IP MODULE INSTALL ASSIST

Operation Manual

“Skill-Assist” is
a system which assists a worker’s operating force to put forth his
skills such as “positioning” and “controlling loading path” with
installation auxiliary unit.

2015．12．04
2015．09．19
2013．04．26
2013．03．29
2005．06．07

ARAKI MANUFACTURING CO.,LTD.

㈱アラキ製作所

0565-31-1783

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１．Overview
①．Basic Functions
②． Skill-Assist and power-assist bicycles operate on the
same basic principles

Servomotor

Assist unit
ＰＬＣ
Work ＋

Move
Intelligenet work + Assist unit
force sensor with
Moter force + Man force

③．Control steps

Step 1: operating force for the auxiliary unit is

measured by an intelligent force sensor.
Step 2: Compute a force gain (force amplification) with
CPU
Step 3: Send a force command to the servomotor.
Step 4: The servomotor produces the force.

※The steps 1 to 4 are processed at extremely high speeds

to develop smooth movements.
Processing speed: approximately 0.0004 seconds
(2,500 times/second)
→ The system performs precisely guided by computer
control. Sequencer control does not effect.
※ Computing in Step 2
Impedance control system is adapted. The system is
capable to develop various properties (such as a
sense of resistance to weight or friction).

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２．System Configuration
Servomotor for traversing

Servomotor for travelling

Motor rate

SKILL
SW

GOT
Force Servo amplifier

Intelligent ＰＬＣ
COM D/A
I/O
force
ＰＬＣ Safety circuit
sensor

①Servomotor for traveling (Max. thrust: 836 N, 100% rated

thrust: 280 N)
The servomotor generates thrust according to a force
command from the servo amplifier.
It also outputs location pulses of the encoder embedded
in the motor to the motor driver.
② Servomotor for traversing (Max. thrust: 836 N, 100% rated
thrust: 280 N)
③Intelligent force sensor

Intelligent force sensor

The intelligent force sensor measures a force with which

a worker moves the auxiliary unit using with an internal
strain gauge.

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 The measured force is digitized through the processing
circuit in the intelligent force sensor, then output into
the DSP board of the computer.
④SKILL SW
The SKILL SW operates as the “Start Switch” of the
Skill-Assist.
If you feel unusual operation, take your hand off the
switch (or push the switch off), the system stops moving.
(Circuit with contact)
(Same as the enable switch on the teach pendant of the
robot.)
High credibility with OFF-check monitoring by the PLC as
well as 2 contacts/2 relays.
⑤PLC (sequencer)
The PLC controls the whole install auxiliary unit
(control parent).
Also, it controls the GENERAL ON, manual operation,
errors and line control input-output.

⑥Control PLC（C language controller）

The computer, as a sub-function of the PCL, controls only
the Skill-Assist control (operating force assist control).
⑦Servo amplifier
The servo amplifier controls servomotor generating force
according to a force command from the computer.
It also outputs location pulses of the encoder embedded in
the motor to the computer.
It has also the function to monitor motor errors (overload,
thermal error and etc.).

* Refer to the electrical diagram for details.

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3. Assembly operation
Start procedure (check before opening)

① It is ON with panel Maine power supply.

"A driving preparations power supply" confirms lamp lighting of "the
atmospheric pressure" (lighting / blinking) during "PLC driving"

② It is ON with "Master ON" button

"Driving preparations," "power supply" confirms lamp lighting of "assist
PRG-RUN"
※ In driving preparations ON, I regulate 0 points.
When you turn on driving preparations, please do not touch the Force sensor
by all means.

③ After confirmation, I let deadman SW of the operation steering wheel part of

the assist device turn on and operate it as things mentioned above.
※Between ①～③, do not touch the deployment machine body.
(the point zero of the Force sensor slips off when I touch it, and the operation
balance of the XY axis might be out of order)

④ Please turn off a "conveyer stop cancellation" button of the hanger part control
panel.
This button is turning red on; when remain it, is outputting a stop signal to a
conveyer.
Because this button turns on, at every driving preparations OFF, please turn
it off again.

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When error indication of the PC abnormality turned on while driving or there is
abnormal movement.

You turn on a "PC PRG stop" button, and please wait until you are displayed
by a touch panel screen (approximately ten seconds).

If the screen mentioned above is displayed, I switch off the control PLC once.
You accept driving preparations, and please use a device after enforcement in
start procedure ①～④ mentioned above.

A different method.
You push "RESTART" after abnormal cancellation, and please reboot.
You accept driving preparations, and please use a device after enforcement in
start procedure ②～④ mentioned above.

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4. Backup procedures
Using the apparatus when the assist mechanism has failed.
- In a state where the power is turned OFF of the assist for the equipment
(PC / servo amplifier) put a "Preparation for operation" of the device.
It is operated by pressing the device in hand.
It is the "skills assist ON-OFF" select SW to OFF.
("Skill assist OFF" lamp lighting of the control board)

We will press the "Preparation for operation" button on the control panel door
surface.
("Preparation for operation", "power supply" lamp lit)

Because I do not hang assist you press the deadman SW, please operate the
unit in hand.
Operation of the device is the same as the normal work.

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【PLC error message】

"ZeroForceZone(※) Error"
※ = ZeroForceZone(X,Y,Z)
When a power signal is output more than the rated value in driving
preparations ON by force sensor, it is displayed. When you turn on driving pre
parations, please do not touch the force sensor. Do not touch the
force sensor; Make sure that the Master On is off, while ON the
"drift value Force write" button, please ON the "Master On" button.

"ZeroDriftZone(※) Error"
※ = ZeroDriftZone(X,Y,Z)
When I revise a drift revision value at the time of the last start and
the installation of the force sensor which is displayed when there is
the error of the drift revision level at the time of the start more than
the rated value this time in driving preparations ON, it occurs in the
cases that exchanged a sensor. Make sure the "Master On" is off,
please push the "drift level compulsion note" button in the door in a
panel list.

"DriftData SRAM ReadError"

In driving preparations ON, please reset the control PLC which is
displayed when I cannot begin to read drift data from control PLC
inside memory (SRAM).
When the same abnormality occurs again, the trouble of the CPU
unit is thought about.

"DriftData SRAM WriteError"

Master ON, please reset the control PLC which is displayed when I
cannot write in drift data at control PLC inside storage device
(SRAM).
When the same abnormality occurs again, the trouble of the CPU
unit is thought about.

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"Short Deadman Switch"
Deadman SW is displayed at the time of the short circuit of ON or
the cable at the time of OFF check abnormality start of deadman
SW.

"ERROR!! OVER FORCE (※) "

※ = (X,Y,Z)
The set point which is displayed when an output order is beyond an
upper limit limiter set point on PC inside operation is the Y-axis by
the power input from most upper limit output limiter over force
sensor:
The initial set point is the Y-axis:3,000N X-axis: 3,000N.
Set in the set 7/8 "49.AbsMaxForce" of each traveling axis.

" ERROR!! OVER TIME (※)"

※ = (X,Y,Z)
I exceed the rating output at constant time.
When output orders exceed a rating output level on CPU inside operation
at setting time, it is displayed by the power input from force sensor.
The initial set point is common throughout all axes and is 300N/6 second.
Set in the set 7/8 "51.OverTime" of each traveling axis.

"Convert Data Error"

Motor thrust revision data setting does not have consistency
[setting menu], with → [each axis revision data] screen, please
review each axial revision data.
Please reset control PLC afterwards

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"PLC UnitError (※※)"
Some kind of abnormality is produced by a unit of the control PLC
※※Because a unit name becomes available, please refer to the
following lists
Please confirm the error outbreak contents of a unit targeted with a
screen [I/O monitor] of the touch panel.
When an error does not return control PLC after reboot, possibility
of the hard trouble is thought about.
※※ Contents
Bus Open Cannot access to all unit
DI It is abnormal by an input card
DO It is abnormal by an outpu card
AO It is abnormal by an analog outpu card
CNT#1 It is abnormal by a high-speed countercard
COM It is abnormal by a serial communication card

"SensorError (Timeout)"
When there is not a reply, by the communication (RS-422) with the
force sensor, it is displayed by the sensor side.
When I am cut off more than about 500ms, the communication withthe
force sensor becomes abnormal.
The following causes are thought about.
・Disconnection of the communication line with the sensor
・A connection connector of the sensor side falls out or slacks
・A communication line comes off because of an authority of trust
terminal stand of the control PLC
Or it is poor in contact

"SensorError (RecvData)"
When measurement data information from the sensor side has an
error by the communication (RS-422) with the force sensor, it is
displayed.
The following causes are thought about.
・Influence by the noise
・Data loss by the poor contact of the communication line

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