CADM MC600

ROBOTICS
 TOPICS
• Industrial Robot and programming
• Course Information
• Robot types
• How to operate them
• Safety and safety related operation
 COURSE OUTCOMES
• Be able to discuss the parameters of importance in a
small robot work cell.
• Be able to evaluate the basic safety of a small robot
work cell.
• Power up and jog the robot.
• Create, Edit and Run a material handling program.
• Deal with common faults in operation
 COURSE OUTCOMES
• Create, edit and use MACROs
• Make system and file backups and restore the backup
• Utilize input / output signals
 GRADING

• Lab completion 35%

• Lab Test 15%
• Lab test/project 15%
• Quiz/homework 15%
• Exam 20%
 Academic Honesty Policy
We are committed to Academic Integrity in the
Department of Technology. An academic offence
reflects badly on the student and on our School.
Those committing the offence and those assisting
will both be cited and penalized for the offence.
 Academic Honesty Policy
– Penalties
• First Offence – A grade of zero on assignment, test
or lab.
• Second Offence – A grade of zero on the course.
• Third Offence – Suspension from the College.
– Process
• First Offence – Meeting with the Professor.
• Second and Third Offence – Meeting with the
Professor and the Associate Dean. The Associate
Dean determines the penalty.

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 Academic Honesty

Please be sure to submit your own individual work.

It may be difficult to recognize where the line is
between "helping" and academic dishonesty.
Here are some guidelines:
DO work side-by-side and talk about the
lab/assignment, and possible algorithms and
coding techniques.
DO ask others to look at your code on your monitor
or laptop and discuss techniques and
troubleshooting ideas.

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 Academic Honesty
DO type only on your own keyboard.
DO NOT type on someone else's keyboard,
or use their mouse.
DO NOT provide your files to someone else,
not even as an "example" of working code.

9
 LOCK DOWN
• Lock down
• Exit the building and move away if possible
• Move into a secure area
• Class room
• Office
• Stay quiet and calm
• Obey the directions of security and / or Members of the
emergency response team
• A 3 minute recorded announcement will indicate the
end of the lockdown
 HOLD AND SECURE
• All entrances to the college are closed
• Only allowed in or out by the front entrance
• Otherwise business as usual
• Follow instructions given by security and / or
emergency response team
 TYPES OF ROBOTS (BY
Industrial robots - APPLICATION)
Articulated arms
specifically
developed for
such applications
as welding,
material
handling,
painting and
others.
 DOMESTIC OR HOUSEHOLD ROBOTS
Robotic vacuum cleaners, surveillance robots, servant

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 MEDICAL ROBOTS
• Robots used in medicine and medical institutions.
• Surgical robots , Rehabilitation robots Telepresence robots

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 MILITARY ROBOTS
bomb disposal robots, different transportation robots, combat
robot, etc.
 ENTERTAINMENT ROBOTS
• These are robots used for entertainment, toys.

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 HOBBY AND COMPETITION ROBOTS
• Robots that you create. Line followers, wall climbing, pole
balancing, sumo-bots, Robocup, etc.

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 CONSTRUCTION OF ROBOTS
• Body: all kinds of mechanical system, arm, joint, gripper,
wheel, etc.
• Brain: computers and program code
• Eye: camera, sonar, Infra-red, light, radar…
• Sensing: Force (touch sensing), tilt, gyro, compass,
temperature, chemical (for smell), microphone and
vibration sensor (hearing) etc.
• Muscle: motor, pneumatic system, etc.
 ROBOT TYPES (LOCOMOTION)
1. Stationary robots
1.1 Cartesian/Gantry robots (X/Y/Z table)
• At least 3 axis
• Also called linear robot
• Pick and place job
• Gantry robots can be made very large
• Have much better position accuracy than
other types.
• Application: PCB components pick and place
https://www.youtube.com/watch?v=2qk5vxWY46A
GANTRY
Cheese Cam Shaft
packaging on rails
 1 STATIONARY ROBOTS
1.2 Cylindrical robots
 1. STATIONARY ROBOT
• Spherical robots (arms with a spherical work envelope
(reach)
 STATIONARY ROBOTS
SCARA robots (Selective Compliance Assembly Robot
Arm)
Its arm was rigid in the Z-axis and pliable in the XY-axes
 STATIONARY ROBOTS
• Articulated robots (robotic arms)
• uses rotary joints arranged in a “chain”, one joint supports
another further in the chain
 ROBOT TYPES (LOCOMOTION)
• 2. Wheeled robots
• 2.1 Single wheel (ball) robots
• 2.2 Two-wheel robots
• 2.3 Three and more wheel robots (eg,
unmanned vehicle)
 3. LEGGED ROBOTS
• 3.1 Bipedal robots (humanoid robots)
• 3.2 Tripedal robots
• 3.3 quadrupedal robots
• 3.4 hexapod robots
 VISION FOR ROBOT
• Machine vision allows:
• parts to be located and orientated
• inspection of parts
• Identification of parts
• More flexibility for the robot cell.
 WHAT DO ALL ROBOTS
SHARE?
• Each must have a coordinate system
• Programmed to work
• Each must be calibrated after maintenance
• Each manufacturer supports their own language.
• Basic like
• C like
• Graphical
 SAFETY! SAFETY!!!
• Like any machine, a robot can be a monster
• ISO industry standard (ISO 10218)
• CSA standard (z434)
• Two separate stopping circuit functions
• safety stops initiated by safeguarding devices
• emergency stops
• https://www.youtube.com/watch?v=b_Y9fJbiTKw
• https://www.youtube.com/watch?v=GtNKX4kpC18
 SAFETY
• Safety is an in depth subject.
• This is not a course on safety.
• Mohawk College is not and does not
represent itself as an expert in safety
systems, equipment, or application specific
safety design.
• It is the responsibility of the owner,
employer, or user to take all necessary
steps to guarantee the safety of all
personnel in the workplace.
 SAFETY OVERVIEW 32

It is important to read the Operator’s and Products

Manuals for the robots that you are working with in order to
know the safety specifications for each robot
The following is the list of priorities in a robot cell:
• People
• External Devices
• Robot(s)
• Tooling
• Work piece
 SETTING UP A SAFE WORKCELL 33

• Require all personnel to undergo training before working in

robot cell
• Install lockout devices (optional: device with access code)
• Use logic to prevent operators from bypassing safety measures
(ex. Anti-tie-down logic in PLCs)
• Identify the work area with clear markings and ensure that the
cell is arranged in such a way that the operator faces the work
cell and has a clear view of the interior of the cell at all times
• Place all controllers outside the work cell
• Mount EMERGENCY STOP buttons or switches within reach of
critical points inside and outside of the work cell.
• Lights and audible warning devices (louder than ambient noise)
should be in place to alert the operator to the status of the
workcell
 SETTING UP A SAFE WORKCELL 34

CONTD.
• Safety fences are installed to prevent unauthorised entry
into cell
• Install guarding to prevent operators from reaching into
the cell
• Use interlocks
• Presence or proximity sensing devices may be used
• Ensure that all external devices are properly filtered,
grounded, shielded and supressed to prevent hazardous
motion due to electro-magnetic interference (EMI), radio
frequency interference (RFI) and electro-static discharge
(ESD)
• Create a controller power lockout/tagout protocol
• Eliminate pinch points
 SETTING UP A SAFE WORK CELL 35

CONTD.
• Ensure there is enough space within the cell
for personnel to teach the robot and safely
perform maintenance
• Create robot program to load and unload
material safely
• In the presence of high voltage
electrostatics, be sure to provide appropriate
interlocks, warnings
• If materials are being applied at dangerously
high pressure, provide electrical interlocks for
lockout of material flow and pressure
 SAFETY PRECAUTIONS 36

• DO NOT wear watches, rings, neckties, scarves or loose

clothing that could get caught in moving material
• Before working in the cell, visually inspect the robot and
work envelope to ensure your and others safety (including
tooling)
• Ensure the area is clear of debris and liquids that could
result in a fall or injury
• If at all possible, perform all teaching from outside of the
robot cell
• BEFORE you enter a cell, ensure that the robot is either
powered off or that the robot is in teach mode (preferably
T1) and that the teach pendant is in your possession AT
ALL TIMES, do not test using T2 while inside robot cell
• NO more than one person should be in an energised cell
at one time
 AUTOMATIC OPERATION SAFETY 37

• Ensure that you are familiar with the work cell and that all safety
precautions are active
• Understand the full scope of the tasks that the robot is
programmed to execute before switching to automatic mode
• DO NOT switch to automatic mode until all personnel are
outside of the work envelope
• Be aware of all of the components communicating with the
robot which could cause the robot to move
• Know where all of the EMERGENCY STOP buttons are located
• NEVER assume the program has completed execution if the
robot has stopped moving
• If the robot has been running in a pattern, so not assume that it
will continue to do so
• NEVER try to stop the robot or break its motion with your body.
The only way to safely stop a robot motion immediately is by
pressing an EMERGENCY STOP button
 INSPECTION SAFETY
38

• TURN OFF power to the controller

• LOCKOUT & TAGOUT the power source at the controller
according to the policies of your employer/facility
• Turn off the compressed air source and release the air pressure
• If robot motion is not required for inspection of the electrical
circuits, press an EMERGENCY STOP button either on the
operator panel or the teach pendant
• Ensure you have removed any jewellery or clothing that could
get caught in moving machinery
• If power is required during inspection, be prepared to press the
EMERGENCY STOP button in case of an emergency
• Be aware that when a servomotor or brake is removed from the
robot, it will fall if not properly supported; SUPPORT the arm with
a solid support before releasing a brake
 MAINTENANCE SAFETY 39

• NEVER enter the work cell while the robot and/or program is
in operation
• Visually inspect the work cell BEFORE entering to ensure
there are no potentially hazardous conditions
• DO NO wear any jewellery or loose clothing that could get
caught in moving machinery
• Consider all work envelopes of adjoining robots when
standing in a work cell
• Test the teach pendant BEFORE entering the work cell to
ensure it is operating properly
• If you are entering the cell with the robot on, you must have
the teach pendant with you at all times
• Perform maintenance with the POWER OFF whenever
possible
• Be aware that when you remove a servomotor or brake,
the associated robot arm WILL fall if not properly supported
 MAINTENANCE SAFETY 40

CONTD.
• Release or block all stored energy (before working on a
pneumatic system, shut off the system air supply and
purge the air lines)
• Isolate robot(s) from ALL remote control signals
• Make sure personnel cannot become trapped between
the moving robot and other equipment or barriers
• Use blocks, mechanical stops and pins to prevent
hazardous movement by the robot (ensure they do not
create pinch points)
• When replacing or installing components, ensure no dirt or
debris enter the system
• Only use specified parts for replacement
• BEFORE restarting robot, ensure all personnel have exited
the work cell
 PROGRAMMING SAFETY 41

• Know the robot you are working with

• Understand the type of robot and how it moves at
different speeds
• Plan out your program before you touch the
robot/software/teach pendant
• Understand your task and the limitations of the cell
• Keep a safe distance when teaching the robot
• Be mindful of other personnel when teaching robot
• Communicate what changes are to be made and
have been made when working on a working cell
• Document your work on robot
• Ensure you properly comment your changes in the
robot
PINCH POINTS
42

A pinch point is a place

where a person may
become pinched
between the robot and
itself.
 ACCIDENT RISKS 43

• Teaching or re-teaching points

• Program changes
• Fault tracing
• Maintenance
• Test run*
 REDUCING RISK 44

Safety Enhancing Devices Design

• Safety fences, barriers or •Cell layout
chains
• Light curtains •Limiting the
workspace
• Interlocks
• Pressure mats
• Floor markings Training &
• Warning lights Documentation
• Mechanical stops •Ensure all personnel
• EMERGENCY STOP
buttons
• DEADMAN switches
 LOCKOUT TAGOUT
45

Always Lock Out robot(s) when performing maintenance

 OPERATING MODE
46

• Automatic Mode
Production Mode (full speed varies by robot)

• Manual Mode
< 250 mm/s (max velocity)
 ENABLING DEVICE / DEADMAN 47

SWITCH
The enabling device is
also known as the
DEADMAN SWITCH.
This is a three position
switch witch enables
robot motion. R-30iA and later teach
pendants have three positions

The switch MUST be in

the middle position in
order to allow for robot
motion.

If the switch is released

or pulled in as far as
possible all robot
motion with stop
immediately.
 GRIPPER SAFETY 48

• All grippers should be set up

in such a way that they retain
a part during shut down or
power failure.
• Grippers should have manual
release functionality.
 ELECTRICAL SAFETY 49

High voltages are supplied to both the controller and the

robot
The power source will vary from 480 to 600 VAC. It is
important to know the Power Source voltage before
performing any maintenance on a robot cell.
All other power specifications including the power to the
robot will be dependent on the type and model of robot in
use. Refer to user manuals before attempting to perform any
maintenance on a robot or robot cell.
 PROPRIETARY SAFETY SYSTEM 50

Most Robotics companies now have their own safety system

with an integrated safety board, circuit and software.

For the purpose of this lab, we will discuss Fanuc’s Dual

Check Safety (DCS) which consists of the following safety
features:
• Emergency Stop Control
• Position/Speed Check
• Joint Position Check
• Joint Speed Check
• Cartesian Position Check
• Cartesian Speed Check
• T1 Mode Check
 DCS
• Dual Check Safety (DCS) is a
- OVERVIEW
feature of the R-30iA and higher
controller that consists of the
following safety functions:
− Emergency Stop Control (Standard)
− Position / Speed Check (Option)
• Joint Position Check
• Joint Speed Check
• Cartesian Position Check
• Cartesian Speed Check
• T1 Mode Speed Check

https://www.youtube.com/watch?v=hHVyPfHIwSA
51
 DCS 52

DCS Position/Speed Check features check the speed and

position data of motors with two independent CPUs in the robot
controller. These functions can detect position and speed errors
immediately and shut down the motor power by two
independent channels. Safety data and processes are cross-
checked by two CPUs. Self-diagnosis of safety hardware and
software is executed periodically to prevent potential failure
accumulation.

DCS Position/Speed Check features do not require additional

sensors to monitor speed and position, they use the built in servo
motor sensors.
DCS functions are certified to meet the requirements of
International Standard ISO13849-1 Safety of Machinery by a
notarized body.
DCS can be used to restrict motion capability. Allowing desired
conditions to continue and undesired conditions to result in
different levels of stopping. It can also be used to monitor
situations that may or may not result in loss of motion.
FLOOR SPACE REDUCTION
53

EXAMPLE
 DCS - OVERVIEW 54

LR200iD Full Work Envelope DCS Restricted Work Envelope

 DUAL CHECK SAFETY (DCS)
55

• Safety data and processes are cross-

checked by two CPUs , thus Dual Check
Mutual data and result
Main board checking

Communication
Main CPU
CPU

• It can be used to restrict motion capability

− Desired conditions allow processes to continue
− Undesired conditions can result in different levels
of stopping
• It also can be used to monitor various
situations that may or may not result in
loss of motion
 LAB SAFETY 56

• Do not work on any robot unless an instructor is present

• Work in groups of 2
• Only the person who is teaching the robot (holding the
teach pendant) should be within the work envelop
• Always work in Manual mode unless specified by
professor
• Limit ALL movement in programs to 200 mm/s (any
movements higher than 200 mm/s will result in deductions
due to unsafe behaviour)
• Turn robot off when you are finished
• Only ONE group is permitted to be in front of a robot at
one time
• Be respectful of the equipment and your peers

Failure to follow these guidelines may result in deductions

from your lab mark
 REFERENCE RESOURCES
• http://www.robotics.org/Safety

• Guidelines for robot safety: read this ppt, and robot

manual for quiz 1 questions.
https://www.osha.gov/pls/oshaweb/owadisp.show_docu
ment?p_table=DIRECTIVES&p_id=1703