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User Manual UR5/CB3

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1. 4 3 6 General purpose analog I O The analog I O interface is the green terminal It can be used to set or measure voltage 0 10V or current 4 20mA from and to other equipment The following is recommended to achieve a high accuracy Use the AG terminal closest to the I O The pair share a common mode filter Use the same gnd 0V for equipment and control box The analog I O is not galvanically isolated from the control box e Use shielded cable or twisted pairs Connect the shield to the GND termi nal at the terminal called Power Use of equipment that works in current mode Current signals are less sensi tive to interferences Input modes can be selected in the GUI see part II The electrical specifications are shown below Version 3 1 I 25 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 4 3 Controller I O Terminals Parameter Min Typ Max Unit Analog input in current mode AIx AG Current 4 20 mA AIx AG Resistance 20 ohm AIx AG Resolution 12 bit Analog input in voltage mode AIx AG Voltage 0 10 V AIx AG Resistance 10 Kohm AIx AG Resolution 12 bit Analog output in current mode AOx AG Current 4 20 mA AOx AG Voltage 0 10 V AOx AG Resolution 12 bit Ana
2. File 16 51 02 CCCC Q Program Installation Move VO Log lt unnamed gt Command I Graphics Structure Variables Init Variables i m P ni Relative position V Robot Program Waypo int 1 Rename V MoveJ Waypoint V Moves Relative Motion given by the difference between from and to positions n 4 E From point To point Distance 0 0 mm e Pallet Set this point Set this point Angle 179 1 e Pattern Square 9 alst Corner Move robot here Move robot here a2nd Corne Corne 9 a4th Corner PalletSequence Approach 9 PatternPoint e Set Wait 9 Exit Show advanced options e Destack 9 StartPos o Stop at this point Direction Blend with radius 9 FromPos 9 ToPos PickSequence StackPos __ Add waypoint before m Set x Mh 4 nnn Add waypoint after Remove this waypoint simulation lt gt Speed 00 Previous Next o Real Robot A waypoint with the position given relative to the robot arm s previous position such as two centimeters to the left The relative position is defined as the dif ference between the two given positions left to right Note that repeated relative positions can move the robot arm out of its workspace Th
3. When stacking the robot arm moves to the starting position and then moves op posite the direction to search for the next stack position When found the robot remembers the position and performs the special sequence The next time round the robot starts the search from the remembered position incremented by the item thickness along the direction The stacking is finished when the stack hight is more than some defined number or when a sensor gives a signal Version 3 1 c 82 I 71 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 25 Command Seek Destacking File 16 50 03 CCCC Program Installation Move Log lt unnamed gt Command Graphics Structure Variables V Robot V Move Destack Waypoint V Movej Destacking remove items one by one from a stack Waypoint The stack is defined by the following of parameters Set s The starting position 2 9 Pallet The direction of the stack d ee Pattern i The item thickness ee PalletSequence T Approach PatternPoint e Set Wait 9 Exit Destack 9 StartPos 9 ee Direction Oe PickSequence q The next position is found when Wait V Fol
4. DANGER 1 The robot resumes movement automatically when the safe guard signal is re established Do not use this configuration if signal can be re established from the inside of the safety perimeter 4 3 2 5 Safeguard stop with reset button If the safeguard interface is used to interface a light curtain a reset outside the safety perimeter is required The reset button must be a two channel type In this example the I O configured for reset is CIO CI1 see below Version 3 1 1 23 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 4 3 Controller I O 4 3 3 General purpose digital I O This section describes the general purpose 24V I O Gray terminals and the con figurable I O Yellow terminals with black text when not configured as safety I O The common specifications in section 4 3 1 must be observed The general purpose I O can be used to drive equipment like pneumatic relays directly or for communication with other PLC systems All digital outputs can be disabled automatically when program execution is stopped see more in part II In this mode the output is always low when a program is not running Examples are shown in the following subsections These examples use regular digital outputs but any configurable outputs could also have be used if they are not
5. Speed 10096 Previous Next gt o Real Robot Sets either digital or analog outputs to a given value Version 3 1 rev 17782 55 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 11 Command Popup Can also be used to set the payload of the robot arm for example the weight that is picked up as a consequence of this action Adjusting the weight can be neccesary to prevent the robot from triggering a protective stop unexpectedly when the weight at the tool is different from the expected one The active TCP can also be modified using a Set command Simply tick the check box and select one of the TCP offsets from the menu If the active TCP for a par ticular motion is known at the time of writing of the program consider using the TCP selection on the Move card instead see 13 5 For further information about configuring named TCPs see 12 6 13 11 Command Popup File 16 50 06 CCCC Program Installation Move I O Log lt unnamed gt Command Graphics Structure Variables V Moves Waypoint Set Popup c Pallet eo Pattern Shows the message below on the screen and waits for the user to press OK ee PalletSequence Approach 9 PatternPoint Set Popup type Preview Popup Wait Exit Me
6. 6 Wait 0 01 seconds Wait for Digital Input lt Di Input gt w wait for An Input gt v 4 0 mA Q wait for lt l lt gt Simulation Speed c 1009 Previous Next gt o Real Robot Waits for a given amount of time or for an I O signal 13 10 Command Set File 165004 CCCC Program Installation Move Log lt unnamed gt Command I Graphics Structure Variables V Robot V Move Waypoint Set T Y Move 3 Select the action you wish the robot to perform at this point in the program You can also Waypoint specify changes in the robot s payload Set Pallet No Action ee Pattern ee PalletSequenc ae Approach set Digital Output lt Di output gt X loft 9 PatternPoin Set set Analog Output lt An Output gt M 4 0 Wait 9 Exit Destack Q set lt Output gt gt 9 StartPos amp Direction G Increment installation variable by one Variable FromPos 9 ToPos Qe PickSequence 9 StackPos Wait Set the total payload to 0 00 9 Exit Wait O Set TCP V Folder SUD gt Perform action now ele e 0
7. v Loops Forever lt 4 gt Track program execution Q simulation M Speed 00 Previous Next gt o Real Robot A thread is a parallel process to the robot program A thread can be used to control an external machine independently of the robot arm A thread can communicate with the robot program with variables and output signals 13 22 Command Pattern File 155010 CCCC Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Variables oe Pallet a 2 Patter Pattern ee PalletSequence Approach A pattern is a group of positions to be cycled through PatternPoint Patterns can be used for making much more palletizing etc Set Wait Exit Positions on a line Line RN ee Destack 9 StartPos Ge Direction 9 FromPos Positions in a square Square ES 9 ToPos cim c PickSequence 9 StackPos Set Positions in a box Box Wait 3 9 Exit Wait V Folder Dem oe A list of positions Comment Halt Popup V Loop Simulation Speed 100 Previous Next o Real Robot CB3 II 64 Version 3 1 rev 17782 13 22 Command Pattern UNIVERSAL ROB
8. ll a 1 30 Version 3 1 iii UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS Copyright 2009 2015 by Universal Robots A S All rights reserved 45 Ethernet x s do woe Boe ge We cm CE Goose amp do wei I 31 4 6 Mains connection 4 4 4 4 4 4 4 44 1 32 47 Robotconnection 4 4 4 444 1 33 5 Safety related Functions and Interfaces I 35 5 1 LimitingSafetyrelated Functions e 1 35 52 SafetyModes s em s x doa fewa 187 5 3 Safety related Electrical Interfaces 5 lll ll ls 1 37 5 3 1 Safety related Electrical Inputs n 5 l l ls s 1 37 5 3 2 Safety related Electrical Outputs 0 0 1 39 6 Maintenance and Repair I 41 61 Safety Instructions ll 4 4 4 4 4 2 2 1 41 7 Disposal and Environment 1 43 8 Certifications I 45 81 Third Party Certifications ll on 1 45 82 Declarations According to 0 _ 1 45 9 Warranties I 47 91 Product Warranty 2 4 4 4 4 4 4 2 2 I 47 92 Disclaimer s s s x xo xoc woa momo xo o 5 poo Row ox I 47 A Stopping Time and Stopping Distance 1 49 A 1 CATEGORY 0 stopping distances and times ee 1 49 B Declarations and Certificates I 51 B 1 Declaration of Incorporation original I 51 B 2 Safety System Certificate
9. Unit Input voltage in voltage mode 0 5 26 V Input voltage in current mode 0 5 5 0 V Input current in current mode 2 9 z 25 mA Input resistance range OV to 5V 29 kQ Input resistance range OV to 10V 15 kQ Input resistance range 4mA to 20mA 200 Q Two examples of how to use an analog inputs are shown in the following subsec tions CAUTION 1 Analog inputs are not protected against over voltage in cur rent mode Overrating the limit in the electrical specification can cause permanent damage to the input UR5 CB3 1 30 Version 3 1 4 5 Ethernet UNIVERSAL ROBOTS 4 4 3 1 Using the Tool Analog Inputs Non differential The example below shows how to connect an analog sensor with a non differential output The output of the sensor can be either current or voltage as long as the input mode of that analog input is set to the same on the I O tab Remember to check that a sensor with voltage output can drive the internal resistance of the tool or the measurement might be invalid POWER 4 4 3 2 Using the Tool Analog Inputs Differential The example below shows how to connect an analog sensor with a differential out put Connect the negative output part to GND 0V and it works in the same way as a non differential sensor 4 5 Ethernet An Ethernet connection is provided at the bottom of the control box see illustration below The Ethernet interface can be
10. Move I O Log 16 51 16 CCCC Q Safety Configuration General Limits Joint Limits Boundaries Safety I O jf SITS Input Signal Function Assignment Wanani config in 0 config in 1 Reduced Mode Y ariables MODBUS client config in 2 config in 3 Safeguard Reset v Features config in 4 config in 5 Unassigned Y Conveyor Tracking config in 6 config in 7 Unassigned SA Output Signal config out 0 config out 1 Robot Moving Y config out 2 config out 3 System Emergency Stopped X config out 4 config out 5 Unassigned v config out 6 config out 7 Unassigned Function Assignment Lock Apply This screen defines the Safety functions for configurable inputs and outputs I Os The I Os are divided between the inputs and outputs and are paired up so that each function is providing a Category 3 and PLd I O Each Safety function can only control one pair of I Os Trying to select the same safety function a second time removes it from the first pair of I Os previously de fined There are 3 Safety functions for input signals and 4 for output signals Input Signals For input signals the following Safety functions can be selected Emergency Stop When selected this allows the option of having an alter native Emergency Stop button in inclusion of the one
11. 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 23 Command Force motion Note when the robot arm is not moving If force mode is entered with the robot arm standing still there will be no compliant axes until the TCP speed is above zero If later on while still in force mode the robot arm is again standing still the task frame has the same orientation as the last time the TCP speed was larger than zero For the last three types the actual task frame can be viewed at runtime on the graphics tab 13 28 when the robot is operating in force mode Force value selection A force can be set for both compliant and non compliant axes but the effects are different Compliant The robot arm will adjust its position to achieve the selected force Non compliant The robot arm will follow its trajectory set by the program while accounting for an external force of the value set here For translational parameters the force is specified in Newtons N and for rota tional the torque is specified in Newton meters Nm Limits selection For all axes a limit can be set but these have different meaning corresponding to the axes being complian or non compliant Compliant The limit is the maximum speed the TCP is allowed to attain along about the axis Units mm s and deg s Non compliant The limit is the maximum deviation from the program trajec tory which is allowed before the
12. 4 1 Introduction This chapter describes all the electrical interfaces of the robot arm and control box The different interfaces are divided into five groups with different purposes and properties Controller I O Tool I O Ethernet Mains connection Robot connection The term I O refers both digital and analog control signals going from or to an interface These five groups are described in the following sections Examples are given for most types of I O The warnings and cautions in the following section are relevant for all five groups and must be observed 4 2 Electrical warnings and cautions The following warnings and cautions must be observed when a robot application is designed and installed The warnings and cautions also apply for service work DANGER 1 Never connect safety signals to a PLC which is not a safety PLC with the correct safety level Failure to follow this warn ing could result in serious injury or death as one of safety stop functions could be overridden It is important to keep safety interface signals separated from the normal I O interface sig nals All safety related signals are constructed redundantly Two independent channels Keep the two channels separate so that a single fault cannot lead to loss of the safety function Some I O inside the control box can be configured for either normal or safety related I O Read and understand the com plete
13. Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 14 1 Language and Units 14 1 Language and Units Setup Robot Language Selection Initialize Robot Int l English v lv Language and Units Update Robot Units Selection Set Password Metric units u s customary Calibrate Screen Setup Network Set Time Restart PolyScope for new settings to take effect Restart Now Back Language and units used in PolyScope can be selected on this screen The selected language will be used for the text visible on the various screens of PolyScope as well as in the embedded help Tick off English programming to have the names of commands within robot programs written in English PolyScope needs to be restarted for changes to take effect CB3 80 Version 3 1 14 2 Update Robot UNIVERSAL ROBOTS 14 2 Update Robot Setup Robot Update robot software Initialize Robot Language and Units Search Update Robot Set Password Click Search to download a list of possible updates for this robot r Calibrate Screen Description Setup Network Set Time Back Software updates can be installed from USB flash memory Insert an USB memory stick and click Search to
14. 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 9 General Limits Confirmation of applied Safety Configuration General Limits Joint Limits Boundaries Safety 1 0 Normal Mode Reduced Mode Force 150 00 120 00 N Power 300 00 200 00 W Speed 1 50 0 75 m s Momentum 25 00 10 00 kg m s Confirm Safety Configuration Decline Furthermore on confirmation the changes are automatically saved as part of the current robot installation See 12 5 for further information on saving the robot in stallation 15 9 General Limits The general safety limits serve to limit the linear speed of the robot TCP as well as the force it may exert on the environment They are composed of the following values Force A limit for the maximum force that the robot TCP exerts on the environment Power A limit for the maximum mechanical work produced by the robot on the environment considering that the payload is part of the robot and not of the environment Speed A limit for the maximum linear speed of the robot TCP Momentum limit for the maximum momentum of the robot arm There are two means available for configuring the general safety limits within the installation Basic Settings and Advanced Settings which are described more fully below Defining the general safety limits only defines the limits for the tool a
15. 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 10 2 PolyScope Programming Interface 9 10 11 12 13 14 15 Press OK Press Add waypoint before Press the Set this waypoint button next to the picture On the Move screen move the robot by pressing the various blue arrows or move the robot by holding the Freedrive button while pulling the robot arm Press OK with 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 Congratulations You have now produced your first robot program that moves the robot between the two given waypoints WARNING 1 Do not drive the robot into itself or anything else as this may cause damage to the robot 2 Keep your head and torso outside the reach workspace of the robot Do not place fingers where they can be caught 3 This is only a quick start guide to show how easy it is to use a UR robot It assumes a harmless environment and a very careful user Do not increase the speed or acceleration above the default values Always conduct a risk assessment before placing the robot into operation 10 2 PolyScope Programming Interface PolyScope runs on the touch sensitive screen attached to the control box CB3 II 6 Version 3 1 10 2 PolyScope Programming Interface UNIVERSAL ROBOTS PolyScope Robot User Int
16. 3 Use the selector on the sequence command screen to define which of the way points in the sequence should correspond to the pattern positions Pallet Sequence Anchorable Sequence In an Pallet Sequence node the motions of the robot arm are relative to the pallet position The behavior of a sequence is such that the robot arm will be at the po sition specified by the pattern at the Anchor Position Pattern Point The remaining positions will all be moved to make this fit Do not use the Move command inside a sequence as it will not be relative to the anchor position BeforeStart The optional BeforeStart sequence is run just before the operation starts This can be used to wait for ready signals Version 3 1 II 69 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 25 Command Seek AfterEnd The optional AfterEnd sequence is run when the operation is finished This can be used to signal conveyor motion to start preparing for the next pallet 13 25 Command Seek A seek function uses a sensor to determine when the correct position is reached to grab or drop an item The sensor can be a push button switch a pressure sensor or a capacitive sensor This function is made for working on stacks of items with varying item thickness or where the exact positions of the items are not kn
17. Simulation gt Speed 00 Previous Next o Real Robot The program execution stops at this point 13 13 Command Comment File 16 50 05 CCCC Program Installation Move 1 0 Log lt unnamed gt Command I Graphics Structure Variables V Movej ES 9 Waypoint bw move Comment 9 Waypoint Set oe Pallet ee Pattern Please enter comment ee PalletSequence Approach 9 PatternPoint Set Wait 9 Exit ee Destack 9 StartPos e Direction 9 FromPos 9 ToPos PickSequence StackPos Set o Wait 9 Exit simulation Me Speed c 3 1009 Previous Next B o Real Robot Gives the programmer an option to add a line of text to the program This line of text does not do anything during program execution Version 3 1 rev 17782 II 57 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 15 Command Loop 13 14 Command Folder File 16 50 05 CCCC Program Installation Move 1 0 Log lt unnamed gt f Command Graphics Structure Variables V Robot E V MoveJ e Waypoint Folder V Move Waypoint A folder is simply
18. WARNING Tolerances are specific to the version of the software Updating the software may change the tolerances Consult the release notes for changes between versions 15 4 Safety Checksum The text in the top right corner of the screen gives a shorthand representation of the safety configuration currently used by the robot When the text changes this indicates that the current safety configuration has changed as well Clicking on the checksum displays the details about the currently active safety configuration 15 5 Safety Modes Under normal conditions i e when no protective stop is in effect the safety system operates in one of the following safety modes each with an associated set of safety limits Normal mode The safety mode that is active by default Reduced mode Active when the robot TCP is positioned beyond a Trigger Reduced mode plane see 15 11 or when triggered using a configurable input see 15 12 Recovery mode When the robot arm is in violation of one of the other modes i e Normal or Reduced mode and a category 0 stop has occurred the robot arm will start up in Recovery mode This mode allows the robot arm to be manu ally adjusted until all violations have been resolved It is not possible to run programs for the robot in this mode WARNING Note that limits for joint position TCP position and TCP orientation are disabled in Recovery mode so take caution when moving the robot arm back wi
19. 126 22 E 9 Wrist 1 4629 Wrist 2 I gt 91 39 Wrist 3 em j 1 78 Or po Speed 10096 3 cancel eal Robo 12 1 1 Robot The current position of the robot arm is shown in 3D graphics Push the magnifying glass icons to zoom in out or drag a finger across to change the view To get the best feel for controlling the robot arm select the View feature and rotate the viewing angle of the 3D drawing to match your view of the real robot arm If the current position of the robot TCP comes close to a safety or trigger plane or the orientation of robot tool is near the tool orientation boundary limit see 15 11 a 3D representation of the proximate boundary limit is shown Note that when the robot is running a program the visualization of boundary limits will be disabled Safety planes are visualized in yellow and black with a small arrow representing the plane normal which indicates the side of the plane on which the robot TCP is allowed to be positioned Trigger planes are displayed in blue and green and a small arrow pointing to the side of the plane where the Normal mode limits see 15 5 are active The tool orientation boundary limit is visualized with a spherical cone together with a vector indicating the current orientation of the robot tool The inside of the cone represents the allowed area for the tool orientation vector Version 3 1 rev 17 II 17 CB3 Copyri
20. Apply changes and restart the system This will apply the Safety configuration modifications to the system and restart Note This does not imply that any changes have been saved shutdown of the robot at this point will lose all changes to the robot installation including the Safety configuration 2 Revert back to the previously applied Safety configuration This will disregard all changes and allow you to continue to the desired selected destination 15 3 Tolerances In the Safety Configuration physical limits are set The input fields for these limits are excluding the tolerances where applicable tolerances are displayed next to the field The Safety System receives the values from the input fields and detects any violation of these values The Robot Arm attempts to prevent any violations of the safety system and gives a protective stop by stopping the program execution when the limit minus the tolerance is reached Note that this means that a program might not be able to perform motions very close to a limit e g the robot may not be able to obtain the exact maximum speed specified by a joint speed limit or the TCP speed limit Version 3 1 II 87 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 5 Safety Modes WARNING A risk assessment is always required using the limit values with out tolerances
21. Simulation IE gt Speed E 10096 Previous Next o Real Robot A waypoint with the position given by a variable in this case calculated pos The variable has to be a pose such as var p 0 5 0 0 0 0 3 14 0 0 0 0 The first three are x y z and the last three are the orientation given as a rotation vector given by the vector rx ry rz The length of the axis is the angle to be rotated in radians and the vector itself gives the axis about which to rotate The position is always given in relation to a reference frame or coordinate system defined by the selected feature The robot arm always moves linearly to a variable waypoint For example to move the robot 20 mm along the z axis of the tool var_l p 0 0 0 02 0 0 0 Movel Waypoint 1 varibale position Use variable var 1 Feature Tool CB3 II 54 Version 3 1 13 9 Command Wait UNIVERSAL ROBOTS 13 9 Command Wait File 16 50 04 CCCC O Program Installation Move Log zi lt unnamed gt Command Graphics Structure Variables V Robot Wait V MoveJ Please select what should trigger the robot s next action 9 Waypoint V Move 9 Waypoint Set e Pallet ee Pattern lt Palletsequenc 9 Approach 9 PatternPoin Set Wait 9 Exit ee Destack StartPos Direction 9 FromPos 9 ToPos ee PickSequence 9 StackPos e Set Wait 9 Exit Wait V Folder No wait
22. Variables SubProgram file No File Selected SubProgram 1 A subprogram can either point to a file on disk or can be contained in this program Rename s Tr Save SubProgram Load File Clear SubProgram P SubProgram 1 v Show Subprogram Tree I Il c 4 Track program execution o bi Speed 00 Previous Next gt Real Robot A Sub Program can hold program parts that are needed several places A Sub Program can be a seperate file on the disk and can also be hidden to protect against accidental changes to the SubProgram Version 3 1 II 59 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 17 Command Assignment Command Call SubProgram File 16 50 09 CCCC Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Variables Set a Wait o Exit Call Subroutine ee Destack 9 StartPos Choose which subroutine to call at this point at the program execution 9 Direction 9 FromPos SubProgram 1 Y 9 ToPos _ ee PickSequence 9 StackPos Set Wait 9 Exit Wait V Folder Comm Halt Popup V Loop e lt empty gt Bl Script
23. ond one being the endpoint of the movement The robot will start the circle movement from its current position and then move through the two specified waypoints The orientation change of the tool through the circle move is de termined only by the starting orientation and the orientation at the endpoint so the orientation of the via point does not influence the circle move A Circle Move must always be preceeded by a waypoint under the same moveP Shared parameters The shared parameters in the bottom right corner of the Move screen apply to the movement from the previous position of the robot arm to the first waypoint un der the command and from there to each of the following waypoints The Move command settings do not apply to the path going from the last waypoint under that Move command Recalculate motions Tick this check box if the positions within this move command should be adjusted based on the active TCP TCP selection The TCP used for the waypoints under this Move command can be selected by ticking the check box and selecting a TCP from the drop down menu The selected TCP is then set as active each time the robot arm moves to one of the Waypoints under this Move command If the check box is not ticked then the active TCP is not modified in any way If the active TCP for this motion is determined during runtime of the program it needs to be set dynamically using the Set command see 13 10 or by using script command
24. robot It is an uncontrolled stop where the robot can deviate from the pro grammed path as each joint brake as fast as possible This protective stop is used if a safety related limit is exceeded or in case of a fault in the safety related parts of the control system For more information see EN 15013850 2008 or IEC60204 1 2006 Category 1 stop Robot motion is stopped with power available to the robot to achieve the stop and then removal of power when the stop is achieved It is a con trolled stop where the robot will continue along the programmed path Power is removed after one second or as soon as the robot stands still For more in formation see EN 15013850 2008 or IEC60204 1 2006 Category 2 stop controlled stop with power left available to the robot The robot can use up to one second to stop all motion The safety related control system monitors that the robot stays at the stop position For more information see IEC 60204 1 2006 Diagnostic coverage DC is a measure of the effectiveness of the diagnostics imple mented to achieve the rated performance level For more information see EN 15013849 1 2008 Integrator The integrator is the entity that designs the final robot installation The integrator is responsible for making the final risk assessment and must ensure that the final installation complies with local laws and regulations MTTFd The Mean time to dangerous failure MTTFd is a value based on calcu lations a
25. 19 EU Waste of Electrical and Electronic Equipment WEEE Declarations of conformity with the above Directives are included in the declara tion of incorporation in appendix B Version 3 1 I 45 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 8 2 Declarations According to EU directives A CE mark is affixed according to CE marking directives above Regarding waste of electric and electronic equipment see chapter 7 For information about standards applied during the development of the robot see appendix C UR5 CB3 I 46 Version 3 1 9 1 Product Warranty Without prejudice to any claim the user customer may have in relation to the dealer or retailer the customer shall be granted a manufacturer s Warranty under the conditions set out below In the case of new devices and their components exhibiting defects resulting from manufacturing and or material faults within 12 months of entry into service max imum of 15 months from shipment Universal Robots shall provide the necessary spare parts while the user customer shall provide working hours to replace the spare parts either replace the part with another part reflecting the current state of the art or repair the said part This Warranty shall be invalid if the device defect is attributable to improper treatment and or failure to comply with infor
26. 5 kg The test on the Joint 0 was carried out by performing a horizontal movement i e the axis of rotation was perpendicular to the ground During the tests for Joint 1 and 2 the robot followed a vertical trajectory i e the axes of rotation were parallel to the ground and the stop was performed while the robot was moving downwards Stopping Distance rad Stopping time ms Joint 0 BASE 0 31 244 Joint 1 SHOULDER 0 70 530 Joint 2 ELBOW 0 22 164 Version 3 1 1 49 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS A 1 CATEGORY 0 stopping distances and times UR5 CB3 I 50 Version 3 1 B 1 CE Declaration of Incorporation original According to European directive 2006 42 EC annex II 1 B The manufacturer Universal Robots A S Energivej 25 5260 Odense S Denmark 45 8993 8989 hereby declares that the product described below Industrial robot UR5 Robot serial number Control box serial number may not be put into service before the machinery in which it will be incorporated is declared to comply with the provisions of Directive 2006 42 EC as amended by Directive 2009 127 EC and with the regulations transposing it into national law The safety features of the product are prepared for compliance with all essential requirements of Direc tive 2006 42 EC under the correct i
27. By using the file filter one can limit the files shown to include the type of files that one wishes By selecting Backup Files the file selection area will display the latest 10 saved versions of each program where o1d0 is the newest and o1d9 is the oldest File field Here the currently selected file is shown The user has the option to manually enter the file name of a file by clicking on the keyboard icon to the right of the field This will cause an on screen keyboard to pop up where the user can enter the file name directly on the screen Open button Clicking on the Open button will open the currently selected file and return to the previous screen Cancel button Clicking on the Cancel button will abort the current loading pro cess and cause the screen to switch to the previous image Action buttons A series of buttons gives the user the ability to perform some of the actions that normally would be accessible by right clicking on a file name in a conventional file dialog Added to this is the ability to move up in the directory structure and directly to the program folder Parent Move up in the directory structure The button will not be enabled in two cases when the current directory is the top directory or if the screen is in the limited mode and the current directory is the program folder Goto program folder Go home Actions Actions such as create directory delete file etc CB3 I 40 Version 3 1 12 17 Run
28. CAUTION 1 The digital outputs in the tool are not current limited and overriding the specified data can cause permanent damage 4 4 4 4 Using the Tool Digital Outputs The example below illustrates how to turn on a load when using the internal 12V or 24V power supply Remember that you have to define the output voltage at the I O tab Keep in mind that there is voltage between the POWER connection and the shield ground even when the load is turned off Version 3 1 1 29 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 4 4 Tool I O 4 4 2 Tool Digital Inputs The digital inputs are implemented as PNP with weak pull down resistors This means that a floating input will always read low The electrical specifications are shown below Parameter Min Typ Unit Input voltage 0 5 26 V Logical low voltage 2 0 V Logical high voltage 5 5 V Input resistance 47k An example of how to use a digital input is shown in the following subsection 4 4 2 1 Using the Tool Digital Inputs The example below shows how to connect a simple button 4 4 3 Tool Analog Inputs The tool analog inputs are non differential and can be set to either voltage and current on the I O tab see part II The electrical specifications are shown below Parameter Min Typ
29. Cartesian space limiting robot TCP position TCP speed Max speed of the robot TCP TCP force Max pushing force of the robot TCP Momentum Max momentum of the robot arm Power Max applied robot arm power Advanced path control software decreases speed or issues a program execution stop if the robot arm approaches a safety related limit Violations of limits will hence only occur in exceptional cases Nevertheless if a limit is violated the safety system issues a category 0 stop with the performance listed in the table Version 3 1 1 35 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 5 1 Limiting Safety related Functions Figure 5 1 Certain areas of the workspace should receive attention regarding pinching hazards due to the physical properties of the robot arm One area is defined for radial motions when the wrist 1 joint is at a distance of at least 750 mm from the base of the robot The other area is within 200 mm of the base of the robot when moving in the tangential direction Worst Case Limiting Safety Trueness Detection De energizing Reaction Function Time Time Time Joint position 1 15 100 ms 1000 ms 1100 ms Joint speed 1 15 s 250 ms 1000 ms 1250 ms TCP position 20mm 100 ms 1000 ms 1100 ms TCP orientation 1 15 100 ms 1000 ms 1100 ms TCP speed 50 mm s 250 ms 1000 ms 125
30. Conveyor Tracking When using a conveyor the robot can be configured to track the movement of the conveyor Two program nodes are available for tracking a conveyor Start Version 3 1 I 73 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 28 Graphics Tab Conveyor Trackingand Stop Conveyor Tracking When the Conveyor Track ing defined in the installation is configured correctly a linear or circular conveyor can be tracked The nodes can be added from the Wizard Program nodes under the Structure tab When the program is executing between a Start Conveyor Tracking anda Stop Conveyor Tracking node the robot adjusts it s move ments to follow the conveyor 13 27 Command Suppress Suppressed program lines are simply skipped when the program is run A sup pressed line can be unsuppressed again at a later time This is a quick way to make changes to a program without destroying the original contents 13 28 Graphics Tab File 16 51 04 CCCC Q Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Variables Init Variables V Robot Program amp a 9 7 Move 9 Waypoint V MoveJ Waypoint 1 9 Variable Set ee Pallet ee Pattern Square 9 alst a2nd Corne 9 Cornet a4th s PalletS
31. I 83 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 14 6 Set Time Panel for setting up the Ethernet network An Ethernet connection is not necessary for the basic robot functions and is disabled by default 14 6 Set Time Setup Robot Initialize Robot Language and Units Update Robot Set Password Calibrate Screen Setup Network Set Time Back Set Time Time format Please select the current time o 24 hour 12 hour r 16 49 46 Set Date Please select today s date June 8 2015 Date format Q June 8 2015 Q Jun 2015 Q eens Restart PolyScope for new settings to take effect Restart Now Set the time and date for the system and configure the display formats for the clock The clock is displayed at the top of the Run Program and Program Robot screens Tapping on it will show the date briefly The GUI needs to be restarted for changes to take effect CB3 II 84 Version 3 1 The robot is equipped with an advanced safety system Depending on the particu lar characteristics of its workspace the settings for the safety system must be config ured to guarantee the safety of all personnel and equipment around the robot For details on the safet
32. TCP Configuration Input Output Setup Mounting Input Names Output Names yo Setup digital in O default digital out 0 default digital 1 default digital out 1 defaults vh Safety j digital in 2 default digital out 2 default Variables digital in 3 default digital out 3 default MODBUS client digital in 4 default digital out 4 default Features digital in 5 default digital out 5 default digital in 6 default digital out 6 default Conveyor Tracking a digital in 7 default digital out 7 default Default Program tool in 0 default tool out 0 defaults Load Save tool in 1 default tool out 1 default analog in 0 default analog out 0 default analog in 1 default analog out 1 default analog in 2 default i config out 0 default e Rename to Input and output signals can be given names This can make it easier to remember what the signal does when working with the robot Select an I O by clicking on it and set the name using the on screen keyboard You can set the name back by setting it to only blank characters The eight standard digital inputs and the two tool inputs may configured to trigger an action Available actions include the ability to start the current program stop the current program pause the current program and enter leave Freedrive mode when the input is high lo
33. Tab UNIVERSAL ROBOTS 12 17 Run Tab File 16 49 53 CCCC O Run Move 1 0 Log UNIVERSAL ROBOTS Variables Program ABCDE Status Stopped Time 0000d00h00m45 232s This tab provides a very simple way of operating the robot arm and control box with as few buttons and options as possible This can be usefully combined with password protecting the programming part of PolyScope see 14 3 to make the robot into a tool that can run exclusively pre written programs Furthermore in this tab a default program can be automatically loaded and started based on an external input signal edge transition see 12 14 The combination of auto loading and starting of a default program and auto initialization on power up can for instance be used to integrate the robot arm into other machinery Version 3 1 41 Copyright 2009 2015 by Universal Robots A S All rights reserved 12 17 Run Tab UNIVERSAL ROBOTS penJesei suu S v sioqog jesienum Aq s L02 6002 1uBuKdoo Version 3 1 II 42 CB3 13 Programming 13 1 New Program File 16 49 57 CCCC g M Program New Program Load From File Use Template Pick and Place Empty Program A new robot program can start from either a template or from an existing saved robot program A template can provide the overall program structure so only the details of t
34. a collection of program lines Set amp Pallet Please enter text to be displayed in the program tree ee Pattern amp PalletSequence 9 Approach 9 TM Set Wait 9 Exit ee Destack StartPos e Direction 1 9 FromPos 9 ToPos PickSequence 9 StackPos e Set Wait 9 Exit Wait V Folder o Folder lt gt Hide Folder Program Tree simulation Ke gt Speed 100 Previous Next gt o Real Robot A folder is used to organize and label specific parts of a program to clean up the program tree and to make the program easier to read and navigate A folder does not in itself do anything 13 15 Command Loop File 16 50 06 CCCC Program Installation Move I O Log fl lt unnamed gt Graphics Structure Variables 9 Waypoint a Set Loop e Pallet Pattern e PalletSequenc 9 Approach 9 PatternPoin Set Wait Loop times using variable Loop 1 9 Exit E ee Destack StartPos Loop as long as the following expression is true e Direction 9 FromPos pem o ToPos fod SESS o PickSequence 9 StackPos Set Wait 9 Exit IE o Please select how many times the program in this loop should be executed o Loop always o Check exp
35. a poor grip or power interruption 9 Mistakes due to different emergency stop buttons for different machines Information on stopping times and stopping distances are found in appendix A 1 8 Emergency Stop Activate the emergency stop button to immediately stop all robot motion Emergency stop shall not be used as a risk reduction measure but as a secondary protective device The risk assessment of the robot application shall conclude if more emergency stop buttons must be connected Emergency stop buttons should comply with IEC 60947 5 5 see more in section 4 3 2 1 9 Movement Without Drive Power In the unlikely event of an emergency situation where one or more robot joints need to be moved and robot power is either not possible or unwanted there are two different ways to force movements of the robot joints 1 Forced back driving Force a joint to move by pushing or pulling the robot arm hard 500 N Each joint brake has a friction clutch which enables movement during high forced torque 2 Manual brake release Remove the joint cover by removing the few M3 screws that fix it Release the brake by pushing the plunger on the small electromag net as shown in the picture below WARNING 1 Moving the robot arm manually is intended for urgent emer gencies only and might damage the joints 2 If the brake is released manually gravitational pull can cause the robot arm to fall Always support the robot arm to
36. be useful in complex programs 13 18 Command If File Program Installation Move 1 0 Log 16 50 09 CCCC Q lt unnamed gt Command Graphics Structure Variables Set Wait 9 Exit If ee Destack ee Direction be executed 9 StartPos Depending on the state of the given sensor input or program variable the following lines will FromPos ToPos If ee PickSequence L 9 StackPos C Check expression con Set Wait 9 Exit Wait V Folder Comment Halt Popup V Loop Bl Script var 2 22 force P Call SubProgram 1 V IF tinuously lt empty gt Add Elself l Remove Elself SubProgram 1 X ll U addeise lt gt _ o Real Robot o bl Speed 10096 Previous Next gt An if else construction can make the robot change its behavior based on sensor inputs or variable values Use the expression editor to describe the condition under which the robot should proceed to the sub commands of this 1 f If the condition is evaluated to True the lines inside this are executed Each If can have several ElseIf and one 1 using the buttons on the screen An i screen for that command ElseIl Else command These can be added command can be removed from the The open Check Expressi
37. between program executions The vari able will get its value from the expression if the program is run for the first time or if the value tab has been cleared A variable can be deleted from the program by setting its name to blank only spaces Version 3 1 II 77 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 31 Command Variables Initialization CB3 II 78 Version 3 1 Setup Robot Initialize Robot Language and Units Update Robot Set Password Calibrate Screen Setup Network Polyscope 3 1 17784 Jun 08 2015 Set Time Back Initialize Robot Goes to the initialization screen see 10 4 Language and Units Configure the language and units of measurements for the user interface see 14 1 Update Robot Upgrades the robot software to a newer version see 14 2 Set Password Provides the facility to lock the programming part of the robot to people without a password see 14 3 Calibrate Screen Calibrates the touch of the touch screen see 14 4 Setup Network Opens the interface for setting up the Ethernet network for the robot control box see 14 5 Set Time Set the time and date for the system and configure the display for mats for the clock see 14 6 Back Returns to the Welcome Screen I 79 CB3
38. have the conflicting variables renamed automat ically 12 11 Installation MODBUS client I O Setup File 16 50 26 CCCC Program Installation Move Log TCP Configuration MODBUS client IO Setup S Mounting 10 0 0 1 Setup IP 10 0 0 1 fi amnad Safety m a o Digital Output 0 285 MODBUS En Variables MODBUS client 10 0 0 2 Features Conveyor Tracking Default Program o o Register Output ka Load S 1 lel D Digital Input z 0 novus E C Show advanced options Here the MODBUS client master signals can be set up Connections to MOD BUS servers or slaves on specified IP addresses can be created with input output signals registers or digital Each signal has a unique name so it can be used in programs Refresh Push this button to refresh all MODBUS connections Add unit Push this button to add a new MODBUS unit Delete unit Push this button to delete the MODBUS unit and all signals on that unit Version 3 1 I 29 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 11 Installation MODBUS client I O Setup Set unit IP Here the IP address of the MODBUS unit is
39. in installations where the risk assessment allows it Tools and obstacles shall not have sharp edges or pinch points Make sure that all personnel remain outside the reach of the robot arm 12 2 I O Tab File Program Installation Move 1 0 Log 16 50 53 CCCC Q Robot MODBUS client Analog output analog out 0 4mA 20mA Current Digital Input 00 04 190 905 20 06 30 07 Analog input analog in 0 analog in 1 0 00 V Voltage v 0 00 V Voltage ov 10v ov 10v Digital Output og ga 1 5 20 6 30 97 analog 1 Tool Input Digital o0 o1 analog in 2 0 00 V analog in 3 Voltage MA Tool Output Digital Qo Qi Voltage current 4 4mA 20mA 0 12 24 Voltage v Current simulation o Real Robot On this screen you can always monitor and set the live I O signals from to the robot control box The screen displays the current state of the I O inluding during program execution If anything is changed during program execution the program will stop At program stop all output signals will retain their states The screen is updated at only 10Hz so a very fast signal might not display properly Configurable I O s can be reserved for special safety settings defined in the safety I O configuration section of the installaton se
40. integrators UR has chosen to certify their robots at the following recognized test institutes T V NORD UR robots are safety approved by T V NORD a notified body under the machinery directive 2006 42 EC in EU A copy of the T V NORD safety approval certificate can be found in ap pendix B DELTA UR robots are safety and performance tested by DELTA An electromagnetic compatibility EMC certificate can be found in appendix B An en vironmental test certificate can be found in ap pendix B 8 2 Declarations According to EU directives EU declarations are primarily relevant for European countries However some countries outside Europe recognize or even require them too European directives are available from the official homepage http eur lex europa eu UR robots are certified according to the directives listed below 2006 42 EC Machinery Directive MD UR Robots are partly completed machinery according to the Machinery Directive 2006 42 EC Note that a CE mark is not affixed according to this directive for partly completed machinery If the UR robot is used in a pesticide application then note the presence of directive 2009 127 EC The declaration of incorporation according to 2006 42 EC annex II 1 B is shown in appendix B 2006 95 EC Low Voltage Directive LVD 2004 108 EC Electromagnetic Compatibility EMC 2011 65 EU Restriction of the use of certain Hazardous Substances RoHS 2012
41. is essential In PolyScope motions of the tool are given using a series of waypoints i e points in the robot s workspace A waypoint can be given by moving the robot to a certain position or it can be calculated by software In order to move the robot arm to a certain position use either the Move tab see 12 1 or simply pull the robot arm into place while holding the Freedrive button at the back side of the teach pendant Besides moving through waypoints the program can send I O signals to other ma chines at certain points in the robot s path and perform commands like if then and loop based on variables and I O signals To create a simple program on a robot that has been started up do the following 1 Touch the Program Robot button and select Empty Program N Touch the Next button bottom right so that the lt empty gt line is selected in the tree structure on the left side of the screen Go to the Structure tab Touch the Move button Go to the Command tab Press the Next button to go to the Waypoint settings Press the Set this waypoint button next to the picture Oo B On the Move screen move the robot by pressing the various blue arrows or move the robot by holding the Freedrive button placed on the backside of the teach pendant while pulling the robot arm Version 3 1 II 5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright
42. list its contents To perform an update select a file click Update and follow the on screen instructions WARNING Always check your programs after a software upgrade The up grade might change trajectories in your program The updated software specifications can be found by pushing the button lo cated at the top right corner of the GUI Hardware specifications remain the same and can be found in the original manual Version 3 1 II 81 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 14 3 Set Password 14 3 Set Password Setup Robot Initialize Robot Language and Units Update Robot Set Password Calibrate Screen Setup Network Set Time Back Change System Password Passwords ensure changes to the robots functionality and behavior are protected Any areas where modifications can be made will be secured Password Confirm password Apply Change Safety Password To set a password for the Safety Configuration enter and confirm a new password then click the button To clear the password enter current password and click the button Enter current password Password Confirm password Apply Two passwords are supported The first is an optional System password which pre vents unauthorized m
43. of ticks the encoder generates when the conveyor rotates one full revolution 12 14 Installation Default Program File 16 50 26 CCCC Q Program Installation Move 1 0 Log TCP Configuration Set Default Program Mounting Setup Default Program File A Safety Automatically load a default program when the robot is turned on variables O Load default program MODBUS client No Program Selected Features Select Default Program Conveyor Tracking A If the Auto Initialize option below is enabled too the robot can start moving on ower up Default Program a C Auto Start the default program in the Run Tab On edge to Auto Initialize fal Load Save Automatically initialize the robot when the main power is turned on The robot can move due to the brake releasing procedure O Auto brake release the robot On lt Di Input gt Y edge to Low v This screen contains settings for automatically loading and starting a default pro gram and for auto initializing the robot arm on power up WARNING If auto load auto start and auto initialize all three are enabled the robot will start running the selected program as soon as the control box is powered up II 36 Version 3 1 12 14 Installation Default Program UNIVERSAL ROBOTS 12 14 1 Loading a Default Program A default program can be chosen to be loa
44. percent age is the maximum achievable speed for the running program without violating the safety limits To the left of the Dashboard the Simulation and Real Robot buttons toggle be tween running the program in a simulation or running it on the real robot When running in simulation the robot arm does not move and thus cannot damage itself or any nearby equipment in collisions Use simulation to test programs if unsure about what the robot arm will do DANGER 1 Make sure to stay outside the robot workspace when the Play button is pressed The movement you programmed may be different than expected 2 Make sure to stay outside the robot workspace when the Step button is pressed The function of the Step button can be difficult to understand Only use it when it is absolutely necessary Make sure to always test your program by reducing the speed with the speed slider Logic programming errors made by the integrator might cause unexpected movements of the robot arm 4 When a emergency stop or protective stop has occured the robot program will stop It can be resumed as long as no joint has moved more than 10 When pressing play the robot will move slowly back onto the trajectory and continue program execution While the program is being written the resulting motion of the robot arm is illus trated using a 3D drawing on the Graphics tab described in 13 28 Next to each program command is a small icon which is eit
45. robot arm or control box UR5 CB3 1 42 Version 3 1 UR robots must be disposed of in accordance with the applicable national laws regulations and standards UR robots are produced with restricted use of hazardous substances to protect the environment as defined by the European RoHS directive 2011 65 EU These sub stances include mercury cadmium lead chromium VI polybrominated biphenyls and polybrominated diphenyl ethers Fee for disposal and handling of electronic waste of UR robots sold on the Danish market is prepaid to DPA system by Universal Robots A S Importers in countries covered by the European WEEE Directive 2012 19 EU must make their own regis tration to the national WEEE register of their country The fee is typically less than 1 robot A list of national registers can be found here https www ewrn org national registers The following symbols are affixed on the robot to indicate conformity with the above legislations ome RoHS Version 3 1 1 43 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS penJesei suu S v sioqog jesienum Aq s L02 6002 1uBuKdoo Version 3 1 I 44 UR5 CB3 This chapter presents a range of different certifications and declarations that have been prepared for the product 8 1 Third Party Certifications Third party certifications are voluntary However to provide the best service to robot
46. safety planes can be configured The constraint on the orientation of tool can be utilized to ensure that the robot tool orientation does not deviate more than a certain specified amount from a desired orientation WARNING Defining safety planes only limits the TCP and not the overall limit for the robot arm This means that although a safety plane is spec ified it does not guarantee that other parts of the robot arm will obey this restriction The configuration of each boundary limit is based on one of the features defined in the current robot installation see 12 12 CB3 I 94 Version 3 1 15 11 Boundaries UNIVERSAL ROBOTS NOTE It is highly recommended that you create all features needed for the configuration of all the desired boundary limits and assign them appropriate names before editing the safety configuration Note that since the robot arm is powered off once the Safety tab has been unlocked the Too1 feature containing the current po sition and orientation of the robot TCP as well as Freedrive mode see 12 1 5 will not be available When in Freedrive mode see 12 1 5 and the current position of the robot TCP is close to a safety plane or the deviation of the orientation of the robot tool from the desired orientation is close to the specified maximum deviation the user will feel a repelling force which increases in magnitude as the TCP approaches the limit The force is generated when the TCP is with
47. section 4 3 Version 3 1 I 17 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 4 2 Electrical warnings and cautions Copyright 2009 2015 by Universal Robots A S All rights reserved DANGER 1 Make sure that all equipment not rated for water exposure remains dry If water comes inside the product lockout and tagout all power and then contact your supplier 2 Use original cables supplied with the robot only Do not use the robot for applications where the cables will be subjected to flexing Contact your supplier if longer or flexible cables are needed 3 Minus connections are referred to as GND and are con nected to the shield of the robot and the controller box AII mentioned GND connections are only for powering and sig nalling For PE Protective Earth use the M6 sized screw con nections marked with earth symbols inside the control box The grounding conductor shall have at least the current rat ing of the highest current in the system 4 Care must be taken when installing interface cables to the robot I O The metal plate in the bottom is intended for inter face cables and connectors Remove the plate before drilling the holes Make sure that all shavings are removed before reinstalling the plate Remember to use correct gland sizes CAUTION 1 The robot has been tested according to international IEC stan dards for EMC ElectroMagnetic Compati
48. sideration during risk assessment CB3 Il 66 Version 3 1 13 23 Command Force UNIVERSAL ROBOTS File 16 50 20 CCCC Q Program Installation Move Log lt unnamed gt Command Graphics Structure Variables Wait V Folder Force e lt empt E Comment Feature Base Type Simple x Halt Popup V Loop Bl Script var 2 22 force r The program part under this force command p Call SubProgram 1 will be run in force mode In force mode the V if E robot will be free in the direction of the e lt empty gt selected feature to apply the specified force 5 Pallet e Pd ee Pattern Use the test button below in combination with l the freedrive button on the Teach Pendant to PalletSequence Force 0 0 N Approach n test the force mode 9 PatternPoint e Set Wait 9 Exit 1 Test P SubProgram 1 e Event lt empty gt V Thr V Force 4 Il gt a Q simulation pi Speed 100 Previous Next gt o Real Robot L Feature selection The Feature menu is used to select the coordinate system axes the robot will use while it is operating in force mode The features in the menu are those which have been defined in the installation see 12 12 Force mode type The are four different types of force mode e
49. that is on the Teach Pendant This will provide the same functionality that the Emergency Stop button provides on the Teach Pendant when a device complying with ISO 13850 2006 is attached Reduced Mode safety limits have two modes in which they can be ap plied Normal mode which specifies the default safety configuration and Re duced mode see 15 5 for more details When this input safety function is selected a low signal given to the inputs causes the safety system to transi tion to Reduced mode If necessary the robot arm then decelerates to satisfy the Reduced mode limit set Should the robot arm still violate any of the Re duced mode limits it performs a category 0 stop The transition back to Normal mode happens in the same manner Note that safety planes can also cause a transition to Reduced mode see 15 11 3 for more details Version 3 1 II 101 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 12 Safety I O Safeguard Reset If Safeguard Stop is wired in the safety I Os then Safeguard Reset is used to ensure the Safeguard Stopped state continues until a reset is triggered The robot arm will not move when in Safeguard Stopped state WARNING By default the Sa eguard Reset input function is configured for input pins 0 and 1 Disabling it altogether implies that the robot arm ceas
50. to be saved to be preserved after power down If there are unsaved changes in the installation a floppy disk icon is shown next to the Load Save text on the left side of the Installation tab Saving an installation can be done by pressing the Save or Save As button Alternatively saving a program also saves the active installation To load a different installation file use the Load button The Create New button resets all of the settings in the Robot Installation to their factory defaults CAUTION Using the robot with an installation loaded from a USB drive is not recommended To use an installation stored on a USB drive first load it and then save it in the local programs folder using the Save As button CB3 22 Version 3 1 12 6 Installation TCP Configuration UNIVERSAL ROBOTS 12 6 Installation TCP Configuration Q File 16 50 22 CCCC Q Program Installation Move Log Configuration Setup for the Tool Center Point Mounting Available TCPs Setup r Set as default Qs Safety n X 0 9 mm 9 Variables w Y 0 0 X Position MODBUS client S Features L 00 TENI si orisntation 9 9 Conveyor Tracking RX 0 0000 Default Program RY 0 0000 Load Save RZ 0 0000 i Payload 0 00 kg L Center of gravity ell 7 A Tool Center Point is a characteristic po
51. to conduct the risk assessment The risk assessment shall consider two scenarios Teaching the robot while developing the robot installation Normal operation of the robot installation If the robot is installed in a non collaborative installation E g when using a haz ardous tool the risk assessment might conclude that the integrator needs to connect additional safety devices E g an enable device to protect him while program ming Universal Robots has identified the potential significant hazards listed below as hazards which must be considered by the integrator Note that other significant hazards might be present in a specific robot installation Version 3 1 1 7 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 1 9 Movement Without Drive Power 1 Entrapment of fingers between robot foot and base joint 0 2 Entrapment of fingers between wrist 1 and wrist 2 joint 3 and joint 4 3 Penetration of skin by sharp edges and sharp points on tool or tool connector 4 Penetration of skin by sharp edges and sharp points on obstacles near the robot track Bruising due to stroke from the robot 6 Sprain or bone fracture due to strokes between a heavy payload and a hard surface 7 Consequences due to loose bolts that hold the robot arm or tool 8 Items falling out of tool e g due to
52. to the current state They are defined below CB3 Il 86 Version 3 1 15 3 Tolerances UNIVERSAL ROBOTS Configuration Synchronized Shows the GUI installation is identical to the cur rently applied Safety configuration No changes have been made Configuration Altered Shows the GUL installation is different from the currently applied Safety configuration When editing the Safety configuration the shield icon will inform you whether or not the current settings have been applied If any of the text fields in the Safety tab contain any invalid input the Safety configuration is in an error state This is indicated in several ways A red error icon is displayed next to the text Safety on the left side of the screen The subtab s with errors are marked with a red error icon at the top Text fields containing errors are marked with a red background When errors exist and attempting to navigate away from the Installation tab a dialog appears with the following options 1 Resolve the issue s so that all errors have been removed This will be visible when the red error icon is no longer displayed next to the text Safety on the left side of the screen 2 Revert back to the previously applied Safety configuration This will disregard all changes and allow you to continue to the desired destination If no errors exist and attempting to navigate away a different dialog appears with the following options 1
53. used for the following e MODBUS I O expansion modules See more in part II Remote access and control The electrical specifications are shown below Parameter Min Typ Max Unit Communication speed 10 x 100 Mb s Version 3 1 1 31 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 4 6 Mains connection 4 6 Mains connection The mains cable from the controller box has a standard IEC plug in the end Con nect a country specific mains plug or cable to the IEC plug In order to energize the robot the control box must be connected to the mains This must be done through the standard IEC C20 plug at the bottom of the control box through a corresponding IEC C19 cord see illustration below The mains supply shall be equipped with the following as a minimum Connection to earth Main fuse Residual current device It is recommended to install a main switch to power of all equipment in the robot application as an easy means for lockout and tagout under service The electrical specifications are shown in the table below Parameter Min Typ Unit Input voltage 100 240 External mains fuse 100 200V 8 16 A External mains fuse 8 200 240V 8 16 A Input frequency 47 63 Hz Stand by power 0 5 W Nominal operating power 90 150 325 W UR5 CB3 1 32 Ver
54. 0 I 52 Environmental Test Certificate 5 s s 2 2 2 1 53 B 4 EMC Test Certificate 2 4 4 4 4 4 I 54 C Applied Standards I 55 D Technical Specifications I 61 PolyScope Manual II 1 10 Introduction II 3 10 4 Getting Started s s e s 9o xoc wo koc co Yo wx 3 x o a 3 10 1 1 Installing the Robot Arm and Control ee ee II 3 10 1 2 Turning the Control Box On and Off e 4 10 1 3 Turning the Robot Arm On and Off 4 10 14 2 2 2 II 4 10 1 5 The First Program a II 5 10 2 PolyScope Programming Interface a Il 6 103 Welcome Screen 4 4 4 4 4 44 4 II 8 10 4 Initialization Screen 4 2 4 ll 4 4 4 4 2 2 9 UR5 CB3 iv Version 3 1 UNIVERSAL ROBOTS 11 On screen Editors II 11 111 On screen Keypad II 11 11 2 On screen Keyboard II 12 11 3 On screen Expression Editor II 12 11 4 Pose Editor Screen II 13 12 Robot Control II 17 121 MoveTab II 17 12 1 1 Robot 2 II 17 12 1 2 Feature and Tool Position II 18 12 1 3 Move Tool II 18 12 1 4 Move Joints II 18 12 1 5 Freedrive II 18 122 I OTab um II 19 123 MODBUS client I O II 20 124 AutoMove Tab II 20 12 5 Installation gt Load Save II 22 12 6 Installation TCP Configuration II 23 12 6 1 Adding modifying and removing TCPs II 23 12 6 2
55. 0 ms TCP force 25N 250 ms 1000 ms 1250 ms Momentum 3kgm s 250 ms 1000 ms 1250 ms Power 10W 250 ms 1000 ms 1250 ms The system is considered de energized when the 48 V bus voltage reaches an electri cal potential below 7 3 V The de energizing time is the time from a detection of an event until the system has been de energized WARNING There are two exceptions to the force limiting function that are im portant to notice when designing the work cell for the robot These are illustrated in Figure 5 1 As the robot stretches out the knee joint effect can give high forces in the radial direction away from the base but at the same time low speeds Similarly the short leverage arm when the tool is close to the base and moving tan gential around the base can cause high forces but also at low speeds Pinching hazards can be avoided for instance by removing obstacles in these areas placing the robot differently or by using a combination of safety planes and joint limits to remove the hazard by preventing the robot moving into this region of its workspace UR5 CB3 1 36 Version 3 1 rev 17782 5 2 Safety Modes UNIVERSAL ROBOTS 5 2 Safety Modes Normal and Reduced mode The safety system has two configurable safety modes Normal and Reduced Safety limits can be configured for each of these two modes Reduced mode is active when the robot TCP is positioned beyond a Trigger Reduced mode plane or when triggered by
56. 2 ee ee a 1 5 16 IntendedUse s aa ee 1 7 17 Risk Assessment 2 2 1 7 18 EmergencyStop s sos soa acus s s t o Pos I 8 19 Movement Without Drive Power 5 2 5 4 I 8 2 Transportation I 11 3 Mechanical Interface 1 13 31 Workspace of the Robot 2 2 1 13 3 2 Mounting lt s 4 amp amp 4 Rowe OR od sh oe boa I 13 4 Electrical Interface I 17 41 Introduction 4 2 4 s s 4 4 s s s I 17 42 Electrical warnings and cautions ee ll ll ll s I 17 43 ControlerI O s 1 19 43 1 Common specifications for all digital I O 119 43 2 SafetyI O 2 2 o uoc ok odo X dp on de cx X Y oe od I 20 43 3 General purpose digital I O 0 0 I 24 43 4 Digital input from a button s a I 24 4 3 5 Communication with other machines or PLCs 1 25 4 3 6 General purpose analog I O 2 125 43 7 Remote ON OFF control 2 2 2 2 I 27 4A TOLO S uc mox ln XD OR We oS XS Wess I 28 441 Tool Digital Outputs a 1 29 44 2 Tool Digital Inputs 2 2 a I 30 443 ToolAnalogInputs
57. 2 22 force P Call SubProgram 1 Yf SubProgram 1 X il simulation gt Speed 00 Previous Next o Real Robot A call to a sub program will run the program lines in the sub program and then return to the following line 13 17 Command Assignment File 165008 CCCC Program Installation Move I O Log lt unnamed gt f Command Graphics Structure Variables ee Pattern a Eu Source Expression v e PalletSequenc i yea ini Assignment 9 PatternPoin Set Assigns the selected variable with the value of the expression Wait 9 Exit Variable Expression s Destack 9 StartPos e Direction var 2 x 2 force 9 FromPos ToPos Rename o PickSequence 9 StackPos Set Wait 9 Exit Wait V Folder Comm Halt Popup V Loop Script EN var 2 2 force 4 Il j lt gt Simulation b Speed 710096 Previous Next gt o Real Robot CB3 II 60 Version 3 1 rev 17782 13 18 Command If UNIVERSAL ROBOTS Assigns values to variables An assignment puts the computed value of the right hand side into the variable on the left hand side This can
58. 33 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 12 Installation Features File Program Installation Move 1 0 Log 16 50 33 CCCC Q TCP Configuration Mounting Setup 9 Safety Variables MODBUS client Features Base Tool X Point 1 Conveyor Tracking Default Program fl Load Save Point_1 Show axes Joggable Variable Rename ER Delete Move robot here Change this point Add Line Push this button to add a line feature to the installation A line is defined as an axis between two point features This axis directed from the first point towards the second point will constitute the y axis of the line coordinate system The z axis will be defined by the projection of the z axis of the first sub point onto the plane perpendicular to the line The position of the line coordinate system is the same as the position for the first sub point Q File 16 50 42 CCCC Q Program Installation Move 1 0 Log TCP Configuration Line 1 Delete Mounting ge VO Setup a Safety Variables MODBUS client Features 1 Base Tool 9 Line 1 X Point 1 NS X Po
59. 8 Pendant controls This section defines protective features for the teach pendant when it is to be used within a hazardous safeguarded space Since UR robots are power and force limited there is no hazardous safeguarded space like with traditional robots UR robots are safer to teach than traditional robots Instead of having to release a three positioning enabling device the operator can simply stop the robot with his hand 510 Collaborative operation requirements The power and force limiting function of UR robots is always active The visual design of the UR robots indicates that the robots are capable of being used for collaborative operations The power and force limiting function is designed according to clause 5 10 5 5 12 3 Safety rated soft axis and space limiting This safety function is one of more safety func tions configurable through software A hash code is generated from the sittings of all these safety functions and is represented as a safety check identifier in the GUI UR5 CB3 I 56 Version 3 1 UNIVERSAL ROBOTS ISO DTS 15066 Draft Robots and robotic devices Safety requirements for industrial robots Collaborative operation This is a Technical Specification TS under preparation A 5 is not a standard The purpose of a TS is to present a set of immature requirements to see if they are useful for a given industry This TS presents technologies and force related safety limits for collaborative ro
60. A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 12 Installation Features 12 12 Installation Features File 16 50 28 CCCC Program Installation Move 1 0 Log TCP Configuration Features Mounting Setup Qs Safety Variables MODBUS client Features Base Tool Conveyor Tracking Default Program Load Save Ep New Point Line Plane Customers that buy industrial robots generally want to be able to control or ma nipulate a robot arm and to program the robot arm relative to various objects and boundaries in the surroundings of the robot arm such as machines objects or blanks fixtures conveyers pallets or vision systems Traditionally this is done by defining frames coordinate systems that relate the internal coordinate system of the robot arm the base coordinate system to the relevant object s coordinate sys tem Reference can both be made to tool coordinates and to base coordinates of the robot arm A problem with such frames is that a certain level of mathematical knowledge is required to be able to define such coordinate systems and also that it takes a con siderable ammount of time to do this even for a person skilled in the art of robot programming and installation Often this task involves the calculation of 4x4 matri ces Particularly the represe
61. B3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 6 Command Fixed Waypoint waypoint has a blend radius the following I O command is executed when the robot arm enters the blend Example Program Starting point movel WaypointStart Straight line segment Waypoint Waypoint2 if digital_input 1 then Waypoint 1 WaypointEndl 5 cm blend else WaypointEnd2 Straight line segment endif Waypoint 2 10 cm blend This is where the input port is read Ending point 2 Ending point 1 A small example in which a robot program moves the tool from a starting position to one of two ending positions depending on the state of digital input 1 Notice that the tool trajectory thick black line moves in straight lines outside the blend areas dashed circles while the tool trajectory deviates from the straight line path inside the blend areas Also notice that the state of the digital input 1 sensor is read just as the robot arm is about to enter the blend area around Waypoint 2 even though the if then command is after Waypoint 2 in the program sequence This is somewhat counter intuitive but is necessary to select the right blend path CB3 II 52 Version 3 1 13 7 Command Relative Waypoint UNIVERSAL ROBOTS 13 7 Command Relative Waypoint
62. Collecting all documentation in a technical file Guidance on how to find and read applicable standards and laws is provided on http support universal robots com Version 3 1 1 3 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 1 4 Warning Symbols in this Manual 1 3 Limitation of Liability Any information given in this manual regarding safety must not be construed as a warranty by UR that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with 1 4 Warning Symbols in this Manual The table below defines the captions specifying the danger levels used throughout this manual The same warning signs are used on the product gt DANGER This indicates an imminently hazardous electrical situation which if not avoided could result in death or serious injury DANGER This indicates an imminently hazardous situation which if not avoided could result in death or serious injury WARNING This indicates a potentially hazardous electrical situation which if not avoided could result in injury or major damage to the equip ment WARNING This indicates a potentially hazardous situation which if not avoided could result in injury or major damage to the equipment WARNING This indicates a potentially hazardou
63. DI9 White Analog input 2 AI2 Brown Analog input 3 AI3 The internal power supply can be set to either 12V or 24V at the I O tab the GUI see part II The electrical specifications are shown below UR5 CB3 I 28 Version 3 1 4 4 Tool I O UNIVERSAL ROBOTS Parameter Min Unit Supply voltage in 24 mode 24 V Supply voltage in 12V mode 12 V Supply current in both modes 600 mA The following sections describe the different I O s of the tool DANGER 1 Construct tools and gripper so that an interruption of power does not create any hazards E g a work piece falling out of the tool 2 Take care when using 12V since an error made by the pro grammer can cause the voltage to change to 24V which might damage the equipment and cause a fire NOTE The tool flange is connected to GND same as the red wire 4 4 1 Tool Digital Outputs The digital outputs are implemented as NPN When a digital output is activated the corresponding connection is driven to GND and when it is deactivated the cor responding connection is open open collector open drain The electrical specifi cations are shown below Parameter Min Unit Voltage when open 0 5 26 V Voltage when sinking1A 005 020 V Current when sinking 0 gt 1 Current through GND 0 1 A An example of how to use a digital output is shown in the following subsection
64. Graphics Structure Variables Init Variables 4 V Robot Program Initial Variable Values V Move Waypoint V Move The variable Loop 1 has no initial value 9 Waypoint cnt 1 0 27 Set cnt_2 0 es Pallet interpolate 1 0 0 s Pattern Square alst Corner a2nd Corne Corner 9 a4th Cornen J 9 n The variable pose 1 has no initial value The variable pose 2 has no initial value The variable pose 3 has no initial value The variable var 2 has no initial value Approach 9 PatternPoin Set Wait 9 Exit e Destack 9 t S Variable Expression 9 FromPos 9 ToPos 9 PickSequence 1 9 StackPos Set EA I Rename Clear Expression aol simulation hed gt Speed c 100 Previous Next gt o Real Robot This screen allows setting variable values before the program and any threads start executing Select a variable from the list of variables by clicking on it or by using the variable selector box For a selected variable an expression can be entered that will be used to set the variable value at program start If the Prefers to keep value from last run checkbox is selected the variable will be initialized to the value found on the Variables tab described in 13 30 This permits variables to maintain their values
65. I O If more current is needed an external power supply can be connected as shown below The electrical specifications for both the internal and an external power supply are shown below Terminals Parameter Min Typ Unit Internal 24V power supply PWR GND Voltage 23 24 25 V PWR GND Current 0 2 A External 24V input requirements 24V OV Voltage 20 24 29 V 24V OV Current 0 6 The digital I O are constructed in compliance with 61131 2 The electrical spec ifications are shown below Terminals Parameter Min Unit Digital outputs COx DOx Current 0 1 A COx DOx Voltage drop 0 0 5 V Leakage current 0 01 mA COx DOx Function PNP Type COx DOx 61131 2 1A Type Digital Inputs EIx SIx CIx DIx Voltage 3 30 V EIx SIx CIx DIx OFF region 3 5 V EIx SIx CIx DIx ON region 11 30 V EIx SIx CIx DIx Current 11 30V 2 15 mA EIx SIx CIx DIx Function PNP EIx SIx CIx DIx IEC 61131 2 3 Type NOTE The word configurable is used for I O that can be configured as either safety related I O or normal I O These are the yellow terminals with black text 4 3 2 Safety I O This section describes the dedicated safety inputs Yellow terminal with red text and the configurable I O Yellow terminals with black text when configured as safety I O The common
66. NAK 19 13752 Revision 1 Other document s Conclusion The two robot arms URS and UR10 including their control box and teach pendant have been tested according to the below listed standards The test results are given in the DELTA report listed above The tests were carried out as specified and the test criteria for environmental tests as specified in Annex 1 of the report were fulfilled TEC 60068 2 1 Test Ae 5 C 16h 60068 2 2 Test Be 50 16h IEC 60068 2 64 Test Fh 5 20 Hz 0 05 g Hz 20 150 Hz 3 dB octave 1 66 grms 3 x 1 2 h IEC 60068 2 27 Test Ea Shock 160 g 1 ms 3 x 6 shocks Date Assessor p Horsholm 14 March 2014 adit CLL Susanne Otto B Sc E E B Com Org 20ass sheet j Version 3 1 1 53 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS B 4 EMC Test Certificate Copyright 2009 2015 by Universal Robots A S All rights reserved B 4 EMC Test Certificate EMC assessment sheet no 1277 DELTA client DELTA project no Universal Robots A S T207371 Energivej 25 5260 Odense S Denmark Product identification URS robot arm with control box and teach pendant UR5 AE CB3 URIO robot arm with control box and teach pendant UR10 AE CB3 DELTA report s EMC test of UR10 and URS project no T207371 DANAK 1913884 Other document s Conclus
67. OTS The Pattern command can be used to cycle through positions in the robot program The pattern command corresponds to one position at each execution Ho uH A pattern can be given as one of four types The first three Line Square or Box can be used for positions in a regular pattern The regular patterns are de fined by a number of characteristic points where the points define the edges of the pattern For Line this is the two end points for Square this is three of the four corner points where as for Box this is four of the eight corner points The pro grammer enters the number of positions along each of the edges of the pattern The robot controller then calculates the individual pattern positions by proportionally adding the edge vectors together If the positions to be traversed do not fall in a regular pattern the List option can be chosen where a list of all the positions is provided by the programmer This way any kind of arrangement of the positions can be realized Defining the Pattern When the Box pattern is selected the screen changes to what is shown below File 16 50 17 CCCC Program Installation Move Log lt unnamed gt Command Graphics Structure Variables Pallet 4 Pattern Box 9 alst Corner 9 a2nd Corner 9 a3rd Corner a8th Corner rename Change this Position 9 a6th Corner Move robot here 9 a7th Corne
68. OTS 12 5 Installation Load Save 12 5 Installation Load Save File 16 50 26 CCCC Q Program Installation Move 1 0 Log TCP Configuration Load Save Robot Installation to File Mounting The Robot Installation covers all aspects of how the robot is placed in its working Setup environment It includes the mechanical mounting of the robot electrical connections to other equipment as well as all options on which the robot program depends It does not vh Safety include the program itself Variables MODBUS client Save the current installation Features default Conveyor Tracking Save Save As Default Program Load a different installation file Load Save Load Create New The Robot Installation covers all aspects of how the robot arm and control box are placed in the working environment It includes the mechanical mounting of the robot arm electrical connections to other equipment as well as all options on which the robot program depends It does not include the program itself These settings can be set using the various screens under the Installation tab except for the I O domains which are set in the 1 0 tab see 12 2 Itis possible to have more than one installation file for the robot Programs created will use the active installation and will load this installation automatically when used Any changes to an installation need
69. SO 10218 2 is intended for the robot integrator as it deals with the installation and design of the robot application The writers of the standard implicitly envisioned traditional industrial robots which are traditionally safeguarded by fences and light curtains UR robots are designed with force and power limiting enabled at all times Therefore some concepts are clarified and explained below If a UR robot is used in a hazardous application additional safety measures might be required see chapter 1 of this manual Clarification 3 24 3 Safeguarded space is defined by the perimeter safeguarding Typically the safeguarded space is a space behind a fence which protects people from the hazardous traditional robots UR robots are designed to work without a fence using a built in power and force limiting safety func tion where there is no hazardous safeguarded space defined by the perimeter of a fence 5 42 Performance requirement All safety functions are constructed as PLd according to ISO 13849 1 2006 The robot is constructed with redundant encoder systems in each joint and the safety rated I Os are constructed with a category 3 structure The safety rated I Os must be connected accord ing to this manual to category 3 safety rated equipment to form a PLd structure of the complete safety function 5 7 Operating modes UR robots do not have different operating modes and therefore they do not have a mode selector 5
70. The default and the active TCP II 23 12 63 Teaching TCP position II 24 12 6 4 Teaching TCP orientation II 25 12 65 Payload II 25 12 6 6 Center of gravity II 25 127 Installation gt Mounting II 26 128 Installation I O Setup II 27 129 Installation Safety II 28 12 10 Installation Variables II 28 12 11 Installation MODBUS client I O Sedo II 29 12 12 Installation Features II 32 12 13 Conveyor Tracking Setup II 35 12 14 Installation Default Program 36 12 14 1 Loading a Default Program II 37 12 14 2 Starting a Default Program II 37 12 143 Auto Initialization II 37 12 15 Log Tab II 38 12 16 Load Screen II 38 12 17 Run Tab II 41 13 Programming II 43 13 1 New Program II 43 13 2 Program Tab II 44 13 2 1 Program Tree II 44 13 2 2 Program Execution Indication II 45 13 2 3 Undo Redo Buttons II 45 13 2 4 Program Dashboard II 45 Version 3 1 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 3 13 4 13 5 13 6 13 7 13 8 13 9 13 10 13 11 13 12 13 13 13 14 13 15 13 16 13 17 13 18 13 19 13 20 13 21 13 22 13 23 13 24 13 25 13 26 13 27 13 28 13 29 13 30 13 31 Variables Command Empty Command Move Command Fixed Waypoint Command Relative Waypoint Command Variable Waypoint Command Wait Command Set Command Popup Comman
71. UNIVERSAL ROBOTS User Manual UR5 CB3 Original instructions en UNIVERSAL ROBOTS User Manual UR5 CB3 Version 3 1 Original instructions en Serial number UR5 Serial number CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS The information contained herein is the property of Universal Robots A S and shall not be repro duced in whole or in part without prior written approval of Universal Robots A S The informa tion herein is subject to change without notice and should not be construed as a commitment by Universal Robots A S This manual is periodically reviewed and revised Universal Robots A S assumes no responsibility for any errors or omissions in this document Copyright O 2009 2015 by Universal Robots A S The Universal Robots logo is a registered trademark of Universal Robots A S UR5 CB3 ii Version 3 1 Preface ix What do the Boxes Contain 2 l4 4 ix Important Safety Notice How to Read This Manual Where to Find More Information I Hardware Installation Manual I 1 1 Safety I 3 11 Introduction s e s a w s E aw k I 3 12 Validity and Responsibility 2 2 2 2 I 3 13 Limitation of Liability 2 ll 8 1 4 14 Warning Symbols in this Manual s ll s 1 4 15 General Warnings and Cautions 2 2
72. Variable feature If any of the features in the currently loaded installation are se lected as variable these corresponding variables are also selectable in the fea ture selection menu If a feature variable named with the name of the fea ture suffixed by var is selected robot arm movements except to Relative waypoints are relative to the actual value of the variable when the program is running The initial value of a feature variable is the value of the actual feature as configured in the installation If this value is modified then the movements of the robot change II 50 Version 3 1 13 6 Command Fixed Waypoint UNIVERSAL ROBOTS 13 6 Command Fixed Waypoint File 16 51 01 CCCC Q Program Installation Move Log zi lt unnamed gt Command Graphics Structure Variables Init Variables V Robot Program Waypoint 1 Rename MoveJ Waypoint V Move e Waypoint 1 e Set Qe Pallet Pattern Square alst Corne 7 Change this Waypoint Fixed position Move robot here a2nd Corne Corne 9 a4th Cornel Palletseguencd 9 Approach 9 PatternPoint Set Wait 9 Exit Show advanced options e Destack 9 StartPos o Stop at this point 39 adis Blend with radius 9 FromPos 9 ToPos 9 PickSequence StackPos Add waypoint before Set 4 Il gt 4 Add way
73. a safety input On the side of the Trigger Reduced mode planes where the normal mode limit set is defined there is an area of 20mm where the reduced mode limit set is accepted When Reduced mode is triggered by a safety input both limit sets are accepted for 500 ms Recovery Mode When a safety limitis violated the safety system must be restarted If the system is outside a safety limit at start up e g outside a joint position limit the special Recovery mode is entered In Recovery mode it is not possible to run pro grams for the robot but the robot arm can be manually moved back within limits either by using Freedrive mode or by using the Move tab in PolyScope see part II of the PolyScope Manual The safety limits of Recovery mode are Limiting Safety Function Limit Joint speed 30 s TCP speed 250 mm s TCP force 100N Momentum 10 kgm s Power 80W The safety system issues a category 0 stop if a violation of these limits appears WARNING Notice that limits for the joint position the TCP position and the TCP orientation are disabled in Recovery Mode Take caution when moving the robot arm back within the limits 5 3 Safety related Electrical Interfaces The robot is equipped with several safety related electrical inputs and outputs safety related electrical inputs and outputs are dual channel They are safe when low e g the emergency stop is not active when the signal is high 24V 5 3 1 Safety
74. a small blue ball Note Release the button to stop the motion at any time 12 1 4 Move Joints Allows the individual joints to be controlled directly Each joint can move from 360 to 360 which are the default joint limits illustrated by the horizontal bar for each joint If a joint reaches its joint limit it cannot be driven any further If the limits for a joint have been configured with a position range different from the default see 15 10 this range is indicated with red in the horizontal bar 12 1 5 Freedrive While the Freedrive button is held down it is possible to physically grab the robot arm and pull it to where you want it to be If the gravity setting see 12 7 in the Setup tab is wrong or the robot arm carries a heavy load the robot arm might start moving falling when the Freedrive button is pressed In that case just release the Freedrive button again CB3 Il 18 Version 3 1 12 2 I O Tab UNIVERSAL ROBOTS WARNING 1 Make sure to use the correct installation settings e g Robot mounting angle weight in TCP TCP offset Save and load the installation files along with the program Make sure that the TCP settings and the robot mounting set tings are set correctly before operating the Freedrive but ton If these settings are not correct the robot arm will move when the Freedrive button is activated The freedrive function impedance backdrive shall only be used
75. ach determining the way in which the selected feature will be interpreted Simple Only one axis will be compliant in force mode The force along this axis is adjustable The desired force will always be applied along the z axis of the selected feature However for Line features it is along their y axis Frame The Frame type allows for more advanced usage Here compliance and forces in all six degrees of freedom can be independently selected Point When Point is selected the task frame has the y axis pointing from the robot TCP towards the origo of the selected feature The distance between the robot TCP and the origo of the selected feature is required to be at least 10 mm Note that the task frame will change at runtime as the position of the robot TCP changes The x and z axis of the task frame are dependent on the original orientation of the selected feature Motion Motion means that the task frame will change with the direction of the TCP motion The x axis of the task frame will be the projection of the TCP movement direction onto the plane spanned by the x and y axis of the selected feature The y axis will be perpendicular to the robot arm s motion and in the x y plane of the selected feature This can be usefull when debur ring along a complex path where a force is needed perpendicular to the TCP Version 3 1 II 67 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright
76. all arrow representing the plane normal which indicates the side of the plane on which the robot TCP is allowed to be positioned Trigger planes are displayed in blue and green and a small arrow pointing to the side of the plane where the Normal mode limits see 15 5 are active The tool orientation boundary limit is visualized with a spherical cone together with a vector indicating the current orientation of the robot tool The inside of the cone represents the allowed area for the tool orientation vector When the target robot TCP no longer is in the proximity of the limit the 3D rep resentation disappears If the target TCP is in violation or very close to violating a boundary limit the visualization of the limit turns red Feature and tool position In the top right corner of the screen the feature selector can be found The feature selector defines which feature to control the robot arm relative to Below the feature selector the name of the currently active Tool Center Point TCP is displayed For further information about configuring several named TCPs see 12 6 The text boxes show the full coordinate values of that TCP relative to the selected feature X Y and Z control the position of the tool while RX RY and RZ control the orientation of the tool Use the drop down menu above the RX RY and RZ boxes to choose the orientation representation Available types are Rotation Vector rad The orientation is given as a rota
77. all disk icon that can be clicked to quickly save the program In the program tree the command that is currently being executed is highlighted as described in 13 2 2 CB3 44 Version 3 1 13 2 Program Tab UNIVERSAL ROBOTS 13 2 2 Program Execution Indication File 16 49 54 CCCC Program Installation Move 1 0 Log StartABCDE Command Graphics Structure Variables V Robot Program Fixed position x V Move Rename Start ec e D Move robot here Change this Waypoint Show advanced options o Stop at this point G Blend with radius Add waypoint before Add waypoint after Remove this waypoint uu yp H Bn Speed E 710096 Previous Next gt Real Robot J CLLLOLU The program tree contains visual cues informing about the command currently be ing executed by the robot controller A small indicator icon is displayed to the left of the command icon and the name of the executing command and any commands of which this command is a sub command typically identified by the Y com mand icons are highlighted with blue This aids the user in locating the executing command in the tree For example if the robot arm is moving towards a waypoint the corresponding waypoint sub command is marked with the icon and its name together with the name of the Move command see 13 5 to which i
78. and actions at several different positions This can be useful for palletizing or similar operations A pallet t Fateor operation consist of the following features Set Wait Program Sequence to be performed at several positions 9 Exit The Pattern either given as a list or as a lattice amp Destack optional before start sequence that will be performed before the first position o StartPos An optional after end sequence that will be performed after the last position amp Direction 9 FromPos 9 ToPos 9 PickSequence 9 StackPos Set Wait 9 Exit Wait V Folder Comment Halt Popup V Loop e lt er Bl Script Optional program sequences I Ul C Special program sequence before the first point lt gt Special program sequence after the last point o el Speed 100 Previous Next gt Real Robot A pallet operation can perform a sequence of motions in a set of places given as a pattern as described in 13 22 At each of the positions in the pattern the sequence of motions will be run relative to the pattern position Programming a Pallet Operation The steps to go through are as follows 1 Define the pattern 2 Make a PalletSequence for picking up placing at each single point The sequence describes what should be done at each pattern position
79. ariables Installation variables are special because they keep their value even if a program is stopped and then started again and when the robot arm and or control box is powered down and powered up again Their names and values are stored with the installation so it is possible to use the same variable in multiple programs Create new installation variable Name Value var 1 Cancel Pressing Create New will bring up a panel with a suggested name for the new variable The name may be changed and its value may be entered by touching either text field The OK button can only clicked if the new name is unused in this installation It is possible to change the value of an installation variable by highlighting the variable in the list and then clicking on Edit Value CB3 28 Version 3 1 12 11 Installation MODBUS client I O Setup UNIVERSAL ROBOTS To delete a variable select it in the list then click Delete After configuring the installation variables the installation itself must be saved to keep this configuration see 12 5 The installation variables and their values are also saved automatically every 10 minutes If a program or an installation is loaded and one or more of the program variables have the same name as the installation variables the user is presented with two options to resolve the issue either use the installation variables of the same name instead of the program variable or
80. ase will be OK button If this screen was activated from the Move tab see 12 1 clicking the OK button will return to the Move tab where the robot arm will move to the specified target If the last specified value was a tool coordinate the robot arm will move to the target position using the MoveL movement type while the robot arm will move to the target position using the Move movement type if a joint position was specified last The different movement types are described in 13 5 Cancel button Clicking the Cancel button leaves the screen discarding all changes Version 3 1 II 15 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved 11 4 Pose Editor Screen UNIVERSAL ROBOTS penJesei suu S v sioqog jesienum Aq 6108 6002 1uBuKdoo Version 3 1 II 16 CB3 12 1 Move Tab On this screen you can always move jog the robot arm directly either by translat ing rotating the robot tool or by moving robot joints individually File 16 50 14 CCCC Program Installation Move Log Move Tool Robot Feature View 120 11 mm 431 76 mm 253 93 mm 0 0012 RY 3 1664 0 0395 lt Move Joints Home Ey aa Shoulder 98 96 Elbow E n
81. atures are available Choosing the Undefined item clears the configuration of the plane CB3 II 96 Version 3 1 15 11 Boundaries UNIVERSAL ROBOTS The z axis of the selected feature will point to the disallowed area and the plane normal will point in the opposite direction except when the Base feature is se lected in which case the plane normal will point in the same direction If the plane is configured as a Trigger Reduced mode plane see 15 11 3 the plane normal indi cates the side of the plane that does not trigger transition into Reduced mode It should be noted that when the safety plane has been configured by selecting a feature the position information is only copied to the safety plane the plane is not linked to that feature This means that if there are changes to the position or orientation of a feature which has been used to configure a safety plane the safety plane is not automatically updated If the feature has changed this is indicated by A icon positioned over the feature selector Click the amp button next to the selector to update the safety plane with the current position and orientation of the feature The A icon is also displayed if the selected feature has been deleted from the installation Safety mode The drop down menu on the right hand side of the Safety Plane Properties panel is used to choose the safety mode for the safety plane with the following modes available Disabled The safet
82. b folders under the programs folder Screen layout Load Program T _ Current Directory home hudson programs 7 tt o ll urcaps 3 lt ungenannt gt urpABCDE_NEW urp unnamed urpABCDE NEW urp ABCDE urp StartaBCDE urp Filename StartABCDE Filter Universal Robots Program files gt This image shows the actual load screen It consists of the following important areas and buttons Path history The path history shows a list of the paths leading up to the present location This means that all parent directories up to the root of the computer are shown Here you will notice that you may not be able to access all the directories above the programs folder By selecting a folder name in the list the load dialog changes to that directory and displays it in the file selection area 12 16 Version 3 1 II 39 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 16 Load Screen File selection area In this area of the dialog the contents of the actual area is present It gives the user the option to select a file by single clicking on its name or to open the file by double clicking on its name In the case that the user double clicks on a directory the dialog descends into this folder and presents its contents File filler
83. bility Disturbing signals with levels higher than those defined in the specific IEC standards can cause unexpected behavior of the robot Very high signal levels or excessive exposure can damage the robot permanently EMC problems are found to happen usu ally in welding processes and are normally prompted by error messages in the log Universal Robots cannot be held respon sible for any damages caused by EMC problems 2 I O cables going from the control box to other machinery and factory equipment may not be longer than 30m unless ex tended tests are performed NOTE voltages and currents are in DC Direct Current unless other wise specified UR5 CB3 1 18 Version 3 1 4 3 Controller I O UNIVERSAL ROBOTS 4 3 Controller I O This chapter explains how to connect equipment to I O inside the control box This I O is extremely flexible and can be used for wide range of different equipment including pneumatic relays PLCs and emergency stop buttons The illustration below shows the layout of electrical interface inside the control box Digital Inputs Digital Outputs 24V 24V OV OV DIO 014 IDO4 24V 24V OV OV DI1 015 DO1 DOS 24V 24V ov OV 012 016 002 24V 24V OV OV DI3 DI7 The meaning of the different colors must be observed see below Yellow with red text Dedicated safety
84. bot A modification might create haz ards that are unforeseen by the integrator All authorized reassembling shall be done according to the newest version of all relevant service manuals UNIVERSAL ROBOTS DIS CLAIMS ANY LIABILITY IF THE PRODUCT IS CHANGED OR MODIFIED IN ANY WAY If the robot is purchased with an extra module e g eu romap67 interface then look up that module in the respective manual WARNING 1 The robot and controller box generate heat during operation Do not handle or touch the robot while in operation or imme diately after operation To cool the robot down power off the robot and wait one hour Never stick fingers behind the internal cover of the controller box CAUTION 1 When the robot is combined with or working with machines capable of damaging the robot then it is highly recom mended to test all functions and the robot program sepa rately Itis recommended to test the robot program using tem porary waypoints outside the workspace of other machines Universal Robots cannot be held responsible for any damages caused to the robot or to other equipment due to program ming errors or malfunctioning of the robot Do not expose the robot to permanent magnetic fields Very strong magnetic fields can damage the robot UR5 CB3 1 6 Version 3 1 1 6 Intended Use UNIVERSAL ROBOTS 1 6 Intended Use UR robots are industrial and intended for handling tools and fixtures or for pro cessin
85. bots where the robot and the human work together to perform a work task Universal Robots is an active member of the international committee that develops this 5 ISO TC 184 SC 2 A final version might be published in 2016 ANSI RIA R15 06 2012 Industrial Robots and Robot Systems Safety Requirements This American standard is the ISO standards ISO 10218 1 see above and ISO 10218 2 combined into one document The language is changed from British English to American English but the content is the same Note that part two ISO 10218 2 of this standard is intended for the integrator of the robot system and not Universal Robots CAN CSA Z434 14 Industrial Robots and Robot Systems General Safety Requirements This Canadian standard is the ISO standards ISO 10218 1 see above and 2 combined into one docu ment CSA added additional requirements for the user of the robot system Some of these requirements might need to be addressed by the robot integrator Note that part two ISO 10218 2 of this standard is intended for the integrator of the robot system and not Universal Robots IEC 61000 6 2 2005 IEC 61000 6 4 A1 2010 EN 61000 6 2 2005 2004 108 EC EN 61000 6 4 A1 2011 2004 108 EC Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments Part 6 4 Generic standards Emission standard for industrial environments These standards define requirements for t
86. ch pendant can be hung on a wall or on the control box Extra brackets for mounting the teach pendant can be bought Make sure that no one can trip over the cable DANGER 1 Make sure that the control box teach pendant and cables do not come into contact with liquids wet control box could cause death 2 The control box and teach pendant must not be exposed to dusty or wet environments that exceed IP20 rating Pay spe cial attention to environments with conductive dust UR5 CB3 1 14 Version 3 1 3 2 Mounting UNIVERSAL ROBOTS Surface on which the robot is fitted It should be flat within 0 05mm SJ Ww Outer diameter of robot ed _____ 58 5 mounting flange muet un OR 132 10 5 149 Figure 3 1 Holes for mounting the robot Use four 8 bolts All measurements mm Version 3 1 1 15 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 3 2 Mounting Copyright 2009 2015 by Universal Robots A S All rights reserved 6 5 0 1 SONS TQ 1 RRN i RSS SSS SS ME g ENNEN ON N BE BN AE 8 d aes Figure 3 2 The tool output flange ISO 9409 1 50 4 6 This is where the tool is mounted at the tip of the robot All measures are in mm UR5 CB3 1 16 Version 3 1
87. configured to perform a safety function 4 3 3 1 Load controlled by a digital output This example shows how to connect a load to be controlled from a digital output see below Digital Outputs 4 3 4 Digital input from a button The example below shows how to connect a simple button to a digital input Digital Inputs 24 24V M DIO Bl 014 24V W 24V DI1 l 015 24 24V E DI2 W 016 E 24V 22 E DI3 W 017 E UR5 CB3 I 24 Version 3 1 4 3 Controller I O UNIVERSAL ROBOTS 4 3 5 Communication with other machines or PLCs The digital I O can be used to communicate with other equipment if a common GND is established and if the machine uses PNP technology see below Digital Inputs Digitaf Outputs igital Inputs Digital Outputs 24V W 24V I OV ov 24 24V M ov Doo DIO poa m 24V E 24v 24 2av m m ov m DIL 015 D01 bos m 015 88 po1N pos m 24V W 24V OV I OV I 24v M 24v M ov M H DI2 Bi Di6 W DOG NI DI2 W 016 I W DOG m 24V 24 W OV INI OV NI 24V N 24v N ov M OV i DI3 W 017 DO7 DI3 B 017 8
88. d Halt Command Comment Command Folder Command Loop Command SubProgram Command Assignment Command If Command Script Command Event Command Thread Command Pattern Command Force Command Pallet Command Seek Command Start Stop Conveyor Tracking Command Suppress Graphics Tab Structure Tab Variables Tab Command Variables Initialization 14 Setup Screen 14 1 142 14 3 14 4 14 5 14 6 Language and Units Update Robot Set Password Calibrate Screen Setup Network Set Time 15 Safety Configuration 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 Changing the Safety Configuration Safety Synchronization and Errors Tolerances Safety Checksum Safety Modes Freedrive Mode Password Lock Apply II 46 II 47 II 48 II 51 II 53 II 54 II 55 II 55 II 56 II 57 II 57 II 58 II 58 II 59 II 60 II 61 II 62 II 63 II 64 II 64 II 66 II 69 II 70 73 II 74 II 74 II 75 II 76 II 77 II 79 II 80 II 81 II 82 II 83 II 83 II 84 II 85 II 86 II 86 II 87 II 88 II 88 II 89 II 89 II 89 UR5 CB3 vi Version 3 1 UNIVERSAL ROBOTS 15 9 General Limits 90 15 10 Joint Limits II 93 15 11 Boundaries II 94 15 11 1 Selecting a boundary to configure II 95 15 11 23D visualization F 95 15 11 3 Safety plane configuration Il 96 15 11 4 Tool Boundary configuration Il 99 15 12 Safety I O II 101 Glossary 103 Ind
89. d Electrical Interfaces UR5 CB3 1 40 Version 3 1 It is essential for both maintenance and repair work that it be performed in compli ance with all safety instructions in this manual Maintenance calibration and repair work must be performed according to the newest versions of Service Manuals found on the support website http support universal robots com All UR distributors have access to this support site Repairs shall only be performed by authorized system integrators or by Universal Robots parts returned to Universal Robots shall be returned according to the service manual 6 1 Safety Instructions After maintenance and repair work checks must be carried out to ensure the re quired safety level The valid national or regional work safety regulations must be observed for this check The correct functioning of all safety functions shall also be tested The purpose of maintenance and repair work is to ensure that the system is kept operational or in the event of a fault to return the system to an operational state Repair work includes troubleshooting in addition to the actual repair itself The following safety procedures and warnings must be observed when working on the robot arm or control box DANGER 1 Do not change anything in the safety configuration of the software e g the force limit The safety configuration is de scribed in the PolyScope Manual If any safety parameter is cha
90. ded when the control box is powered up Furthermore the default program will also be auto loaded when the Run Program screen see 10 3 is entered and no program is loaded 12 14 2 Starting a Default Program The default program can be auto started in the Run Program screen When the default program is loaded and the specified external input signal edge transition is detected the program will be started automatically Note on startup the current input signal level is undefined and chosing a transition that matches the signal level on startup will start the program immediately Fur thermore leaving the Run Program screen or pressing the stop button in the Dash board will disable the auto starting feature until the run button has been pressed again 12 14 3 Auto Initialization The robot arm can be automatically initialized for instance when the control box is powered up On the specified external input signal edge transition the robot arm will be completely initialized irrespective of the visible screen The final stage of initialization is brake release When the robot is releasing the brakes it moves a bit and makes a sound Furthermore the brakes cannot be au tomatically released if the configured mounting does not match the mounting de tected based on sensor data In this case the robot needs to be initialized manually in the initialization screen see 10 4 Note on startup the current input signal level is undef
91. defines safety planes in Cartesian space and a tool orientation boundary for the robot TCP The safety planes can be configured either as hard limits for the position of the robot TCP or triggers for activating the Reduced mode safety limits see 15 5 The tool orientation boundary puts a hard limit on the orientation of the robot TCP For further details see 15 11 e The Safety I O subtab defines safety functions for configurable inputs and outputs see 12 2 For example Emergency Stop can be configured as an input For further details see 15 12 15 1 Changing the Safety Configuration NOTE The recommended procedure for changing the safety configura tion is as follows 1 Make a risk assessment 2 Adjust safety settings to the appropriate level refer to rele vant directives and standards from our manual on how to set the safety limits 3 Test the setting on the robot 4 Put the following text in the operators manuals Before working near the robot make sure that the safety configura tion is as expected This can be verified e g by inspecting the checksum in the top right corner of the PolyScope see 15 4 in the PolyScope Manual 15 2 Safety Synchronization and Errors The state of the applied Safety configuration in comparison to what robot installa tion the GUI has loaded is depicted by the shield icon next to the text Safety on the left side of the screen These icons provide a quick indicator
92. der fod Comment Halt Item thickness Shared Parameters P se FEIN 9 V nd od mm Tool Speed 250 mm s empty Tool Acceleration 1200 mm s 4 seri Sequence before start PETI e e Sequence after end Reset to defaults p t gt gt Speed 0 Previous Next eal Robo When destacking the robot arm moves from the starting position in the given di rection to search for the next item The condition on the screen determines when the next item is reached When the condition becomes satisfied the robot remem bers the position and performs the special sequence The next time round the robot starts the search from the remembered position incremented by the item thickness along the direction Starting position The starting position is where the stack operation starts If the starting position is omitted the stack starts at the robot arm s current position CB3 72 Version 3 1 13 26 Command Start Stop Conveyor Tracking UNIVERSAL ROBOTS Direction File 16 50 03 CCCC Q Program Installation Move Log V Robot aj V Move 9 V Move Set e Pallet ee PalletSequence Approach PatternPointi e Set Wait 9 StartPos ee Direction PickSequence lt unnamed gt Command Graphics Structure Variables Waypoint Direction Waypoin
93. dify this value by tapping the text field and entering the new value The accepted value range together with the tolerance and unit of the deviation are listed next to the text field Copy Feature The desired orientation of the robot tool is specified using a feature see 12 12 from the current robot installation The z axis of the selected feature will be used as the desired tool orientation vector for this limit Use the drop down box in the lower left portion of the Tool Boundary Properties panel to select a feature Only the point and plane type features are available Choosing the Undefined item clears the configuration of the plane It should be noted that when the limit has been configured by selecting a feature the orientation information is only copied to the limit the limit is not linked to that feature This means that if there are changes to the position and orientation of a feature which has been used to configure the limit the limit is not automatically updated If the feature has changed this is indicated by a A icon positioned over the feature selector Click the button next to the selector to update the limit with Version 3 1 II 99 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 11 Boundaries the current orientation of the feature The A icon is also displayed if the selected feature
94. direction of gravity The controller uses an advanced dynamics model to give the robot arm smooth and precise motions and to make the robot arm hold itself when in Freedrive mode For this reason it is very important that the mounting of the robot arm be set correctly WARNING Failure to set robot arm s mounting correctly might result in fre quent protective stops and or a possibility that the robot arm will move when the freedrive button is pressed The default is that the robot arm is mounted on a flat table or floor in which case no change is needed on this screen However if the robot arm is ceiling mounted wall mounted or mounted at an angle this needs to be adjusted using the push buttons The buttons on the right side of the screen are for setting the angle of the robot arm s mounting The three top right side buttons set the angle to ceiling 180 wall 90 floor 0 The Tilt buttons can be used to set an arbitrary angle The buttons on the lower part of the screen are used to rotate the mounting of the robot arm to match the actual mounting CB3 Il 26 Version 3 1 12 8 Installation I O Setup UNIVERSAL ROBOTS WARNING Make sure to use the correct installation settings Save and load the installation files along with the program 12 8 Installation I O Setup Q File 16 50 25 CCCC Q Program Installation Move Log
95. e 15 12 those which are reserved will have the name of the safety function in place of the default or user defined Version 3 1 rev 177 II 19 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 4 AutoMove Tab name Configurable outputs that are reserved for safety settings are not togglable and will be displaed as LED s only The electrical details of the signals are described in the user manual Analog Domain Settings The analog I O s can be set to either current 4 20mA or voltage 0 10V output The settings will be remembered for eventual later restarts of the robot controller when a program is saved 12 3 MODBUS client I O Here the digital MODBUS client I O signals as set up in the installation are shown If the signal connection is lost the corresponding entry on this screen is disabled File 16 50 53 CCCC Q Program Installation Move 1 0 Log Robot MODBUS client Inputs Outputs a simulation o Real Robot Inputs View the state of digital MODBUS client inputs Outputs View and toggle the state of digital MODBUS client outputs A signal can only be toggled if the choice for I O tab control described in 12 8 allows it 12 4 AutoMove Tab The AutoMove tab is used when the robot arm has to move to a specific position in it
96. e corresponding text field and entering the new value The highest accepted value is listed in the column titled Maximum None of the values can be set below the tolerance value Note that the fields for limits in Reduced mode are disabled when neither a safety plane nor a configurable input is set to trigger it see 15 11 and 15 12 for more de tails Furthermore the limits for Reduced mode must not be higher than their Nor mal mode counterparts The tolerance and unit for each limit are listed at the end of the row that corre sponds to it When a program is running the speed of the robot arm is automat ically adjusted in order to not exceed any of the entered values minus the toler ance see 15 3 Note that the minus sign displayed with each tolerance value is Version 3 1 93 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 11 Boundaries only there to indicate that the tolerance is subtracted from the actual entered value Nevertheless should the angular velocity of some joint exceed the entered value without tolerance the safety system performs a category 0 stop Position Range This screen defines the position range for each joint This is done by tapping the corresponding text fields and entering new values for the lower and upper joint position boundary The entered interval must fall within the va
97. e distance here is the Cartesian distance between the tcp in the two positions The angle states how much the tcp orientation changes between the two positions More precisely the length of the rotation vector describing the change in orientation Version 3 1 c 82 53 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 8 Command Variable Waypoint 13 8 Command Variable Waypoint File 16 51 02 CCCC Q Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Variables Init Variables ES Variable position v V Robot Program Variable rename V Movej Waypoint V Waypoint 1 Variable Set e Pallet lt Pattern Square 9 alst Corner a2nd Corne 9 Cornet a4th PalletSequence 9 Approach 9 PatternPoint Set Wait Show advanced options 9 Exit 9 4 Destack o Stop at this point SEAS Blend with radius Direction 9 FromPos 9 ToPos Picksequence __ Add waypoint before 9 StackPos 4 IM 11 lt gt Add waypoint after Remove this waypoint Move the robot to a variable position Use variable lt Variable gt
98. entially of six robot joints and two aluminum tubes connect ing the base with the tool of the robot The robot permits the tool to be translated and rotated within the workspace The next section describes the basics of mount ing the various parts of the robot system Electrical installation instructions in chapter 4 must be observed 3 1 Workspace of the Robot The workspace of the UR5 robot extends 850 mm from the base joint 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 cylin drical volume should be avoided if possible because it causes the joints to move fast even though the tool is moving slowly causing the robot to work inefficiently and the conduction of the risk assessment to be difficult Front Tilted 3 2 Mounting Robot Arm The robot arm is mounted using four 8 bolts using the four 8 5 mm holes on the base It is recommended to tighten these bolts with 20 N m torque If very accurate repositioning of the robot arm is desired two 28 holes are provided for use with a pin Also an accurate base counterpart can be purchased as an accessory Figure 3 1 shows where to drill holes and mount the screws Mount the robot on a sturdy surface strong enough to withstand at least ten times the full torque of the base joint and at least five times the weight of the robot arm Furthermore the su
99. equence 4 9 Approach 9 PatternPoint Set Wait 9 Exit Destack 9 StartPos 9 ee Direction 9 FromPos 9 ToPos s PickSequence 9 StackPos s 4 Ill eons v 2 Simulation d o bi Speed c 00 Previous Next gt o Real Robot Graphical representation of the current robot program The path of the TCP is shown in the 3D view with motion segments in black and blend segments transi tions between motion segments shown in green The green dots specify the posi tions of the TCP at each of the waypoints in the program The 3D drawing of the robot arm shows the current position of the robot arm and the shadow of the robot arm shows how the robot arm intends to reach the waypoint selected in the left hand side of the screen If the current position of the robot TCP comes close to a safety or trigger plane or the orientation of robot tool is near the tool orientation boundary limit see 15 11 a 3D representation of the proximate boundary limit is shown Note that when the robot is running a program the visualization of boundary limits will be disabled CB3 74 Version 3 1 13 29 Structure Tab UNIVERSAL ROBOTS Safety planes are visualized in yellow and black with a small arrow representing the plane normal which indicates the side of the plane on which the robot TCP is allowed t
100. er machines By doing so the operator does not need to think about which emergency stop buttons to use The normal emergency stop input cannot be used for sharing purposes since both machines will wait for the each other to go out of the emergency stopped condition In order to share the emergency stop function with other machinery the following configurable I O functions must be configured through the GUI Configurable input pair External emergency stop Configurable output pair System emergency stop The illustration below shows how two UR robots share their emergency stop func tions In this example the configured I Os used are CIO CT1 and CO0 CO1 UR5 CB3 1 22 Version 3 1 rev 17782 4 3 Controller I O UNIVERSAL ROBOTS If more than two UR robot or other machines needs to be connected a safety PLC is needed to control the emergency stop signals 4 3 2 4 Safeguard stop with automatic resume An example of a basic safeguard stop device is a door switch where the robot is stopped when a door is opened see illustration below This configuration is only intended for application where the operator cannot pass the door and close it behind him The configurable I O can be used to setup a reset button outside the door to reactivate robot motion Another example where automatic resume can be appropriate is when using a safety mat or a safety related laser scanner see below
101. erface Please select Run Program UNIVERSAL EN ROBOTS Setup Robot About Shutdown Robot The picture above shows the Welcome Screen The bluish areas of the screen are buttons that can be pressed by pressing a finger or the backside of a pen against the screen PolyScope has a hierarchical structure of screens In the programming environment the screens are arranged in tabs for easy access on the screens File 16 49 59 CCCC Q Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Variables ij In this example the Program tab is selected at the top level and under that the Structure tab is selected The Program tab holds information related to the cur rently loaded program If the Move tab is selected the screen changes to the Move screen from where the robot arm can be moved Similarly by selecting the 1 0 tab the current state of the electrical I O can be monitored and changed It is possible to connect a mouse and a keyboard to the control box or the teach pendant however this is not required Almost all text fields are touch enabled so touching them launches an on screen keypad or keyboard Non touchable text fields have an editor icon next to them that launches the associated input editor Ed AXE f x The icons of the on screen keypad keyboard and expression editor are shown above The vario
102. es an indicaton of the robot arm s running state A bright red LED indicates that the robot arm is currently in a stopped state where the reasons can be several A bright yellow LED indicates that the robot arm is powered on but is not ready for normal operation Finally a green LED indicates that the robot arm is powered on and ready for normal operation The text appearing next to the LED further specifies the current state of the robot arm Active payload and installation When the robot arm is powered on the payload mass used by the controller when operating the robot arm is shown in the small white text field This value can be modified by tapping the text field and entering a new value Note that setting this value does not modify the payload in the robot s installation see 12 6 it only sets the payload mass to be used by the controller Similarly the name of the installation file that is currently loaded is shown in the grey text field A different installation can be loaded by tapping the text field or Version 3 1 II 9 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 10 4 Initialization Screen by using the Load button next to it Alternatively the loaded installation can be customized using the buttons next to the 3D view in the lower part of the screen Before starting up the robot ar
103. es to be Safeguard Stopped as soon as the Safeguard Stop input becomes high In other words without a Safeguard Reset input the Safeguard Stop inputs SIO and SII see the Hardware Installation Manual fully determine whether the Safe guard Stopped state is active or not Output Signals For the output signals the following Safety functions can be ap plied signals return to low when the state which triggered the high signal has ended System Emergency Stop Low signalis given when the safety system has been triggered into an Emergency Stopped state It is in a high signal state otherwise Robot Moving A low signal is given whenever the robot arm is in a mobile state When the robot arm is in a fixed position a high signal is given Robot Not Stopping When the robot arm has been requested to stop some time will pass from the request until the arm stops During this time the signal will be high When the robot arm is moving and has not been re quested to stop or when the robot arm is in a stopped position the signal will be low Reduced Mode Sends a low signal when the robot arm is placed in Reduced mode or if the safety input is configured with a Reduced Mode input and the signal is currently low Otherwise the signal is high e Not Reduced Mode This is the inverse of the Reduced Mode defined above CB3 II 102 Version 3 1 Category 0 stop Robot motion is stopped by immediate removal of power to the
104. essment is always re quired Switching to Advanced Settings Should none of the predefined sets of values be satisfactory the Advanced Settings button can be pressed to enter the advanced general limits screen Advanced Settings File 16 51 11 Fil CCCC Program Installation Move Log Pee configuration Safety Configuration Mounting General Limits Joint Limits Boundaries Safety I O WO Setup Limit Maximum Normal Mode Reduced Mode Safety Force max 250 N 150 ON Variables MODBUS client Speed max 5000 mm s 1500 150 mm s Features 3kg m s Power max 1000 W 300 0 W Momentum max 100 kg m s 25 Conveyor Tracking Default Program Load Save Basic Settings Lock Apply 91 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 9 General Limits Here each of the general limits described in 15 9 can be modified independently of the others This is done by tapping the corresponding text field and entering the new value The highest accepted value for each of the limits is listed in the column titled Maximum The force limit can be set to a value between 100 N and 250 and the power limit can be set to a value between 80 W and 1000 W Note that the fields
105. ety Configuration Mounting General Limits Joint Limits Boundaries Safety O Setup Each of the following joint limits can be configured independently BAEN Maximum speed Variables Position range MODBUS client Features Conveyor Tracking Joints Range Normal Mode Reduced Mode Default Program Minimum Maximum Minimum Maximum Base 363 363 363 363 43 3 Load Save 1 Shoulder 363 363 363 363 3 3 Elbow 363 363 363 e 3 3 Wrist1 363 363 363 363 3 3 Wrist 2 363 363 363 363 ae Ie oe Wrist 3 363 363 363 363 437137 Lock Apply Joint limits restrict the movement of individual joints in joint space i e they do not refer to Cartesian space but rather to the internal rotational position of the joints and their rotational speed The radio buttons in the upper portion of the subpanel make it possible to independently set up Maximum Speedand Position Range for the joints When in Freedrive mode see 12 1 5 and the current position or speed of a joint is close to the limit the user will feel a repelling force which increases in magnitude as the joint approaches the limit The force is generated when joint speed is within approximately 20 s of the speed limit or joint position is within approximately 8 of the position limit Maximum Speed This option defines the maximum angular velocity for each joint This is done by tapping th
106. ew 15 11 3 Safety plane configuration TheSafety Plane Properties section at the bottom of the tab defines the con figuration of the selected safety plane in the Safety Boundaries panel in the upper left portion of the tab Q File 16 51 13 CCCC Q Program Installation Move Log TCP Configuration Safety Configuration Mounting General Limits Joint Limits Boundaries Safety 1 0 Setup Safety Boundaries 3D View Safety Safety plane 0 OS Q amp Variables Safety plane 1 Ce MODBUS client Sarety Rane amp e Features pole pane Safety plane 4 Conveyor Tracking Safety plane 5 Default Program fety plane 6 fal Load Save Safety plane 7 taaa Tool Boundary oj Safety Plane Properties Name Boundary restricts Safety plane 1 oO Normal Copy Feature Displacement wall v 0 1 mm Lock Apply Name The Name text field allows the user to assign a name to the selected safety plane Change the name by tapping the text field and entering a new name Copy Feature The position and normal of the safety plane is specified using a feature see 12 12 from the current robot installation Use the drop down box in the lower left portion of the Safety Plane Properties section to select a feature Only the point and plane type fe
107. ew displays the configured safety planes and the orientation boundary limit for the robot tool together with the current position of the robot arm configured boundary entries where the visibility toggle is selected i e Showing icon in the Sa ety Boundaries section are displayed together with the current selected boundary limit The active safety planes are shown in yellow and black with a small arrow repre senting the plane normal which indicates the side of the plane on which the robot Version 3 1 II 95 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 11 Boundaries TCP is allowed to be positioned Trigger planes are displayed in blue and green A small arrow illustrates the side of the plane that does not trigger the transition into Reduced mode If a safety plane has been selected in the panel on the left side of the tab the corresponding 3D representation is highlighted The tool orientation boundary limit is visualized with a spherical cone together with a vector indicating the current orientation of the robot tool The inside of the cone represents the allowed area for the tool orientation vector When a plane or the tool orientation boundary limit is configured but not active the visualization is gray Push the magnifying glass icons to zoom in out or drag a finger across to change the vi
108. ex II 105 Version 3 1 vii UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS penJesei suu S v sioqog jesienum Aq s L02 6002 1uBuKdoo Version 3 1 viii UR5 CB3 Congratulations on the purchase of your new Universal Robot UR5 The robot can be programmed to move a tool and communicate with other ma chines using electrical signals It is an arm composed of extruded aluminum tubes and joints Using our patented programming interface PolyScope it is easy to pro gram the robot to move the tool along a desired trajectory What do the Boxes Contain When you order a complete robot you receive two boxes One contains the the robot arm and the following items are included in the other one Control box with teach pendant Mounting bracket for the control box Mounting bracket for the teach pendant Key for opening the control box Mains cable compatible with your region Tool cable Stylus pen with laser UR production test certificate This manual Version 3 1 ix UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS Where to Find More Information Important Safety Notice The robot is partly completed machinery see 8 2 and as such a risk assessment is required for each installation of the robot It is particularly important
109. f machinery Electrical equipment of machines Part 1 General requirements The general principles of this standard are applied IEC 60664 1 2007 IEC 60664 5 2007 EN 60664 1 2007 2006 95 EC EN 60664 5 2007 2006 95 EC Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests Part 5 Comprehensive method for determining clearances and creepage distances equal to or less than 2 mm The electrical circuitry of UR robots is designed in compliance with this standard EUROMAP 67 2015 V1 10 Electrical Interface between Injection Molding Machine and Handling Device Robot UR robots equipped with the E67 accessory module to interface injection molding machines comply with this standard UR5 CB3 I 60 Version 3 1 Robot type Weight Payload Reach Joint ranges Speed Repeatability Footprint Degrees of freedom Control box size W x H x D Control box I O ports Tool I O ports I O power supply Communication Programming Noise IP classification Power consumption Collaboration operation Temperature Power supply Calculated operating life Cabling UR5 18 4 kg 40 616 5kg 1116 850mm 33 5in 360 for all joints Joints Max 180 75s Tool Approx 1 ms Approx 39 4 ins 0 1 mm 0 0039 in 4 mils 0149 mm 5 9 in 6 rotating joints 475 mm x 423mm x 268 mm 18 7 x 16 7in x 10 6in 16 digital in 16 digital out 2 analogue in 2 a
110. fety related interfaces only Make sure to use the correct installation settings e g Robot mounting angle weight in TCP TCP offset safety configura tion Save and load the installations file along with the pro gram The freedrive function Impedance back drive shall only be used in installations where the risk assessment allows it Tools and obstacles shall not have sharp edges or pinch points Make sure that all people keep their heads and faces outside the reach of the robot Be aware of robot movement when using the teach pendant Do not enter the safety range of the robot or touch the robot when the system is in operation Version 3 1 I 5 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 1 5 General Warnings and Cautions 11 12 13 14 2 Collisions can release high portions of kinetic energy which are significantly higher at high speeds and with high pay loads Kinetic Energy 1Mass Speed Combining different machines might increase hazards or cre ate new hazards Always make an overall risk assessment for the complete installation When different safety and emer gency stop performance levels are needed always choose the highest performance level Always read and understand the manuals for all equipment used in the installation Never modify the ro
111. for limits in Reduced mode are disabled when neither a safety plane nor a configurable input is set to trigger it see 15 11 and 15 12 for more de tails Furthermore the Speed and Momentum limits in Reduced mode must not be higher than their Normal mode counterparts The tolerance and unit for each limit are listed at the end of the row that corre sponds to it When a program is running the speed of the robot arm is automati cally adjusted in order to not exceed any of the entered values minus the tolerance see 15 3 Note that the minus sign displayed with the tolerance value is only there to indicate that the tolerance is subtracted from the actual entered value The safety system performs a category 0 stop should the robot arm exceed the limit without tolerance WARNING The speed limit is imposed only on the robot TCP so other parts of the robot arm may move faster than the defined value Switching to Basic Settings Pressing the Basic Settings button switches back to the basic general limits screen and all general limits are reset to their Default preset Should this cause any customized values to be lost a popup dialog is shown to confirm the action CB3 92 Version 3 1 15 10 Joint Limits UNIVERSAL ROBOTS 15 10 Joint Limits Q File 16 51 12 CCCC Q Program Installation Move 1 0 Log configuration Saf
112. function is configured and the input signals are low see 15 12 for more details When none of the above is the case any longer the safety system transitions back to Normal mode When the transition from Normal to Reduced mode is caused by passing through a Trigger Reduced mode plane a transition from the Normal mode limit set to the Re duced mode limit set occurs As soon as the robot TCP is positioned 20 mm or closer to the Trigger Reduced mode plane but still on the Normal mode side the more per missive of the Normal and Reduced mode limits is applied for each limit value Once the robot TCP passes through the Trigger Reduced mode plane the Normal mode limit set is no longer active and the Reduced mode limit set is enforced When a transition from Reduced to Normal mode is caused by passing through a Trigger Reduced mode plane a transition from the Reduced mode limit set to the Nor mal mode limit set occurs As soon as the robot TCP passes through the Trigger Reduced mode plane the more permissive of the Normal and Reduced mode limits is applied for each limit value Once the robot TCP is positioned 20 mm or further from the Trigger Reduced mode plane on the Normal mode side the Reduced mode limit set is no longer active and the Normal mode limit set is enforced If the predicted trajectory takes the robot TCP through a Trigger Reduced mode plane the robot arm will start decelerating even before passing through the plane if it i
113. g or transferring components or products For details about the environmen tal conditions under which the robot should operate see appendices B and D UR robots are equipped with special safety related features which are purposely designed for collaborative operation where the robot operates without fences and or together with a human Collaborative operation is only intended for non hazardous applications where the complete application including tool work piece obstacles and other machines is without any significant hazards according to the risk assessment of the specific application Any use or application deviating from the intended use is deemed to be impermis sible misuse This includes but is not limited to Use in potentially explosive environments Use in medical and life critical applications Use before performing a risk assessment Use where the rated performance levels are insufficient Use where the reaction times of the safety functions are insufficient Use as a climbing aid Operation outside the permissible operating parameters 1 7 Risk Assessment One of the most important things that an integrator needs to do is to make a risk assessment The robot itself is partly completed machinery as the safety of the robot installation depends on how the robot is integrated E g tool obstacles and other machines It is recommended that the integrator uses guidelines in ISO 12100 and ISO 10218 2
114. ght 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 1 Move Tab When the robot TCP no longer is in the proximity of the limit the 3D representation disappears If the TCP is in violation or very close to violating a boundary limit the visualization of the limit turns red 12 1 2 Feature and Tool Position In the top right corner of the screen the feature selector can be found It defines which feature to control the robot arm relative to The name of the currently active Tool Center Point is displayed below the feature selector The text boxes show the full coordinate values of that TCP relative to the selected feature For further information about configuring several named TCPs see 12 6 Values can be edited manually by clicking on the coordinate or the joint position This will take you to the pose editor screen see 11 4 where you can specify a target position and orientation for the tool or target joint positions 12 1 3 Move Tool Holding downatranslate arrow top will move the tool tip of the robot in the direction indicated e Holding down a rotate arrow button will change the orientation of the robot tool in the indicated direction The point of rotation is the Tool Center Point TCP i e the point at the end of the robot arm that gives a characteristic point on the robot s tool The TCP is shown as
115. h surfaces Part 1 Hot surfaces The UR robots are designed so that the surface temperature is kept under the ergonomic limits defined in this standard IEC 61140 A1 2004 EN 61140 A1 2006 2006 95 EC Protection against electric shock Common aspects for installation and equipment UR robots are constructed in compliance with this standard to provide protection against electrical shock A protective earth ground connection is mandatory as defined in the Hardware Installation Manual IEC 60068 2 1 2007 IEC 60068 2 2 2007 IEC 60068 2 27 2008 IEC 60068 2 64 2008 EN 60068 2 1 2007 EN 60068 2 2 2007 EN 60068 2 27 2009 EN 60068 2 64 2008 Environmental testing Part 2 1 Tests Test A Cold Part 2 2 Tests Test B Dry heat Part 2 27 Tests Test Ea and guidance Shock Version 3 1 I 59 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS Part 2 64 Tests Test Fh Vibration broadband random and guidance UR robots are tested according to the test methods defined in these standards IEC 61784 3 2010 EN 61784 3 2010 SIL 2 Industrial communication networks Profiles Part 3 Functional safety fieldbuses General rules and profile definitions This standards defines requirements for safety rated communication buses IEC 60204 1 A1 2008 EN 60204 1 A1 2009 2006 42 EC Safety o
116. has been deleted from the installation Safety mode The drop down menu on the right hand side of the Tool Boundary Properties panelis used to choose the safety mode for the tool orientation bound ary The available options are Disabled The tool boundary limit is never active Normal When the safety system is in Normal mode the tool boundary limit is active Reduced When the safety system is in Reduced mode the tool boundary limit is active Normal amp Reduced When the safety system is either in Normal or Re duced mode the tool boundary limit is active The selected safety mode is indicated by an icon in the corresponding entry in the Safety Boundaries panel If the safety mode is set to Disabled no icon is shown Effect Program execution is aborted when the deviation of the tool orientation is about to exceed the entered maximum deviation minus the tolerance see 15 3 if it continues moving along the predicted trajectory Note that the minus sign displayed with the tolerance value is only there to indicate that the tolerance is subtracted from the actual entered value The safety system will perform a cate gory 0 stop should the deviation of the tool orientation exceed the limit without tolerance CB3 II 100 Version 3 1 15 12 Safety I O UNIVERSAL ROBOTS 15 12 Safety I O File Program Installation TCP Configuration Mounting Default Program Load Save
117. he braking initiates within 24 ms see Fig ure 52 2 If a joint is moving its speed is monitored to never be higher than the speed obtained by constantly decelerating from the maximum joint speed limit for Normal mode to 0 rad s in 500 ms 3 If a joint is at rest joint speed is less than 0 2 rad s it is monitored that it does not move more than 0 05rad from the position it had when the speed was measured below 0 2 rad s Additionally for a category 1 stop the safety system monitors that after the robot arm is at rest the powering off is finalized within 600 ms Furthermore after a safeguard stop input the robot arm is only allowed to start moving again after a positive edge on the safeguard reset input occurs If any of the above properties are not satisfied the safety system issues a category 0 stop UR5 CB3 I 38 Version 3 1 5 3 Safety related Electrical Interfaces UNIVERSAL ROBOTS A transition to Reduced mode triggered by the reduced mode input is monitored as follows 1 The safety system accepts both Normal and Reduced mode limit sets for 500 ms after the reduced mode input is triggered 2 After 500 ms only the Reduced mode limits are in effect If any of the above properties are not satisfied the safety system issues a category 0 stop A category 0 stop is performed by the safety system with the performance de scribed in the following table The worst case reaction time is the time to stop and to de energi
118. he electrical and electromagnetic disturbances Conforming to these standards ensures that the UR robots perform well in industrial environments and that they do not disturb other equipment Version 3 1 1 57 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS IEC 61326 3 1 2008 EN 61326 3 1 2008 Electrical equipment for measurement control and laboratory use EMC requirements Part 3 1 Immunity requirements for safety related systems and for equipment intended to perform safety related functions functional safety General industrial applications This standard defines extended EMC immunity requirements for safety related functions Conforming to this standard ensures that the safety functions of UR robots provide safety even if other equipment exceeds the EMC emission limits defined in the IEC 61000 standards IEC 61131 2 2007 E EN 61131 2 2007 2004 108 EC Programmable controllers Part 2 Equipment requirements and tests Both normal and safety rated 24V I Os are constructed according to requirements of this standard to ensure reliable communication with other PLC systems ISO 14118 2000 E EN 1037 A1 2008 2006 42 EC Safety of machinery Prevention of unexpected start up These two standards are very similar They define safety principles for avoiding unexpected start up both as a res
119. he program need to be filled in Version 3 1 rev 17782 II 43 Ro bo ts AS All rights reserved serve D Copyright 2009 2015 by Universa Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 2 Program Tab 13 2 Program Tab File 16 49 58 CCCC Q Program Installation Move I O Log lt unnamed gt Command Graphics Structure Variables Robot Program m Program The window on the left shows the program tree Use the Next and Previous buttons to navigate through the program tree Use the Structure tab to modify the program tree C Add BeforeStart Sequence O Set Initial Variable values lt gt v Program Loops Forever Hid gt PI Speed 100 Previous Next gt o Real Robot The program tab shows the current program being edited 13 2 1 Program Tree The program tree on the left side of the screen displays the program as a list of com mands while the area on the right side of the screen displays information relating to the current command The current command is selected by clicking the com mand list or by using the Previous and Next buttons on the bottom right of the screen Commands can be inserted or removed using the St ructure tab de scribed in 13 29 The program name is shown directly above the command list with a sm
120. he selected feature shall be visible on the 3D graphics The choice applies on this screen and on the Move screen Joggable Select whether the selected feature shall be joggable This determines whether the feature will appear in the feature menu on the Move screen Variable Select whether the selected feature can be used as a variable If this option is se lected a variable named the name of the feature suceeded by var will then be available when editing robot programs and this variable can be assigned a new value in a program which can then be used to control waypoints that depend on the value of a feature Set or Change Position Use this button to set or change the selected feature The Move screen will appear and a new position of the feature can be set Move Robot to Feature Pressing this button will move the robot arm towards the selected feature At the end of this movement the coordinate systems of the feature and the TCP will coin cide except for a 180 degree rotation about the x axis Add Point Push this button to add a point feature to the installation The position of a point feature is defined as the position of the TCP at that point The orientation of the point feature is the same as the TCP orientation except that the feature coordinate system is rotated 180 degrees about its x axis This makes the z axis of the point feature directed opposite than that of the TCP at that point Version 3 1
121. her red yellow or green A red icon means that there is an error in that command yellow means that the command is not finished and green means that all is OK A program can only be run when all commands are green 13 3 Variables A robot program can make use of variables to store and update various values during runtime Two kinds of variables are available Installation variables These can be used by multiple programs and their names and values are persisted together with the robot installation see 12 10 for further details CB3 II 46 Version 3 1 13 4 Command Empty UNIVERSAL ROBOTS Regular program variables These are available to the running program only and their values are lost as soon as the program is stopped The following variable types are available bool A boolean variable whose value is either True or False int A whole number in the range from 32768 to 32767 float A floating point number decimal string sequence of characters pose vector describing the location and orientation in Cartesian space It is a combination of a position vector x y z and a rotation vec tor rx ry rz representing the orientation written p x y z rx ry rz list A sequence of variables 13 4 Command Empty File Program Installation Move 1 0 Log 16 49 58 CCCC Q lt unnamed gt V Robot Program empty Command Graph
122. ics Structure Variables Insert program lines here In the Structure tab you will find various program statements that can be inserted Structure o Real Robot lt gt Speed 00 Previous Next gt Program commands need to be inserted here Press the Structure button to go to the structure tab where the various selectable program lines can be found A program cannot run before all lines are specified and defined Version 3 1 II 47 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 5 Command Move 13 5 Command Move s Pattern Square e PalletSequence Approach 9 PatternPoint Set Wait Shared Parameters 9 C Recalculate motions 9 StartPos Set TCP o Direction 9 FromPos Joint Speed 60 5 Rd oint Acceleration 80 ejs e PickSequence File 16 50 55 CCCC Q Program Installation Move 0 Log lt unnamed gt Command Graphics Structure Variables a Init Variables ma Move v V Robot Program Move 9 V Moves Waypoint Here you specify how the robot should perform the movements between the waypoints below Use the menu in the upper right corner to switch between various movement type
123. in approximately 5 cm of a safety plane or the deviation of the orientation of the tool is approximately 3 from the specified maximum deviation When a plane is defined as a Trigger Reduced mode plane and the TCP goes beyond this boundary the safety system transitions into Reduced mode which applies the Reduced mode safety settings Trigger planes follow the same rules as regular safety planes except they allow the robot arm to pass through them 15 11 1 Selecting a boundary to configure The Safety Boundaries panel on the left side of the tab is used to select a boundary limit to configure To set up a safety plane click on one of the top eight entries listed in the panel If the selected safety plane has already been configured the corresponding 3D repre sentation of the plane is highlighted in the 3D View see 15 11 2 to the right of this panel The safety plane can be set up in the Safety Plane Properties section see 15 11 3 at the bottom of the tab Click the Tool Boundary entry to configure the orientation boundary limit for the robot tool The configuration of the limit can be specified in the Tool Boundary Properties section see 15 11 4 at the bottom of the tab Click the button to toggle the 3D visualization of the boundary limit on off If a boundary limit is active the safety mode see 15 11 3 and 15 11 4 is indicated by one of the following icons ID e 8 amp 15 11 2 3D visualization The 3D Vi
124. ined and chosing a transition that matches the signal level on startup will initialize the robot arm immediately Version 3 1 II 37 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 16 Load Screen 12 15 Log Tab File 16 50 54 CCCC Q Program Installation Move Log Readings Joint Load 0 0A Controller Temp 30 0 C Base OK T 0 0 V Main Voltage 48 0 V Shoulder OK 0 0 V Avg Robot Power 11 W Elbow OK we 0 0 V Robot Current 2 2 A Wrist 1 ad 0 0V 10 Current OA Wrist 2 xL 0 0 V Tool Current 0 mA Wrist 3 OK 0 0V 1 E9 2015 06 08 16 50 54 9 A 2015 06 08 16 49 40 000 RobotInterface C10240 Real Robot not connected Simulating Robot a 2015 06 08 16 49 40 000 RobotInterface C10240 Real Robot not connected Simulating Robot Clear ed gt Robot Health The top half of the screen displays the health of the robot arm and control box The left part shows information related to the control box of the robot while the right part shows information about each robot joint Each robot joint shows information for temperaure of the motor and electronics the load of the joint and the voltage at the joint Robot Log On the bottom half of the screen log messages are shown The first column categorizes the severity of
125. int 2 Conveyor Tracking Default Program Load Save v Show axes Move robot here v Joggable Variable II 34 Version 3 1 rev 17 12 13 Conveyor Tracking Setup UNIVERSAL ROBOTS Add Plane Push this button to add a plane feature to the installation A plane is defined by three sub point features The position of the coordinate system is the same as the position for the first sub point The z axis is the plane normal and the y axis is directed from the first point towards the second The positive direction of the z axis is set so that the angle between the z axis of the plane and the z axis of the first point is less than 180 degrees Q File 16 50 52 CCCC Q Program Installation Move 1 0 Log TCP Configuration Delete Plane 1 rename Lessa Mounting Setup a Safety Variables MODBUS client Features Base Tool 4 Plane 1 X Point 1 X Point 2 X Point 3 Conveyor Tracking Default Program Load Save v Show axes Move robot here v Joggable Variable 12 13 Conveyor Tracking Setup When using a conveyor the robot can be configured to track the movement of the conveyor The Conveyor Tracking Setup provides options for configuring the robot to work with absolute and incremental encoders and linear and circular conveyors Conveyor Parameters Incremental encoders can be connected to digital inputs 0 to 3 Using a Quadrature encode
126. int on the robot s tool Several named TCPs can be defined on this screen Each TCP contains a translation and a rotation relative to the center of the tool output flange as indicated on the on screen graph ics The position coordinates X Y and 7 specify the position of the TCP while Rx RY and RZ specify its orientation When all of the specified values are zero the TCP coincides with the center point on the tool output flange and adopts the coordinate system depicted on the right side of the screen 12 6 1 Adding modifying and removing TCPs To define a new TCP hit the New button The created TCP then automatically re ceives a unique name and becomes selected in the drop down menu The translation and rotation of the selected TCP can be modified by tapping the respective white text fields and entering new values To remove the selected simply tap the Remove button The last remaining TCP cannot be deleted 12 6 2 The default and the active TCP Precisely one of the configured TCPs is the default one The default TCP is marked by a green icon to the left of its name in the drop down TCP menu To set the currently selected TCP as the default one hit the Set as default button One TCP offset is always used as the active one to determine all linear motions in Cartesian space Also it is the motion of the active TCP that is visualized on the Graphics tab see 13 28 Before any program is run as well as before the start
127. ion The two robot arms UR5 and UR10 including their control box and teach pendant have been tested according to the below listed standards Both systems meet the EMC requirements of the standards and the essential requirements of the European EMC directive 2004 108 EC The test results are given in the DELTA report listed above EN 61326 3 1 2008 Industrial locations EN 61000 6 2 2005 EN 61000 6 4 2007 Date Assessor Puud Duvald Christensen Senior Technology Specialist EMC H rsholm 27 March 2014 20ass sheet j UR5 CB3 I 54 Version 3 1 This section describes relevant standards applied under the development of the robot arm and control box Whenever a European Directive number is noted in brackets it indicates that the standard is harmonized according to that Directive A standard is not a law A standard is a document developed by stakeholders within a given industry defining the normal safety and performance requirements for a product or product group Standard type abbreviations mean the following ISO International Standardization Organization International Electrotechnical Commission EN European Norm TS Technical Specification TR Technical Report ANSI American National Standards Institute RIA Robotic Industries Association CSA Canadian Standards Association Conformity with the following standards is only guaranteed if all assembly instructions safety i
128. ioqog jesienum Aq s L02 6002 1uBuKdoo Version 3 1 I 34 UR5 CB3 UR robots are equipped with a range of built in safety related functions as well as safety related electrical interfaces to connect to other machines and additional protective devices Each safety function and interface is monitored according to ISO 13849 1 see Chapter 8 for certifications with Performance Level d PLd NOTE If the robot discovers a fault in the safety system e g one of the wires in the emergency stop circuit is cut or a position sensor is broken a category 0 stop is initiated The worst case reaction time from the time an error occurs to the point in time that it is detected and the robot is stopped and powered off is 1250 ms Part II of the PolyScope Manual describes configuration of the safety related fea tures inputs and outputs See Chapter 4 for descriptions on how to connect safety devices to the electrical interface 5 1 Limiting Safety related Functions The robot has a number of safety related functions that can be used to limit the movement of its joints and of the robot Tool Center Point TCP The TCP is the center point of the output flange with the addition of the TCP offset see Part II the PolyScope Manual The limiting safety related functions are Limiting Safety Description Function Joint position Min and max angular joint position Joint speed Max angular joint speed TCP position Planes in
129. l box is turned on text from the underlying operating system will appear on the touch screen After about one minute a few buttons appear on the screen and a popup guides the user to the initialization screen see 10 4 To shut down the control box press the green power button on the screen or use the Shut Down button on the welcome screen see 10 3 WARNING Shutting down by pulling the power cord from the wall socket may cause corruption of the robot s file system which may result in robot malfunction 10 1 3 Turning the Robot Arm On and Off The robot arm can be turned on if the control box is turned on and if no emergency stop button is activated Turning the robot arm on is done in the initialization screen see 10 4 by touching the ON button on that screen and then pressing Start When a robot is started it makes a sound and moves a little while releasing the brakes The power to the robot arm can be turned off by touching the OFF button on the initialization screen The robot arm is also powered off automatically when the control box shuts down 10 1 4 Quick Start To quickly start up the robot after it has been installed perform the following steps 1 Press the Emergency Stop button on the front side of the teach pendant 2 Press the power button on the teach pendant 3 Wait a minute while the system is starting up displaying text on the touch screen 4 When the system is ready a popup will be sh
130. ld function code 0x06 Write Single Register is used to set the value on the remote MODBUS unit Set signal address This field shows the address on the remote MODBUS server Use the on screen keypad to choose a different address Valid addresses depends on the manufacturer and configuration of the remote MODBUS unit Set signal name Using the on screen keyboard the user can give the signal a name This name is used when the signal is used in programs CB3 30 Version 3 1 12 11 Installation MODBUS client I O Setup UNIVERSAL ROBOTS Signal value Here the current value of the signal is shown For register signals the value is expressed as an unsigned integer For output signals the desired signal value can be set using the button Again for a register output the value to write to the unit must be supplied as an unsigned integer Signal connectivity status This icon shows whether the signal can be properly read written green or if the unit responds unexpected or is not reachable gray If a MODBUS exception re sponse is received the response code is displayed The MODBUS TCP Exception responses are E1 ILLEGAL FUNCTION 0x01 The function code received in the query is not an allowable action for the server or slave E2 ILLEGAL DATA ADDRESS 0x02 The function code received in the query is not an allowable action for the server or slave check that the entered signal addres
131. log output in voltage mode AOx AG Voltage 0 10 V AOx AG Current 20 20 mA AOx AG Resistance 1 ohm AOx AG Resolution 12 bit The following examples show how to use the analog I O 4 3 6 1 Using an analog output Below is an example of how to control a conveyor belt with an analog speed control input 4 3 6 2 Using an Analog Input Below is an example of how to connect an analog sensor UR5 CB3 I 26 Version 3 1 4 3 Controller I O UNIVERSAL ROBOTS 4 3 7 Remote ON OFF control Remote ON OFF control can be used to turn the control box on and off without using the teach pendant It is typically used in the following applications When the teach pendant is inaccessible When a PLC system must have full control When several robots must be turned on or off at the same time The remote ON OFF control provides a small auxiliary 12V supply which is kept active when the controller box is turned off The on and off inputs are intended for short time activation only The on input works in the same way as the power button Always use the off input for remote off control as this signal allows the control box safe files and shut down nicely The electrical specifications are shown below Terminals Parameter Min Typ Unit 12V GND Voltage 10 12 13 V 12V GND Current 100 mA ON OFF Inactive vol
132. lues listed in the column titled Range and the lower boundary cannot exceed the upper boundary Note that the fields for limits in Reduced mode are disabled when neither a safety plane nor a configurable input is set to trigger it see 15 11 and 15 12 for more de tails The tolerances and unit for each limit are listed at the end of the row that corre sponds to it The first tolerance value applies to the minimum value and the second applies to the maximum value Program execution is aborted when the position of a joint is about to exceed the range resulting from adding the first tolerance to the entered minimum value and subtracting the second tolerance from the entered maximum value if it continues moving along the predicted trajectory Note that the minus sign displayed with the tolerance value is only there to indicate that the tolerance is subtracted from the actual entered value Nevertheless should the joint position exceed the entered range the safety system performs a category 0 stop 15 11 Boundaries In this tab you can configure boundary limits consisting of safety planes and a limit on the maximum allowed deviation of the robot tool orientation It is also possible to define planes that trigger a transition into Reduced mode Safety planes can be used to restrict the allowed workspace of the robot by enforc ing that the robot TCP stay on the correct side of the defined planes and not pass through them Up to eight
133. m it is very important to verify that both the active payload and the active installation correspond to the actual situation the robot arm is currently in Initializing the robot arm DANGER Always verify that the actual payload and installation are correct before starting up the robot arm If these settings are wrong the robot arm and control box will not function correctly and may be come dangerous to people or equipment around them CAUTION Great care should be taken if the robot arm is touching an obstacle or table since driving the robot arm into the obstacle might dam age a joint gearbox The large button with the green icon on it serves to perform the actual initialization of the robot arm The text on it and the action it performs change depending on the current state of the robot arm After the controller PC boots up the button needs to be tapped once to power the robot arm on The robot arm state then turns to Power on and subsequently to Idle Note that when an emergency stop is in place the robot arm cannot be powered on so the button will be disabled When the robot arm state is Idle the button needs to be tapped once again to start the robot arm up At this point sensor data is checked against the configured mounting of the robot arm If a mismatch is found with a tolerance of 30 the button is disabled and an error message is displayed below it If the mounting verification passes tap
134. mation contained in the user guides This Warranty shall not apply to or extend to services performed by the authorized dealer or the customer themselves e g installation configuration software downloads The purchase receipt together with the date of purchase shall be required as evidence for invoking the Warranty Claims un der the Warranty must be submitted within two months of the Warranty default becoming evident Ownership of devices or components replaced by and returned to Universal Robots shall vest in Universal Robots Any other claims resulting out of or in connection with the device shall be excluded from this Warranty Nothing in this Warranty shall attempt to limit or exclude a Customer s Statutory Rights nor the manufacturer s liability for death or personal injury resulting from its neg ligence The duration of the Warranty shall not be extended by services rendered under the terms of the Warranty Insofar as no Warranty default exists Universal Robots reserves the right to charge the customer for replacement or repair The above provisions do not imply a change in the burden of proof to the detriment of the customer In case of a device exhibiting defects Universal Robots shall not be liable for any indirect incidental special or consequential damages including but not limited to lost profits loss of use loss of production or damage to other production equipment In case of a device exhibiting defects Universal Robots
135. nalogue out 2 digital in 2 digital out 2 analogue in 24V 2 in control box and 12 V 24 V 600 mA in tool TCP IP 100 Mbit IEEE 802 3u 100BASE TX Ethernet socket amp Modbus TCP PolyScope graphical user interface on 12 touchscreen with mounting Comparatively noiseless IP54 Approx 200 W using a typical program Collaborative operation according to ISO 10218 1 2011 The robot can work in a temperature range of 0 50 C 100 240 VAC 50 60 Hz 35 000 hours Cable between robot and control box 6m 2361 Cable between touchscreen and control box 4 5 m 177 in Version 3 1 I 61 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS penJesei suu S v sioqog jesienum Aq s L02 6002 1uBuKdoo Version 3 1 1 62 UR5 CB3 Part II PolyScope Manual The Universal Robot arm is composed of extruded aluminum tubes and joints The joints with their usual names are shown in Figure 10 1 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 base PolyScope is the graphical user interface GUI which lets you operate the robot arm and control box execute robot programs and easily create new ones The following section gets you started with the rob
136. ncorporation conditions see product manual Compliance with all essential requirements of Directive 2006 42 relies on the specific robot installation and the final risk assessment Relevant technical documentation is compiled according to Directive 2006 42 EC annex VII part B Additionally the product declares in conformity with the following directives according to which the product is CE marked 2006 95 EC Low Voltage Directive LVD 2004 108 EC Electromagnetic Compatibility Directive EMC 2011 65 EU Restriction of the use of certain hazardous substances RoHS A complete list of applied harmonized standards including associated specifications is provided in the product manual This list is valid for the product manual with the same serial numbers as this document and the product Odense January 27th 2015 Version 3 1 I 51 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS B 2 Safety System Certificate B 2 Safety System Certificate ZERTIFIKAT CERTIFICATE Hiermit wird bescheinigt dass die Firma This certifies that the company Universal Robots A S Energivej 25 DK 5260 Odense S Denmark berechtigt ist das unten genannte Produkt mit dem abgebildeten Zeichen zu kennzeichnen is authorized to provide the product mentioned below with the mark as illustrated Fertigungssta
137. nd can be used in expres sions 13 23 Command Force Force mode allows for compliance and forces in selectable axis in the robot s workspace robot arm movements under a Force command will be in Force mode When the robot arm is moving in force mode it is possible to select one or more axes in which the robot arm is compliant Along around compliant axes the robot arm will comply with the environment which means it will automatically adjust its position in order to achieve the desired force It is also possible to make the robot arm itself apply a force to its environment e g a workpiece Force mode is suited for applications where the actual tcp position along a prede fined axis is not important but in stead a desired force along that axis is required For example if the robot TCP should roll against a curved surface or when pushing or pulling a workpiece Force mode also supports applying certain torques around predefined axes Note that if no obstacles are met in an axis where a non zero force is set the robot arm will try to accelerate along about that axis Although an axis has been selected to be compliant the robot program will still try to move the robot along around that axis However the force control assures that the robot arm will still approach the specified force WARNING If the force function is used incorrectly it can produce a force of more than 150N The programmed force shall be taken into con
138. nd not the overall limits of the robot arm This means that although a speed limit is specified it does not guarantee that other parts of the robot arm will obey this same limitation CB3 II 90 Version 3 1 rev 177 15 9 General Limits UNIVERSAL ROBOTS When in Freedrive mode see 12 1 5 and the current speed of the robot TCP is close to the Speed limit the user will feel a repelling force which increases in magnitude the closer the speed comes to the limit The force is generated when the current speed is within approximately 250 mm s of the limit Basic Settings The initial general limits subpanel shown as the default screen features a slider with the following predefined sets of values for the general limits in both Normal and Reduced modes Very Restricted Intended to be used where it is particularly dangerous for the robot arm or its payload to hit a human Restricted Intended to be used where there is a high risk of the robot arm or its payload hitting a human and the robot arm along with its payload has no sharp edges Default Intended to be used where people are aware of the robot arm and its pay load and or when application has no sharp edges and no pinching hazards Least Restricted Intended to be used where there is little risk of the robot arm or its payload hitting a human such as inside CNC machines behind fences or in hard to reach places These modes are merely suggestions and a proper risk ass
139. nd tests used to achieve the rated performance level For more infor mation see EN 15013849 1 2008 Risk assessment risk assessment is the overall process of identifying all risks and reducing them to an appropriate level A risk assessment should be docu mented Consult ISO 12100 for further information Performance Level A Performance Level PL is a discrete level used to specify the ability of safety related parts of control systems to perform a safety functions under foreseeable conditions PLd is the second highest reliability classifica tion meaning that the safety function is extremely reliable For more informa tion see EN 15013849 1 2008 Version 3 1 II 103 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved 15 12 Safety I O UNIVERSAL ROBOTS penJesei suu S v s ogoy jesienum Aq s L02 6002 1uBuKdoo Version 3 1 II 104 CB3 Version 3 1 rev 17782 TI 105 CB3
140. nged the complete robot system shall be considered new meaning that the overall safety approval process including risk assessment shall be updated accordingly 2 Replace faulty components using new components with the same article numbers or equivalent components approved by Universal Robots for this purpose 3 Reactivate any deactivated safety measures immediately after the work is completed 4 Document all repairs and save this documentation in the tech nical file associated with the complete robot system Version 3 1 I 41 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 6 1 Safety Instructions DANGER 1 Remove the mains input cable from the bottom of the control box to ensure that it is completely unpowered Deenergize any other source of energy connected to the robot arm or con trol box Take necessary precautions to prevent other persons from energizing the system during the repair period Check the earth connection before re powering the system Observe ESD regulations when parts of the robot arm or con trol box are disassembled Avoid disassembling the power supplies inside the control box High voltages up to 600 V can be present inside these power supplies for several hours after the control box has been switched off Prevent water and dust from entering the
141. not control the robot arm directly Robot Feature v 32011 mm L Y 431 76 mm amp z 30000mm Rotation Vector tradi se RX 0 0012 RY 3 1664 RZ 0 0395 Joint Positions Base 91 71 qP Shoulder 98 55 Elbow 36 88 9 Wrist 1 136 04 wrist 2 91 39 oP Wrist 3 1 78 qP 3 cancel Robot The current position of the robot arm and the specified new target position are shown in 3D graphics The 3D drawing of the robot arm shows the current position of the robot arm and the shadow of the robot arm shows the target position of the robot arm controlled by the specified values on the right hand side of the screen Push the magnifying glass icons to zoom in out or drag a finger across to change the view Version 3 1 II 13 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 11 4 Pose Editor Screen If the specified target position of the robot TCP is close to a safety or trigger plane or the orientation of robot tool is near the tool orientation boundary limit see 15 11 a 3D representation of the proximate boundary limit is shown Safety planes are visualized in yellow and black with a sm
142. nstruc tions and guidance in this manual are followed ISO 13849 1 2006 PL d ISO 13849 2 2012 EN ISO 13849 1 2008 E PLd 2006 42 EC EN ISO 13849 2 2012 E 2006 42 EC Safety of machinery Safety related parts of control systems Part 1 General principles for design Part 2 Validation The safety control system is designed as Performance Level d PLd according to the requirements of these standards ISO 13850 2006 Stop category 1 EN ISO 13850 2008 E Stop category 1 2006 42 EC Safety of machinery Emergency stop Principles for design The emergency stop function is designed as a stop category 1 according to this standard Stop category lis a controlled stop with power to the motors to achieve the stop and then removal of power when the stop is achieved Version 3 1 I 55 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS ISO 12100 2010 EN ISO 12100 2010 E 2006 42 EC Safety of machinery General principles for design Risk assessment and risk reduction UR robots are evaluated according to the principles of this standard ISO 10218 1 2011 EN ISO 10218 1 2011 E 2006 42 EC Robots and robotic devices Safety requirements for industrial robots Part 1 Robots This standard is intended for the robot manufacturer not the integrator The second part I
143. ntation of orientation is complicated for a person that lacks the required experience to understand this problem Questions often asked by customers are for instance e Will it be possible to move the robot 4 cm away from the claw of my comput erised numerically controlled CNC machine Is it possible to rotate the tool of the robot 45 degrees relative to the table Can we make the robot arm move vertically downwards with the object let the object loose and then move the robot arm vertically upward again The meaning of such and similar questions is very straightforward to an average customer who intends to use a robot arm for instance at various stations in a pro duction plant and it may seem annoying and incomprehensible to the customer to CB3 II 32 Version 3 1 12 12 Installation Features UNIVERSAL ROBOTS be told that there may not be a simple answer to such relevant questions There are several complicated reasons for this being the case and in order to address these problems Universal Robots has developed unique and simple ways for a customer to specify the location of various objects relative to the robot arm Within a few steps it is therefore possible to do exactly what was asked for in the above ques tions Rename This button makes it possible to rename a feature Delete This button deletes the selected feature and if any all sub features Show Axes Choose whether the coordinate axes of t
144. o be positioned Trigger planes are displayed in blue and green and a small arrow pointing to the side of the plane where the Normal mode limits see 15 5 are active The tool orientation boundary limit is visualized with a spherical cone together with a vector indicating the current orientation of the robot tool The inside of the cone represents the allowed area for the tool orientation vector When the target robot TCP no longer is in the proximity of the limit the 3D repre sentation disappears If the TCP is in violation or very close to violating a boundary limit the visualization of the limit turns red The 3D view can be zoomed and rotated to get a better view of the robot arm The buttons in the top right side of the screen can disable the various graphical components in the 3D view The bottom button switches on off the visualization of proximate boundary limits The motion segments shown depend on the selected program node If a Move node is selected the displayed path is the motion defined by that move If a Waypoint node is selected the display shows the following 10 steps of movement 13 29 Structure Tab File 16 49 59 CCCC Q Program Installation Move Log lt unnamed gt Command Graphics Structure Variables V Robot Program empty Program Str
145. odification of the setup of the robot When the System pass word is set programs can be loaded and executed without the password but the user must enter the correct password in order to create or change programs The second is a required Safety password which must be entered correctly in order to modify the safety configuration NOTE In order to change the safety configuration the Safety password must be set WARNING Add a System password to prevent non authorized personnel from changing the robot installation CB3 Il 82 Version 3 1 14 4 Calibrate Screen UNIVERSAL ROBOTS 14 4 Calibrate Screen X Point very precisely in the center of the blue cross Cancel Calibrating the touch screen Follow the on screen instructions to calibrate the touch screen Preferably use a pointed non metallic object such as a closed pen Patience and care help achieve a better result 14 5 Setup Network Setup Robot Initialize Robot Setup Network Select your network method Language and Units puce Q static Address Update Robot o Disabled network Network detailed settings Senne eae IP address 0 0 0 0 Subnet mask 0 0 0 0 Calibrate Screen Default qateway 0 0 0 0 Setup Network Preferred DNS server 0 0 0 0 Alternative DNS server 0 0 0 0 Set Time Apply Update Back Version 3 1
146. of Version 3 1 23 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 6 Installation TCP Configuration a program the default TCP is set as the active one Within a program any of the specified TCPs can be set as the active one for a particular movement of the robot see 13 5 and 13 10 12 6 3 Teaching TCP position File 16 50 22 CCCC Program Installation Move I O Log Configuration Setup for the Tool Center Point Mounting Setup Teach TCP Position I A Safety More points are needed Variables Move the to the same position MODBUS client e from different angles Features 1 Conveyor Tracking Default Program Load Save m t 3 Cancel TCP position coordinates can be calculated automatically as follows 1 Tap the Position button 2 Choose a fixed point in the workspace of the robot 3 Use the buttons on the right side of the screen to move the TCP to the cho sen point from at least three different angles and to save the corresponding positions of the tool output flange 4 Verify the calculated TCP coordinates and set them onto the selected TCP us ing the Set button Note that the positions must be sufficiently diverse for the calculation to work cor rectly If they a
147. ol and work item when releasing the brake UR5 CB3 1 8 Version 3 1 UNIVERSAL ROBOTS 1 9 Movement Without Drive Power penjesei suu S v sioqog jesienum Aq s L02 6002 1uBuKdoo UR5 CB3 1 9 Version 3 1 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 1 9 Movement Without Drive Power UR5 CB3 1 10 Version 3 1 Transport the robot in the original packaging Save the packaging material in a dry place you may need to pack down and move the robot later on Lift both tubes of the robot arm at the same time when moving it from the pack aging to the installation place Hold the robot in place until all mounting bolts are securely tightened at the base of the robot The controller box shall be lifted by the handle WARNING 1 Make sure not to overload your back or other bodyparts when the equipment is lifted Use proper lifting equipment regional and national guidelines for lifting shall be followed Universal Robots cannot be held responsible for any damage caused by transportation of the equipment 2 Make sure to mount the robot according to the mounting in structions in chapter 3 Version 3 1 I 11 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS penJesei suu S v sioqog jesienum Aq s L02 6002 1uBuKdoo Version 3 1 I 12 UR5 CB3 The robot consists ess
148. on 12 6 5 Payload The weight of the tool of the robot is specified in the lower part of the screen To change this setting simply tap the white text field and enter a new weight The setting applies to all defined TCPs 12 6 6 Center of gravity The center of gravity of the tool may optionally be specified using the fields CX CY and CZ The tool center point is assumed to be the tool s center of gravity if nothing else has been specified The setting applies to all defined TCPs WARNING Make sure to use the correct installation settings Save and load the installation files along with the program Version 3 1 II 25 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 7 Installation Mounting 12 7 Installation Mounting File 16 50 24 CCCC Program Installation Move Log Umm Machu Robot Mounting and Angle Mounting T Setup vh Safety in Variables i MODBUS client Features Tilt Conveyor Tracking f 45 Default Program Load Save 0 0 eas Rotate Robot Base Mounting 45 lt 0 0 gt 45 gt Here the mounting of the robot arm can be specified This serves two purposes 1 Making the robot arm look right on the screen 2 Telling the controller about the
149. on Continuously allow the conditions of the If and ElseIf statements to be evaluated while the contained lines are executed If a expression evaluates to False while inside the body of the I f part the following ElseIf or Else statement will be reached Version 3 1 II 61 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 19 Command Script 13 19 Command Script File 16 50 06 CCCC Q Program Installation Move Log lt unnamed gt Command Graphics Structure Variables Pallet j ee Pattern e PalletSequence Scri pt Code Line v Approach PatternPoint__ e Set Wait 9 Exit eo Destack StartPos Direction 9 FromPos 9 ToPos lI PickSequence 9 StackPos Set Wait 9 Exit Wait V Folder e lt empty gt Below you can enter text that will be executed as script code by the URController foo Comment Halt Popup V Loop Script q il lt lt gt o Speed 10096 Previous Next gt Real Robot This command gives access to the underlying real time script language that is ex ecuted by the robot controller It is intended for advanced
150. ot Afterwards the screens and functionality of PolyScope are explained in more detail 10 1 Getting Started Before using PolyScope the robot arm and control box must be installed and the control box switched on 10 1 1 Installing the Robot Arm and Control Box To install the robot arm and control box do the following Unpack the robot arm and the control box Mount the robot arm on a sturdy and vibration free surface 1 2 3 4 5 Place the control box on its foot Plug on the robot cable between the robot and the control box Plug in the mains plug of the control box Figure 10 1 Joints of the robot A Base B Shoulder C Elbow and D E F Wrist 1 2 3 Version 3 1 II 3 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 10 1 Getting Started WARNING Tipping hazard If the robot is not securely placed on a sturdy surface the robot can fall over and cause an injury Detailed installation instructions can be found in the Hardware Installation Man ual Note that a risk assessment is required before using the robot arm to do any work 10 1 2 Turning the Control Box On and Off The control box is turned on by pressing the power button at the front side of the panel with the touch screen This panel is usually referred to as the teach pendant When the contro
151. ove linearly between waypoints This means that each joint performs a more complicated motion to keep the tool on a straight line path The shared parameters that can be set for this movement type are the desired tool speed and tool acceleration specified in mm s and mm s respec tively and also a feature The selected feature will determine in which feature space the tool positions of the waypoints are represented in Of specific in terest concerning feature spaces are variable features and variable waypoints Variable features can be used when the tool position of a waypoint need to be CB3 II 48 Version 3 1 13 5 Command Move UNIVERSAL ROBOTS determined by the actual value of the variable feature when the robot program runs moveP will move the tool linearly with constant speed with circular blends and is intended for some process operations like gluing or dispensing The size of the blend radius is by default a shared value between all the way points A smaller value will make the path turn sharper whereas a higher value will make the path smoother While the robot arm is moving through the waypoints with constant speed the robot control box cannot wait for ei ther an I O operation or an operator action Doing so might stop the robot arm s motion or cause a protective stop A Circle Move can be added to a moveP command consisting of two way points the first one specifying a via point on the circular arc and the sec
152. own on the touch screen stating that the robot needs to be initialized 5 Touch the button on the popup dialog You will be taken to the initialization screen CB3 Il 4 Version 3 1 10 1 Getting Started UNIVERSAL ROBOTS 6 Wait for the Confirmation of applied Safety Configuration dia log and press the Confirm Safety Configuration button This applies an initial set of safety parameters that need to be adjusted based on a risk assessment 7 Unlock the Emergency Stop button The robot state changes from Emergency Stopped to Power off 8 Step outside the reach workspace of the robot 9 Touch the On button on the touch screen Wait a few seconds until robot state changes to Idle 10 Verify that the payload mass and selected mounting are correct You will be notified if the mounting detected based on sensor data does not match the selected mounting 11 Touch the Start button on the touch screen The robot now makes a sound and moves a little while releasing the brakes 12 Touch the OK button bringing you to the Welcome screen 10 1 5 The First Program program is a list of commands telling the robot what to do PolyScope 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 an important part of a robot program a way of teaching the robot how to move
153. own or too hard to program Stacking Destacking 4 4 7 i ta f d i When programming a seek operation for working on a stack one must define s the starting point d the stack direction and i the thickness of the items in the stack On top of this one must define the condition for when the next stack position is reached and a special program sequence that will be performed at each of the stack positions Also speed and accelerations need to be given for the movement involved in the stack operation CB3 II 70 Version 3 1 13 25 Command Seek UNIVERSAL ROBOTS Stacking File 16 50 02 CCCC Q Program Installation Move Log lt unnamed gt Command Graphics Structure Variables V Rob a gp sec dmm Select Seek Type V Move Waypoint A seek operation is given by a Set starting position s and a direction d e Pallet ee Pattern ee PalletSequence Approach Please select between stacking and destacking 9 PatternPoint__ Set E Wait 9 Exit oo Seek Stacking Destacking Wait V Folder Comment Halt Popup V Loop f EX f o empty Bl script ear li P Call Vif JEN Ti 1 lt gt o bi Speed c 00 Previous Next gt o Real Robot
154. ping the button releases all joint brakes and the robot arm becomes ready for normal operation Note that the robot makes a sound and moves a little while releasing the brakes Ifthe robot arm violates one of the safety limits after it starts up it operates in a special Recovery mode In this mode tapping the button switches to a recovery move screen where the robot arm can be moved back within the safety limits Ifa fault occurs the controller can be restarted using the button f the controller is currently not running tapping the button starts it Finally the smaller button with the red icon on it serves to power off the robot arm CB3 10 Version 3 1 11 On screen Editors 11 1 On screen Keypad mE DDDEIO ase FIF m X caneet Simple number typing and editing facilities In many cases the unit of the typed value is displayed next to the number Version 3 1 rev 17782 11 Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 11 3 On screen Expression Editor 11 2 On screen Keyboard abcdef lt lt 3 Cancel Simple tex
155. point after Remove this waypoint Q simulation gt Speed c 1009 Previous Next gt o Real Robot A point on the robot path Waypoints are the most central part of a robot program telling the robot arm where to be A fixed position waypoint is given by physically moving the robot arm to the position Setting the waypoint Press this button to enter the Move screen where you can specify the robot arm s position for this waypoint If the waypoint is placed under a Move command in linear space moveL or moveP there needs to be a valid feature selected at that Move command in order for this button to be pressable Waypoint names Waypoint names can be changed Two waypoints with the same name is always the same waypoint Waypoints are numbered as they are specified Blend radius If a blend radius is set the robot arm trajectory blends around the waypoint al lowing the robot arm not to stop at the point Blends cannot overlap so it is not possible to set a blend radius that overlaps a blend radius for a previous or follow ing waypont A stop point is a waypoint with a blend radius of 0 0 Note on I O Timing If a waypoint is a stop point with an I O command as the next command the I O command is executed when the robot arm stops at the waypoint However if the Version 3 1 II 51 C
156. r 9 a8th Corner es PalletSequence 9 Approach 9 PatternPoint Set Wait 9 Exit ee Destack 9 StartPos Direction em 9 FromPos D 38 ToPos 6 T D so PickSequence StackPos 7i Set 4 Wait 1 oe re CS 9 Exit Due I Previous Next gt simulation Speed 00 o Real Robot A Box pattern uses three vectors to define the side of the box These three vectors are given as four points where the first vector goes from point one to point two the second vector goes from point two to point three and the third vector goes from point three to point four Each vector is divided by the interval count numbers A specific position in the pattern is calculated by simply adding the interval vectors proportionally The Line and Square patterns work similarly A counter variable is used while traversing the positions of the pattern The name of the variable can be seen on the Pattern command screen The variable cycles Version 3 1 II 65 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 23 Command Force through the numbers from 0 to X Y x Z 1 the number of points in the pattern This variable can be manipulated using assignments a
157. r requiring two inputs the robot is able to determine the speed and direc tion of the conveyor If the direction of the coneyor is constant a single input can be used counting on Rising Falling or Rise and Fall edges to determine the speed of the conveyor Absolute encoders can be used when connected through a MODBUS signal This requires that a digital MODBUS input register is preconfigured in the 12 11 Version 3 1 II 35 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 14 Installation Default Program Linear conveyors When a linear conveyor is selected a line feature must be configured to determine the direction of the conveyor The line feature should be parallel to the direction of the conveyor and there should be a large distance between the two points defining the line feature It is recommended to configure the line feature by by placing the tool firmly against the side of the conveyor when teaching the two points The value of Ticks per meter must be the number of ticks the encoder gener ates when the conveyor moves one meter ticks per revolution of encoder 2 radius of encoder disc m Ticks per meter 12 1 Circular conveyors When tracking a circular conveyor the center point of the conveyor circle must be defined The value of Ticks per revolution must be the number
158. re not the status LED above the buttons turns red Furthermore even though three positions are usually sufficient to determine the correct TCP the fourth position can be used to further verify that the calculation is correct The quality of each saved point with respect to the calculated TCP is indicated using a green yellow or red LED on the respective button CB3 I 24 Version 3 1 12 6 Installation TCP Configuration UNIVERSAL ROBOTS 12 6 4 Teaching TCP orientation Q File 16 50 23 CCCC Q Program Installation Move Log Configuration Setup for the Tool Center Point Mounting Setup Teach TCP Orientation vh Safety No feature has been selected Variables Choose a feature and set a point with the tool pointing in the direction of the Z axis of the MODBUS client Features selected feature Conveyor Tracking PENES 7 Default Program Load Save Set point X cancel orientation can be calculated automatically as follows 1 Tap the Orientation button 2 Select a feature from the drop down list For additional information about how new features can be defined see 12 12 3 Use the button below to move to a position in which the orientation of the tool corresponding to the TCP coincides with the coordinate system of the selected feature 4 Verify the calculated TCP orientation and set it onto the selected TCP using the Set butt
159. related Electrical Inputs The table below gives an overview of the safety related electrical inputs Version 3 1 1 37 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 5 3 Safety related Electrical Interfaces rad s Max joint speed in normal mode time 0 024 0 524 s Figure 5 2 The green area below the ramp is the allowed speeds for a joint during braking At time 0 an event emergency stop or safeguard stop is detected at the safety processor Deceleration begins after 24 ms Safety Input Description Robot emergency stop Performs a category 1 stop informing other machines using the System emergency stop output Emergency stop button Performs a category 1 stop informing other machines using the System emergency stop output System emergency stop Performs a category 1 stop Safeguard stop Performs a category 2 stop Safeguard reset input Resumes the robot from a Safeguard stopped state when an edge on the Safeguard reset input occurs Reduced mode The safety system transitions to Reduced mode limits A category 1 and 2 stop decelerates the robot with drive power on which enables the robot to stop without deviating from its current path Monitoring of safety inputs Category 1 and 2 stops are monitored by the safety system in the following way 1 The safety system monitors that t
160. ression continuous Wait V Folder Comment Halt Popup et m TRE 4 D FERNER Simulation Speed 00 Previous Next gt o Real Robot CB3 II 58 Version 3 1 rev 17782 13 16 Command SubProgram UNIVERSAL ROBOTS Loops the underlying program commands Depending on the selection the under lying program commands are either looped infinitely a certain number of times or as long as the given condition is true When looping a certain number of times a dedicated loop variable called Loop_1 in the screen shot above is created which can be used in expressions within the loop The loop variable counts from 0 to N 1 When looping using an expression as end condition PolyScope provides an option for continuously evaluating that expression so that the loop can be interrupted anytime during its execution rather than just after each iteration 13 16 Command SubProgram File Program Installation Move VO Log 16 50 09 CCCC Q lt unnamed gt Set Wait 9 Exit so Destack 9 StartPos 9 Direction 9 FromPos 9 ToPos PickSequence 9 StackPos Set Wait 9 Exit Wait V Folder Comment Halt Popup V Loop e empt Bl Script var 2 2 force P Call SubProgram 1 vf lt empty gt a Command Graphics Structure
161. rface shall be vibration free If the robot is mounted on a linear axis or a moving platform then the acceleration of the moving mounting base shall be very low A high acceleration might cause Version 3 1 rev 17782 I 13 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 3 2 Mounting the robot to stop thinking it bumped into something DANGER Make sure the robot arm is properly and securely bolted in place The mounting surface shall be sturdy CAUTION If the robot is bathed in water over an extended time period it might be damaged The robot should not be mounted in water or in a wet environment Tool The robot tool flange has four M6 thread holes for attaching a tool to the robot The holes need to be tightened with 9 N m If very accurate repositioning of the tool is desired the 06 hole is provided for use with a pin Figure 3 2 shows where to drill holes and mount the screws DANGER 1 Make sure the tool is properly and securely bolted in place 2 Make sure that the tool is constructed such that it cannot cre ate a hazardous situation by dropping a part unexpectedly Control Box The control box can be hung on a wall or it can be placed on the ground A clearance of 50mm on each side is needed for sufficient airflow Extra brackets for mounting can be bought Teach Pendant The tea
162. robot protective stops Units are mm and deg Test force settings The on off button labeled Test toggles the behavior of the Freedrive button on the back of the Teach Pendant from normal Freedrive mode to testing the force command When the Test button is on and the Freedrive button on the back of the Teach Pen dant is pressed the robot will perform as if the program had reached this force command and this way the settings can be verified before actually running the complete program Especially this possibility is useful for verifying that compliant axes and forces have been selected correctly Simply hold the robot TCP using one hand and press the Freedrive button with the other and notice in which directions the robot arm can cannot be moved Upon leaving this screen the Test button au tomatically switches off which means the Freedrive button on the back of the Teach Pendant is again used for regular Freedrive mode Note The Freedrive button will only be effectual when a valid feature has been selected for the Force command CB3 Il 68 Version 3 1 13 24 Command Pallet UNIVERSAL ROBOTS 13 24 Command Pallet File 16 50 10 CCCC Q Program Installation Move VO Log lt unnamed gt Command Graphics Structure Variables amp Pallet 4 Pattern Pallet 4 PalletSequence Approach A pallet operation allows the robot to perform the same sequence of motions
163. s For further information about configuring named TCPs see 12 6 Feature selection For MoveL and MoveP it is possible to select which feature space the waypoints un der the Move command should be represented when specifying these waypoints This means that when setting a waypoint the program will remember the tool co ordinates in the feature space of the selected feature There are a few circumstances that need detailed explanation Version 3 1 II 49 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 5 Command Move Cruise Deceleration 5 o D Acceleration Time Figure 13 1 Speed profile for a motion The curve is divided into three segments acceleration cruise and deceleration The level of the cruise phase is given by the speed setting of the motion while the steepness of the acceleration and deceleration phases is given by the acceleration parameter Relative waypoints The selected feature has no effect on relative waypoints The relative movement is always performed w r t to orientation of the Base Variable waypoints When the robot arm moves to a variable waypoint the tool tar get position is calculated as the coordinates of the variable in the space of the selected feature Therefore the robot arm movement for a variable waypoint changes if another feature is selected
164. s The values aypoint set under Shared Parameters apply to all waypoints below and depend on the selected Set movement type ee Pallet 9 alst Corner a2nd Cornei 9 a4th Cornen J 9 StackPos Reset to defaults Set B il D gt t e Add Waypoint Q simulation gt Speed 00 Previous Next gt Real Robot The Move command controls the robot motion through the underlying waypoints Waypoints have to be under a Move command The Move command defines the acceleration and the speed at which the robot arm will move between those way points Movement Types It is possible to select one of three types of movements Move MoveL and MoveP each explained below e moveJ will make movements that are calculated in the joint space of the robot arm Each joint is controlled to reach the desired end location at the same time This movement type results in a curved path for the tool The shared parameters that apply to this movement type are the maximum joint speed and joint acceleration to use for the movement calculations specified in deg 5 and deg s respectively If it is desired to have the robot arm move fast be tween waypoints disregarding the path of the tool between those waypoints this movement type is the favorable choice moveL will make the tool m
165. s about to exceed joint speed tool speed or momentum limit in the new limit set Note that since these limits are required to be more restrictive in the Reduced mode CB3 Il 98 Version 3 1 15 11 Boundaries UNIVERSAL ROBOTS limit set such premature deceleration can occur only when transitioning from Nor mal to Reduced mode 15 11 4 Tool Boundary configuration Q File 16 51 15 CCCC Q Program Installation Move Log Pee contigratton Safety Configuration Mounting General Limits Joint Limits Boundaries Safety Wo Setup Safety Boundaries 3D View Safety Safety plane 0 O Variables Safety plane 1 MODBUS client Safety plane 2 amp ie Safety plane 3 Features afety plane 4 Conveyor Tracking Safety plane 5 Default Program ica are ane 6 Load Save Safety plane 7 Tool Boundary e Tool Boundary Properties Deviation Boundary restricts 35 5 181 1 0 soth M Copy Feature lt Undefined gt v Lock Apply The Tool Boundary Properties panelat the bottom of the tab defines a limit on the orientation of robot tool composed of a desired tool orientation and a value for the maximum allowed deviation from this orientation Deviation The Deviation text field shows the value for the maximum allowed deviation of the orientation of the robot tool from the desired orientation Mo
166. s accessible on this screen and its subtabs are required to be set according to the risk assessment 3 The integrator is required to ensure that all changes to the safety settings are done in agreement with the risk assess ment The safety settings consist of a number of limit values used to constrain the move ments of the robot arm and of safety function settings for the configurable inputs and outputs They are defined in the following subtabs of the safety screen Version 3 1 Il 85 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 2 Safety Synchronization and Errors The General Limits subtab defines the maximum force power speed and momentum of the robot arm When the risk of hitting a human or colliding with a part of its environment is particularly high these settings need to be set to low values If the risk is low higher general limits enable the robot to move faster and exert more force on its environment For further details see 15 9 The Joint Limits subtab consists of joint speed and joint position limits The joint speed limits define the maximum angular velocity of individual joints and serve to further limit the speed of the robot arm The joint position limits define the allowed position range of individual joints in joint space For further details see 15 10 The Boundaries subtab
167. s around can 13 30 Variables Tab File Program Installation Move 1 0 Log 16 51 03 CCCC Q Init Variables a Variables lt unnamed gt Command Graphics Structure Variables M ML qm Var 2 2 9874386E 6 9 Waypoint V Move Waypoint 1 Variable Set oe Pallet 4 Pattern Square 9 alst Corner a2nd 9 a3rd_Corner a4th s PalletSequence 9 Approach 9 PatternPoint Set Wait 9 Exit ee Destack 9 StartPos 4 Direction 9 FromPos 9 ToPos ss PickSequence 9 StackPos 52 i o o Clear ae E ae G Simulation IE gt bi Speed 21 0096 Previous Next gt Real Robot The Variables tab shows the live values of variables in the running program and keeps a list of variables and values between program runs It only appears when it has information to display The variables are ordered alphabetically by their names The variable names on this screen are shown with at most 50 characters and the values of the variables are shown with at most 500 characters CB3 II 76 Version 3 1 13 31 Command Variables Initialization UNIVERSAL ROBOTS 13 31 Command Variables Initialization File 16 50 21 CCCC Program Installation Move 1 0 Log lt unnamed gt Command
168. s corresponds to the setup of the remote MODBUS server E3 ILLEGAL DATA VALUE 0x03 A value contained in the query data field is not an allowable value for server or slave check that the enterd signal value is valid for the specified address on the remote MODBUS server E4 SLAVE DEVICE FAILURE 0x04 An unrecoverable error occurred while the server or slave was attempting to perform the requested action E5 ACKNOWLEDGE 0x05 Specialized use in conjunction with program ming commands sent to the remote MODBUS unit E6 SLAVE DEVICE BUSY 0x06 Specialized use in conjunction with pro gramming commands sent to the remote MODBUS unit the slave server is not able to respond now Show Advanced Options This check box shows hides the advanced options for each signal Advanced Options Update Frequency This menu can be used to change the update frequency of the signal This means the frequency with which requests are sent to the remote MODBUS unit for either reading or writing the signal value Slave Address This text field can be used to set a specific slave address for the requests corresponding to a specific signal The value must be in the range 0 255 both included and the default is 255 If you change this value it is recommended to consult the manual of the remote MODBUS device to verify its functionality when changing slave address Version 3 1 II 31 CB3 Copyright 2009 2015 by Universal Robots
169. s hot surface which if touched could result in injury CAUTION This indicates a situation which if not avoided could result in damage to the equipment UR5 CB3 1 4 Version 3 1 1 5 General Warnings and Cautions UNIVERSAL ROBOTS 1 5 General Warnings and Cautions This section contains some general warnings and cautions Some of which are re peated or explained in different parts of the manual Other warnings and cautions are present throughout the manual 4 10 11 DANGER Make sure to install the robot and all electrical equipment accord ing to the specifications and warnings found in the Chapters 3 and WARNING 1 Make sure the robot arm and tool are properly and securely bolted in place Make sure the robot arm has ample space to operate freely Make sure that safety measures and or robot safety configu ration parameters have been set up to protect both program mers operators and bystanders as defined in the risk assess ment Do not wear loose clothing or jewellery when working with the robot Make sure long hair is tied back when working with the robot Never use the robot if it is damaged If the software prompts a fatal error immediately activate emergency stop write down the conditions that led to the er ror find the corresponding error codes on the log screen and contact your supplier Do not connect any safety equipment to normal I O Use sa
170. s workspace Examples are when the robot arm has to move to the start position of a program before running it or when moving to a waypoint while modifying a program CB3 Il 20 Version 3 1 12 4 AutoMove Tab UNIVERSAL ROBOTS o 16 49 53 CCCC Q Run Move 1 0 Log Automove Move Robot into Position Hold down Auto to perform the movement shown Release the button to abort Push Manual to move the robot into position manually Auto Speed 10096 Xx Cancel Animation The animation shows the movement the robot arm is about to perform CAUTION Compare the animation with the position of the real robot arm and make sure that the robot arm can safely perform the movement without hitting any obstacles CAUTION The automove function moves along the robot along the shadow trajectory Collision might damage the robot or other equipment Auto Hold down the Auto button to move the robot arm as shown in the animation Note Release the button to stop the motion at any time Manual Pushing the Manual button will take you to the MoveTab where the robot arm can be moved manually This is only needed if the movement in the animation is not preferable Version 3 1 II 21 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROB
171. shall not cover any conse quential damage or loss such as loss of production or damage to other production equipment 9 2 Disclaimer Universal Robots continues to improve reliability and performance of its products and therefore reserves the right to upgrade the product without prior warning Universal Robots takes every care that the contents of this manual are precise and correct but takes no responsibility for any errors or missing information Version 3 1 1 47 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved 9 2 Disclaimer UNIVERSAL ROBOTS penJesei suu S v sioqog jesienum Aq s L02 6002 1uBuKdoo Version 3 1 1 48 UR5 CB3 The information about stopping times and distances is available for both CATE GORY 0 and CATEGORY 1 stops This appendix includes the information re garding stop CATEGORY 0 Information on CATEGORY 1 stop is available on http support universal robots com A 1 CATEGORY O0 stopping distances and times The table below includes the stopping distances and times measured when a CAT EGORY 0 stop is triggered These measurements correspond to the following con figuration of the robot Extension 10076 the robot arm is fully extended horizontally Speed 100 the general speed of the robot is set to 100 and the movement is performed at a joint speed of 183 5 Payload maximum payload handled by the robot attached to the TCP
172. shown Press the button to change it Add signal Push this button to add a signal to the corresponding MODBUS unit Delete signal Push this button to delete a MODBUS signal from the corresponding MODBUS unit Set signal type Use this drop down menu to choose the signal type Available types are Digital input A digital input coil is a one bit quantity which is read from the MODBUS unit on the coil specified in the address field of the signal Function code 0x02 Read Discrete Inputs is used Digital output A digital output coil is a one bit quantity which can be set to either high or low Before the value of this output has been set by the user the value is read from the remote MODBUS unit This means that function code 0x01 Read Coils is used When the output has been set by a robot program or by pressing the set signal value button the function code 0x05 Write Single Coil is used onwards Register input A register input is a 16 bit quantity read from the address specified in the address field The function code 0x04 Read Input Registers is used Register output A register output is a 16 bit quantity which can be set by the user Before the value of the register has been set the value of it is read from the remote MODBUS unit This means that function code 0x03 Read Holding Registers is used When the output has been set by a robot program or by specifying a signal value in the set signal value fie
173. signals Yellow with black text Configurable for safety Gray with black text General purpose digital I O Green with black text General purpose analog I O The configurable I O can be configured as either safety related I O or general purpose I O in the GUI See more in part II How to use the digital I O is described in the following subsections The section describing the common specifications must be observed 4 3 1 Common specifications for all digital I O This section define electrical specifications for the following 24V digital I O of the control box Safety I O Configurable I O General purpose I O It is very important that UR robots are installed according the electrical specifica tions which are the same for all three different kinds of inputs It is possible to power the digital I O from an internal 24V power supply or from an external power source by configuring the terminal block called Power This block consists of four terminals The upper two PWR and GND are 24V and ground from the internal 24V supply The lower two terminals 24V and OV in the block are the 24V input to supply the I O The default configuration is to use the internal power supply see below Version 3 1 1 19 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 4 3 Controller
174. sion 3 1 4 7 Robot connection UNIVERSAL ROBOTS DANGER 1 Make sure that the robot is grounded correctly Electrical connection to earth Use the unused bolts associated with grounding symbols inside the controller box to create com mon grounding of all equipment in the system The ground ing conductor shall have at least the current rating of the high est current in the system 2 Make sure that the input power to the controller box is pro tected with a RCD Residual Current Device and a correct fuse 3 Lockout and tagout all power for the complete robot installa tion during service Other equipment shall not supply volt age to the robot I O when the system is locked out 4 Make sure that all cables are connected correctly before the controller box is powered Always use an original and correct power cord 4 7 Robot connection The cable from the robot must be plugged into the connector at bottom of the con trol box see illustration below Ensure that the connector is properly locked before turning on the robot arm Disconnecting the robot cable may only be done when the robot power is turned off CAUTION 1 Do not disconnect the robot cable when the robot arm is turned on 2 Do not extend or modify the original cable Version 3 1 1 33 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved 4 7 Robot connection UNIVERSAL ROBOTS penJesei suu S v s
175. specifications in section 4 3 1 must be observed UR5 CB3 1 20 Version 3 1 4 3 Controller I O UNIVERSAL ROBOTS Safety devices and equipment must be installed according to the safety instructions and the risk assessment see chapter 1 safety I O are pairwise redundant and must be kept as two separate branches A single fault shall not cause loss of the safety function The two permanent safety inputs are the emergency stop and the safeguard stop The emergency stop input is for emergency stop equipment only The safeguard stop input is for all kinds of safety related protective equipment The functional difference is shown below Emergency Stop Safeguard Stop Robot stops moving Yes Yes Program execution Stops Pauses Robot power Off On Reset Manual Automatic or manual Frequency of use Infrequent Every cycle to infrequent Requires re initialization Brake release only No Stop category IEC 60204 1 2 Performance level of monitoring function ISO 13849 1 PLd PLd It is possible to use the configurable I O to set up additional safety I O function ality e g emergency stop output Configuring a set of configurable I O for safety functions are done through the GUI see part II Some examples of how to use safety I O are shown in the following subsections DANGER 1 Never connect safety signals to a PLC which is not a safety PLC with the correct safety level Failure to follow this warn ing could re
176. ssage o Destack G Warning 9 StartPos 9 Direction Error 9 FromPos 9 ToPos ee PickSequence 9 StackPos Set Wait 9 Exit Wait V Folder e Comment Halt Popup I il Ii bow a_a Halt program execution at this popup i a d o Speed 100 Previous Next gt Real Robot The popup is a message that appears on the screen when the program reaches this command The style of the message can be selected and the text itself can be given using the on screen keyboard The robot waits for the user operator to press the OK button under the popup before continuing the program If the Halt program execution item is selected the robot program halts at this popup CB3 II 56 Version 3 1 13 12 Command Halt UNIVERSAL ROBOTS 13 12 Command Halt File 16 50 05 CCCC Program Installation Move 1 0 Log lt unnamed gt Command Graphics Structure Variables Waypoint a V Move Waypoint r3 Halt enr P tion stops at this point Pallet rogram execution stops at this point ee Pattern e PalletSequencel 9 Approach 9 PatternPoint e Set Wait 9 Exit ee Destack 9 StartPos e Direction 9 FromPos 9 ToPos PickSequence 9 StackPos lt o
177. sult in serious injury or death as one of safety stop functions could be overridden It is important to keep safety interface signals separated from the normal I O interface sig nals 2 All safety related I O are constructed redundantly Two in dependent channels Keep the two channels separate so that a single fault cannot lead to loss of the safety function 3 Safety functions must be verified before putting the robot into operation Safety functions must be tested regularly 4 The robot installation shall conform to these specifications Failure to do so could result in serious injury or death as the safety stop function could be overridden Version 3 1 1 21 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 4 3 Controller I O 4 3 2 1 Default safety configuration The robot is shipped with a default configuration which enables operation without any additional safety equipment see illustration below 4 3 2 2 Connecting emergency stop buttons In most applications it is required to use one or more extra emergency stop buttons The illustration below show how one or more emergency stop buttons 4 3 2 3 Sharing emergency stop with other machines It is often desired to set up a common emergency stop circuit when the robot is used together with oth
178. t Itis essential that all assembly instructions and guidance provided in other chapters and parts of this manual are observed and followed Special attention shall be paid to text associated with warning symbols See Chap ter 5 for detailed descriptions of the safety related functions and interfaces 1 2 Validity and Responsibility The information does not cover how to design install and operate a complete robot application nor does it cover all peripheral equipment that can influence the safety of the complete system The complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed The integrators of UR robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that any significant hazards in the complete robot application are eliminated This includes but is not limited to Making a risk assessment for the complete system Interfacing other machines and additional safety devices if defined by the risk assessment Setting up the appropriate safety settings in the software Ensuring that the user will not modify any safety measures Validating that the total system is designed and installed correctly Specifying instructions for use Marking the robot installation with relevant signs and contact information of the integrator
179. t A direction is given by the line between the TCP position of two waypoints O Stop after 500 0 mm O Stop when food x T e Wait V Folder cempiys omen Shared Parameters Halt Popup Tool Speed 10 mm s V Loop lt emp Tool Acceleration 1200 mm s B Script Reset to defaults 4 lt gt ren o Speed c 00 Previous Nex gt The direction is given by two positions and is calculated as the position difference from the first positions TCP to the second positions TCP Note A direction does not consider the orientat ions of the points Next Stacking Position Expression The robot arm moves along the direction vector while continuously evaluating whether the next stack position has been reached When the expression is eval uated to True the special sequence is executed BeforeStart The optional BeforeStart sequence is run just before the operation starts This can be used to wait f or ready signals AfterEnd The optional After End sequence is run when the operation is finished This can be used to signal conveyor motion to start preparing for the next stack Pick Place Sequence Like for the Pallet operation 13 24 a special program sequence is performed at each stack position 13 26 Command Start Stop
180. t belongs to are shown in blue If the program is paused the program execution indicator icon marks the last com mand that was in the process of being executed Clicking the button with the icon below the program tree jumps to the current executing or the last executed command in the tree If a command is clicked while a program is running the Command tab will keep displaying the information re lated to the selected command Pressing the 9 button will make the Command tab continuously show information about the currently executing commands again 13 2 3 Undo Redo Buttons The buttons with icons and below the program tree serve to undo and redo changes made in the program tree and in the commands it contains 13 2 4 Program Dashboard The lowest part of the screen is the Dashboard The Dashboard features a set of but tons similar to an old fashioned tape recorder from which programs can be started Version 3 1 II 45 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 3 Variables and stopped single stepped and restarted The speed slider allows you to adjust the program speed at any time which directly affects the speed at which the robot arm moves Additionally the speed slider shows in real time the relative speed at which the robot arm moves taking into account the safety settings The indicated
181. t typing and editing facilities The Shift key can be used to get some additional special characters 11 3 On screen Expression Editor uy 2 force lt lt not True HI gt i z gt False LO Input lt Output gt v lt Variable gt z lt Pose gt v lt gt v Shift CB3 I 12 Version 3 1 rev 17782 11 4 Pose Editor Screen UNIVERSAL ROBOTS While the expression itself is edited as text the expression editor has a number of buttons and functions for inserting the special expression symbols such as for multiplication and lt for less than or equal to The keyboard symbol button in the top right of the screen switches to text editing of the expression defined variables can be found in the Variable selector while the names of the input and output ports can be found in the Input and Output selectors Some special functions are found in Function The expression is checked for grammatical errors when the Ok button is pressed The Cancel button leaves the screen discarding all changes An expression can look like this digital in 1 True and analog in 0 0 5 11 4 Pose Editor Screen On this screen you can specify target joint positions or a target pose position and orientation of the robot tool This screen is offline and does
182. tage 0 0 5 V ON OFF Active voltage 5 12 V ON OFF Input current 1 mA ON Activation time 200 600 ms The following examples show how to use remote ON OFF NOTE A special feature in the software can be used to load and start pro grams automatically see part II CAUTION 1 Never use the on input or the power button to turn off the control box Version 3 1 I 27 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 4 4 Tool I O 4 3 7 4 Remote ON button The illustration below shows how to connect a remote on button 4 3 7 2 Remote OFF button The illustration below shows how to connect a remote off button 4 4 Tool I O At the tool end of the robot there is a small connector with eight pins see illustration below This connector provides power and control signals for grippers and sensors used on a specific robot tool The following industrial cables are suitable Lumberg RKMV 8 354 The eight wires inside the cable have different colors The different colors designate different functions see table below Color Signal Red 0V GND Gray 0V 412V 24V POWER Blue Digital output 8 008 Pink Digital output 9 DO9 Yellow Digital input 8 DI8 Green Digital input 9
183. ted The magnitude of the force increases as the robot arm comes closer to the limit 15 7 Password Lock settings on this screen are locked until the correct Safety password see 14 3 is entered in the white text field at the bottom of the screen and the Unlock but ton is pressed The screen can be locked again by clicking the Lock button The Safety tab is automatically locked when navigating away from the Safety Config uration screen When the settings are locked a lock icon is visible next to the text Safety on the left side of the screen An unlock icon is shown when the settings are unlocked NOTE Note that the robot arm is powered off when the Safety Configu ration screen is unlocked 15 8 Apply When unlocking the safety configuration the robot arm will be powered off while changes are being made The robot arm cannot be powered on until the changes have been applied or reverted and a manual power on is performed from the ini tialization screen Any changes to the safety configuration must be applied or re verted before navigating away from the Installation tab These changes are not in effect until after the Apply button is pressed and confirmation is performed Confirmation requires visual inspection of the changes given to the robot arm For safety reasons the information shown is given in SI Units An example of the con firmation dialog is shown in figure 15 8 Version 3 1 II 89 CB3 Copyright
184. that all of the safety instructions in chapter 1 are followed How to Read This Manual This manual contains instructions for installing and using the robot It consists of the following parts Hardware Installation Manual The mechanical and electrical installation of the robot PolyScope Manual Programming of the robot This manual is intended for the integrator who is expected to have a basic level of mechanical and electrical training It is also helpful though not necessary to be familiar with elementary concepts of programming No special knowledge about robots in general or Universal Robots in particular is required Where to Find More Information The support website http support universal robots com available to all UR distributors contains additional information such as Other language versions of this manual PolyScope Manual updates after the PolyScope is upgraded to a new version The Service Manual with instructions for troubleshooting maintenance and re pair of the robot The Script Manual for advanced users UR5 CB3 x Version 3 1 Part I Hardware Installation Manual 1 1 Introduction This chapter contains important safety information which must be read and un derstood by the integrator of UR robots The first subsections in this chapter are more general and the later subsections con tain more specific engineering data relevant for setting up and programming the robo
185. the log entry The second column shows the time of arrival of the message The next column shows the sender of the message While the last column shows the message itself Messages can be filtered by selecting the toggle buttons which correspond to the severity The figure above now shows that errors will be displayed while information and warning messages will be filtered Some log messages are designed to provide more information this can be accessed by selecting the log entry 12 16 Load Screen On this screen you choose which program to load There are two versions of this screen one that is to be used when you just want to load a program and execute it and one that is used when you want to actually edit a program CB3 Il 38 Version 3 1 12 16 Load Screen UNIVERSAL ROBOTS NOTE Running a program from a USB drive is not recommended To run a program stored on a USB drive first load it and then save it in the local programs folder using the Save As option in the Filemenu The main difference lies in which actions are available to the user In the basic load screen the user will only be able to access files not modify or delete them Furthermore the user is not allowed to leave the directory structure that descends from the programs folder The user can descend to a sub directory but he cannot get any higher than the programs folder Therefore all programs should be placed in the programs folder and or su
186. thin the limits The subtabs of the Safety Configuration screen enable the user to define sep arate sets of safety limits for Normal and Reduced mode For the tool and joints Reduced mode limits regarding speed and momentum are required to be more re strictive than their Normal mode counterparts When a safety limit from the active limit set is violated the robot arm performs a category 0 stop If an active safety limit such as a joint position limit or a safety boundary is violated already when the robot arm is powered on it starts up in CB3 Il 88 Version 3 1 15 6 Freedrive Mode UNIVERSAL ROBOTS Recovery mode This makes it possible to move the robot arm back within the safety limits While in Recovery mode the movement of the robot arm is limited by a fixed limit set that is not customizable by the user For details about Recovery mode limits see the Hardware Installation Manual 15 6 Freedrive Mode When in Freedrive mode see 12 1 5 and the movement of the robot arm comes close to certain limits the user will feel a repelling force This force is generated for limits on the position orientation and speed of the robot TCP and the position and speed of the joints The purpose of this repelling force is to inform the user that the current position or speed is close to a limit and to prevent the robot from violating that limit However if enough force is applied by the user to the robot arm the limit can be viola
187. tion vector The length of the axis is the angle to be rotated in radians and the vector itself gives the axis about which to rotate This is the default setting Rotation Vector The orientation is given as a rotation vector where the length of the vector is the angle to be rotated in degrees RPY rad Roll pitch and yaw RPY angles where the angles are in radians The RPY rotation matrix X Y Z rotation is given by Rrpy y B x Ry B Rxy RPY Roll pitch and yaw RPY angles where angles are in degrees Values can be edited by clicking on the coordinate Clicking on the or buttons just to the right of a box allows you to add or subtract an amount to from the current value Pressing and holding down a button will directly increase decrease the value The longer the button is down the larger the increase decrease will be Joint positions Allows the individual joint positions to be specified directly Each joint position can have a value in the range from 360 to 360 which are the joint limits Values can be edited by clicking on the joint position Clicking on the or buttons just to the CB3 II 14 Version 3 1 11 4 Pose Editor Screen UNIVERSAL ROBOTS right of a box allows you to add or subtract an amount to from the current value Pressing and holding down a button will directly increase decrease the value The longer the button is down the larger the increase decre
188. tte Universal Robots A S Manufacturing plant Energivej 25 DK 5260 Odense S Denmark Beschreibung des Produktes Universal Robots Safety System URSafety 3 1 Details s Anlage 1 for UR10 UR5 and robots EN ISO 13849 1 Description of product d Details see Annex 1 Gepr ft nach EN ISO 13849 1 2008 PL d Tested in accordance with Registrier Nr Registration No 44 207 14097602 G ltigkeit Validity Pr fbericht Nr Test Report No 3515 4327 von from 2015 06 02 Aktenzeichen File reference 8000443298 bis until 2020 06 01 CERT GmbH Essen 2015 06 02 T V NORD CERT GmbH Langemarckstra amp e 20 45141 Essen www tuev nord cert de technology tuev nord de Bitte beachten Sie auch die umseitigen Hinweise Please also pay attention to the information stated overleaf UR5 CB3 1 52 Version 3 1 rev 17782 B 3 Environmental Test Certificate UNIVERSAL ROBOTS B 3 Environmental Test Certificate Climatic and mechanical assessment sheet no 1275 DELTA client Universal Robots A S Energivej 25 5260 Odense S Denmark DELTA project no T207415 1 Product identification URS robot arm UR5 AE CB3 OA series URS control box AE CB3 URS teach pendant AE CB3 URIO robot arm UR10 AE CB3 OA series URIO control box URIO AE CB3 UR10 teach pendant AE CB3 DELTA report s DELTA project no T207415 1 DA
189. ucture Editor Set placement of node After selected M Insert Basic Advanced Wizards Move Waypoint Wait Set Popup Halt Comment Folder Edit Move Copy Paste Suppress Move Cut Delete lt gt b Speed c 100 Previous Next gt o Real Robot L The program structure tab gives an opportunity for inserting moving copying and removing the various types of commands To insert new commands perform the following steps 1 Select an existing program command 2 Select whether the new command should be inserted above or below the se lected command II 75 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 30 Variables Tab 3 Press the button for the command type you wish to insert For adjusting the details for the new command go to the Command tab Commands can be moved cloned deleted using the buttons in the edit frame If a command has sub commands a triangle next to the command all sub commands are also moved cloned deleted Not all commands fit at all places in a program Waypoints must be under a Move command not necessarily directly under are required to be after an If In general moving ElseIf and be messy Variables must be assigned values before being used Else commands Elself command
190. ulation o Real Robot gt Speed 100 Previous Next gt An event can be used to monitor an input signal and perform some action or set a variable when that input signal goes high For example in the event that an output signal goes high the event program can wait for 200ms and then set it back to low again This can make the main program code a lot simpler in the case on an external machine triggering on a rising flank rather than a high input level Events are checked once every control cycle 8ms Version 3 1 CV II 63 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 13 22 Command Pattern 13 21 Command Thread File 16 50 20 CCCC Q Program Installation Move I O Log lt unnamed gt Command Graphics Structure Variables 9 Exit a wait Thread 9 7 Folder a lt gt A thread is a parallel program that runs along with the main program A thread can perform 1 0 Comment wait for signals and set variables s Halt Useful for controlling other machines while the robot is running Popup V Loop E Script var 2 2 force P Call SubProgram 1 9 V ee Pallet ee Pattern s PalletSequence Approach 9 PatternPoint Set E Wait 9 Exit P SubProgram 1
191. ult of unintended repowering during maintenance or repair and as a result of unintended start up commands from a control perspective IEC 60947 5 5 A1 2005 EN 60947 5 5 A11 2013 2006 42 EC Low voltage switchgear and controlgear Part 5 5 Control circuit devices and switching elements Electrical emergency stop device with mechanical latching function The direct opening action and the safety lock mechanism of the emergency stop button comply with requirements in this standard IEC 60529 2013 EN 60529 A2 2013 Degrees of protection provided by enclosures IP Code This standard defines enclosure ratings regarding protection against dust and water UR robots are designed and classified with an IP code according to this standard see robot sticker UR5 CB3 I 58 Version 3 1 UNIVERSAL ROBOTS IEC 60320 1 A1 2007 EN 60320 1 A1 2007 2006 95 EC Appliance couplers for household and similar general purposes Part 1 General requirements The mains input cable complies with this standard ISO 9409 1 2004 Type 50 4 M6 Manipulating industrial robots Mechanical interfaces Part 1 Plates The tool flange on UR robots conforms to type 50 4 M6 of this standard Robot tools should also be constructed according to this standard to ensure proper fitting ISO 13732 1 2006 EN ISO 13732 1 2008 2006 42 EC Ergonomics of the thermal environment Methods for the assessment of human responses to contact wit
192. us screens of PolyScope are described in the following sections Version 3 1 II 7 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 10 3 Welcome Screen 10 3 Welcome Screen PolyScope Robot User Interface Please select Run Program UNIVERSAL ROBOTS a Setup Robot About Shutdown Robot After booting up the controller PC the welcome screen is shown The screen offers the following options Run Program Choose and run an existing program This is the simplest way to operate the robot arm and control box Program Robot Change a program or create a new program Setup Robot Set passwords upgrade software request support calibrate the touch screen etc Shutdown Robot Powers off the robot arm and shuts down the control box CB3 Il 8 Version 3 1 10 4 Initialization Screen UNIVERSAL ROBOTS 10 4 Initialization Screen Initialize Robot Make sure that the installation and payload are correct and press the button with the green icon to initialize the robot Robot Normal Current Payload 0 00 kg OFF Installation file default Load Installation 3D View RRA Configure TCP Configure Mounting On this screen you control the initialization of the robot arm Robot arm state indicator The status LED giv
193. users only and instruc tions on how to use it can be found in the Script Manual on the support website http support universal robots com Note that only UR distributors and OEM customers have access to the website If the File option in the top left corner is choosen it is possible to create and edit script programs files This way long and complex script programs can be used together with the operator friendly programming of PolyScope CB3 Il 62 Version 3 1 13 20 Command Event UNIVERSAL ROBOTS 13 20 Command Event File Program Installation Move Log 16 50 20 CCCC Q lt unnamed gt Set Wait 9 Exit Wait V Folder e lt empty gt nd Comment Halt Popup V Loop Bl Script P Call SubProgram 1 V If ee Pallet Pattern Approach 9 PatternPoint Set Wait 9 Exit P SubProgram 1 lt empty gt Event 4 il D gt var 2 2 force e PalletSequence lt Command Graphics Structure Variables Event An Event is simmilar to an Interrupt however in an event the execution of the main program continues while the event code is being executed While the event is being executed new events will have no effect Depending on the state of the given sensor input or program variable the following ines will be executed sim
194. w like the Freedrive button on the back of the Teach Pendant The default behavior of outputs is that their values are preserved after a program stops running It is also possible to configure an output with a default value that is applied whenever no program is running The eight digital standard outputs and the two tool outputs may furthermore be configured to reflect whether a program is currently running so that the output is high when a program is running and otherwise low Finally it is also possible to specify whether an output can be controlled on the I O tab by either programmers or both operators and programmers or if it is only Version 3 1 II 27 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 12 10 Installation Variables robot programs that may alter the output value 12 9 Installation Safety See chapter 15 12 10 Installation Variables File 16 50 25 CCCC Q Program Installation Move 1 0 Log TCP Configuration Installation Variables Mounting Setup Variable 4 Value vh Safety Variables MODBUS client Features Conveyor Tracking Default Program Load Save Create New Variables created here are called installation variables and can be used just like normal program v
195. y Universal Robots A S All rights reserved UNIVERSAL ROBOTS 15 11 Boundaries normal while entering a negative value decreases the allowed area by moving the plane in the direction of the plane normal The tolerance and unit for the displacement of the boundary plane are shown to the right of the text field Effect of strict limit planes Program execution is aborted when the TCP position is about to cross an active strict limit safety plane minus the tolerance see 15 3 if it continues moving along the predicted trajectory Note that the minus sign displayed with the tolerance value is only there to indicate that the tolerance is subtracted from the actual entered value The safety system will perform a category 0 stop should the TCP position exceed the specified limit safety plane without tolerance Effect of Trigger Reduced mode planes When no protective stop is in effect and the safety system is not in the special Recovery mode see 15 5 it operates either in Normal or Reduced mode and the movements of the robot arm are limited by the respective limit set By default the safety system is in Normal mode It transitions into Reduced mode whenever one of the following situations occurs a The robot TCP is positioned beyond some Trigger Reduced mode plane i e it is located on the side of the plane that is opposite to the direction of the small arrow in the visualization of the plane b The Reduced Mode safety input
196. y plane is never active Normal When the safety system is in Normal mode a Normal mode plane is active and it acts as a strict limit on the position of the robot TCP Reduced When the safety system is in Reduced mode a Reduced mode plane is active and it acts as a strict limit on the position of the robot TCP Normal amp Reduced When the safety system is either in Normal or Re duced mode a Normal amp Reduced mode plane is active and it acts as a strict limit on the position of the robot TCP Trigger Reduced mode When the safety system is either in Normal or Re duced mode a Trigger Reduced mode plane is active and it causes the safety system to switch to Re duced mode for as long as the robot TCP is posi tioned beyond it The selected safety mode is indicated by an icon in the corresponding entry in the Safety Boundaries panel If the safety mode is set to Disabled no icon is shown Displacement When a feature has been selected in the drop down box in the lower left portion of the Safety Plane Properties panel the safety plane can be translated by tapping the Displacement text field in the lower right portion of this panel and entering a value Entering in a positive value increases the allowed workspace of the robot by moving the plane in the opposite direction of the plane Version 3 1 II 97 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 b
197. y system see the Hardware Installation Manual The Safety Configuration screen can be accessed from the Welcome screen see 10 3 by pressing the Program Robot button selecting the Installation tab and tap ping Safety The safety configuration is password protected see 15 7 File 16 51 10 CCCC Q Program Installation Move O Log CP Configuration Safety Configuration Mounting General Limits Joint Limits Boundaries Safety 0 Setup A risk assessment is always required JA Safety Select Safety Preset Variables Default MODBUS client Features Very restricted Intended to be used where it is particularly dangerous for the Conveyor Tracking robot arm or its payload to hit a human Default Program Restricted Intended to be used where there is a big risk of the robot arm or its payload hitting a human and the robot arm along with its payoad has no Load Save sharp edges Default Intended to be used where people are aware of the robot arm and its payload and or when application has no sharp edges and no pinching hazards Least restricted Intended to be used where there is little risk of the robot arm or its payload hitting a human such as 1 Inside CNC machines 2 behind fences 3 hard to reach places Advanced Settings Safety password Unlock Lock Apply WARNING 1 A risk assessment is always required 2 All safety setting
198. ze discharge to an electrical potential below 7 3 V a robot running at full speed and payload Worst Case Safety Input Function Detection De energizing Reaction Time Time Time Robot emergency stop 250 ms 1000 ms 1250 ms Emergency stop button 250 ms 1000 ms 1250 ms System emergency stop 250 ms 1000 ms 1250 ms Safeguard stop 250 ms 1000 ms 1250 ms 5 3 2 Safety related Electrical Outputs The table below gives an overview of the safety related electrical outputs Safety Output Description System emergency stop Activated by an active Robot emergency stop input or by the Emergency stop button Robot moving While this signal is inactive no single joint of the robot arm moves more than 0 1 rad Robot not stopping Inactive when the robot arm has been requested to stop and has not stopped yet Reduced mode Active when the safety system is in Reduced mode Not reduced mode The Reduced mode output negated If a safety output is not set properly the safety system issues a category 0 stop with the following worst case reaction times Safety Output Worst Case Reaction Time System emergency stop 1100 ms Robot moving 1100 ms Robot not stopping 1100 ms Reduced mode 1100 ms Not reduced mode 1100 ms Version 3 1 I 39 UR5 CB3 Copyright 2009 2015 by Universal Robots A S All rights reserved Copyright 2009 2015 by Universal Robots A S All rights reserved UNIVERSAL ROBOTS 5 3 Safety relate

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