Commonplace Robotics igus robolink DCi User manual

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Operating Instructions for the Embedded Control System of the igus robolink DCi
Version 2018/11 V01.1-EN
Software Version TinyCtrl V980-04-031
Software Version CPRog V902-10
Firmware Version Supply 0x37 - 0x0302
Firmware Version Stepper 0x42 - 0x0210
Firmware Version DigitalIO 0x39-0x0309
© Commonplace Robotics GmbH, 2011 – 2018
The terms igus® and robolink® are protected trademarks of igus GmbH.
Commonplace Robotics GmbH
Im Innovationsforum Bissendorf
Gewerbepark 9-11
49143 Bissendorf, Germany
[phone]
[email protected]
www.cpr-roboter.de

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Content
1. Safety instructions ................................................................................................................................................... 3
2. Introduction ................................................................................................................................................................. 4
2.1 Robot components .......................................................................................................................................... 4
2.2 Specification ........................................................................................................................................................ 5
3. Dimensions ................................................................................................................................................................... 6
3.1 Lateral view .......................................................................................................................................................... 6
3.2 Hole pattern flange (axis 5) and bottom ............................................................................................... 7
4. Connections and LEDs ........................................................................................................................................... 8
4.1 Connections ......................................................................................................................................................... 8
4.2 Digital Inputs/Outputs ................................................................................................................................... 9
4.3 LEDs ........................................................................................................................................................................ 12
5. Commissioning .......................................................................................................................................................... 13
6. Operation ..................................................................................................................................................................... 14
6.1 Reset errors/Enable robot ......................................................................................................................... 14
6.2 Manual method of the robot ...................................................................................................................... 15
6.3 Referencing the robot ................................................................................................................................... 16
6.4 Starting and stopping a programme ..................................................................................................... 17
6.5 Set the digital inputs/outputs .................................................................................................................. 17
6.6 Display of status information ................................................................................................................... 18
7. Programming .............................................................................................................................................................. 19
7.1 Establish connection ...................................................................................................................................... 19
7.2 Creating a programme ................................................................................................................................. 20
7.3 Uploading a programme .............................................................................................................................. 20
8. Integration in safety circuit ................................................................................................................................ 21
9. Interfaces .................................................................................................................................................................... 22
9.1 Digital inputs and outputs .......................................................................................................................... 22
9.2 PLC interface .................................................................................................................................................... 22
9.3 Plug-in interface .............................................................................................................................................. 22
9.4 CRI interface ...................................................................................................................................................... 23
10. Extensions / Adjustments .................................................................................................................................. 24
10.1 Galvanic isolation of digital outputs .................................................................................................... 24
11. Troubleshooting and support .......................................................................................................................... 25
11.1 Error codes ......................................................................................................................................................... 25
11.2 CAN-Bus and CPRog status information ........................................................................................... 26
11.3 Hardware ..............................................................................................................................................................27
11.4 Software .............................................................................................................................................................. 28
11.5 Support contact ............................................................................................................................................... 29

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1. Safety instructions
 Always pay attention to safety of people while operating a robot arm or
commissioning a robot cell! Make sure that nobody is within the operating range of
the arm or other danger spots!
 CE marking: Robot arm and control system are just a part of one facility, which is
assessed in its entirety for risks and must comply with currently applicable safety
regulations. The commissioning engineer of the facility is responsible for this.
 The robot's control system has no protective devices. To ensure the essential
safety of people, suitable components, such as safety relays and door switches,
must be connected.
 Always disconnect the power supply before inserting or removing connectors, such
as the display with joystick, emergency stop, digital I/Os or external relays.
No hot plugging!
 Work on the robot's electronic system should only be carried out by qualified
personnel. Observe the common ESD guidelines.
 Do not install or remove modules during operation, nor should you plug or unplug
any connections during operation. For this, always turn off the system and unplug
the mains connector.
 The robot arm must be set up on a stable surface and bolted or otherwise secured.
 Use and store the system only in a dry, clean environment.
 Use the system only at room temperature (15° to 32°C).
 The ventilation of the system must be able to operate without hindrance. There
must be at least 10cm of space next to the robot's fan to ensure sufficient airflow to
cool the motor modules.

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2. Introduction
2.1 Robot components
Components of the robot: robot, emergency stop, control unit with joystick
Rear view of the robot

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2.2 Specification
Type
igus robolink DCi
Number of axes
Depending on the type: 4
-
5
Payload
Depending on the type: 0.5kg
Power electronics
Voltage supply
24V >= 5A
Communication
Internal CAN field bus 500kBaud
External via Ethernet
Supply module
SlowStart function to prevent overload of the power
supply.
1-channel emergency stop function without safety
classification, connection option of an external safety
relay.
Stepper module
For operation of a bipolar stepper motor
Microstepping up to 1/256
RS422 quadrature encoders
24V reference switch input
Digital In/Out module
4 external and 3 internal digital inputs, 12
-
24V, based on
optocouplers
4 external and 3 internal digital outputs, solid state
relay, max. 500mA
Integrated control
system
Platform
Phytec Wega, ARM Cortex A8 (or comparable)
Operating system
Linux
Software
TinyCtrl Robot Control Software
Interfaces
Control of the drives and I/O modules via
the CAN bus, connection to CPR via Ethernet, RS232
display connection

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3. Dimensions
3.1 Lateral view
Diagram 1: Side view of the DCi robot. The robot axes (motors) are basically counted from the
robot base. So axis 1 is the vertical axis in the robot base. An effector (e.g., gripper) can be
attached to axis 4/5 (4 or 5-axis version).
A 4-axis robot has a mounting plate instead of the last axis.

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3.2 Hole pattern flange (axis 5) and bottom
Diagram 2: Top: Hole pattern flange of the axis 5; Bottom: Hole pattern of the robot base.

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4. Connections and LEDs
4.1 Connections
Diagram 3: Rear view of the robot base, here in the 5-axis version. In the 4-axis version the
values in parentheses apply to the motor modules.

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4.1.1 Pin assignment of support module and power supply
DC24V In
0V Outer
24V Inner
Ethernet
RJ45 Standard Ethernet socket
Ext. Relay /
Motor bridge
Motor bridge For motors, power supply
can be interrupted here.
Pin 1: 24V output
Pin 2: 24V Input for
power electronics
Connection
display
View of the plug contacts
Pin 1: 24V
Pin 2: Emergency stop signal (active
low)
Pin 3: TX
Pin 4: CAN-L
Pin 5: GND
Pin 6: GND
Pin 7: RX
Pin 8: CAN-H
Pin 9: GND
Caution! The connection is proprietary.
It is not suitable for a null modem cable
or the like.
4.2 Digital Inputs/Outputs
4.2.1 Digital I/Os and the back wall
From the Digital Input/Output (DIO) board, 4 digital outputs and 4 digital inputs are routed to
the outside. If further inputs and outputs are required, 3 more each can be achieved on the same
module in the housing of the robot. Plug-in connectors are included.
The outputs are not galvanically isolated in delivery condition; 24V and GND of the robot
control system are used. If galvanic isolation is required, this can be done as described in
section 10.1 "Galvanic isolation".
For testing, an LED with series resistor (e.g., 2K) can be connected between e.g. DOut1
(switched + 24V) and GND of the right 6-pin plug-in connector. This can be switched later in the
software.