Mecademic Meca500 User manual

User Manual
Original instructions
Meca500 (R3)
Robot Firmware: 8.1
Document Revision: B
October 15, 2020

The information contained herein is the property of Mecademic Inc. and shall not be
reproduced in whole or in part without prior written approval of Mecademic Inc. The
information herein is subject to change without notice and should not be construed as a
commitment by Mecademic Inc. This manual will be periodically reviewed and revised.
Mecademic Inc. assumes no responsibility for any errors or omissions in this document.
Copyright c  2020 by Mecademic Inc.

Contents
1 Introduction 1
2 Warning messages, notes and emphases 1
3 What's inside the box 2
4 Safety 3
4.1 Power supply and stopping functions ................... 4
4.2 Disabling the brakes of the robot ..................... 5
4.3 Functioning of the brakes .......................... 5
5 Technical specications 6
6 Installing the Meca500 7
7 The web interface 12
7.1 Updating the robot's rmware ....................... 12
7.2 Overview ..................................... 13
7.3 The programming panel ........................... 13
7.3.1 The status control checkboxes . . . . . . . . . . . . . . . . . . . . . . 13
7.3.2 The program editor eld . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3.3 The Response Log eld . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.3.4 TheRequestLog ............................. 16
7.4 The robot joint set and end-eector pose panel ............. 16
7.5 The 3D view window ............................. 16
7.6 The Quick Command panel ......................... 16
7.7 The jogging panel ............................... 17
7.7.1 TheJointJogtab............................. 17
7.7.2 The Cartesian Jog tab . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.7.3 TheJoysticktab ............................. 19
7.8 Opening and closing the MEGP 25 gripper ............... 20
8 Operating the robot 21
8.1 Power-up procedure .............................. 21
8.1.1 Poweringtherobot............................ 21
8.1.2 Connecting to the robot . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1.3 Activating the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.1.4 Homingtherobot............................. 22
i

8.2 Moving the robot ............................... 22
8.3 Power-o procedure .............................. 24
8.3.1 Zeroing the robot joints (optional) . . . . . . . . . . . . . . . . . . . 24
8.3.2 Deactivating the robot . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3.3 Disconnecting the robot . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3.4 Removingpower ............................. 25
8.4 Oine mode ................................... 25
8.4.1 Saving the program via the web interface . . . . . . . . . . . . . . . . 25
8.4.2 Running an oine program . . . . . . . . . . . . . . . . . . . . . . . 25
8.5 Robot control panel .............................. 26
8.5.1 LEDs ................................... 26
8.5.2 Buttons .................................. 27
9 Operating the intelligent power supply 28
9.1 LEDs ....................................... 29
9.2 External connections ............................. 30
10 Installing an end-eector 33
11 Examples 35
11.1 Draw a square ................................. 35
12 Troubleshooting 36
13 Storing the robot in its shipping box 37
14 EC Declaration of Incorporation (original) 38
ii

User Manual
1 Introduction
There are two manuals that come with the Meca500 (R3): this one and the programming
manual. This manual will guide you through the steps required for setting up your Meca500
and for using it in a safe manner. You must read this user manual thoroughly during the
unpacking and rst use of your Meca500.
The Meca500 is a six-axis industrial robot arm that is relatively easy to use, robust and
lightweight. The robot is, however, a precision device with rapidly moving parts. This
robot should therefore be used only by technical personnel who have read and understood
every part of this user manual, in order to avoid damages to the robot, its end-eector, the
workpiece and adjacent equipment, and, most importantly, in order to avoid injuries.
2 Warning messages, notes and emphases
Particular attention must be paid to the warning messages in this manual. There are only
two types of warning messages, as shown bellow:
B
WARNING
This presents instructions that must be followed in order to prevent injuries
and possibly damage to your robot cell (robot arm, power supply, end-eector,
workpiece and/or adjacent equipment).
B
CAUTION
This presents instructions that must be followed in order to prevent damage
to your robot cell (robot arm, power supply, end-eector, workpiece and/or
adjacent equipment).
In addition, important notes and denitions are formatted as follows:
NOTICE
This highlights important suggestions or denitions, the purpose of which is to
improve the understanding of this manual and of how the robot works.
Finally, occasionally, small portions of the text in this manual that are particularly important
are underlined (as already done in the previous section).
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3 What's inside the box
Your shipping box contains a Meca500 robot arm (Fig. 1a), a 24 V DC intelligent power
supply with an integrated safety module (Fig. 1b) and a D-SUB 15-position dongle (Fig. 1c),
a 2-meter M12 D-Code to RJ45 Ethernet cable (Fig. 1d), and a 2-meter M12 circular male
to M12 circular female DC power cable (Fig. 1e).
Your box may also contain the MEGP 25 electric gripper and other accessories. Remove
all items carefully and do not discard your shipping box. If your order contained a gripper,
do not open its package immediately. You must read the MEGP 25 user manual prior to
installing the gripper.
Note, that you must provide your own AC power cord, with three-prong IEC C13 con-
nector on one end, and your own country's power plug on the other. You must also provide
M6 screws of proper length for xing the robot's base and the power supply.
(a) The Meca500 robot arm
(b) D-SUB dongle
(c) Power supply
(d) Ethernet cable
(e) DC power cable
Figure 1: The main contents of your shipping box (optional items not shown)
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B
CAUTION
• Handle the robot with care.
• The Meca500 is equipped with brakes on the rst three joints (the ones close
to the base). When the robot is not activated, these brakes are automatically
applied. Do not force the brakes of the robot, unless there is an emergency!
• Inspect the robot and the power supply for damages. If you think either of
them is damaged, do not use them and contact us immediately.
• Do not modify or disassemble the robot arm or the power supply.
• Do not use or store the Meca500 in a humid environment.
• Do not operate the Meca500 at temperatures bellow +5◦ C or above +45◦ C.
• Do not use any other power supply but the one provided.
• Do not replace the Ethernet and DC power cables provided with longer ones,
without contacting us rst.
4 Safety
The Meca500 weighs less than 5 kg. It can, however, move fast and cause injuries, especially
when certain end-eectors are attached to its ange (e.g., a sharp tool or a laser). The robot
also has pinch regions where two adjacent links of the robot can squeeze a nger (Fig. 2).
It is imperative that you follow the guidelines of ISO 12100:2010 and ISO 10218-2:2011
and conduct a risk assessment of your complete robot cell, including the Meca500, its end-
eector and all adjacent equipment.
B
WARNING
• When the Meca500 is activated, stand away from it, wear safety goggles and
be attentive and alert.
• If deemed necessary, place the robot in a safety enclosure.
• In case of an emergency, press immediately the E-STOP button located on
the power supply.
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Figure 2: When the Meca500 is activated, keep away from the zones labeled with the pinch-
point warning sign, to avoid injuries.
4.1 Power supply and stopping functions
To power your Meca500 robot arm, you can only use the intelligent power supply provided by
us. If you use one of our older power supplies or your own 24 V DC source, the robot would
not function. Our new power supply has an integrated safety module, including a button for
emergency stop (Stop Category 1), a reset button, status LEDs, and a D-SUB 15-position
interface for connecting an external emergency stop (Stop Category 1), a protective stop 1
(Stop Category 1), and a protective stop 2 (Stop Category 2). The emergency stops and the
protective stop 1 are designed as PL=d with Safety Category 3.
To start using your robot immediately, connect the dongle provided to the D-SUB 15-
position interface. This would deactivate the additional protective stops and emergency
stop. Read section 9.2 if you want to remove the dongle and install such additional stops.
Furthermore, to connect the power supply to the robot, you must use the DC power cable
provided and never modify it.
B
CAUTION
Never install an emergency stop or any kind of on/o switch on the DC side of
the power supply.
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When disconnecting the AC power, either by using the on/o switch on the power supply
or by unplugging the AC cord, the brakes on joints 1, 2 and 3 will be immediately applied
and the joints will be immobilized instantly. Therefore, to avoid premature use of the brakes,
do not disconnect the AC power when the robot is moving.
When disconnecting the AC power or activating the emergency stop or the external pro-
tective stop 1 and emergency stop, the wrist joints of the robot become free. This minimizes
the risks of pinning and pinching from the wrist and the end-eector. However, beware that
the end-eector might slowly move downwards under the eects of gravity. Depending on
the type of end-eector used, this residual motion might lead to an injury.
By denition, the protective stop 2 does not cut power to the robot, so after the robot
stops all motors are active and maintain the position of all joints. The brakes are not applied
and there is no residual motion due to gravity.
4.2 Disabling the brakes of the robot
In case of a collision, you can disable the brakes of joints 1, 2 and 3. This can only be done
if the robot is powered AND not activated. How to activate and deactivate the robot is
explained later in this manual, but for now, it suces to say that the robot is deactivated
after pressing the E-STOP button. Thus, in case of a collisionthough ideally prior to
thatyou must press the E-STOP button.
Then, to release the brakes of joints 1, 2 and 3, press one of the two 0G buttons on the
base of the robot continuously while holding the robot with your other hand. After 3 seconds,
you will hear the deactivation of the brakes. Continue holding the 0G button pressed and
move the robot as far as possible from obstacles. Finally, release the 0G button, and move
away from the robot. Note that there is a pair of commands to disable and re-enable the
brakes. These are described in the programming manual.
B
WARNING
In case of an emergency, it is relatively easy to force the robot brakes and move
the robot's joint manually. However, forcing the brakes too often will damage
the robot.
4.3 Functioning of the brakes
It is extremely important to remember that the robot has brakes on joints 1, 2 and 3 only.
Therefore, when the robot is deactivated or powered o, the robot's end-eector will go down
under the eects of gravity.
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In addition, it is important to remember that the brakes used on joints 1, 2 and 3 are
emergency brakes, not locking brakes. Therefore, if you leave the robot in a conguration
where the robot's forearm is nearly horizontal, the robot will very slowly fall down under
the effects of gravity (e.g., after several hours), especially if you have the maximum payload.
Therefore, always deactivate the robot in a conguration that minimizes the static torques
on joints 1, 2 and 3.
5 Technical specications
Table 1 lists the main technical specications of the Meca500 robot arm. Note that the
maximum tool-center point (TCP) speed is software limited to 1,000 mm/s when the robot
executes Cartesian-space motion commands, regardless of the denition of the TCP with
respect to the robot's ange. However, if the robot is fully stretched and all joints move at
maximum speed, due to a joint-space command, the TCP speed can surpass 2,000 mm/s.
B
WARNING
Note that in some special congurations, the robot's end-eector can move at
2,000 m/s or even faster. You must consider this fact in your risk assessment.
Figure 3 shows the main dimensions of the Meca500. Note that all joints are at zero
degrees in the conguration drawn in black line. Also note that the gray zone is the area
attainable by the center of the robot's wrist (the intersection point of the last three axes),
for a xed angle of joint 1. This area, or even the volume obtained by sweeping this area
about the axis of joint 1 is NOT the workspace of the robot. The workspace of the robot
is a six-dimensional entity depending on the denition of your tool reference frame. The
workspace is the set of attainable poses (positions and orientations) of the tool reference
frame with respect to the robot's base. Even for a specic choice of a tool reference frame,
it is impossible to represent this six-dimensional workspace (read this tutorial of ours).
The CAD les of the Meca500 (in STEP format) can be downloaded from our web site.
Alternatively, you can use one of several robot simulation and oine programming software
packages that include a model of our Meca500, including Visual Components and RoboDK.
Finally, as already mentioned, the power supply provided has an IEC C14 connector that
accepts an AC power cord with three-prong IEC C13 connector on one end, and your own
country's power plug on the other. You can connect this power cord to any AC source that
supplies voltage between 90 V and 264 V at frequency between 50 Hz to 60 Hz.
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Table 1: Technical specications for the Meca500
Position repeatability 0.005 mm
Rated payload 0.5 kg
Maximum payload 1.0 kg (under special conditions)
Weight of robot arm 4.5 kg
Range for joint 1 [−175◦,175◦]
Range for joint 2 [−70◦,90◦]
Range for joint 3 [−135◦,70◦]
Range for joint 4 [−170◦,170◦]
Range for joint 5 [−115◦,115◦]
Range for joint 6 [−36,000◦,36,000◦]
Maximum speed for joint 1 150◦ /s
Maximum speed for joint 2 150◦ /s
Maximum speed for joint 3 180◦ /s
Maximum speed for joint 4 300◦ /s
Maximum speed for joint 5 300◦ /s
Maximum speed for joint 6 500◦ /s
Maximum TCP speed 1,000 mm/s
Max.imum power consumption 200 W
Input voltage 24 VDC
Operating ambient temperature range [5
◦
C, 45
◦
C]
Operating ambient relative humidity range [10%,80%] (non-condensing)
IP rating IP 40
6 Installing the Meca500
You are surely eager to start using your Meca500. It is, however, imperative that you x
solidly the base of your robot arm before activating the robot. We typically use metric bread-
boards such as those from Thorlabs, but you can also use our adaptor plate for aluminum
T-slotted framing, or even build your entire robot cell at Vention.
B
WARNING
Fix securely the robot's base via the mounting holes (Fig. 4a) with four M6
screws, on any at surface of a rigid body.
Do not install any end-effector yet. We will cover this topic in Section 10.
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135 135 38
120 70
R260
boundary for
wrist center
45 units: mm
Figure 3: The dimensions of the Meca500
Note that the robot will automatically detect the angle between the axis of joint 1 and
the gravity vector. Also, note that you can mount the robot's base on a mobile body (e.g.,
on the carriage of a linear guide), but only if you do not intend to move the robot's joints,
while the robot's base is moving with respect to the ground.
Next, you must solidly attach the power supply using four M6 screws (Fig. 5), at a
location suciently close to the robot's base to allow connection with the 2-meter DC cable
provided. However, unless you are using an external emergency stop wired via the D-SUB
connector, you must x the power supply at a location that makes the integrated E-STOP
button readily accessible by an operator and outside the working range of the robot.
The following steps must then be executed before you can start using your Meca500:
1. Attach the circular connector of the Ethernet cable to the ETHERNET1 port on the
robot's base and connect the RJ-45 jack to your computer or router (Fig. 4b-c). The
two Ethernet ports on the robot's base act as a bridge, so you can daisy-chain several
Meca500 robots, or connect an Ethernet I/O module on the ETHERNET2 port.
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2. Use the DC power cable provided to connect the unpowered power supply to the robot's
DC power connector (Fig. 4b-c). Make sure the connectors are completely screwed on
both sides, or else you may damage the robot controller. Then, connect the power
supply to your country-specic AC power cord (not provided by us). Only then, can
you connect the AC power cord to an AC outlet, and, if not already done, switch the
power supply on using its on/o button.
B
CAUTION
• Do not use any other power supply but the one provided, or else the warranty
will be voided and the CE certication no longer valid.
• Always connect the DC power cable before connecting the power supply to
an AC outlet.
• Always disconnect the power supply from the AC outlet (or switch it o)
before disconnecting the DC power cable.
• Avoid un-plugging the DC power supply too often and always make sure both
connectors are completely screwed.
115
90
100
75
4X thru holes for M6
units: mm
(a) Dimensions
(b) Connectors (c) Connectors properly attached
Figure 4: The base of the Meca500
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Power
Status
Error
RESETE-STOP
Safety I/O
Port
Robot Power
24 VDC 8.34 A
AC Power
90-264 VAC
50-60 Hz
units: mm
4X thru counterbored holes for M6
120
90
75
100
48
68
Figure 5: Dimensions of the power supply
4. The green LED on the power supply (next to Power) will be illuminated. Now, you
must provide power to the robot by pressing the RESET button on the power supply.
5. You will hear a clicking sound coming from the power supply, and the robot's LEDs
will start ashing for a few seconds while the robot's controller is booting. Once the
controller ready, the red LED on the robot's base will start ashing intermittently.
6. Depending on which of the two Ethernet ports was used in step 1, the Link/Act
IN (for ETHERNET1) or Link/Act OUT (for ETHERNET2) green LED should be
illuminated. If it is not, detach the Ethernet cable and repeat step 1.
7. Congure your computer with a static IP address. The way to do this diers from one
operating system to another. Figure 6 shows how to do this in Windows and in Linux.
8. Open (preferably) the latest version of Google Chrome and type Meca500's default IP
address 192.168.0.100 in the address bar.
9. Meca500's web interface should load instantaneously. If it doesn't, repeat the previous
step with a dierent browser.
It is also possible to change the robot's network conguration. This option is available
through the robot's web interface, which will be described in detail in Section 8. Here is the
procedure for doing so:
1. Click on the Options dropdown menu and then on Settings (Fig. 7).
2. Depending on your conguration, choose DHCP to automatically receive an address
from your router or Static to force a specic IP. You don't need to reboot the robot;
the new conguration will be applied as soon as you click on the Save button (Fig. 8).
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(a) Windows (b) Linux
Figure 6: Two examples of how to congure the IP address of your computer
Figure 7: Options dropdown menu
(a) DHCP (b) Static
Figure 8: Two ways to change the robot's network conguration
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7 The web interface
Meca500's web interface is more or less the equivalent of the teach pendant's interface of a
traditional industrial robot. The interface is essentially an HTML 5 web page with JavaScript
and WebGL scripts. All of these les reside in the robot's controller, so you do not need to
install anything on your computer, but Google Chrome.
The interface basically translates your mouse clicks, joystick movements and keyboard
entries into proprietary commands that are sent to the robot's controller. These are the
same commands described in the programming manual that you will eventually start sending
from your own application, written in C++, Java, Python or any other modern programming
language. In addition, the web interface displays the feedback messages received from the
robot and the 3D model of the actual robot.
The web interface is intended mainly for testing and writing simple programs. You must
create your own software application or program if you intend to use the robot for complex
tasks, such as interacting with inputs and outputs (in which case you also need a third-party
I/O module).
The web interface is also used for updating the rmware of your robot.
7.1 Updating the robot's rmware
Before you continue to read any further, make sure that you have the latest rmware in-
stalled on the robot and that you read the manuals corresponding to that rmware. Go to
https://www.mecademic.com/Downloads/Updates/Robot%20Meca500/R3/ and download
the most recent zip le. Unzip it. Then, while the robot is still not activated, click on
Update in the Options menu in the web interface (Fig. 7). A new interface will load in the
same browser tab. Click on Choose File and select the le with the extension *.update that
you just extracted. Then click on the Upload button. Wait a couple of minutes for the
update to be completed. Once completed, the robot will reboot and the new web interface
will reload.
Now that you have installed the latest robot rmware, make sure to download the latest
user and programming manuals from https://www.mecademic.com/resources/documentation
and keep these manuals until you update again your rmware.
Next time you update your robot's rmware, you must also read the PDF le that is in
the zip package (i.e., the Release Notes). That document lists of all the recent rmware
changes.
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7.2 Overview
Figure 9 shows the main elements of the web interface. These are:
• The menu bar
• The programming panel
• The quick command panel
• The jogging panel
• The current joint set and TRF pose panel
• The 3D view window
You can hide the programming panel, the jogging panel and the quick command panel
from the View Panel drop-down menu in the menu toolbar.
Menu bar
Jogging panel
Quick command panel
Programming panel
Current joint set and TRF pose panel
Figure 9: Overview of Meca500's web interface
7.3 The programming panel
The programming panel has two tabs: the Main Control and the Request Log tabs.
7.3.1 The status control checkboxes
Once the web user interface is loaded, the rst step is to connect it to the robot. So far,
you have only established an HTTP connection with the robot, but not activated the socket
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messaging which is the only communication channel for controlling the robot via the web
interface. To connect to the robot, select the J checkbox.
A pop-up window will be displayed with two radio buttons. For now, leave the Control
radio button selected. The Monitoring option can be used to see in real-time the motion of
the robot when another client (other than the web interface, e.g., Matlab running on the
same PC) is controlling the actual robot.
Next, you need to activate the robot by selecting the  checkbox. Once, the robot is
activated, you need to home it by selecting the  checkbox. During homing, all joints rotate
slightly for approximately 4 seconds.
B
CAUTION
Before homing, make sure that there is no risk for mechanical interference.
Finally, whenever you have a motion error, the V checkbox will become selected and red.
To reset the error, you will need to clear the checkbox (or press the Ù below the Program
eld, as we will explain later).
7.3.2 The program editor eld
The program editor is used mainly for writing and executing very simple programs, i.e.,
for testing. These programs are sequences of the proprietary commands described in the
programming manual. The robot's command interface does not support conditionals, loops,
or other ow control statements, nor variables. The robot only accepts request commands
(to get information from the robot) and motion commands (to tell the robot to perform an
action). The editor also supports comments in C/C++ style (e.g., // and /* */).
For complex tasks, you must write a program outside the web interface (e.g., in your
preferred integrated development environment) that parses the robot's feedback, controls
the robot, and handles all ow control logic. For this, you can use any language that
supports communication over TCP/IP (e.g., C/C++, C#, Python, Java or even Structured
Text, in the case of a PLC).
The control buttons bellow the editor eld have the following functionality:
Ù Execute the complete program.
 Execute the command where the cursor is, and move the cursor to the next line.
Ñ Hold motion (pauses the robot and keeps the current program; motion is restarted
with the same button, when it becomes red).
 Clear motion (stops the motion and clears the command queue).
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õ Loop the program.
I Save the program in the robot for oine execution (Section 8.4), with the id num-
ber dened in the number eld on the right of this button, only when the robot is
deactivated.
é Delete all entries in the program editor eld.
} Open an existing program.
ú Save the contents of the program editor eld to a le.
In the event of a motion error, the Ù button changes to V and all other buttons on the
same row are disabled. Pressing V resets the error.
In addition, you can use the keyboard shortcut Ctrl+Enter, instead of the  button.
Finally, an important feature of the programming editor is the context menu called by
pressing the right mouse button when the mouse cursor is over the programming editor
(Fig. 10). Essentially, this gives us access to inserting all available commands at the current
position of the cursor in the programming editor. This functionality is quite similar to the
quick command menu, with a few dierences. The only major dierence is the possibility
to insert the commands MoveJoints, MoveLin, and MovePose with the current joint set or
end-eector pose.
To cancel the context menu without inserting a command, press Esc or click away.
Figure 10: Context menu in the programming editor
7.3.3 The Response Log eld
The log eld displays all the messages that are sent by the robot. The control buttons
associated with this eld are self explanatory:
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é Clear the log.
ú Save the log.
/ Show/hide timestamp for each message.
7.3.4 The Request Log
The request log is the log of all commands sent to the robot, by using the programming
panel, the quick command panel, or the jogging panel. The only commands that are not
logged are the velocity-mode motion commands sent while jogging the robot.
7.4 The robot joint set and end-eector pose panel
Once the robot is activated and homed, you will be able to see its current joint values as well
as the current pose of the TRF ( Tool Reference Frame ) with respect to the WRF ( World
Reference Frame ). The TRF and WRF are those dened by the user, but not necessarily in
the programming editor or the quick command eld. For example, you can connect to your
robot and change these two reference frames from a PLC, and then connect your browser to
the robot. The TRF and WRF are shown in the 3D view window (the x-axes are in ref, the
y axes are in green, and the z axes are in blue). You can show or hide these two reference
frames from the r drop-down menu.
Finally, you can choose between several preset views for the 3D view window from the i
drop-down menu.
7.5 The 3D view window
The 3D view window shows an orthographic projection of the robot in its current position
and the current WRF and TRF. To zoom in and out, place your mouse cursor over the 3D
view window and use your mouse wheel. To change the view angle, press the left mouse
button inside the 3D view window, hold it down and drag the mouse. To change the view
angle along a dierent choice of two axes, press the left and right mouse buttons inside the
3D view window, hold them down and drag the mouse. Finally, to pan, press the mouse
wheel inside the 3D view window, hold it down and drag the mouse.
7.6 The Quick Command panel
The drop-down list in the quick command panel has all proprietary commands supported by
the Meca500. If a command selected has arguments, additional numerical elds will appear.
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