Universal Robots UR5 User manual

User Manual
Version 1.6
Robot:
UR5 with CB2

All Rights Reserved 2 UR5

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 . . . . . . . . . . . . . . . . . . . . . . 10
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 Screen . . . . . . . . . . . . . . . . . . . . . . . . 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 Importantnotices............................... 17
2.3 TheSafetyInterface ............................. 18
2.3.1 The Emergency Stop Interface . . . . . . . . . . . . . . . . . . . 18
2.3.2 The Safeguard Interface . . . . . . . . . . . . . . . . . . . . . . 22
2.3.3 Automatic continue after safeguard stop . . . . . . . . . . . . 23
2.4 ControllerI/O ................................. 24
2.4.1 DigitalOutputs ............................ 25
2.4.2 DigitalInputs.............................. 26
2.4.3 Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4.4 AnalogueInputs ........................... 28
2.5 ToolI/O..................................... 29
2.5.1 DigitalOutputs ............................ 30
2.5.2 DigitalInputs.............................. 31
2.5.3 AnalogInputs............................. 31
3 PolyScope Software 33
3.1 Introduction .................................. 34
3.1.1 WelcomeScreen........................... 35
3.1.2 Initialization Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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Contents
3.2 On-screenEditors............................... 37
3.2.1 On-screen Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2.2 On-screen Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.3 On-screen Expression Editor . . . . . . . . . . . . . . . . . . . . 38
3.3 RobotControl................................. 39
3.3.1 MoveTab ............................... 39
3.3.2 I/OTab................................. 40
3.3.3 ModbusI/O .............................. 41
3.3.4 AutoMoveTab ............................ 42
3.3.5 Installation →Load/Save ...................... 43
3.3.6 Installation →TCPPosition...................... 43
3.3.7 Installation →Mounting....................... 44
3.3.8 Installation →I/OSetup....................... 45
3.3.9 Installation →Default Program . . . . . . . . . . . . . . . . . . . 46
3.3.10 Modbus I/O Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.11Features ................................ 48
3.3.12LogTab................................. 52
3.3.13LoadScreen.............................. 53
3.3.14RunTab................................. 54
3.4 Programming ................................. 55
3.4.1 Program →NewProgram...................... 56
3.4.2 ProgramTab.............................. 56
3.4.3 Program →Command Tab, <Empty>.............. 57
3.4.4 Program →Command Tab, Move . . . . . . . . . . . . . . . . . 58
3.4.5 Program →Command Tab, Fixed Waypoint . . . . . . . . . . . 60
3.4.6 Setting the waypoint . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.4.7 Program →Command Tab, Relative Waypoint . . . . . . . . . 62
3.4.8 Program →Command Tab, Variable Waypoint . . . . . . . . . 62
3.4.9 Program →Command Tab, Wait . . . . . . . . . . . . . . . . . 63
3.4.10 Program →Command Tab, Action . . . . . . . . . . . . . . . . 64
3.4.11 Program →Command Tab, Popup . . . . . . . . . . . . . . . . 64
3.4.12 Program →Command Tab, Halt . . . . . . . . . . . . . . . . . . 65
3.4.13 Program →Command Tab, Comment . . . . . . . . . . . . . . 65
3.4.14 Program →Command Tab, Folder . . . . . . . . . . . . . . . . 66
3.4.15 Program →Command Tab, Loop . . . . . . . . . . . . . . . . . 66
3.4.16 Program →Command Tab, SubProgram . . . . . . . . . . . . . 67
3.4.17 Program →Command Tab, Assignment . . . . . . . . . . . . . 68
3.4.18 Program →CommandTab,If ................... 68
3.4.19 Program →Command Tab, Script . . . . . . . . . . . . . . . . . 69
3.4.20 Program →Command Tab, Event . . . . . . . . . . . . . . . . . 69
3.4.21 Program →Command Tab, Thread . . . . . . . . . . . . . . . . 70
3.4.22 Program →Command Tab, Pattern . . . . . . . . . . . . . . . . 70
3.4.23 Program →Command Tab, Force . . . . . . . . . . . . . . . . . 72
3.4.24 Program →Command Tab, Pallet . . . . . . . . . . . . . . . . . 74
3.4.25 Program →Command Tab, Seek . . . . . . . . . . . . . . . . . 75
3.4.26 Program →Command Tab, Suppress . . . . . . . . . . . . . . . 78
3.4.27 Program →GraphicsTab ...................... 79
3.4.28 Program →StructureTab ...................... 80
3.4.29 Program →VariablesTab...................... 81
3.4.30 Program →Command Tab, Variables Initialization . . . . . . . 81
3.5 Setup ...................................... 82
3.5.1 SetupScreen ............................. 82
3.5.2 Setup Screen →Initialize ...................... 83
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Contents
3.5.3 Setup Screen →Language Select . . . . . . . . . . . . . . . . . 83
3.5.4 Setup Screen →Update ...................... 83
3.5.5 Setup Screen →Password ..................... 84
3.5.6 Setup Screen →Calibrate Touch Screen . . . . . . . . . . . . . 84
3.5.7 Setup Screen →Network ...................... 85
4 Safety 87
4.1 Introduction .................................. 87
4.2 Statutory documentation . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.3 Riskassessment ................................ 88
4.4 Emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5 Warranties 91
5.1 ProductWarranty............................... 91
5.2 Disclaimer ................................... 91
6 Declaration of Incorporation 93
6.1 Introduction .................................. 93
6.2 Product manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.3 Person Authorised to Compile the Technical Documentation . . . . 93
6.4 Description and Identification of Product . . . . . . . . . . . . . . . . 93
6.5 Essential Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.6 National Authority Contact Information . . . . . . . . . . . . . . . . . 96
6.7 ImportantNotice............................... 96
6.8 Place and Date of the Declaration . . . . . . . . . . . . . . . . . . . . 96
6.9 Identity and Signature of the Empowered Person . . . . . . . . . . . 97
A Certifications 99
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Contents
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Chapter 1
Getting started
1.1 Introduction
Congratulations on the purchase of your new Universal Robot, UR5.
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.
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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 ’Teach’ button on the 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.
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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. Chapter 4.1 describes how to perform a safety evalua-
tion.
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 power button, at the front side
of the teach pendant. When the controller box is turned on, a lot of text will
appear on the screen. After about 20 seconds, the Universal Robot’s Logo will
appear, with the text ’Loading’. After around 40 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 ini-
tialization screen, by touching the ’ON’ button at the screen, and then pressing
’Start’. When a robot is started, a noise can be heard as the brakes unlock.
After the robot has powereded up, 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.
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1.3. Quick start, Step by Step
Figure 1.1: The initialization screen
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
automatically turned off when the controller box is shutting down.
1.2.5 Shutting Down the Controller Box
Shut down the system by pressing the green power button on the screen, or by
using the ’Shut Down’ button on the welcome screen.
Shutting down by pulling the wall socket may cause corruption of the robot’s
file system, which may result in robot malfunction.
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 teach pendant.
7. Press the power button on the teach pendant.
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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. Wait a few seconds.
13. Touch the Start button on the touch screen. The robot now makes a noise
and moves a little while unlocking the breaks.
14. 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.
15. All joints are now OK. Touch the exit button, bringing you the Welcome
screen.
16. Touch the PROGRAM Robot button and select Empty Program.
17. Touch the Next button (bottom right) so that the <empty> line is selected
in the tree structure on the left side of the screen.
18. Go to the Structure tab.
19. Touch the Move button.
20. Go to the Command tab.
21. Press the Next button, to go to the Waypoint settings.
22. Press the Set this waypoint button next to the "?" picture.
23. On the Move screen, move the robot by pressing the various blue arrows, or
move the robot by holding the Teach button while pulling the robot arm.
24. Press OK.
25. Press Add waypoint before.
26. Press the Set this waypoint button next to the "?" picture.
27. On the Move screen, move the robot by pressing the various blue arrows, or
move the robot by holding the Teach button while pulling the robot arm.
28. Press OK.
29. 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’.
30. 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.
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1.4. Mounting Instructions
Front Tilted
Figure 1.2: The workspace of the robot. The robot can work in an approxi-
mate 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 UR5 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 pro-
vided for use with a pin. Also an accurate base counterpart can be purchased
as accessory. 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.
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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 mea-
surements are in mm.
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1.4. Mounting Instructions
31,5
0
+
0,025
(H7)
50
63
-
0,05 0
(h8)
75
6 0
+
0,015
(H7)
90°
(x4)
45°
A
A
Lumberg RKMV 8-354 connector
M6
6,0 (x4)
33
46,6
19,5
6,5
5
6,5
6
SECTION A-A
Figure 1.4: The tool output flange, ISO 9409-1-50-4-M6. This is where the tool
is mounted at the tip of the robot. All measures are in mm.
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1.4. Mounting Instructions
1.4.4 Mounting the Controller Box
The controller box can be hung on a wall, or it can be placed on the ground. A
clearance of 50mm on each side allows for sufficient airflow.
1.4.5 Mounting the Screen
The 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.
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.
If the current rating of the specific plug is insufficient or if a more permanent
solution is prefered then wire the controller box directly. The mains supply shall
be equiped with the following as a minimum:
1. Main fuse.
2. Residual current device.
3. Connection to earth.
Mains input specification is shown below.
Parameter Min Typ Max Unit
Input voltage 200 230 260 VAC
External mains fuse 8 - 10 A
Input frequency 47 50 63 Hz
Stand-by power - - 0.5 W
Nominal operating power 110 150 750 W
Use the screw connection marked with earth symbol inside the controller box
when potential equalization with other machinery is required.
Note: It is technically possible to use 110V mains supply. However, when the
robot moves at high speed or high acceleration the mains current will exceed
its maximum rating, causing cables, plugs and the main fuse to be overloaded.
Also the fan runs at a lower speed.
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1.4. Mounting Instructions
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Chapter 2
Electrical Interface
2.1 Introduction
The robot is a machine that can be programmed to move a tool around in the
robots workspace. Often, it is desired to coordinate robot motion with nearby
machines or equipment on the tool. The most straightforward way to achieve
this is often by using the electrical interface.
There are electrical input and output signals (I/Os) inside the control box and
at the robot tool flange. This chapter explains how to connect equipment to
the I/Os. Some of the I/Os inside the control box are dedicated to the robot
safety functionality, and some are general purpose I/Os for connecting with
other machines and equipment. The general purpose I/Os can be manipulated
directly on the I/O tab in the user interface, see section 3.3.2, or by the robot
programs.
For additional I/O, Modbus units can be added via the extra Ethernet con-
nector in the control box.
2.2 Important notices
Note that according to the IEC 61000 and EN 61000 standards cables going
from the control box to other machinery and factory equipment may not be
longer than 30m, unless extended tests are performed.
Note that every minus connection (0V) is referred to as GND, and is connected
to the shield of the robot and the control box. However, all mentioned GND con-
nections are only for powering and signaling. For PE (Protective Earth) use one
of the two M6 sized screw connections inside the control box. If FE (Functional
Earth) is needed use one of the M3 screws close to the screw terminals.
Note that in this chapter, all unspecified voltage and current data are in DC.
It is generally important to keep safety interface signals seperated from the nor-
mal I/O interface signals. Also, the safety interface should never be connected
to a PLC which is not a safety PLC with the correct safety level. If this rule is not
followed, it is not possible to get a high safety level, since one failure in a normal
I/O can prevent a safety stop signal from resulting in a stop.
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2.3. The Safety Interface
2.3 The Safety Interface
Inside the control box there is a panel of screw terminals. The leftmost part,
in black above, is the safety interface. The safety interface can be used to
connect the robot to other machinery or protective equipment, to make sure
the robots stops in certain situations.
The safety interface is comprised of two parts; the emergency stop interface
and the safeguard stop interface, further described in the following sections.
The table below summarize their differences:
Emergency Stop Safeguard Stop
Robot stops moving Yes Yes
Initiations Manual Manual or automatic
Program execution Stops Pauses
Brakes Active Not active
Motor power Off Limited
Reset Manual Automatic or manual
Use frequency Infrequent Every cycle to infrequent
Requires re-initialization Brake release only No
EN/IEC 60204 and NFPA 79 Stop category 1 Stop category 2
Performance level ISO 13849-1 PLd ISO 13849-1 PLd
2.3.1 The Emergency Stop Interface
[TA] Test Output A
[TB] Test Output B
[EO1] Emergency Stop Output Connection 1
[EO2] Emergency Stop Output Connection 2
[EO3] Emergency Stop Output Connection 3
[EO4] Emergency Stop Output Connection 4
[EA] Robot Emergency Stop Input A (Positive)
[EB] Robot Emergency Stop Input B (Negative)
[EEA] External Emergency Stop Input A (Positive)
[EEB] External Emergency Stop B (Negative)
[24V] +24V supply connection for safety devices
[GND] 0V supply connection for safety devices
The Emergency Stop interface has two inputs, the Robot Emergency Stop input
and the External Emergency Stop input. Each input is doubled for redundancy
due to the safety performance level d.
The Robot Emergency Stop interface will stop the robot, and will set the Emer-
gency Stop output, intended for use by safety equipment near the robot. The
External Emergency Stop will also stop the robot, but will not affect the Emer-
gency Stop output, and is intended for connecting to other machines only.
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2.3. The Safety Interface
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.
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.
Connecting Emergency Stop to Other Machinery
When the robot is used together with other electro-mechanical machinery, it is
often required to set up a common emergency stop 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.
An example with two UR robots emergency stopping each other is shown
below.
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2.3. The Safety Interface
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