OnRobot HEX-E v1 User manual

USER MANUAL
HEX
Force Torque Sensor
For the Universal Robots
Edition E10
OnRobot FT URCap Plugin Version 3.1.3
June 2018

OnRobot © 2018 www.onrobot.com
Content
1Preface ...........................................................................................................................................6
1.1 Target Audience .....................................................................................................................6
1.2 Intended Use ..........................................................................................................................6
1.3 Important safety notice .........................................................................................................6
1.4 Warning Symbols ...................................................................................................................6
1.5 Typographic Conventions ......................................................................................................7
2Getting Started ..............................................................................................................................8
2.1 Scope of Delivery....................................................................................................................8
2.2 Mounting ............................................................................................................................. 10
2.3 Cable Connections............................................................................................................... 12
2.4 Software Upload to Robot Controller................................................................................. 13
2.5 URCap Plugin Installation ................................................................................................... 13
2.6 URCap Plugin Setup ............................................................................................................ 16
2.6.1 Example Setup ............................................................................................................ 18
3Using the URCap Plugin............................................................................................................. 20
3.1 OnRobot Feedback Variables ............................................................................................. 20
3.1.1 Effects of the TCP Position......................................................................................... 23
3.2 Hand Guide Toolbar............................................................................................................. 23
3.3 OnRobot URCap Commands .............................................................................................. 25
3.3.1 F/T Center Command............................................................................................ 25
3.3.2F/T Control Command ......................................................................................... 26
3.3.3 F/T Destack Command ......................................................................................... 29
3.3.4 F/T Fix and Rotate Command ........................................................................ 31
3.3.5 F/T Guard Command.............................................................................................. 33
3.3.6F/T Insert Box Command .................................................................................. 34
3.3.7 F/T Insert Pin Command .................................................................................. 36
3.3.8 F/T Move Command ................................................................................................ 37
3.3.9 F/T Path Command ................................................................................................ 39
3.3.10 F/T Search Command............................................................................................ 41

OnRobot © 2018 www.onrobot.com
3.3.11 F/T Stack Command.............................................................................................. 42
3.3.12 F/T Waypoint Command....................................................................................... 44
3.3.13 F/T Zero Command ................................................................................................ 46
3.4 TCP Offset Propagation ...................................................................................................... 47
3.5 Application Examples.......................................................................................................... 47
3.5.1 Collision Detection ...................................................................................................... 47
3.5.2 Center Point Detection................................................................................................ 47
3.5.3 Polishing and Sanding................................................................................................. 47
3.5.4 Stacking and Destacking............................................................................................. 48
3.5.5 Palletizing .................................................................................................................... 48
3.5.6 Pin Insertion ................................................................................................................ 49
3.5.7 Box Insertion ............................................................................................................... 49
3.5.8 Fix and Rotate ............................................................................................................. 50
4Glossary of Terms ...................................................................................................................... 51
5List of Acronyms......................................................................................................................... 52
6Appendix ..................................................................................................................................... 53
6.1 Changing the IP of the Compute Box ................................................................................. 53
6.2 Updating the software on the Compute Box..................................................................... 55
6.3 Software Uninstallation...................................................................................................... 55
6.4 Return Values...................................................................................................................... 55
6.4.1 F/T Center Command Return Values................................................................... 55
6.4.2 F/T Control Command Return Values................................................................. 55
6.4.3 F/T Destack Command Return Values................................................................. 56
6.4.4 F/T Fix and Rotate Command Return Values................................................ 56
6.4.5 F/T Guard Command Return Values ..................................................................... 57
6.4.6 F/T Insert Box Command Return Values.......................................................... 57
6.4.7 F/T Insert Pin Command Return Values.......................................................... 57
6.4.8 F/T Move Command Return Values........................................................................ 58
6.4.9 F/T Path Command Return Values........................................................................ 58
6.4.10 F/T Search Command Return Values................................................................... 58

OnRobot © 2018 www.onrobot.com
6.4.11 F/T Stack Command Return Values ..................................................................... 58
6.4.12 F/T Waypoint Command Return Values .............................................................. 59
6.4.13 F/T Zero Command Return Values........................................................................ 59
6.5 Troubleshooting .................................................................................................................. 60
6.5.1 “The Robot has no IP address”................................................................................... 60
6.5.2 “Discovery Tool was able to find OnRobot Device available in the Network”.......... 63
6.5.3 Too Close to Singularity .............................................................................................. 64
6.5.4 Warning sign on Hand Guide Bar................................................................................ 65
6.5.5 “socket_read_binary_integer: timeout” ................................................................... 65
6.5.6 “Socket vectorStream opening was unsuccessful.”.................................................. 65
6.5.7 Path Replay is Slower than Expected ........................................................................ 66
6.5.8 “Error number -2” on Path Saving ............................................................................. 66
6.5.9 “Error number -3” on Path Saving ............................................................................. 66
6.6 Editions................................................................................................................................ 67

Preface 5
OnRobot © 2018 www.onrobot.com
Copyright © 2017-2018 OnRobot A/S. All rights Reserved. No part of this publication
may be reproduced, in any form or by any means, without the prior written
permission of OnRobot A/S.
Information provided within this document is accurate to the best of our knowledge
at the time of its publication. There may be differences between this document and
the product if the product has been modified after the edition date.
OnRobot A/S. does not assume any responsibility for any errors or omissions in this
document. In no event shall OnRobot A/S. be liable for losses or damages to persons
or property arising from the use of this document.
The information within this document is subject to change without notice. You can
find the latest version on our webpage at: https://onrobot.com/.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
All trademarks belong to their respective owners. The indications of (R) and TM are
omitted.

Preface 6
OnRobot © 2018 www.onrobot.com
1Preface
1.1 Target Audience
This document is intended for integrators who design and install complete robot
applications. Personnel working with the sensor are expected to have the following
expertise:
1. Basic knowledge of mechanical systems
2. Basic knowledge of electronic and electrical systems
3. Basic knowledge of the robot system
1.2 Intended Use
The sensor is designed for measuring forces and torques, installed on the end
effector of a robot. The sensor can be used within the specified measurement range.
Using the sensor outside of its range is considered misuse. OnRobot is not liable for
any damage or injury resulting from misuse.
1.3 Important safety notice
The sensor is partly completed machinery and a risk assessment is required for each
application the sensor is a part of. It is important that all safety instructions herein
are followed. The safety instructions are limited to the sensor only and do not cover
the safety precautions of a complete application.
The complete application must be designed and installed, in accordance with the
safety requirements specified in the standards and regulations of the country where
the application is installed.
1.4 Warning Symbols
DANGER:
This indicates a very dangerous situation which, if not avoided, could
result in injury or death.
WARNING:
This indicates a potentially hazardous electrical situation which, if not
avoided, could result in injury or damage to the equipment.
WARNING:
This indicates a potentially hazardous situation which, if not avoided,
could result in injury or major damage to the equipment.
CAUTION:

Preface 7
OnRobot © 2018 www.onrobot.com
This indicates a situation which, if not avoided, could result in
damage to the equipment.
NOTE:
This indicates additional information such as tips or
recommendations.
1.5 Typographic Conventions
The following typographic conventions are used in this document.
Table 1: Conventions
Courier Text File paths and file names, code, user input and computer
output.
Italicized text Citations and marking image callouts in text.
Bold text
UI elements, including text appearing on buttons and
menu options.
Bold, blue text
External links, or internal cross-references.
<angle brackets> Variable names that must be substituted by real values
or strings.
1. Numbered lists Steps of a procedure.
A. Alphabetical lists Image callout descriptions.

Getting Started 8
OnRobot © 2018 www.onrobot.com
2Getting Started
2.1 Scope of Delivery
In the Universal Robots OnRobot HEX Sensor Kit everything is provided that is
required to connect the OnRobot force/torque sensor to your UR robot.
There are two versions of the OnRobot Universal Robots (UR) Kit, depending on
the HW version of the sensor.
2.1.1 OnRobot (OptoForce) UR Kit (v1)
The contents of the OnRobot (OptoForce) UR Kit v1 are the following:
•OnRobot (OptoForce) 6-axis force/torque sensor (variant HEX-E v1 or
HEX-H v1)
•OnRobot (OptoForce) Compute Box
•OnRobot (OptoForce) USB drive
•adapter-A
•overload plug
•sensor cable (4 pin M8 - 4 pin M8, 5 m)
•Compute Box power cable (3 pin M8 – open ended)
•Compute Box power supply
•UTP cable (RJ45 - RJ45)
•USB cable (Mini-B – Type A)
•PG16 cable gland
•plastic bag, containing:
4. cable holder
5. M6x30 screws (2 pcs)
6. M6x8 screws (10 pcs)
7. M5x8 screws (9 pcs)
8. M4x8 screws (7 pcs)
9. M4x12 screws (2 pcs)
10. M4 washer (8 pcs)
2.1.2 OnRobot UR Kit (v2)
The contents of the OnRobot UR Kit v2 are the following:
11. OnRobot 6-axis force/torque sensor (variant HEX-E v2 or HEX-H v2)
12. OnRobot Compute Box
13. OnRobot USB drive
14. adapter-A2

Getting Started 9
OnRobot © 2018 www.onrobot.com
15. sensor cable (4 pin M8 - 4 pin M8, 5 m)
16. Compute Box power cable (3 pin M8 – open ended)
17. Compute Box power supply
18. UTP cable (RJ45 - RJ45)
19. USB cable (Mini-B – Type A)
20. PG16 cable gland
21. plastic bag, containing:
22. cable holder, with integrated screw
23. M6x8 Torx screws (10 pcs)
24. M5x8 Torx screws (9 pcs)
25. M4x6 Torx screws (7 pcs)
26. M6 washer (10 pcs)
27. M5 washer (9 pcs)
2.2 Sensor Description
2.2.1 HEX-E v1 and HEX-H v1
The sensor consists of a sensor body, an adapter, and a overload plug. The sensor
cable connector, the cable holder, and markers for the reference frame are on the
sensor body. The tool is fastened to the sensor body directly, onto the tool
interface. The sensor is fastened to the robot tool flange by the adapter.
2.2.2 HEX-E v2 and HEX-H v2

Getting Started 10
OnRobot © 2018 www.onrobot.com
The sensor consists of a sensor body, an adapter, and a overload plug. The sensor
cable connector, the cable holder, dust sealing, serial number and markers for the
reference frame are on the sensor body. The tool is fastened to the sensor body
directly, onto the tool interface. The sensor is fastened to the robot tool flange by
the adapter.
2.3 Mounting
Use only the screws provided with the sensor. Longer screws could damage the
sensor or the robot.
2.3.1 HEX-E v1 and HEX-H v1
To mount the sensor, follow this process:
1. Fasten Adapter-A to the Robot by four M6x8 Screws. Use 6 Nm tightening
torque.
2. Fasten the Sensor to the adapter by five M4x8 screws with M4 washers. Use
1,5 Nm tightening torque.
3. Fasten the cable to the Sensor with the Cable Holder by one M4x12 screw
and M4 washer. Use 1,5 Nm tightening torque.
4. Fasten the Plug to the Sensor by one M6x30 Screw. Use 6 Nm tightening
torque.

Getting Started 11
OnRobot © 2018 www.onrobot.com
Legend: 1 –robot tool flange, 2 – Adapter A, 3 - M6x8 screws, 4 – M4x8
screws, 5 – overload plug, 6 – M6x30 screw, 7 – sensor, 8 – M4 washer, 9 –
M4x12 screw, 10 – cable holder
5. Fasten the tool to the Sensor, according to the instructions from the tool
manufacturer.
The overload protection is not fully functional, if the tool is not joined
to the Sensor with a flat surface.
2.3.2 HEX-E v2 and HEX-H v2
To mount the sensor, follow this process:
1. Fasten Adapter-A2 to the Robot by four M6x8 Torx Screws with M6
washers. Use 6 Nm tightening torque.
2. Fasten the Sensor to the adapter by five M4x86 screws with M4 washers.
Use 1,5 Nm tightening torque.
3. Fasten the cable to the Sensor with the Cable Holder by one M4x12 screw
and M4 washer. Use 1,5 Nm tightening torque.
4. Fasten the Plug to the Sensor by one M6x30 Screw. Use 6 Nm tightening
torque.
Legend: 1 –robot tool flange, 2 – Aadapter- A2, 3 - M6 washer, 4 – M6x8 Torx
screws, 4, 5 – sensor, 6 – M4x6 Torx screws, 7 – cable holder

Getting Started 12
OnRobot © 2018 www.onrobot.com
5. Fasten the tool to the Sensor, according to the instructions from the tool
manufacturer.
The overload protection is not fully functional, if the tool is not joined
to the Sensor with an interface described in ISO 9409-1-50-4-.
2.4 Cable Connections
To connect the sensor, follow this process:
1. Connect the 4 pin M8 cable (5m long) to the sensor. Ensure that the holes of
the cable are aligned with the pins of the connector on the sensor.
Do not rotate the cable, only rotate the connector lock.
2. Secure the cable to the robot with cable ties.
Make sure that enough extra cable length is available around
the joints for bending.
3. Place the Compute Box somewhere near or inside the UR robot control
cabinet and connect the 4 pin M8 sensor cable. The provided cable gland
can be used to lead the cable into the UR Control cabinet.
4. Connect the Compute Box‘s Ethernet interface with the UR controller’s
Ethernet interface via the supplied UTP cable.
5. Use the 3 pin M8 cable (1m long) to power the Compute Box from the UR’s
control box. Connect the brown cable to the 24V and the black cable to the
0V.
Power Configurable Inputs Configurable
Outputs
PWR 24V 24V 0V OV 
GND CI0 CI4 CO0 CO4 
24V 24V 24V 0V 0V 
0V CI1 CI5 CO1 CO5 
24V 24V 0V 0V 
CI2 CI6 CO2 CO6 
24V 24V 0V 0V 
CI3 CI7 CO3 CO7 
For more information, refer to the UR’s documentation.
6. Apply the correct network settings to both the Compute Box and the UR
robot. The default Compute Box IP address is 192.168.1.1, to change it, see
Changing the IP of the Compute Box.

Getting Started 13
OnRobot © 2018 www.onrobot.com
2.5 Software Upload to Robot Controller
To upload the OnRobot examples and URCap plugin, insert the USB drive in the
USB slot on the right side of the Teach Pendant.
1. A red "!USB!" warning sign appears, indicating the upload is in progress.
2. Wait for a green "USB" sign to appear, indicating the upload is completed.
3. Remove USB drive. The example codes are now in the program folder of the
UR robot.
The URCap plugin and a few examples are automatically copied to a new
programs/OnRobot_UR_Programs folder.
Continue with URCap Plugin Installation.
2.6 URCap Plugin Installation
Ensure that the robot controller has PolyScope version 3.5 or higher.
1. Select the Setup Robot option from the main menu.

Getting Started 14
OnRobot © 2018 www.onrobot.com
2. Press the URCaps Setup button.
3. Press the + sign.
4. Select the OnRobotForceTorqueSensor-x.y.z.urcap file from the
programs/OnRobot_UR_Programs folder.
5. Press the Open button.

Getting Started 15
OnRobot © 2018 www.onrobot.com
6. The screen shows that the OnRobot Force Torque Sensor URCap plugin has
been installed.
7. Press the Restart button to finalize installation process.
8. Click on the Program Robot button after the restart is finished.

Getting Started 16
OnRobot © 2018 www.onrobot.com
9. Select the Installation tab.
10. Select OnRobot FT Setup.
11. The welcome screen of the newly installed OnRobot Force Torque Sensor
URCap plugin is shown.
12. The OnRobot Hand Guide Toolbar is now also visible.
Continue with URCap Plugin Setup.
2.7 URCap Plugin Setup
Select the Installation tab, then select OnRobot Setup. The following screen is
shown:

Getting Started 17
OnRobot © 2018 www.onrobot.com
The following information is shown on this screen:
•Information about the steps needed for the sensor setup.
•Navigation buttons to move between pages of the guide.
•A list of discovered sensors which can be reached with the current network
configuration. Make sure that the correct sensor is selected by checking the
sensor IP and serial number.
•Connected sensors can be discovered by pressing the Discover Devices button.
•The selected OnRobot device must be tested first.
•General information about the tested device.
•IP and Subnet mask of the currently used UR robot.
•Enable/Disable buttons for the OnRobot Hand Guide Toolbar.

Getting Started 18
OnRobot © 2018 www.onrobot.com
The OnRobot Force Torque Sensor URCap plugin must be enabled (as the screen
above is shown). If the plugin is not enabled, the button shown under mark A has the
text ENABLE ALL FEATURES. Press the button, then start the toolbar with the
Enable Overlay button (mark B).
Here the Hand Guide behavior can also be set (mark C). If the Hold Enable button
checkbox is checked, the Enable button on the Teach Pendant functions as a live-
man switch, that is, the Enable button has to be pressed continuously for the Hand
Guide to function. If the Hold Enable buttoncheckbox is unchecked, the Enable
button acts as a normal switch, that turns the Hand Guide function on and off. By
default, the Hold Enable button checkbox is checked.
2.7.1 Example Setup
1. Press the Discover Devices button.
2. In the Discovered Devices drop-down list, select the Compute Box.
3. Press the Test Connection button.
The following screen is shown:

Getting Started 19
OnRobot © 2018 www.onrobot.com
The following information is shown on this screen:
•A message indicating that the OnRobot commands can be used in your own
UR programs.
•A drop-down list with the pairs of the Compute Box IP addresses and the
Sensor Serial Numbers available in the network.
•In this example, the Device with serial number HEXEA040 was selected as
the IP address is matched to HEXEA040.
•After pressing the Test Connection button, basic information is shown
about the device:
•The status of overall process
•The serial number of the sensor
•The Health String of the sensor
•The SW version of the Compute Box
•The green check marks indicate that both the Discover Devices and Test
Connection procedures were successful.
•You can save the current configuration by pressing the Load/Save button.

Using the URCap Plugin 20
OnRobot © 2018 www.onrobot.com
3Using the URCap Plugin
3.1 OnRobot Feedback Variables
Simple features are demonstrated in this section through an example program. The
program shows how to gain data from the OnRobot sensor and how to zero the
Force/Torque values of the sensor.
1. Click on Program Robot.
2. Click on Empty Program.
3. Select the Structure tab.
4. Press the Wait button to avoid infinite loop in the program.