Manual Motoman

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Part Number: Release Date: Document Version: Document Status:

133388-1 May 13, 1997 2 Final

Motoman, Incorporated 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-Hour Service Hotline: (937) 847-3200

The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman, Inc. ©2003 by MOTOMAN All Rights Reserved Because we are constantly improving our products, we reserve the right to change specifications without notice. MOTOMAN is a registered trademark of YASKAW YASKAWA Electric Manufacturing.

The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman, Inc. ©2003 by MOTOMAN All Rights Reserved Because we are constantly improving our products, we reserve the right to change specifications without notice. MOTOMAN is a registered trademark of YASKAW YASKAWA Electric Manufacturing.

Se ct io n 4.3

Page

CONFIRM CONFIRMING ING RELATIVE RELATIVE JOB INFORMAT INFORMATION... ION..... .... ..... ..... .... .... ..... ..... .... .... ..... ....2 .26 6 4.3. 4.3.11 4.3.2 4.3.3 4.3 .3

4.4

Coord Coordina inate te Confi Confirma rmati tion. on.... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...26 26 Comm Comman andd Posi Positi tion on Conf Confir irma mati tion on ...... ............. .............. ............. ............. .............. .......27 27 Disp Displa layi ying ng Diff Differ eren ence cess bet betwe ween en Comm Comman andd and and Curr Curren ent t Position........................................................................27 EDITING EDITING THE RELATIVE RELATIVE JOB ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....27 27

5.0 SIMPLIFIED OFF-LINE TEACHING SYSTEM................... SYSTEM...... .......................... .......................... ...............29 ..29 5.1 5.1

JOB DATA FORMAT ....... .......... ....... ....... ...... ....... ....... ...... ....... ....... ....... ....... ...... ....... ....... ...... ....... ....... ...... ......2 ...29 9

5.2

EXAMPLES EXAMPLES OF JOB DATA........ DATA........... ....... ....... ...... ....... ....... ....... ....... ...... ....... ....... ...... ....... ....... ...... ......3 ...35 5 5.2. 5.2.11 Rela Relati tive ve Job Job Wit Withh R Robo obott Axes Axes and User User Fram Framee 3 ....... .......... ....... .....35 .35 5.2. 5.2.22 Robo Robott Axes Axes + Base Axes Axes (Bas (Basee Frame Frame)... )..... .... .... .... .... .... .... .... .... .... .... .... ....3 ..36 6 5.2. 5.2.33 Robo Robott Axe Axess + Base Base Axes Axes + Sta Stati tion on Axes Axes (Bas (Basee Fra Frame me,, Synchr Synchrono onous us Job) Job) ................................................... .............................................................36 ..........36 5.2. 5.2.44 Robo Robott Axe Axess + Base Base Axes Axes + Sta Stati tion on Axes Axes (Bas (Basee Fra Frame me,, Coordi Coordinat nated ed Job) Job) ..................................................... ...............................................................37 ..........37 5.2. 5.2.55 Robo Robott Axe Axess + Robo Robott Axe Axess (Ba (Base se Fram Frame, e, Coordi Coordinat nated ed Job) Job) ..................................................... ...............................................................38 ..........38 CONFIGURA CONFIGURATION TION OF POSITI POSITION ON DATA..... DATA....... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... ....3 ..39 9

5.3 5.3 5.4 5.4

5.5 5.5

CONFIGURA CONFIGURATION TION OF THE THE MANIP MANIPULATO ULATOR... R..... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... ....4 ..411 5.4. 5.4.11 Spec Specif ific icat atio ionn of Wris Wristt Angle..... Angle........ ....... ....... ...... ....... ....... ....... ....... ...... ....... ....... ...... .....41 ..41 5.4.2 5.4 .2 Specif Specifica icati tion on of the Base Base Three Three Axes.. Axes..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....43 .43 ROBOT ROBOT FORM CONTROL CONTROL METHOD METHODS S .... ....... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... ....4 ..45 5 5.5. 5.5.11 Movi Moving ng the the R-a R-and nd T-Ax T-Axes es to Pres Preser erve ve the the Sig Sign n of the B-Axis....................................................................45 5.5. 5.5.22 Movi Moving ng R-, R-, B-, B-, and and T-Ax T-Axes es to to Pres Preser erve ve the the Rob Robot ot's 's Form of the Destination Destination Point ...........................................47 ...........................................47

6.0 ALARM AND ERROR MESSAGES....................................................... MESSAGES ................................................................ ......... 51 6.1 6.1

ALARM ALARM MESSAG MESSAGES ES ....... .......... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ....... ....... ....... ...... ....... .....5 .511

6.2

ERROR ERROR MESSAG MESSAGES. ES.... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ..... 51

7.0 INSTRUCTIONS USED IN RELATIVE JOB ........................................ ................... ...............................53 ..........53 8.0 MRC TOOL TOOL CENTER POINT DEFINITION.. DEFINITION................ ........................... .......................... ......................55 .........55 8.1

MANUAL TCP DEFINITION ....... .......... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ....... ....... ....... ...... .....55 ..55

8.2 8.2

AUTOMATIC AUTOMATIC TCP DEFINITIO DEFINITION N .... ...... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..56 56

I N D E X .................................................. ......................................................................................................... .......................................................... ...Index Index

Relative Job Function, MRC

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LIST OF FIGURES Figure

Page

Figure 3-1 Standard Job Pulse Position Data........................................................9 Figure 3-2 Relative Job X, Y, and Z Position Data.............................................. 10 Figure 3-3 Base, Robot, and User Coordinates................................................... 11 Figure 3-4 Relative Job Shift Function ...............................................................12 Figure 3-5 Teaching Job in Standard Position..................................................... 15 Figure 3-6 Teaching X, Y, and Z Points..............................................................16 Figure 3-7 User Frame Before and After Modification....................................... 16 Figure 3-8 Example of Searching Out Defined Points Using External Vision Controller.....................................................................................17 Figure 3-9 After Job is Initially Taught, Job is Shifted to Other Positions ........... 18 Figure 3-10 Shift to Multiple Manipulators..........................................................20 Figure 5-1 Command Levels Used in Relative Job................................................30 Figure 5-2 Base Coordinate System...................................................................39 Figure 5-3 Robot Coordinate System..................................................................40 Figure 5-4 User Coordinate System...................................................................40 Figure 5-5 Flip and No-Flip Positions of Wrist Angle...........................................42 Figure 5-6 Angle of R-Axis................................................................................42 Figure 5-7 Angle of T-Axis ................................................................................43 Figure 5-8 Front and Back Positions of S-Axis Turned at 0˚ and 180˚.................44 Figure 5-9 Upper and Lower Elbow Positions of L- and U- Axes .........................44 Figure 5-10 B-Axis "+" and "-" Range .................................................................45 Figure 5-11 Actual Motion of the R-Axis.............................................................46 Figure 5-12 Anticipated Motion of the R-Axis......................................................46 Figure 5-13 Flip and No-Flip Positions of the R-Axis............................................47 Figure 5-14 Robot Motion During a Job Shift ......................................................48 Figure 8-1 Tool Center Point .............................................................................55 Figure 8-2 Pointer.............................................................................................56


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LIST OF TABLES Table

Page

Table 5-1 Parameter and Values Used in Robot Form Control Methods ..............48 Table 6-1 Alarm Messages ................................................................................ 51 Table 6-2 Error Messages.................................................................................51 Table 6-3 Messages ..........................................................................................52 Table 7-1 List of Instructions.............................................................................53


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1.0 INTRODUCTION The relative job function is a software option used when programming a robot offline. It allows a job to be converted from pulse counts to Cartesian coordinates so that it may be edited off-line with a software package or shifted by a sensor. This enables the user to develop robot programs without having an in-depth knowledge of the robot arm configuration and the complicated mathematics required to convert between joint angles and Cartesian coordinates. It also allows users to create programs that are independent of the robot arm type (e.g., a program that is written in Cartesian coordinates for a K10 will also run on a K6 or K30). Relative Job is used with: •

Vision systems

•

Sensor systems

•

Off-line programming (Robot Calibration and Tool Calibration should be performed on robots that are running jobs that have been created off-line.)

•

Touch Sense

Relative job also has the ability of on-line 3-D shift. Jobs can be created based on a part frame. Sensor input can be used to make a new frame, and the program can then be executed for a new part position. Because the positions are based on the Tool Center Point (TCP) position, updates can be made to the tool information and translated to the path.

1.1

1.2

REFERENCE TO OTHER DOCUMENTATION •

Motoman MRC Robotic Arc Welding Manual (Part Number 132335-1)

•

Motoman MRC User Functions (Part Number 132331-1)

•

Motoman MRC Operator's Manual for Arc Welding (Part Number 132332-1)

•

Motoman MRC Operator's Manual for Handling (Part Number 132332-2)

•

Motoman MRC Operator's Manual for Jigless (Part Number 132332-3)

•

Motoman MRC Operator's Manual for Spot Welding (Part Number 132332-4)

•

Motoman Manipulator Manual (Part Number 132330-x) (for your robot type)

CUSTOMER SERVICE INFORMATION If you are in need of technical assistance, contact the Motoman service staff at (513) 847-3200. Please have the following information ready before you call: •

Robot Type (K3, K6, K10, etc.)

•

Robot Serial Number (located on the back side of the robot arm)

•

Application Type (palletizing, welding, handling, etc.)

•

Software version (appears on power-up screen)


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NOTES


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2.0 SAFETY It is the purchaser's responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed. We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots Robots and Robot Systems. This information information can be obtained from the Robotic Industries Association by requesting ANSI/RIA R15.06. The address is as follows: Robotic Industries Association 900 Victors Way P.O. Box 3724 Ann Arbor, Arbor, Michigan Michigan 48106 TEL: 313/994-6088 FAX: 313/994-3338 Ultimately, the best safeguard is trained personnel. personnel. The user is responsible for providing personnel who are adequately trained to operate, program, and maintain the robot cell. The robot must not be operated by personnel who have not been trained! We recommend that all personnel who intend to operate, program, repair, or use the robot system be trained in an approved Motoman training course and become familiar with the proper operation of the system. This safety section addresses the following: •

Stan Standa dard rd Conv Conven enti tion onss (Sec (Sectio tion n 2.1) 2.1)

•

Gene Genera rall Safe Safegu guar ardi ding ng Tip Tipss (Sec (Secti tion on 2.2) 2.2)

•

Mechan Mechanica icall Safe Safety ty Device Devicess (Sec (Sectio tion n 2.3) 2.3)

•

Inst Instal alla lati tion on Safe Safety ty (Sec (Secti tion on 2.4) 2.4)

•

Prog Progra ramm mmin ing g Safe Safety ty (Sec (Secti tion on 2.5) 2.5)

•

Oper Operat atio ion n Safe Safety ty (Sec (Secti tion on 2.6) 2.6)

•

Main Mainte tena nanc ncee Saf Safet ety y (Se (Sect ctio ion n 2.7 2.7))


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2.1

STAN DAR D CO NV ENTI ON S This manual includes information essential to the safety of personnel and equipment. As you read through this manual, be alert to the four signal words: • • • •

DANGER WARNING CAUTION NOTE

Pay particular attention to the information provided under these headings which are defined below (in descending order of severity).

DANGER! Information appearing under the DANGER caption concerns the protection of personnel from the immediate and imminent hazards that, if not avoided, will result in immediate, serious personal injury or loss of life in addition to equipment damage.

WARNING! Information appearing under the WARNING caption concerns the protection of personnel and equipment from potential hazards that can result in personal injury or loss of life in addition to equipment damage.

CAUTION! Information appearing under the CAUTION caption concerns the protection of personnel and equipment, software, and data from hazards that can result in minor personal injury or equipment damage. NOTE: NOTE:

Info Inform rmat atio ionn app appea eari ring ng in a NOT NOTEE cap capti tion on prov provid ides es addi additi tion onal al info inform rmat atio ionn whi which ch is help helpfu full in in understanding the item being explained.


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2.2

GE N ER A L SA F EG U A R DI N G T I PS All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must must understand potential potential dangers of operation. General safeguarding safeguarding tips are as follows:

2.3

•

Improper Improper operatio operation n can result result in perso personal nal injur injury y and/or and/or dama damage ge to the equipment. Only trained personnel personnel familiar with the operation of this robot, robot, the operator's manuals, the system equipment, and options and accessories should be permitted to operate this robot system.

•

Do not not enter enter the the robot robot cell while while it is in automati automaticc operat operation. ion. Programm Programmers ers must must have the teach pendant when they enter the robot cell.

•

Improper Improper connections connections can damage damage the robot. All connections connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

•

The robot robot must must be be placed placed in Emer Emergen gency cy Stop Stop (E-Stop (E-Stop)) mode mode wheneve wheneverr it is not not in use.

•

In accord accordance ance with ANSI/RI ANSI/RIA A R15.06 R15.06,, section section 6.13.4 6.13.4 and and 6.13.5, 6.13.5, use lockout/tagout procedures procedures during equipment maintenance. maintenance. Refer also to Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).

MEC H A N I C A L SA FE TY D E VI C E S The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's re responsibility. sponsibility. The conditions under which the equipment will be operated safely should be reviewed by the user. The user must be aware of the various national codes, ANSI/RIA R15.06 safety standards, and other local codes that may pertain to the installation and use of industrial equipment. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. The following safety measures are available: •

Safe Safety ty fenc fences es and and bar barri rier erss

•

Light curtains

•

Door in interlocks

•

Safety mats

•

Floor ma markings

•

Warning lights

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately.


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2.4

INSTALLATION SAFETY Safe installation is essential for protection of people and equipment. The following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. Installation tips are as follows:

2.5

•

Be sure that only qualified personnel familiar with national codes, local codes, and ANSI/RIA R15.06 safety standards are permitted to install the equipment.

•

Identify the work envelope of each robot with floor markings, signs, and barriers.

•

Position all controllers outside the robot work envelope.

•

Whenever possible, install safety fences to protect against unauthorized entry into the work envelope.

•

Eliminate areas where personnel might get trapped between a moving robot and other equipment (pinch points).

•

Provide sufficient room inside the workcell to permit safe teaching and maintenance procedures.

PROGRAMMING SAFETY All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Programming tips are as follows: •

Any modifications to PART 1 of the MRC controller PLC can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to PART 1. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY!

•

Some operations require standard passwords and some require special passwords. Special passwords are for Motoman use only. Y O U R WARRANTY WILL BE VOID if you use these special passwords.

•

Back up all programs and jobs onto a floppy disk whenever program changes are made. To avoid loss of information, programs, or jobs, a backup must always be made before any service procedures are done and before any changes are made to options, accessories, or equipment.

•

The concurrent I/O (Input and Output) function allows the customer to modify the internal ladder inputs and outputs for maximum robot performance. Great care must be taken when making these modifications. Double-check all modifications under every mode of robot operation to ensure that you have not created hazards or dangerous situations that may damage the robot or other parts of the system.

•

Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this robot should be permitted to operate the system.


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2.6

•

Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

•

Be sure that all safeguards are in place.

•

Check the E-STOP button on the teach pendant for proper operation before programming.

•

Carry the teach pendant with you when you enter the workcell.

•

Be sure that only the person holding the teach pendant enters the workcell.

•

Test any new or modified program at low speed for at least one full cycle.

OPERATION SAFETY All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Operation tips are as follows: •

Be sure that only trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories are permitted to operate this robot system.

•

Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.

•

Inspect the robot and work envelope to ensure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

•

Ensure that all safeguards are in place.

•


•

Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the cell.

•

The robot must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

•

This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller, external servo box, and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

•

All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot. This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modifications. Check and test all changes at slow speed.


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2.7

MAINTENANCE SAFETY All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Maintenance tips are as follows: •

Do not perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual.

•

Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.

•


•

Back up all your programs and jobs onto a floppy disk whenever program changes are made. A backup must always be made before any servicing or changes are made to options, accessories, or equipment to avoid loss of information, programs, or jobs.

•

Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the cell.

•

The robot must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

•

Be sure all safeguards are in place.

•

Use proper replacement parts.

•

This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller, external servo box, and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

•

All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot. This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modifications. Check and test all changes at slow speed.

•

Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).


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3.0 RELATIVE JOB USAGE This section will discuss the differences between relative job and standard job, introduce the three coordinate systems used in relative job, as well as illustrate several examples of relative job usage.

3.1

RELATIVE JOB DESCRIPTION Relative job is distinguished from standard job in that the latter is based on a joint coordinate system using S-, L-, U-, R-, B-, and T-axes (see Figure 3-1). Relative Job, however, utilizes a Cartesian coordinate system, using X-, Y-, and Z-axes to define position data (see Figure 3-2).

U+ R+

B+

T+

URL-

T-

S+

S-

Figure 3-1


B-

L+

Standard Job Pulse Position Data

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When teaching points with the programming pendant, the actual position values are not relevant to the operator. They are, however, relevant to the robot's memory, enabling the robot to recognize a particular position in space. Coordinate numbers are also important when any off-line programming is taking place, as the actual coordinate numbers are defined in the computer before being transferred to the MRC controller (see Section 5.0 ). If desired, the MRC controller can display the current or taught robot position as X, Y, and Z coordinates or as encoder pulse counts for each axis. Downloaded jobs will display positional information with encoder pulse count values or X, Y, and Z, depending on whether the job is standard or relative.

Z Axis

X Axis

Y Axis

Figure 3-2

Relative Job X, Y, and Z Position Data

Other software functions will allow individual points or whole programs to be temporarily shifted or permanently moved in X, Y, or Z directions. With relative job, programs are taught as usual and then converted to X, Y, and Z positions relative to a particular coordinate frame. When a new frame position is defined, all points in the job are shifted in the X, Y, and Z directions as well as rotated with respect to the origin.


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3.1.1

Coordinate Systems In relative job, the following three different coordinate systems may be used (see Figure 3-3), which include base coordinates, robot coordinates, and user coordinates.

Tool Coordinates

Robot Coordinates

Base Coordinates User Coordinates

User Coordinates

Figure 3-3 •

Base, Robot, and User Coordinates

Base Coordinate System Base coordinates apply when the robot is on a track, otherwise they are the same as robot coordinates.

•

Robot Coordinate System Robot coordinates are centered on the base rotation with zero elevation even with the L- and U- axis motors.

•

User Coordinate System (24 Frames) User coordinates are defined by three points; an origin, X direction, and Y direction. Most relative job applications will be based on user coordinates. The user coordinate (frame) is defined by an origin point, and X-axis datum, and a Y-axis reference. The origin point is used to establish the location of the frame. The XX point establishes the positive X direction. It does not matter how far the XX point is from the origin. The Z-axis is at a right angle from the XX point. The XY point establishes the angle of XY plane and the positive Z direction. For more information on user coordinates, see the User Coordinate System Section in the Operator's Manual for your specific application.


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3.1.2

Relative Job Shift Function

WARNING! If the user coordinate number selection is changed carelessly, it is possible that the manipulator may not move in the anticipated direction when executing the job. Use caution when modifying coordinate systems.

CAUTION! If the steps taught in MOVJ are shifted, the motion to the instructed steps might differ. Use caution so that the fixture or other parts do not interfere with the robot's movement. If a user coordinate system is being used in the relative job and the ORG, XX, or XY points are modified, creating a different user coordinate (frame), a shift to the program will occur. The relative job's programmed positions always remain the same. Job shifting is accomplished by changing or specifying a new coordinate location (see Figure 3-4). Z Axis

Z Axis

Y Axis

Y Axis

X Axis X Axis

User Coordinate No. 1 Figure 3-4

3.1.3

Defined Points After User Coordinate Shift Relative Job Shift Function

Tool Center Point A well-defined Tool Center Point (TCP), also referred to as Tool Control Point (see Section 8.0 for MRC TCP definition), is necessary for relative job. The robot will move the TCP to the X, Y, Z position in the relative job. Changing the TCP will affect the position to which the robot will move. The TCP is also used in the calculation required to convert a pulse job to a relative job. Refer to the Operator's Manual for your specific application for information on defining a TCP.


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3.1.4

Standard Pulse Job Format An encoder is connected to the motor shaft of each axis. When a point is taught the encoder pulse count value for each axis is stored. The encoder values are an easy reference for the robot because they relate to the angles for each joint of the arm. Encoder information also eliminates redundant position or direction information which can occur with Cartesian coordinates. Redundant positions can be illustrated with a circle in which 0 degrees and 360 degrees define the same position. The job header information indicates that the job is in a pulse format. The positional information is referenced separately from the move instructions. Separation of the positional information and move instructions allows motion type of a point to be edited without affecting its position. The position references use the following format: C0000 = S-axis, L-axis, U-axis, R-axis, B-axis, T-axis The following represents the standard pulse format of a simple job, ROBCAL: /JOB //NAME ROBCAL //POS ///NPOS 5,0,0,0,0,0 ///TOOL 0 ///POSTYPE PULSE ///PULSE C0000=10837,26902,-37781,3031,5985,-2564 C0001=12537,24145,-42521,8902,6556,-6188 C0002=8112,37524,-34331,138,1362,-998 C0003=14160,30655,-40077,5519,3881,-2961 C0004=7555,22735,-39080,-841,8992,-1254 //INST ///DATE 1995/07/10 09:25 ///ATTR SC,RW ///GROUP1 RB1 NOP MOVJ C0000 VJ=0.78 MOVJ C0001 VJ=0.78 MOVJ C0002 VJ=0.78 MOVJ C0003 VJ=0.78 MOVJ C0004 VJ=0.78 END


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3.1.5

Relative Job Format Relative job positioning is based on Cartesian coordinates. Three dimensional space is defined by X-,Y-, and Z-axes. The point located at 0,0,0 is defined as the origin. Every point also has specified angles about the X-, Y-, and Z-axes to define the tool orientation (Rx, Ry, Rz). The frames of robot and base coordinates are in a fixed position. With user coordinates, however, frames can be programmed anywhere in the robot's envelope in a variety of orientations. The job header information indicates that the job is in a relative job format. The positional information is referenced from the robot frame. The position references use the following format: C0000 = X (0.000 mm), Y (0.000 mm), Z (0.000 mm) Rx (0.00 deg), Ry (0.00 deg), Rz (0.00 deg) The following represents the format of the same job, ROBCALR, in Relative Job format: /JOB //NAME ROBCALR //POS ///NPOS 5,0,0,0,0,0 ///TOOL 0 ///POSTYPE ROBOT ///RECTAN ///RCONF 0,0,0,0,0 C0000=953.401,420.794,31.145,176.00,1.34,4.95 ///RCONF 1,0,0,0,0 C0001=956.305,419.772,30.668,173.42,-26.15,5.55 ///RCONF 0,0,0,0,0 C0002=951.477,420.561,31.288,-179.97,39.83,6.51 C0003=953.168,419.189,29.995,145.17,-0.67,6.17 C0004=954.199,422.637,33.045,-153.07,-5.73,2.31 //INST ///DATE 1995/07/10 12:19 ///ATTR SC,RW,RJ ////FRAME ROBOT ///GROUP1 RB1 NOP MOVJ C0000 VJ=0.78 MOVJ C0001 VJ=0.78 MOVJ C0002 VJ=0.78 MOVJ C0003 VJ=0.78 MOVJ C0004 VJ=0.78 END


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3.2

EXAMPLES OF RELATIVE JOB USAGE This section will provide examples of several different types of relative job usage including shift for a damaged tool, job shift, shift to multiple manipulators, and simplified off-line teaching.

3.2.1

Shift for Damaged Tool Relative job moves the Tool Center Point (TCP) to the programmed coordinates. If the tool is bent, it will not be in the proper position. A bent tool can be easily compensated for by teaching a new TCP (see Section 8.0 for TCP programming procedure). With the new TCP defined, the tool will now be aligned in the proper position. All relative jobs that use this tool will be aligned.

3.2.2

Job Shift After a job is taught as a standard job in the standard position, a user frame is set up and the job is converted to a relative job. If the fixture location is incorrect, during execution of the job, the user frame can be recreated in the new position, allowing the robot to continue executing the job. An example follows: 1. Place the work in a standard position and teach the job as usual as usual (see Figure 3-5). Name the job [STDJOB-1]. (The name of the job should not exceed 8 characters in length.)

Figure 3-5

Teaching Job in Standard Position

2. Create a user frame. Initially teach the frame using the programming pendant to teach the origin (ORG), X direction (XX), and Y plane (XY). (See Figure 3-6.)


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Z Axis

Y Axis

X Axis

Figure 3-6

Teaching X, Y, and Z Points

3. Convert the job to a relative job. The actual operation of the job conversion is as follows: [STDJOB -1] is modified to User Coordinate No. 1, and the relative job, [RELJOB -1], is created. (See Section 4.0 Relative Job Operation for keystroke information on converting the standard job.) 4. If the fixture or workpiece is moved, the user frame can be realigned by teaching the ORG, XX, and XY points. The job can then be executed using the modified user frame (see Figure 3-7).

User Frame Before Modification

User Frame After Modification

Position During Teaching

Figure 3-7


User Frame Before and After Modification

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5. Teach frames manually for periodic movement. The following is an example where user frames are updated for every part: The vision controller searches out the three defined points of the user frame (see Figure 3-8) and each subsequent job is executed on that newly established coordinate frame.

Camera YA SN MR AC C

Z Axis

Y Axis c

External Computer, Vision Controller, etc.

a

Position Data of a, b, and c to MRC Controller

b

X Axis

Figure 3-8

Example of Searching Out Defined Points Using External Vision Controller An example of a program that would read the three defined points from the vision controller and create the frame follows:

FUNCTION NOP LOADV P000 LOADV P001 LOADV P002

COMMENTS

}

MFRAME UF# (1) P000 P001 P002

Position data detected by the external sensor are received and the position variable is stored.

User coordinate is generated. Moved to stand-by position.

MOVJ VJ = 50.0

Execution of User Coordinate #1 [RELJOB-1]. (The name of the job should not exceed 8 characters in length.)

CALL JOB: RELJOB-1

END


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3.2.3

Using One Manipulator for Work in Multiple Positions

CAUTION! In some cases, the robot may not be able to reach all points of the job. Try to orient the fixture so that the robot can reach all points without modification. NOTE:

In the first example, it is possible to adjust individual points of each job since they are separate jobs. The second example, however, is a better use of the robot's memory. Each situation and its usage should be taken into consideration. Once the manipulator has been taught a job, that job can be shifted to other positions (see Figure 3-9).

Work

Robot

B

A

C

Figure 3-9

After Job is Initially Taught, Job is Shifted to Other Positions

An example of this follows: 1. Teach a job on the fixture. 2. Create user coordinates on the fixture that the above job was taught on; for example, UF#1. 3. Convert the job created in Step 1 using the user coordinate in Step 2 to a relative job. (See Section 4.0, Relative Job Operation, for keystroke information on converting the standard job.)


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4. Move the workpiece to another position, and in that position, a different user coordinate (for example, UF#2) is taught. 5. The job header screen of the relative job created in Step 3 displays the user coordinate (UF#1) which was taught in Step 1. Edit this to be the user coordinate which was taught in Step 4 (UF#2). 6. Use the relative job function to convert the job in Step 5 back to a pulse-type job. 7. If another job needs to be created, repeat Steps 4 through 6 can be used. One relative job can also be executed in multiple positions. An example of this follows: 1. Teach a job (for example, ABCDEF) on the fixture. 2. Create user coordinates on the fixture that the above job was taught on; for example, UF#1. 3. Use the relative job function and convert the job from Step 1 using the user coordinate frame from Step 2. 4. Set up an identical fixture in a new position and create a different user coordinate on the fixture; for example, UF#2. 5. You can specify in the CALL instruction which fixture (user frame) to execute the job on. EXAMPLE: NOP CALL JOB : ABCDEF UF#(2) END When the CALL command is executed, relative job ABCDEF, which was taught on UF#1, works on UF#2. 6. If you need to set up additional user fixtures on which the job needs to be executed, repeat Steps 4 and 5, creating additional user frames on the additional fixtures.

3.2.4

Shift to Multiple Manipulators

CAUTION! There is a possibility that the robot will not be able to execute the job in the playback position. Be sure to press FWD/BKWD to confirm the playback position. A job that has been taught on one robot can be shifted to other robots on the production line (see Figure 3-9). An example of copying a job to the next manipulator follows: 1. Teach the job on robot 1. 2. Set up a user frame (for example UF#1) around the fixture on which the job was taught.


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3. Convert the job created in Step 1 to a relative job using the user frame in Step 2. 4. Save the relative job to a floppy disk, using the FC1/FC2 floppy disk drive. 5. Set up a user frame using the same user frame number as was used in Step 2 on robots 2 and 3 on their fixtures. 6. Load the relative job which was saved in Step 4. 7. Convert the job back to a standard pulse job in robots 2 and 3 if desired.

Work

Robot

No. 1

No. 2

No. 3

Figure 3-10 Shift to Multiple Manipulators

3.2.5

Simplified Off-Line Teaching

CAUTION! Positions that are taught off-line should be verified in Teach Mode before executing a program in play. Simplified off-line teaching of the relative job can be executed when using a FC1/FC2 floppy disk drive or a computer. 1. Load the following data into the computer: •

Manipulator position data (X,Y,Z)

•

Instructions

2. Convert the data into a program (relative job) for the MRC using the computer. 3. Transfer the relative job to the MRC controller. The following two methods can be used for data transfer: •

Save job data on a floppy disk and transfer to the MRC via the Yasnac FC1 or FC2 floppy disk drive.

•

Send job data from the computer to the MRC controller with communication software.


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3.3

INSTRUCTIONS USED IN RELATIVE JOB This section includes an overview of CALL and JUMP instructions used when executing a relative job, as well as MFRAME instructions used when generating new user coordinates (frames).

3.3.1

CALL/JUMP

CAUTION! When executing a relative job, the manipulator maintains its current orientation. For this reason, during teaching, the robot should be oriented similar to how it will be oriented in the first step of the relative job. If the position of the robot is extremely different from that of the robot in the first step of the relative job, there is a possibility that the robot will not perform the work as anticipated. Calling a relative job is executed by using the CALL or JUMP instruction. If the coordinate number is omitted, the job is automatically executed using the coordinates on which it was originally converted on, for example: CALL JOB: JOB -1 JUMP JOB: JOB -1 IF IN#(1)= OFF If the coordinate system used during teaching is a user coordinate, when the CALL or JUMP instruction is called up, another coordinate system other than the one used during teaching can be used. The following is an example: The relative job [JOB-1], which has been converted in user frame No. 1, can be executed using a different frame by specifying it in the call instruction. [JOB-1] is executed with the user coordinate value of No. 2. CALL JOB : JOB - 1 UF# (2) To enter a CALL or JUMP instruction, follow these steps: 1. While in Teach Mode, move the cursor to Address side of the screen and press EDIT. 2. Press CONTROL (F2). 3. Press JUMP (F1) or press CALL (F2). 4. Press NAME (F1). 5. Move the cursor to Call or Jump Job and press ENTER. 6. Press the ARROW UP soft key. 7. Press UF# (F1). 8. Enter the coordinate number that job will be run on and press ENTER. 9. Press ENTER.


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3.3.2

MFRAME MFRAME is the instruction used to generate or change user coordinates based on the position data which has been detected by the sensor, etc. The MFRAME instruction references points that are stored in position variables. The following is an example: MFRAME UF#(2) PX(ORG) PX(XX) PX(XY) To enter an MFRAME instruction, follow these steps: 1. Press EDIT. 2. Press the ARROW UP soft key. 3. Press ARITH (F2). 4. Press the ARROW UP soft key. 5. Press the ARROW UP soft key. 6. Press MFRAME (F5). 7. Press CONST (F1) or VAR (F2).

NOTE:

Be sure the User Coord No. used is not already in use because it will be overwritten. 8. Enter the User_coord_no. If you need to create a user coordinate frame, refer to Creating User Frames. 9. Press ENTER. 10. Press PX(F1), LPX (F2), PX [], or LPX[]. 11. Enter the position variable with the origin (ORG). 12. Press ENTER. 13. Enter the position variable with the XX coordinate. 14. Press ENTER. 15. Enter the position variable with the XY coordinate. 16. Press ENTER. 17. Press INSERT. 18. Press ENTER.


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3.3.3

CREATING USER FRAMES A user frame is created by taking an external reference point and defining the origin, xx, and xy direction. 1. Press TEACH on the playback box. 2. Press CUSTOMER. 3. Press USER (F2). 4. Use FILE UP/FILE DOWN keys to find a user frame not currently in use. 5. Press SET (F5). 6. Press MORE. 7. Press TEACH (F5). The LCD will display "Available to User Frame File." 8. Enable the programming pendant. 9. Press ORG (F1). 10. Move the robot TCP to the desired origin point.

NOTE:

Ensure the robot is not in User Coordinates to define these points. 11. Press MODIFY. 12. Press ENTER. 13. Press XX (F2). 14. Move the robot to a point on the X-axis. 15. Press MODIFY. 16. Press ENTER. 17. Press XY (F3). 18. Move to a point on the +XY plane. 19. Press MODIFY. 20. Press ENTER. 21. Disable the programming pendant. 22. Press EXIT. The user coordinate frame is now defined. 23. To return to the job display: a. Press DISP. b. Press JOB. c. Press COORD until the red lamp is lit for User Coordinate.


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NOTES


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4.0 RELATIVE JOB OPERATION This section contains easy-to-follow, step-by-step instructions for converting a standard job to a relative job, converting a relative job back to a standard job, confirming both coordinates and command position, displaying differences between command and current position, and information on editing a relative job.

CAUTION! When executing a relative job, the manipulator maintains its current orientation. For this reason, during teaching, the robot should be oriented similar to how it will be oriented in the first step of the relative job. If the position of the robot is extremely different from that of the robot in the first step of the relative job, there is a possibility that the robot will not perform the work as anticipated.

CAUTION! When teaching points in a pulse-type job created for relative job conversion, the amount of movement between the S-, R-, and T- axis teaching points must not exceed 180 . If it does exceed 180 , the S-, R-, or T-axis will operate in the opposite direction. °

°

4.1

STANDARD JOB TO RELATIVE JOB CONVERSION To change from standard job to relative job mode, follow these steps: 1. Press FUNC (F5). 2. Press MORE. 3. Press REL JOB (F2). 4 . Press SEL JOB (F1) to display the job view screen. 5. Move the cursor to the desired job. 6. Press ENTER. 7. Press XYZ (F4). 8. Use soft keys to choose one of the following coordinate systems (frames): BASE (F1), ROBOT (F2), or USER (F3)

NOTE:

If ROBOT (F2) was selected, skip step 9. If BASE (F1) or USER (F3) was selected, complete step 9 before proceeding to step 10. 9. If BASE (F1) or USER (F3) is selected, proceed as follows: a. Enter User_coord no. b. Press ENTER.


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10. Enter the new job name. 11. Press ENTER. 12. Press EXECUTE (F5) to generate a new job. The relative job is the edited job and the status display area indicates the job name.

4.2

RELATIVE JOB TO STANDARD JOB CONVERSION To change from relative job to standard job mode, follow these steps: 1. Press FUNC (F5). 2. Press MORE. 3. Press REL JOB (F2). 4. Press SEL JOB (F1) to display the job view screen. 5. Move the cursor to the desired job. 6. Press ENTER. 7. Press PULSE (F3). 8. Move the ARROW UP soft key and press ABC to display the alphabet. 9. Press CANCEL to erase the old job name. 10. Enter a new job name. 11. Press QUIT (F5) to exit the alphabet screen. 12. Press ENTER. 13. Press EXECUTE (F5) to generate a new job. The standard job is the edited job and the status display area indicates the job name.

4.3

CONFIRMING RELATIVE JOB INFORMATION

4.3.1

Coordinate Confirmation To confirm coordinates during teaching, follow these steps: 1. Press DISP. 2. Press JOB (F1). 3. Press MORE. 4. Press DIS CHG (F1). 5. Press HEADER (F1). 6. To change the user coordinate number from this screen, follow these steps: a. Display the relative job header screen. b. Press EDIT c. Press MORE.


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d. Press COORD (F1). e. Use the number keys to enter the coordinate number. The job is now a relative job with coordinate numbers that have been changed.

4.3.2

Command Position Confirmation To confirm command position, follow these steps: 1. Display the relative job command value screen to display the XYZ form command value screen. 2. Press DISP (F1). 3. Press POSN (F2). 4. Press CMD POS (F3) to display command position.

4.3.3

Displaying Differences between Command and Current Position To display differences between command and current position, follow these steps: 1. Press MORE. 2. Press DIFF (F1).

4.4

EDITING THE RELATIVE JOB As in standard job, the relative job can be edited using the programming pendant. This includes addition, modification, and deletion of positions. However, there are some differences between editing operations for standard job and relative job. When converting a job from standard to relative, it is not possible to paste and then reverse. It is also not possible to paste and reverse between relative jobs in different coordinate systems.


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NOTES


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5.0 SIMPLIFIED OFF-LINE TEACHING SYSTEM 5.1

JOB DATA FORMAT When relative job data is output with the FC1/FC2 floppy disk drive or data transmission, the output file will appear as follows: FILE NAME

JOB NAME. JBI

/JOB //NAME

JOB NAME

//POS ///NPOS

C, BC, EC, PO, BP, EX

///TOOL

N

///POSTYPE

t

///RECTAN ///RECONF

l, m, n, o, p

Cxxxx =

X, Y, Z, Rx, Ry, Rz

BCxxxx =

X0, Y0, Z0

ECxxxx =

1, 2

//INST ///DATE

YY/MM/DD HH:TT

///COMM

Command Letter Row

///ATTR

Attribution 1, Attribution 2,...Attribution 16

///FRAME

‹C›

///GROUP1

m1, m2, m3

///GROUP2

m1, m2, m3

NOP MOVJ

Cxxx BCxxx ECxxx VJ=xxx.x

END

The pseudo command is distinguished by a single slash. Double, triple, and four slashes are used to indicate sub-level commands. The levels of commands used are as shown below in Figure 5-1.


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JOB

NAME POS

NPOS USER TOOL POSTYPE PULSE RECTAN RECONF

INST

Figure 5-1 1. JOB 2. NAME

DATE COMM ATTR FRAME GROUP1 GROUP2 LVARS

Command Levels Used in Relative Job

Function: Shows job. Syntax: /JOB Function: Shows job name. Syntax: //NAME

‹NAME›

‹NAME›: = Up to 8 small characters, no spaces 3. POS

Function: Shows position data. Syntax: //POS • NPOS Function: Shows number of position data. Syntax: //NPOS

• USER

‹C›, ‹BC›, ‹EC›, ‹P›, ‹BP›, ‹EX›

‹C› : = ‹BC› : = ‹EC› : =

Number of robot axis instructed positions.

‹ P› : = ‹BP› : = ‹EX› : =

Number of robot axis position variables.

Number of base axis instructed positions. Number of external (station) axis instructed positions.

Number of base axis position variables.

Number of external (station) axis position variables. Function: Shows which user coordinate number is currently selected. Syntax: ///USER ‹N›

‹ N›


: = User coordinate number (1-24)

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• TOOL

Function: Shows which tool number is currently selected. Syntax: ///TOOL ‹N›

‹ N› • POSTYPE

: = Tool number (0-23)

Function: Shows position data type.

Syntax: ///POSTYPE ‹t›

‹t› : = PULSE | BASE | ROBOT | TOOL | USER | MTOOL

‹PULSE› : Pulse data ‹BASE› : Rectangular data • Base coordinate ‹ROBOT› : Rectangular data • Robot coordinate ‹TOOL› : Rectangular data • Tool coordinate ‹USER› : Rectangular data • User coordinate ‹MTOOL› : Rectangular data • Master tool • PULSE Function: Shows pulse data. Syntax: ///PULSE

‹Pulse Data› : = ‹C› | ‹BC› | ‹EC› | ‹P› | ‹BP› | ‹EX › ‹C› : = ‹Cxxxx› = ‹S›, ‹L›, ‹U›, ‹R›, ‹B›, ‹T›, ‹E1 ›, ‹E2 › ‹BC› : = ‹BCxxxx› = ‹1›, ‹2›, ‹3›, ‹4›, ‹5›, ‹6›, ‹E1 ›, ‹E2 › ‹EC› : = ‹ECxxxx › = ‹1›, ‹2›, ‹3›, ‹4›, ‹5›, ‹6›, ‹E1›, ‹E2› ‹P› : = ‹Pxxx› = ‹S›, ‹L›, ‹U›, ‹R›, ‹B›, ‹T›, ‹E1 ›, ‹E2 › ‹BP› : = ‹BPxxx› = ‹1›, ‹2›, ‹3›, ‹4›, ‹5›, ‹6›, ‹E1 ›, ‹E2 › ‹EX› : = ‹EXxxx› = ‹1›, ‹2›, ‹3›, ‹4›, ‹5›, ‹6›, ‹E1 ›, ‹E2 › ‹Cxxxx› : = Robot axis teach position ‹BCxxxx › : = Base axis teach position ‹ECxxxx › : = External (station) axis teach position ‹Pxxx› : = Robot axis position variable Relative Job Function, MRC

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‹BPxxx› : = Base axis position variable ‹EXxxx› : = External (station) axis position variable ‹S› : = S-axis pulse data ‹L› : = L-axis pulse data ‹U› : = U-axis pulse data ‹R› : = R-axis pulse data ‹B› : = B-axis pulse data ‹T› : = T-axis pulse data ‹E1› : = Trepan axis 1 ‹E2› : = Trepan axis 2 xxxx : = Numbered from 0 up to 999 • RECTAN Function: Shows that defined data following the pseudo command are rectangular data. Syntax: ///RECTAN

‹Rectangular Data› : ‹C› | ‹BC› | ‹P› | ‹BP› | ‹C› : = ‹Cxxxx› = ‹X›, ‹Y›, ‹Z›, ‹Rx›, ‹Ry›, ‹Rz›, ‹E1›, ‹E2› ‹BC› : = ‹BCxxxx › = ‹1›, ‹2›, ‹3›, ‹4›, ‹5›, ‹6›, ‹E1›, ‹E2› ‹EC› : = ‹ECxxxx› = ‹1›, ‹2›, ‹3›, ‹4›, ‹5›, ‹6›, ‹E1›, ‹E2› ‹P› : = ‹Pxxx› = ‹X›, ‹Y,› ‹Z›, ‹Rx›, ‹Ry›, ‹Rz›, ‹E1›, ‹E2› ‹BP› : = ‹BPxxx› = ‹1›, ‹2›, ‹3›, ‹4›, ‹5›, ‹6›, ‹E1›, ‹E2› ‹EX› : = ‹EXxxx› = ‹1›, ‹2›, ‹3›, ‹4›, ‹5›, ‹6›, ‹E1›, ‹E2› ‹Cxxxx› = Robot axis teach position ‹BCxxxx› = Base axis teach position ‹Pxxx› = Robot axis position variable ‹BPxxx› = Base axis position variable ‹X› = X angular data ‹Y› = Y angular data


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‹Z› = ‹Rx› = ‹Ry› = ‹Rz› =

Z angular data Rx-axis rectangular data Ry-axis rectangular data Rz-axis rectangular data

• RCONF Function : Shows configuration of defined rectangular data that follow the pseudo command.

‹l›, ‹m›, ‹n›, ‹o›, ‹p›

Syntax : ///RCONF

‹l› : = 0 : Flip Position, ‹m›: = 0 : Upper Elbow Position, ‹n› : = 0 : Front Position, ‹o› : = 0 : R < 180, ‹p› : = 0 : T < 180, 4. INST

1 : No-Flip 1 : Lower Elbow Position 1 : Back Position 1 : R > = 180 1 : T > = 180

Function: Shows instructions. Syntax: //INST • DATE Function : Shows date and time. Syntax : ///DATE

‹YYYY› : = ‹MM› : = ‹DD› : = ‹HH› : = ‹TT› : = • COMM

‹YYYY› / ‹MM› / ‹DD› ‹HH› : ‹TT›

Year Month Day Hour Minute

Function : Shows job commentary. Syntax : ///COMM

‹Comment Line›

‹Comment Line› : Displays up to 32 small characters. • ATTR

Function : Shows job attributes Syntax : ///ATTR

‹Attribute 1›, ‹Attribute2 ›,...‹Attribute n›

n : Up to 16

‹Attribute › : JD | DD | SC | (RO | WO | RW) | RJ | CJ | VJ ‹JD› : = Job Destroy ‹DD› : = Directory Destroy ‹SC› : = Save Complete Relative Job Function, MRC

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(RO | WO | RW):

‹RO› : = ‹WO› : = ‹RW› : = ‹RJ› : = ‹CJ› : = ‹VJ› : =

Read Only Write Only Read/Write Relative Job Concurrent Job Vision Job

• FRAME Function: Shows relative job coordinate (frame). Syntax: ///FRAME ‹C›

‹C› : = BASE | ROBOT | USER | ‹N› ‹N› : = User coordinate number (1-24) ‹BASE› : = Base coordinate (rectangular) ‹ROBOT› : = Robot coordinate (rectangular) ‹USER› : = User coordinate (rectangular) • GROUP1 Function: First MOVE Control Group (Slave side of coordinated job). Syntax: ///GROUP1

‹m›

=

‹m1›, ‹m2›

RB1

(Robot 1)

= RB2 (Robot 2) = BS1 (Base 1) = BS2 (Base 2) = ST1 (Station 1) = ST2 (Station 2) = ST3 (Station 3) = ST4 (Station 4) = ST5 (Station 5) = ST6 (Station 6) • GROUP2 Function: Second MOVE Control Group (Master side of coordinated job). Syntax: ///GROUP2

‹m›

=

‹m1›, ‹m2›

RB1

(Robot 1)

• LVARS Function: Shows number of local variables. Syntax: ///LVARS

‹LB› ‹LI› Relative Job Function, MRC

‹LB›, ‹LI›, ‹LD›, ‹LR›, ‹LP›, ‹LBP›, ‹LEX›

: = Shows number of byte type local variables. : = Shows number of integer type local variables.

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‹LD›

: = Shows number of double accuracy type local variables.

‹LR›

: = Shows number of actual number type variables.

‹LP›

: = Shows number of robot axis position type variables.

‹LBP› : = Shows number of base axis position type variables.

‹LEX› : = Shows number of station axis position type variables.

5.2

EXAMPLES OF JOB DATA

5.2.1

Relative Job With Robot Axes and User Frame 3 The following is an example of job data for a job which uses a single robot and User Frame 3. FILE NAME: SAMPLE 1.JBI Robot Axes and User Frame 3 Relative Job /JOB //NAME SAMPLE1 //POS ///NPOS 5,0,0,0,0,0 ///USER 3 ///TOOL 0 ///POSTYPE USER ///RECTAN ///RCONF 0,0,0,0,0 C0000 = 171.314, 36.037, 36.032, 179.99, -1.52, 85.23 C0001 = 39.290, 36.037, 36.014, 179.99, -1.51, 85.23 C0002 = 39.292, -65.965, 36.016, 179.99, -1.51, 85.23 C0003 = 39.288, -65.949, -75.987, 179.99, -1.52, 85.24 C0004 = 171.314, 36.037, 36.032, 179.99, -1.52, 85.23 //INST ///DATE 1993/07/23 16:34 ///ATTR SC, RW, RJ ///GROUP1 RB1 NOP MOVJ C0000 VJ = 50.00 MOVL C0001 V = 46.0 MOVL C0002 V = 46.0 MOVL C0003 V = 46.0 MOVJ C0004 VJ = 50.00 END


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5.2.2

Robot Axes + Base Axes (Base Frame) The following is an example of job data for a job which uses a single robot on a 2-axis track. FILE NAME: SAMPLE 2.JBI Robot Axes + Base Axes (Base Frame) /JOB //NAME SAMPLE2 //POS ///NPOS 3,3,0,0,0,0 ///TOOL 0 ///POSTYPE BASE ///RECTAN ///RCONF 0,0,0,0,0 C0000 = -415.000, 0.000, 770.000, 180.00, -90.00, 0.00 C0001 = 874.552, -626.159, 1031.906, 64.76, -37.91, 95.22 C0002 = 1344.117, 582.515, 1090.264, 52.72, -37.72, 18.41 BC0000 = 0.000, 0.000 BC0001 = 1343.952, -531.981 BC0002 = 1838.601, 830.637 //INST ///DATE 1993/07/23 17:36 ///ATTR SC, RW, RJ ///GROUP1 RB1, BS1 NOP MOVJ C0000 BC0000 VJ = 25.00 MOVJ C0001 BC0001 VJ = 25.00 MOVJ C0002 BC0002 VJ = 25.00 END

5.2.3

Robot Axes + Base Axes + Station Axes (Base Frame, Synchronous Job) The following is an example of job data for a synchronous job which uses a single robot on a 2 axis track with a 2 axis positioner. FILE NAME: SAMPLE3.JBI Robot Axes + Base Axes + Station Axes (Base Frame, Synchronous Job) /JOB //NAME SAMPLE3 //POS ///NPOS 2,2,2,0,0,0 ///TOOL 0


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///POSTYPE BASE ///RECTAN ///RCONF 0,0,0,0,0 C0000 = -494.484, -248.122, 1090.264, 52.72, -37.2, 118.41 C0001 = 157.216, -187.240, 1079.290, 84.07, -35.63, 118.76 BC0000 = 0.000, 0.000 BC0001 = 550.647, 485.316 ///POSTYPE PULSE ///PULSE EC0000 = 7103, 27536 EC0001 = 7230, 27577 ///INST ///DATE 1993/07/23 18:11 ///ATTR SC, RW, RJ ///GROUP1 RB1, BS1, ST1 NOP MOVJ C0000 BC0000 EC0000 VJ = 25.00 MOVJ C0001 BC0001 EC0001 VJ = 25.00 END

5.2.4

Robot Axes + Base Axes + Station Axes (Base Frame, Coordinated Job) The following is an example of job data for a coordinated job which uses a single robot on a 2 axis track coordinated with a 2 axis positioner. FILE NAME: SAMPLE4.JBI Robot Axes + Base Axes + Station Axes (Base Frame, Coordinated Job) /JOB //NAME SAMPLE4 //POS ///NPOS 2,2,2,0,0 ///TOOL 0 ///POSTYPE BASE ///RECTAN ///RCONF 0,0,0,0,0 C0000 = -494.484, -248.122, 1090.264, 52.72, -37.2, 118.41 C0001 = 157.216, -187.240, 1079.290, 84.07, -35.63, 118.76 BC0000 = 0.000, 0.000 BC0001 = 550.674, 485.316 ///POSTYPE PULSE


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///PULSE EC0000 = 7103, 27536 EC0001 = 7230, 27577 ///INST ///DATE 1993/07/23 18:11 ///ATTR SC, RW, RJ ///GROUP1 RB1, BS1 ///GROUP2 ST1 NOP MOVJ C000 BC000 VJ = 25.00 +MOVJ EC000 VJ = 25.00 MOVJ C001 BC001 VJ = 25.00 +MOVJ EC001 VJ = 25.00 END

5.2.5

Robot Axes + Robot Axes (Base Frame, Coordinated Job) The following is an example of job data for a coordinated job which uses two robots. FILE NAME: SAMPLE5.JBI Robot Axes + Robot Axes (Base Frame, Coordinated Job) /JOB //NAME SAMPLE5 //POS ///NPOS 10,0,0,0,0,0 ///TOOL 0 ///POSTYPE BASE ///RECTAN ///RECONF 0,0,0,0,0 C0000 = -765.337, 202.936, 1118.673, 0.00, 1.59. 160.42 ///TOOL 1 C0001 = 856.025, -93.532, 1134.850, 1.43, -25.69, 172.39 ///TOOL 0 C0002 = -831.637, 122.110, 1130.506, -0.36, 6.81, 167.30 ///TOOL 1 C0003 = 812.058, -39.516, 1162.852, 1.42, -25.68, 172.39 ///TOOL 0 C0004 = 767.908, 249.592, 1071.301, 0.00, 1.59, 157.08 ///TOOL 1 C0005 = 882.057, -101.531, 10700.875, 1.42, -25.68, 172.40 ///TOOL 0 C0006 = 557.794, 402.473, 1033.164, 0.63, -7.68, 137.99


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///TOOL 1 C0007 = 920.071, -149.510, 1042.893, 1.41, -25.67, 172.41 ///TOOL 0 C0008 = 765.337, 202.936, 1118.673, 0.00, 1.59, 160.42 ///TOOL 1 C0009 = 856.025, -93.532, 1134.850, 1.43, -25.69, 172.39 //INST ///DATE 1993/07/23 16:41 ///ATTR SC, RW, RJ ///GROUP1 RB1 ///GROUP2 RB2 NOP MOV C000 VJ = 50.00 +MOVJ C0001 VJ = 50.00 SMOVL C0002 V =46.0 +MOVL C0003 SMOVL C0004 V = 46.0+MOVL C0005 MOVL C0006 V = 46.0 +MOVL C0007 V=11.0 MOVJ C0008 VJ = 50.0 +MOVJ C0009 VJ = 50.0 END

5.3

CONFIGURATION OF POSITION DATA This section includes information on the configuration of position data for a robot axis, robot and station axes, and robot and base axes. The robot axis, base axis, and station axis position data in each of the coordinate systems are as shown below (see Figures 5-2, 5-3, and 5-4).

Zb

Base Coordinate

0b

Yb

Base Axis Coordinate Value (Xb, Yb, Zb, RXb, RYb, RZb) Station Axis Pulse Value (W1, W2)

Xb

Base Axis Coordinate Value (X0, Y0, Z0)

Figure 5-2


Base Coordinate System

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Zr

Zb

Robot Coordinate

Base Coordinate Robot Axis Coordinate Value (Xr, Yr, Zr, RXr, RYr, RZr) 0b

Yb Yr

Station Axis Pulse Value (W1, W2) Xb


Figure 5-3

Xr

Robot Coordinate System

Zb Zu

User Coordinate

Base Coordinate User Axis Coordinate Value (Xu, Yu, Zu, RXu, RYu, RZu) 0b

Yb

Station Axis Pulse Value (W1, W2) Yu Xb


Figure 5-4

Xu

User Coordinate System

The configuration of position data for a robot axis, robot and station axes, and robot and base axes is as shown below: 1. ROBOT AXIS R1 = X, Y, Z, RX, RY, RZ + TYPE •

The position of the specified coordinate system has a coordinate value.

2. ROBOT AXIS + STATION AXIS R1 = X, Y, Z, RX, RY, RZ + TYPE


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S1 = W1, W2 •

The robot has the coordinate value of the specified coordinate system. The station axis, however, continues to have a pulse value.

3. ROBOT AXIS + BASE AXIS R1 = X, Y, Z, RX, RY, RZ + TYPE B1 = X0 , Y0 , Z0

5.4

•

The robot has the coordinate value of the specified coordinate system. The base axis.

•

Distance from base coordinate point of origin if base coordinate system is specified.

•

Distance from robot coordinate point of origin if robot coordinate system is specified.

•

Distance from user coordinate point of origin if user coordinate system is specified.

CONFIGURATION OF THE MANIPULATOR In the description of the job position data using X, Y, and Z coordinates, there are several configurations of the robot that satisfy data. One configuration must be specified. Up to five types of configurations are used with the MRC Controller. The number of configurations depends on the type of robot. The five types of configurations used with the MRC Controller are as follows:

5.4.1

Specification of Wrist Angle 1. The angle at the R-axis for a three-axis wrist robot can be specified by either of the following two methods: •

The "flip, no-flip" method (as shown in Figure 5-5)

•

The "R < 180 or R > = 180 " method (as shown in Figure 5-6 ) °

°

When the R-axis is in range A, it is in the flip position. When it is in range B, it is in the no-flip position (see Figure 5-5). For robots with an R-axis that turns 180 or more, it must be specified that the axis has made a turn from -90 to 90 , 270 to 360 , or -360 to -270 . Similar specification is also required for position B (see Figure 5-6). °

°


°

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°

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Flip Position

No-Flip Position

A

0°

0° B

-90° < ® < 90 270° < ® <= 360, -360 < ®

90° < ® <= 270 -270° < ® <= -90

<= -270

NOTE: ® is the angle measured from the home position of the R-axis.

Figure 5-5

Flip and No-Flip Positions of Wrist Angle

R >180°

R < 180°

0°

360° -360°

-180° 180° -180° < ® <180

180°< ® <360, -360 < ® <-180

NOTE: ® is the angle measured from the home position of the R-axis.

Figure 5-6


Angle of R-Axis

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2. The angle at the T-axis for a three-axis wrist robot must be specified as either greater or less than 180 (see Figure 5-7). °

T >180°

T < 180°

0°

360° -360°

-180° 180° -180°<

T

180°<

<180

T

<360, -360 <

T

<-180

NOTE: T is the angle measured from the home position of the T-axis.

Figure 5-7

Angle of T-Axis

The above specifications determine the positions of the R-, B-, and T-axes. This operation is required for L, K, and V type six-axis robots.

5.4.2

Specification of the Base Three Axes 1. Specify whether the pivot of the B-axis is on the right or left side of the S-axis pivot, as seen from the right side of the L-and U-axes. When the B-axis pivot is on the right side of the S-axis pivot, the robot is in the front position. If the B pivot is left of the S pivot, the robot is in the back position. Figure 5-8 shows the S-axis turned at 0 and 180 . The front and back positions are determined as seen from the right side of the L-and U-axes. °


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A

S-axis Turned at 0 BACK POSITION

Figure 5-8

B

°

S-axis Turned at 180 BACK POSITION

FRONT POSITION

°

FRONT POSITION

Front and Back Positions of S-Axis Turned at 0˚ and 180˚

These specifications are required for K and V type six-axis robots. They are, however, not applicable for Type L robots because they always take the front position. 2. Specify the form of the L-and U-axis as seen from the right. The upper elbow position (A) and lower elbow position (B) are shown below in Figure 5-9. This specification is required for V type six-axis robots. This is not applicable for L or K type robots because they always take the upper elbow position.

A

Upper Elbow Position

Figure 5-9


B

Lower Elbow Position

Upper and Lower Elbow Positions of L- and U- Axes

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5.5

ROBOT FORM CONTROL METHODS When a relative job is executed, because the robot is not being programmed in pulse counts, the robot is not always able to use the desired form to reach a defined point. The following two methods are ways in which the robot is able to decide on which form it will use to reach defined points of a particular job: 1. Moving the R-and T-axes to preserve the sign of the B-axis. 2. Moving R-, B-, and T-axes to preserve the robot's form of the destination point.

5.5.1

Moving the R-and T-Axes to Preserve the Sign of the B-Axis This method is used to keep the angle of the B-axis from deviating from the "+" range to the "-" range. It can be used to prevent the B-axis from moving past 0 in a job (see Figure 5-10). The R-and T-axes move to reach a defined point, preserving the sign of the B-axis. This method is especially useful in a job shift, however should not be used with off-line programming because the form of the robots arm will be changed with the movement of the R-and T-axes. °

+ 0°

Figure 5-10 B-Axis "+" and "-" Range


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If the angle of the B-axis moves past 0 , this method will control the robot's arm to move the R-axis 180 in the opposite position so that the B-axis does not deviate from "+" or "-" (see Figures 5-11 and 5-12). °

°

0

°

0

°

Figure 5-11 Actual Motion of the R-Axis

0

°

0

°

Figure 5-12 Anticipated Motion of the R-Axis


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5.5.2

Moving R-, B-, and T-Axes to Preserve the Robot's Form of the Destination Point

CAUTION! Use caution when using this method with a job shift. Robot movement can be unpredictable, resulting in personal injury or damage to equipment.

CAUTION! When teaching points in a pulse-type job created for relative job conversion, the amount of movement between the S-, R-, and T- axis teaching points must not exceed 180 . If it does exceed 180 , the S-, R-, or T-axis will operate in the opposite direction. °

°

Because the encoder which reads pulse position is not used in relative job, the robot recognizes the position of a job using X, Y, and Z coordinates. In this method, the B-axis is moved to reach a defined point or changing the sine of the R-axis to preserve the form of all other axes. Because the form of all other axes is preserved, this method is especially useful when used with off-line teaching. Caution should be used when using this method with a job shift. If the teaching position is too close to the pole changing point, the robot may move in a direction opposite to that of the anticipated motion. An example follows: If during teaching, for example, a standard job, the angle of the R-axis is near 90 or less and the position is shifted, the angle of the R-axis may exceed 90 . Before the shift, the wrist is in a flip position. After shifting it is in a no-flip position (see Figure 5-13). °

°

R Axis 0° Flip -90°

90° No-Flip

Figure 5-13 Flip and No-Flip Positions of the R-Axis \


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As shown below in Figure 5-14, if the wrist is already in a flip position, when shifted, the wrist will remain in a flip position. The wrist of the robot will not deviate between flip and no-flip positions as anticipated. The upper left-hand figure shows the current robot position. The anticipated motion of the robot is as shown in the lower figure, however it is possible that the robot's motion may be as shown in the upper right-hand figure. The tool angle remains the same between the original and shifted positions, however, the motion is different and may cause interference with the workpiece or other equipment. Be sure to confirm the motion of the robot when using this method.

R Axis 0

0

°

-90

°

90

°

-90

°

ACTUAL ROBOT POSITION

-90

°

90

°

0

°

°

ACTUAL ROBOT MOTION

90

°

ANTICIPATED ROBOT MOTION

Figure 5-14 Robot Motion During a Job Shift

The parameter and values for the robot form control methods are as shown below in Table 5-1:

Table 5-1

Parameter and Values Used in Robot Form Control Methods

PARAMETER

CONTENTS AND SET VALUE

INITIAL VALUE

S2C195

0: Moving the R-and T-axes to preserve the sign of the B-axis

0

1: Moving R-, B-, and T-axes to preserve the robot's form of the destination point


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To change the parameter to use either of the above mentioned methods, follow these steps: 1. Go to CUST. 2. Press MORE. 3. Press ORG. 4. At the prompt, enter your 8-digit code. 5. Press ENTER. 6. Press PMTR. 7. Choose parameter SC. 8. Select S2C. 9. Press SEARCH. 10. Enter the numbers 195. 11. Press MODIFY. 12. Press 0 or 1. 13. Press ENTER. The parameter has now been changed to use the desired method. 14. Cycle power from Off to On.


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NOTES


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6.0 ALARM AND ERROR MESSAGES 6.1

ALARM MESSAGES Table 6-1

6.2

Alarm Messages

ALARM #

MESSAGE

MEANING

5760

Undefined User Frame

Specified Frame Not Registered When CALL Instruction Executed

5960

MFRAME Error

User Frame Could Not Be Generated Because File Is Broken

5990

Two Steps Same Line (3 Steps)

Frame is Invalid When Position Data for All 3 Points are on Same Line

ERROR MESSAGES Table 6-2

Error Messages

ERROR #

MESSAGE

MEANING

0300

Undefined User Frame

User Frame Specified During Conversion Has Not Been Registered

2460

Specified Job is Already Converted

Job Specified During Conversion Has Already Been Converted To This Job Type

2470

Wrong Job Type

Standard Job Coordinate Cannot Be Established

2480

Wrong Job Coordinates Setting

Coordinates Other Than User Coordinate Cannot Be Modified

2490

Execute FWD/BWD Operation Once Before Editing the Relative Job, Press FWD/BWD Operation Once

2500

Cannot Convert the Job


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A Job Which Only Has a Station Axis and No Group Axes Cannot Be Converted to a Relative Job

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Table 6-3

Messages

MESSAGE

MEANING

Steps Outside of Working Range Have Been Created

When the Relative Job or Standard Job is Modified, Steps Outside of the Working Range are Calculated


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7.0 INSTRUCTIONS USED IN RELATIVE JOB Table 7-1

List of Instructions

MFRAME FUNCTION (Make Frame)

Instruction used for creating a user frame after 3 defined points of position data have been established. Format: MFRAME UF#(xx) (Data1) (Data2) (Data3)

ADDITIONAL INFORMATION

UF# (User Frame Number) DATA 1 Position Data of Defined Point ORG DATA 2 Position Data of Defined Point XX DATA 3 Position Data of Defined Point XY IF Syntax

CALL

EXAMPLE OF USAGE

MFRAME UF#1 P001 P002 P003

FUNCTION

Instruction used to call specific job to be executed. When relative job is called, if there is a designated user frame number, the job with that frame number will be executed.


JOB: (Job Name) IG# (Input Group Number) B (Variable Number) UF# (User Frame Number) IF Syntax

EXAMPLE OF USAGE

CALL JOB : TEST-1 CALL JOB: TEST -1 UF#(2) CALL IG# (02) (The job is called by the input signal pattern. In this case, it is not possible to call JOB 0.)


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Table 7-1 JUMP

List Of Instructions (continued) FUNCTION

Instruction used to jump to a specified job or label. When JUMP is used during a relative job, if a user frame has been specified, that job number's frame will be executed.


JOB: (Job Name) IG# (Input Group Number) B (Variable Number) (Label Name) UF# (User Frame Number) IF Syntax

EXAMPLE OF USAGE


JUMP JOB: TEST1 IF IN# (14) = OFF

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8.0 MRC TOOL CENTER POINT DEFINITION A well-defined Tool Center Point (TCP) is necessary for most applications, especially any type of process work. A well-defined TCP allows easier teaching and a much more accurate travel speed. An accurate TCP definition is a must for welding, sealing, and cutting. The MRC is capable of storing up to 24 different TCP's: •

The first TCP is called the Standard Tool, or Tool 0. Robots with one tool are concerned only with the Standard Tool.

•

The remaining 23 TCP's are called Universal Tools, or Tools 1-23. Robots with multiple tools (such as two-handed grippers) use Universal Tools along with the Standard Tool.

There are two methods for defining the TCP: manual TCP definition and automatic TCP definition.

8.1

MANUAL TCP DEFINITION Manual TCP is used when a tool has definite dimensions and orientation. To define a TCP manually, follow these steps: 1. Press TEACH. 1. Press CUSTOMER. 2. Press TOOL (F1). 3. Move the cursor to the first tool dimension. 4. Press MODIFY. 5. Using the data keys, input the dimension of the tool relative to the wrist flange. 6. Press ENTER. 7. Repeat steps 3 through 6 for each tool dimension. The TCP is now defined. To ensure accuracy of the TCP, use the rotate-about X, Y, and Z keys to roll, bend, and twist the tool around the TCP (see Figure 8-1). The TCP should not move. FLANGE COORDINATES Xf TOOL COORDINATES Yf Zf

Zf

TOOL CENTER POINT

Figure 8-1 Tool Center Point


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8.2

AUTOMATIC TCP DEFINITION Automatic TCP definition is used when a tool has a more complex geometry (for example, angles or offsets). To define a TCP automatically, follow these steps: 1. Put a pointer (with the sharp end up) on the fixture. Ensure that the pointer is placed so that it will not move. 2. Press TEACH on the playback box. 3. Press CUSTOMER. 4. Press TOOL (F1). 5. Press CALIB (F4).

NOTE:

If calibration points have already been taught, it will be necessary to press DATA CL (F3) and EXECUTE (F5) in order to clear the old values. 6. Press TEACH on the programming pendant. 7. Enable the programming pendant by pressing ENABLE. 8. Using the axis keys, move the robot towards the pointer until the tip of the wire touches the tip of the pointer (see Figure 8-2).

TOOL

WIRE POINTER

Figure 8-2

Pointer

9. Press MODIFY. 10. Press ENTER. The first TC point is now programmed. 11. Press TC down arrow (F1) to select the next point to be programmed. 12. Repeat steps 8 through 10 for each TC point. 13. After all five TC points have been programmed, press CALC (F5). The tool display screen (which shows the newly calculated XYZ dimensions of the tool) appears. 14. Move the cursor to the right side of the screen to input tool angle dimensions.


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EXAMPLE OF ENTERING TOOL ANGLE DIMENSIONS FOR A STANDARD TORCH: a. Move the cursor to the Ry dimension. b. Press MODIFY. c. Using the data keys, manually enter -45 degrees. d. Press ENTER.


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NOTES


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Manual Motoman

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