SCHUNK FTD Training manual

Translation of original commissioning instructions
Commissioning instructions
FTD
Force-torque sensor system

Imprint
2 01.00 | FTD | Commissioning instructions | en | 389627
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389627
Version: 01.00|07/04/2021|en
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
Table of Contents
1 General.................................................................................................................... 5
1.1 About this manual ................................................................................................ 5
1.1.1 Presentation of Warning Labels ...............................................................5
1.1.2 Applicable documents ..............................................................................6
1.1.3 Variants.....................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
2 Basic safety notes ................................................................................................... 7
2.1 Intended use......................................................................................................... 7
2.2 Inappropriate use ................................................................................................. 7
2.3 Constructional changes ........................................................................................ 7
2.4 Spare parts ........................................................................................................... 7
2.5 Personnel qualification......................................................................................... 7
2.6 Disposal ................................................................................................................ 8
2.7 Notes on particular risks....................................................................................... 8
3 Technical data.......................................................................................................... 9
3.1 Ambient conditions and operating conditions .....................................................9
3.2 Force-torque sensor ............................................................................................. 9
3.3 Calculating the forces and moments.................................................................. 10
4 Design and description............................................................................................12
4.1 Design ................................................................................................................. 12
4.2 Description ......................................................................................................... 17
5 Assembly and installation .......................................................................................18
5.1 Installing and connecting.................................................................................... 18
5.2 Electrical connection .......................................................................................... 19
5.2.1 Force-torque sensor ...............................................................................26
5.2.2 PS / IFPS box ...........................................................................................28
5.2.3 IFPSMC box.............................................................................................34
5.3 Installing the software........................................................................................ 39
6 Operation ...............................................................................................................41
6.1 Available software interfaces and demo programs............................................ 41
6.2 Manual calculations............................................................................................ 42
6.3 Creating your own application ........................................................................... 42
7 Troubleshooting .....................................................................................................43
7.1 Saturation ........................................................................................................... 43
7.2 Signal noise......................................................................................................... 43
7.3 Measurement data deviation / drift................................................................... 43
7.4 Hysteresis ........................................................................................................... 43
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Table of Contents
8 Maintenance ..........................................................................................................44
9 EU Declaration of Conformity .................................................................................45
10 Appendix ................................................................................................................46
10.1 ............................................................................................................................ 46
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General
1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
Applicable documents [}6] are applicable.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
CAUTION
Material damage!
Information about avoiding material damage.
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General
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1.1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Assembly and operating manual of the sensor*
• Help files for FTD DAQ software (ATI DAQ F/T software)**
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
The documents labeled with an asterisk (**) can be downloaded
from schunk.com/ft-downloads.
1.1.3 Variants
This operating manual applies to the following variations:
• Force-torque sensor system FTD with USB data acquisition card
for one force-torque sensor
• Force-torque sensor system FTD with USB data acquisition card
for up to six force-torque sensors
• Force-torque sensor system FTD with PCI data acquisition card
for one force-torque sensor
• Force-torque sensor system FTD with PCI data acquisition card
for up to six force-torque sensors
• Force-torque sensor system FTD with terminal block with BNC
inputs for up to six force-torque sensors
1.2 Warranty
If the product is used as intended, the warranty is valid for 12
months from the ex-works delivery date under the following
conditions:
• Observe the ambient conditions and operating conditions
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Force-torque sensor system FTD in the ordered model
• Force-torque sensor FT with sensor cable
• DAQ cable
• PS box, IFPS box or IFPSMC box
• Commissioning instructions
• Assembly and operating manual force-torque sensor FT
• Commissioning CD with calibration certificates
• Accessory pack

Basic safety notes
2 Basic safety notes
2.1 Intended use
The product is used to record, convert and evaluate analog output
signals into electrical signals using a data acquisition card.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Inappropriate use
The product is not a safety component in accordance with the EC
Machine Directive 2006/42/EC and must not be used in safety-
relevant parts of machine control units.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
2.5 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
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Basic safety notes
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2.6 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.7 Notes on particular risks
DANGER
Danger from electric voltage!
Touching live parts may result in death.
•Switch off the power supply before any assembly, adjustment
or maintenance work and secure against being switched on
again.
•Only qualified electricians may perform electrical installations.
•Check if de-energized, ground it and hot-wire.
•Cover live parts.

Technical data
3 Technical data
3.1 Ambient conditions and operating conditions
Ambient conditions and operating conditions for PS box and IFPS box
Designation PS box / IFPS box
Ambient temperature [°C]
during storage
min.
max.
during operation
min.
max.
-30
75
0
60
3.2 Force-torque sensor
NOTE
All forces and torques acting on the sensor must be within the
specified range of measurement. Exceeding the range of
measurement will reduce the maximum number of load cycles
and may lead to damage of the sensor.
Information on the range of measurement of each individual
force-torque sensor is provided in the catalog data sheet. The
latest version is always applicable.
Dimensions and max. loads on the force-torque sensor
Detailed information on the mounting, installation and
maintenance of the sensor is provided in the Assembly and
Operating Manual for the sensor, Applicable documents [}6].
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Technical data
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3.3 Calculating the forces and moments
Force-
torque
sensor
Amplifier
DAQ data
acquisition card
Signals of
the strain
gauges
Open
calibration file
FTxxx.cal
Forces and
moments
Offset correction *
6 analog
output
signals
Calibration matrix
Copy UserAxis calibration matrix
from FTxxx.cal and copy it to the
runtime matrix
Open FTxxx.cal and copy the
working matrix into the area
highlighted in blue.
Temperature compensation is
normally not required.
Runtime matrix
is executed for
each
measurement
is only executed
at the beginning
of a
measurement
(if available)
As an alternative to the specified procedure, the file "DAQ F/T Manual Calculations.xml" can also be used to generate the current matrix.
Calculating the forces and moments

Technical data
Signals
of the
strain
gauges
Forces and
moments
Offset correction *
Calibration matrix
Runtime matrix
is performed
for each
measurement
is only
performed at the
beginning of a
measurement
Divide each matrix
element by the
correction value of the
amplifier
Customer-
provided
amplifier
Determine the
correction value of
the amplifier ***
*** Example 1: customer-
provided hardware amplified
by 2 > 1 V becomes 2 V >
correction value of the
amplifier is 2 ** Example 2:
customer-provided hardware
amplified by 0.5 (or weakened
by 2) > 1 V becomes 0.5 V >
correction value of the
amplifier is 0.5 **
DAQ data
acquisition card
(if available)
Amplifier
Force-
torque
sensor
6 analog
output
signals
Open
calibration file
FTxxx.cal
Copy UserAxis calibration matrix
from FTxxx.cal and copy it to the
runtime matrix
As an alternative to the
specified procedure, the file
"DAQ F/T Manual
Calculations.xml" can also
be used to generate the
current matrix.
Open FTxxx.cal and copy the working matrix into the area
highlighted in blue. Temperature compensation is normally not
required.
Calculating the forces and moments when using an amplifier provided by the customer
* Offset correction The offset correction sets the force and moment data to zero in
order to avoid falsifications due to external influences. Without
offset correction, for example, the weight of the tool would be
measured as a force on the sensor. The offset correction sets
this measured weight to zero.
** Correction value of
the customer-
provided amplifier
The correction value of the customer-provided amplifier is only
required if an additional amplifier is used. The factor
compensates for the entire calculation.
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Design and description
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4 Design and description
4.1 Design
NOTE
For the sake of clarity, the sizes of the force-torque sensors have
been combined into two size groups in some places in this
manual:
• FT Nano and FT Mini
• FT Gamma, FT Delta, FT Theta and FT Omega
Force-torque sensor
Top: Force-torque sensor with interface electronics (from gamma and larger) /
Bottom: Force-torque sensor with sensor cable (Nano and Mini)
1 Sensor cable connection
2 Integrated sensor cable
3 Tool side adapter plate
4 Robot side adapter plate

Design and description
Sensor cables
Sensor cables
1 Force-torque sensor connection
2 PS box / IFPS box / IFPSMC box connection
IFPS box NOTE
The power supply for the box is either supplied via the 12V power
supply unit provided or via a 5V power supply through the
connected DAQ cable of the customer-provided data acquisition
card. Only one power supply is required; if both are connected,
the power supply via the 12V power supply unit is automatically
selected.
Power supply box for nano / mini force-torque sensors with integrated sensor
electronics
1 12-pin socket, sensor cable connection
2 26-pin connector, DAQ cable connection
3 Power supply unit 12V
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Design and description
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PS box NOTE
The power supply for the box is either supplied via the 12V power
supply unit provided or via a 5V power supply through the
connected DAQ cable of the customer-provided data acquisition
card. Only one power supply is required; if both are connected,
the power supply via the 12V power supply unit is automatically
selected.
Power supply box for force-torque sensors starting from gamma and larger
1 20-pin socket, sensor cable connection
2 26-pin connector, DAQ cable connection
3 Power supply unit 12V
DAQ cable
DAQ cable from PS box / IFPS box to customer-provided data acquisition card
1 Unterminated cable ends
2 68-pin connector (type D) for customer-provided data
acquisition card
3 26-pin connector, PS box / IFPS box connection

Design and description
IFPSMC box
A = front view / B = rear view
1 68-pin socket, customer-provided connection 1
2 68-pin socket, connection 1 to data acquisition card
3 68-pin socket, connection 0 to data acquisition card
4 68-pin socket, customer-provided connection 0
5 Power supply connection
6 20-pin socket, sensor cable connection
7 Power supply unit
DAQ cable for IFPSMC
box
DAQ cable from IFPSMC box to customer-provided data acquisition card
1 68-pin connector (VHDCI), customer-provided data
acquisition card connection
2 68-pin connector (type D), customer-provided data
acquisition card connection
3 68-pin connector (type D), IFPSMC box connection
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Design and description
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BNC interface box
1 BNC output connection
2 Connection for sensor signal input
3 Earth
4 Power supply
Data collection
1 USB data acquisition (DAQ) device with screw terminal
connections
2 USB data acquisition (DAQ) device
3 PCI DAQ card
4 PCI DAQ card
5 Terminal block with BNC inputs

Design and description
4.2 Description
The force-torque sensor is connected to the PC by means of a
customer-provided data acquisition card. The six analog output
signals from the force-torque sensor are converted to digital
signals by means of the electronics in the data acquisition card.
Afterwards, the software (provided by the customer) uses the
calibration matrix to graphically display the occurring forces and
torques on the PC if required.
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Assembly and installation
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5 Assembly and installation
5.1 Installing and connecting
DANGER
Danger from electric voltage!
Touching live parts may result in death.
•Switch off the power supply before any assembly, adjustment
or maintenance work and secure against being switched on
again.
•Only qualified electricians may perform electrical installations.
•Check if de-energized, ground it and hot-wire.
•Cover live parts.
CAUTION
Risk of damage to the electronics!
A faulty connection can cause damage to the internal electronics.
•The supply network must be a network of type "PELV" for
power and logic.
•Observe the PIN assignment of the connecting terminals.
•Make sure that all components are grounded correctly.
1. Connect components of the force-torque sensor system with
each other, Electrical connection [}19].
2. Optional: Install the software, Installing the software [}39].
3. Check for functionality.
4. Mount the force-torque sensor on the robot, see the
installation and operating instructions for the sensor.

Assembly and installation
5.2 Electrical connection
"PCI DAQ card with one force-torque sensor" variant
Connection shown as an example with theta force-torque sensor
1. Connect data acquisition card(1) to PC.
2. Connect DAQ cable(2) to data acquisition card(1).
3. Connect the DAQ cable(2) to the power supply box(4) and
tighten the clamping screws on the connector.
4. Connect power supply unit 12V(3) to power supply box(4).
5. For FT sensors starting from gamma and larger: Connect
sensor cable(5) to force-torque sensor(6).
6. Connect sensor cable(5) to power supply box(4).
7. Check for functionality.
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Assembly and installation
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"PCI DAQ card for up to six force-torque sensors" variant
Connection shown as an example with Mini58 force-torque sensor
1. Connect data acquisition card(1) to PC.
2. Connect DAQ cable(2) to data acquisition card(1).
3. Connect DAQ cable(2) to IFPSMC box(4) and tighten screw
terminals on the connectors.
4. Connect power supply unit 12V(3) to IFPSMC box(4).
5. For FT sensors starting from gamma and larger: Connect
sensor cable(5) to force-torque sensors(6).
6. Connect sensor cable(5) to IFPSMC box(4). The serial number
of the sensor must match the serial number on the connector
on the IFPSMC box.
7. Check for functionality.