CP15

SEMESTER 5
Robotics LAB

Prepared by: Mrs. Johnyasha J [NEC] & Mr. Manigandan S [NEC]

Verified by: Mr. Surendhar Kumar K
Approved by: Mr. Shankar G
Rev No : 03
Released Date : 01/01/2022
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Contents
1.0 ROBOT COMPONENT RECOGNITION ............................................................................................................ 3
1.1 Robot Component – Handling of Teach pendant and Controller .......................................................................3
1.2 Selection factors .............................................................................................................................................. 10
1.3 General safety precautions .............................................................................................................................. 11
1.4 Safety precautions – Operator Safety, Programmer Safety, Maintenance Safety .......................................... 12
2.0 MANIPULATING THE ROBOT...................................................................................................................... 14
2.1 Sequence of Jogging ........................................................................................................................................ 14
2.2 Joint Co-ordinate & XYZ Co-ordinates ............................................................................................................. 16
2.3Three Switch Mode: Manual Mode & Auto Mode ........................................................................................... 20
2.4 Robot working limits, Changing a speed.......................................................................................................... 23
2.5 Homing ............................................................................................................................................................. 25
3.0 RECORDING THE POSTION ......................................................................................................................... 26
3.1 Program Creation ............................................................................................................................................. 26
3.2 Recording desired robot positions................................................................................................................... 28
3.3 Moving robot to the recorded positions ......................................................................................................... 30
3.4 Editing comments for recorded positions: Inserting & deleting ..................................................................... 31
3.5 Modifying the program .................................................................................................................................... 33
4.0 Writing and running the robot programs ................................................................................................... 35
4.1 Program line description.................................................................................................................................. 35
4.2 Writing a simple program ................................................................................................................................ 37
4.3 Saving and running the program ..................................................................................................................... 40
4.4 Aborting program ............................................................................................................................................ 41
4.5 Inserting and deleting the program ................................................................................................................. 43
5.0 CREATING A PROGRAM ............................................................................................................................. 45
5.1 Joint Motion ..................................................................................................................................................... 45
5.2 Linear Motion................................................................................................................................................... 47
5.3 Circular Motion ................................................................................................................................................ 48
5.4 FINE Positioning path ....................................................................................................................................... 48
5.5 CNT Positioning path........................................................................................................................................ 49
6.0 CONTROL INSTRUCTIONS ........................................................................................................................... 52
6.1 Register Instruction.......................................................................................................................................... 52
6.2 Position Register Instruction............................................................................................................................ 53
6.3 I/0 Instructions - RI/RO, DI/DO,AI/AO............................................................................................................. 55
6.4 Branch Instruction............................................................................................................................................ 56
6.5 Wait Instruction ............................................................................................................................................... 56
6.6 User Alarm Instruction ..................................................................................................................................... 57
6.7 Message Instruction......................................................................................................................................... 57

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6.8 Timer Instruction ............................................................................................................................................. 58

6.9 Override Instruction......................................................................................................................................... 58
6.10 Selecting Timeout Option .............................................................................................................................. 58
6.11 Cycle Time ...................................................................................................................................................... 59
7.0 CREATE A PICK AND PLACE PROGRAM USING CONTROL INSTRUCTION ....................................................... 60
7.1 Control Instruction ........................................................................................................................................... 60
8.0 ROBOT SIMULATION ................................................................................................................................. 63
8.1 Introduction to Simulation Software ............................................................................................................. 63
8.2 Familiarization of library functions – menu bar,tool bar and status bar ........................................................ 71
8.3 Creating a new workcell................................................................................................................................... 78
8.4 Creating a Rectangular pattern – Linear Interpolation .................................................................................... 85
8.5 Creating a Circular Pattern – Circular Interpolation ....................................................................................... 92
8.6 Familiarization of adding elements to workcell – e.g Fixtures, Grippers ........................................................ 96
8.7 Design and Simulate Pick and Place Operation in a Work cell ..................................................................... 104
8.8 Create and adding a Rail Unit in a Work cell ................................................................................................. 118
9.0 COORDINATE SYSTEM ............................................................................................................................. 122
9.1 Setting a user a coordinate system ( user frame setting : 3- point method )................................................ 122
9.2 Create an orient origin point ......................................................................................................................... 125
9.3 Setting a tool co ordinate system ( setting up tool frame ) in 3 – point method and 6- point method ........ 130
10. MACROS, MASTERING, BACKUP AND RESTORE ........................................................................................ 136
10.1 Macros ......................................................................................................................................................... 136
10.2 Mastering ..................................................................................................................................................... 139
10.3 Backup and restore ...................................................................................................................................... 149

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1.0 ROBOT COMPONENT RECOGNITION

AIM:
To learn and understand in detail about the Fanuc Industrial Robot components.

1.1 Robot Component – Handling of Teach pendant and Controller

COMPONENTS OF FANUC INDUSTRIAL ROBOT:

The major components of Fanuc Industrial Robot includes the following:

1.Manipulator
2.Controller
3.Teach pendant.

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1.Manipulator:

Industrial Manipulators or robotics manipulators are machines which are used to

manipulate or control material without making direct contact.

An industrial robot is an automatically controlled, reprogrammable, multipurpose

manipulator programmable in three or more axes.
An industrial manipulator is equipment for facilitating handling operations. It can pick up
and manipulate heavy loads, enabling the user to carry out fast, convenient and safe
handling.

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2.Robot controller:

The Robot controller is the "brain" of the industrial robotic arm and allows the parts of
the robot to operate together.

It works as a computer and allows the robot to also be connected to other systems.

The robotic arm controller runs a set of instructions written in code called a program. The
program is inputted with a teach pendant.

Accessories of Robot Controller:

The robot Controller internally consists of

1. Main board.
2. Emergency Stop Unit.
3. Servo amplifier.
4. Circuit breaker and heat exchange.
5. Process I/O ports

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3.Teach pendant:

The Teach Pendant (TP) is a hand-held operator interface device that has been designed
to make using the software associated with your robot easy.

It is used to:
➢ Move the robot
➢ Create Teach Pendant Programs (TPP)
➢ Test programs
➢ Run programs in production
➢ Check robot status

The teach pendant provides the operator access to robot information such as process
information, faults, and alarms on a user-friendly interface.

The teach pendant allows the operator to move around and watch the robot movement
more closely.

The Teach Pendant has 6 main parts:

1. E-stop button
2. Teach pendant enable switch
3. Display
4. Deadman switch
5. Usb port
6. Keypad

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1.E-stop button: The Emergency Stop button is used in

emergency situations to stop robot motion. The teach pendant
E-stop button (the large red knob at the top right of the
pendant) is a safety feature which disables the arm power,
immediately stopping the robot.
Once activated, the E-stop switch must be reset before the arm
power can be turned on. The pendant E-stop switch is reset by
turning it clockwise until the knob clicks and pops up.

2.Teach pendant enables switch: Enables teach pendant control and programming when
turned “ON”.

3.Display: Display Screen contains the menus and allows you to interact with the robot.

4.Deadman switch: The DEADMAN Switch, which is located on the back of the Teach
Pendant, is used to:
• Ensure personal safety when the Teach Pendant is on.
• Interrupt robot motion in emergency situations.
• The “DEADMAN SWITCH” is used as an enabling device. When the teach pendant is
enabled, these switches allows the robot motion only when at least one switch is
gripped.
• If you release the switch, the robot stops immediately.
The enabling switch (Dead Man Switch) has 3 positions:
1)Not pressed
2) Center position
3) Panic position.

NOTE: Press the Dead man switch at the intermediate position (half condition).

5.USB port: This allows easier access to controller backup and file storage.

6.Keypad: The teach pendant keypad is for navigating menus and programming.

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TEACH PENDANT KEY AND ITS FUNCTION

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1.2 Selection factors

The most important criteria for the selection of industrial robot for right job includes the
following:
1. Payload: Robot payload is the maximum weight a robot arm can handle. Improper
payload selection affects the robot performance and shortens the life.
2. Reach: Robot reach is the distance from the center of the robot to the fullest
extension of the robotic arm. It is a measure of how far the robotic arm can reach
when it's completely outstretched.
3. Speed: Robot speed refers to the absolute velocity of the manipulator at its end-of
arm which depends on the Cycle-time of the job to be completed. Robot Speed is
expressed in degree/second.
4. Number of axis: An axis in robotic terminology represents a degree of freedom
(DOF).

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1.3 General safety precautions

Robot manipulator General Safety Procedures

When operating robot manipulators

1. Before starting any robot movement, communicate with lab in-charge, as “Starting
Robot Motion”
2. Disable the robot after experimentation is complete.
3. Use extra caution when performing motion experiments for the first time or if
recovering from a collision
4. When approaching a damaged or possibly stuck robot arm, you should first remove the
power.
5. Do not enter the work envelope of operating robot.
6. E-stops must be operational and within reach at all times when the robot will be
moving
7. When running any new code, observe the robot carefully with a hand on the E-Stop
(Emergency-Stop) button.
8. If there are planned experiments with new potential safety hazards, a risk assessment
must be performed and approved, reviewed with the Lab Coordinator.
9. Always check for the speed before operating the robot. The robot operation speed may
be default to 100% upon start-up. Adjust the speed to below 30% so that the operator
can react in time for unexpected behaviors and be able to press the E-Stop button.
10. The workspace for the robot (without gripper) is roughly a one-meter radius sphere
centered on the base. Stay out of and away from the robot workspace when it will be
moving, >1m

Robot Manipulator Start-up Safety Guidelines

1. Read the safety sections of the manufactures manual before operating a robot for the
first time
2. Do not operate a robot without proper lab safety training.
3. Check for signs of damage to the robots, observe if there are any fluid spills, broken
wires, loose cables, etc., if then report to lab in-charge immediately.
4. Dress properly and use appropriate safety equipment:
Wear safety glasses and other suitable PPE.
Remove loose-fitting clothing.

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1.4 Safety precautions – Operator Safety, Programmer Safety, Maintenance

Safety

Safety Precautions – Operator Safety:

1. Install safety fence.

2. Do not go inside the robot fence.
3. Provide interlock for fence door.
4. Emergency stop buttons must be within operators reach.
5. Emergency stop button should be pressed when the ROBOT is not operation.

Safety precautions – Programmer safety:

1. Perform teaching by T1 Mode.

2. Check the Program by T1/T2 modes with step.
3. No one should enter into fence during teaching.
4. Remove the key from the SOP.

Safety Precautions – Maintenance Safety:

1. DO not enter into fence during motion.

2. Lock the Power switch, if necessary.
3. Do not touch the servo amplifier until D7 LED goes off.
4. Replace the Fuses by same rating.
5. Replace the PCBs with same specification.

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DON’T’S

1. Do not walk on Teach Pendant cable and do not bend the Teach Pendant cables.
2. Do not open the Robot Cabinet cover unnecessarily.
3. Do not use force air on controller PCB
4. Do not Step-On any part of the robot.
5. Do not remove the Mechanical unit battery in Power off condition.
6. Do not plug/unplug cables or fuses in Power ON condition.
7. Do not jog/ run the robot in 100% speed.
8. Do not attempt to move near to robot [Work Envelope], when in operating
condition.

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2.0 MANIPULATING THE ROBOT

AIM:
To learn in detail the sequence and methods of manipulating the robot.

2.1 Sequence of Jogging

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2.2 Joint Co-ordinate & XYZ Co-ordinates

A coordinate system defines a plane or space by axes from a fixed point called the
origin. Robot targets and positions are located by measurements along the axes of
coordinate systems. A robot uses several coordinate systems, each suitable for specific
types of jogging or programming.

JOINT COORDINATE SYSTEM:

In joint coordinate system all the 6 joints will move
independently.
The angle-position and length of each axis of an
articulate robot axes describe the orientation of the
TCP exactly. With the joint coordinate-system each
robot axis can be moved particularly in positive or
negative sense rotation.
Coordinates: P (angle A1, angle A2,... angle A6).

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XYZ OR CARTESIAN COORDINATE SYSTEM:

In Cartesian coordinate system all the joints will be dependent with one more joints.
These coordinates give tool position &orientation.

Cartesian coordinate systems:

1.World Coordinate System – The Default frame of the robot which is non-editable.
2.User Coordinate system – can be defined by user
3.Jog Frame Coordinate system – can be defined by user
4.Tool coordinate system – can be defined by user

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1.World Coordinate System:

The world coordinate system defines a reference to the floor, which is the starting point
for the other coordinate systems.

The default frame is the origin of the Robot

which is predefined by the manufacturer.
Using this coordinate system, it is possible to
relate the robot position to a fixed point in the
workshop.
The world coordinate system is also very useful
when two robots work together or when using
a robot carrier.
The base coordinate system is attached to the
base mounting surface of the robot.
The tool coordinate system specifies the tool’s
center point and orientation.

2. User Coordinate System:

The user frame by default has world frame as its reference. When the user frame is
setup, all the positions are automatically recorded in the user frame in the program.

The USER is useful for

representing equipment that
holds other coordinate systems,
like work objects.
User frame is setup so that it’s
easy for the programmer to
program with respect to the
defined user frame and it eases
re-teaching when the object is
shifted without actually
teaching all points.
The user coordinate system (UCS) is an essential tool for many precision operations.

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3.Jog frame Coordinate System:

The jog frame is a frame in which to jog easily. It allows you to align the x, y, z
coordinate system about a fixture or work-piece that is rotated with respect to the world
frame of the robot

The purpose of a Jog frame provides a convenient way to move along a part when the part
is oriented differently from the world frame.

4.Tool Coordinate System:

The default tool frame is located at robot’s J6 Flange center. This is the default tool frame
which is a Cartesian co-ordinate system and is known as Tool Center Point (TCP).

A) Default tool frame origin (TCP) is defined to be located at the center of robots
faceplate
B) Once EOAT (End of arm tooling) has been put into place, the TCP is relocated to that
point where positions will be taught and the work will be performed.

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2.3Three Switch Mode: Manual Mode & Auto Mode

The Mode select switch is installed on the operator's panel of the robot controller. You
can select one of the operating modes using this switch.

The selected operating mode can be locked by removing its key.

Robot controllers normally come with a two or three position key switch (Auto/T1/T2
modes) mounted directly on the control cabinet face.

• Automatic mode,
• Teach 1 (slow speed teach mode),
• Teach 2 (higher speed teach mode).

The “External Mode Select” option in the FANUC R30iB robot controller allows the
robot cell integrator to use Safe I/O SSO (6) and SSO (7) to toggle the selector switch
instead of using the actual switch itself.

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Manual Mode
T1 Mode
The robot program can be activated from the teach pendant only.
The robot cannot be operated at speeds higher than 250mm/sec.
The safety fence is disabled

T2 Mode
The robot program can be activated from the teach pendant only.
The robot can be operated at the specified maximum speed.
The safety fence is disabled (even when the fence is opened. the robot does not stop)

AUTO Mode
The robot program can be started from the operator’s panel.
The robot program can be called by the operator from the operator panel itself by pressing
the cycle start or peripheral device I/O.
The safety fence is enabled (when the fence is opened, emergency stop occurs).
The robot can be operated at the specified maximum speed.
When the robot is switched into AUTO, you’re running programs without the teach
pendant.
In fact, if the teach pendant is enabled; the robot will be in a fault condition.

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Note:
Due to safety constraints two separate inputs cannot be used to select a robot’s operating
mode. So, the External Mode Select option cannot be used in conjunction with the regular
robot controller key switch.

NOTE :
FREQUENTLY GENERATED ALARMS

1. In singularity.
2. Deadman switch released.
3. Jog pressed before shift.
4. Position not reachable.
5. Press shift key to jog.
6. Release the E-stop in TP

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2.4 Robot working limits, Changing a speed

Robot working limits

A robot's work envelope is its range of movement.

It is the shape created when a manipulator reaches forward, backward, up and down.
These distances are determined by the length of a robot's arm and the design of its axes.
Each axis contributes its own range of motion.

Robot reach is the distance from the center of the robot to the fullest extension of the
robotic arm. This measurement determines the robot's work envelope.

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NOTE:
When the robot is jogged beyond the maximum reach, it indicates singularity alarm,
flashing in teach pendant.

In Singularity: In robotics, singularity is a configuration where the robot end effector

becomes blocked in some directions. For example, a serial robot or any six-axis robot arm
will have singularities.

CHANGING A SPEED:
This override key adjusts the federate override.

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2.5 Homing

In robotics, homing can be defined as that behavior which enables a robot to return to its
initial (home) position, after traveling a certain distance along an arbitrary path.

As soon as homing is activated, the robot selects intermediate target positions on the
original path.

Homing procedure represents set of actions automatically leading the all robot elements
from initial generally unknown position that is arbitrary position from a robot workspace
to predefined known deterministic position, so-called HOME POSITION.

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3.0 RECORDING THE POSTION

AIM:
To study the detailed process of recording the position of the Fanuc robot with the help of
teach pendant.

3.1 Program Creation

STEP 1:
Go to home / default page in teach pendant
(Press “Menu” button, then select “1”for
UTILITIES.) Now press the “select” button

STEP 2:
Immediately, press “F2” key for creating the
new program.
NOTE: Existing program can also be selected
from the program list directly.

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STEP 3:
In the new page, program name should be
typed, for which “Upper case” option to be
selected.

STEP 4:
Now type the program name with the help
of function / alphabetic keys.
Example: Program name - DEMO

STEP 5:
After typing the program name double
Press the “ENTER” key
NOTE:
First ‘ENTER’ – To save the program name.
Second ‘ENTER’ – To go to Program page.

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3.2 Recording desired robot positions

Point
• Pressing this key brings up a menu of default motion instructions. The last chosen
motion instruction can be quickly added in quantity by holding SHIFT and pressing
POINT.
• Adding a motion instruction to the program will automatically record the current
position of the robot to the position number it contains.
• This means if you jog the robot to the next position before adding the motion
instruction for that position, you do not need to use the TOUCHUP function.

PROCEDURE 1: STANDARD MOTION INSTRUCTIONS BASED RECORDING

1. Jog the robot to desired position in the workspace.

2. Press “F1” key for point option to display the standard Motion instruction menu.
3. Select the required motion path.

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NOTE: Ensure before recording the desired position “point” mode is enabled, else press
“Next” button in the teach pendant to bring the point mode option

PROCEDURE 2: DIRECT RECORDING

1. Jog the robot to desired position in the work area.
2. Press shift & “F1” key [for point option] to directly recorded the current position.

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3.3 Moving robot to the recorded positions

PROCEDURE:
1. Check for the “Fault” indication in the teach pendant.
2. Make sure the Fault indication is in green color.
3. If there is any Fault, color changes to red, then reset the Fault for which refer unit
2.1-step 6.
4. Place the cursor in the first program line.
5. Hold the “Deadman switch” [Half condition] & press “Swift” key together.
6. Then press “FWD” key one time to move/jog the robot.
7. During the robot jogging operation, don’t release the deadman switch & swift key.

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3.4 Editing comments for recorded positions: Inserting & deleting

Edit comments: (EDCMD)

It is used for editing the program during the program creation. Some of the edit
comments include:

Insert comment:

Insert comments are used to add one or more blank lines in between to the program as
required.

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Procedure for inserting the new line:

1. Insert comment will always add the line above the currently selected line.
2. Move the cursor to the required line.
3. Press “Next” key in teach pendant.
4. Select “f5”key for edit comment options.
5. Finally select insert option & press “enter” which will prompt to enter a numeric value
representing “How many lines to insert”.
6. Enter the required value, and then press “enter”.

Delete Comment:
Delete comment is used to delete the required line from the program.

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3.5 Modifying the program

The program lines can be modified by the following methods:

Procedure for motion format modification:

Move the cursor to motion path in the program; this will enable “choice” option in the
bottom of the screen.
Press “F4”key – for choice option.
Select the required motion from the format such as (joint, linear, circular, circle arc).

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1) PROCEDURE FOR FEED RATE MODIFICATION

• Move the cursor to feed rate in the program line.
• Press “F4”key-for choice option.
• Select required feed rate such as (mm/sec, cm/min, inch/min, deg/sec, sec, and msec).

2) PROCEDURE FOR POSITIONING MODIFICATION

• Place the cursor on positioning path in the program line.
• Press “F4”key-for choice option.
• Select required feed rate such as (Fine,Cnt).

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4.0 Writing and running the robot programs

AIM:
To learn and understand the procedure for writing and running the simple robot program.

4.1 Program line description

1.PROGRAM LINE NUMBER: Indicates the line number in program

2.MOTION PATH:
• L (Linear) – Move from one point to another in a straight line. This motion is a slow,
but more precise
• J (Joint) – This motion Moves from point to point without the requirement of
maintaining a straight line. It does not need to maintain a specific path; therefore it
is the quickest motion type to reach a position. Programs should ideally begin with a
joint move to a known starting point. Do not use joint when your path may be
obstructed by objects or fixtures.
• C (Circular) – This motion Moves in a circular path. The circle always begin at the
robot's current position, and flows through the two positions given in the
instruction. The first position in the circle instruction is the midpoint, and the second
position is the endpoint (Touchup). For circular motion maintain the circular path
angle around 180degree Limit the usage to 180 degrees otherwise robot will
encounter an error as "Circle angle too large".
• A (Circular Arc) – This motion is similar to circular path but with accurate
Curved/Arc path.

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3.POSITION DATA:
• P - Position Data determines the direct position space. Typically recorded by jogging
to point and setting as position value. Each position is unique to the program it is
in.P[1] in one program has no relation to P[1] in another.
• PR (position register) – corresponds to predefined location where position can be
found. Position registers are "global" variables that stay the same in all programs.
PR[1] used in one program is the same as PR[1] in another. Modifying the contents
of a position register will affect all future uses, across all programs.

4.POSITION NUMBER:
Position numbers are assigned in the order they are placed. They serve as places to store
location information.
When a motion instruction is added to a program, it is automatically assigned the next
available position number, and the position is recorded as where the robot currently is.
This makes it convenient to first jog to the position you intend to record, and then add the
motion instruction, as you won't need to "touch up" at all.

5. FEED RATE:
The speed units are first chosen, and then the
value is entered.

XX% - The robot will move at a percentage of its

rated speed and given payload.

XXmm/s - The robot will move at a speed

determined by the velocity of the tool's end

POSITIONING PATH:
FINE – When completing a motion instruction, the robot will reach each point. If the next
point is at an angle relative to the path to reach the current point, the robot will accelerate
and decelerate as necessary to ensure the point is actually reached.
CONTINUOUS (CNT) – When completing a motion instruction, the robot will decelerate as
it approaches the point and "round off" the corner as it goes from point to point as a
percentage. The number following the CNT option represents the percentage of speed it is
allowed to slow to, to make a "best effort" to go toward the point.

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4.2 Writing a simple program

AIM:
To write and execute a program to move the end effector for the given diagram.

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PROCEDURE:

1. For the given task, mark the points from start to end & label as P1, P2, P3….Pn.
2. Create the new program & type the suitable program name.Ex:Program name -
ARROW
3. Select the required coordinates & set the speed of the robot to minimum.
4. Clear the fault.
5. Jog the robot to position P1 & record the position P1.
6. Similarly, jog the robot to the other marked points & record the position at each point.

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FLOW CHART:

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4.3 Saving and running the program

PROCEDURE:

1. Move the cursor to first line of the program.

2. For Continuous test operation, enable the “STEP” Button in teach pendant with
onetime press.(step by step execution )

3. Run & Execute the program.

4. For direct execution, disable the “STEP” option.

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4.4 Aborting program

Aborting program is immediate action to stop or Bringing the process to an end.

The robot program will be aborted for the following reasons:
1. During the fault condition.
2. During the emergency period.
3. Due to execution of wrong program.

PROCEDURE 1:

1. Press “FUNCTION” key in teach pendant, which prompts abort option.

2. Select “ABORT” and press enter.

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PROCEDURE 2:
1. In the program page select “INST” option.
2. Go to option 8.Next page
3. Choose program control then select “ABORT”.

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4.5 Inserting and deleting the program

Inserting the programs:

Inserting an existing program to the current program is done with the following
procedure:
1. Place the cursor to the line where existing program to be added.
2. Press “F1” key for selecting (INST) instructions.
3. Select call option, and then select the call program.
4. Choose the required program from the list.(EX:HOME)

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Deleting the program :

Deleting the program from the program list includes the following procedure.
1. Select the program to be deleted from the program list.
2. Press delete option.

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5.0 CREATING A PROGRAM

AIM
To Know to create a program for Joint , Linear and Circular Motion.
EQUIPMENTS

SL. NO EQUIPMENTS SPECIFICATION QTY

1. Manipulator LR MATE 200iD / LR MATE 200iC 1

THEORY

5.1 Joint Motion

J Joint Motion is a method of path interpolation that commands the movement of the
robot by moving each joint directly to the commanded position so that all axis arrive to the
position at the same time.
All joints will move independently and simultaneously (Called as Non Linear Motion).
Speed is given in %

Eg: J P [8] 70% Fine

If we run the above line, the robot will move in Joint motion towards point 8 with 70% of
maximum joint speed of joints. (Override is also Applicable).

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MANIPULATING ROBOT IN JOINT COORDINATES

Procedure:
• Switch ON the supply and panel board.
• Verify the panel board and pendent E-stop, if pressed then release it.
• Verify the teach pendent ON/OFF switch, if it is OFF change it to ON.
• Hold the dead man switch in half position and clear the fault by RESET button.
• Change the co-ordinates in JOGFORM.

For Creating the Program:

• Press the select key and create [F2].
• Select upper case and enter job name.
• Teach the job to the robot and record the points [F2].
• For executing the program press SHIFT and FORWARD key

Program:
1: J P [1] 100% FINE
2: J P [2] 100% FINE
3: J P [3] 100% FINE
4: J P [4] 100% FINE
5: J P [5] 100% FINE
6: J P [6] 100% FINE
7: J P [7] 100% FINE
8: J P [8] 100% FINE
9: J P [9] 100% FINE
10: J P [10] 100% FINE
11: J P [11] 100% FINE
12: J P [12] 100% FINE
END

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5.2 Linear Motion

Linear movements are those movements in which the tip of the end-effector moves
along the straight line between two points, from current point (M1) to target point (M2)
in 3D space. Path is programmed by defining the coordinates of target position.
In L linear , the tool tip move linearly towards the destination.All the joints are coordinates
so that straight line motion achieved

E.g: 1: JP [1] 100% FINE

2: LP [2] 500mm/sec Fine

If we run the above line , the robot will move in linear motion toward point 2 with
500mm/sec.
The speed is given by mm/sec (or) cm/min (or) Inch/min (or) Sec .

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5.3 Circular Motion

A calculated path that the robot executes, and is circular in shape.
Ensure that passing point is in the middle of the Arc. The arc need to be less than or equal
to Semi Circle. If full circle need to be made , divide it into 2 or more pieces . Orientation
need to be changed if required.

Steps for Manipulator

▪ Move the robot to start point of arc and record P1.

▪ Bring the robot to passing point and record as C point.
▪ Move robot to end point and record by “ Touch Up

5.4 FINE Positioning path

Eg : 1: JP [1] 100% FINE

2: CP [2]

: P [3] 500mm/sec FINE

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5.5 CNT Positioning path

Eg : 1 : JP [1] 100% FINE

2 : CP [2]

: P [3] 500mm/sec CNT 50

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MANIPULATING ROBOT IN LINEAR AND CIRCULAR MOTION

Procedure:
• Switch ON the supply and panel board.
• Verify the panel board and pendent E-stop, if pressed then release it.
• Verify the teach pendent ON/OFF switch, if it is OFF change it to ON.
• Hold the dead man switch in half position and clear the fault by RESET button.
• Change the co-ordinates in JOGFORM.
For creating the program:
• Press the select key and create [F2].
• Select upper case and enter job name.
• Teach the job to the robot and record the points [F1].
• For executing the program press SHIFT and FORWARD key.

Diagram - 1

P2 P1,P5

P3 P4

1: L P [1] 100mm/sec FINE

2: L P [2] 100mm/sec FINE
3: L P [3] 100mm/sec FINE
4: L P [4] 100mm/sec FINE
5: L P [5] 100mm/sec FINE
6: L P [6] 100mm/sec FINE {all the joints at 0 degree/ Home position}
[END]

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MANIPULATING ROBOT IN CIRCULAR INTERPOLATION

For creating the program :
• Move robot to start point of arc and record P1
• Bring the robot to passing point and record as C point
• Move robot to end point and record it by “Touch-up”
• Ensure that passing point is somewhere in the middle of the arc
• Teaching should be as good as possible
• The arc need to be less than or equal to semi-circle
• If full circle need to be made, divide it into 2 or more pieces .

Diagram - 2

1: J P [1] 100% CNT 50

2: C P [2]
P [….] 100% CNT 50
3: C P [3]
P [….] 100% CNT 50
4: C P [4]
P [….] 100% CNT 50
5: C P [4]
P [….] 100% CNT 50
6: CALL HOME END

CONCLUSION :
Thus a program is created to know the Joint, linear and Circular Motion.

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6.0 CONTROL INSTRUCTIONS

AIM
To work on the control Instructions of the robot.

EQUIPMENTS
SL. NO EQUIPMENTS SPECIFICATION QTY
1. Manipulator LR MATE 200iD / LR MATE 200iC 1

6.1 Register Instruction

THEORY

• Registers are used for Data storage

• Arithmetic and logical operations can be performed with registers.
• There are 200 Registers
• They are represented by R [i], where i= 1.2,..200.
• Registers can be initialized as R [i]= Constant
SYNTAX:
R[ X : comment ] =* , where X = 1,2,3 … 100

Eg: R[1] =100

After execution the value 100 will be transferred to register R[1]

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6.2 Position Register Instruction

THEORY
• Position Registers is capable of storing – A Position, Home Position, Safe Position,
Tool Change, Tool Modification etc. Users can call the position register in any
program for a given robot.
• Position register instruction function as a general purpose registers for holding
the position data.
• There are 100 positions available.
• This is also used to record a position of a robot which holds 6 data of a particular
position.
• “R” in a position register indicated that the position register already holds a
taught value
• “*” indicates that the position register is empty.
SYNTAX:
PR[ X : comment ] =* , where X = 1,2,3 … 100

Eg: PR [ 1 : Home Position ] = R

Steps to be followed :
1. Access to Position Register in Teach Pendant is via DATA
Button.
2. Click on [ TYPE ] and in turn select Position Reg
(Option 2) to enable the Position Registers

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Position registers is a variable for holding position data (x, y, z, w, p, r). In the above
syntax, the position register must set the values of all SIX elements at once.

CAUTION
If teaching is made by joint coordinates, changing the user coordinate system does
not affect the position variables and position registers. If teaching is performed in
cartesian coordinates, and the user coordinate system input option is not used, the
position variable is not influenced by the user coordinate system. In other cases, both the
position variable and position registers are influenced by the user coordinate system.
WARNING
Position registers are used in a program. Never change the value of a position
registers before checking how the register is used in the system. Otherwise, the program
can be adversely affected.

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6.3 I/0 Instructions - RI/RO, DI/DO,AI/AO

THEORY
• Analog – An Analog I/O signal (Ai or AO) allows for varying states.
• Digital – A digital I/O signal (Di or DO) is a control signal sent to or from the controller.
Digital signals can have only one of two possible states: ON or OFF. Digital signals
provide access to data on a single input or output signal line.
• Robot – Robot I/O signals (RI or RO) consist of the input and output signals between
the controller and the robot. These signals are sent to the EE (End Effector) connector
located on the robot. The number of robot input and output signals varies depending
on the number of axes in your system.
• This instruction is used to change the state of signal output to peripheral devices and
read the state of input signal
SYNTAX:
DIGITAL ANALOG ROBOT
DO [1] = ON AI [1] = ON RI [1] = ON
DO [1] = OFF AO [2]=OFF RO[2]=OFF

Eg : DO[1] = Pulse , 5 Sec

R[1] = DI[10]

DO[1] = R[1]
Steps To Be Followed:
1. Press the MENUS Key. The Screen Menu is displayed.
2. Select 5 (I/O)
3. Press the F1 Key , [TYPE]. The screen change menu is displayed.
4. Select “Robot”.

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6.4 Branch Instruction

• A Branch Instruction causes a jump from one line of program to another line or to
another program.

MP LBL [ 1 ] Jump Instruction

[ R[1] ]

Instruction Syntax
This instruction consists of a mnemonic “JMP LBL” followed by a variable.
When this instruction is reached
The program’s pointer will jump up (or down) to wherever that label happens to be.
Anything between the jump and its destination is ignored. The operation is unconditional.

6.5 Wait Instruction

• To stop the program execution for a specified period of time or until a condition is
satisfied.
• Two types of Wait instructions are available
1. Time-Specified Wait Instruction
SYNTAX :
WAIT ……Sec

Eg : WAIT 5sec

2. Conditional Wait Instruction

Eg : WAIT DI[1]=ON

WAIT R[1]=100

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6.6 User Alarm Instruction

• The instruction “ ULAM [1] is used to generate the alarm
• When this instruction is executed the controller will go to alarm state and it will stop
the robot motion.
• The alarm text can be defined in “ User Alarm Setup screen”
• We can set up to 10 user alarms.
• In program, it can be inserted by pressing,
Instruction Miscellaneous UALM
• The alarm text can be defined here
• Menu Setup User Alarm

SYNTAX :
ALARM NO MESSAGE
[1] Close the Program

6.7 Message Instruction

• This instruction displays the specified message on the user screen
• The message consists of 24 characters max
• Press “ MENU’ then “ USER’ to view the message

Eg : Message [ Robot is in Home]

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6.8 Timer Instruction

• The timers can be used for calculating the cycle time.
• 10 Timers are available.
• These timers are retentive type timers (If we start after stop, it will start counting
from the time that we stopped earlier).
• Timers can be represented by TIMER [1]…..
• Instructions to control the timer functions are,
1. TIMER [1]=RESET
2. TIMER [1]=START
3. TIMER [1]=STOP
• Status of the timer can be monitored by pressing
“STATUS” ->”F1 Type” ->”Program Timer”
• Timer instruction can be inserted by pressing instruction
-> Miscellaneous -> Timer
• The value of the timer can be transferred to the Registers

Eg : R[1]=TIMER[1]

6.9 Override Instruction

• The override instruction changes a federate override when it executed.

Eg : OVERRIDE=100%

6.10 Selecting Timeout Option

This Instructions gives a time out for a particular action such as Gripper Closed.

Eg : 1:RO[4:GRIPPERCLOSE]=ON;
2:WAIT.75(sec);
3: WAIT RI[5:GRIPPER CLOSED]=ON TIMEOUT,LBL[6] ;

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6.11 Cycle Time

Standard cycle time' is the time it takes for the robot arm to travel up 1 inch, go
across 1 foot, travel down 1 inch, and come back through the same path.

CONCLUSION:
Thus all the control instructions are learned and practiced.

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7.0 CREATE A PICK AND PLACE PROGRAM USING CONTROL

INSTRUCTION
7.1 Control Instruction
AIM
To create a program for Pick and place using Control instructions.

EQUIPMENTS
SL. NO EQUIPMENTS SPECIFICATION QTY
1. Manipulator LR MATE 200iD / LR MATE 200iC 1
2. Gripper 1
3. Part 1

THEORY:
Pick and place robots are commonly used in modern manufacturing environments.
Pick and place automation speeds up the process of picking up parts or items and placing
them in other locations. Automating this process helps to increase production rates. Pick
and place robots handle repetitive tasks while freeing up human workers to focus on more
complex work.
Typically mounted on a stable stand, pick and place robots are positioned to reach
different areas to perform work. They use advanced vision systems to identify, grasp and
move objects from one place to another. With a variety of design options available, pick
and place robots can be configured with various end-of-arm tooling options for use in
different applications, such as assembly, packaging or bin picking. For example, pick and
place robots may be used to pick up items for an order and place them in a box for
packaging, or they may be used to pick up parts needed for assembly and move them to
the next location.

MANIPULATING ROBOT TO PICK AND PLACE :

Procedure :
• Switch ON the supply and panel board.
• Verify the panel board and pendent E-stop, if pressed then release it.
• Verify the teach pendent ON/OFF switch, if it is OFF change it to ON.
• Hold the dead man switch in half position and clear the fault by RESET button.
• Change the co-ordinates.

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For creating program :

• Press the select key and create [F2].
• Select upper case and enter job name.
• Teach the job to the robot and record the points [F1].
• Use the different control instructions for open and close of gripper
• Similarly for Pick and Place the Part.
• For executing the program press SHIFT and FORWARD key.

Creating pick and place Program using Control functions

1: LBL [1] ; Label to Jump To Beginning
2: UFRAME _ NUM =1 ; Frame Number Similar to Work Coordinates
3: UTOOL_NUM=1 ; ToolNumber to Offset
4: JP [1] 50 % CNT100 ; Jog to the recording Position with round off going to the point
5: RO[1] = ON ; Turns an Output RO 1
6: RO[2] = OFF ; Turns Off an Output RO2
7: RO[3] = ON ; Turns on an Outpur RO 3
8: RO[4] = OFF ; Turns on an Outpur RO 4
9: JP [9] 50% CNT100 ; Jog to recorded Position at 50%
10: LBL [ 2] ; Label to jump the part to from another part of Program
11: $WAITTMOUT =2000 ; If waiting to long timeout
12: LP[2] 500mm/sec CNT100 ; Move in a astraight line to the point at 500mm/sec rounding off corner
13: WAIT DI[2] = ON ; wait for an input DI2 to come on
14: R[15] is for the part style ; Utilizing register 15 for part style
15: IF R[15] = 1 , JMP LBL[3] ; If register 15 is a 1 (some part style) jump to label 3
16: IF R[15] = 2 , JMP LBL[4] ; If register 15 is a 2 (some part style) jump to label 4
17: PAUSE
18: ABORT ; If no part style selected abort program
19: : LBL[3] ; Pick part style #1
20:L P[11] 100mm/sec FINE ; L=move in a straight line to a recorded position at a specific speed
21:JMP LBL[5] ; jump over part style #2 to label 5
22: LBL[4:Pick Part#2] ; Pick part style #2
23: L P[12] 100mm/sec FINE ; L=move in a straight line to a recorded position at aspecific speed
24: CALL CLSGRP1 ; Call subprogram to close gripper
25: L P[8] 100mm/sec CNT100 ; move in a straight line to depart position point
26: IF DI[2] = ON , JMP LBL[35} ; If the input Digital input #2(something with conveyor) is on jump to
label 35 problem with conveyor

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27: LBL[6:Continue] ; Go to Label 6

28: J P[1] 50% CNT100 ; move to recorded position the fastest possible using joint moves
29:JMP LBL[99] ; jump to label 99
30:LBL[98] ; conveyor problem was present
31:macro_119 ; Run Macro Program
32: DO[14]= OFF ; Turn digital output #14 off
33:DO[14]= ON ; Turn digital output #14 on
34:MESSAGE[Alarm indicating]; Message with the said text displayed
35:MESSAGE[Dropped part] ; Message with the said text displayed
36:MESSAGE[Remedy- check sensor] ; Message with the said text displayed
37:PAUSE
38:Jmp LBL[6] ; Jump to Label 6
39:LBL[99:End]
40: J P[2:"Approch"] ; joint move to recorded position #2 commented as approach point
41:J P[1:"Perch"] ; joint move to recorded position #1 commented as perch point
42:END ; End of Program

CONCLUSION:

Thus a program is executed in the manipulator to Pick and Place the object by using
different Control Instructions.

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8.0 ROBOT SIMULATION

8.1 Introduction to Simulation Software
AIM
To get familiarized with simulation Software
EQUIPMENTS
SL. NO EQUIPMENTS SPECIFICATION QTY
1. Software Simulation Robo Guide- Intelligent 3D Simulation - FANUC -

THEORY:
FANUC ROBOGUIDE is an offline simulation package that simulates both the robot’s
motion and application commands, significantly reducing the time it takes to create new
motion setups.
The ROBOGUIDE family of process-focused robot simulation software packages
allows users to create, program and simulate a robotic work cell in 3D without the physical
need and expense of a prototype work cell setup. With virtual robots and work cell
models, ROBOGUIDE reduces risk by enabling visualization of single and multi-robot work
cell layouts before actual installation.
To ensure minimal impact on production, cells can be designed with imported CAD
tested and modified entirely offline. Designed to be intuitive and extremely easy to use
ROBOGUIDE requires very little or even no training. Built on Virtual Robot Controllers to
give you accurate motion and cycle times.

• Easy creation of layouts with devices and machines

Enhance and debug offline without experiencing downtime or lost production

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Import of CAD data to give a real look and feel to the application

Simple path planning with animation

Accurate simulation between the virtual and real world

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Highly efficient application tools to simplify programming efforts

Features Of Fanuc Roboguide are :

Features of ROBOGUIDE
• PC tool that easily enables a quick and low cost verification of robot application
systems.
• Easy creation of layout for devices and Machines. Special skills are not required.
• Program creation using graphic screen
• Extreme reduction of start-up time and maintenance time with offline checking.
• Achievable even on the shop floor
• Accurate simulation of robot movement and application commands by virtual robot
• Robot application specific tools with highly efficient operation
- Weld PRO
‐ Chamfering PRO
‐ Spot PRO
‐ Pallet PRO
‐ Paint PRO
‐ Motion PRO
‐ iRPick PRO

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ASCII translator package which converts various robot files between binary and ASCII

FANUC ROBOGUIDE SIMULATION SOFTWARE

FANUC ROBOGUIDE – Handling PRO

Handling PRO is used for material handling applications including load/unload,
packaging,assembly and material removal. Features of Handling PRO include CAD to Path
programming, conveyor line tracking, machine modelling and programming.

FANUC ROBOGUIDE – Paint PRO

FANUC Paint PRO software is a graphical of offline programming solution that simplifies
robotic path, teach and paint process development. The operator automatically generates
robot programs by graphically selecting the area of the part to be painted and chooses
between several painting methods.

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FANUC ROBOGUIDE – Pallet PRO and Pallet Too

Pallet PRO simulation software can be used to completely build, debug and test a
palletizing application offline. Pallet PRO allows users to create a work cell layout, in feed
and pallet stations, slip sheet and pallet dispensers. Hundreds of unit load pallet
configurations can be created and visualized in 3-D using Pallet PRO’s built-in library of
industry standard patterns. The data created in Pallet PRO can be downloaded to a real
robot controller containing Pallet Tool® software.

FANUC ROBOGUIDE - WeldPRO

Weld PRO simulates robotic arc welding process. WeldPRO CAD to Path programming
capability supports auto generation of multiple robot group coordinated motion programs
with de ned torch angles and process parameters. Programs and settings from the virtual
workcell can be transferred to the real robot to decrease installation time.

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Standard software
Modeling function
Reduce time for modeling devices
• Select objects from the library and modify using dimension settings
• Import CAD data for creating the parts
• Create the parts by modeling function
Selection from library

Layout function
• Change layout by mouse operation on graphic screen
• Change layout by numerical input

Simulation function
•Highly accurate simulation by using virtual robot
•Simulate not only of robot movement but also application commands
•Virtual camera for +RVision simulation

Virtual
robot

Program function
• Same user interface as the Robot Teach Pendant
• Create the actual program
‐ Using visual jog enables to move robot and to teach points

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Virtual
TP

Simulation function
• Highly accurate simulation by using virtual robot
• Simulate not only of robot movement but also application commands
• Virtual camera for +RVision simulation
Software Specifications
Modeling
Standard software Layout
Programming
Simulation
Vision function
Profiler
Auto place PC option Calculate robot position to minimize cycle time in the specified range
Duty estimation PC option Estimate OVC, OH alarm by motor torque
Standard PC option Life estimation PC option Estimate reducer life by motor torque
Consumption power estimation Estimate consumption power by motor torque
PC option
Coord PC option Program generation for muti-robots coordinated motion
Spray PC option Simulate the lubricant spray to die-cast mold
Robot integration setup PC Creates a robot setup file on PC and downloads the file to robot controller
option
Servo gun integration setup PC Creates a servo sun setup file on PC and downloads the file to robot controller
option
Weld PRO Navigation menu
Program generation for arc welding
Simulation for arc welding
Chamfering PRO Navigation menu
Application option Program generation for chamfering
Spot PRO Program generation for spot welding
I/O interlock automatic setting
Pallet PROTP Program generation for palletizing
Simulation for palletizing
Paint PRO Navigation menu
Program generation for painting
iR Pick PRO Simulation for picking

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Condition
The PC with the following condition is required
Item Contents
OS Windows®7（32bit, 64bit）, Windows®8.1（32bit, 64bit）,
Windows®10（32bit, 64bit),（64bit recommended）*1,
CPU More than Athlon™ 64 3200+, Pentium® IV 2.4 GHz,
Core™ 2 Quad *2 *3
Memory More than 1 GB（4 GB or more recommended）
HDD More than 4 GB
Others Communication with robot controller via Ethernet
Display with more than 1280x1024, 24bit color
Mouse and DVD drive available under Windows

RESULT
Thus Familiarized with Simulation software of Robo guide.

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8.2 Familiarization of library functions – menu bar,tool bar and status bar
AIM
To get familiarized with the library functions – Menu Bar, Tool Bar and Status Bar in
simulation Software

EQUIPMENTS
SL.
EQUIPMENTS SPECIFICATION QTY
NO
1. Software Simulation Robo Guide- Intelligent 3D Simulation - FANUC -

THEORY:
The configuration of ROBOGUIDE is as follows. With ROBOGUIDE, a robot system
can be simulated with high accuracy by a virtual robot controller that has the same
software structure as an actual robot controller. Moreover, it provides superb functions to
support designing layout and programming, and the user can design a robot system easily
without the actual robo

START A ROBOGUIDE
In order to start ROBOGUIDE, click ‘ROBOGUIDE’ under ‘Start’ menu-‘All programs’-
‘FANUC Robotics’.

EXITING ROBOGUIDE
This is to describe the procedures to exit ROBOGUIDE. In order to exit the ROBOGUIDE,
click ‘Exit’ under ‘File’, or click X (Close) button at the top right on the window.

HOW TO USE THE TUTORIAL

The tutorial is described in the online help of ROBOGUIDE. In order to open the online
help, run ROBOGUIDE, and click ‘Contents’ under ‘Help’. When you click ‘Roboguide / PRO
Software Workcell Examples’, the list of the tutorial is displayed.

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FUNCTIONS OF ROBOGUIDE
USER INTERFACE
WINDOW LAYOUT
The window layout of ROBOGUIDE is as follows.

Menu
Tool Bar
Bar
Process
Navigator

Cell
Browser

Status
Bar

Process Navigator
The Process Navigator is a function that supports creation of a workcell. The
workcell can be C ELL BR OW SER

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Created easily according to the procedure that Process

Navigator shows.
All the elements (a robot, a program, a part, etc.) of a workcell are displayed on
the Cell Browser by a tree structure. The user can get to these elements from the
Cell Browser.
Fixtures
Fixtures are defined as objects that put a part. A part is used associated with a
fixture. When fixtures are moved, The associated part also moves together. In
order to add fixture, right-click the 'Fixtures' in the cell browser, and click 'Add
Fixture', or click 'Add Fixture' from the 'Cell' of a menu.
Parts
Parts are defined as objects that are handled by a robot. In order to add parts,
right-click the 'Parts' in the cell browser, and click 'Add Part', or click 'Add Part'
from the 'Cell' of a menu.

Robot Controllers
Robot Controllers are defined as created virtual robots on ROBOGUIDE. Programs,
tool frame, user frame, etc. can be set.

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Obstacles
Obstacles are defined as an object that a robot should not contact. In order to add
obstacles, right-click the 'Obstacles' in the cell browser, and click 'Add Obstacle', or
click 'Add Obstacle' from the 'Cell' of a menu.

Profiles
Information including the cycle time of a simulation is displayed on profiles. when a
simulation starts, profile data is added automatically.

Dimensions
Dimensions are defined as the distance for two points specified on the object in a
work cell. In order to add dimensions, right-click 'Dimensions' in the cell browser,
and click 'Add Dimension', or click on tool bar, and use distance
measurement tool.

Targets
Targets are defined as position information on workcell. In order to add targets,
click on the tool bar, and use target tool. Please refer to online help about how
to use a target tool.

Target Groups
Target groups are defined as what grouped the targets. TP program can be created
from target groups. In order to add target groups, right-click ‘Target Groups’ in the
cell browser, and click ‘Add Target Group’, or click ‘Add Target Group’ from the
‘Cell’ of a menu.

Machines
Machine are defined as peripheral equipments that operate by a servo motor or
an I/O signal, such as a rail axis and the robot hand opens and closes, and a
machine tool whose door opens and closes. In order to add a machine, right-click
the ‘Machines’ in the cell browser, and click ‘Add Machine’, or click "Add Machine"
from the ‘cell’ of a menu.

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TOOL BAR

At the tool bar, frequently used operations are arranged as a button. If you click
the button, the function can be called easily.

: Create a new workcell, open workcell, and save workcell.

: Undo / Redo

: Show Cell Browser. / Show Process Navigator.

: Select a teach tool.

: Show a virtual teach pendant.

: Show a Run Panel.

: Execute program, stop program, record movie,

etc. : Zoom in / out.

: Change view direction.

: View wire-frame.

: Run measure tool

MENU BAR

At the menu bar, the functions of ROBOGUIDE are classified for each item. Select
the functions from here.

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STATUS BAR

At the status bar, the name of selected robot controller and program, and error
information are displayed.

PROCEDURE:
FOR MENUS AND TOOLS
1.Navigate through each option

• STATUS BAR: the name of the selected robot controller/ manipulator and program,
and error information are displayed
• MENU BAR: In the menu, the functions of Robo guide are classified for each item
 File: Options like creating, opening, saving, editing, selecting the packages are
available.
 Edit: options for editing the current work cell is available

 View: This menu helps in adjusting the appearance of work cell

 Cell: This menu helps in fetching the parts, fixtures, obstacles and other required
things based on the application to the work cell
 Teach: Through this menu we get options for adding a program, loading the
program, obtaining the TP files.
 Test-Run: This menu helps to run the program

 Window: Window menu is used to obtain different 3D view panes

• TOOL BAR: Here frequently used operations are arranged as button.

FOR OPERATIONS OF ROBOGUIDE
1. Rotate view: Right drag

2. Pan view: Right-drag while holding down the CTRL key

3. Select and open property page of an object: Left-click an object to select it and double
click on the object to alter its properties
4. Move an object: To move an object select an object, a green triad is displayed on it.
Left drag the green triad while holding control key. To move along one axis, left drag
on one of the axes on the green triad

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5. Rotate object: Select an object, green triad is displayed

on it, left- drag one of the axes while holding SHIFT key
6. Moving TCP (Tool Centre Point) of robot/ manipulator:
• To the surface of object: LEFT click the surface, holding CTRL+SHIFT key
• To the edge of object: LEFT click the edge, holding CTRL+ALT key
• To the top of object: LEFT click the top, holding CTRL+ALT+SHIFT key
FOR BASIC FUNCTIONS OF ROBOGUIDE

1. Joint jog tool: This function can execute joint jog operation in the 3D world. A robot
is jogged by dragging green T-shaped bar on axis to move
2. Measurement function: This function can measure the distance between two points

3. Move and Copy object function: This function can move objects or teaching point
to the specified position. This function can copy the moved object to the position
after movement.
4. KCL window: This function executes KAREL Command.

RESULT
Thus Familiarized with the Libraries – Menu, Tool and Status Bar in Simulation software of
Robo guide.

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8.3 Creating a new workcell

AIM:
To create a new workcell and select LRMATE 200iD/4s manipulator/robot model
and jog the manipulator using virtual teach pendant.

EQUIPMENTS

SL.
EQUIPMENTS SPECIFICATION QTY
NO
1. Software Simulation Robo Guide- Intelligent 3D Simulation - FANUC -

THEORY :

WORK CELL

WorkCell is a complete system that includes the robot, controller, and other
peripherals such as a part positioner and safety environment.

Things to Be Considered Before Design A Work Cell:

• Determine what job the work cell will be doing.

• Develop an outline of the tasks
• Choose robots with the right applications to do the job
• Select a positioner to move the product down the line
• Create a layout to efficiently and safety complete the task
Applying the same in our Simulation software of Robo Guide:
If you create a new work cell, click ‘New Cell’ under ‘File’ or click ‘1. Start
New Cell’ on the Process Navigator. The Process Navigator is a function that support
creation of a work cell. According to the procedure of the Process Navigator, a work cell
can be created easily.

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PROCEDURE:
1. Start menu, Select FANUC ROBOTICS, select HANDLINGPRO

2. Click on FILE menu, select NEWCELL, WORKCELL CREATION WIZARD is opened

3. Name the workcell, click on NEXT, select the method to create a robot, select
the software version.

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4.Select the application package- Handling robot

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5. Select the Robot model – LRMATE 200iD/4s

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6. At the summary page click on FINISH

7. After finishing, a virtual robot is started in initial start mode, the system software and
application software are loaded to the virtual robot
8. A new workcell with LRMATE 200iD/4s is created

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9. Double click on the manipulator and change the properties according to the
requirements, click APPLY, click OK.

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10. From TOOL BAR, select show/hide teach pendant tool, a virtual teach pendant is
displayed

11. TURN ON the teach pendant, JOG the robot.

RESULT:
Using ROBOGUIDE software tool, a new work cell with LRMATE 200iD/4s manipulator is
created and the manipulator is made to jog using virtual teach pendant.

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8.4 Creating a Rectangular pattern – Linear Interpolation

AIM:
To make rectangular pattern with LR MATE 200iD/4s using roboguide software, uploading
the same in real manipulator (LR MATE 200iD/4s) and verifying for its working.

EQUIPMENTS
SL.
EQUIPMENTS SPECIFICATION QTY
NO
Software
Simulation, Pc or
1. RoboGuide- Intelligent 3D Simulation - FANUC -
Laptop and Pen
Drive
THEORY :
To Draw a rectangular Pattern using Robo guide Simulation Software .
DIAGRAM:

P2 P1,P5

P3 P4

PROGRAM:
1: L P[1] 100mm/sec FINE
2: L P[2] 100mm/sec FINE
3: L P[3] 100mm/sec FINE
4: L P[4] 100mm/sec FINE
5: L P[5] 100mm/sec FINE
6: L P[6] 100mm/sec FINE {all the joints at 0 degree/ Home position}
[END]

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PROCEDURE:
1. Repeat the steps of exercise – 1

2. Click on the CELL BROWSER, right-click on PART, select ADD PART, select BOX

3. In the popped-up TAB, change the properties of BOX (Ex: Name, Mass, Size), Click
APPLY. (Note: The size (x, y) of the box should be relative to the size of the rectangle
expected)

By the end of this step there should be a LR MATE 200iD/4s manipulator and a box with
necessary requirements in the work-cell.

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4. Move the part- rack in front of manipulator, make use of object view tools for proper
positioning. (Note: The part should be placed within the work envelope, to check click
on SHOW/HIDE WORK ENVELOPE tool-button from tool bar)

5. Select VIRTUAL TEACH PENDANT, turn ON the Teach pendant, create a Program.

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To create a program:
• Click on SELECT button, in the popped-up tab, select CREATE by using F2 button, give
a name for program, double-click ENTER

• JOG the robot, once point is located click F1, select the type (joint/linear), click
ENTER.

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• Jog and locate all the four points at the four corners of box, which gives a rectangular
pattern.

Or
5. Select ADD SIMULATION PROGRAM from TEACH menu, in the popped-up tab
give name for the program, click APPLY, click OK

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To create a program:
• JOG the robot using JOINT JOG TOOL or entering current position values in the
VIRTUAL TEACH PENDANT

• Once the point is located, click on RECORD by selecting the type in the SIMULATION
PROGRAM EDITOR tab.

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• Repeat the above two steps to locate the all four points at the corners of box, which
gives a rectangular pattern.

6. After recording all the points click on SHOW/HIDE RUN PANEL tool to run the
program.

RESULT:
Rectangular pattern is simulated using ROBOGUIDE software, the TP program is uploaded
in the REAL robot (LR MATE 200iD/4s) and verified.

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8.5 Creating a Circular Pattern – Circular Interpolation

AIM:
To make Circular pattern with LR MATE 200iD/4s using Roboguide software, uploading
the same in real manipulator (LR MATE 200iD/4s) and verifying for its working.
EQUIPMENTS
SL. NO EQUIPMENTS SPECIFICATION QTY
Software
Simulation, Pc or
1. RoboGuide- Intelligent 3D Simulation - FANUC -
Laptop and Pen
Drive
THEORY :
To Draw a Circular Pattern using Robo guide Simulation Software.
DIAGRAM :

PROGRAM:
1:JP[1] 100% FINE
2:C P[2]
P[…..]100% FINE
3:CP[3]
P[…]100%FINE
4:CP[4]
P[….]100% FINE
5:CP[4]
P[….]100% FINE
6:CALL HOME
7:END

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PROCEDURE:

1. Create a new work-cell

2. Click on the CELL BROWSER, right-click on PART, select ADD PART, select CYLINDER
3. In the popped-up TAB, change the properties of CYLINDER (Ex: Name, Mass, Size),
Click APPLY. (Note: The diameter of the cylinder should be relative to the size of the
circle expected)

4. Move the part-rack in front of manipulator, make use of object view tools for proper
positioning. (Note: The part should be placed within the work envelope, to check click
on SHOW/HIDE WORK ENVELOPE tool-button from tool bar)

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5. Select VIRTUAL TEACH PENDANT, turn ON the Teach pendant, create a Program.
To Create a Program
• Click on SELECT button, in the popped-up tab, select CREATE by using

F2 button, give a name for program, double-click ENTER

• Jog the Robot and locate points along with the touch up points

6. After recording all the points click on SHOW/HIDE RUN PANEL tool to run the
program.

RESULT:
Circular pattern is simulated using ROBOGUIDE software, the TP program is uploaded in
the REAL robot (LR MATE 200iD/4s) and verified.

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8.6 Familiarization of adding elements to workcell – e.g Fixtures, Grippers

AIM:
To get Familiarized of adding elements ( Fixtures and Grippers) to the work Cell with LR
MATE 200iD/4s using Robo Guide software.

EQUIPMENTS
SL.
EQUIPMENTS SPECIFICATION QTY
NO
Software Simulation,
Robo
1. Pc or Laptop and Pen -
Guide- Intelligent 3D Simulation - FANUC
Drive

THEORY :
To add elements to the work cell to perform an action using Robo guide Simulation
Software .
Fixtures
Fixtures are defined as objects that put a part. A part is used associated with a
fixture. When fixtures are moved, The associated part also moves together. In
order to add fixture, right-click the 'Fixtures' in the cell browser, and click 'Add
Fixture', or click 'Add Fixture' from the 'Cell' of a menu.

Parts
Parts are defined as objects that are handled by a robot. In order to add parts,
right-click the 'Parts' in the cell browser, and click 'Add Part', or click 'Add Part'
from the 'Cell' of a menu.

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PROCEDURE:
1. Create a new work-cell (refer exercise-1)

2. Open CELL BROWSER

3. To add fixtures (like conveyor, tables, pallets, racks and so on) to the work-cell

i. Right-click on Fixture , select add fixture, select CAD library. This leads to the
image library of FANUC ROBOGUIDE

ii. In IMAGE LIBRARY tab , click on any of the fixture, list of fixture image
appears, select according to the requirements. Click OK

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iii. A fixture along with its property tab appears in the work-cell. Changes in the
location, scale, mass etc., are made based on the application.

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4. To add a GRIPPER
i. Under cell browser, select Robot Controllers, select Tooling.

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ii. Double click on UT:1(Eoat1)

iii. In the popped - up Property tab under general , at the option CAD file, click on

the folder icon , select Eoat folder, select gripper folder , select any
gripper, click apply

iv. Now change gripper location, size, physical characteristics click apply
v. To simulate (open/close) the gripper, select simulation tab, under gripper

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settings in function’s dropdown select “Material Handling- Clamp”

vi. In AutoCAD heading click on which directs to Image Library, under Eoat,
grippers select any gripper

vii. Click apply.

viii. By clicking OPEN/CLOSE or opening and closing action of gripper can

be seen. Finally Click OK.

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RESULT:

Thus got familiarized to fix the parts and Fixture in a work cell.

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8.7 Design and Simulate Pick and Place Operation in a Work cell

AIM:
Simulate a work-cell to pick and place an object using LR Mate 200iD manipulator
EQUIPMENTS
SL.
EQUIPMENTS SPECIFICATION QTY
NO
Software Simulation, Pc or Robo
1. -
Laptop and Pen Drive Guide- Intelligent 3D Simulation - FANUC

THEORY :
A pick and place robot is any robot that can pick up an object from one location
and drop it in another. They are used for a wide variety of tasks in manufacturing and
other industries, including sorting, stacking, moving, and packaging products.
Automated pick and place robots are typically mounted on a stand to allow the
robots to reach the entire work envelope. Parts or assemblies will enter the robotic work
envelope, often on a conveyor belt or presented in a bin. Robotic vision inspection
technology will enable the robot to accurately identify the part, based on characteristics
like shape, size, color, orientation, or location. From there, custom end-of-arm tooling will
enable the robot to grab and move the object from one place to the desired position or
location.
Here we are going to Create a work-cell for pick and place action having LR Mate
200iD with a mechanical gripper. The manipulator must pick and place two boxes one
after the other from basket to moving pallet .

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PROGRAM

: LP [1] 2000mm/Sec Fine

: LP [2] 2000mm/sec Fine
: Pickup (‘Green’) from ( ‘ Basket’) with (‘GP:1 –
UT:1 (‘gripper’))
: LP[3] 2000mm/sec CNT 100
: LP[4] 2000mm/sec Fine
: Drop(‘green’) From (‘GP:1 –UT-1 (‘ Gripper’) on
(‘Pallet’)
: LP[5] 2000mm/Sec Fine
: LP[5] 2000mm/Sec Fine
: Pickup (‘Red’) from ( ‘ Basket’) with (‘GP:1 –
UT:1 (‘gripper’))

: LP[5] 2000mm/Sec Fine

: LP[5] 2000mm/Sec Fine
: Drop(‘Red’) From (‘GP:1 –UT-1 (‘ Gripper’) on
(‘Pallet’)
:LP[5] 2000mm/Sec Fine
: LP[5] 2000mm/Sec Fine
: End

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PROCEDURE:
1. Create a new work-cell selecting LR Mate 200iD controller.

2. Double click on manipulator, select lock all location variables check box, then
click on OK

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3. From Cell Browser

GP:1 - GR mate 200id/4s
Tooling

UT:1(Eoat 1) (Double click)

It leads to property window of Eoat1, there click on ,under Eoat, select grippers ,
select36500f-200, click OK

4. In the property tab appeared, click apply

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5. Now change the properties

Name: Gripper
Mass: 1.0kg
Scale X,Y,Z: 0.3
Location W=90 deg; R= 90deg
Color: Black
Select the Lock all Location Values checkbox. Click on OK

6. From Cell Browser, Right click on fixtures option, select add fixture, select CAD library
from the dropdown

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7. In the Image library , select pallets under fixture, select basket, Click OK

8. Now change the properties of the fixture1

Name: basket
Scale X,Y,Z: 0.5
Location X= 180mm, Y= -235mm, Z=0
Change colour if necessary
Select the lock all location values checkbox, click OK

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8. Similarly add a fixture named as pallet to the work-cell. And change the properties as
below:
Name: Pallet
Scale X,Y,Z : 0.3
Location X= -250mm, Y= -550mm, R=-90 mm
Select Lock all location values check box. Click OK

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9. Make sure both basket and pallet are within the work envelope

10. To add boxes to the work-cell, Right-click on PARTS in cell browser, select Add part,
select Box

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Repeat the above step and add one more box to the work-cell.

9. Change the properties of the boxes by double clicking on each part

Name Green Red

Mass 1.0 kg 1.0 kg
Color Green Red

Scale X,Y,Z 150 mm 150 mm

Click OK

13. Add parts to the fixtures i.e., to the basket and pallet

Double click on basket, it leads to property tab of basket,

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Parts

Follow the below screen shots

Part Offset Values

Parts X Y Z
Green 230 230 230
mm mm mm
Red 255 420 420
mm mm mm

14. Similarly add parts to the Pallet

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At the end of this step a robot controller (LR Mate 200iD), a basket with two boxes and a

pallet with two boxes should be present in the work-cell.

15. Before programming we must simulate each part that has to be picked and
placed.
Double click on basket/ open basket property tab , open simulation , click on each
part and select the “allow part to be picked” check box. Enter 2 sec at create delay
option. (follow the image)

16. Repeat the above step for pallet but select the “allow part to be placed” check
box.

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17. To program for pick and place,

Select Add Simulation Program from Teach Menu

In the popped window enter the program name as “picknplace” click apply , aclick
OK

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18. In the below figure

Record is used to record the position

Move To is used to move the robot controller to part/ position.
Inst is used to use standard Instructions like Pick, Drop, Call, Wait etc..
19. The program for Pick and place is as below

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20. Once programming is done , click on run tool to see the action of pick and place.

RESULT:

Thus, LR Mate 200iD/4s is programmed to pick and place two boxes one after the
other.

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8.8 Create and adding a Rail Unit in a Work cell

AIM:

Simulate a work-cell to create and add a Rail Unit by using LR Mate 200iD manipulator

EQUIPMENTS
SL.
EQUIPMENTS SPECIFICATION QTY
NO
Software Simulation, Pc or Robo
1. -
Laptop and Pen Drive Guide- Intelligent 3D Simulation - FANUC
THEORY :
Here we are going to Create a work-cell for creating and adding a Rail Unit .
PROCEDURE:
1.Create a new Work cell
2. Open CELL BROWSER

To add Rail Unit Click Machinesto the work-cell

i. Right-click on MAchines , select add Machines, select CAD library. This leads
to the image library of FANUC ROBOGUIDE

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ii. In IMAGE LIBRARY tab , click on any of the Machines, list of fixture image
appears, select according to the requirements. Click ‘Box” as OK

iii. A Box Can be extended By changing their Values on the Cell Browser.

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(iv) Then Add a link to connect them to the robot and Machine , name them
accordingly. Kindly check in to join positions of the Robot

(v) Now set their positions of the robot so that it can be moved on the rail unit.

(Vi) Set up the measurements on cell Browser to fit it according to the rail Unit

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(vii) After setting all the requirements run the unit As shown

(Viii) Now the rail Unit is set for its movement .

RESULT:

Thus creating and adding a rail unit is explored using Robo guide Simulation
Software.

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9.0 COORDINATE SYSTEM

AIM:
To learn and understand the co-ordinate system settings for user frame co-ordinate and
tool frame co-ordinate.

9.1 Setting a user a coordinate system ( user frame setting : 3- point method )

USER FRAME CO-ORDINATE SYSTEM:

The user frame by default has world frame as its reference. When the user frame is setup,
all the positions are automatically recorded in the user frame in the program. User frame
setup will be easy to program with respect to the defined user frame and it eases re-
teaching when the object is shifted without actually teaching all points. Up to 10 numbers
of user frame can be set up.

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USER FRAME SETTING: 3-POINT METHOD

STEP 1:
Click menu button from teach pendant then
select “SETUP” followed by Select Frames
from the option.

STEP 2:
From the display Choose “OTHER” option by
clicking F3 button then select User Frame
from the option.

STEP 3:
From the display Choose “METHOD”
optionby clicking F2 button.

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STEP 4:
Then select “THREE POINT” method from the
options.

STEP 5:
From the new display page move the cursor to
comment option, then press ENTER button to
type the new UFRAME name.

STEP 6:
RENAME the UFrame name as per the
program.
EX: UFRAME NAME - FIXTURE1

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9.2 Create an orient origin point

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1) ORIENT ORIGIN POINT:

After Renaming the Uframe name as per program next step is to jog the robot to origin
point of the fixture (Depending on Applications).

Step 1:
To fix the origin point of the fixture navigate
the cursor in display to “ORIENT ORIGIN
POINT”.

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Step 2:
To fix the origin point of the fixture, Record
the ORIGIN point by selecting SHIFT + F5
button.

2) X- AXIS DIRECTION POINT:

After recoding the ORIENT ORIGIN POINT “X Direction point” need to recorded, hence
jog the robot from Orient origin point to End of X Axis point.

Step 1:
To fix the X Axis point of the fixture navigate
the cursor in display to X Direction Point.

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Step 2:
Record the X Direction point by selecting
SHIFT + F5 button.

3) Y- AXIS DIRECTION POINT:

After recoding the X Direction point “Y Direction Point” need to recorded, hence jog the
robot from Y Direction point to End of Y Axis point.

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Step 1:
To fix the Y Axis point of the fixture navigate
the cursor in display to Y Direction Point.

Step 2:
Record the Y Direction point by selecting SHIFT
+ F5 button.

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9.3 Setting a tool co ordinate system ( setting up tool frame ) in 3 – point

method and 6- point method

➢ Tool Frame Setup: - A maximum of 10 different tool frames can be set.

Any one of the following methods can be used to define the tool frame.
✓ Three Point
✓ Six Point
✓ Direct Entry

✓ Three Point Method: - Three different positions are recorded as three approach
positions. In each case at minimum angle difference of 45° is necessary to get a good
TCP.
✓ Six Point Method: - The six point method has three approach points similar to three
point methods along with Origin, X-direction point and Z-direction point.
✓ Direct Entry Method: - Directly the TCP values are entered from the cad file of the tool.

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SETTING UP TOOL FRAME IN 3-POINT METHOD

STEP 1:
Click menu button from teach pendant then
select “SETUP” followed by Select Frames
from the option.

STEP 2:
From the display Choose “OTHER” option by
clicking F3 button then select Tool Frame
from the option.

STEP 3:
Select the “DETAIL” option by clicking F2
button.

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STEP 4:
From the display Choose “METHOD”
option by clicking F2 button. Then select
“THREE POINT” method from the options.

STEP 5:
From the new display page move the
cursor to comment option, then press
ENTER button to type the new TOOL
FRAME name (EOAT NAME).

STEP 6:
RENAME the TOOL FRAME name as per
the program.
EX: TOOL FRAME NAME – WELDING
TOOL.

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First Approach Point: from the top

Second Approach Point: from the

right, near the robot with the tool
tilted

Third Approach Point: from the left,

further from the robot and the tool
tilted in the opposite direction

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Three point Method:

Three point Method is used for tools that are straight and in line with the J6 faceplate that
is Straight tool, not for bend tool.

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SETTING UP TOOL FRAME IN 6-POINT METHOD

With the Six point method it is able to twist the coordinate system in such a way that is
aligned with the tool tip, so that tool moves automatically. Tool frame in 6-point method is
similar to three point method.

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10. MACROS, MASTERING, BACKUP AND RESTORE

AIM:
To learn and understand the process, operation and need for macros, Mastering, back-up
& restore functions in Fanuc Industrial robot.

10.1 Macros
A macro is a short sequence of code that automatically expands into a set of instructions to
perform a single task.
Macro instruction is a function for registering a program consisting of a sequence of
instruction and calling such a set of instruction for execution as required.
Note: Macros is Shortcut command code particularly for Gripper open and close operation.
PROCEDURE:

STEP 1:
• Go-to main/default page in teach
pendant, press “Menu” button.
• Select the “SETUP” option in the Display
Screen.

STEP 2:
• From the “Setup” options, choose the Macro
Function.

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STEP 3:
In macro setting screen 4 columns are
generally available.
• INSTRUCTION NAME: Comment can be
given.
• PROGRAM: Select the required
program.
• “- -“: select the macro function.
• ASSIGN: Assign the input number of the
macro function

STEP 4: PROGRAM
• Place the cursor to program column in
the particular empty line.
• In the bottom of the Display, Select the
“CHOICE” option.
• Select the appropriate “pre- recorded
program” from the available program
list.
Example: Pre-recorded program: Gripper
Close

STEP 5: INSTRUCTION NAME

• Enter the Instruction (as required) in the
“Instruction name” column.
Example: Instruction Name: Gripper Close

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STEP 5: MACRO FUNCTION (- -)

• Place the cursor in the “Macro Function”
column.
• Select the choice option below the screen.
• From the macro function list, choose the
required Function.

Note: Macro Functions

UK – USER KEY (1 TO 7)
SU – SHIFT + USER KEY (1
TO 7)
MF – MANUAL FUNCTION (1 TO 99)
DI – DIGITAL INPUT
RI – ROBOT INPUT

STEP 6: ASSIGN
• Choose an integer value to assign the input
number for Macro function.
Example: for Gripper close operation- “1” is the
input number.

STEP 7: Gripper Open Macro Command

• Similar, to the above steps, Create the
macro function for Gripper open operation.

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10.2 Mastering

• The mastering process is a type of calibration that increases the positioning accuracy
of the robotic arm of an industrial robot. Robot mastering is performed to set the
correct positions of each axis of the robot arm, relative to the base Cartesian
coordinate system (x, y, z).
• Mastering the robot is done to find the zero joint position value. When programming a
robot's movement, specific tool-center-point (TCP) positions are setup. These TCP
positions are based on that zero point set for each robot joint. Setting this zero point is
called mastering.
• Mastering is an operation performed to associate the angle of each robot axis with the
pulse count value supplied from the absolute pulsecoder connected to the
corresponding axis motor.
To be specific, mastering is an operation for obtaining the pulse count value
corresponding to the zero position.

RESETTING ALARMS AND PREPARING FOR MASTERING:

Firstly, reset the relevant alarm created such as (Before performing mastering “SERVO-062
BZAL alarm”, “SERVO 075 PULSE NOT ESTABLISHED”.

NOTE: Mastering must be done compulsory, when there is “SRVO-062 BZAL alarm”

To reset the “servo 062 BZAL” alarm, follow the below mentioned steps

1. Press the menu button

2. Press [0-Next] and Select [6-SYSTEM].
3. Press F1 button for TYPE option and Select [Master/Cal] from the menu.
4. Press the F3 key [RES_PCA], then Press F4 key for Choosing TRUE option.
5. Turn off the robot controller power and ON again.

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NEED FOR MASTERING

PULSE CODER BATTERIES DEAD: Fanuc robot consists of 4 batteries for recording the
position of the pulsecoder.If the batteries are gone completely dead, mastering process
need to be followed.

PULSE ENCODER REPLACEMENT: Due to sudden failure of pulse coder (like PCB board)
leads to replacement of pulse coder which disturbs the zero-position of robot. Hence
mastering is done after replacement.

REDUCER REPLACEMENT: Reducers in robots are similar to gears for reduce speed &
increase torque.If reducer need to be replaced, then mastering need to be done.

CABLE REPLACEMENT: Cables in robots such as (power supply, signal cable, brake cable)
may cause failures such as continuity issues, wire damage etc.Hence after cable
replacement mastering will be done.

MOTOR REPLACEMENT: Servo motor is one of the key parts of robot for movements,
problems like winding damage etc needs service & replacement. Therefore to recover the
zero-position mastering will be done.

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TYPES FOR MASTERING

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1) FIXTURE POSITION MASTERING:

This is performed using a mastering Fixture before the machine is shipped from the factory

2) ZERO – POSITION MASTERING:

• This is performed with all axes set at the 0-degree position.
• A zero-position mark (witness mark) is attached to each robot axis.
• This mastering is performed with all axes aligned to their respective witness mark.

PROCEDURE OF ZERO-POSITION MASTERING

STEP 1:
• Before starting the zero position mastering process the first step is to check the
current position of the 6 Axis of robot.
• Press POSN button at the bottom in the teach pendant.(Robot Axis Position data will
be displayed)

Step 2: To start the Zero position mastering most important step is to identify the
“WITNESS MARK” for each axis (J1 to J6).

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Mastering of J1 Axis
• Select the coordinate system as “JOINT” Coordinate system
• Jog the robot of J1 axis to exactly match the Vernier scale of
witness
mark

STEP 3: Similarly repeat the process of witness mark matching for the entire remaining axis
(J2 to J6)

NOTE: After the witness mark matching the axis position data of the robot will be
changed to ZERO.

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STEP 4:

• Now press the MENU button from teach

pendant
• Then select 0-Next option from the display.

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STEP 5:

Then select 0-Next option from the display.

STEP 6:

From the display, Change the value of as

Example: 405 $MASTER ENB 0 TO 1

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STEP 7:

• After changing the MASTER ENB

value to 1, select “TYPE” option
from bottom of the display.

• Then select the “Master/Cal”

option and Press enter.

STEP 8:

• Select “ZERO POSITION

MASTER” option from the display
and press enter.

• Finally, Press YES option to save

the mastering process at zero
position.

Hence robot will be mastered successfully.

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STEP 9:
• To calibrate the robot at “ZERO
POSITION MASTER”, move the
cursor to “CALIBRATE” option.
• Select Enter, and finally press YES
option.
• To complete calibration, enter
DONE option.

3) QUICK MASTERING:
Quick mastering is performed at a user-specified position. The corresponding count value
is obtained from the rotation speed of the Pulsecoder connected to the relevant motor
and the rotation angle within one rotation. Quick mastering uses the fact that the absolute
value of a rotation angle within one rotation will not be lost.

Procedure of Quick Mastering:

1. Display the Master/Cal Screen.
2. Jog the robot to the quick mastering reference position.
3. Move the Cursor to QUICK MASTERING and Press ENTER, then Press F4 ,YES
4. Move the Cursor to Calibrate and Press ENTER.

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4) SINGLE AXIS MASTERING:

Single axis mastering is performed for one axis at a time. The mastering position for each
axis can be specified by the user. Single axis mastering can be used, if mastering data for a
specific axis is lost, for example, because a low voltage has been detected on the pulse
counter backup battery or because the Pulsecoder has been replaced.

Single Axis mastering is same as the procedure of Zero position mastering but the
advantage is this mastering is suitable only for the required axis for mastering or
calibration.

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10.3 Backup and restore

FILE BACKUP (SRAM BACKUP)

A Fanuc File Backup will backup all

files accessible in the teach pendant
one to one to an USB Stick. This are
for example
TP (.ls/.tp) and KAREL (.kl/.pc)
programs
System configurations (I/O
configuration, Frames, Mastering,
Menu settings, etc.)
System variables

NOTE: File Backups are not a complete controller backup. If you lose a main board or
FROM/SRAM module, or otherwise have to completely reload your robot controller, a File
Backup will not get you up and running by itself.

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One way to solve the problem of lost mastering values is to make sure you always have
an updated backup available to load to your robot.

CREATE FILE BACKUP: (SRAM BACKUP – STATIC RANDOM ACCESS MEMORY)

To create a File Backup performs the following steps:

STEP 1:

• Plug a USB-Stick (pen drive) into the

Controller or teach pendants USB port.

Note: It’s recommended that the USB Stick

size is not bigger than 2GB as the whole drive
is read when backing up.

STEP 2:
Select the MENU button and then when the
menu screen pops up using the arrows
navigate to FILE.
On the right-side menu also select FILE by
hitting enter.

STEP 3:
Press the UTIL button at the bottom bar,
select the entry Set Device.

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STEP 4:
On the next menu select Option 6 – USB
Disk (UD1) using the down arrow key and
then select Enter.
NOTE: USB DISK (UD1 :) – FLASH DRIVE
INSERTED IN ROBOT CONTROLLER.

STEP 5:
Create a directory on the USB stick with the
UTIL button at the bottom bar with the
help of F5 button. Select the option Make
DIR.

STEP 6:
Then Select the Upper case Option at the
bottom bar and type a Directory name.

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STEP 7:
Press the BACKUP button at the bottom
bar (F4 BUTTON) and select the entry All
of above.

STEP 8:
Confirm with YES with the help of F4
button in the bottom bar.

STEP 9:
The screen now reads Backing up #/# files
and you can follow the backup progress.
Once backup progress done remove the
USB flash drive, and store it in a safe place.

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RESTORE FILE BACKUP

To restore a File Backup perform the following steps:

1. Obtain a USB-Stick with a previous IMG backup for the robot you are working on.
2. Plug a USB-Stick into the teach pendants USB port.
3. Restart the robot controller and enter the Configuration Monitor menu by holding the
soft buttons PREV and NEXT on the teach pendant as soon as the robot starts to power
back up.
4. Type 3 and press the soft button to initiate a controlled start.
5. Once the teach pendant is booted back up, press the soft button , enter
the FILE menu and there the File section.
6. Press the UTIL button at the bottom bar, select the entry Set Device and there the
entry USB on TP (UT1 :).
7. Navigate to the directory in which your File backup backup is stored. If no files or
directories are shown, you will have to press ENTER on (all files) to see the USB-Sticks
contents.
8. Press the RESTOR button at the bottom bar.
9. Select the type of restore action you want. If you don't know which you need, use 'All of
above':
• System files (system variables, servo parameter data, and mastering data)
• TP programs (.TP, .DF, and .MN files)
• Application ("Non-program application files")
• Applic.-TP (All of the above, except system files)
• Vision data
• All of above

10.You will be prompted with “Restore from UT1: (OVERWRT)?” Press YES at the bottom
bar.
11.The TP will show “Accessing device. PREV to exit.” for about 30-60 seconds, then the
restore will commence. Once it begins, typical restore time is about 2-6 minutes,
depending on the contents of your robot.
As many files as possible will be restored. Once the restore is complete, you will
need to perform a Cold Start

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NTTF_DIPLOMA IN MECHATRONICS ENGINEERING & SMART FACTORY (CP15)_SEMESTER 5_ROBOTICS LAB_WORK INSTRUCTION 153