ready robotics Forge/CTRL User manual

Forge/CTRL User Manual
P/N R-400015
Version 2.0
Welcome
You’re READY to unleash the power of industrial automation! The Forge/CTRL system is the future of easy-to-
program manufacturing automation. With this system, your business has the tools to enter a world of more
efficient and more precise manufacturing processes. This user manual, along with the included “Quick Reference
Guide” and “Risk Assessment Procedure,” will get you on the path to setting up your Forge/CTRL as soon as
possible.
Safety and risk assessment
The Forge/CTRL system is partly completed machinery and as such a risk assessment is required for each
installation of the system. It is particularly important that all relevant safety standards be observed. The system
itself is considered party completed machinery as the safety of the Forge/CTRL installation depends on how the
system is integrated (e.g. tool, obstacles, and other machines). A comprehensive risk assessment is often required
to comply with local and national safety standards and is always recommended. It is also recommended you follow
the guidelines in ISO 12100 and ISO 10218-2 to conduct the risk assessment.
Industrial robots can cause severe and fatal injuries to workers during interventions such as maintenance,
unjamming, adjustments, and setup.
The information contained herein is the property of READY Robotics Corporation and shall not be reproduced in
whole or in part without prior written approval of READY Robotics Corporation. The information herein is subject
to change without notice and should not be construed as commitment by READY Robotics. This manual is
periodically reviewed and revised.
Any information given in this manual regarding safety must not be construed as a warranty by READY Robotics that
the Forge/CTRL system will not cause injury or damage even if all safety instructions are complied with.
READY Robotics assumes no responsibility for any errors or omissions in this document.

Forge/CTRL User Manual
P/N R-400015
Version 2.0
Table of Contents
Safety and Precautions
4
Overview
General safety
Robot safety
Electrical safety
Pneumatic safety
Introduction to the Forge/CTRL
8
Overview
Choosing the right task
Overview of your system
TeachMate
Primary axes
Hardware Set Up
14
Overview
Connecting power and air
Starting the Forge/CTRL system
Attaching an end effector to the robot arm
Attaching devices to the air and PLC modules
Connect to a camera
103
Overview
Before you Begin
Setup the Camera
Setup the Camera in Forge/OS
Use the camera in a task
Troubleshooting and Technical Support
111
Technical Specifications
107
System technical specifications
Force sensor threshold values

Forge/CTRL User Manual
Safety and Precautions
Version 2.0
Safety and Precautions
Overview
The Forge/CTRL system connects to a variety of robotic arms and devices. Although some robot arms are
collaborative and designed to be used in proximity to people, there are still safety considerations that come with
working with any system that uses electric and air power for high-speed handling of parts.
General safety
!
Be sure to follow all the safety rules and regulations of your workplace while using the Forge/CTRL
system. None of the safety features built in to the Forge/CTRL overrule your workplace’s standards for
safety.
•Always wear all recommended personal protective equipment in accordance with your workplace’s safety
standards, including:
oSafety glasses
oHearing protection
oHard hats
oSteel-toe boots
oChemical protective material
•Always use proper safety precautions when working with tools that contain sharp edges, pinching
surfaces, or generate heat.
•Always lift heavy objects with your legs, not your back. If you cannot lift an object alone, ask for help or
find another method to move it.
•Always store sharp objects, including robot tools and peripherals, in a safe location with sharp edges
covered.
•Always inspect all electrical and pneumatic cables to ensure that they are in good condition.
•Never allow minors to operate the Forge/CTRL system.
•Never enter the workspace of the robot while it is in motion or executing a task.
•Never use defective, dull, or broken tools.
•Never use the Forge/CTRL in an environment over 122º F (50º C).
•Never open the enclosure of the Forge/CTRL or attempt maintenance on the system’s internal
components.

Forge/CTRL User Manual
Safety and Precautions
Version 2.0
Robot safety
!
Although safety devices and collaborative robot arms increase the safety of the work environment, it
does not mean that all devices used with the Forge/CTRL system or functions the system performs are
inherently safe as well.
•Always use caution around fast-moving objects, heavy objects, and sharp edges.
•
A risk assessment must be performed for all collaborative applications.
The Forge/CTRL system is designed to connect to a variety of robot arms. Some robot arms are human-safe and
designed to enter a protective stop when they contact any object, including a person. Whether the arm is
collaborative or not, there are some guidelines that should be considered when working with a robot arm.
•Know the motion limitations of your system and be sure to remove any objects that could be easily
damaged or destroyed from the reach of the arm. See your robot arm’s manual for specific details.
•The safest way to stop the robot arm is with either of the emergency stop buttons located on either the
monitor or the teach pendant.
•The main power switch is not an emergency stop switch. Do not use the main power switch for
emergency situations.
•Do not wear loose fitting clothing that could get stuck in a moving robot joint, end effector, or devices.
For safety information specific to the Universal Robots arm, see the included manual for the robot arm.
Collaborative robot arms
Forge/CTRL systems that include a human-safe, collaborative robot arm are designed to enter a protective stop
when they contact any object in their path, including a person. The force threshold for each robot arm varies,
consult your robot arm’s manual for specific information. When the force threshold is met the robot arm enters a
protective stop. Although this meets the threshold for a “human-safe” system, the robot arm can still cause injury
if carrying a sharp object or moving above shoulder height.
Safety modes
Depending on your set up, there are different safety modes you may experience during operation. The most
common safety mode is an emergency stop. If you are using a collaborative arm, the robot arm may enter a
protective stop. Reduced mode and safeguard stop are safety modes triggered by attached safety devices.

Forge/CTRL User Manual
Safety and Precautions
Version 2.0
Safety modes - continued
Emergency stop
The robot arm enters an emergency stop when either an emergency stop button is pressed or when a high-speed
collision occurs. When in an emergency stop:
•The robot arm applies internal brakes to ensure rigidity.
•Attached end effectors and devices release grip and turn off.
•The TeachMate LEDs turn red.
•Forge/OS notifies you the robot is in an emergency stop and the margins are red and display “Robot
Error.”
If an emergency stop occurs because of an emergency stop button, Forge/OS instructs you to turn the emergency
stop button clockwise, releasing the stop. Once the stop is released, the robot arm enters idle mode.
If an emergency stop occurs because of a high-speed collision, Forge/OS instructs you to clear the system through
the teach pendant, connected to the controller of the robot arm. Follow all on-screen instructions to restart the
robot arm from the teach pendant. Once the stop is released, the robot arm enters idle mode.
Protective stop
The robot arm enters a protective stop when it encounters an obstacle that triggers the human-safe force sensors
inside the robot arm. When in a protective stop:
•The robot arm applies internal brakes to ensure rigidity.
•Attached end effectors and devices release grip and turn off.
•The TeachMate LEDs turn yellow.
•Forge/OS notifies you the robot is in a protective stop and the margins are yellow and display “Robot
Warning.”
To clear the protective stop and turn on the robot arm, tap Turn Robot On from the Robot Mode panel, see
section the “Robot Mode” section of the “Control Suite” chapter for more information.
Reduced mode
The robot arm enters reduced mode when a connected safety device detects a condition that causes the robot
arm to slow movement to maintain a safe work environment. Reduced mode can be triggered by a person or
object entering the work area or coming within a defined distance of the system.
•The robot arm continues to execute the task at a reduced speed.
•The TeachMate’s LEDs blink green.
•Forge/OS notifies you the robot arm is in reduced mode by displaying “Reduced Mode” in the margins.
To return the system to Active mode, clear the condition that triggered the safety devices.

Forge/CTRL User Manual
Safety and Precautions
Version 2.0
Safety modes – continued
Safeguard stop
The robot arm enters a safeguard stop when a connected safety device detects a condition that that causes the
robot arm to stop to prevent harm or injury and maintain a safe work environment. Safeguard stops can be
triggered by a person or object entering the work area or coming within a defined distance of the system.
•The robot arm applies internal brakes to ensure rigidity.
•Attached end effectors and devices maintain their state.
•The TeachMate LEDs blink green.
•Forge/OS notifies you the robot is in a safeguard stop and the margins are yellow and display “Safeguard
Stop.”
To return the system to Active mode, clear the condition that triggered the safety device.
The safeguard stop can be overridden to perform things like maintenance, task programming, or error recovery.
Follow these steps to override the safeguard stop.
Step
Action
1
Enter the work area, stop the task in Forge/OS, and enter the override key into the key switch.
Result: Forge/OS mutes the safety device and puts the system into Active mode.
2
Perform the necessary actions to the task or system.
3
Remove the override key, start the task in Forge/OS, and exit the work area.
Result: Forge/OS resumes executing the task.

Forge/CTRL User Manual
Safety and Precautions
Version 2.0
Electrical safety
The Forge/CTRL system uses a standard 120V cable for power.
•Do not open the Forge system’s enclosure to attempt maintenance on any electrical system within.
•Only use cables provided by READY Robotics that are in good condition and do not show signs of wear.
•Unplug the Forge/CTRL system in these situations:
oDuring electrical storms or power outages.
oWhen turning on circuit breakers to which the system is connected.
•Regularly inspect the cable harness running from the Forge/CTRL to the TeachMate. If electrical cables
appear frayed or worn, unplug the system and contact READY Robotics.
•Ensure that any electrical device that is attached to the system operates within the parameters of the
Forge/CTRL electric tool add-on.
Pneumatic safety
The Forge/CTRL system uses 90 psi to actuate end effectors and attached devices.
•Never have your hand or face near any end effector or device when it is actuating. Pneumatic end
effectors and devices can exert hundreds of pounds of force.
•Do not attach a device rated for less than 90 psi to the system without an air regulator.
•Do not open the Forge/CTRL enclosure to attempt maintenance on any pneumatic system within.
•Regularly inspect the cable harness running from the Forge/CTRL to the TeachMate. If pneumatic cables
appear frayed or worn, unplug the system and contact READY Robotics.
•Ensure that any pneumatic devices attached to the system operate within the parameters of the
Forge/CTRL air device specifications.

Forge/CTRL User Manual
Introduction to the Forge/CTRL
Version 2.0
Introduction to the Forge/CTRL
Overview
The Forge/CTRL system is designed to be flexible, efficient, and easy-to-use. Understanding the role that a robotic
system can fulfill in your business will help you employ the system to its fullest capability. In general, robotic
systems are best suited for repetitive or non-value-added tasks.
Choosing the right task
The best way to learn the capabilities of your Forge/CTRL system is to work with it yourself! Try various tasks at
different machines and with different end effectors, parts, and devices. If there’s a task you believe your system
can handle but you don’t have the tools for it, reach out to READY Robotics to discuss expanding the capability of
your system.
Here are some questions to consider when choosing a task that is right for your system. Answers to each question
are provided as an example of where your system is suited for the task.
Questions to consider
Example answers where the system is best suited
How complex is the task for the machine
operator to perform?
This task involves minimal dexterity or complex part interaction.
How repetitive is the task?
This task involves the same motions or processes, repeated many
times in succession.
How is the part introduced to the machine?
The part is placed in a rigid jig in the machine.
How is the part packaged?
The part is placed in a rigid box or package after processing.
How much time does the operator spend
waiting for the machine to process the
part?
This task involves downtime during which the operator is waiting
for the machine.
How much does the operator interact with
the part compared to the machine?
The machine does most of the work in this task and the operator
simply loads or unloads the part.
What decision points or feedback
determine how the operator will proceed
in this task?
This task is a very straightforward process and doesn’t require
the operator to make complex decisions.
Example of tasks where the system is best employed.
•Machine tending
•Product packaging
•Material loading and unloading
•Holding parts for processing

Forge/CTRL User Manual
Introduction to the Forge/CTRL
Version 2.0
Overview of your system
Your system is comprised of three major pieces of the Forge/CTRL system. Each piece plays an important role in
helping you create a task for your system to complete.
Piece
Description
Forge/CTRL
The system that connects Forge/OS and you to the robot arm. Forge/CTRL also acts as
the hub to provide power and air to the TeachMate and attached devices.
Forge/OS
The READY Robotics software through which you interact with and program the robot
arm. Forge/OS enables you to create, save, load, and execute tasks. Through Forge/OS
you can track the performance of the system throughout the execution of tasks.
TeachMate
The LED module at the end of the robot wrist that provides power and air to the
attached end effector. When moving the robot arm by hand, the TeachMate is the
recommended gripping point, see the “TeachMate” section of this chapter for more
information.

Forge/CTRL User Manual
Introduction to the Forge/CTRL
Version 2.0
Overview of your system – continued
Forge/CTRL left side
The following labels the main interaction points of the left side of the Forge/CTRL system.
Forge/CTRL right side
The following labels the main interaction points of the left side of the Forge/CTRL system.

Forge/CTRL User Manual
Introduction to the Forge/CTRL
Version 2.0
The TeachMate
The TeachMate is the LED module at the end of the robot wrist. The
TeachMate provides power and air to the attached end effector. When
moving the robot arm by hand, the TeachMate is the recommended
gripping point.
With the TeachMate you can:
•Identify the current mode of the Forge/CTRL
•Switch the Forge/CTRL between active mode and teach mode
•Toggle the state of the attached tool
•Invoke the rapid teach feature
See the “TeachMate button control” section of this chapter for more
information on the TeachMate’s button functionality.
TeachMate mode indicator
The TeachMate LEDs indicate the current operating mode of the Forge/CTRL system. Use this table for information
on the status:
Color
Mode
Description
White
Idle
The robot arm is rigid, and tasks cannot be executed. The margins in Forge/OS are
white and display “Robot Idle”.
To exit idle mode, switch to Active mode or Teach mode from the TeachMate or
Robot Controls, see the “Robot Controls” section of the “Control Suite” chapter for
more information.
Green
Active
The robot arm is rigid and waiting for instruction. Tasks are executable when in this
mode. The margins in Forge/OS are green and display “Active Mode”.
!
Before executing a task, executing a block on the Canvas, or toggling the
state of a end effector,
•Always warn anyone in the robot workspace.
•
Always confirm the robot workspace is clear of obstacles or persons.

Forge/CTRL User Manual
Introduction to the Forge/CTRL
Version 2.0
TeachMate mode indicator - continued
Color
Mode
Description
Blue
Teach
The robot arm is compliant and can be moved by hand. Tasks cannot be executed
when in this mode. The margins in Forge/OS are blue and display “Teach Mode”.
Use this mode to teach the set waypoints. See the “Robot Moves” section of the
“Blocks” chapter for more information on waypoints.
!
Because the arm is easily moved by hand, the robot arm can fall suddenly
and unexpectedly if the weight of the end effector is not properly
configured, see the “Attaching an end effector to the robot arm” section
of the “Hardware Set Up” for more information.
Blinking
green
Executing task
The robot arm is moving and executing a task. The margins in Forge/OS are green
and display “Active Mode”.
Reduced mode
The robot arm is moving and executing a task at a reduced speed. The margins in
Forge/OS are green and display “Reduced Mode”.
Reduced mode happens when attached safety devices detect conditions that cause
the robot arm to slow movement to maintain a safe work environment.
Reduced mode can be triggered by a person or object entering the work area or
coming within a defined distance of the system. When the system enters
Reduced mode, clear the condition to return the system to active mode.
Safeguard stop
The robot arm is rigid, and tasks cannot be executed. The margins in Forge/OS are
yellow and display “Safeguard Stop”.
A safeguard stop happens when the safety devices detect conditions that cause the
robot arm to stop to prevent harm or injury and maintain a safe work environment.
Safeguard stop can be triggered by a person or object entering the work area or
coming within a defined distance of the system. When the system encounters a
safeguard stop, clear the condition to return the system to active mode.

Forge/CTRL User Manual
Introduction to the Forge/CTRL
Version 2.0
TeachMate mode indicator - continued
Color
Mode
Description
Yellow
Warning
The robot arm is rigid, and tasks cannot be executed. The margins in Forge/OS are
yellow and display “Robot Warning”.
A warning happens when the robot arm encounters a condition that causes an
error that is corrected through Forge/OS. Warnings include recovery after an
emergency stop has been released or when a protective stop occurs; see the
“Robot Safety” section of the “Safety and Precautions” chapter for more
information on protective and emergency stops.
When a warning happens, follow the instructions in Forge/OS to resolve the
condition and return the Forge/CTRL system to active mode.
Red
Error
The robot arm is rigid, and tasks cannot be executed. The margins in Forge/OS are
white and display “Robot Error”.
An error happens when the robot arm encounters a condition that causes an error
that is only corrected externally. Errors include robot faults or violations,
emergency stops, and loss of connection between Forge/OS and the robot arm.
When an error occurs, follow the instructions in Forge/OS to resolve the condition
and return the Forge/CTRL system to active mode.

Forge/CTRL User Manual
Introduction to the Forge/CTRL
Version 2.0
TeachMate button control
The TeachMate buttons are the primary user interface for mode control, end effector control, and the rapid teach
feature. The buttons on the TeachMate are labeled 01, 02, 03, and 04. Buttons 01 and 04 are on opposing sides of
the TeachMate; buttons 02 and 03 are on the face of the TeachMate.
The following functionalities are available through the TeachMate’s buttons:
Function
Action
Description
Mode control
Simultaneously
press 01 and 04
Switch between Active mode and Teach mode. When the robot arm is
in idle mode, the mode control puts the robot arm into teach mode.
Rapid teach
Short/long press 02
Record waypoints and end effector state as blocks on the Canvas. See
the “Rapid Teach” section of this chapter for more information.
Toggle end
effector
Double press 03
Toggle the end effector state. On the first press, the TeachMate LED
will blink yellow; on the second press, the end effector state changes.
Press any other button after the first press to cancel the gripper state
change.

Forge/CTRL User Manual
Introduction to the Forge/CTRL
Version 2.0
Rapid teach
Rapid teach allows you to interact with the robot arm and record actions from the TeachMate. For rapid teach to
work, you must be on the Canvas. When rapid teach is invoked the TeachMate provides feedback so that you know
if the input was accepted or not.
When using rapid teach, the TeachMate flashes
•White once if the input was accepted.
•Four times if the input was rejected.
If your input is rejected, it could be because a window is open on the Canvas or an end effector is not properly
setup.
Rapid teach is invoked by pressing the 02 button on the TeachMate. Rapid teach works in either Active mode or
Teach mode. The 02 button responds to two inputs:
•Short press (less than a second)
•Long press (hold until the LED turns white, then release).
On the Canvas, short press 02 to open the settings of a Blend and save the current position of the robot arm as a
waypoint. With the Blend settings open, short press 02 to add the current position of the robot arm as a waypoint
to the Blend. This can be done in either Active mode or Teach mode.
The following are the available actions when using rapid teach.
Action
Result on Canvas
Result in Blend settings or Pattern settings
Short press
Open a Blend and save the current position
as a waypoint.
Save the current positions as a waypoint in
the current Blend or Pattern.
Long press
Place a Tool block for the current state of the
end effector. For example, if a Schunk two-
finger gripper is configured and the fingers
are in the open position, an Open Gripper
block is placed.
Accept the settings and place the Blend or
Pattern on the Canvas.
For more information on Blend, Pattern, waypoints, and Tool blocks, see sections “Robot Moves” and “Tools” of
the “Blocks” chapter for more information.

Forge/CTRL User Manual
Hardware Set Up
Version 2.0
Hardware Set Up
Overview
The Forge/CTRL system is designed with flexibility and ease-of-use in mind. To that end, setting up the hardware is
easy. Connect the system to power and air, turn it on, and connect an end effector. After that, you are ready to
start programming your task.
Connecting power and compressed air
The Forge/CTRL system requires 120V power and 90 psi of
compressed air to operate.
•Removing power from the system without safely shutting
down the system may damage the robot arm.
•Removing air from the system may prevent certain
peripherals and end effectors from working properly.
The power and compressed air inlets are located on the left side of
the system.
Power
The main power cable for the Forge/CTRL system must be attached to AC power for the system to turn on and
operate.
Compressed air
The compressed air connection takes a standard 1/4-inch industrial quick coupler. READY Robotics recommends
that air provided to the Forge/CTRL system be between 80 - 110 psi. Providing compressed air above or below this
range could cause the system to operate in an unexpected manner. Note: Your system’s set-up may differ.
!
Do not attach compressed air greater than 110 psi to the system.

Forge/CTRL User Manual
Hardware Set Up
Version 2.0
Starting the system
Power on the Forge/CTRL
The Power Disconnect switch, on the left side of the Forge/CTRL provides the system with power. It does not start
up the system. Once the Power Disconnect is on and power is available, pressing the Power button starts up the
system.
Before turning the main power switch to the on position, ensure that AC power and compressed air are both
attached to the system.
Startup procedure
When the Power button is pressed, the system goes through its startup procedure. The monitor and TeachMate
LEDs turn on. While starting up, the robot arm may move slightly and make a clicking sound, and the monitor
displays a loading status. Allow the system to fully startup before attempting to use the system. When the system
is ready for use, the monitor displays the End User License Agreement in Forge/OS.

Forge/CTRL User Manual
Hardware Set Up
Version 2.0
Startup the system
Follow these steps to turn on and startup the Forge/CTRL system.
Step
Action
1
Rotate the Power Disconnect switch a quarter turn clockwise to the On position.
Result: Power is supplied to the system. The Forge/CTRL can be turned on.
2
Press the Power button
Result: The green LED lights up and the startup procedure begins. When ready, Forge/OS displays the
End User License Agreement.
3
Read through the End User License Agreement (EULA) and tap Accept.
Result: The System Loadout screen appears.
Note: Declining the EULA or closing the EULA window causes the system to shutdown.
Attaching an end effector to the robot arm
End effectors attach to the robot arm by securing the end effector’s tool flange to the wrist flange. The wrist flange
at the end of the robot arm is designed to interface with a variety of end effectors provided by READY Robotics.
The tool flange connects to the wrist flange with the end effector in only one position. If an adjustment to the end
effector’s position needs to be made, to allow for clearance beneath the TeachMate for example, the tool flange
can be removed, adjusted, and reattached to the end effector.
Note: Extra and replacement tool flanges can be provided by READY Robotics for damaged flanges or custom end
effectors.

Forge/CTRL User Manual
Hardware Set Up
Version 2.0
Attach an end effector to the arm
Follow these steps to attach an end effector to the end of the robot arm.
Step
Action
1
Release the locking bolt.
a. Pulling button out on the end of the locking lever.
b. Pull the locking lever all the way open.
2
Line up the alignment pin on the wrist flange with the alignment slot on the tool flange. Push the two
flanges together.
Result: The face of the tool flange is touching the face of the wrist flange.
3
Lock the locking bolt by pushing the locking lever all the way closed.
4
Configure the end effector in System Loadout, see the “System Loadout” chapter for more
information.
In System Loadout, you
•Receive instructions on how to attach the end effector’s air hoses or power cables to the
TeachMate.
•Provide the measurements for the tool center point (TCP).
•Define the center of mass (COM) of the tool.