Fig. 4.12 - Display ing I/Os

4.4.2.1 User Help I/Os

The I/Os comments, describing signals of each component configured on the GRIPPER

X ( where 'X' is the gripper number), are string variables included in hn_help_gripX.var

file.

The I/Os comments, describing inputs of the pressure switches which are NOT mounted

onto the gripper(s), are string variables included in hn_help_station_air.var file,

instead.

Such files, placed in UD:\\appl\\hio directory, are automatically generated by the

application only when the User modifies any values in the Setup Page. Depending on

the performed modification, the application will either generate a new var file or will

update the already existing one.

At the first installation, it is then possible that they are not present yet.The help strings aare never changed depending on the selected language; this allows

the User to directly customize them.

Let us suppose of modifying the configuration of sequence 1, input open 2, referred to

gripper 1, automatically generated by the application within hn_help_grip1.var file; it it

then:

hnvs_din_11_help STR Len: 128 Priv 'Grip 1 Seq 1 Input Open 2'

The item in Italic style is the string type variable name for the configured input: in this

case it is $DIN [11].

The item in bold style is the being modified string instead.

Example:

hnvs_din_11_help STR Len: 128 Priv 'Second input open of seq. 1, gripper 1'

To activate the new help string, it is necessary to perform a Restart Cold operation if

the string variable has been created for the first time; otherwise, if it was already exixting

and it has just been updated, issuing command 'ML/V'(Memory Load / Variables) of

the modified var file, is enough.

NOTE THAT such s trings are always and only generated in English language.


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Fig. 4.13 - Example of Help I/O

4.5 Integration with IDE environmentIn this section a detailed description is given on how to insert Technological Instructions

in the application program in IDE environment. A full analysis of such instructions is

given in par. 5.2 Technological Instructions on page 43.

4.5.1 Technological Instruction insertion in IDE environment

To insert Technological Instructions from within IDE environment, act as follows:

a. select the wished holdable program by pressing Prog (L3) key;

b. press ENTER to open the program in IDE environment, in order to edit it and insert

the required Technological Instructions

c. move the cursor to the line in which the required instruction is to be added, press

PDL2 (F3) key, choose Empty line and confirm with ENTER.

Fig. 4.14 - Inserting a Technological Instruction - example

NOTE THAT to con figure input and output signals ($DIN and $DOUT), it is neededto use IO_MAP program, available on the Teach Pendant in the SETUP age; please

refer to C5G Control Unit use manual, chap. SETUP Page, for further details.


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d. Press Statement (F1),

e. select SMARTHAND directory and confirm with ENTER; SmartHand application

Technological instructions are displayed and the User is requested to select the

wished one to be inserted in the program

Fig. 4.15 - Selecting the Technological instruction

f. In the shown above example (see Fig. 4.15), gripper_sequence instruction is

selected when pressing ENTER.

g. The System inserts the corresponding template (mask) for the required instruction

and the User must fill in all the fields and press ENTER to confirm.

Fig. 4.16 - Insertion complet ion

The above described insertion procedure is the same for each Technological

Instruction.

A functionality exists which makes inserting an application instruction faster, in IDE

environment.

Press SHIFT + '1' to activate such a functionality; a table is open, called Numeric

Keypad , which associates the numeric keys of the TP Alphanumeric Keypad, to the

application Technological Instructions (see Fig. 4.17).


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Fig. 4.17 - Use of the Numeric Keypad

By pressing any numeric key corresponding to an instruction, that same instruction will

be entered in the program.It is possible to enter instructions in an even quicker way: in the IDE environment, press

SHIFT + the numeric key associated to the desired instruction, at the same time,

without opening the numeric Keypad; the system will add the instruction to the program.

For example, (refer to Fig. 4.17) if the user presses SHIFT and 2 at the same time,

without opening the keypad, gripper_sequence technological instruction will be added

to the program.

Summarizing, the keys to control the numeric Keypad are the following ones:

– SHIFT + ‘1’ - opens the numeric Keypad

– ‘n’ - when the numeric Keypad IS OPEN, adds the instruction corresponding to ‘ n’

key and closes the numertic Keypad. – SHIFT + ‘n’ - when the numeric Keypad IS NOT OPEN, adds the instruction

corresponding to ‘n’ key, to the program.

– PAGE UP / PAGE DOWN - changes the numeric Keypad pages.

– up/down/right/left arrows - allows moving within the numeric Kaypad.

– ESC - closes the numeric Keypad without adding any instruction to the program.

– ENTER - adds the currently selected instruction (in the numeric keypad) to the

program and closes the numeric Keypad.


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5. PROGRAMMING

5.1 IntroductionThis chapter gives detailed information to the user who has to write programs for the

Handling application.

The following topics are dealt with in detail:

– Technological Instructions

– Handling RESET key

– Using the System shared resources.

5.2 Technological Instructions

The user has several technological instructions available, dedicated to the handling

process. They are grouped in the following classes:

– Process routines

– Advanced variables and routines.

5.2.1 Process routines

– Gripper_sequence

– Gripper_vacuum

– Gripper_vacuum_blow

– Gripper_chkpart

– Grip_part_supervision

– Grip_air_supervision.

Find below a detailed description of each Technological Instruction related to the

SmartHand application software.

5.2.1.1 Gripper_sequence

Name Gripper_sequence

Function/Usage Manages the clamps opening and closing command. Used to command a clamping.

Parameters

– ai_grip: gripper to be used - 1 .. 3 (INTEGER)

– ai_seq: sequence to be used - 1 .. 6 (INTEGER)

– ab_state: ON -> calls the sequence closure

OFF -> calls the sequence opening ON / OFF(BOOLEAN)

– ab_check (optional parameter): ON -> inputs checked

OFF -> inputs check excluded - ON / OFF(BOOLEAN)

Statementgripper_sequence (ai_grip, ai_seq:INTEGER; ab_state,

ab_check:BOOLEAN) EXPORTED FROM H_hand GLOBALEntering from IDE NO


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5.2.1.2 Gripper_vacuum

5.2.1.3 Gripper_vacuum_blow

Calling example

ROUTINE gripper_sequence (ai_grip, ai_seq:INTEGER; ab_state,

ab_check:BOOLEAN) EXPORTED FROM H_hand GLOBAL

BEGIN

Gripper_sequence( 1, 1, ON, ON)

...

END prog_1

Name Gripper_vacuum

Function/UsageManages the vacuum work and idle command. Used when a vacuum is to becontrolled.

Parameters


– ai_seq: suction device to be used - 1 .. 6 (INTEGER)

– ab_state: ON -> calls aspiration

OFF -> stops aspiration - ON / OFF(BOOLEAN) – ab_check (optional parameter): ON -> vacuum meter check

OFF -> vacuum meter check off - ON / OFF(BOOLEAN)

Statementgripper_vacuum (ai_grip, ai_vac : INTEGER; ab_state, ab_check :

BOOLEAN)EXPORTED FROM H_hand GLOBAL

Entering from IDE NO

Calling example

ROUTINE gripper_vacuum (ai_grip, ai_vac : INTEGER; ab_state,

ab_check : BOOLEAN)EXPORTED FROM H_hand GLOBAL

BEGIN

Gripper_vacuum( 1, 1, ON, ON)

...

END prog_1

Name Gripper_vacuum_blow

Function/Usage Manages the vacuum blowing. Used issue vacuum blowing.

Parameters


– ai_seq: suction device to be used - 1 .. 6 (INTEGER)

– ab_state: ON -> calls blowing

OFF -> stops blowing - ON / OFF(BOOLEAN) – ab_check (optional parameter): ON -> vacuum meter check

OFF -> vacuum meter check off - ON / OFF(BOOLEAN)

Statementgripper_vacuum_blow(ai_grip, ai_vac:INTEGER; ab_state,

ab_check:BOOLEAN)EXPORTED FROM H_hand GLOBAL


Calling example

ROUTINE gripper_vacuum_blow(ai_grip, ai_vac:INTEGER; ab_state,

ab_check:BOOLEAN)EXPORTED FROM H_hand GLOBAL

BEGIN

Gripper_vacuum_blow( 1, 1, ON, OFF)

...

END prog_1


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5.2.1.4 Gripper_chkpart

5.2.1.5 Grip_part_supervision

5.2.1.6 Grip_air_supervision

Name gripper_chkpart

Function/UsageManages the part presence or absence check. Used to check the presence or absenceof the part.

Parameters


– ai_part : part presence to be used - 1 .. 5 (INTEGER)

– ab_state: ON -> check presence

OFF -> check absence - ON / OFF(BOOLEAN)

Statementgripper_chkpart(ai_grip, ai_part : INTEGER; ab_state :



Calling example

ROUTINE gripper_chkpart(ai_grip, ai_part : INTEGER; ab_state :

BOOLEAN) EXPORTED FROM H_hand GLOBAL

BEGINgripper_chkpart( 1, 1, ON)

...

END prog_1

Name grip_part_supervision

Function/UsageManages the part presence or absence dynamic check. Used to activate or deactivatethe part presence dynamic check.

Parameters

– ai_grip: gripper to be used - 1 .. 3 (INTEGER) – ai_part : part presence to be used - 1 .. 5 (INTEGER)

– ab_state: ON -> enable dynamic check

OFF -> disable dynamic check - ON / OFF(BOOLEAN)

Statementgrip_part_supervision(ai_grip, ai_part : INTEGER; ab_state :



Calling example

ROUTINE grip_part_supervision(ai_grip, ai_part

handling System Robotic

Documents

Transcript of handling System Robotic