RealMan RML63 User manual

RealMan RML63 Robot Manual V1.1
RealMan Intelligent Technology (Beijing) Co., Ltd.

生活美好，臂不可少
http://www.realman-robotics.com
1
Version History
Version
Date
Comment
V1.0
2022-5-30
Init
V1.1
2022-6-9
Corret errors

生活美好，臂不可少
http://www.realman-robotics.com
2
Contents
Foreword ................................................................................................................................................................... 5
Product Components ..............................................................................................................................................5
1. Safety .....................................................................................................................................................................6
1.1 Introduction ..............................................................................................................................................6
1.2 Safety Warning Signs and Symbols ...................................................................................................6
1.3 Safety Precautions ..................................................................................................................................7
1.4 Responsibility and Regulation ..........................................................................................................10
1.5 Hazard Identification ...........................................................................................................................11
2. Handling and Precautions ..............................................................................................................................12
3. Maintenance, Repair and Disposal..............................................................................................................13
4. Quality Assurance............................................................................................................................................15
4.1 Product Quality Assurance ................................................................................................................ 15
4.2 Disclaimer ..............................................................................................................................................15
5. Robot Hardware System ................................................................................................................................ 17
5.1.1 Robot System Overview ........................................................................................................17
5.1.2 Electrical Interface ..................................................................................................................18
5.2 Controller I/O ........................................................................................................................................19
5.2.1 Digital Input..............................................................................................................................21
5.2.2 Digital Output .......................................................................................................................... 22
5.2.3 Analog Input .............................................................................................................................22
5.2.4 Analog Output ..........................................................................................................................22
5.3 The Tool End Interface Board ...........................................................................................................23
5.3.1 Digital I/O Input...................................................................................................................... 24
5.3.2 Digital I/O Output................................................................................................................... 25
5.3.3 Power Output........................................................................................................................... 25
5.3.4 Communication Interface ......................................................................................................25
6. Robot Installation ............................................................................................................................................ 26
6.1 Introduction ........................................................................................................................................... 26
6.2 Important Safety Instruction ............................................................................................................. 26
6.3 Robot Workspace ................................................................................................................................. 27
6.4 Robot Installation .................................................................................................................................28
6.5 The End Tool Installation...................................................................................................................29
7. Robot Power-On and Power-Off..................................................................................................................29
7.1 Before Power On ..................................................................................................................................29
7.2 Power On................................................................................................................................................30
7.3 Power Off...............................................................................................................................................30
8. Robot Online Programming ..........................................................................................................................31
8.1 Introduction ........................................................................................................................................... 31
8.2 Robot Teaching .....................................................................................................................................32
8.2.1 Full-screen Button ...................................................................................................................34
8.2.2 Power Button ............................................................................................................................34
8.2.3 Robot Emergency Stop Button ............................................................................................ 34

生活美好，臂不可少
http://www.realman-robotics.com
3
8.2.4 Communication Status Display ........................................................................................... 35
8.2.5 Menu Bar ...................................................................................................................................35
8.2.6 Position Control .......................................................................................................................35
8.2.7 Pose Control............................................................................................................................. 36
8.2.8 Joint Control ............................................................................................................................. 36
8.2.9 Operation Mode Selection .................................................................................................... 37
8.2.10 Operation Coordinate System Selection ......................................................................... 38
8.2.11 Tool Coordinate System Selection ....................................................................................39
8.2.12 3D Simulation Model .......................................................................................................... 40
8.2.13 Move in Base Coordinate System .................................................................................... 40
8.2.14 Move in Tool End Coordinate System ............................................................................ 41
8.2.15 Draw Trajectory.................................................................................................................... 41
8.2.16 Clear Trajectory .....................................................................................................................41
8.2.17 Step Mode Setting................................................................................................................ 42
8.2.18 Robot Position and Posture Information Display ......................................................... 43
8.2.19 Speed Display ........................................................................................................................ 43
8.2.20 Origin Pose Button ............................................................................................................... 43
8.2.21 Initial Pose Button ................................................................................................................ 43
8.3 Online Programming ...........................................................................................................................44
8.3.1 New Project Button ................................................................................................................ 45
8.3.2 Select Project Button ..............................................................................................................45
8.3.3 Save Project .............................................................................................................................. 46
8.3.4 Project Content Display .........................................................................................................46
8.3.5 Add Trajectory Point .............................................................................................................. 47
8.3.6 Basic Commands .....................................................................................................................48
8.3.7 Advanced Commands ............................................................................................................ 64
8.3.8 Edit ..............................................................................................................................................72
8.3.9 Start Button ...............................................................................................................................73
8.3.10 Pause Button .......................................................................................................................... 75
8.3.11 Stop Button.............................................................................................................................75
8.3.12 Single Step Button ................................................................................................................76
8.3.13 Joints Move There ................................................................................................................ 77
8.3.14 Move Straight There ............................................................................................................ 78
8.3.15 Robot Simulation Preview ..................................................................................................79
8.4 Configuration ........................................................................................................................................ 80
8.4.1 System Configuration ............................................................................................................ 80
8.4.2 Robot Configuration ...............................................................................................................87
8.5 System Information ...........................................................................................................................108
8.6 Extension............................................................................................................................................. 108
8.6.1 Tool I/O Configuration ........................................................................................................109
8.6.2 Drag Teaching........................................................................................................................110
8.6.3 Lift Control.............................................................................................................................111
9. Online Programming Demo....................................................................................................................... 112
10. System Update via USB Flash Drive .....................................................................................................117

生活美好，臂不可少
http://www.realman-robotics.com
4
11. Technical Specifications ............................................................................................................................119

生活美好，臂不可少
http://www.realman-robotics.com
5
Foreword
On behalf of RealMan Intelligent Technology (Beijing) Co., Ltd., we thank you for
the purchase and use of our ultra-lightweight 6-DoF RML63 collaborative robot. The
RML63 robot series include RML63-B (standard), RML63-ZF (integrated 1-axis
force) and RML63-6F (integrated 6-axis force). The manual can refer to this
document.
RML63 adopts modular joint design. It integrates the controller at its base therefore
no extra control cabinet needed. Users can build their own robot control system by
accessing the APIs of our collaborative RML63. Besides, this product also provides
online programmable software through which users can monitor the real-time status
of RML63, adjust the settings, and simulate offline.
Product Components
A full packaged RML63 collaborative robot includes the components as follows.
Table 1 Product Components of RML63
Name
Quantity
Robot body
1
Power cord
1

生活美好，臂不可少
http://www.realman-robotics.com
6
6-pin tool end IO cable
1
26-pin IO cable
1
Teach pendant tablet (optional)
1
1. Safety
1.1 Introduction
This section includes the safety principles and regulations that should be followed
when operating the robot. Users and integrators must read this manual carefully
before operating the robot. They need to have full security awareness. They shall
always follow the principles and regulations particularly the warning signs. Since
robot system is complex and could be dangerous if not properly operated, users shall
always be aware of this and follow the instructions in this document.
1.2 Safety Warning Signs and Symbols
Table 2 lists all the safety warning signs and symbols of the robot. It is crucial and the
instructions shall be followed.
Table 2 Warning Signs and Symbols, and Instructions
Sign/Symbol
Instruction
An impending hazardous electrical condition that, if not avoided, can
result in casualty to persons or damage to device.
An impending hazardous high temperature, which can result in
casualty to persons or damage to device if touched.
A situation that is about to cause danger and, if not avoided, can lead
to casualty to persons or damage to device.
A warning on a hazardous electrical condition that, if not avoided, may
result in casualty to persons or damage to device.

生活美好，臂不可少
http://www.realman-robotics.com
7
A warning on hazards that, if not avoided, may result in casualty to
persons or damage to device. Matters marked with such a sign may
sometimes, depending on the circumstances, have the potential to have
significant consequences.
A condition that, if not avoided, may result in casualty to persons or
damage to device. Matters marked with such a sign may, depending on
the circumstances, sometimes have the possibility of significant
consequences.
1.3 Safety Precautions
This manual contains safety measures to protect users and prevent device damage.
Users need to read all the relevant descriptions in this manual and fully understand the
safety issues. In this manual, although we’ve tried our best to describe various
situations regarding safety, it is impossible to record all situations that users may
encounter.
The following essential information needs to be understood and followed when
starting the robot for the first time. Other safety-related information is introduced in
other sections of the manual. However, it is impossible to cover all aspects. In
practical applications, specific situations need to be analyzed accordingly.
Table 3 Safety Precautions
1. Please be sure to install the robot and all electrical equipment in
accordance with the requirements and specifications in this manual.
2. A preliminary test and inspection of the robot and its protection
system should be carried out before the first use of the robot and
production.
3. Before starting the robot for the first time, you must check that
the hardware, software, and appearance of the robot is complete.
Also, you should be aware of whether it complies with the effective

生活美好，臂不可少
http://www.realman-robotics.com
8
safety production rules and regulations of the country or region.
Remember that all safety features must be tested before use.
4. Users must check and ensure that all safety-related
hyperparameters and user programs are correctly set, and all safety
features are working properly. A person qualified to operate the
robot is required to check each safety feature. The robot can only be
started after passing a comprehensive and careful safety test and
reaching a certain safe level.
5. Professionals are required to install and configure the robot in
accordance with the installation standards.
6. Once the robot has been installed and configured, a
comprehensive risk assessment should be performed again and
recorded.
7. The safety-related hyperparameters are set and changed by
authorized personnel only. Passwords or isolation measures are
applied to prevent unauthorized personnel from changing or setting
safety-related hyperparameters. After the safety-related factors are
modified, the related safety features need to be double checked.
8. In case of an accident or abnormal operation of the robot, the
emergency stop switch can be pressed to immediately stop the
action of the robot.
1. The robot body and control cabinet will generate heat during
operation. Please do not touch the robot when the robot is operating
or just stopped.
2. Turn off the power and wait for one hour before the robot cools
down.
3. Do not put your finger into the hot part of the controller.

生活美好，臂不可少
http://www.realman-robotics.com
9
1. Ensure that the robot and end tools are properly and securely
installed in place.
2. Ensure that the robot arm has enough space to move freely.
3. Do not use the robot if it is damaged.
4. Do not connect a secure device to a normal I/O port but only the
secure port.
5. Ensure a correct installation and setting (e.g., robot body
installation angle, end tool weight, TCP offset, safety configuration
etc.). Save the installation file and load it into the program.
6. Tools and obstacles shall not have sharp corners or twist points.
Make sure all present users are out of reach of the robot.
7. Pay attention to the movement of the robot when using the teach
pendant software.
8. Any collision will release a lot of kinetic energy, which is much
larger than the cases of high speeds and high payloads.
9. Jointing different machinery can exacerbate a hazard or create
new ones. Always conduct a comprehensive risk assessment for the
entire installation. When safety levels and emergency stop criterion
levels are asked, always select the highest performance level. Please
read and understand the manuals for all equipment used during the
installation.
10. Do not modify the robot. Non-authorized changes to the robot
can create dangers that the integrator cannot predict. The authorized
change of robot shall be in accordance with the latest version of
relevant service manuals. If the robot is manipulated or altered in
any way, we, as RealMan Intelligent Technology (Beijing) Co., Ltd.,
do not take full responsibility.
11. Users need to check insulation and protection measures before
transporting the robot.
12. When moving the robot, follow the transportation requirements
and handle it carefully to avoid bumps.

生活美好，臂不可少
http://www.realman-robotics.com
10
1. When a robot is connected to or collaborating with machinery
that can cause damage to the robot, it is highly recommended that
all functionalities and procedures of the robot should be checked
separately. It is recommended to use a temporary workspace outside
of the workspaces of other machinery to inspect the robot program.
2. We, as RealMan Intelligent Technology (Beijing) Co., Ltd., will
not be responsible for the damage to the robot or personal injury
caused by human reason.
3. Do not expose the robot to permanent magnetic fields. Strong
magnetic fields can damage the robot.
1.4 Responsibility and Regulation
RML63 robots itself is not complete to accomplish certain tasks but can be combined
with other peripheral equipment to achieve that. Therefore, the information contained
in this manual does not indicate the design, installation, and operation of a complete
robot, nor does it include all the possibilities that may affect the safety of the
peripheral equipment of such a complete system. The safety of a complete robot
installation depends on how the robot is ensembled. The integrator is required to
conduct a risk assessment for the design and installation of the complete system in
accordance with the laws, regulations and safety codes and standards of the host
country or region. Risk assessment is one of the most important tasks that must be
performed by an integrator. An integrator can perform the risk assessment process by
referring to the following standards. Risk assessment is one of the most important
tasks that must be performed by an integrator. An integrator can perform the risk
assessment process by referring to the following standards.
ISO 12100:2010 Machinery Safety-General Design Principles-Risk
Assessment and Risk Reduction.
ISO 10218-2:2011 Robots and Robotic Equipment-Safety Requirements-Part
2: Industrial Robot System and Integration.

生活美好，臂不可少
http://www.realman-robotics.com
11
RIA TR R15.306-2014 Technical Report of Industrial Robots and Robotic
Systems-Safety Requirements, Task-Based Risk Assessment Methods.
ANSI B11.0-2010 Machinery Safety; General Requirements and Risk
Assessment.
The integrator of the RML63 robot is required to perform but is not limited to the
following responsibilities:
A comprehensive risk assessment of a complete robotic system.
To confirm the design and installation of the entire system is accurate.
To provide training to users and staff.
To create operation specification of a complete system, and clear description
of use process.
To establish appropriate safety measures.
To use appropriate methods to eliminate hazards or minimize all hazards to
acceptable levels at the time of final installation.
1.5 Hazard Identification
The risk assessment should take into account all potential contacts between the
operator and the robot and foreseeable maloperations during normal use. The neck,
face and head of the operator should not be exposed to avoid touching. The use of a
robot without the use of peripheral safety guards requires first a risk assessment to
determine whether the associated hazards pose an unacceptable risk, including but not
limited to:
The use of sharp actuator or tool connectors which may be dangerous.
Handling toxic or other hazardous substances which may be dangerous.
The operator's fingers being caught by the robot base or joint.
The operator being hit by robots.
The fastness of robot and tool connected to its end.
Impact between the robot payload and the firm surface.
The integrator must measure such hazards and their associated risk levels through a

生活美好，臂不可少
http://www.realman-robotics.com
12
risk assessment and identify and perform appropriate measures to reduce the risk to an
acceptable level. Be aware that there may be other significant hazards associated with
certain robotic devices.
By combining the inherent safety design measures applied by the RML63 robot with
the safety specifications or risk assessments implemented by the integrator and user,
the risks associated with collaborative robot operation are minimized to a reasonable
and feasible level. This document is used to communicate any residual risks of the
robot prior to installation to the integrator and users. If the integrator's risk assessment
indicates that there are risks in its application that may pose an unacceptable risk to
users, the integrator must take appropriate risk mitigation measures to eliminate or
minimize these risks until the risk is reduced to an acceptable level. It is not safe to
use until appropriate risk mitigation measures, if needed, have been taken.
If the robot is installed uncooperatively (e.g., when using hazardous tools), the risk
assessment may infer that the integrator needs to connect additional safety devices
(e.g., safe start devices) to ensure the safety of personnel and equipment while it is
programmed.
2. Handling and Precautions
When the robot is hoisted, proper measures and positioning should be taken for the
moving parts, so as not to cause accidental movement and damage during hoisting and
transportation. Before transportation, the packing shall be carried out in accordance
with the packing standard, and the required marks shall be marked on the outside of
the packing cases.
During transportation, the robot needs to be fastened and kept in a fixed position.
When unpackaging the to the installation position, hold the robot until all bolts on the
base of the robot are fastened.

生活美好，臂不可少
http://www.realman-robotics.com
13
There is no brake installed inside the robot Joint4~6. Before power off, please keep
the robot in the proper position to prevent the joint from rotating and colliding under
the gravity. (When the robot is vertical, place the robot in the origin position before
powering off.)
Keep the original packaging after transportation and store the packaging box in a dry
place in case you need to repackage and ferry the robot in the future.
3. Maintenance, Repair and Disposal
All safety instructions in this manual must be followed in maintenance.
After changing the control system and robot joint, it is necessary to re-calibrate the
robot and tool end origin on site. You also need to check the hyperparameter settings.
If there is a hyperparameter backup, you can import the backup hyperparameters,
otherwise, you need to reset the hyperparameters.
Repairs must be conducted by the authorized integrators or us as RealMan Intelligent
Technology (Beijing) Co., Ltd. The parts shall be returned to us, as RealMan
Intelligent Technology (Beijing) Co., Ltd., in accordance with the regulations of the
manual.
Assure the required safety level for maintenance and repair. Comply with national or
regional safety regulations. Test whether all safety features can work properly.
The purpose of maintenance is to ensure the proper operation of the system or to help
bring it back to a normal status in the event of a system failure.
Maintenance includes fault diagnosis and undergoing maintenance.

生活美好，臂不可少
http://www.realman-robotics.com
14
The following safety procedures and cautions must be followed when operating the
robot arm or controller:
Safety procedures：
1. Move away the power source from the controller ports to ensure it is completely
powered off. Necessity precautions should be taken to prevent others from accidently
powering on the system during maintenance. Double check the system to ensure the
power is off.
2. When disassembling the robot or control box, comply with ESD (electrostatic
discharge) regulations.
3. Avoid water or dust entering the robot arm or controller.
Cautions:
1. Replace the faulty part with a new part that has the same serial number or we, as
RealMan Intelligent Technology (Beijing) Co., Ltd., replace the faulty part.
2. Reactivate all disabled safety features as soon as maintenance is accomplished.
3. Keep maintenance records in the technical documents related to the whole robot
system.
4. The controller has no parts that users can repair by themselves. Please contact your
supplier or us, as RealMan Intelligent Technology (Beijing) Co., Ltd., to maintain or
repair the controller.
Disposal:
RML63 Robots must be disposed in accordance with applicable national laws,
regulations and standards.
Maintenance:
The safety features of the robot must be tested at least once a year to ensure it
constantly works properly.

生活美好，臂不可少
http://www.realman-robotics.com
15
4. Quality Assurance
4.1 Product Quality Assurance
RML63 robot includes a 12-month limited warranty.
If the new device and its components are found to be defective due to faulty
manufacturing or material defects within 12 months (or no more than 15 months
including transportation time) after commissioning, we, as RealMan Intelligent
Technology (Beijing) Co., Ltd., shall provide necessary spare parts to replace or repair
the relevant parts.
The ownership of the device or components replaced or returned to RealMan
Intelligent Technology (Beijing) Co., Ltd. shall remain with us as RealMan Intelligent
Technology (Beijing) Co., Ltd.
If the product is no longer under warranty, we, as RealMan Intelligent Technology
(Beijing) Co., Ltd., reserves the right to charge the customer for the replacement or
repair.
Out of the warranty period, we, as RealMan Intelligent Technology (Beijing) Co., Ltd.,
shall not be responsible for any damage or loss, such as loss of production or damage
to other production equipment.
4.2 Disclaimer
If the defect is caused by improper operating or failure to follow the relevant
instructions set out in the user's manual, the warranty of product quality is void.
Failure caused by the following conditions is not covered by this warranty:
1. Fail to install, wire and connect other control equipment according to the user
manual.

生活美好，臂不可少
http://www.realman-robotics.com
16
2. The usage exceeds the specifications or standards specified in the user manual.
3. Use the product for purposes other than those specified.
4. The storage and workspace environment exceed the specified scope in the user
manual (such as pollution, salt damage, condensation, etc.).
5. Product damage caused by improper transportation.
6. Damage caused by accident or collision.
7. Install non-authentic parts and accessories.
8. Damage caused by the modification, commissioning, or maintenance of the original
parts by a third party other than RealMan Intelligent Technology (Beijing) Co., Ltd. or
its designated integrator.
9. Natural disasters such as fires, earthquakes, tsunamis, lightning strikes, strong
winds and floods.
10. The production date or warranty start date cannot be identified.
11. Changes to software or internal data.
12. Failure that cannot be reimplemented or failure that cannot be identified by us, as
RealMan Intelligent Technology (Beijing) Co., Ltd.
13. Use the product in radioactive equipment, biological test equipment or in the use
that we, as RealMan Intelligent Technology (Beijing) Co., Ltd., judge to be
dangerous.
14. Failures other than the mentioned above is not caused by the duties of RealMan
Intelligent Technology (Beijing) Co., Ltd.
Under the Product Quality Assurance Agreement, we, as RealMan Intelligent
Technology (Beijing) Co., Ltd., are responsible for the defects of the products and
parts sold only to the distributor. We, as RealMan Intelligent Technology (Beijing)
Co., Ltd., are not responsible for any other express or implied warranty or liability,
including but not limited to any implied warranty of merchantability or a particular
purpose. In addition, we, as RealMan Intelligent Technology (Beijing) Co., Ltd., shall
not be responsible for any indirect damages or consequences of the relevant products.

生活美好，臂不可少
http://www.realman-robotics.com
17
In the case of robot malfunction, it is necessary to contact RealMan Intelligent
Technology (Beijing) Co., Ltd. at the first time to seek a solution, and the user shall
not carry out robot disassembly and maintenance for any reason, otherwise the
warranty service will be terminated.
5. Robot Hardware System
5.1.1 Robot System Overview
Fig. 5-1 The overview of the robot system.
As shown in Fig. 5-1, RML63 cooperative robot system is mainly composed of robot
body or the robot arm, controller (integrated in the body base) and tablet/pad with
teach pendant software (optional). The robot body mimics a human arm that has six
rotating joints, each representing one degree of freedom (DoF). As shown in Figure
5-2, the robot joints include shoulder (joint 1), shoulder (joint 2), elbow (joint 3),
wrist 1 (joint 4), wrist 2 (joint 5), and wrist 3 (joint 6). After the teach pendant
software is connected to the controller, the user can control the rotation of each joint
of the robot thus move the end tool to different positions and poses.

生活美好，臂不可少
http://www.realman-robotics.com
18
Fig. 5-2 The distribution map of robot joints.
5.1.2 Electrical Interface
A controller is integrated at the bottom part of the robot for controlling the robot and
communicating. The robot arm is powered by DC 24 volts (when using a DC power
supply, select a DC power supply with an output of not less than 20A), and the power
supply interface is a 2-core aviation plug, located at the lower left corner of the
controller panel. In the 2-core power cable, the brown core is the positive power
supply, and the blue core is the negative power supply. The robot also integrates a
variety of communication interfaces for data transmission with various devices as
shown in Figure 5-3. The maximum energy consumption of the robot is less than
200W, and normally, the combined energy consumption is less than 100W.
The positive and negative power cables must not be reversed, otherwise the
robot will be damaged! (The factory standard power cord, brown is positive, blue is
negative) In addition, the power supply range of the robot is DC20V~DC27V,
exceeding this range may also damage the robot.

生活美好，臂不可少
http://www.realman-robotics.com
19
Fig. 5-3 Robot electrical interface.
Table 4 Robot electrical interface description.
#
Interface
Functionality
1
power switch
control the power supply of the robot
the blue light on once powered on
2
power socket
plug in the power cable
3
extension plug
outlet the RS485、I/O etc. interface of the controller
4
WIFI/Bluetooth antenna
wireless communication
5
USB 1
update software, import and export files
6
USB 2
control the robot
7
Ethernet 1
connect to ethernet devices
8
Ethernet 2
connect to teaching devices and remote access
5.2 Controller I/O
USB 1
Extension plug
Power plug
WIFI/Bluetooth antenna
USB 2
Ethernet 1
Ethernet 2
Power switch