GTE CoboSafe-Tek User manual

Operating Manual
GTE Industrieelektronik GmbH
Helmholtzstr. 21, 38-40 | 41747 Viersen, GERMANY | [e-mail] | Tel. [phone] | www.gte.de
325-2810-014US13
EN
Pressure Measurement Set
CoboSafe-Tek
CoboSafe-Tek
Force and Pressure Measurement System

Operating Manual: CoboSafe-Tek
Document version: 325-2810-014US13
– Translation from German–
Manufacturer and publisher:
GTE Industrieelektronik GmbH
Helmholtzstr. 21, 38-40
41747 Viersen
Germany
Support-Hotline: [phone]
E-mail: [email protected]
© 2022 GTE Industrieelektronik GmbH – This document and all illustrations contained therein are protec-
ted by copyright and may not be removed, altered or distributed without the express consent of the
manufacturer!
Technical changes reserved!

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CoboSafe-Tek 325-2810-014US13
PREFACE
This operating manual describes the pressure measurement procedure CoboSafe-Tek and its
handling. The measuring method is part of a system and can only be used in conjunction with
the following components:
■Software CoboSafe-Vision
■Force gauge from the CoboSafe-CBSF product series
Before beginning work of any kind, read
this manual and the general safety instruc-
tions. Keep for later use!
Pay special attention to the associated document "CoboSafe – General Safety Instructions" as
well as the safety instructions and warnings in this document in order to prevent injuries and
product damage. Keep this documentation handy for future reference. Share this documentati-
on with future users of the product.
Associated with this manual is the document:
■CoboSafe – General Safety Instructions

Table of Contents
4CoboSafe-Tek325-2810-014US13
Table of Contents
1 About this Manual .......................................... 6
1.1 Symbols and Warnings in this Manual ........................ 6
1.1.1 Warnings ........................................ 6
1.1.2 Explanation of Symbols ............................... 7
1.2 Appearance of Instructions ................................ 8
2 For your Safety ............................................ 9
2.1 Intended Use ......................................... 9
2.2 Qualification Required of Personnel .......................... 9
2.3 Responsibility of the Operator .............................. 9
2.4 Residual Risks......................................... 9
3 Brief Description ...........................................10
4 Scope of Delivery ..........................................10
5 Hardware Components.......................................11
5.1 Safety Information ......................................11
5.2 Overview VersaTek Handle ...............................11
5.3 Overview VersaTek 8-Port Hub .............................12
5.4 Installing and connecting the components ......................12
6 Updates and Upgrades.......................................13
7 Information about the Pressure Measuring Film ........................13
7.1 Functionality of the Pressure Measuring Film .....................14
7.2 Safety Information when handling the pressure measuring film .........14
7.3 Durability............................................15
7.4 Storage.............................................15
7.5 About the Measurement Data ..............................15
7.6 Equilibration..........................................15
7.7 Calibration ..........................................16
7.8 Datasheets Sensor......................................16
8 Preparing the Measurement ....................................17
8.1 Selecting Suitable Pressure Measuring film ......................18
8.2 Testing and Cleaning ...................................18
8.2.1 Checking pressure measuring film.........................18
8.2.2 Checking and Cleaning the Collision Surface of the Robot ........18
8.3 Inserting the Pressure Sensor ...............................19
8.4 Positioning Pressure Sensor ................................20
9 Perform Measurement ........................................21
10 Transferring Measurement Data..................................21
10.1 Temperature and Humidity ................................21

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CoboSafe-Tek 325-2810-014US13
Table of Contents
11 Detectingand Remedying Malfunctions .............................22
12 Technical Data ............................................23
12.1 Storage Conditions .....................................23
12.1.1 Storage conditions pressure measurement film.................23
12.1.2 Storage conditions for components ........................23
12.2 Requirements for Temperature and Humidity Measurement ...........24
13 Costumer Service ...........................................25
14 Disposal.................................................25
14.1 Disposal by the manufacturer ..............................25
12.2 Requirements for Temperature and Humidity Measurement ...........24
13 Costumer Service ...........................................25
14 Disposal.................................................25
14.1 Disposal by the manufacturer ..............................25

ABOUT THIS MANUAL
6CoboSafe-Tek325-2810-014US13
1 About this Manual
This operating manual describes the pressure measurement procedure CoboSafe-Tek and its
handling. The measuring method is part of a system and may be used only in conjunction with
the following components:
:
■CoboSafe-Vision
■CoboSafe-CBSF and variants
Carefully and thoroughly read this document and the documentation for all of the systems to be
used to become familiar with the product before using it.
To prevent injury and damage to the product, pay particular attention to the associated docu-
ment “General Safety Instructions” as well as to the safety and warning notes in this document.
Keep this documentation nearby to serve as a reference when needed. Pass the documentation
along to later users of the product.
■The operating manual with safety instructions is a component of the measuring
system and has to be stored near the measuring system, ensuring that it is
readily accessible to personnel at all times.
■Operating personnel must read the entire manual and be familiar with the
product before beginning any work.
■The fundamental requirement for working safely is consideration of all of the
safety and warning notes as well as following the instructions in this and all
associated CoboSafe manuals.
■In addition, the local accident prevention regulations and general safety regu-
lations apply to the area of application of the measuring system.
The illustrations in this manual are intended to aid in fundamental understanding of the product.
They may deviate from the actual model.
1.1 Symbols and Warnings in this Manual
1.1.1 Warnings
Safety and warning notes in this manual are indicated by symbols. The safety and warning
notes are preceded by signal words indicating the extent of the hazard.
To prevent accidents, personal injury and property damage, comply with the safety and warn-
ing notes and proceed with caution.

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ABOUT THIS MANUAL
Warnings
DANGER
This combination of symbol and signal word indicates an im-
mediately dangerous situation that will lead to death or severe
injuries if not avoided.
GEFAHR
WARNING
This combination of symbol and signal word indicates a possibly
dangerous situation that could lead to death or severe injuries if
not avoided.
CAUTION
This combination of symbol and signal word indicates a possibly
dangerous situation that could lead to minor injuries if not avoi-
ded.
NOTICE
This signal word indicates a possibly dangerous situation which
could lead to property damage if not avoided.
1.1.2 Explanation of Symbols
The following symbols are used in this manual to emphasize instructions, results, lists, notes
and other elements:
Symbol Explanation
Introductory information relevant to safety
Helpful tips and recommendations as well as information to ensure effi-
cient and uninterrupted use
ZPrecedes instructions
1 ►
Step-by-step instructions. The instructions are numbered in the order of
the respective steps.
Results of steps
References to sections of this manual and to other applicable documents
Lists with no specific order

ABOUT THIS MANUAL
8CoboSafe-Tek325-2810-014US13
1.2 Appearance of Instructions
The initial requirements in regard to personnel qualifications, personal protective equipment
(PPE), special tools and materials are different for each step/process.
It is imperative that the specified requirements for all instructions are met.
The following illustration shows an example of how a set of instructions is structured.
Explanations to the gure "Example of instructions"
1. A triangle precedes the title of instructions or a step to be performed.
2. Indicates the qualification required of personnel to be able to safely perform the action
described. In the above example, the person performing the task has to be a laboratory
scientist or a system integrator. For a description of the personnel qualifications, refer to
chapter “Qualification Required of Personnel” in the document "CoboSafe – General
Safety Instructions”.
2.
ZInspect and clean CoboSafe CBSF-75
Personnel Protective Equipment
■Laboratory scientists
■System integrators
■Protective gloves
■Safety shoes
Special Tools Material
■Set of Allen keys ■Cleaning agent
■Soft, lint-free cloth
To provide reliable measured data, the measuring system has to
be regularly cleaned and inspected for external damage
1 ►Place the measurement system on a free, flat surface
 The measurement system rests securely and cannot fall off.
2 ►...
Fig. 1: Example of instructions
1.
3.
4. 5.
6.
7.
8.

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CoboSafe-Tek 325-2810-014US13
FOR YOUR SAFETY
3. List of Personal Protective Equipment (PPE) required. In the above example, protective
gloves and safety shoes have to be worn; chapter “Personal Protective Equipment” in
the document "CoboSafe – General Safety Instructions”.
4. If necessary: List of special tools required. A set of Allen keys is needed to check and
clean the device.
5. If necessary: List of consumables required. In the example above, a cleaning agent and
a soft, lint-free cloth is needed.
6. Introductory note on why action is required and what has to be kept in mind.
7. Step in the set of instructions. Always perform the steps one after the other and as de-
scribed.
8. Result of the previous step.
ZAlways verify that the result is the same as what is described here.
2 For your Safety
The separate document “CoboSafe – General Safety Instructions” provides users with further
information and must also be observed.
2.1 Intended Use
CoboSafe-Tek is a pressure measurement method used to determine the pressure forces and
pressure distribution in collisions with collaborating robots. The pressure values are calculated
using the CoboSafe-Vision software on the basis of the underlying standards and publications
(Read the related document 'CoboSafe – General Safety Instructions',  chapter 'Underlying
Standards and Information Material'). CoboSafe-Tek may only be used for this purpose.
2.2 Qualication Required of Personnel
Only qualified personnel may work with the measuring and test system to avoid serious physi-
cal injury or considerable damage to property. Qualified are persons who are familiar with the
commissioning and operation of robots. They must have the appropriate qualifications. They
must be able to assess the work assigned to them, identify possible sources of danger and take
appropriate safety measures.
2.3 Responsibility of the Operator
Please read the chapter of the same name in the corresponding document "CoboSafe – Ge-
neral Safety Instructions".
2.4 Residual Risks
Please read the chapter of the same name in the corresponding document "CoboSafe – Ge-
neral Safety Instructions".

BRIEF DESCRIPTION
10 CoboSafe-Tek325-2810-014US13
3 Brief Description
The pressure measurement system consists of hardware components and the software CoboSa-
fe-Vision. Using hardware components, the pressure signals of the film sensor are recorded and
transmitted to the software. The pressure measurement takes place simultaneously with the force
measurement. The software synchronizes the force measurement with the pressure measurement
and calculates the force and pressure values. It visualizes the pressure distribution in different
colors and creates a pressure illustration over the course of the pressure effect.
The application-oriented evaluation is realized by our software CoboSafe-Vision.
4 Scope of Delivery
■Transport case
■USB stick with equilibration files and user manual
■CAT5 network cable and RJ45 connector
■Versa Tek Sensor Handle
■USB transfer cable
■Versa Tek 8-Port Hub
■Film sensors with different resolutions, Type 5051 or 5027
Fig. 2: Scope of delivery

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CoboSafe-Tek 325-2810-014US13
HARDWARE COMPONENTS
5 Hardware Components
5.1 Safety Information
NOTICE
Property damage by incorrect connection to the PC
■The VersaTek Handle must only be inserted in the VersaTek
Hub.
■Only high-quality USB cables approved by the manufactu-
rer may be used.
Incorrectly connecting the VersaTek handle to the PC can cause
property damage.
NOTICE
Material damage caused by external inuences on the
VersaTek handle.
■Avoid impacts, falls and high loads.
■Avoid liquids, dirt, or dust from entering the VersaTek
Handle.
Improper use of the VersaTek Handle may cause damage to the
hardware component.
5.2 Overview VersaTek Handle
The VersaTek Handle captures the
pressure sensor data and transmits
it to the VersaTek Hub. The Ver-
saTek Handle cable is a shielded
CAT5E cable with RJ45 connec-
tor. If required, it can be easily
extended to a maximum of 30 m
with an RJ45 extension cable of
the same quality without sacrifi-
cing performance.
The VersaTek Handle has a lug on
the front, with which the handle is
opened. In the 'open' position it
retracts the contact pins and thus
enables the insertion of the pres-
sure measuring film. When the
lug is closed, the contact pins are
pressed against the contact points
of the sensor.
Fig. 3: Overview handle

HARDWARE COMPONENTS
12 CoboSafe-Tek325-2810-014US13
5.3 Overview VersaTek 8-Port Hub
The VersaTek Hub is used to convert the VersaTek Handle communication protocol to USB.
5.4 Installing and connecting the components
Fig. 4: Overview hub
Fig. 5: Connecting the components

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CoboSafe-Tek 325-2810-014US13
UPDATES AND UPGRADES
6 Updates and Upgrades
The updating and further development of peripherals and software is necessary due to norma-
tive adaptations. The changes are provided by the manufacturer in the form of upgrades and
updates. In order to maintain full functionality, updating to the latest version is necessary and
must be ensured.
Information about important changes can be obtained using the CoboSafe-Vision software.
When the PC software CoboSafe-Vision is started, the version status is automatically queried
online. The information window also informs about changes to the CoboSafe-Tek system.
After updating the current status, the current instructions for use are also available. The opera-
ting instructions must be available in printed form (Read the related document ' General Safety
Instructions'). If hardware components are required, please contact the service cobosafe@gte.
An update may require adjustment of the pressure measurement system. An update
and upgrade must then be carried out to ensure correct evaluation via the software.
7 Information about the Pressure Measuring Film
The pressure measuring films are available in different pressure ranges and resolutions. Types
5051 and 5027 are used for measurements with CoboSafe-CBSF.
■Part number and serial number [1]
■Type designation [2]
■Measuring surface [3]
■Connecting lug [4]
■"This Side Up" marker [5]
■Contact area or connection panel [6]
■Protective film (remove during use) [7]
Fig. 6: Pressure measuring film

INFORMATION ABOUT THE PRESSURE MEASURING FILM
14 CoboSafe-Tek325-2810-014US13
7.1 Functionality of the Pressure Measuring Film
The film sensor is an ultra-thin, flexible circuit board. The measuring surface consists of pres-
sure-sensitive points which are also referred to as 'sensor elements', 'sensels' or 'cells'. Each
sensor cell behaves in the circuit like a variable electrical resistance. In the unloaded state, the
resistance is high and decreases under load. The output value is converted into a digital value
via the handle and assigned to a scale of 0-255 RAW (raw data value).
The sensor cells are arranged in rows and columns. Conductor tracks connect the sensor cells
to the contact points in the connection panel via the terminal lug.
The top of the pressure sensor is marked 'This Side Up' near the connection panel. The connec-
ting lug must be inserted into the handle in such a way that the marking is on the upper side of
the lever, i.e. on the side of the lug.
7.2 Safety Information when handling the pressure measuring lm
NOTICE
Defect of the pressure measuring lm
Improper handling of the pressure measuring film may cause da-
mage to property.
■Do not force the pressure measuring film into the handle
■Avoid drawing on the inserted pressure measuring film.
■Act free of load when handling the pressure measuring film.
■Avoid sharp objects.
■Avoid slipping or sliding collisions.
■If necessary, use Teflon foil with a thickness of 0.05 mm on
the measuring surface.
■Use an equilibration file that corresponds to the current
state of the pressure measuring film.
For strong visible kinks, the pressure measuring film should be re-equilibrated. Ho-
wever, equilibration should take place once a year. Replace heavily damaged
pressure measuring films.
The correct specification of the types used is required for the evaluation. An incor-
rect type specification will generate incorrect measured values.

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CoboSafe-Tek 325-2810-014US13
INFORMATION ABOUT THE PRESSURE MEASURING FILM
GEFAHR
WARNING
Personal injury due to incorrectly classied robots
■Make sure that there is no surface change of the pressure
sensor.
■Make sure the correct equilibration file has been used.
Wrongly classified robots can cause serious injuries to collabo-
rating personnel.
7.3 Durability
Tekscan pressure films have an unlimited shelf life. The shelf life is affected by use and traces
of use.
Regular equilibration extends the durability of the pressure measurement film.
7.4 Storage
After use, return the pressure sensors to a protective container. Protect the packaging unit from
moisture.
7.5 About the Measurement Data
The pressure measurement is carried out in combination with the force measurement. The
measured values are directly transmitted and evaluated. The pressure curve is synchronized to
the force curve. This makes it possible to display both the force and the pressure value and the
pressure distribution at the same time of the measurement. The pressure measurement method
thus enables the quasi-static pressure to be determined.
The significance of the measurement results is limited exclusively to the respective contact
situation.
7.6 Equilibration
The individual sensors of the pressure measuring film can produce different values under the
same load. In order to generate a relevant measurement result, the values of the individual
cells must be compared with each other using scaling factors. This is achieved by the process
of equilibration. The result is a data set that contains a scaling factor for each cell. This data
record is used for the evaluation.
A typical application for equilibration is also when the sensor is repeatedly loaded at the same
physical location. Typically, the unloaded region of the pressure sensor retains its original
sensitivity. The region that receives constant load changes, on the other hand, will change its
sensitivity. This circumstance can be compensated with the aid of equilibration.

INFORMATION ABOUT THE PRESSURE MEASURING FILM
16 CoboSafe-Tek325-2810-014US13
Further information on the process can be found in the CoboSafe-Vision user manual.
7.7 Calibration
The calibration of the pressure sensor is not necessary because only the pressure distribution
has to be determined. The time course of the pressure measurement is calibrated to the force
curve. This allows the pressure distribution and the application of force to be determined for
the same point in time. The compression force is then calculated using the recorded force of
the calibrated force sensor.
7.8 Datasheets Sensor
Fig. 7: Sensor 5051

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PREPARING THE MEASUREMENT
8 Preparing the Measurement
The definition of possible collisions and the choice of force and pressure sensor must be taken
into account when preparing the measurement environment. The collision positions determine
the body localizations and, if necessary, the specific localizations.
Fig. 8: Sensor 5027

PREPARING THE MEASUREMENT
18 CoboSafe-Tek325-2810-014US13
8.1 Selecting Suitable Pressure Measuring lm
If several pressure measuring films are available for selection, the selection of the sensor type
depends on the expected pressure area and the expected maximum pressure. Generally, the
pressure area should be at least one third of the sensor area.
In the case of objects with too sharp edges, the resolution of the sensor may not be sufficient,
as only a few sensors are hit. The sensor can be hit differently during repeated measurements.
This can lead to larger differences in the measurement results. The resolution of the sensor is
then too low. If even the smallest film cannot address enough sensors, it may be more sensible
to measure with the CoboSafe-Scan measuring system.
8.2 Testing and Cleaning
Impurities (e.g. sand grains or metal chips) in the measurement setup can lead to considerable
exceedances of the limit value during pressure measurement. All contact surfaces must therefore
be cleaned before measurement. Damaged components of the measuring system prevent a
reliable measurement and must therefore be replaced.
Personnel Protective Equipment Materials
■Laboratory scientist
■System integrator
■Protective clothing
■Protective gloves
■Safety shoes
■Soft, lint-free cloth
■Detergents
■Reference-weight
8.2.1 Checking pressure measuring lm
■Damaged pressure sensors must not be used for the measurement. Check the pressure
sensor for external damage (e.g., cracks, kinks).
■The areas to be used must be free of damage.
■Check whether a current equilibration file exists (CoboSafe-Vision).
8.2.2 Checking and Cleaning the Collision Surface of the Robot
Clean the collision surface of the robot (e.g., gripper) with a clean cloth. In particular, remove
coarse particles (e.g., grains of sand or metal chips).

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CoboSafe-Tek 325-2810-014US13
PREPARING THE MEASUREMENT
8.3 Inserting the Pressure Sensor
Personell
■Laboratory scientist
■System integrator
1 ►Remove the protective foil
from the pressure sensor.
2 ►Open the lug of the handle.
3 ►Align the mark 'This Side Up' of the
pressure sensor with the handle.
4 ►Insert the pressure sensor slowly and in a
controlled manner without force into the
opening slot until the stop can be felt.
Fig. 9: Inserting pressure sensor in handle
5 ►Close the lever.
6 ►Control lamp 'Sensor ok' on the handle
must light green.
 You have correctly inserted the pressure measurement foil into the handle.
Fig. 10: Closing lug

PREPARING THE MEASUREMENT
20 CoboSafe-Tek325-2810-014US13
8.4 Positioning Pressure Sensor
After inserting the pressure sensor, the measuring surface is placed on the force measuring
device CBSF.
Example CoboSafe-CBSF:
Personnel Personal Protective Equipment
■Laboratory scientist
■System integrator
■Protective clothing
■Protective gloves
■Safety footwear
ZPlace the pressure measuring film on the force gauge CoboSafe-CBSF.
1 ►The specified compression element is dis-
played in CoboSafe-Vision in the measu-
rement plan.
Position the specified compression ele-
ment (Fig. 10/1) on the measuring surfa-
ce of the CBSF force sensor.
2 ►Place the measuring surface of the pressu-
re sensor (Fig. 10/2) on the compression
element.
3 ►Carefully fix the applied film to the edges
of the measuring surface, e.g., with ad-
hesive tape.
4 ►If intended: Carefully cover the measuring
unit with a microfibre cloth.
 The measuring unit is ready combined.
1
2
Fig. 11: Positioning the pressure sensor