Denso VS-6556G User manual

This instructional manual includes information on the DENSO Robotic arm and the modular
work-cell designed for it. Information discussed in this manual includes general information on
safety, manual operation, basic programming, and advanced programming using WINCAPS III
software.
UI ROBOTIC WORKCELL
SETUP, OPERATION, AND PROGRAMMING OF
THE ENGINEERING DEPT. ROBOTIC WORKCELL

1
UI ROBOTIC
WORKCELL
SETUP, OPERATION, AND
PROGRAMMING OF THE ENGINEERING
DEPT. ROBOTIC WORKCELL
INTRODUCTION
Project History
In the spring of 2013 The Boeing Company donated four DENSO robotic
arms to the College of Engineering. That fall Team Roboshow, learned
programming and created a work-cell which incorporated multiple safety
features as well as a clear poly-carbonate enclosure for public
demonstration. The team programmed the robot to use a dry-erase
marker to create logos and patterns on a white board.
The following year Team Vandalbot designed a manufacturing process
which could assemble various rivet and nut-plate assemblies in order to
automate a repetitive task currently done by factory workers. The team
was able to validate this process and provide records for future teams.
Our Contribution
In 2016 Team Do-All Robotics was tasked to design a 2
nd
generation
work-cell to improve the cell’s manufacturing capabilities. Our team
designed a work-cell with a standalone pedestal for each arm that
eliminated settling time and vibration during operation.
We also created a customizable grid system for a work surface for a
customizable workspace to suit various different manufacturing
capabilities. We retained a clear polycarbonate enclosure for safety and
demonstration purposes.
Our team has also worked towards adding a second arm to the workcell.
By allowing two controllers to interact and running two simultaneous
programs that start at the same time, the robots will not collide so long
as the user has tested the programs in a virtual environment to ensure
the robots do not collide.
THANK
YOU TO
PROJECT
SUPPORT
AND
SPONSORS
The Boeing Company
DENSO Robotics
Steve Beyerlein
Team Roboshow
Team Vandalbot

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TABLE OF CONTENTS
Introduction...............................................................................................................................................1
Project History.......................................................................................................................................1
Our Contribution....................................................................................................................................1
Table of Contents .....................................................................................................................................2
DENSO VS-577G Specifications..............................................................................................................3
Modular Work-cell design .........................................................................................................................4
Previous Design....................................................................................................................................4
New Modular Design.............................................................................................................................4
Workcell Safety.........................................................................................................................................5
OSHA Robotic Safety Standards ..........................................................................................................5
e-Gard Interface....................................................................................................................................6
Using The Teach Pendant........................................................................................................................7
Powering Up the Workcell.....................................................................................................................7
Teach Pendant Controls........................................................................................................................7
Motion Mode......................................................................................................................................9
Speed Key.........................................................................................................................................9
Programming With The Teach Pendant..................................................................................................10
Running a Stored Program..................................................................................................................10
Writing/Editing a Program Using the Teach Pendant..........................................................................10
Importing Coordinates from the Arm’s Current Position..................................................................11
Robot I/O ................................................................................................................................................12
Interpolation Control ...............................................................................................................................13
Figures ................................................................................................................................................13
Programming with WINCAPS III.............................................................................................................14
Starting a New Project.........................................................................................................................14
Writing a Program ...............................................................................................................................15
3D Simulation......................................................................................................................................15
Importing 3D Data ...........................................................................................................................15
3D View Pane..................................................................................................................................16
Uploading Data from WINCAPS to the Robot.....................................................................................17
Appendix.................................................................................................................................................18
Error Code Tables...............................................................................................................................18
PAC Library.........................................................................................................................................18

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DENSO VS-577G SPECIFICATIONS

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MODULAR WORK-CELL DESIGN
Our team decided to update the existing work-cell to a newer, more modular configuration. This will allow
future users to easily arrange the work-cell into a configuration that allows for many different
manufacturing capabilities.
Previous Design
New Modular Design
In 2013 – 2014 Team Roboshow designed and
fabricated a work-cell for one DENSO VS-G
arm shown in Figure 1.1. Although this cell
worked well for demonstration purposes two of
its limitations were a slow settling time (being
“wobbly”) and being difficult to reconfigure for
different projects or worker entry.
Our new design was created by building a standalone pedestal for each robot and then attaching work
“tables” that can be arranged in different patterns. The configuration shown below is a 3x3 square
that allows a worker to walk around the workspace in the manufacturing cell.
TEAM ROBOSHOW PREVIOUS WORKCELL DESIGN
RENDER OF NEW WORKCELL DESIGN WITH ONE ROBOT AND A 3X3 WORKSPACE

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WORKCELL SAFETY
OSHA Robotic Safety Standards
Summary of Occupational Safety and Health Administration Safety Standards related to robotics and
safety enclosures. The below list includes all standards relevant to the UI Robotic Work-cell.
1910.144
Color identification
Red- Danger, fire protection, emergency stop
Yellow- designating caution and marking physical hazards
1910.145
Accident prevention signs and tags
oCaution signs: warn against unsafe practices
oSafety instruction signs
General operation instructions
Safety measures
1910.212
Machine Guarding Methods
oBarriers
oTwo-handed tripping devices
oElectronic safety devices
Workspace guarding (protecting the area of possible operation)
Guarding device shall prevent operator from having any body part in the danger zone during
operating cycle
PUB 8-1.3
Protection Practices:
oInterlocked Barrier: physical barrier around robot incorporating interlock gates
oFixed Barrier: fence that requires tools
oAwareness barrier: railing or suspended chain
oPresence sensing device: pressure mats, and light curtains
Emergency Braking:
oDynamic braking systems cutting off all power
Visible warning systems
oEasily recognizable and enhance effectiveness of safeguards
Control Devices:
oMain Control panel is located outside robot work area and in sight of robot
oEasy accessible emergency stops
Controls that initiate power or motion are constructed and guarded against accidental operation
All devices are clearly marked and labeled to purpose

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e-Gard Interface
This device acts as an alternative interface to the controller along with providing
extra safety precautions. The e-Gard system is connected to both the mini and
safety I/O allowing for slight monitoring and external control of the robot.
Solenoid Lock
The features at the top of the e-Gard act as a door lock. It is equipped with a
solenoid locking system for the front of the enclosure along with a built in safety
relay, which detects when the door is open, instantly cutting power to the robot.
E-Stop
The emergency stop has a key reset adding extra security. This ensures that
when non-authorized users try getting into the enclosure they cannot do so
without a key.
Start/Re-Start
This feature is connected to the program start input of the mini I/O. With the first
touch of the button the program is re-started and the second push starts the
program.
Step Stop
When the stop button is pushed the robot will continue to the next coded in
position allowing for a gentle stop. This button is also illuminated when power
is being supplied to the robot. This is done by connecting the robot running
indicator off of the mini I/O.
Selector Switch
This gives the ability to choose between two different programs pre-loaded on
the controller. This is connected to data bit 0. The selector switch will be able
to select between two programs determined on the controller by their
designated name. To operate a program using the selector switch, the program
file names must be pro0 and pro1. Only these file names will work with the
selector switch.
E-GARD LOCKOUT

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USING THE TEACH PENDANT
Powering Up the Workcell
First ensure all I/O connections are secure:
Teach Pendant
“Enable Auto” Switch
E-Gard Lockout
Robot motor and encoder cable
After this has been checked use the power
switch to turn the unit on. The Power lamp
will be lit if it is on
Teach Pendant Controls

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Deadman Switch
The dead man switch is needed to control the robot in manual mode. It must be held down in order for
the robot to move during manual operation. Release the switch to stop the robot, or press harder to stop
it. The switch has 3 states. Released and strongly pressed are off. Lightly pressed is the only state where
it is on.
Motor Key
Each time the robot is powered up or the mode of operation is changed this switch must be pressed to
manually turn on the motor. If the Deadman switch is released or if the emergency stop is activated, the
motor will shut itself off and need to be restarted.
Mode Selector Switch
This switch changes the mode of operation for the robot, there are
three different settings:
Auto – Allows the robot to run programs saved in the Teach
Pendant or WINCAPS (the Enable Auto Switch on the enclosure
must be “on” for the robot to run in this mode)
Manual – Allows the operator to control the robot manually using
the Arm Transverse Keys (the Enable Auto Switch on the
enclosure must be “off” for the robot to run in this mode)
Teach/Check – Allows the operator to manually run through
programs step-by-step or at a slower speed, the Deadman switch
must be used to operate in this mode (the Enable Auto Switch on
the enclosure must be “off” for the robot to run in this mode).
Arm Transverse Keys
These are the keys the operator uses to manually operate the robot. There are three different motion
modes but most often used is the “Joint” mode where each key performs the following operation:
J1 – Rotates the robot on its base J4 – Rotates the wrist of the robot arm
J2 – Moves the shoulder of the robot arm J5 – Moves the head the tool face is attached to
J3 – Moves the elbow of the robot arm J6 – Rotates the tool face or end effector
ENABLE-AUTO SWITCH

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MOTION MODE
There are three motion modes the robot is able to be operated in during manual mode: Joint mode, X-Y
mode, and tool mode. The operation in Joint mode is shown above. Operation in X-Y mode and Tool
mode assigns the buttons the following operations but with different origins:
J1 – Moves parallel to X-axis
J2 – Moves parallel to Y-axis
J3 – Moves parallel to Z-axis
J4 – Rotates with X-axis as rotation center
J5 – Rotates with Y-axis as rotation center
J6 – Rotates with Z-axis as rotation center
When the robot is in X-Y mode the center of the bottom
of the base is used as the origin
When the robot is in Tool mode the center of the flange
surface on the tool face is used as the origin.
SPEED KEY
The speed key allows the user to set the speed at which the robot runs either during manual operation
or while running a selected program.
In Auto mode, the robot will run at the (programmed speed x reduced ratio (%)). If set to 80%, the robot
will run at 80% of the programmed speed.
In Manual mode or Teach check mode, the robot controller is designed to run the robot at 10% of the
programmed speed. If set to 80% speed, therefore, the robot will run at 10% x 80% of the programmed
speed, that is, at 8% (0.1 x 0.8 = 0.08).
At the start, set the speed to 20% or less. By running the robot manually at high speeds from the
beginning, it may mistakenly strike against the surrounding objects.
X-Y MOTION MODE COORDINATE SYSTEM