Bosch rexroth APAS CDE V01.00.00 User manual

Operating instructions
3 842 565 042, Edition: 11.2020
APAS sensor head
CDE, V01.00.00-V01.00.99
3 842 565 000
ENGLISH

The information in this manual is for product
description purposes only. Any information
in this manual on how to use the product only
constitute examples and recommendations.
Catalog information is not binding.
The information given does not exempt the
user from the obligation of own judgment
and verification. Our products are subject to
natural wear and aging.
© All rights reserved by BoschRexrothAG,
also for the registration of industrial
property rights.
This document may not be reproduced or
distributed to third parties without our
consent.
An example configuration is shown on
the title page.
The delivered product may thus vary from
the illustration.
The original operating instructions are in
German.

3 842 565 042, Edition 11.2020, BoschRexrothAG
Contents | APAS sensor head 3/52
Contents
1 About this documentation ......................................................... 5
1.1 Validity of the documentation.................................................... 5
1.2 Required and supplementary documentation ............................ 5
1.3 Presentation of information....................................................... 5
1.3.1 Safety instructions .................................................................... 6
1.3.2 Symbols..................................................................................... 6
1.3.3 Designations.............................................................................. 7
2 Safety instructions .................................................................... 8
2.1 About this section ..................................................................... 8
2.2 Intended use.............................................................................. 8
2.3 Improper use ............................................................................. 8
2.4 Personnel qualifications............................................................ 9
2.5 General safety instructions ..................................................... 10
2.6 Product-specific and technology-specific safety instructions.. 11
2.7 Installed safety equipment...................................................... 12
2.8 Residual risk............................................................................ 13
2.9 System integrator responsibilities........................................... 14
2.10 System integrator responsibilities........................................... 16
3 Scope of delivery..................................................................... 17
4 About this product................................................................... 18
4.1 Product description................................................................. 18
4.2 Product overview .................................................................... 19
4.3 Mechanical interface for the end effector installation............. 20
4.4 Cable entries at the sensor head ............................................. 21
4.5 CDE function ........................................................................... 21
4.5.1 Triggering the proximity switches............................................ 21
4.5.2 Tilting the pendulum plate ...................................................... 22
4.5.3 Deflecting the pendulum plate ................................................ 23
4.5.4 Admissible CDE applications................................................... 24
4.5.5 Inadmissible CDE applications ................................................ 25
4.5.6 Faulty CDE triggering due to inertia......................................... 26
4.5.7 Typical triggering forces at the pendulum plate....................... 28
4.6 Electrical interfaces ................................................................ 29
4.6.1 Overview ................................................................................. 29
4.6.2 Requirements on the electrical connection ............................. 31
4.7 Technical data ......................................................................... 32
4.7.1 MTTF values of the proximity switches.................................... 32
4.7.2 Safety functions SF1 and SF2 .................................................. 33
5 Transport and storage.............................................................. 34
5.1 Product storage and preparation ............................................. 34
6 Installation.............................................................................. 35
6.1 Disassembling the sensor skin................................................. 35
6.2 Exchanging the spring ............................................................. 36
6.2.1 Disassembling the spring........................................................ 37
6.2.2 Available spring assemblies .................................................... 38
6.2.3 Mounting the spring ................................................................ 39
6.3 Disassembling the sensor skin................................................. 39
6.4 Establishing electrical connections between end effector and
collision detection element..................................................... 40
6.5 Assembling the sensor skin ..................................................... 42
6.6 Assembling the sensor head at the APAS assistant.................. 43
6.7 Disassembling the sensor head from the APAS assistant......... 44
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7 Commissioning ........................................................................ 45
7.1 Commissioning requirements .................................................. 45
7.2 Commissioning the sensor skin ............................................... 45
7.3 Changing the password............................................................ 45
8 Maintenance and repair ........................................................... 46
8.1 Cleaning and care .................................................................... 46
8.2 Maintenance plan .................................................................... 46
8.2.1 Checking the pendulum mechanics for ease of movement ....... 46
8.2.2 Checking the proximity switch for functioning......................... 47
8.2.3 Checking the safety circuits of the sensor skin ........................ 47
9 Disposal .................................................................................. 47
10 Upgrading and modification..................................................... 47
11 Checklist for functional safety acceptance.............................. 48

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About this documentation | APAS sensor head 5/52
1 About this
documentation
1.1 Validity of the documentation
This documentation applies to the following products:
• APAS sensor head CDE, V01.00.00 - V01.00.99,
Material number: 3842565041
The APAS sensor head is exclusively intended for assembly at the
following product:
• APAS assistant K1100-10i, V01.00.XX, material number: 3842562910
It is intended for system integrators (see chapter 2.4 Personnel
qualifications) to integrate the option into existing products or systems.
The documentation provides information on the proper installation and
use of the option and is version V01.00.01.
This documentation contains important information relating to the safe
and proper installation of the product.
fFully read this documentation and particularly chapter2
"Safety instructions" before working with the product.
1.2 Required and supplementary documentation
fOnly commission the product if he documentation marked with the
book symbol is available and you have understood and followed
the instructions in it.
Table 1: Required and supplementary documentation
Title Document number Document type
APAS assistant K1100-10i,
V01.00.00 - V01.00.99 1)
3842563137 Assembly
instructions
Electrical documentation sensor
head CDE 1)
3842563625
Supplier documentation of the
company KUKA Roboter GmbH 2)
1) Download at: www.boschrexroth.com/mediadirectory
2) Included in the scope of delivery of the robot system
1.3 Presentation of information
Standardized safety instructions, symbols, terms and abbreviations are
used so that you can use this documentation to work quickly and safely
with your product. These are explained in the following sections to help
you understand them better.
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1.3.1 Safety instructions
This document includes safety instructions before asequence whenever
there is arisk of injury or damage to property. Be sure to observe all
safety precautions.
Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger
Consequences of non-compliance
fMeasures to prevent danger
• Warning sign: points out the danger
• Signal word: indicates the severity of the danger
• Type and source of danger: indicates the type and source of danger
• Consequences: describes the consequences of non-compliance
• Prevention: states how the danger can be avoided
Table 2: Types of risk according to ANSI Z535.6-2006
Warning sign, signal word Meaning
DANGER Indicates ahazardous situation that will
result in severe injury or death if not
avoided.
WARNING Indicates ahazardous situation that may
result in severe injury or death if not
avoided.
CAUTION Indicates ahazardous situation that may
result in minor to moderate injury if not
avoided.
NOTICE Property damage: the product or the
surrounding area could get damaged.
1.3.2 Symbols
The following symbols indicate important information that is not
safety-relevant but increases the comprehensibility of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is not observed, the product cannot be used and/or
operated as designed.
fSingle, independent action
1.
2.
3.
Numbered steps:
The numbers indicate that the action steps are sequential.

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1.3.3 Designations
This document uses the following designations:
Table 4: Designations
Designation Meaning
APAS assistant Short name of APAS assistant K1100-10i
CDE Collision detection element
Robot system General designation of the APAS assistant K1100-10i
Sensor skin Capacitive sensor system for operator detection.
sensor head Assembly consisting of collision detection element (CDE)
and sensor skin.
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2 Safety instructions
2.1 About this section
The product has been manufactured in accordance with the generally
accepted rules of current technology. Nevertheless, there is arisk of
personal injury and property damage if you do not read this sectionand
follow the safety instructions in this document.
fRead this documentation carefully and completely before you start
working with the product.
fKeep the documentation accessible to all users at all times.
fAlways include them when giving the product to athird party.
2.2 Intended use
The sensor head CDE is an optional component that may only be
integrated at the following robot system:
• APAS assistant K1100-10i, V01.00.XX, material number: 3842562910
The product is exclusively intended for the following intended use:
• For the adaptation of end effectors to the corresponding APAS robot
system.
• For the safe stopping of the robot system if a collision of the end
effector or any workpiece grabbed with the end effector occurs.
• For the safe stopping of the robot system if there is a person or object
in the detection area of the CDE sensor head sensor skin.
• Use exclusively in industrial applications and indoors. Use within
the admissible environmental conditions (see chapter 4.7 Technical
data).
This product is intended only for professional use and not for private use.
The intended use also includes having read and understood these
instructions, especially section2 "Safety instructions".
2.3 Improper use
Any use other than that described in the section"Intended use" is
considered improper and is not permitted.
If unsuitable products are installed or used in safety-relevant applications,
unexpected operating conditions may occur in the application that could
result in injury or property damage. Products should only be used in
safety-relevant applications that are expressly specified and approved
in the product documentation. For example, in ex-protection areas or in
safety-related parts of acontrol system (functional safety).

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BoschRexrothAG is not liable for any damage resulting from improper
use. The user alone bears any risks associated with improper use.
Improper use of the product includes:
• Integration of the product without successfully completed compulsory
training sessions by BoschRexrothAG.
• Use of sensor skin monitor software for the corresponding APAS
assistant older than V1.3.2.0.
• Use for the detection of torsion movements. As regards its design,
the sensor head CDE is not intended for this application.
• Applications in which the pendulum plate of the collision detection
element is subjected to tensile load.
• With other springs that those included in the scope of delivery or with
several, simultaneously mounted springs.
• Use of an entire sensor skin with more than 192 two-channel sensor
elements on the APAS assistant including collision detection element
and application-specific options.
• Operation with an end effector weight (end effector and workpiece,
if applicable) > 2 kg.
• Traverse movements and stop during which the inertia exceeds the
admissible values. This results in an undesired EMERGENCY STOP.
• Operation without compliance with the biomechanical limit values
according to DIN ISO/TS 15066.
2.4 Personnel qualifications
Different knowledge is required for the set-up, assembly and disassembly,
transport, commissioning, operation as well as maintenance and
troubleshooting of the product. These activities may only be carried out
by qualified personnel and according to this documentation.
Therefore, in order to ensure safe use, these activities may only be
carried out by a suitable specialist.
"Qualified personnel" refers to those who can recognize potential hazards
and take appropriate safety measures based on their technical training,
knowledge, experience, and understanding of the relevant regulations
pertaining to the work being performed. Qualified personnel must
observe all specific professional rules.
The system integrator is a trained specialist with knowledge in the
following areas:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• System knowledge of robot control
• Knowledge of sensor skin maintenance and commissioning
Due to his/her training, knowledge and experience, the system integrator
is able to perform the following tasks:
• Installing the product at an APAS assistant
• Mounting an application-specific end effector at the product and
connecting it, if necessary.
• Removing and installing the sensor skin.
• Parameterizing the sensor skin.
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• Implementing safety regulations for the operation of the sensor skin.
• Detecting potential hazards during integration and defining suitable
safety measures.
• Properly commissioning of the product.
• Programming and editing programs and automatic sequences.
• Completing the functional safety acceptance.
• Troubleshooting, maintaining and servicing the product.
For the work of the system integrator, the following mandatory training
courses at the BCI Training Center are required:
Table 5: Compulsory training for the system integrator
Designation Reference code
Basic course "Safe handling" [BCI-SP-AP031]
Advanced course "Sensor skin maintenance" [BCI-SP-AP015]
Advanced course "Preparation of work schedules" [BCI-SP-AP038]
Advanced course "Integration into projects" [BCI-SP-AP037]
You can find an overview of the current training courses and training
content online at: https://www.bosch-apas.com/downloads/.
2.5 General safety instructions
• Before the initial commissioning of the product, you, as the operator,
must carry out arisk assessment in accordance with the national
regulations in your country (in Germany: according to the Occupational
Health and Safety Act).
• As distributing company/manufacturer of the machine, observe the
following:
– Before the initial commissioning of a conveyor system, conduct a risk
assessment in accordance with DINENISO12100.
– The product is intended for use in the area of collaborative robotics.
Comply with the specifications of the standard ISO/TS 15066
"Robots and robotic devices - collaborative robot".
• Observe the applicable accident prevention and environmental
protection regulations.
• Observe the safety rules and regulations of the country in which the
product is being used.
• Only use Rexroth products that are in proper working order.
• Heed all the notices on the product.
• Persons who assemble, operate, disassemble or maintain Rexroth
products should not be under the influence of alcohol, drugs or
medication that may affect their ability to respond.
• Only use genuine, manufacturer-approved accessories and spare parts
to ensure there is no risk to personnel from unsuitable spare parts.
• Observe the technical data and ambient conditions specified in the
product documentation.

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2.6 Product-specific and technology-specific safety
instructions
DANGER
Risk of injury due to non-triggering of the sensor skin
Non-triggering of the sensor skin and/or missing detection of objects
may cause serious personal injuries.
fImplement the error messages of the autodiagnostics of the sensor
skin according to the specifications in the assembly instructions of
the APAS assistant.
fCheck the autodiagnostics during every commissioning and re-
commissioning.
DANGER
Risk of injury due to non-triggering of the collision detection element
Non-triggering of the CDE or too high a triggering threshold, e.g. due to
damage at the triggering mechanics or objects in the deflection area may
cause serious personal injuries.
fCarry out a regular visual and functional check of the CDE deflection
mechanics.
fCheck the autodiagnostics during every commissioning and
re-commissioning.
fCheck the CDE mechanics after collisions.
WARNING
Risk of crushing and shearing due to exceedance of the provided
stopping distances
Late stopping of the robot arm may cause medium to serious personal
injuries.
fDetermine the stopping distances according to the relevant
application.
fSet the safely monitored velocity so that the robot arm stops before
an inadmissible collision occurs.
fMove the sensor head CDE with the lateral areas in the direction of
motion.
NOTICE
Property damage due to ESD
Due to its surface finish, the sensor skin tends to be electrostatically
charged. During discharging at the product, the latter or other operating
equipment in the direct vicinity may be damaged. Use of the APAS
assistant and/or the collision detection element in an ESD-sensitive
environment must be coordinated with the operator in the individual
case and assessed in the application-specific risk assessment.
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• The ease of movement of the collision detection element mechanics
must be checked every day and after every collision in all directions
of movement.
• Observe the requirements according to the valid standards and
directives regarding adapted end effectors in the corresponding
application (e.g. ISO/TS 15066 as amended).
• Error messages of the sensor skin autodiagnostics must be considered
by the systems integrator according to the specifications in the APAS
assembly instructions, the implementation must be checked in the
commissioning. After error messages, an automatic restart is not
admissible.
• The stopping distances of the corresponding APAS assistant are to be
adjusted to the deflection distances of the collision detection element
with adapted end effector. If necessary, the end effector must be
adjusted in an application-specific manner.
• The additional sensor elements on the collision detection element and
other assemblies that might be available may cause an extension of the
reaction time. If necessary, the process sequences must be adjusted
accordingly.
2.7 Installed safety equipment
The sensor head CDE has the following safety equipment:
Table 6: Safety device
Safety device Description Function
Capacitive sensor skin Detection of
persons and
detectable objects
in the vicinity of the
sensor head CDE.
Safe, contactless stop of the robot
arm before a collision occurs.
Pendulum plate with
inductive sensors
Detection of
collisions at the
end effector by
deflecting the
pendulum plate.
When the pendulum plate is
deflected far enough, two proximity
switches will be operated. If the
proximity switches are triggered,
a safe stop of the robot arm will
be performed. The max. velocity
of the robot must be set by the
integrator so that it is possible to
free the operator after collision
(recommended residual spring path:
10mm).
Observe also the specifications in the assembly instructions of the
corresponding APAS assistant.

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2.8 Residual risk
DANGER
Risk of injury due to non-triggering of the proximity switches at the
pendulum mechanics
Foreign body ingress in the pendulum mechanics and deformation due to
increased force effect (e.g. due to collision) may lead to jamming and
non-triggering of the proximity switches and cause serious personal
injuries due to the failure to stop the robot arm.
fCheck the ease of movement of the pendulum mechanics and
the triggering of the proximity switches every day and after every
collision.
DANGER
Risk of injury due to non-triggering of the proximity switches at the
pendulum mechanics
The proximity switches will be triggered when the pendulum plate is
deflected by a force or in the direction of the CDE. Foreign body ingress
in the pendulum mechanics or deformation due to increased force
application may lead to jamming and non-triggering of the proximity
switches and cause serious personal injuries due to the failure to stop
the robot arm. If the pendulum plate is subjected to tensile load, it will
not trigger.
fThe traverse movements of the APAS assistant must be selected so
that the pendulum plate will trigger in case of collision.
fAfter every collision, ensure ease of movement and intactness of the
pendulum mechanics. In case of damage, do not operate the APAS
assistant.
DANGER
Danger due to magnetic radiation
In the CDE, permanent magnets are installed. The magnetic radiation
may cause failure or malfunction of implants.
fPersons with active and passive implants as well as pregnant women
must keep a distance of 2 m to the magnets.
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CAUTION
Risk of injury due to improper selection of the spring
Improper selection of the spring may cause minor personal injuries and
damage to property.
fSelect the spring according to the type of application.
fUse only the spring assemblies included in the scope of delivery.
The latter do in each case contain the corresponding holders.
fCheck the biomechanical loads with the installed spring and replace
it by a weaker one if the admissible values are exceeded.
fRepeat the measurement of the biomechanical loads if a spring was
replaced.
fMinimize the residual risk by shearing and crushing in the area of
the adapted end effector and the workpiece, if applicable, and
movements in the area of eyes and larynx in accordance with 15066.
"Contact-related exposure to sensitive parts of the body, including
skull, front, head, eyes, ears or face, must be avoided if reasonably
feasible.
Inform the responsible personnel about existing residual risks.
Observe also the specifications in the assembly instructions of the
corresponding APAS assistant.
2.9 System integrator responsibilities
The system integrator must comply with the following requirements:
• Integrate the product according to the information in these operating
instructions incl. attachment and further relevant documentation
(see chapter 1.2 Required and supplementary documentation).
• Make sure that the national standards and regulations are complied
with during the installation of the product.
• Make sure that the permissible surface pressure in case of collision
is complied with according to valid standards. Document and archive
this proof.
• Perform a risk assessment according to ENISO12100 as amended for
each application in which the product is used. Please note that for the
supplied safety functions of the collision detection element, a maximum
performance level PL d of category 3 may be claimed.
• When implementing the safety logics, observe the valid standards with
regard to safety (emergency stop and safe stop) such as EN 60204-1.
Implement the safety logics according to the electric documentation.
• Select a suitable spring assembly to ensure collision protection
according to the present application.
• Make sure that the traverse movements of the APAS assistant are
selected so that in case of collision, the forces are applied laterally
or in the direction of the CDE to the pendulum plate.

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• The traverse velocity of the APAS assistant must be set so that the
movements are stopped before the maximum deflection and/or the
maximum deflection of the pendulum plate is reached.
• Integrate the inductive proximity switches of the CDE into the APAS
assistant safety circuit according to the electronic documentation.
During the functional safety acceptance, the proximity switches must be
checked for proper functioning.
• To prevent components from falling down or being ejected, it must be
possible to grab them safely during the motion sequence. Factors such
as insufficient dimensional stability or oily and greasy surfaces have
to be considered.
• Reduce the residual risk by shearing and crushing in the area of the
adapted end effector and the workpiece, if applicable, and movements in
the area of eyes and larynx in accordance with 15066. "Contact-related
exposure to sensitive parts of the body, including skull, front, head, eyes,
ears or face, must be avoided if reasonably feasible."
• Parameterize the sensor skin of the sensor head via the APAS assistant
SSKU according to the commissioning specifications.
• Check the sensor skin autodiagnostics during every commissioning and
re-commissioning.
• Check the function of the sensor skin during the functional safety
acceptance.
• Movements of the robot with bridged safety functions are only
admissible in manual mode if the risks are reduced accordingly by other
measures (reduced velocity, enabling button, etc.)
• Automatic mode of the APAS assistant is only admissible when the
sensor head safety functions are active.
• Adjust the application, the safely reduced velocity of the robot and
the sensor skin parameterization so that when approaching a person,
the robot will come to a standstill before collision of the robot parts
monitored by the sensor skin. The smallest detectable part is the
average human hand.
• Ensure electromagnetic compatibility of the entire application.
• In the application-specific risk assessment, determine the necessary
safety functions and the required performance level.
• Instruct the personnel and/or the operator on any existing residual risks.
• Compile the technical documentation (operating and
• maintenance instructions, vendor documentation, etc.) for the owner
and their personnel.
• Inform the operator about tasks they must perform according to these
operating instructions. This also includes the definition of non-defined
maintenance cycles.
• Attach the CE mark in a visible location on the system.
ENGLISH

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2.10 System integrator responsibilities
The operator must comply with and implement the following product-
specific regulations:
• Daily functional check of sensor skin and collision detection element.
• The ease of movement of the pendulum mechanics and/or the triggering
of the proximity switches must be checked every day and after every
collision.
• Carry out a biomechanical measurement with the selected and installed
springs as well as verification and documentation of the biomechanical
measurement.
• Completion of maintenance works and service works according
to maintenance plan.

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Scope of delivery | APAS sensor head 17/52
3 Scope of delivery
Table 7: Scope of delivery
Graphics Name Material number
Interface module 3842565134
Sensor module 3842562703
Clamping flange 0804FR6198
Hexagon socket head cap screw
ISO4762- M4x16-8.8 (2x)
2910141126
Standard spring assembly with
spring D-145F (assembled upon
delivery)
R313075747
Spring assembly with spring
D-232L
R313075750
Spring assembly with spring
VD-212D
R313075751
Spring assembly with spring
VD-232L
R313075752
Cable hole grommet (2x) R913078252
Cable set functional earth 3842565164
Declaration of conformity 3842565579
Operating instructions 3842565041
Electrical documentation 3842563625
Packaging
Upon delivery, the sensor skin is mounted at the sensor head and the
spring assembly R313075747 is installed.
Only open the sensor skin for maintenance, the connection of more
electrical periphery and for exchanging the spring.
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4 About this product
4.1 Product description
The CDE sensor head is an optional component of the APAS assistant
detecting collisions of the end effector (e.g. gripper) and triggering a
safe stop of the robot arm. Regardless of the direction of approach of
the robot, two proximity switches in the collision detection element
are opened when the end effector collides with a person or an object.
The proximity switches must be analyzed by the safety control installed in
the APAS assistant. For the sensor head, there is a pre-defined interface
in the APAS assistant. In the delivery condition of the APAS assistant,
this input is bridged. After collision detection, an automatic restart is not
intended.
In addition, the sensor head is equipped with a capacitive sensor skin
that is connected to the sensor skin of the APAS assistant. The sensor
skin detects interventions in the APAS assistant sensor area or detectable
objects located therein in a contactless manner. In this case, the APAS
assistant is stopped in a safe way. The robot arm will only automatically
resume its motion sequence when the sensor area is free again.

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4.2 Product overview
1
2
3
4
5
6
7
8
2
Fig. 1: Product overview
1 Clamping ring
2 Sensor skin
3 Collision detection element
(interface module)
4 Pendulum plate, mechanical
interface for end effector
(e.g. gripper)
5 2x screw for clamping ring
M4x16-8.8
6 Connection for sensor skin
segment 6
7 Blind plate with 2 cable
grommets
8 Flange, mechanical interface
for the rotary coupling of the
APAS assistant
ENGLISH

20/52 APAS sensor head | About this product
BoschRexrothAG, Edition 11.2020, 3 842 565 042
4.3 Mechanical interface for the end effector installation
Fig. 2: Mechanical interface for the end effector installation
The end effector may be fastened at the 4 threaded holes (M6) of
the pendulum plate. The screw length must be selected so that the
maximum screw-in depth is 7 mm.