Intelitek SCORBOT-ER 9 User manual

SCORBOT-ER 9
User Manual
Catalog #100066 Rev. B

Copyright 2003 Intelitek Inc.
SCORBOT-ER 9
Catalog # 100066 Rev. B
March 1996
Every effort has been made to make this book as complete and accurate as possible. However, no
warranty of suitability, purpose, or fitness is made or implied. Intelitek is not liable or responsible
to any person or entity for loss or damage in connection with or stemming from the use of the
software, hardware and/or the information contained in this publication.
Intelitek bears no responsibility for errors that may appear in this publication and retains the right
to make changes to the software, hardware and manual without prior notice.
Safety Warning!
Use the SCORBOT ER-9 with extreme caution.
The SCORBOT ER-9 can be dangerous and can cause severe injury.
Setup up a protective screen or guard rail around the robot to keep people away from its
working range.
INTELITEK INC.
444 East Industrial Park Drive
Manchester NH 03109-537
Tel: [phone]
Fax: [phone]
Web site www.intelitek.com

Table of Contents
CHAPTER 1 Unpacking and Handling
Unpacking the Robot . . . . . . . . . . . . . . . . . . . . . 1-1
Handling Instructions . . . . . . . . . . . . . . . . . . . . . 1-2
Acceptance Inspection . . . . . . . . . . . . . . . . . . . . 1-2
Repacking for Shipment . . . . . . . . . . . . . . . . . . . 1-3
CHAPTER 2 Specifications
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Work Envelope . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CHAPTER 3 Safety
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
CHAPTER 4 Installation
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Controller and Computer/Terminal Setup . . . . . . . . 4-1
Robot Setup . . . . . . . . . . . . . . . . . . . . . . . 4-1
SCORBOT-ER IX Installation . . . . . . . . . . . . . . . . 4-3
Controller Installation . . . . . . . . . . . . . . . . . . 4-3
Robot Installation . . . . . . . . . . . . . . . . . . . . 4-3
Homing the Robot . . . . . . . . . . . . . . . . . . . . 4-4
Gripper Installation . . . . . . . . . . . . . . . . . . . . . . 4-5
Pneumatic Gripper . . . . . . . . . . . . . . . . . . . . 4-5
DC Servo Gripper . . . . . . . . . . . . . . . . . . . . 4-7
Activating the Gripper . . . . . . . . . . . . . . . . . . 4-8
CHAPTER 5 Operating Methods
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ACL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ACLoff-line . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SCORBASE Software . . . . . . . . . . . . . . . . . . 5-2
Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . 5-2
CHAPTER 6 Drive System
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
DC Motor Structure . . . . . . . . . . . . . . . . . . . 6-3
SCORBOT-ER IX Motors . . . . . . . . . . . . . . . . 6-4
Harmonic Drive Gears . . . . . . . . . . . . . . . . . . . . 6-5
Harmonic Drive Gear Ratios . . . . . . . . . . . . . . . 6-6
Axis Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . 6-7
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CHAPTER 7 Position and Limit Devices
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Encoder Resolution . . . . . . . . . . . . . . . . . . . 7-3
End of Travel (Limit) Switches . . . . . . . . . . . . . . . . 7-4
Hard Stops . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Home Switches . . . . . . . . . . . . . . . . . . . . . . . 7-6
CHAPTER 8 Wiring
Robot (Power) Cable and Connector . . . . . . . . . . . . 8-2
Encoder Cable and Connector . . . . . . . . . . . . . . . . 8-3
CHAPTER 9 Maintenance
Daily Operation . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . 9-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9-2
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
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CHAPTER 1
Unpacking and Handling
This chapter contains important instructions for unpacking and inspecting the
SCORBOT-ER IX robot arm.
)Read this chapter carefully before you unpack the SCORBOT-ER IX robot and
controller.
Unpacking the Robot
The robot is packed in expanded foam, as shown in Figure 1-1.
To protect the robot during shipment, a metal plate holds the gripper- mounting
flange to the robot base. The plate is fixed to the flange with three bolts and to the
base with two bolts. Use a 3mm hex socket wrench to detach these bolts.
Save these bolts and the plate. You will need them should you repack the robot
for shipment.
Save the original
packing materials and
shipping carton. You
may need them later for
shipment or for storage
of the robot.
Figure 1-1: SCORBOT-ER IX in Packing
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Handling Instructions
The robot arm weighs 38 kilos (83 pounds). Two people are needed to lift or
move it.
Lift and carry the robot arm by grasping its body and/or base. Do not lift or
carry the robot arm by its upper arm or forearm.
Acceptance Inspection
After removing the robot arm from the shipping carton, examine it for signs of
shipping damage. If any damage is evident, do not install or operate the robot.
Notify your freight carrier and begin appropriate claims procedures.
The following items are standard components in the SCORBOT-ER IX package.
Make sure you have received all the items listed on the shipment’s packing list. If
anything is missing, contact your supplier.
Item Description
SCORBOT-ER IX
Robot Arm Includes: Cabling with air hoses; Hardware for mounting robot: 3 M8x60 bolts; 3 M8 washers; 3 M8 nuts.
Gripper: 2 options
Pneumatic Gripper includes: pneumatic solenoid valve;
Hardware for mounting gripper: 6 4Mx8 screws.
Electric DC Servo Gripper with encoder includes: Hardware for
mounting gripper: 4 M4x10 screws.
ACL Controller-B
Includes: Power Cable 100/110/220/240VAC; RS232 Cable;
3 driver cards for 6 axes.
Optional:
Emergency By-Pass Plug (required when TP not connected)
Additional driver cards for control of up to 12 axes;
Auxiliary multiport RS232 board, cable and connectors.
Teach Pendant: optional Includes: mounting fixture; connector adapter plug;
Teach Pendant for Controller-B User’s Manual
Software ATS (Advanced Terminal Software) diskette;
includes ACLoff-line software
SCORBASE Level 5 Software diskette
Documentation
SCORBOT-ER IX User’s Manual
ACL Controller-B User’s Manual
ACL for Controller-B Reference Guide
ATS for Controller-B Reference Guide
ACLoff-line User’s Manual
SCORBASE Level 5 for Controller-B Reference Guide
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Repacking for Shipment
Be sure all parts are back in place before packing the robot.
When repacking the robot for shipping, bolt the flange and base to the metal
plate. Failure to do so may result in irreversible damage to the arm, particularly
to the Harmonic Drive transmissions. Also be sure to secure the cables around the
foam spool.
The robot should be repacked in its original packaging for transport.
If the original carton is not available, wrap the robot in plastic or heavy paper. Put
the wrapped robot in a strong cardboard box at least 15 cm (about 6 inches)
longer in all three dimensions than the robot. Fill the box equally around the unit
with resilient packing material (shredded paper, bubble pack, expanded foam
chunks).
Seal the carton with sealing or strapping tape. Do not use cellophane or
masking tape.
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CHAPTER 2
Specifications
The following table gives the specifications of the SCORBOT-ER IX robot arm.
Robot Arm Specifications
Mechanical Structure Vertical articulated, enclosed casting
Number of Axes 5 plus gripper
Axis Movement
Axis 1: Base rotation
Axis 2: Shoulder rotation
Axis 3: Elbow rotation
Axis 4: Wrist pitch
Axis 5: Wrist roll
Axis Range Effective Speed
270° 79°/sec 112°/sec
145° 68°/sec 99°/sec
210° 76°/sec 112°/sec
196° 87°/sec 133°/sec
737° 166°/sec
Maximum Operating Radius 691mm (27.2") without gripper
End Effector: options: Pneumatic Gripper
Electric DC Servo Gripper
Hard Home Fixed position on all axes
Feedback Incremental optical encoders with index pulse
Actuators DC servo motors
Transmission Harmonic Drive gears and timing belts
Maximum Payload 2 kg (4.4 lb.), including gripper
Position Repeatability ±0.09mm (0.0035")
Weight 38 kg (83 lb.)
Ambient Operating Temperature 2°–40°C (36°–104°F)
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Structure
The SCORBOT-ER IX is a vertical articulated robot, with five revolute joints. With
gripper attached, the robot has six degrees of freedom. This design permits the
end effector to be positioned and oriented arbitrarily within a large work space.
Figures 2-1 and 2-2 identify the joints and links of the mechanical arm.
Each joint is driven by a permanent magnet DC motor via a Harmonic Drive gear
transmission and timing belt.
The movements of the joints are described in the following table:
Axis No. Joint Name Motion Motor No.
1 Base Rotates the body. 1
2 Shoulder Raises and lowers the upper arm. 2
3 Elbow Raises and lowers the forearm. 3
4 Wrist Pitch Raises and lowers the end effector. 4
5 Wrist Roll Rotates the end effector. 5
Figure 2-1: SCORBOT-ER IX Joints Figure 2-2: SCORBOT-ER IX Links
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Work Envelope
The length of the links and the degree of rotation of the joints determine the
robot’s work envelope. Figure 2-3 shows the dimensions and reach of the
SCORBOT-ER IX, while Figure 2-4 gives a top view of the robot’s work envelope.
The base of the robot is normally fixed to a stationary work surface. It may,
however, be attached to a slidebase, resulting in an extended working range.
Figure 2-3: Operating Range (Side View)
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Figure 2-4: Operating Range (Top View)
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CHAPTER 3
Safety
The SCORBOT-ER IX is a potentially dangerous machine. Safety during operation
is of the utmost importance. Use extreme caution when working with the robot.
Precautions
The following chapters of this manual provide complete details for proper
installation and operation of the SCORBOT-ER IX. The list below summarizes the
most important safety measures.
1. Make sure the robot base is properly and securely bolted in place.
2. Make sure the cable from the body to the base can move freely during all
movements of the robot’s base axis.
3. Make sure both the encoder cable and the robot power cable are properly
connected to the controller before it is turned on.
4. Make sure the robot arm has ample space in which to operate freely.
5. Make sure a guardrail or rope has been set up around the SCORBOT-ER IX
operating area to protect both the operator and bystanders.
6. Do not enter the robot’s safety range or touch the robot when the system is in
operation.
7. Press the controller’s EMERGENCY switch before you enter the robot’s
operating area.
8. Turn off the controller’s POWER switch before you connect any inputs or
outputs to the controller.
)To immediately abort all running programs and stop all axes of motion, do any of
the following:
press the teach pendant’s EMERGENCY button;
use the ACL command A <Enter>;
press the controller’s red EMERGENCY button.
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Warnings
1. Do not operate the SCORBOT-ER IX until you have thoroughly studied both this
User’s Manual and the ACL Controller-B User’s Manual. Be sure you follow the
safety guidelines outlined for both the robot and the controller.
2. Do not install or operate the SCORBOT-ER IX under any of the following conditions:
•Where the ambient temperature drops below or exceeds the specified limits.
•Where exposed to large amounts of dust, dirt, salt, iron powder, or similar
substances.
•Where subject to vibrations or shocks.
•Where exposed to direct sunlight.
•Where subject to chemical, oil or water splashes.
•Where corrosive or flammable gas is present.
•Where the power line contains voltage spikes, or near any equipment which
generates large electrical noises.
3. Do not abuse the robot arm:
•Do not operate the robot arm if the encoder cable is not connected to the
controller.
•Do not overload the robot arm. The combined weight of the workload and
gripper may not exceed 2kg (4.4 lb.). It is recommended that the workload be
grasped at its center of gravity.
•Do not use physical force to move or stop any part of the robot arm.
•Do not drive the robot arm into any object or physical obstacle.
•Do not leave a loaded arm extended for more than a few minutes.
•Do not leave any of the axes under mechanical strain for any length of time.
Especially, do not leave the gripper grasping an object indefinitely.
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CHAPTER 4
Installation
Preparations
Before you make any cable connections, set up the system components according
to the following “Preparation” instructions.
Controller and Computer/Terminal Setup
Place the controller and computer at a safe distance from the robot—well outside
the robot’s safety range.
Make sure the setup complies with the guidelines defined in the chapter,
“Safety,” in the ACL Controller-B User’s Manual.
Robot Setup
Refer to Figures 4-1, 4-2 and 4-3.
1. Set up the SCORBOT-ER IX
on a sturdy surface with at
least one meter of free space
all around the robot.
2. Note that the robot cable
clamp is located at the
midpoint of the robot’s
horizontal range. Using this
midpoint as a reference, set
up the robot so that it faces in
the proper direction—
towards the application or
machine it will serve.
3. Fasten the base of the robot to
the work surface with three sets
of M8 bolt, washer and nut. Figure 4-1: Robot Safety Range
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Make sure the robot is securely bolted in place. Otherwise the robot could
become unbalanced and topple over while in motion.
4. Grasp the robot body and turn the robot to each extreme of its base axis.
)Make sure the segment of cable from
the body to the base is not
obstructed, and/or cannot become
caught under a corner of the robot’s
platform or work surface during all
movements of the base axis.
Make sure the robot is mounted on a
surface large enough to provide
support for this segment of the robot
cable during all movements of the
base axis.
5. Set up a guardrail or rope around the
SCORBOT-ER IX operating area to
protect both the operator and
bystanders.
Figure 4-2: Robot Base Layout
Figure 4-3: Robot Setup
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SCORBOT-ER IX Installation
Controller Installation
Perform the installation procedures detailed in the following sections of
Chapter 2, “Installation,” in the Controller-B User’s Manual:
•Computer/Terminal–Controller Installation
•Power On
•Controller Configuration
)When the Peripheral Setup screen appears at the end of the controller
configuration, select Gripper Connection: None. (You will change this setting
after the gripper is installed.) Refer to the section, “Peripheral Devices and
Equipment--Robot Gripper,” in the Controller-B User’s Manual.
Robot Installation
)Before you begin, make sure the controller POWER switch is turned off.
The robot cable has a number of connectors. Connect them to the controller
according to following three steps. Refer to Figure 4-4.
1. Connect the green/yellow wire to the Safety Ground:
Unscrew and remove the ground nut and washer from the Safety Ground stud.
Place the ground wire terminal onto the stud, then replace and tighten the washer
and nut.
2. Plug the the D37 connector into the Robot Encoders port.
Tighten the retaining screws on the connector.
3. Plug the 19-pin round connector into the Robot Power port.
AIR HOSES
(for pneumatic
gripper only)
3
2
1
Figure 4-4: Robot—Controller Cable Connections
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Note: When disconnecting the robot from the controller, do it in the reverse order; that
is:
•Disconnect the 19-pin round Robot Power connector.
•Disconnect the 37-pin Encoders connector.
•Disconnect the ground wires.
Homing the Robot
After you have completed the robot installation, execute the robot’s Home
routine, as described below.
)The robot must be homed before you mount the gripper.
)Before you begin the homing procedure, make sure the robot has ample space in
which to move freely and extend its arm.
1. Turn on the controller. Turn on the computer.
2. From the ATS diskette or directory, activate the ATS software. Type:
ats <Enter>
If the controller is connected to computer port COM2, type:
ats /c2
3. When the ATS screen and > prompt appear, you may proceed.
4. Give the ACL command to home the robot. Type:
home <Enter>
The monitor will display:
WAIT!! HOMING...
During the Home procedure, the robot joints move and search for their home
positions in the following sequence: shoulder, elbow, pitch, roll, base.
If home is found, a message is displayed:
HOMING COMPLETE (ROBOT)
If the HOME process is not completed, an error message identifying the failure is
displayed. For example:
*** HOME FAILURE AXIS 3
If the home switch is found, but not the encoder’s index pulse, the following
message is displayed:
* * * INDEX PULSE NOT FOUND AXIS 2
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