Mobile Industrial Robots MiR500 User manual

User guide
MiR500
en
Revision: 1.1
Date: 2019/03

Copyright and disclaimer
All rights reserved. No parts of this manual may be reproduced in any form without the express written
permission of Mobile Industrial Robots ApS (MiR). MiR makes no warranties, express or implied, in respect of
this document or its contents. In addition, the contents of the document is subject to change without prior notice.
Every precaution has been taken in the preparation of this manual. Nevertheless, MiR assumes no responsibility
for errors or omissions or any damages resulting from the use of the information contained.
Copyright © 2017-2019 by Mobile Industrial Robots.
Contact the manufacturer:
Mobile Industrial Robots
Emil Neckelmanns Vej 15F
DK-5220 Odense SØ
www.mir-robots.com
Phone: [phone]
Email: [e-mail]
CVR: 35251235

Table of contents
1. About this document 3
1.1. Where to find more information 3
1.2. Document history 4
2. Safety 5
2.1. Safety message types 6
2.2. General safety precautions 6
2.3. Intended use 7
2.4. Foreseeable misuse 7
2.5. Risk assessment 8
2.6. Residual risks 8
2.7. Safety-related functions and interfaces 9
2.8. Limiting safety-related functions 9
2.9. Safety-related electrical interfaces 10
2.9.1. Safety-related electrical inputs 10
2.9.2. Safety-related electrical outputs 11
2.10. Lithium battery 11
3. Getting started 12
3.1. In the box 13
3.2. Unpacking MiR500 13
4. Commissioning 16
4.1. Powering up 17
4.2. Connecting to the robot interface 18
4.3. Driving the robot in manual mode 19
4.4. Checking the hardware status 21
4.5. Charging the robot 21
4.6. Shutting down the robot 22
4.7. Creating and configuring a map 23
5. Planning 24
5.1. Analysis of the work environment 25
5.1.1. What does the robot see? 25
5.2. MiR500 user roles 27
5.2.1. Types of users 27
5.2.2. Interface and dashboards 28
5.2.3. Training of the users 28
5.3. Creating an efficient map 29
5.3.1. Use zones on the map 29
5.4. Creating efficient missions 33

5.5. Error handling 33
5.6. Handover testing 34
6. Product presentation 36
6.1. Main features of MiR500 37
6.2. Identification label 38
6.3. MiR500 control panel 38
6.3.1. The Operating mode key 39
6.3.2. The control panel buttons 39
6.4. MiR500 operating modes 40
6.4.1. Muting of the personnel detection means 40
6.5. MiR500 external parts 41
6.6. MiR500 internal parts 43
6.6.1. Front compartment 43
6.6.2. Rear compartment 45
6.6.3. Side compartments 46
6.6.4. Top compartments 47
6.7. Sensor system 48
6.7.1. Safety laser scanners 48
6.7.2. 3D cameras 51
6.7.3. Proximity sensors 54
6.7.4. Internal sensors 54
6.8. Light indicators 54
7. Maintenance 56
7.1. Regular weekly checks and maintenance tasks 57
7.2. Regular checks and replacements 57
7.3. Packing for transportation 59
7.3.1. Original packaging 59
7.3.2. Packing the robot for transportation 59
7.3.3. Battery 60
8. Applications 61
8.1. Mounting a top module 61
9. Payload specifications 63
10. Interface specifications 65
10.1. General purpose interfaces 65
10.2. Safety interfaces 69
10.3. Connector list 71

About this document
1. About this document
This document contains the following information:
• How to start up and operate MiR500.
• Product presentation.
• Typical applications.
• Guidelines for proper maintenance of the robot.
1.1. Where to find more information
At www.mir-robots.com, the following extra resources are available. To access the pages in the Distributor site,
sign in with your distributor account at http://www.mobile-industrial-robots.com/en/account/.
• Distributor site > Manuals
http://www.mobile-industrial-robots.com/en/account/manuals/
This page contains the following resources:
• MiR500 Quick Start
The short guide that lets you start operating the robot quickly. This document is in the box with the
robot in the printed format. Available in multiple languages.
• MiR500Lift Operating guide
The operating guide that describes how to set up and use MiR500 with MiR500Lift.
• MiR500EUPalletLift Operating guide
The operating guide that describes how to set up and use MiR500 with MiR500EUPalletLift.
• MiRCharge500 Operating guide
The operating guide that describes how to set up MiRCharge500 and configure MiR500 for
automatic battery charging at the charging station.
• MiR Robot Interface 2.0 Reference Guide
The reference that describes the elements of MiR500 interface. Available in multiple languages.
• MiR500 REST API reference.
The REST API reference for the robot.
• Distributor site > Download
http://www.mobile-industrial-robots.com/en/account/download/
This page contains the following resources:
• CAD drawings.
Click Show CAD-files to see the list of available CAD drawings.
• Certificates.
Click Show Certificates to see the list of certificates for the robot.
• Distributor site > How to
http://www.mobile-industrial-robots.com/en/account/how-to/
This page contains how-to articles that describe how to perform specific tasks with the robot.
MiR500 user guide, 2019/03, rev.1.1 3

About this document
• MiR500 product page
http://www.mobile-industrial-robots.com/en/products/mir500/
This page contains specifications, pictures, and brochures for MiR500.
1.2. Document history
This table shows latest and previous versions of this document and their interrelations with product software
releases.
Revision Release date Description SW HW
1.0 2018-10-29 First edition. 2.4.0 1.0
1.1 2019-01-31 New section: Maintenance.
Updated styles.
2.6.0 1.0
MiR500 user guide, 2019/03, rev.1.1 4

Safety
2. Safety
Read the information in this section before powering up and operating MiR500.
Pay particular attention to the safety instructions and warnings.
NOTICE
Mobile Industrial Robots disclaims any and all liability if MiR500 or its accessories are
damaged, changed or modified in any way. Mobile Industrial Robots can not be held responsible
for any damages caused to MiR500, accessories or any other equipment due to programming
errors or malfunctioning of MiR500.
The section contains the following topics:
2.1. Safety message types 6
2.2. General safety precautions 6
2.3. Intended use 7
2.4. Foreseeable misuse 7
2.5. Risk assessment 8
2.6. Residual risks 8
2.7. Safety-related functions and interfaces 9
2.8. Limiting safety-related functions 9
2.9. Safety-related electrical interfaces 10
2.10. Lithium battery 11
MiR500 user guide, 2019/03, rev.1.1 5

Safety
2.1. Safety message types
This document uses the following safety message types.
WARNING
Indicates a potentially hazardous situation that could result in death or serious injury.
• Take proper precautions to avoid damage or injury.
CAUTION
Indicates a potentially hazardous situation that could result in minor or moderate injury. Alerts
against unsafe practices.
• Take proper precautions to avoid damage or injury.
NOTICE
Indicates important information, including situations that can result in damage to equipment or
property.
2.2. General safety precautions
This section contains general safety precautions.
WARNING
If the load on the robot is not positioned or fastened correctly, the load may fall or the robot may
overturn.
• Ensure that the load is positioned according to the specifications and fastened
correctly. See Payload specifications on page63.
WARNING
Using a charger different from the one supplied by the manufacturer can cause a fire.
• Use only the original charger.
CAUTION
The robot can not see staircases going downwards and holes in the floor.
• Mark staircases or holes on maps with Forbidden zones.
• Keep the maps up to date.
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Safety
WARNING
Lithium battery packs may get hot, explode or ignite and cause serious injury if they are abused
electrically or mechanically.
Observe the following precautions when handling and using lithium batteries:
• Do not short-circuit, recharge or connect with false polarity.
• Do not expose to temperature beyond the specified temperature range or incinerate
the battery.
• Do not crush, puncture or disassemble the battery. The battery contains safety and
protection devices, which, if damaged, may cause the battery to generate heat,
explode or ignite.
• Do not allow the battery to get wet.
• In the event the battery leaks and the fluid gets into one’s eye, do not rub the eye.
Rinse well with water and immediately seek medical care. If left untreated, the battery
fluid could cause damage to the eye.
• Use only the original charger (cable charger or charging station) and always follow the
instructions from the battery manufacturer.
2.3. Intended use
MiR500 is intended to be commissioned and used in indoor industrial environments where access for the public is
restricted. For details about the environmental conditions in which the robot should operate, see Technical
specifications on our website.
MiR500 is equipped with special safety-related features, which are purposely designed for collaborative
operation, where the robot operates without fences and/or together with humans.
MiR500 can be used with the lift modules MiR500Lift, MiR500EUPalletLift and pallet racks
MiR500LiftPalletRack and MiR500EUPalletRack, or it can be used with a customized top module or top
manipulator. See details for add-ons on our website or in the operating guides.
2.4. Foreseeable misuse
Any use or application deviating from the intended use is deemed to be impermissible misuse. This includes, but
is not limited to:
•Use of the robot to transport people.
Risk of personal injury and/or damage to the robot.
•Steep ramps on the route.
Risk of personal injury and/or damage to the robot. Steep surface grades (ramps etc.) may cause the
robot to skid. See Technical specifications on the website.
•Use outdoor.
Risk of personal injury and/or damage to the robot. MiR500 is designed and intended for indoor use
only.
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Safety
•Overloading of the robot.
Risk of personal injury and/or damage to the robot. If the maximum payload on top of the robot is
exceeded, it may cause overturning, falling load and damage to the robot. See Technical specifications
on the website.
•Failure to follow the guidelines for commissioning.
See Getting started on page12 and Planning on page24.
•Failure to make a risk assessment of the full installation.
See Risk assessment below. This applies to the robot with any extra modules installed.
•Failure to configure audible and light warning signal(s) according to the environment.
The risk reduction is not sufficient.
•Operation outside the permissible operating rating parameters and environmental
specifications.
Risk of instability, impact or tipping over.
•Transportation of liquids or food.
Risk of instability.
•Use in potentially explosive environments.
•Use in medical and life critical applications.
•Use for towing.
•Use on board ships.
Risk of personal injury and/or damage to the robot. Unstable surface caused by moving vessel may
cause the robot to skid.
2.5. Risk assessment
One of the most important steps in achieving a safe installation is to make a risk assessment. The risk
assessment is the responsibility of the individuals who are commissioning MiR500 in the environment it will be
used in. Most often it will be an integrator who also designs and/or builds work cells or other required
infrastructure related to MiR500.
The risk assessment must cover not only MiR500 itself, but also take into account potential top
module/manipulator, load transfer, work cells and the environment it will be used in.
It is recommended that the integrator uses guidelines in ISO 12100, EN 1525, ANSI B56.5 or other relevant
standards to conduct the risk assessment.
The risk assessment should consider two scenarios:
• Teaching (setup where maps are made and the missions are defined and verified) the robot while
developing the robot installation.
• Normal operation of the robot installation.
In EN 1525, clause 4 there is a list of significant hazards, hazardous situations and events which can be used for
inspiration.
2.6. Residual risks
Mobile Industrial Robots has identified the potential significant hazards listed below as hazards that must be
considered by the integrator.
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Safety
• Being run over, drawing-in, trapping or impact if a person steps into the route or walks towards MiR500
while in motion.
• Crushing, drawing-in or trapping at load transfer stations, work cells or charging stations.
NOTICE
Other significant hazards might be present in a specific robot installation.
2.7. Safety-related functions and interfaces
MiR500 is equipped with a range of built-in safety-related functions as well as safety-related electrical interfaces
designed for integration with a top module and/or top manipulator. Each safety function and interface is designed
according to the standard ISO 13849-1.
The safety-related functions and interfaces are selected to support compliance with EN 1525.
2.8. Limiting safety-related functions
MiR500 has several built-in safety-related functions that are used to ensure safe operation in the environment it is
designed to be used in.
Advanced control software ensures that locomotion and the drive pattern are within safety related limits and
thereby avoid triggering a safety function. Violations of limits will hence only occur in exceptional cases.
Nevertheless, if a limit is violated, the safety system issues a category 0 stop (stopping by “immediate removal
of power to the machine actuators according to IEC 60204-1”) followed by a controlled brake which brings
MiR500 to a stop.
See Technical specifications on our website for more details.
Collision avoidance
The collision avoidance safety function ensures that the robot will come to a stop before it collides with a human
or object.
The function measures the speed on the two driving wheels and switches between the predefined protective
fields accordingly. The faster the speed, the larger the protective fields will be.
This ensures that the robot will be brought to a stop in case a human or object is detected within the active
protective field.
Collision avoidance is automatically deactivated two seconds after the protective field is free.
Safe load position
The safe load position safety function ensures that the robot will not locomote, while MiR500Lift
orMiR500EUPalletLift is not in the lowest position and hence there is a risk of compromising stability.
The safe load position safety system consists of interlock switches that detect if the lift modules are in the
lowest position or not.
The input can be used for a customized top module/manipulator when a MiR500Lift or MiR500EUPalletLift is
not installed.
The safe load position safety function must be manually deactivated by activation of the restart button.
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Safety
Overspeed avoidance
The safety system monitors if the speed of each motor is above limits for maximum speed and hence an
indication of speed control is lost for any reason.
The overspeed avoidance safety function must be manually deactivated by activation of the restart button.
Stability
The safety system monitors if the speed difference between the two motors are above predefined limits and
hence an indication of speed control is lost for any reason.
The stability safety function must be manually deactivated by activation of the restart button.
Emergency stop
MiR500 has four emergency stop buttons and an option to connect additional emergency stop buttons through
the electrical interface.
The emergency stop should only be activated in case of an emergency.
Emergency stop must be manually deactivated by activation of the restart button.
2.9. Safety-related electrical interfaces
The robot is equipped with several safety-related electrical inputs and outputs. All safety-related electrical inputs
and outputs are dual channel. They are safe when low, e.g. the emergency stop is not active when the signal is
high (+24V).
2.9.1. Safety-related electrical inputs
This section contains the safety-related electrical inputs of the robot.
External emergency stop button input
This input is for connection of an optional emergency stop button. If activated, the safety system issues a
category 0 stop followed by a controlled brake which brings MiR500 to a stop.
Must be manually deactivated by activation of the restart button.
System emergency stop input
This input should be used in case a top manipulator has its own emergency stop circuit. The input must be used
in combination with a system emergency stop output. With this, it is possible to ensure that activation of any
emergency stop button will cause an emergency stop of both MiR500 and top manipulator. If activated, the
safety system issues a category 0 stop followed by a controlled brake which brings the robot to a stop.
Must be manually deactivated by activation of the restart button.
Safeguard stop input
This input can be used to issue a category 0 stop followed by a controlled brake which brings MiR500 to a stop.
Will be automatically deactivated when signal is driven high again.
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Safety
Load handling position (position control of load)
This input can be used to apply the safe load position (position control of load) safety function on a system with
customized top modules or manipulators. A variety of sensors or interlock switches that detect load handling
position or position of load can be connected and thereby enable the safe load position safety function.
2.9.2. Safety-related electrical outputs
This section contains the safety-related electrical outputs of the robot.
Locomotion
This safety related output is activated if the robot is in locomotion or intend to locomote within two seconds.
Note
The safety function is limited if locomotion is detected while the output is deactivated.
Shared emergency stop output
This output should be used in case a top manipulator has its own emergency stop circuit. The output should be
used in combination with a system emergency stop input. With this, it is possible to ensure that activation of any
emergency stop button will cause an emergency stop of both the robot and top manipulator.
Activated by an emergency stop button or emergency stop input.
2.10. Lithium battery
This section contains safety precautions related to lithium batteries in MiR robots.
WARNING
Lithium battery packs may get hot, explode or ignite and cause serious injury if they are abused
electrically or mechanically.
Observe the following precautions when handling and using lithium batteries:
• Do not short-circuit, recharge or connect with false polarity.
• Do not expose to temperature beyond the specified temperature range or incinerate
the battery.
• Do not crush, puncture or disassemble the battery. The battery contains safety and
protection devices, which, if damaged, may cause the battery to generate heat,
explode or ignite.
• Do not allow the battery to get wet.
• In the event the battery leaks and the fluid gets into one’s eye, do not rub the eye.
Rinse well with water and immediately seek medical care. If left untreated, the battery
fluid could cause damage to the eye.
• Use only the original charger (cable charger or charging station) and always follow the
instructions from the battery manufacturer.
MiR500 user guide, 2019/03, rev.1.1 11

Getting started
3. Getting started
This section describes how to get started with MiR500.
The section contains the following topics:
3.1. In the box 13
3.2. Unpacking MiR500 13
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Getting started
3.1. In the box
This section describes the content of the MiR500 box.
The box contains:
1. The MiR500 robot
2. MiR500 document folder containing the printed documents and the USB flash drive.
3. Printed documents:
• MiR500 Quick Start.
• MiR username and passwords.
• CE declaration of conformity.
4. USB flash drive with the following content:
• MiR500 User Guide.
• MiR Robot Interface 2.0 Reference guide.
• MiR robot REST API reference.
• MiRCharge500 Operating Guide.
• MiR500Lift Operating Guide.
• MiR username and passwords.
• CE declaration of conformity.
3.2. Unpacking MiR500
This section describes how to unpack MiR500.
Note
Keep the original packaging for the future transportation of the robot.
1. Place the box with the robot so that there is 3m of free space at the front or the back of the box. This is
necessary since the robot drives out of the box on the ramp.
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Getting started
2. Remove the screws that attach the walls of the box to the box lid and the base of the box.
3. Remove the lid from the box.
4. Take the folder with the printed documents and the USB drive out of the box.
5. Remove the walls of the box and the protective foam blocks.
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Getting started
6. Cut the protective straps.
7. Place the lid of the box so that you can use it as a ramp. Align the lid so that it is flush with the base of
the box.
8. Remove the wheel stop board from the pallet to let the robot drive on the ramp.
MiR500 user guide, 2019/03, rev.1.1 15

Commissioning
4. Commissioning
This section describes how to get started with MiR500.
NOTICE
Read the Safety chapter before powering up the robot.
The section contains the following topics:
4.1. Powering up 17
4.2. Connecting to the robot interface 18
4.3. Driving the robot in manual mode 19
4.4. Checking the hardware status 21
4.5. Charging the robot 21
4.6. Shutting down the robot 22
4.7. Creating and configuring a map 23
MiR500 user guide, 2019/03, rev.1.1 16

Commissioning
4.1. Powering up
Follow these steps to power up MiR500.
1. Open the rear maintenance hatch. To open the hatch, push two buttons on the hatch and pull the hatch.
2. Turn the battery disconnect switch to position ON.
3. The On/Off button turns blue.
4. Close the maintenance hatch.
5. Ensure that all 4 emergency stop buttons are in the released state. Turn an emergency stop button
clockwise to release it.
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Commissioning
6. Press the On/Off button for five seconds.
7. The robot turns on the yellow indicator lights and starts the software initialization process. When the
initialization process ends, the robot goes into the emergency stop mode.
8. Press the Restart button to clear the emergency stop. The robot is ready for operation, the status lights
turn constant yellow.
4.2. Connecting to the robot interface
When the robot is on, it enables the connection to its WiFi access point. The name of the access point appears in
the list of available connections on your laptop, tablet, or a phone.
NOTICE
The username and password for the robot’s WiFi access point and for accessing the web
interface are in the MiR username and passwords document. The document is in the box with
the robot.
MiR500 user guide, 2019/03, rev.1.1 18