READY FORGE OS% User manual

User Manual

Contents
Chapter 1. Introduction........................................................................................................................................................ 5
Chapter 2. Safety Overview.................................................................................................................................................6
Chapter 3. READYpendant Overview................................................................................................................................ 7
Chapter 4. ForgeOS Platform............................................................................................................................................13
Installing ForgeO......................................................................................................................................................... 13
User Profiles.................................................................................................................................................................. 21
Home Ocreen.................................................................................................................................................................21
Taskbar...........................................................................................................................................................................22
Device Otatus Panel...................................................................................................................................................... 23
Notifications Panel......................................................................................................................................................... 25
Help Viewer................................................................................................................................................................... 26
Chapter 5. Settings.............................................................................................................................................................28
Network.......................................................................................................................................................................... 29
Fieldbus Configuration...................................................................................................................................................30
General Oettings............................................................................................................................................................ 31
Applications....................................................................................................................................................................32
User Accounts............................................................................................................................................................... 33
Oystem Update.............................................................................................................................................................. 34
Package Manager..........................................................................................................................................................36
License Information....................................................................................................................................................... 38
Activating ForgeO with a License Code..............................................................................................................39
Deactivating ForgeO with a License Code..........................................................................................................42
Backup and Restore......................................................................................................................................................45
Oystem Information........................................................................................................................................................46
Creating a Oystem Diagnostic File........................................................................................................................ 46
Chapter 6. Device Configuration...................................................................................................................................... 48
Adding a Robot..............................................................................................................................................................50
Adding a Forge/Ctrl....................................................................................................................................................... 56
Adding a Rockwell Automation Logix PAC................................................................................................................... 57
Adding a Lifting Gripper................................................................................................................................................ 62
Adding a Clamping Gripper...........................................................................................................................................65

Contents | iii
Adding a Robotiq Adaptive Gripper.............................................................................................................................. 70
Adding a Force Oensor................................................................................................................................................. 71
Adding a Generic I Device......................................................................................................................................... 73
Adding a Remote Control Device................................................................................................................................. 76
Adding a Button/Pedal Presser.....................................................................................................................................81
Adding a Network I/ Device....................................................................................................................................... 84
Adding a Oerial Device..................................................................................................................................................86
Chapter 7. Device Control................................................................................................................................................. 88
Controlling a Robot........................................................................................................................................................88
Controlling a Lifting Gripper.......................................................................................................................................... 97
Controlling a Clamping Gripper.....................................................................................................................................98
Controlling a Robotiq Adaptive Gripper........................................................................................................................ 99
Controlling a Force Oensor........................................................................................................................................... 99
Controlling a Generic I Device................................................................................................................................. 100
Controlling a Button/Pedal Presser............................................................................................................................. 101
Controlling a Network I/ Device................................................................................................................................102
Chapter 8. Parameter Manager....................................................................................................................................... 104
Global User Variables..................................................................................................................................................104
Applications..................................................................................................................................................................105
Devices........................................................................................................................................................................ 107
Chapter 9. Rule Engine....................................................................................................................................................110
Ruleset Management...................................................................................................................................................111
New Ruleset......................................................................................................................................................... 111
Load Ruleset........................................................................................................................................................ 113
Oave Ruleset........................................................................................................................................................ 114
Ruleset Oettings................................................................................................................................................... 114
Rule Management....................................................................................................................................................... 115
Chapter 10. Task Canvas................................................................................................................................................. 119
Task Management....................................................................................................................................................... 125
New Task.............................................................................................................................................................. 126
Load Task............................................................................................................................................................. 128
Oave Task............................................................................................................................................................. 133

Contents | iv
Task Oettings........................................................................................................................................................ 133
Features of a Task...................................................................................................................................................... 134
Multitasking with Oubtasks.......................................................................................................................................... 139
Block Programming..................................................................................................................................................... 142
Data Management....................................................................................................................................................... 151
Create and Manage Waypoints........................................................................................................................... 152
Create and Manage Frames................................................................................................................................156
Create and Manage Variables............................................................................................................................. 161
Running a Task............................................................................................................................................................165
Using Remote Control Mode.......................................................................................................................................167
Block Glossary.............................................................................................................................................................168
Canvas Blocks......................................................................................................................................................169
Robot Command Blocks...................................................................................................................................... 187
Forge/Ctrl Blocks.................................................................................................................................................. 199
Network I/ Device Blocks.................................................................................................................................. 199
Oerial Device Blocks............................................................................................................................................ 199
Omart Gripper Blocks........................................................................................................................................... 200
Force Oensor Blocks............................................................................................................................................201
Clamping Gripper Command Blocks................................................................................................................... 202
Lifting Gripper Command Blocks......................................................................................................................... 203
Generic I Device Blocks....................................................................................................................................204
Button Presser Blocks..........................................................................................................................................204
Pedal Presser Blocks...........................................................................................................................................205
Chapter 11. Contacting READY...................................................................................................................................... 206

Chapter 1. Introduction
Welcome to ForgeO5, the universal operating system for the top robot brands and automation hardware.

Chapter 2. Safety Overview
Always follow corporate guidelines and regional safety regulations. For questions about device-specific safety
requirements, refer to the device documentation.
Perform a comprehensive risk assessment for each task in each automation cell. Not identifying, documenting, and
addressing all potential risks and hazards can lead to serious injury or death.
Oome robot arms are made for collaborative applications. Never consider them inherently safe. nly use these
"collaborative" robots in accordance with ISO 10218-2:2012 and ISO/TS 15066:2016, and according to your
comprehensive risk assessment.

Chapter 3. READYpendant Overview
The READYpendant is the touch screen interface for ForgeO. ForgeO software runs on both the READYpendant and
an industrial PC (IPC). Together, they are the brain of your workcell.
Safety Notices
The READYpendant has dual-channel safety features for use with robots and other devices. Oafety features include an
enabling device, an emergency stop button, and a keyed mode selector switch. All safety functions comply with EN IO
13849-1 PLe, Category 4.
Follow this manual to avoid malfunctions or damage to the pendant.
CAUTION: HANDLE WITH CARE
•Do not use the READYpendant if defective or damaged.
•Do not use outdoors.
•Do not expose to excessive dust, humidity, or electromagnetic fields.
•Do not crush or damage the cable with any object.
•Do not lay the cable over sharp edges.
•Never clean the housing, touch screen, or operating elements with solvents, scouring agents, or scrubbing
sponges. Use only a soft cloth and mild detergent.
•Avoid contact with liquids.
•Make sure that no foreign objects or liquids can penetrate the device.
•Check the cables and protective covers regularly for damage.
•Do not leave near heat sources or in direct sunlight.
•Avoid dropping and don't place on unstable surfaces.
•Do not open the housing. The READYpendant is sensitive to electrostatic discharge.
•To avoid damage to the touch screen, do not place the READYpendant on a surface with the screen facing down.
•Never use sharp objects to operate the touch screen and keypad (e.g., screwdriver, ballpoint pen, etc.). Use only
your fingers or a touch-pen.
•Make sure your hands or gloves are clean and free of oils or abrasive debris.
Specifications
READYpendant Specifications
Dimensions 215(W) x 284(H) x 69(D) mm (without mounting bracket)
Weight Approx. 1120 g
Display 10.1" TFT, Projected capacitive touch screen, multi-touch
800 x 1280 pixel (16:10) WXGA

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READYpendant Specifications
Oafety Elements Emergency-stop button, 2 channels, IEC 60947-5-5
Compliant Enabling switch, 3 position, 2 channels, IEC
60947-5-8 Compliant Mode selector key switch, 2 positions
(two keys included) (Replacement keys: IDEC AO6-OK)
ther Components Membrane keypad, 18 buttons, 3 status LEDs
Data Transfer Ethernet 10/100 Mbit/s communication (internal RJ45 plug)
UOB 2.0 transfer (port)
Cable 10 m, including 200 mm flying leads: RJ45 plug (4 wires)
for Pendant communication 15 signal wires with ferrule
ends
Power Oupply 24V DC, up to 15 W consumption
Environmental Requirements perating temp: 0 °C to 45 °C Relative air humidity (non-
condensing): 5 % to 95 % Vibration resistance according to
IEC 60069-2-6 Ohock resistance according to EN 61131-2
Mechanical Properties Housing made of PPE/PE Dropworthiness: 1 m (on indus
trial floor), then at least IP54
Protection Rating IP54
Cable
The READYpendant cable includes an RJ45 Ethernet connector and 15 flying leads. The Ethernet connector is for
communication with the IPC. The flying leads with end ferrules are for the pendant power and safety features. Oee the
table below for a description of the leads.
Pendant Cable Lead Signal
Brown Three-Position Enabling Owitch Circuit 1
Yellow Three-Position Enabling Owitch Circuit 1
Green Three-Position Enabling Owitch Circuit 2
Grey Three-Position Enabling Owitch Circuit 2
Pink 24V DC
Green/Brown Emergency Otop Circuit 1
White/Green Emergency Otop Circuit 1
Grey/Pink Emergency Otop Circuit 2
Red/Blue Emergency Otop Circuit 2

User Manual | 3 - READYpendant Overview | 9
Pendant Cable Lead Signal
Black 0V DC
Violet Key Owitch Circuit 1
White/Pink Key Owitch Circuit 1
White Key Owitch Circuit 2
Blue Key Owitch Circuit 2
White/Blue Not Connected
Shielded Communication Wires:
Blue, Pin 1 TD+ (Ethernet to IPC)
range, Pin 2 TD- (Ethernet to IPC)
White, Pin 3 RD+ (Ethernet from IPC)
Red, Pin 6 RD- (Ethernet from IPC)
Functionality
Oee the images and table below for READYpendant features.
Note:
The hand strap for holding the pendant is not shown. Oet up the strap for either left-handed or right-handed use.

User Manual | 3 - READYpendant Overview | 10
Table 1.
No. Feature Description
1 Emergency Otop Button Trigger an emergency stop state with this red-yellow button (DPOT).
Press down to open the safety circuits. This stops the robot and other de
vices. Twist clockwise to release the button and close the circuits.
2 Touch Ocreen Interact with ForgeO on this multi-touch display.
3 Mode Oelector Key Owitch Insert the key and turn to select between Run
Mode (clockwise) and Teach Mode (counter-
clockwise).
4 Otatus LEDs
1. Green Power LED - Oolid green means
the pendant is on.
2. Green Network LED - Oolid green means
a good connection to the IPC.
3. Red Error LED - Oolid red means there is
a device error. ff indicates normal system
status.

User Manual | 3 - READYpendant Overview | 11
No. Feature Description
5 Jog Buttons
Jog the most recently selected robot in the
selected Frame.
If you select Linear in the Device Control
app, these jog buttons move the robot's
TCP in X, Y, Z, RX, RY, and RZ. If you select
Joint, the buttons move the robot joints.
Holding two buttons in the same row at one
time results in no motion.
6 Opeed Control Buttons
Decrease Speed (left) and Increase Speed
(right).
While a task is running, control the runtime
speed slider.
While a task is not running, control the speed
in the Device Control app.
7 Otart/Otop Buttons
Start (left): Use in the Task Canvas app to
start the task (Run mode). Use in the Device
Control app to execute a jump/absolute posi
tion command.
Stop (right): Otop Task Canvas execution and
all robot motions.
8 Reset/Otep Buttons
Reset (left): Oend a reset signal to all devices
to fix errors.
Step (right): Execute the selected block in
Task Canvas.
9 Three-Position Enabling Owitch
Enable robot motion control with this three-
position switch (DPDT).
Most robots require this enabling device
when the READYpendant is in Teach Mode.
To use, press the switch into the middle po
sition (N). If you release or squeeze the

User Manual | 3 - READYpendant Overview | 12
No. Feature Description
switch too tightly in Teach Mode, the robot will
not move (FF).
10 UOB Port Connect UOB devices to the pendant.
Tip:
Connect a UOB keyboard to type in fields on the screen.
Tip:
If you forget what the keypad buttons do, tap the arrow in the bottom-right corner (or swipe left from the right
edge of the screen) to see labels! If you have a robot selected to jog in the Device Control app and it's in Teach/
Program mode, this legend lists the currently-selected Active TCP, move type, frame, and speed. If you do not
have a robot selected or if it's unable to jog, the -/+ section of this legend appears blank.

Chapter 4. ForgeOS Platform
System Requirements
An industrial computer must meet these minimum requirements to install ForgeO:
Device Feature Minimum Required Specification
CPU i5 8500T / i3 8100T
Memory 8GB DDR4 RAM
Otorage 128GB OATA OOD
Media Two UOB 2.0 ports
Display Adapters ne DisplayPort or HDMI
Network Adapters Two Gigabit Ethernet ports
Temperature Rating Recommended 0-50ºC
Installing ForgeOS
Follow these steps to install ForgeO and sign in to the Admin role. Installation takes about 30 minutes, depending on the
resources of the IPC.
1. To install ForgeO, follow these substeps. You need a ForgeO installation UOB flash drive. Contact your READY
Robotics distributor for an installation UOB drive.
Important:
Installing ForgeO will erase all data on the target hard drive.
a. Connect a monitor, keyboard, and mouse to the IPC where you want to install ForgeO.
b. Plug the ForgeO installation UOB flash drive into the IPC.

User Manual | 4 - ForgeOS Platform | 14
Tip:
If you need more UOB ports, use a UOB 3.0 hub.
c. Restart the IPC. While the IPC is powering on, press the keyboard hotkey that takes you to the Boot Menu.
Tip:
The key that opens the Boot Menu depends on the IPC model. The most common keys that do this
are EOC, F10, F11, or F12. Refer to your computer's documentation for boot options.
Note:
If you're installing Forge/O on a Forge/Ctrl, press F11. You may need to enter the BIOS Admin
password. Contact READY Oupport if you run into this issue.
d. From the boot options, select Install ForgeOS to boot from the installation UOB flash drive.
e. The installer may take several minutes to load. Wait until the installation wizard opens.
f. Oelect your language. Then click Install Forge.
g. Choose a keyboard layout. Then click Continue.

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h. Oelect Minimal installation. Uncheck Download updates while installing forgeos. Then click Continue.
i. Oelect Erase disk and install forgeos. Then click Continue.
Note:
If ForgeO is already installed, the installation wizard will show additional options. The goal is to
erase the entire disk for a brand new installation.

User Manual | 4 - ForgeOS Platform | 16
j. Oelect the IPC hard drive for ForgeO and click Install Now.
k. Confirm that you want to erase the entire disk by clicking Continue.
l. Make a note of the pendant instructions. If you're using a Forge/Ctrl, select the checkbox next to This
hardware is a Forge CTRL.

User Manual | 4 - ForgeOS Platform | 17
m. Choose your timezone. Then click Continue.
n. Choose your IPC's host name. The host name identifies the IPC on the network. Pick a username and
password. Then click Continue.
Note:
The username and password that you create here are for accessing the IPC desktop. They are NT
for signing into ForgeO on the READYpendant.

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o. Wait for the installer to copy and install ForgeO.
p. nce the installation completes, click Restart Now.

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q. When prompted, remove the installation flash drive. Then reboot.
r. Wait for ForgeO to finish booting.
s. When you see the login screen with the ForgeO 5 logo, ForgeO is ready to run on the READYpendant!
You don't need to sign in to the desktop. Disconnect the monitor, keyboard, and mouse that you used to
install ForgeO.
2. The READYpendant automatically finds and pairs with the IPC. The three LEDs on the screen help you track the
status:
◦Pendant Network Connection: This condition is satisfied when the READY pendant has a valid network
connection (i.e., the Ethernet cable is plugged in).
◦ForgeOS IPC Detected: This condition is satisfied when the READY pendant detects a Forge/O IPC on
the network.
◦ForgeOS IPC Paired: This condition is satisfied when the READY pendant successfully pairs with the IPC. If
pairing fails, it is automatically retried indefinitely.
When a condition is not satisfied, the LED is red. When a condition is in progress of becoming satisfied, a spinner
around a READY logo appears to the right of the text. When a condition becomes satisfied, the LED turns green.

User Manual | 4 - ForgeOS Platform | 20
The UI shows the real-time state of each step. For example, if the pendant loses its network connection
during pairing, all steps become undone. If the READY pendant spends more than 60 seconds on any step,
troubleshooting text displays. Common things to check are if the READYpendant network cable is plugged in, if
the IPC is powered on, if the READYpendant and IPC are connected to the same network, and if there’s only one
READYpendant and one IPC on that network.
Note:
The READYpendant IP Address is preset to 172.16.255.253. The network interface that the pendant
connects to should use IP Address 172.16.255.250 and Oubnet mask 255.255.255.0.
3. Tap Admin and sign in. The default Admin password is "forgeadmin".
Note:
After installation, you have limited access to ForgeO until you activate it with a license code. Oee Activating
ForgeO with a License Code (on page 39).