Universal Robots UR-6-85-5-A User manual

UR-6-85-5-A
User Manual
Version 1.11, January 2010

2 UR-6-85-5-A

Contents
1 Getting started 7
1.1 Introduction .................................. 7
1.1.1 TheRobot ............................... 8
1.1.2 Programs................................ 8
1.1.3 SafetyEvaluation........................... 9
1.2 TurningOnandOff.............................. 9
1.2.1 Turning on the Controller Box . . . . . . . . . . . . . . . . . . . . 9
1.2.2 Turning on the Robot . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.3 Initializing the Robot . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.4 Shutting Down the Robot . . . . . . . . . . . . . . . . . . . . . . 9
1.2.5 Shutting Down the Controller Box . . . . . . . . . . . . . . . . . 10
1.3 Quick start, Step by Step . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.1 The Workspace of the Robot . . . . . . . . . . . . . . . . . . . . 12
1.4.2 Mounting the Robot . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.3 Mounting the Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.4 Mounting the Controller Box . . . . . . . . . . . . . . . . . . . . 15
1.4.5 Mounting the Touch Panel . . . . . . . . . . . . . . . . . . . . . 15
1.4.6 Connecting the Robot Cable . . . . . . . . . . . . . . . . . . . 15
1.4.7 Connecting the Mains Cable . . . . . . . . . . . . . . . . . . . 15
2 Electrical Interface 17
2.1 Introduction .................................. 17
2.2 The Emergency Stop Interface . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.1 The Simplest Emergency Stop Configuration . . . . . . . . . . 19
2.2.2 Connecting an External Emergency Stop Button . . . . . . . . 20
2.2.3 Using an External Emergency Stop Power Supply . . . . . . . . 20
2.2.4 Connecting to Other Machinery . . . . . . . . . . . . . . . . . 20
2.3 ThePauseInterface ............................. 21
2.3.1 Connecting to the Pause Interface . . . . . . . . . . . . . . . . 21
2.4 ControllerI/O ................................. 22
2.4.1 DigitalOutputs ............................ 23
2.4.2 DigitalInputs.............................. 24
2.4.3 AnalogOutputs............................ 26
2.4.4 AnalogInputs............................. 27
2.5 ToolI/O..................................... 28
2.5.1 DigitalOutputs ............................ 29
2.5.2 DigitalInputs.............................. 30
2.5.3 AnalogInputs............................. 31
3

Contents
3 PolyScope Software 33
3.1 Introduction .................................. 34
3.1.1 WelcomeScreen........................... 35
3.1.2 Initialization Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2 On-screenEditors............................... 37
3.2.1 On-screen Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2.2 On-screen Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2.3 On-screen Expression Editor . . . . . . . . . . . . . . . . . . . . 38
3.3 RobotControl................................. 38
3.3.1 MoveTab ............................... 38
3.3.2 I/OTab................................. 40
3.3.3 AutoMoveTab ............................ 41
3.3.4 Setup →Mounting.......................... 42
3.3.5 Setup →TCPPosition......................... 43
3.3.6 LogTab................................. 44
3.3.7 LoadScreen.............................. 44
3.3.8 RunTab................................. 46
3.4 Programming ................................. 46
3.4.1 Program →NewProgram...................... 47
3.4.2 ProgramTab.............................. 47
3.4.3 Program →Command Tab, <Empty> . . . . . . . . . . . . . . . 48
3.4.4 Program →Command Tab, Move . . . . . . . . . . . . . . . . . 49
3.4.5 Program →Command Tab, Fixed Waypoint . . . . . . . . . . . 50
3.4.6 Program →Command Tab, Relative Waypoint . . . . . . . . . 51
3.4.7 Program →Command Tab, Variable Waypoint . . . . . . . . . 52
3.4.8 Program →Command Tab, Wait . . . . . . . . . . . . . . . . . 53
3.4.9 Program →Command Tab, Action . . . . . . . . . . . . . . . . 53
3.4.10 Program →Command Tab, Popup . . . . . . . . . . . . . . . . 54
3.4.11 Program →Command Tab, Halt . . . . . . . . . . . . . . . . . . 54
3.4.12 Program →Command Tab, Comment . . . . . . . . . . . . . . 55
3.4.13 Program →Command Tab, Folder . . . . . . . . . . . . . . . . 55
3.4.14 Program →Command Tab, Loop . . . . . . . . . . . . . . . . . 56
3.4.15 Program →Command Tab, SubProgram . . . . . . . . . . . . . 56
3.4.16 Program →Command Tab, Assignment . . . . . . . . . . . . . 57
3.4.17 Program →CommandTab,If ................... 58
3.4.18 Program →Command Tab, Script . . . . . . . . . . . . . . . . . 59
3.4.19 Program →Command Tab, Event . . . . . . . . . . . . . . . . . 59
3.4.20 Program →Command Tab, Thread . . . . . . . . . . . . . . . . 60
3.4.21 Program →Command Tab, Pattern . . . . . . . . . . . . . . . . 60
3.4.22 Program →Command Tab, Pallet . . . . . . . . . . . . . . . . . 62
3.4.23 Program →Command Tab, Stack . . . . . . . . . . . . . . . . . 63
3.4.24 Program →GraphicsTab ...................... 67
3.4.25 Program →StructureTab ...................... 68
3.5 Setup ...................................... 69
3.5.1 SetupScreen ............................. 69
3.5.2 Setup Screen →Initialize ...................... 70
3.5.3 Setup Screen →Update ...................... 70
3.5.4 Setup Screen →Password ..................... 71
3.5.5 Setup Screen →Calibrate Touch Screen . . . . . . . . . . . . . 71
3.5.6 Setup Screen →Network ...................... 72
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Contents
4 Warranties and Declarations 73
4.1 Warranty .................................... 73
4.1.1 ProductWarranty........................... 73
4.1.2 Disclaimer ............................... 73
4.2 Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2.1 Product manufacturer . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2.2 Person Authorised to Compile the Technical Documentation 74
4.2.3 Description and Identification of Product . . . . . . . . . . . . 74
4.2.4 Essential Requirements . . . . . . . . . . . . . . . . . . . . . . . 74
4.2.5 National Authority Contact Information . . . . . . . . . . . . . 75
4.2.6 ImportantNotice........................... 76
4.2.7 Place and Date of the Declaration . . . . . . . . . . . . . . . . 76
4.2.8 Identity and Signature of the Empowered Person . . . . . . . 76
A Safety Assessment 77
A.1 CE certification of the Robot Installation . . . . . . . . . . . . . . . . . 78
A.1.1 Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 78
A.1.2 ScoringtheRisk............................ 78
A.1.3 RiskAssessment............................ 79
A.1.4 Example ................................ 79
5 UR-6-85-5-A

Contents
6 UR-6-85-5-A

Chapter 1
Getting started
1.1 Introduction
Congratulations on the purchase of your new Universal Robot, UR-6-85-5-A.
The robot is a machine that can be programmed to move a tool, and com-
municate with other machines using electrical signals. Using our patented pro-
gramming interface, PolyScope, it is easy to program the robot to move the tool
along a desired trajectory. PolyScope is described in section 3.1.
The reader of this manual is expected to be technically minded, to be fa-
miliar with the basic general concepts of programming, be able to connect a
wire to a screw terminal, and be able to drill holes in a metal plate. No special
knowledge about robots in general or Universal Robots in particular is required.
The rest of this chapter is an appetizer for getting started with the robot.
7

1.1. Introduction
1.1.1 The Robot
The robot itself is an arm composed of extruded aluminum tubes and joints. The
joints are named A:Base, B:Shoulder, C:Elbow and D,E,F:Wrist 1,2,3. The Base is
where the robot is mounted, and at the other end (Wrist 3) the tool of the robot
is attached. By coordinating the motion of each of the joints, the robot can
move its tool around freely, with the exception of the area directly above and
directly below the robot, and of course limited by the reach of the robot (850mm
from the center of the base).
1.1.2 Programs
A program is a list of commands telling the robot what to do. The user inter-
face PolyScope, described later in this manual, allows people with only little
programming experience to program the robot. For most tasks, programming is
done entirely using the touch panel without typing in any cryptic commands.
Since tool motion is such an important part of a robot program, a way of
teaching the robot how to move is essential. In PolyScope, the motions of the
tool are given using a series of waypoints. Each waypoint is a point in the robot’s
workspace.
Waypoints
A waypoint is a point in the workspace of the robot. A waypoint can be given
by moving the robot to a certain position, or can be calculated by software.
The robot performs a task by moving through a sequence of waypoints. Various
options regarding how the robot moves between the waypoints can be given
in the program.
Defining Waypoints, Moving the Robot. The easiest way to define a waypoint
is to move the robot to the desired position. This can be done in two ways: 1)
By simply pulling the robot, while pressing the ’Back-drive’ button on the touch
screen (see 3.3.1). 2) By using the touch screen to drive the tool linearly or to
drive each joint individually.
Blends. Per default the robot stops at each waypoint. By giving the robot free-
dom to decide how to move near the waypoint, it is possible to drive through
the desired path faster without stopping. This freedom is given by setting a blend
radius for the waypoint, which means that once the robot comes within a cer-
tain distance of the waypoint, the robot can decide to deviate from the path.
A blend radius of 5-10 cm usually gives good results.
8 UR-6-85-5-A

1.2. Turning On and Off
Features
Besides moving through waypoints, the program can send I/O signals to other
machines at certain points in the robot’s path, and perform commands like
if..then and loop, based on variables and I/O signals.
1.1.3 Safety Evaluation
The robot is a machine and as such a safety evaluation is required for each
installation of the robot. Appendix A.1 describes how to perform a safety evalu-
ation.
1.2 Turning On and Off
How to turn the different parts of the robot system on and off is described in the
following subsections.
1.2.1 Turning on the Controller Box
The controller box is turned on by pressing the ’On’ button, at the front side of
the controller box. When the controller box is turned on, a lot of text will appear
on the screen. After about 30 seconds, the Universal Robot’s Logo will appear,
with the text ’Loading’. After around 70 seconds, a few buttons appear on the
screen and a popup will force the user to go to the initialization screen.
1.2.2 Turning on the Robot
The robot can be turned on if the controller box is turned on, and if all emer-
gency stop buttons are not activated. Turning the robot on is done at the initial-
ization screen, by touching the ’ON’ button at the screen. When it is turned on,
a noise can be heard as the brakes unlock. After the robot has been turned on,
it needs to be initialized before it can begin to perform work.
1.2.3 Initializing the Robot
After the robot is powered up, each of the robot’s joints needs to find its ex-
act position, by moving to a home position. Each large joint has around 20
home positions, evenly distributed over one joint revolution. The small joints have
around 10. The Initialization screen, shown in figure 1.1, gives access to manual
and semi-automatic driving of the robot’s joints, to move them to a home po-
sition. The robot cannot automatically avoid collision with itself or the surrounds
during this process. Therefor, caution should be exercised.
The Auto button near the top of the screen drives all joints until they are
ready. When released and pressed again, all joints change drive direction. The
Manual buttons permit manual driving of each joint.
A more detailed description of the initialization screen is found in section 3.1.2.
1.2.4 Shutting Down the Robot
The power to the robot can be turned off by touching the ’OFF’ button at the
initialization screen. Most users do not need to use this feature since the robot is
9 UR-6-85-5-A

1.3. Quick start, Step by Step
Figure 1.1: The initialization screen
automatically turned off when the controller box is shutting down. A third way is
of course to push an emergency stop button.
1.2.5 Shutting Down the Controller Box
The proper way of shutting down the controller box is to use the on-screen menu
system. Go to the ’File’ menu at the top-left corner and choose ’Exit’. Then you
see the ’Welcome’ screen which has a ’Shut Down’ button.
Shutting down by pulling the wall socket may cause corruption of the robot’s
file system, which may result in a robot malfunction. However, if the system locks
up you can force a shutdown by pushing and holding the ’On’ button at the
front side of the controller box for five seconds.
1.3 Quick start, Step by Step
To quickly set up the robot, perform the following steps:
1. Unpack the robot and the controller box.
2. Mount the robot on a sturdy surface.
3. Place the controller box on its foot.
4. Plug the robot cable into the connector at the bottom of the controller
box.
5. Plug in the mains connector of the controller box.
6. Press the Emergency Stop button on the front side of the controller box.
7. Press the power button next to the Emergency Stop button at the controller
box.
10 UR-6-85-5-A

1.3. Quick start, Step by Step
8. Wait a minute while the system is starting up, displaying text on the touch
screen.
9. When the system is ready, a popup will be shown on the touch screen,
stating that the emergency stop button is pressed.
10. Touch the To Initialization Screen button at the popup.
11. Unlock the emergency stop buttons. The robot state then changes from
’Emergency Stopped’ to ’Robot Power Off’.
12. Touch the On button on the touch screen. The robot now makes a noise
and moves a little while unlocking the breaks.
13. Touch the blue arrows and move the joints around until every "light" at the
right side of the screen turns green. Be careful not to drive the robot into
itself or anything else.
14. All joints are now OK. Touch the exit button, bringing you the Welcome
screen.
15. Touch the PROGRAM Robot button and select Empty Program.
16. Touch the Next button (bottom right) so that the <empty> line is selected
in the tree structure on the left side of the screen.
17. Go to the Structure tab.
18. Touch the Move button.
19. Go to the Command tab.
20. Press the Next button, to go to the Waypoint settings.
21. Press the Set this waypoint button next to the "?" picture.
22. On the Move screen, move the robot by pressing the various blue arrows, or
move the robot by holding the Back-drive button while pulling the robot
arm.
23. Press OK.
24. Press Add waypoint before.
25. Press the Set this waypoint button next to the "?" picture.
26. On the Move screen, move the robot by pressing the various blue arrows, or
move the robot by holding the Back-drive button while pulling the robot
arm.
27. Press OK.
28. Your program is ready. The robot will move between the two points when
you press the ’Play’ symbol. Stand clear, hold on to the emergency stop
button and press ’Play’.
29. Congratulations! You have now produced your first robot program that
moves the robot between the two given positions. Remember that you
have to carry out a risk assessment and improve the overall safety condi-
tion before you really make the robot do some work.
11 UR-6-85-5-A

1.4. Mounting Instructions
Front Tilted
Figure 1.2: The workspace of the robot. The robot can work in an appoximate
sphere (Ø170cm) around the base, except for a cylindrical volume directly
above and directly below the robot base.
1.4 Mounting Instructions
The robot consists essentially of six robot joints and two aluminum tubes, con-
necting the robot’s base with the robot’s tool. The robot is built so that the tool
can be translated and rotated within the robot’s workspace. The next subsec-
tions describes the basic things to know when mounting the different parts of
the robot system.
1.4.1 The Workspace of the Robot
The workspace of the UR-6-85-5-A robot extends to 850 mm from the base joint.
The workspace of the robot is shown in figure 1.2. It is important to consider the
cylindrical volume directly above and directly below the robot base when a
mounting place for the robot is chosen. Moving the tool close to the cylindrical
volume should be avoided if possible, because it causes the robot joints to move
fast even though the tool is moving slowly.
1.4.2 Mounting the Robot
The robot is mounted using 4 M8 bolts, using the four 8.5mm holes on the robot’s
base. If very accurate repositioning of the robot is desired, two Ø8 holes are
provided for use with a pin. Figure 1.3 shows where to drill holes and mount the
screws.
1.4.3 Mounting the Tool
The robot tool flange has four holes for attaching a tool to the robot. A drawing
of the tool flange is shown in figure 1.4.
12 UR-6-85-5-A

1.4. Mounting Instructions
90°±0,5°
45°
120
(2)
±0,5°
45°
±0,5
10
(4)
±0,5
5 ±1
132 ±0,5
Outer diameter of robot
0.05mm
mounting flange
Surface on hich the robot is fitted. It should be flat ithin
Cable exit
(2)
0,010
-
8
+0,015
149
M812 (4)
8.5
OR
Figure 1.3: Holes for mounting the robot, scale 1:1. Use 4 M8 bolts. All measure-
ments are in mm.13 UR-6-85-5-A

1.4. Mounting Instructions
Figure 1.4: The tool output flange, EN ISO 9409-1-A50. This is where the tool is
mounted at the tip of the robot. All measures are in mm.
14 UR-6-85-5-A

1.4. Mounting Instructions
Input 100-120VAC Min. 16A current rating
Input 200-240VAC Min. 8A current rating
Frequency 50-60Hz
Stand-by Power 5W
Typical ’On’ Power 200W
Table 1.1: Specifications for mains connection
1.4.4 Mounting the Controller Box
The controller box can be mounted using the two holes on the back of the
controller box, or it can be placed on the ground.
1.4.5 Mounting the Touch Panel
The touch sensitive screen can be hung on a wall or on the controller box. Extra
fittings can be bought.
1.4.6 Connecting the Robot Cable
The cable from the robot must be plugged in to the connector at the button
of the controller box. Ensure that the connector is properly locked. Connecting
and disconnecting the robot cable may only be done when the robot power
is turned off, which is easily ensured by pushing the emergency stop button on
the front side of the controller box.
1.4.7 Connecting the Mains Cable
The mains cable from the controller box has a standard IEC plug in the end.
Connect a country specific mains plug or cable to the IEC plug. Remember
to use a cable with specifications as shown with the mains specifications in ta-
ble 1.1.
The controller box should be connected to earth by the mains cable. If other
earth connections are needed for external equipment, please use the M8 screw
at the bottom right corner of the controller box, as shown below.
15 UR-6-85-5-A

1.4. Mounting Instructions
16 UR-6-85-5-A

Chapter 2
Electrical Interface
2.1 Introduction
There are electrical inputs/outputs (I/Os) inside the controller box and at the
robot tool flange. Some of the I/Os inside the controller box are dedicated
to the robot emergency stop functionality, and some I/Os allows the robot to
communicate with other machines and equipment. The I/O at the robot tool
flange can be used to control grippers and sensors placed on the tool. Both the
controller and the tool I/O can be tested at the I/O tab in the graphical user
interface, as explained in section 3.3.2. The next three sections explain how to
use the electrical I/O.
Note that according to the IEC 61000 standard cables going from the controller
box to other machinery and factory equipment may not be longer than 30m,
unless extended test requirements are performed.
Note that every minus connection (0V) is referred to as GND, and is connected
to the shield of the robot and the controller box. However, all mentioned GND
connections are only for powering and signaling. For a real ground connec-
tion there is an M 10 sized screw connection at the down right corner of the
controller box.
Note that data in this chapter is only valid when the ambient temperature of
the controller box and the robot is within its specified working range, and that
all voltage and current data is implicitly DC.
17

2.2. The Emergency Stop Interface
E24 24V Emergency stop power supply
EG 0V Emergency stop GND connection
SWI Emergency stop button switch input
SWO Emergency stop button switch output
ERI Emergency relay input
ERO Emergency relay output
Table 2.1: Abbreviations for the emergency stop interface
2.2 The Emergency Stop Interface
Inside the controller box there is a panel of screw terminals as shown above.
It is only the leftmost part which is used for the emergency stop functions; the
other terminals are normal I/O as shown below.
The abbreviations are explained in table 2.1.
Note that connecting and configuring the emergency interface relies on the
complete understanding of the emergency circuitry, and the owner of the ma-
chinery takes full responsibility for connecting it correctly and to the right safety
level.
Note the number of safety components that should be used and how they must
work rely on the risk assessment, which is explained in section A.1.
Note that it is important to make regular checks of the emergency stop func-
tionality to ensure that all emergency stop devices are functioning correctly.
The emergency stop interface is different from the normal I/O, because it
has to comply with a certain safety level (EN 954 Category 3). To understand
the emergency stop functionality, a simplified version of the internal schematics
of the robot emergency stop circuitry is shown in figure 2.1. It is important to
notice that any short circuit or lost connection will lead to an emergency stop,
18 UR-6-85-5-A

2.2. The Emergency Stop Interface
Figure 2.1: Simplified schematics of the internal robot emergency stop circuitry.
Parameter Min Typ Max Unit
Voltage available at connection E24 TBD 24 TBD V
Current available at connection E24 - - 800* mA
Short-circuit current protection - 850 - mA
Capacitive load at connection E24 - - TBD uF
Inductive load at connection E24 - - TBD uH
Emergency relay ON voltage 18 24 26 V
Emergency relay OFF voltage - 0 1.5 V
Emergency relay quiescent current - 110 TBD mA
Current through internal switch - - 1.0 A
Table 2.2: Emergency stop interface data. TBD = To Be Determined.
as long as only one error appears at a time. Failure and abnormal behavior
of relays and power supplies results in an error message in the robot log and
prevents the robot from powering up.
It is generally important that the connections to the emergency stop inter-
face are separated from the normal I/O interface, and that it is never con-
nected to a PLC which is not a safety PLC with the right safety level. If this rule
is not followed, it is not possible to get a high safety level, because one failure
in normal I/O can prevent an emergency stop signal from resulting in an emer-
gency stop. Other rules that restrict the use of the emergency stop interface are
shown in table 2.2.
Note that connection E24 is sourced by the same internal 24V regulator as the
normal I/O, and that the maximum of 800mA is for both power sources together.
The internal control system will power off the robot if the current exceeds its
limit. This will also generate an error message in the robot log. The next subsec-
tions show some simple examples of how the emergency stop interface can be
connected to other safety equipment and other safety circuits.
2.2.1 The Simplest Emergency Stop Configuration
The simplest configuration is to use the internal emergency stop button as
the only component to generate an emergency stop. This is done with the
configuration shown above. This configuration is the default when the robot
leaves the factory, and thereby the robot is ready to operate. However, the
emergency configuration should be changed if required by the risk assessment.
19 UR-6-85-5-A

2.2. The Emergency Stop Interface
2.2.2 Connecting an External Emergency Stop Button
In almost every robot application it is required to connect one or more exter-
nal emergency stop buttons. Doing so is simple and easy. An example of how
to connect one extra button is shown above. Remember that only approved
emergency stop buttons with double switches are good enough. It is also possi-
ble to connect light curtains and door switches etc., as long as the equipment
is approved for emergency stop with the right safety level.
2.2.3 Using an External Emergency Stop Power Supply
If the robot is part of a bigger system, it is sometimes preferred or required to use
an external source of 24V for the emergency stop circuitry. How to connect an
external source is shown above.
2.2.4 Connecting to Other Machinery
When the robot is used together with other electro-mechanical machinery, it
is often required to set up a common emergency circuit. This ensures that if a
dangerous situation arises, the operator does not need to think about which
buttons to use. It is also often preferable for every part of a sub-function in a
product line to be synchronized, since a stop in only one part of the product
line can lead to a dangerous situation.
A UR robot uses simple 24V signals for emergency signaling as does most
industrial machinery. It is therefore possible to connect the controller box to
most industrial machinery, without using any special and expensive equipment,
such as safety approved relays and PLCs. The principle is to choose a common
24V voltage source, and connect all emergency stop button in series, and then
all the relays of the machinery. An example with two UR robots is shown below.
Remember to check that all emergency stop buttons are rated for the total
current consumption of all the connected emergency stop relays.
20 UR-6-85-5-A