Intelitek SCORA-ER 14 User manual

SCORA-ER 14
User Manual
Catalog #100067 Rev. B

Copyright 2003 Intelitek Inc.
SCORA-ER 14
Catalog # 100067 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 SCORA-ER 14 with extreme caution.
The SCORA-ER 14 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 and Handling the Robot . . . . . . . . . . . . . 1-1
Repacking for Shipment . . . . . . . . . . . . . . . . . . . 1-1
Acceptance Inspection . . . . . . . . . . . . . . . . . . . . 1-2
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
SCORA-ER 14 Installation . . . . . . . . . . . . . . . . . . 4-2
Controller Installation . . . . . . . . . . . . . . . . . . 4-2
Robot Installation . . . . . . . . . . . . . . . . . . . . 4-2
Homing the Robot . . . . . . . . . . . . . . . . . . . . 4-4
Gripper Installation . . . . . . . . . . . . . . . . . . . . . . 4-5
Pneumatic Gripper . . . . . . . . . . . . . . . . . . . . 4-5
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 . . . . . . . . . . . . . . . . . . . . . . . 5-2
Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . 5-2
CHAPTER 6 Drive System
Axes 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
DC Motor Structure . . . . . . . . . . . . . . . . . . . 6-4
SCORA-ER 14 Motors . . . . . . . . . . . . . . . . . . 6-5
Harmonic Drive Gear . . . . . . . . . . . . . . . . . . . . . 6-6
Pulleys and Timing Belt . . . . . . . . . . . . . . . . . . . 6-8
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Ball Bearing Screw . . . . . . . . . . . . . . . . . . . . . . 6-9
Worm Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Ball Bearing Spline . . . . . . . . . . . . . . . . . . . . . . 6-10
Axis Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . 6-11
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
Power (Robot) Cable and Connector . . . . . . . . . . . . 8-2
Encoder Cable and Conenctor . . . . . . . . . . . . . . . . 8-3
Warning Light Cable and Connector . . . . . . . . . . . . . 8-4
CHAPTER 8 Maintenance
Daily Operation . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . 9-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9-2
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
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CHAPTER 1
Unpacking and Handling
‹Read this chapter carefully before you unpack the SCORA-ER 14 robot and
controller.
Unpacking and Handling the Robot
The robot is packed in expanded foam.
Save the original packing materials and shipping carton. You may need them
later for shipment or for storage of the robot.
The robot arm weighs 35 kilos (77 pounds).Two people are needed in order to
lift or move it.
Lift and carry the robot arm by grasping its column and/or base.
Do not lift or carry the robot arm by its horizontal links.
Repacking for Shipment
Be sure all parts are back in place before packing the robot.
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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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 SCORA.
Notify your freight carrier and begin appropriate claims procedures.
The following items are standard components in the SCORA-ER 14 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
SCORA-ER 14 Robot Arm Includes: Cabling with air hoses;
Hardware for mounting robot: 4 M8x60 bolts;
4 M8 washers; 4 M8 nuts.
Gripper: 2 options
Pneumatic Gripper includes pneumatic solenoid valve and
6 M4x8 screws for mounting gripper.
Electric DC Servo Gripper with encoder includes
4 M4x10 screws for mounting gripper.
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
SCORA-ER 14 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 Version Reference Guide
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CHAPTER 2
Specifications
The following table gives the specifications of the SCORA-ER 14 robot arm.
Robot Arm Specifications
Mechanical Structure Horizontal articulated (SCARA)
Arm Length
Link 1
Link 2 270mm (10.6") 230mm (9.0")
Axis Movement Axis Range Effective Speed
Axis 1: Rotation
Axis 2: Rotation
Axis 3: Translation
288° 117°/sec
218° 114°/sec
182mm 211mm/sec
Axis 4: Roll; without gripper cable:
or Roll; with gripper cable: unrestricted 370°/sec
±527°
Links 1 and 2 combined 1.5m/sec
Maximum Operating Radius Minimum 230mm (9.06")
Maximum 500 mm (19.69")
End Effector 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
Maximum Payload 2 kg (4.4 lb.)
Position Repeatability ±0.05mm (±0.002")
Weight 30 kg (66 lb.)
Ambient Operating Temperature 2°–40°C (36°–104°F)
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Structure
The SCORA-ER 14 is a horizontal articulated (SCARA) robot.
The first two joints are revolute and determine the position of the end effector in
the XY plane. The third joint is prismatic and determines the height (Zcoordinate)
of the end effector.
Figure 2-1 identifies the joints and links of the mechanical arm.
Each joint is driven by a servo DC motor via a Harmonic Drive gear transmission.
The following table describes the movement of the axes:
Axis No. Motion
1 Rotates Link 1 in horizontal (XY) plane.
2 Rotates Link 2 in horizontal (XY) plane.
3 Translates (raises and lowers) the end effector along Z axis.
4 Rotates the end effector.
Figure 2-1: SCORA-14 Mechanical Arm
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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. Figures 2-2 and 2-3 show the dimensions of the
SCORA-ER 14, 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 2-2: Dimensions (Side View)
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Figure 2-3: Dimensions (Top View)
Figure 2-4: Working Range (Top View)
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CHAPTER 3
Safety
The SCORA-ER 14 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 SCORA-ER 14. 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 robot arm has ample space in which to operate freely.
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 a guardrail or rope has been set up around the SCORA-ER 14 operating
area to protect both the operator and bystanders.
5. Do not enter the robot’s safety range or touch the robot when the system is in
operation.
6. Press the controller’s EMERGENCY switch before you enter the robot’s
operating area.
7. 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 SCORA-ER 14 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 SCORA-ER 14 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 weight of the payload 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 and 4-2.
1. Set up the SCORA-ER 14 on a sturdy surface with at least 70 cm of free space all
around the robot.
2. 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
four sets of bolt, washer and
nut.
Make sure the robot is
securely bolted in place.
Otherwise the robot could
become unstable and topple
over while in motion. Figure 4-1: Robot Safety Range
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4. Set up a guardrail or rope
around the SCORA-ER 14
operating area to protect
both the operator and
bystanders.
SCORA-ER 14 Installation
Controller Installation
Perform the installation procedures detailed in the following sections of Chapter
2, “Installation,” in the ACL 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 ACL Controller-B User’s Manual.
Robot Installation
‹Before you begin, make sure the controller POWER switch is turned off.
Refer to Figures 4-3 and 4-4. Refer also to the wiring information and diagram in
Chapter 8.
1. Connect the safety ground wires:
•Unscrew and remove the nuts and washers from the safety ground studs on
both the robot and controller connector panels.
•Connect the green/yellow wires from both the robot cable and the encoders
cable to the safety ground studs on both the robot and controller connector
panels.
Figure 4-2: Robot Base Layout
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•After you have placed
the ground wire terminals onto the studs, replace and tighten the washers and
nuts.
2. Connect the two cables which connect the robot and the controller.
•Plug the the D37 connectors on the encoder cable into the Robot Encoders
port on the controller and into the port on the robot’s connector panel. Tighten
the retaining screws on the connector.
•Plug the 19-pin round connectors on the robot cable into the Robot Power
port on the controller and into the port on the robot’s connector panel.
3. Connect the robot warning light to the controller:
•Plug the 3-pin round connector on the warning light cable into the Warning
Light port on the robot. Connect the red and black wires to any unused relay
output terminal: one wire to NO and one wire to C on the same output.
•Write a routine which will turn on the output whenever the controller is in
CON state and turn off the output whenever the controller is in COFF state.
For automatic activation of this routine, include it in the user-reserved ACL
program BACKG. Refer to the ACL for Controller-B Reference Guide for
more information on BACKG.
Note: When disconnecting the robot from the controller, do it in the opposite order:
•Disconnect the warning light connections.
•Disconnect the power cable connections.
•Disconnect the encoders cable connections.
•Disconnect the ground wires.
Figure 4-4: Controller Connector Panel
Figure 4-3: Robot Connector Panel
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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: axis 3 (vertical stroke), axis 2, axis 4 (roll)
and axis 1.
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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Gripper Installation
The gripper is attached to the flange at the end of the robot arm whose layout is
shown in Figure 4-5.
Pneumatic Gripper
The pneumatic gripper, shown in Figure 4-6,
is controlled by a 5/2 solenoid pneumatic
valve which is activated by one of the
controller’s relay outputs. The valve may be
12VDC or 24VDC and can draw its power
from the controller’s User Power Supply.
‹The robot must be homed before you mount
the gripper.
1. Using a 3mm hex wrench and six M4x8 socket
screws, attach the gripper to the robot arm
flange.
2. Connect the coiled double hose from
the gripper to the quick coupling on
the underside of Link 2, as indicated
in Figure 4-7.
Figure 4-7: Gripper Connectors
Figure 4-5: Gripper Mounting
Flange Layout
Figure 4-6: Pneumatic Gripper
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3. Refer to Figure 4-8.
•Connect the two
transparent 1/4" O.D.
hoses from the robot to
the CYL ports on the
pneumatic valve.
•Connect a 5 bar/90 PSI
air supply to the IN port
on the valve.
4. Refer to Figure 4-9.
Connect the valve to the
controller’s User Power
Supply as follows:
•Connect the black wire
to a common terminal.
•Connect the red wire to
the normally open (NO)
terminal of any unused
relay output.
5. Connect 12VDC or 24VDC
(in accordance with your
valve’s specification) to the
common (C) terminal of the
same relay output, as
shown in Figure 4-9.
6. Attach the valve to the
controller or any other
metalic surface by means of
the valve’s magnetic base.
Figure 4-9: Valve—Controller Connections
Figure 4-8: Pneumatic Solenoid Valve
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