Rethink Robotics Sawyer User manual
Intera 5 - User Guide/Getting Started
Original Instructions
Last updated June 18, 2018 Intera 5.3 User Guide/Getting Started Rev. A
3Intera 5.3
Welcome!
Welcome!
Thank you for purchasing Intera 5 software and Sawyer, our revolutionary new high performance collaborative
robot. This user guide is designed to help you get started using Intera and Sawyer by providing you with an
overview of the software and instructions on how to set up the Sawyer robot.
For the latest and most detailed information on Sawyer and Intera 5, we always recommend you see the Online
User Guide at: mfg.rethinkrobotics.com/intera. The Rethink Robotics support page is here:
Rethink Support.
Safety Statement
Complying with ISO 10218-2 requires performing a risk assessment of each application to determine the
needed safety performance and safeguarding. ANSI RIA R15.06-2012 is a U.S.-
national adoption of ISO 10218-1 & 2.
Users should exercise caution while training the robot and practicing motions. The risk of injury
is increased when using custom end-effectors, movements that lead with the end effector, and potentially
hazardous work pieces.
Rethink Robotics recommends the use of safety glasses when interacting with robots, as is common with
other equipment used in industrial environments.
The safety of any system incorporating Sawyer is the responsibility of the assembler of the system.
For additional information, reference
Rethink Robotics’ Safety Documentation
.
General Information
CAUTION: This symbol indicates that hazards may be present with the equipment. This docu-
mentation provides information on the nature of potential hazards and any actions which have to be taken to
avoid them.
4Intera 5.3
Welcome!
Intended use:
Sawyer is a collaborative robot intended for use in machine tending applications in manufacturing.
Warnings
Rethink Robotics’ collaborative robots are provided as partly completed machinery. The
robots are not supplied for specific applications. The integrator and/or end user is responsible for
ensuring that all appropriate regulations including but not limited to safety, electrical, and environ-
mental regulations are met for the appropriate regions or countries where the application will be
deployed.
The information provided with this robot and online does not cover how to design, fabricate,
install and commission a complete robotic application. If Rethink Robotics’ collaborative robots are
used to create a collaborative robotic workcell, the integrator and/or end user is responsible for
complying with the industrial robot safety standards relevant for the region where the robotic work-
cell will be deployed will apply. Examples of such standards are EN ISO 10218:2011, ANSI/RIA
R15.06:2012, CSA Z434:2014, and JIS B 8433:2015.
As part of complying with these standards, a risk assessment must be performed to identify
and eliminate, substitute or acceptably mitigate risk associated with hazards present in the applica-
tion. For more information see the relevant standards and associated documentation for your
region.
Note that it is possible to integrate and use Rethink Robotics’ collaborative robots in such a
way that presents an injury hazard if contact is made with a person. The integrator and/or end user
is responsible for evaluating the safety of the robotic application and determining and implementing
any risk reduction measures to eliminate, substitute or acceptably mitigate the risks associated with
the hazards. The integrator and/or end user assumes all responsibility for damage and/or harm
caused by use of the robot in a hazardous manner and agrees to indemnify Rethink Robotics from
all liability relating to such damage or harm.
5Intera 5.3
Welcome!
Rethink Robotics’ collaborative robots are NOT provided with a safety-rated enabling device.
The robots are intended for use in applications where inherently safe design measures and/or active
safety-rated limiting functions are sufficient to adequately reduce risks associated with work cell
hazards. Should an integrator and/or end user determine through risk assessment that their specific
application requires the use of an enabling device to reduce risk to an acceptable level, please refer
to the User Guide or contact your distributor for information on how to connect a safety-rated
enabling device.
Rethink Robotics’ collaborative robots are NOT provided with a safety-rated mode selector
switch nor a mode indicator light, as the robots are capable of being collaborative at all times, with-
out a non-collaborative mode. Should the robot be incorporated into a robotic system where the
application involves the robot being operated in two modes, please refer to the User Guide or con-
tact your distributor for information on how to implement a safety-rated mode selector switch and
indicator light.
Note: In some applications, the light integrated into the robot may meet the requirements of a mode
indicator light.
Rethink Robotics’ collaborative robots are not intended for use in explosive atmospheres or
any environment where intrinsic safety of equipment is required.
Rethink Robotics’ collaborative robots ship with an E-Stop device that may be used in the
event of emergency to remove power from the actuators and immobilize the arm. The E-Stop
device is connected to the controller box by a cable which allows for flexibility in its positioning.
Ensure that the E-Stop device is positioned such that it is easy for an operator to access it during
operation.
As is common practice with other industrial equipment, Rethink Robotics recommends per-
sonnel interacting with Rethink Robotics’ collaborative robots wear appropriate personal protective
equipment such as safety glasses.
6Intera 5.3
Welcome!
Rethink Robotics’ collaborative robots are not serviceable or repairable by end-users. In the
event servicing or repairs are required for the robot, please contact your distributor or Rethink
Robotics for technical assistance.
When the robot is moving a heavy part (>2.5 kg) and a user removes the part from the gripper
or the part unintentionally falls (and no logic has been trained to handle these issues), the arm will
still try to compensate for a mass that is no longer there and the arm may move unexpectedly. This
includes having the arm point straight up. In order to mitigate these behaviors, please train your
task accordingly so that it may handle these error cases. In addition, always perform a Risk Assess-
ment so you may understand the risk levels and ways to mitigate these.
Use caution when servicing robot workcell, including following OSHA's Lockout/Tagout Pro-
cedures 1910.147 if Safety Assessment of application recommends it.
If a supplementary audible means of robot operation is necessary, it shall exceed the ambi-
ent noise at the end-use application.
If controller is placed inside the robot workspace, caution needs to be taken when training
tasks to avoid coming in contact with it.
In Europe, Rethink Robotics’ collaborative robots are provided with a Declaration of Incorpo-
ration (DoI) per Annex IIB of the EC Machinery Directive. The Machinery Directive requires that the
integrator and/or end user must ensure that all incomplete machinery must be incorporated into a
complete machine and certified to the Machinery Directive requirements resulting in an EC Declara-
tion of Conformity certificate being generated, and the machine being CE marked. Only then can
the machinery be operated. The system integrator and/or end user is responsible for the following
tasks:
o Installingtheindustrialrobot
7Intera 5.3
Welcome!
o Connectingtheindustrialrobot
o Performingriskassessment
o Implementingtherequiredsafetyfunctionsandsafeguards
o IssuingtheDeclarationofConformity
o AttachingtheCEmark
o Creatingtheoperatinginstructionsforthecompletesystem
Manufacturer address:
For technical assistance, please contact:
Rethink Robotics, Inc.
27-43 Wormwood St
Boston, MA 02210
Website: http://www.rethinkrobotics.com
Customer support: Rethink Support.
Disclaimer
Every effort is made to ensure that the information in this manual is accurate. This publication could include
technical or typographical errors or other inaccuracies. Rethink Robotics, Inc® may make changes to the prod-
uct described in this publication or to this publication at any time, without notice.
Rethink Robotics, Sawyer, and Intera are trademarks of Rethink Robotics, Inc.
EtherNet/IP is a trademark of ODVA, Inc.
PROFINET is a registered trademark of PROFINET International (PI)
1Intera 5.3
Contents
Table of Contents
Welcome! 3
Warnings 4
Table of Contents 1
Getting to Know Sawyer 7
Hardware Overview of Your Robot 8
Dimensions 9
Sawyer Reach 10
Sawyer Nomenclature 11
Workspace and Robot Joint Limits 11
Head 12
Controller 13
Navigator 15
Training Cuff 17
Brakes 17
Active Collision Avoidance 18
Included accessories: 19
Tool Plate 19
Optional accessories: 20
Safety Symbols 21
Getting Started with Sawyer 22
Setting Up Sawyer 22
Power 22
Disconnecting power 22
Tur ning On Sawyer 23
Moving the Arm 24
2Intera 5.3
Contents
Getting Started with Intera 5 26
Some Intera Terms 30
Components of the Intera Studio Screen 32
Top Bar 32
Studio Menu 33
Node Palette 37
Behavior Editor 38
Node Colors - Meaning 38
3D View 49
How to Change the View of the Simulated Robot Arm 51
How to Move the Simulated Robot Arm 52
End of Arm Tooling 54
Attaching End of Arm Tooling 54
How to Configure End Effectors 54
ADDING A CLICKSMART GRIPPER 56
Using the Gripper in a Task 61
How to Calibrate the Rethink Electric Parallel Gripper 65
To Add End of Arm Tooling with Dual Tools 67
How to Actuate the Tips of Third Party End Effectors 70
Assigning a Signal 71
Train a Simple Pick and Place on the Head Screen 72
Train Pick and Place Patterns on the Head Screen 80
Train the Pick Pattern 81
Train the Place Pattern 95
Intera Insights 98
Intera Insights Overview 98
Intera Insights Panel 99
Tracking Cycle Time 103
Tracking Cycle Time in the Intera Insights 103
Viewing Data on Robot when Task is Paused 104
Setting Head Angle 105
3Intera 5.3
Contents
Force Sensing and Selective Arm Stiffness 106
A Practical Application for Using Force Sensing, Selective Stiffness, and Force Limitations 106
How to Access and Modify Force Data in Intera Studio 108
Compliance, Impedance Mode, Force Mode 108
I/O Devices 111
Controller I/O 111
I/O Wiring Diagram 114
External I/O 116
Safety Rated Controller 119
TCP/IP 124
Definitions 124
Intera TCP/IP Communications 125
To Create a Device for TCP/IP 126
Fieldbus Devices 129
Setup Notes 129
Enabling the Fieldbus Protocol 130
Sawyer and Safety 135
Safety Statement 135
How these unique collaborative robots safely manage operational risks 136
Rethink’s Collaborative Robot Safety Features 136
Rethink’s Collaborative Robot Regulatory Certifications 138
IEC 6100-4-2 139
North America 139
Canada 139
Mexico 140
EU 140
China 140
Japan 141
Maintaining and Supporting Sawyer 142
Powering Down Sawyer Properly 142
Maintaining Sawyer 142
4Intera 5.3
Contents
Cleaning Sawyer 142
Calibrating Sawyer 143
Appendix A: Glossary 144
Glossary 144
Appendix B: Support & Warranty 146
Appendix C: Certifications and Information for Integrators 147
Third Party Certifications 147
Declaration of Incorporation 150
EC Declaration of Incorporation (Original) 150
Information for Integrators 151
Risk assessment 151
Use considerations 152
End-effectors 153
Installation 153
PPE 153
General safety 153
SOPs & training 153
Awareness 154
Useful References 154
Appendix D: Ratings and Performance Specs 156
Supply Ratings 156
I/O Ratings 156
Environmental Ratings: 157
Tool Tip Speed 158
E-Stop Performance 160
Payload vs. Reach 161
Performance with Advanced End-effectors 164
Appendix E: Warnings & Notices 169
Warnings & Notices 169
5Intera 5.3
Contents
Appendix F: Safety Subsystem 171
The Safety Subsystem 171
The Banner Safety Controller 172
Appendix G1: Intera PROFINET Reference 178
Overview 178
Default Connection - Standard Modules 178
Setup Resources 179
Summary of Modules 180
From-Robot Modules Summary 180
To-Robot Modules Summary 181
Modules Data Tables 182
Fixed Data 112 From Robot 183
Standard Booleans (113: To-Robot | 114: From-Robot 184
Standard Integers (115: To-Robot | 116: From-Robot) 184
Standard Floats (117: To-Robot | 118: From-Robot) 185
Small Booleans (119: To-Robot | 120: From-Robot) 185
Small Integers (121: To-Robot | 122: From-Robot) 186
Small Floats (123: To-Robot | 124: From-Robot) 186
Small Strings (125: To-Robot | 126: From-Robot 187
Large Bools (127: To-Robot | 128: From-Robot) 187
Large Integers (129: To-Robot | 130: From-Robot) 187
Large Floats (131: To-Robot | 132: From-Robot) 188
Large Strings (133: To-Robot | 134: From-Robot) 188
State Flags Definitions 189
Bit Definitions for State Flags 189
Robot State Flags Meaning 190
Data Addressing and Format 191
Appendix G2: Intera EtherNet/IP Reference 193
Overview 193
Default Connection - Standard Assemblies 193
Setup Resources 193
Summary of Assemblies 195
From-Robot Assemblies Summary 195
To-Robot Assemblies Summary 196
Assembly Data Tables 197
From-Robot Standard Assembly (112) 197
To-Robot Standard Assembly (113) 198
6Intera 5.3
Contents
Small Assembly (114: From-Robot | 115: To-Robot) 199
Large Assembly (116: From-Robot | 117: To-Robot) 200
Floats+ (118: From-Robot | 119: To-Robot) 201
Strings+ (120: From-Robot | 121: To-Robot) 202
State Flags Definitions 203
Bit Definitions for State Flags 203
Robot State Flags Meaning 204
Data Addressing and Format 205
Index 206
For the latest and most detailed information on Sawyer and Intera 5, we always recommend you
see the Online User Guide at: mfg.rethinkrobotics.com/intera. The Rethink Robotics support page
is here:
Rethink Support.
7Intera 5.3
Getting to Know Sawyer
Getting to Know Sawyer
For the latest and most detailed information on Sawyer and Intera 5, we always recommend you
see the Online User Guide at: mfg.rethinkrobotics.com/intera. The Rethink Robotics support page
is here:
Rethink Support.
Transportation and Handling:
Use a Pallet Jack when transporting pallet.
Robot Arm:
Dimensions: 35x20x20 inches (89x51x51 cm)
Weight: Gross: 58 lbs (26 kg), Net: 48 lbs (22 kg)
Controller:
Dimensions: 27x13x20 inches (69x33x51 cm)
Weight: Gross: 55 lbs (25 kg), Net: 45 lbs (20 kg)
Accessory Box (Without Grippers):
Dimensions: 23x26x20 inches (58x66x51 cm)
Weight: Gross: 13lbs (6 kg), Net: 10 lbs (4.5 kg)
Pedestal:
Dimensions: 48x39x19 inches (122x99x48 cm)
Weight: Gross: 240lbs (109 kg), Net 220 lbs (100 kg)
Full Kit (Robot, Controller, and Accessory Box on Pedestal Crate. No Grippers):
Dimensions: 48x39x39 inches (122x99x99 cm)
Weight: Gross: 365 lbs (166 kg), 323 lbs (146.5 kg)
8Intera 5.3
Getting to Know Sawyer
Hardware Overview of Your Robot
9Intera 5.3
Getting to Know Sawyer
Dimensions
10 Intera 5.3
Getting to Know Sawyer
Sawyer Reach
11 Intera 5.3
Getting to Know Sawyer
Sawyer Nomenclature
Workspace and Robot Joint Limits
The ability of Sawyer to perform actions at any given location is affected by the physical limits of the
arm. When training an action, consider:
•The robot’s joints J0 through J3 can rotate a maximum of 350 degrees. Joints J4
and J5 can rotate 341 degrees and J6, the wrist/training cuff, can rotate 540
Base Head L0 L1 L2 L3 L4 L5 L6 Total
Assembly
Mass (kg) 2.07 1.58 5.32 4.50 1.74 2.51 1.11 1.56 0.33 20.73
12 Intera 5.3
Getting to Know Sawyer
degrees. The closer you are to the edge of these limits, the greater the chance
the robot will be unable to train an action.
•If you notice Sawyer cannot reach a location, try moving the location closer to
the robot, or re-train the location.
•The training cuff can rotate 540 degrees. If, when training, the orientation of the
training cuff is twisted near its limit, the robot may have trouble when you run the
task.
The possible vertical range of an action is reduced as you move closer to the edges of the
maximum available workspace of the robot.
The robot’s software, including collision avoidance, can also limit the movement and capabilities of
the arm. For example, you cannot incorrectly train the robot so the arm crashes into itself.
In Intera Studio, you can click on the Joints Tab to see the extent of rotation of each of Sawyer's
joints. A slider near either end of the slider range indicates proximity to a joint limit. You can also see
the joint position indicators on the right side of the robot’s display screen.
Head
Sawyer’s “head” is the LCD display that sits on top of the robot. It houses the Graphical User
Interface (GUI). The head also contains a camera and a light that communicates the robot’s
condition.
The head is back drivable. It has a motor in it, which means you can physically move the head
whether or not the robot has power. The head can be moved along the same joint/axis that it moves
itself. It rotates a total of approximately 350 degrees.
There are two modes for head movement: passive and active. Passive means you can move the
head manually. In active mode, the head automatically follows the movement of the training cuff.
IMPORTANT: It is relatively easy to move the head. Even a single tap of the finger can move it, so do
not use force when moving the head. When you feel resistance, stop.
13 Intera 5.3
Getting to Know Sawyer
Controller
The Controller is the housing for the computer (which runs the Intera software that controls Sawyer),
the I/O, the vacuum connections, and the power to the wall outlet. The controller can be placed on
the Rethink Robotics Sawyer pedestal or nearby, for example, on a shelf.
When installing Sawyer, make sure that the air inlet and exhaust fan ports on the controller are not
blocked or obstructed. These ports must be clear to allow the controller to be properly ventilated.
Right side:
- 1 Ethernet port
(cannot be used on
industrial fieldbus
network)
- 2 USB ports
Left side:
- Power button
- Output Air filter
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