MIR 500 User Manual

PDF

Dokument

Annonce

User guide (en)

Date: 06/2020

Revision: v.1.4

Copyright and disclaimer

All rights reserved. No parts of this manual may be reproduced in any form without the express written permission of Mobile Industrial Robots A/S (MiR). MiR makes no warranties, express or implied, in respect of this document or its contents. In addition, the contents of the document are subject to change without prior notice. Every precaution has been taken in the preparation of this manual. Nevertheless, MiR assumes no responsibility for errors or omissions or any damages resulting from the use of the information contained.

Contact the manufacturer:

Mobile Industrial Robots A/S

Emil Neckelmanns Vej 15F

DK-5220 Odense SØ www.mobile-industrial-robots.com

Phone: +45 20 377 577

Email: [email protected]

CVR: 35251235

1. About this document

1.1 Where to find more information

1.2 Version history

2. Safety

2.1 Safety message types

2.2 General safety precautions

2.3 Intended use

2.4 Users

2.5 Foreseeable misuse

2.6 Risk assessment

2.7 Residual risks

2.9 Limiting safety-related functions

2.11 Lithium battery

3. Getting started

3.1 In the box

3.2 Unpacking MiR500

3. IT security

3.3 Managing users and passwords

3.4 Software security patches

4. Commissioning

4.1 Powering up

4.2 Connecting to the robot interface

4.3 Driving the robot in Manual mode

4.4 Checking the hardware status

4.5 Charging the robot

4.6 Shutting down the robot

4.7 Creating and configuring a map

5. Planning

5.1 Analysis of the work environment

5.2 MiR500 user roles

5.3 Creating an efficient map

5.4 Creating efficient missions

6. Product presentation

6.1 Main features of MiR500

6.2 Identification label

6.3 MiR500 control panel

6.4 MiR500 operating modes

6.5 MiR500 external parts

6.6 MiR500 internal parts

6.7 Sensor system

6.8 Light indicators

7. Applications

7.1 Mounting a top module

7.2 Lift modifications

8. Maintenance

8.1 Regular weekly checks and maintenance tasks

8.2 Regular checks and replacements

8.3 Packing for transportation

9. Payload specifications

10. Interface specifications

10.1 General purpose interfaces

10.2 Safety interfaces

10.3 Connector list

100

103

1. About this document

This user guide explains how to set up and start operating your MiR500 and provides examples of simple missions you can expand to your purposes. This guide also contains information regarding the external and internal components of MiR500 along with a guide for proper maintenance of the robot. You will also find information regarding safety and specifications needed to commission a safe MiR500 robot application.

This guide explains how to set up and start operating your MiR500. You will also find information regarding safety precautions that must be considered when operating MiR500.

NOTICE

Save this manual. It contains important safety and operating instructions.

1.1 Where to find more information

At www.mobile-industrial-robots.com

, several additional resources are available. To access more information, sign in to the Distributor site with your distributor account at http://www.mobile-industrial-robots.com/en/account/ . The following resources are available:

• Quick starts describe how you start operating MiR robots quickly. This document is in print in the box with the robots. Quick starts are available in multiple languages.

• User guides provide all the information you need to operate and maintain MiR robots.

User guides are available in multiple languages.

• Risk Analysis Guides include guidelines on how to create a risk assessment of your robot solution.

• Commissioning guides describe how to commission your robot safely and prepare it to operate in the workplace.

• Operating guides describe how to set up and use top modules and accessories, such as charging stations, hooks, shelf lifts, and pallet lifts.

• Getting started guides describe how to set up products that are mainly software-based, such as MiR Fleet.

• Reference guides contain descriptions of all the elements of the robot interface and MiR

Fleet interface. Reference guides are available in multiple languages.

• REST API references for MiR robots, MiR hooks, and MiR Fleet.

1. About this document

• The MiR network and WiFi guide specifies the performance requirements of your network and how you must configure it for MiR robots and MiR Fleet to operate successfully.

1.2 Version history

This table shows current and previous versions of this document and their interrelations with hardware releases.

Revision

1.0

1.1

1.2

1.3

1.4

Release date

2018-10-

2019-01-

First edition.

Description

2019-07-

New section: Maintenance.

Updated styles.

New sections: Create mission, Mission editor, Lift modifications

Updated status lights

Added notice regarding using smart phones in flight mode for manual driving

New section: Updating MiR500 software 2019-10-

2020-06-

New section: IT security.

Added new information about payload.

1.0

1.1

2. Safety

Read the information in this section before powering up and operating MiR500.

Pay particular attention to the safety instructions and warnings.

NOTICE

Mobile Industrial Robots disclaims any and all liability if MiR500 or its accessories are damaged, changed, or modified in any way. Mobile Industrial

Robots cannot be held responsible for any damages caused to MiR500, accessories, or any other equipment due to programming errors or malfunctioning of MiR500.

2.1 Safety message types

This document uses the following safety message types.

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury. Carefully read the message that follows to prevent serious injury or death.

CAUTION

Indicates a potentially hazardous situation that could result in minor or moderate injury. Alerts against unsafe practices. Carefully read the message that follows to prevent minor or moderate injury.

NOTICE

Indicates important information, including situations that can result in damage to equipment or property.

2. Safety

2.2 General safety precautions

This section contains general safety precautions.

WARNING

Using a charger different from the one supplied by the manufacturer can cause a fire.

• Use only the original charger.

WARNING

Lithium battery packs may get hot, explode or ignite and cause serious injury if they are abused electrically or mechanically.

Observe the following precautions when handling and using lithium batteries:

• Do not short-circuit, recharge or connect with false polarity.

• Do not expose to temperature beyond the specified temperature range or incinerate the battery.

• Do not crush, puncture or disassemble the battery. The battery contains safety and protection devices, which, if damaged, may cause the battery to generate heat, explode or ignite.

• Do not allow the battery to get wet.

• In the event the battery leaks and the fluid gets into one’s eye, do not rub the eye. Rinse well with water and immediately seek medical care. If left untreated, the battery fluid could cause damage to the eye.

• Use only the original charger (cable charger or charging station) and always follow the instructions from the battery manufacturer.

WARNING

Attempting to charge batteries outside the robot can lead to electrical shock or burns.

• Never charge the batteries outside the robot.

2. Safety

CAUTION

The robot cannot see staircases going downwards and holes in the floor.

• Mark staircases or holes on maps with Forbidden zones .

• Keep the maps up to date.

CAUTION

Use Flight Mode with smartphone control of the robot. Risk of personal injury and/or damage to the robot.

• If you use Manual control with a smartphone to drive the robot, make sure that the phone is set to Flight Mode. An incoming call on the smartphone will interrupt control of the robot.

2.3 Intended use

MiR500 is intended to be commissioned and used in indoor industrial environments where access for the public is restricted. For details about the environmental conditions in which the MiR500 robot should operate, see Technical specifications on our website.

MiR500 is intended to be commissioned according to

Commissioning on page 25

and prepared to the environment according to the guidelines. This is a prerequisite for safe usage of MiR500.

MiR500 is designed and all risks are considered when used with one of the following types of top applications:

• MiR500 Pallet Lift used with MiR Lift Pallet Rack.

• MiR500 EU Pallet Lift used with MiR EU Pallet Rack.

• A custom designed top application (including total payload) designed to fulfill the following requirements:

• Must not increase the footprint of MiR500 and be within the requirements in

Payload specifications on page 90

• Must not have any moving parts

2. Safety

MiR500 can be used as a partly complete machine as defined in the EU machinery directive, with top applications that do not meet above limitations. Those who design, manufacture or commission a system that does not meet the limitations of use of MiR500, carry the obligations of a manufacturer and shall ensure a safe design according to EN ISO 12100.

Guidelines outlined in this manual are not sufficient. Examples of top applications, which are not intended use of MiR500, but not limited to, are:

• Shelf on supporting legs (with or without wheels)

• Top applications (including total payload) which increase the footprint of MiR500

• Conveyers (power and non-powered)

• Industrial robot arm

• Towing of trailers

• Customized load transfer station

2.4 Users

MiR500 is only intended to be used by personnel that have received training in their required tasks.

There are three types of intended users for MiR500: commissioners, operators, and direct users.

Commissioners

Commissioners have received extensive training in the full use of MiR500 and have the following main tasks:

• Commissioning the product. This includes creating maps and restricting the user interface for other users.

• Making the risk assessment.

• Determining the payload limit, weight distribution, and safe fastening methods of loads on MiR500.

• Ensuring the safety of nearby personnel when the robot is accelerating, braking, and maneuvering.

Operators

Operators have thorough knowledge of MiR500 and of the safety precautions presented in the user guide of MiR Fleet PCMiR500 and operating guide of MiR500. Operators have the following main tasks:

2. Safety

• Servicing and maintaining MiR500.

• Creating and changing missions and map positions in the robot interface.

Direct users

Direct users are familiar with the safety precautions in the user guide and have the following main tasks:

• Assigning missions to MiR500.

• Fastening loads to MiR500 properly.

All other persons in vicinity of MiR500 are considered indirect users and must know how to act when close to the robot. For example, they must be aware that visibly marked operating hazard zones must be respected.

2.5 Foreseeable misuse

Any use of MiR500 deviating from the intended use is deemed as misuse. This includes, but is not limited to:

• Using MiR500 to transport people

• Using MiR500 on steep surface grades, such as ramps

• Exceeding the total payload of 500 kg

• Positioning or fastening load incorrectly according to the specifications

See the

Payload specifications on page 90

• Failing to make a risk assessment of the full installation

Refer to

Risk assessment below .

• Failing to follow the guidelines for commissioning

Refer to

Commissioning on page 25

• Use in medical and life critical applications

• Operating outside the permissible operating parameters and environmental specifications

• Use in potentially explosive environments

• Use outdoors

• Use in hygiene zones

2.6 Risk assessment

You must make a risk assessment to achieve a safe installation. The risk assessment is the responsibility of the commissioner who must ensure that MiR500 is commissioned safely in the environment it will be used in.

2. Safety

The risk assessment must cover not only MiR500 itself, but also take into account potential load transfer stations, work cells, and the work environment. MiR does not take any responsibility for the creation of the risk assessment, but we provide information and guidelines that may be used in the MiR 500 and MiR1000 Risk Analysis Guide found on the

Distributor Site under Manuals .

It is recommended that the commissioner follows the guidelines in ISO 12100, EN 1525, ANSI

B56.5, or other relevant standards to conduct the risk assessment.

In EN 1525, clause 4, there is a list of significant hazards, hazardous situations, and events that can be used for inspiration.

2.7 Residual risks

Mobile Industrial Robots has identified the following potential hazards that commissioners must inform personnel about and take all precautions to avoid:

• Risk of being run over, drawn in, trapped, or impacted when a person stands in the path of MiR500 or walks towards MiR500 while it is driving in reverse. MiR500 will only drive in reverse when parking or picking up a cart or undocking from a marker such as MiR

Charge 48V.

• Risk of being run over, drawn in, trapped, or impacted when a person stands in the path of MiR500 or walks towards MiR500 while it is in motion.

• Risk of being crushed or trapped when user touches MiR500.

• Risk of being crushed, drawn in, or trapped at pallet racks or other load transfer stations, work cells, or charging stations.

NOTICE

Other significant hazards may be present in a specific robot installation and must be identified during commissioning.

2.8 Safety-related functions and interfaces

MiR500 is equipped with a range of built-in safety-related functions as well as safety-related electrical interfaces designed for integration with a top module and/or top manipulator.

Each safety function and interface is designed according to the standard ISO 13849-1.

The safety-related functions and interfaces are selected to support compliance with EN

1525.

2. Safety

2.9 Limiting safety-related functions

MiR500 has several built-in safety-related functions that are used to ensure safe operation in the environment it is designed to be used in.

Advanced control software ensures that locomotion and the drive pattern are within safety related limits and thereby avoid triggering a safety function. Violations of limits will hence only occur in exceptional cases. Nevertheless, if a limit is violated, the safety system issues a category 0 stop (stopping by “immediate removal of power to the machine actuators according to IEC 60204-1”) followed by a controlled brake which brings MiR500 to a stop.

See Technical specifications on our website for more details.

Collision avoidance

The collision avoidance safety function ensures that the robot will come to a stop before it collides with a human or object.

The function measures the speed on the two driving wheels and switches between the predefined protective fields accordingly. The faster the speed, the larger the protective fields will be.

This ensures that the robot will be brought to a stop in case a human or object is detected within the active protective field.

Collision avoidance is automatically deactivated two seconds after the protective field is free.

Safe load position

The safe load position safety function ensures that the robot will not drive, while

MiR500 Pallet Lift or MiR500 EU Pallet Lift is not in the lowest position and hence there is a risk of compromising stability.

The safe load position safety system consists of interlock switches that detect if the lift modules are in the lowest position or not.

The input can be used for a customized top module/manipulator when a MiR500 Pallet Lift or MiR500 EU Pallet Lift is not installed.

The safe load position safety function must be manually deactivated by activation of the restart button.

2. Safety

Overspeed avoidance

The safety system monitors if the speed of each motor is above limits for maximum rated speed and hence an indication of speed control is lost for any reason.

The overspeed avoidance safety function must be manually deactivated by activation of the restart button.

Stability

The safety system monitors if the speed difference between the two motors are above predefined limits and hence an indication of speed control is lost for any reason.

The stability safety function must be manually deactivated by activation of the restart button.

Emergency stop

MiR500 has four emergency stop buttons and an option to connect additional emergency stop buttons through the electrical interface.

The emergency stop is only intended to be used in case of an emergency and shall not be used for operational stop.

Emergency stop must be manually deactivated by activation of the restart button.

2.10 Safety-related electrical interfaces

The robot is equipped with several safety-related electrical inputs and outputs. All safetyrelated electrical inputs and outputs are dual channel. They are safe when low, e.g. the emergency stop is not active when the signal is high (+24V).

Safety-related electrical inputs

This section contains the safety-related electrical inputs of the robot.

External emergency stop button input

This input is for connection of an optional emergency stop button. If activated, the safety system issues a category 0 stop followed by a controlled brake which brings MiR500 to a stop.

Must be manually deactivated by activation of the restart button.

2. Safety

System emergency stop input

This input should be used in case a top manipulator has its own emergency stop circuit. The input must be used in combination with a system emergency stop output. With this, it is possible to ensure that activation of any emergency stop button will cause an emergency stop of both MiR500 and top manipulator. If activated, the safety system issues a category 0 stop followed by a controlled brake which brings the robot to a stop.

Must be manually deactivated by activation of the restart button.

Safeguard stop input

This input can be used to issue a category 0 stop followed by a controlled brake which brings

MiR500 to a stop.

Will be automatically deactivated when signal is driven high again.

Load handling position (position control of load)

This input can be used to apply the safe load position (position control of load) safety function on a system with customized top modules or manipulators. A variety of sensors or interlock switches that detect load handling position or position of load can be connected and thereby enable the safe load position safety function.

Safety-related electrical outputs

This section contains the safety-related electrical outputs of the robot.

Locomotion

This safety related output is activated if the robot is in locomotion or intend to locomote within two seconds.

The safety function is limited if locomotion is detected while the output is deactivated.

Shared emergency stop output

This output should be used in case a top manipulator has its own emergency stop circuit. The output should be used in combination with a system emergency stop input. With this, it is possible to ensure that activation of any emergency stop button will cause an emergency stop of both the robot and top manipulator.

Activated by an emergency stop button or emergency stop input.

2. Safety

2.11 Lithium battery

This section contains safety precautions related to lithium batteries in MiR robots.

NOTICE

MiR does not support any additional batteries applied to the MiR500 by the customer.

WARNING

Lithium battery packs may get hot, explode or ignite and cause serious injury if they are abused electrically or mechanically.

Observe the following precautions when handling and using lithium batteries:

• Do not short-circuit, recharge or connect with false polarity.

• Do not expose to temperature beyond the specified temperature range or incinerate the battery.

• Do not crush, puncture or disassemble the battery. The battery contains safety and protection devices, which, if damaged, may cause the battery to generate heat, explode or ignite.

• Do not allow the battery to get wet.

• Use only the original charger (cable charger or charging station) and always follow the instructions from the battery manufacturer.

3. Getting started

This section describes how to get started with MiR500.

NOTICE

Read

Safety on page 8

before powering up the robot.

3.1 In the box

This section describes the content of the MiR500 box.

3. Getting started

The box contains:

The MiR500 robot

MiR500 document folder containing the printed documents and the USB flash drive.

Printed documents:

• MiR500 Quick Start

• MiR username and passwords

• CE declaration of conformity

3. Getting started

USB flash drive with the following content:

• MiR500 User Guide

• MiR Robot Interface 2.0 Reference guide

• MiR robot REST API reference

• MiR Charge 48V Operating Guide

• MiR500 Pallet Lift Operating Guide

• MiR500 EU Pallet Lift Operating Guide

• MiR username and passwords

• CE declaration of conformity

3.2 Unpacking MiR500

This section describes how to unpack MiR500.

Keep the original packaging for the future transportation of the robot.

The robot is shown with a EU pallet lift.

Place the box with the robot so that there is 3 m of free space at the front or the back of the box. This is necessary since the robot drives out of the box on the ramp.

Remove the screws that attach the walls of the box to the box lid and the base of the box.

3. Getting started

Remove the lid from the box.

Take the folder with the printed documents and the USB drive out of the box.

Remove the walls of the box and the protective foam blocks.

3. Getting started

Cut the protective straps.

Place the lid of the box so that you can use it as a ramp. Align the lid so that it is flush with the base of the box.

3. Getting started

Remove the wheel stop board from the pallet to let the robot drive on the ramp.

3. IT security

IT security are precautions you can take to prevent unauthorized personnel from accessing

MiR500. This section describes the main IT-security related risks and how to minimize them when commissioning MiR500.

MiR500 communicates all data over the network that it is connected to. It is the responsibility of the commissioner to ensure that it is connected to a secure network. MiR recommends creating an IT-security risk assessment before commissioning the robot.

3.3 Managing users and passwords

Managing your users and passwords is the main way you can control access to MiR500.

There are three default users with predefined passwords for you to start using. These are described in the MiR Robot Interface Reference guide along with instructions to create new users, user groups, and passwords. MiR advises you to:

• Change the default password for all predefined users if you choose to continue to use them. Make sure to choose a strong password since MiR500 does not enforce any password rules nor expire the password.

• Create new user groups if more levels of access are necessary.

• Create dedicated user accounts under the relevant user group for each person accessing

MiR500, and ensure that the users change the password on their first sign-in. It is not recommended to have several users share the same account.

• Only enable users with a minimum level of access to use a pin code to sign in. Users with a higher level of access are recommended to use a strong password to sign in instead.

3.4 Software security patches

To improve the security of MiR500, MiR supplies security patches to the operating system in new MiR software update files. When you install a security patch, it takes approximately 10-

15 minutes longer to update a robot or MiR Fleet.

Security patches are included from software version 2.8.3 and higher.

3. IT security

Understanding MiR software versions

MiR uses the Major.Minor.Patch.Hot fix format to version our software. For example,

2.8.1.1 means that the software is based on the second major release, the eighth minor release of the major version, the first patch release of the minor version, and in this example a single hot fix is included too.

• Major releases include the most significant changes that affect the entire robot software.

• Minor releases often include new features and smaller changes that only affect parts of the software.

• Patch releases focus on fixing small issues in the software and introducing quality improvements.

• Hot fix releases are only created when a patch release has introduced a critical issue that needs to be fixed immediately.

Security patch policy

MiR applies the following policy when supplying security patches:

• New security patches are distributed per every minor release.

• All patch releases under a minor release include the security patches also. In other words, if you chose not to install the first software version in a minor release, such as version

2.9.0, the security patches will still be installed when you update to 2.9.1 or higher.

• Whenever there is a new minor release with new security patches, the security patches are also made available in a separate file. In this way, you are not required to update to the latest software to apply the security patches. You can use any lower software version and just install the security patches to that software instead.

4. Commissioning

This section describes how to get started with MiR500.

4.1 Powering up

Follow these steps to power up MiR500.

Open the rear maintenance hatch. To open the hatch, push two buttons on the hatch and pull the hatch.

Turn the battery disconnect switch to position ON .

The On/Off button turns blue.

See

MiR500 control panel on page 56

Close the maintenance hatch.

4. Commissioning

Ensure that all four emergency stop buttons are in the released state. Turn an emergency stop button clockwise to release it.

Press the On/Off button for five seconds.

The robot turns on the red indicator lights and starts the software initialization process.

When the initialization process ends, the robot goes into the emergency stop mode.

4. Commissioning

Press the Restart button to clear the emergency stop. The robot is ready for operation, the status lights turn constant red.

4.2 Connecting to the robot interface

When the robot is on, it enables the connection to its WiFi access point. The name of the access point appears in the list of available connections on your PC, tablet or phone.

NOTICE

The username and password for the robot’s WiFi access point and for accessing the web interface are in the MiR username and passwords document. The document is in the box with the robot.

Follow these steps to connect to the robot interface:

Using your pc, tablet or phone, connect the WiFi access point of the robot. The access point name has the following format: MiR_UXXXX.

In a browser, go to the address mir.com and sign in.

4. Commissioning

Switch to manual mode, and drive the robot down the ramp, see section

Driving the robot in Manual mode below

4.3 Driving the robot in Manual mode

To drive the robot in Manual mode:

Put the Operating mode key into the Manual mode (turn to the right).

In the robot interface, select the joystick icon. The joystick control appears.

Select Manual control . The Restart button on the robot starts blinking.

4. Commissioning

Press the Restart button. The status lights turn blue indicating that the robot is in Manual mode.

The robot is shown with an EU pallet lift.

Drive the robot using the joystick.

4. Commissioning

4.4 Checking the hardware status

To check that all hardware components work as intended follow the steps below:

Connecting to the robot interface on page 27

Go to Monitoring > Hardware health .

4. Commissioning

Check that all elements on the page have the OK status and that they have green dots on the left.

For more information, see Hardware health in MiR Robot Interface Reference Guide.

4.5 Charging the robot

A charger cable and an external charger is not part of the MiR500 standard delivery.

To charge MiR500 using the cable charger:

Open the maintenance hatch at the back of the robot. To open the hatch, push two buttons on the hatch and pull the hatch.

4. Commissioning

Connect the charger cable to the charging connector on the robot.

For information about the charging time, see the robot specifications at www.mobileindustrial-robots.com

4.6 Shutting down the robot

To shut down MiR500:

Ensure that the robot is not moving or executing an action.

Press the On/Off button for five seconds.

4. Commissioning

The robot starts the shutdown process. Status lights blink yellow, the On/Off button blinks red.

When the robot finishes the shutdown process, the status and the signal lights go off, the

On/Off button turns blue.

If shutting the robot down for transportation or service/repair, the Battery disconnect switch must be turned off as well and the battery cable disconnected.

4.7 Creating and configuring a map

The robot requires a map to operate.

For information about creating a map, refer to MiR Robot Interface Reference Guide.

Section

Creating an efficient map on page 39

describes how to make the map efficient and how to mitigate potential risks.

5. Planning

This chapter describes what needs to be considered before and during the installation of

MiR500 in the company.

It is worth spending some time defining what tasks MiR500 must do in the work environment.

The correct setup and thorough training of the users will result in a successful and safe installation of MiR500.

For more details on the topics below, refer to the MiR Robot Interface Reference Guide.

NOTICE

Read section

Safety on page 8

before going through this chapter.

5.1 Analysis of the work environment

A thorough analysis of the environment where MiR500 is going to be implemented in is necessary for a successful and safe installation.

Read the Technical specifications at www.mobile-industrial-robots.com

for more details on how much space MiR500 requires to operate safely and successfully.

What does the robot see?

Before preparing the environment for MiR500, it is worth understanding how the robot works, what it can see and what it uses for navigation.

MiR500 is an autonomous and collaborative robot. The robot relies on localization techniques to orient itself in its environment. The robot uses path planning that consists of two parts: a global planner that does the general path planning between two positions and a local planner that causes the robot to follow the global path and also take into account the surroundings, so that the robot avoids dynamic obstacles based on sensor input.

MiR500 has two laser scanners that serve three main purposes:

5. Planning

• Emergency stop: the laser scanners trigger the emergency stop as part of the SICK Safety system when an obstacle is within the emergency zone of the laser scanners.

• Mapping: the laser scanners record the environment to gather data that enable the creation of a map.

• Localization: the laser scanners use data to localize the robot in the map that has been generated and loaded into the robot.

The following illustrations show how the robot sees the surrounding environment.

The laser scanners detect a dynamic object in the bottom left corner.

Human eyes see the chair and surrounding details.

5. Planning

Laser scanners of the robot will only detect parts of the chair. Here, the scanners detect the four legs of the chair in the upper left corner of the map.

The 3D camera will detect more details of the chair when it is close enough to it.

5.2 MiR500 user roles

Introducing MiR500 into the company will require some changes to the environment and the people working with the robot to achieve the optimal benefits. Spending some time defining and preparing the users will make the robot a much more effective collaborative robot and will form a positive and safe experience.

It is important to explain to the users what the robot can do, but also what it can not do. For example, the robot can transport heavy pallets, but it can not transport people. Based on the preparation of the environment, it is also worth explaining what is going to be difficult for the installation, both in the environment and for some of the users’ work flow.

Types of users

It is important to analyze and consider who is:

5. Planning

• Working directly with MiR500.

• Working indirectly with MiR500.

• Responsible for MiR500.

Direct user

The direct user of MiR500 could be someone who commands the robot to carry out missions and works closely with the robot. Apart from training on how to use the robot (see

Training of the users on the next page

), the direct user will need to make adjustments to his/her work flow to include the robot in their work. The direct user also needs to know who is responsible for MiR500, so they can get help if the robot is not running missions as it should.

Indirect user

The indirect user of MiR500 could be someone working in the same environment as the robot, but not working directly with the robot. This user might need to change their work flow slightly for the company to make the most out of the robot. For example, if the user walks a certain path several times a day and this path crosses the robots path several times a day – it might be worth creating two paths. This way, the robot does not stop several times a day to let the indirect user pass, wasting valuable work time. It is important to note that

MiR500 is a collaborative robot and will always stop, if someone walks out in front of it.

Responsible

The person responsible for MiR500 is someone who will know what to do if an issue with the robot occurs. The person responsible should know the most common errors and how to troubleshoot them. The responsible should also be instructed in maintenance and inspection of the robot. This user will need a more thorough basic training and should also know who to reach out to in case he/she can not solve the issue at hand.

Superuser

The superuser of MiR500 is usually someone from the development department, who understands how the robot is set up and works with it on a daily basis. The superuser also undergoes continuous training by Mobile Industrial Robots A/S. A superuser is therefore mainly relevant for bigger companies.

Interface and dashboards

Based on the considerations in

Types of users on the previous page

, there will most likely be different users with different tasks using MiR500.

5. Planning

All users of the robot must have a user profile in the system. Users are administered in the

Users section where you set up, edit and delete system users.

To make it as simple as possible for each user, it is worth investing some time in building up a unique dashboard for each user. Dashboards are an easy way for different user groups to control the robot giving direct access to their individual key functions.

Consider the following based on previous considerations on users of the robot:

• How many different users are there?

• What tasks do each user have with MiR500?

• What rights (edit and control) should the different users have?

• What functions or widgets should be available for the different users?

For more details on interface and dashboards, see MiR Robot Interface Reference Guide.

Training of the users

It is very important to spend time on training the different users of MiR500. It is unlikely that all users will need to know all the features of the robot. Teaching should be done at different levels, to make it as simple as possible for the different users. This way, each user will quickly learn how to use the robot in the way they need to.

It is also important to establish a chain of communication for MiR500 in the company. This means that all users (direct, indirect and responsible) always know who to ask, if they have any problems or questions.

See

Handover testing on page 51

for more information on training.

5. Planning

Figure 5.1. Chain of communication.

5.3 Creating an efficient map

After the preliminary analyses of the work environment and the work flows of the people working there, spending time on creating a good map is important for MiR500 to work safely and efficiently.

Creating a robust, reliable map for dynamic environments will pay off, as the map is the basis of the robot’s ability to navigate its surroundings. A good map is also the basis for a safe and efficient robot.

If you have not created a map before, see MiR Robot Interface Reference

Guide and How-to guides on our Distributor website.

5. Planning

Use zones on the map

Adding zones to the map can organize efficient robot traffic. There are several different zones that can optimize the preferred paths and driving behavior of the robot. For example, a Forbidden zone is a zone where the robot will never enter. A Sound and light zone are zones where the robot either blinks or makes a sound to catch attention. In a Preferred zone the robot tries to run within a preferred area taking into account dynamic obstacles. In an

Unpreferred zone, the robot tries to avoid the unpreferred zone but may go into it if there are no other possibilities. A Directional zone lets you organize the motion of robots by specifying the directions in which the robots can move in specific zones.

Adding zones to the map can also solve most of the issues with possible hazards in the work environment.

Downwards going staircases

MiR500 can not see downwards going staircases and holes in the floor.

Issue: The 3D camera can not detect downwards going staircases. Marking a staircase as a wall on the map will only confuse the robot as it will try to navigate from a wall that is not there.

Solution: Mark staircases and areas surrounding staircases or holes in the floor as Forbidden zones on the map.

Permanent low hanging fixtures

A permanent low hanging fixture could be a machine with a PC attached, for example a screen attached to an arm that can be moved in several directions. It could also be a boom barrier or boom gate, as seen near entries in supermarkets.

Issue: MiR500 will not see these dynamic low hanging fixtures. This could be dangerous with a top module attached to the robot.

Solution: Mark the area where the low hanging fixture is located as a Forbidden zone.

Large highly dynamic areas

A large highly dynamic area is an area where objects are moved frequently. This could be a production area where pallets and boxes are often moved back and forth.

5. Planning

Issue: MiR500 will always plan the shortest path from A to B. If this is through a large highly dynamic area, the robot will re-plan its path several times. The re-planning happens because the robot will encounter new dynamic obstacles in the environment often. This can lead to valuable time wasted on readjusting the path several times a day.

Solution: Mark large highly dynamic areas on the map with for example Unpreferred zones or create a path guide. In extreme cases, use Forbidden zones.

Transient work flow areas

A transient work flow area is an area where humans often move around. This could be part of a production area where people are assembling a product. It could also be an area where forklifts or other machines are operated.

Issue: MiR500 will stop if a person steps out in front of it. In a transient work flow area, the robot will stop and reassess its paths many times a day, thereby wasting valuable time.

Solution: Mark transient work flow areas on the map with for example Unpreferred zones or

Forbidden zones, depending on the environment. Directional zones can also be used here to guide the robot in a specific direction.

Unpreferred zones (marked with purple) can be used in large highly dynamic areas and transient work flow areas to solve issues with re-planning of paths.

Doorways and ramps

Going through narrow doorways can cause problems for the robot because of the small space. Going up a ramp can cause similar problems, because of the upwards angle. Narrow doorways can also cause dangerous situations for the people working near the robot, as they

5. Planning might be on the other side of the door and can not see the robot coming.

Issue: The robot stops, because a narrow doorway is seen as an obstacle. Due to sensor input, the robot will not plan a path through a narrow corridor if it has an alternative path.

The robot will always stop if a person steps out in front of it.

Solution: Add a Critical zone to the narrow doorway to force the global planner to make a path through the corridor. Add Sound and light zones in narrow doorways to attract attention. This will warn people near the doorway that the robot is coming through.

Narrow doorways can be marked with a Sound and light zone (marked with yellow) to warn people that it is coming through.

Shelves

Shelves are often placed in a certain height above the floor on four (or more) posts and will often appear as dots on a map for the robot. This may cause the robot to believe that there is enough space (if the posts are far enough apart) below the shelf to pass through. MiR500 will then plan a path underneath the shelves, but when it comes closer, the camera will see the obstacle. This could result in re-planning paths several times a day, thereby wasting valuable work time for the robot.

Issue: The robot will only see shelves as dots on the map and believe that it can make a global plan underneath the shelves.

Solution: Add a Forbidden zone (marked red in the image) around the shelves.

5. Planning

The shelves are marked as a Forbidden zone in the map.

Pallet rack

When MiR500 docks to a pallet rack, personnel detection means are temporarily muted.

This could cause a dangerous situation, if a person steps in front of the robot and the pallet rack.

Issue: MiR500 mutes the personnel detection means temporarily when docking to a pallet rack. This could cause a dangerous situation.

Solution: Follow the mounting guidelines and mark the area around the pallet rack with tape or similar. Inform users of or near the robot of the safety issues regarding the pallet rack so they can take their precautions when working near the pallet rack.

5. Planning

5.4 Creating efficient missions

After creating a good map, it is worth spending time on creating and testing simple missions for MiR500 to work safely and efficiently.

Before building the missions, consider how the tasks could be solved in the simplest and safest way.

For more information on creating missions, see MiR Robot Interface

Reference Guide and How-to guides on our Distributor website.

Make simple missions

Making simple missions will provide a good basis of solving safe and simple tasks. Simple missions include moving from point A to point B, go to waiting position, go to charge, pick up pallet etc.

Missions within missions

By using simple missions, you can set up missions inside missions. This way, simple missions can be re-used in different, bigger and more complex missions.

5. Planning

5.5 Create mission

A mission is made up of actions such as: Move actions, logic actions, cart pick-up/delivery and sounds which can be put together as building blocks to form as many different missions as needed. Most actions have parameters to fill in, for example which position to go to.

Instead of setting a fixed position, it is possible also to put in a variable position which means that the operator is asked which position the robot should go to every time the mission is added to the queue. This may be practical, for example if the robot should perform the same series of actions in different areas of the facility, e.g. picking up something from one place and delivering it to another.

Actions are grouped, and you can select which group the new mission should belong to or use the default Missions group.

The form contains the following elements:

• Name

The name must be unique and is used to identify the mission.

One way of naming missions is to select names that characterize the task that the robot should perform, e.g. “Go to charging station” or “Deliver spare parts”. Another way to name a mission would be to include “from” and “to” positions in the name, e.g.

“Warehouse to production line 1”.

• Mission group

Select which group you want the mission be placed in.

• Description

Enter a short description of the mission (optional).

• Site

If more than one site exists, select which site you want the mission belong to from the list.

5. Planning

Click Create mission to save the settings.

Mission groups

Each group has a number of pre-defined actions that can be selected when you build the mission; one mission can contain actions from several groups. When you save the new mission, it will be placed in the selected group and can be used as an embedded mission of other missions.

5. Planning

Create mission group

If you don't want to use any of the default group names, you can create your own group(s) and save missions here. New groups will be shown in the top bar next to the default groups and contain any mission(s) you want to add to it

A Charging action is used to make the robot go to a charging station for automatic battery recharge. The action is defined by setting a minimum charging time and a minimum charging percentage. When the first of those are reached, the action is completed. For example, if you set the minimum time to 30 minutes and the minimum percentage to 80%, the robot will charge for minimum 30 minutes or until it reaches a battery level of 80%. You may also choose to ignore either time or percentage.

A Charging action must be preceded by a Docking action where the robot moves to a previously defined charging position near the charging station.

5. Planning

5.6 Mission editor

A mission is built from actions that you pick from the menus in the top bar. You can also pick already created missions and embed them in new missions. The idea is that such missions, typically limited to a specific purpose, for example to go to a charging station, can be shared among several larger missions that require the same behavior as part of the mission.

Actions and missions are grouped together in the top bar menus: All predefined actions are identified by a running-man icon. User created missions are placed together with actions in the group to which you append them and can be distinguished from actions by a target icon next to their names.

When you have picked the actions you want to build the mission from, you have a number of options:

Drag the actions up or down with the four-headed arrow at the far left of the action line to sort them in the desired order. The actions are executed in a top-to-bottom order.

Set the parameters for the selected action by selecting the gear icon at the far right of the action line.

Change mission settings

The name of the mission and the group it belongs to may be changed.

5. Planning

In the Mission editor window, move the mouse over the name of the mission and select the gearwheel that appears.

Save mission

When you have completed the missions; i.e. added all actions and sorted them in the wanted order, click Save to save the mission.

Save mission as

You can save a copy of a mission and give it a new name. That way it is easy to create a new mission based on the settings of an existing one.

In the Mission editor window, select Save as .

5.7 Error handling

An error occurs when the robot cannot solve a situation on its own.

5. Planning

Errors include:

• Hardware faults

• Failed localization

• Failure to reach destination

• Unexpected events in the system

An error causes a full system stop. The robot is paused until a person acknowledges the error and clears it.

5. Planning

Proper setup of maps and missions effectively prevent most errors.

• Use Try/Catch actions.

• Define forbidden areas.

• Remove noise from maps.

To clear an error, select the red warning indicator in the interface and select reset.

For more details on setting up missions and error handling, see MiR Robot Interface

Reference Guide.

5.8 Handover testing

It is very important to schedule time for handover testing. The new users of MiR500 might have new questions after they start using the robot or new issues or situations might have appeared.

Handover testing is important because it improves safety, increases users’ happiness with the robot and increases return of investment.

• A good handover ensures that the users:

• Get comfortable with the product.

• Know the robot’s limitations and possibilities.

• Can solve common issues.

• Recognize common errors.

• Know who to contact if they experience issues.

Inform users

Informing users about MiR500 and its functions at a level that matches their user type

(direct, indirect etc.) will help ensure a safe and successful installation of the robot.

Useful information at different levels could be:

• Safety zones, planning of paths and deviations from planned paths, dynamic obstacles.

• Illustrate that MiR500 will stop before driving into obstacles.

• Daily/weekly/monthly cleaning, maintenance and inspection of robots.

• Changing missions, location of positions, zone areas.

• Color indications of the robot. Waiting for mission, pause, emergency stop, planning, carrying out mission, charging.

5. Planning

Simulate common tasks and issues

Try to simulate some common day-to-day tasks with MiR500 while the direct users, superuser and responsible persons use the robot as they would in their daily work.

Common tasks and issues could be:

• Triggering emergency stop and resetting the robot.

• Continue/Pause robot in interface.

• Turning on/off robot.

• Charging the robot, using cable and charging station.

• Manually locate robot on map, adjust localization.

• Manually make robot drive to position and coordinates on map by clicking on the map.

• Run missions, clear missions from queue, see status of missions.

• Maintenance of robot.

• Manual driving.

• Get familiar with dashboard and interface.

• Blocked paths.

• Robot getting stuck in emergency stop when getting pushed into objects or objects being placed close to robot.

• How to recognize that the robot has a problem with charging.

• Narrow paths where the robot might find it difficult to pass. This illustrates the importance of having wide and clear paths for optimal driving of robot.

Future possibilities

After the initial installation of MiR500, it is a good idea to inform users of other possibilities they might find useful after having used the robot for some time. This could include:

• Sound and light zones.

• Preferred zones.

• Directional zones.

• Incorporation with other plant management systems, such as ERP.

• MiR Fleet.

• Rest calls.

Stay in contact

It is important to stay in contact with the users after the installation of MiR500. Make sure to follow up with the following in mind:

5. Planning

• If the customer does not call for support, it might be because the robot is running perfectly, but it might also be because they have problems and gave up on the robot.

• Urge them to contact you with problems, especially in the beginning.

• Contact customers yourself in the beginning to make sure they are happy and the product is working satisfactorily.

A good handover also includes making a risk assessment. Read more in

Risk assessment on page 12

6. Product presentation

MiR500 is an autonomous mobile robot that can transport loads and pallets up to 500 kg indoors within production facilities, warehouses, and other industrial locations.

Users operate MiR500 via a web-based user interface, which is accessed via a browser on a

PC, smartphone or tablet. Each robot has its own network. See

Connecting to the robot interface on page 27 . The robot can be set up to run a fixed route, be called on demand or

perform more complex operations (missions).

The robot performs localization and navigation via a map which can be created or imported the first time the robot is used. The internal map contains defined locations (office, product delivery, production hall etc.) that are used for logistical planning. While operating, the safety laser scanners ensure that the robot avoids dynamic obstacles (people, furniture) that are not mapped.

With a MiR Charge 48V, the robot handles moving to a charging station automatically. All it takes is the definition of a charging mission and a charging position on the map.

6.1 Main features of MiR500

The main features of the MiR500 are:

• Driving in a populated workspace

The robot is designed to operate among people and maneuvers safely and efficiently in even highly dynamic environments.

• Overall route planning and local adjustments

The robot autonomously navigates to find the most efficient path to its destinations. The robot adjusts the path when it encounters obstacles which are not on the map (like people and objects).

• Efficient transportation of heavy loads

The robot is designed to automate transportation of loads up to 500 kg across industries, allowing employees to focus on higher value activities.

• Sound and light signals

The robot continuously signals with light and sounds indicating its current mode, for example waiting for job, driving to destination, destination reached or alert mode.

6. Product presentation

• User friendly and flexible

The web-based user interface, accessed from a PC, tablet or smartphone, gives easy access to operation and monitoring of the robot and can be programmed without any prior experience. Different user group levels and tailored dashboards can be set up to suit the different users.

• Alert for ‘lost’

If the robot enters a situation where it is unable to find a path to its destination, it stops, turns on the yellow-purple running error light and a customer defined ‘catch’ action may be used to alert people or take other actions.

• Automatic deceleration for objects

The built-in sensors ensure that the robot is slowed down when obstacles are detected in front of it.

• Optimal surface operations

The robot is made to run on a level, dry floor with a maximum incline of 5% at 0,5 m/s.

3D cameras detect and avoid objects from 50-1700 mm above floor level.

• Internal map

The robot can either use a floor plan from a CAD system or a map can be created by manual navigation around the entire site in which the robot is going to operate. When mapping, the robot’s sensors detect walls, doors, furniture and then creates a map based on this input. After creation of the map, positions and other features can be added in the map editor.

Top modules

The following top modules are available for the MiR500:

• MiR500 Pallet Lift

A lift platform may be mounted on MiR500 enabling it to automate the internal transport of US standard 40x48 pallets.

• MiR500 EU Pallet Lift

A pallet lift for EU pallets may be mounted on MiR500 enabling it to automate the internal transport of EU pallets.

• MiR Lift Pallet Rack

Use a MiR Lift Pallet Rack with MiR500 Pallet Lift. The lift places and picks up US standard

40x48 pallets from the rack autonomously.

• MiR EU Pallet Rack

Use a MiR EU Pallet Rack with MiR500 EU Pallet Lift. The lift places and picks up EU pallets from the rack autonomously.

6. Product presentation

To read more about the add-ons, go to www.mobile-industrial-robots.com

6.2 Identification label

The identification label of MiR500 is placed above the MiR controller behind the rear maintenance hatch.

Serial number

Mobile Industrial Robots A/S declares that MiR500 meets the requirements of the applicable EC directives.

The 15-digit serial number is a unique identifier of the robot. The last four digits form part of the original name of the robot, e.g.

MiR U0008.

MiR500 1.0

Product name and hardware version.

Figure 6.1. Example of MiR500 CE marking and identification label.

6.3 MiR500 control panel

MiR500 has a control panel in the rear-left corner of the robot.

The Operating mode key

The Operating mode key lets you switch between operating modes.

6. Product presentation

• Left position: Autonomous mode.

Puts the robot in the Autonomous mode.

• Middle position: Stop.

Stops the robot. The robot blocks the wheels, you cannot start a mission or drive the robot manually.

• Right position: Manual mode.

Puts the robot in the Manual mode.

For more information on operating modes, see

MiR500 operating modes on the next page

The control panel buttons

The buttons on the control panel have the following functions.

1. Stop

2. Restart

3. On/Off

Stop

Pressing the button stops the robot. After pressing this button, you must press the Restart button to let the robot continue operating.

Color indication:

• Red: The robot is on.

Restart

Pressing this button:

• Clears the emergency stop state.

• Lets the robot continue operating after the Stop button was pressed.

6. Product presentation

• Lets the robot continue operating after powering up or after the operating mode change.

Color indication:

• Blinking red: The robot is waiting for a user action (clear the emergency stop state, acknowledge the change of operating mode, etc.)

On/Off

Pressing this button for five seconds turns the robot on or shuts it down.

Color indication:

• Blue: The robot is off.

• Blinking green: The robot is starting up.

• Green: Normal operation.

• Red: The robot detected an error.

• Yellow: The battery level is low.

6.4 MiR500 operating modes

MiR500 has the following operating modes:

Manual mode

In this mode, you can drive the robot manually using the joystick in the robot interface. Only one person can control the robot manually at a time. To ensure that nobody else takes control of the robot, the robot issues a token to the device on which you activate the Manual mode.

For information about activating this mode, see section

Driving the robot in Manual mode on page 28

Autonomous mode

In this mode, the robot executes the programmed mission. After switching the key to this mode, you can remove the key and the robot will continue driving autonomously. The joystick is disabled in the robot interface.

Muting of the personnel detection means

When performing tasks that require to move very close to surrounding objects, the robot mutes the personnel detection means. Docking to a pallet rack is the example of such task.

When muting the personnel detection means, the robot does the following:

6. Product presentation

• Reduces the size of the safety zones.

• Turns the collision detection off.

• Decreases the speed.

• Flashes the yellow indicator lights.

You can also mute the personnel detection means using the robot interface:

• Put the robot into the Manual mode. See section

Driving the robot in Manual mode on page 28

• In the robot interface, in the Joystick control, select Mute personnel detection means .

• In the prompt dialog, select Yes to acknowledge the muting of personnel detection means.

The status and the signal lights start flashing yellow, the robot is ready to drive with muted personnel detection means.

6.5 MiR500 external parts

This section presents the parts of MiR500 that are visible on the outside.

1. Left cover plate: access to power interface, GPIO interface and

Ethernet interface

8. Proximity sensors: eight pcs., two in each corner behind corner cover (see

Sensor system on page 69

)

6. Product presentation

2. Right cover plate: access to safety interfaces Aux. safety functions and Aux. Emergency stop

3. Signal light: eight pcs., two on each corner (see

Sensor system on page 69

)

4. Rear maintenance hatch: opens to rear compartment (see

MiR500 internal parts on page 62 )

5. Rear safety laser scanner

6. Right-hand side maintenance hatch

9. 3D depth cameras: two pcs., detect objects in front of the robot

(see

Sensor system on page 69 )

10. Front maintenance hatch: opens to front compartment (see

MiR500 internal parts on page 62

)

11. Front safety laser scanner (see

Sensor system on page 69 )

12. Left-hand side maintenance hatch

13. Status light: on all four sides of the robot (see

Sensor system on page 69

)

7. Emergency stop button: four pcs., two on each side

Figure 6.2. MiR500 external parts

MiR500 top cover

View of MiR500 from the top:

6. Product presentation

1. Not accessible; used for fixation of the top cover.

3. M10 mooring holes for fixation of top module, e.g.

MiR500 EU Pallet Lift or

MiR500 Pallet Lift.

For more information on mounting top modules, see

Mounting a top module on page 77

2. M12 lifting holes; one in each corner used for fixation of transportation eye bolts.

6. Product presentation

6.6 MiR500 internal parts

Most internal parts of MiR500 are reached through maintenance hatches that open to different compartments:

• Front compartment

• Rear compartment

• Side compartments

• Top compartments

Front compartment

The front compartment holds the electronic components that may need regular service or replacement, such as PC, main control board and safety PLC.

To open the front compartment:

Push the two white buttons and pull the hatch.

6. Product presentation

Turn the two levers 180°. The right lever goes from top to bottom and the left lever goes from bottom to top. Then pull out the compartment drawer while holding underneath it and lifting slightly.

Front compartment components

The front compartment contains the following components:

6. Product presentation

1. Cable chain

2. Safe Torque Off contactors

3. Access point/Router

4. Robot computer

5. Loudspeaker

6. Power board: controlling power distribution for motor controller,

PC and safety PLC

7. Motor controller carrier board: contains motor controllers and controller for proximity sensors and light indicators.

8. Safety PLC

Rear compartment

The rear compartment holds the robot’s battery.

To open the rear compartment:

Push the two white buttons.

Pull the hatch.

6. Product presentation

Rear compartment components

The rear compartment contains the following main components:

6. Product presentation

1. Connectors for proximity sensors 5. Charging connection interface, for external charger

2. Battery disconnect switch, shown in Off position

3. Connector for status light band

6. Battery with connector, main power to the robot

7. Connection interface for MiR

Controller

4. Brake release switch, shown in

On position. When turned off, the brakes are released, and the robot can be pushed manually

Side compartments

The side compartments contain the right- and left-hand side bogies and drive wheels.

6. Product presentation

To open a side hatch: turn the two screws 90° counterclockwise with a flat-head screwdriver, and pull the hatch.

Side compartment components

The left- and right-hand side compartments contain the following components (the same on both sides):

1. Connector for status light band 2. Drive wheel

Top compartments

The two top compartments hold interfaces to external units, for example

MiR500 EU Pallet Liftor MiR500 Pallet Lift.

To open a top compartment, remove four screws and lift off the top cover.

6. Product presentation

The two top compartments contain interfaces for top applications and added safety functions.

Top compartment components

The top compartments contain the following electrical interfaces for top applications. For detailed information, see

Interface specifications on page 92

1. Ethernet

2. GPIO: General purpose I/O

3. Power

4. Auxiliary emergency stop

5. Auxiliary safety functions

6. Product presentation

6.7 Sensor system

Collaboration between the robot’s internal and external sensors ensures that the robot can navigate in the environment and most importantly secures that it can operate safely among people and objects like furniture, machines, pallets etc.

This section describes the functionality of the different parts of the sensor system.

The robot is equipped with the following sensors:

• Safety laser scanners

• 3D cameras

• Proximity sensors

• Internal sensors

Safety laser scanners

The safety laser scanners on MiR500 are of the type AOPDDR (active opto-electronic protective device responsive to diffuse reflection). AOPDDR is a protective device that uses opto-electronic transmission and reception elements to detect the reflection of the optical radiation generated by the protective device. The reflection is generated by an object in a defined two-dimensional area. This is a type of ESPE (electro-sensitive protective device). In this guide, the term safety laser scanner is used.

Scanner functions

Two safety laser scanners, diagonally placed on front and rear corners of the robot, scan their surroundings. Each safety laser scanner has a 270° field of view, overlapping and thus providing a full 360° visual protection around the robot.

The safety laser scanners serve three purposes:

• They are used for mapping, see also

Planning on page 34

and MiR Robot Interface

Reference Guide.

• They are used to localize the robot in the environment and plan routes between points.

• They continuously scan the surroundings when the robot operates thereby avoiding collision with objects and people.

6. Product presentation

The safety laser scanners detect objects in a plane approximately 200 mm above ground.

Objects above or below are not detected by the safety laser scanners.

The two safety laser scanners together provide a full 360° view around the robot.

When in motion, the safety laser scanners continuously scan the surroundings using a distance of up to 40 m while taking into account and weighting the viewed objects in a socalled "particle filter".

When mapping, the safety laser scanner’s view is reduced to 20 m to support that maps will get the highest possible quality.

The safety laser scanners see up to 20 m when mapping an area.

6. Product presentation

Signals from safety laser scanners are combined with input from 3D cameras and proximity sensors and used to evaluate if an object or person is in the path of travel. In that case, the robot gradually slows down while trying to avoid the obstacle. If unable to make its way around the obstacle, the robot stops and waits for clearance.

Protective fields

The protective fields are part of the robot’s personnel detection means. The protective fields consist of individually configured contours. The active protective field is automatically selected based on the speed of MiR500. A person or object within an active protective field will bring the robot to a protective stop and the robot will remain stopped until the protective field is free.

Protective fields of the front and rear safety laser scanners.

Protective field settings

The following table shows how the protective fields are configured.

Protective fields in the driving direction:

Safety fields Speed range

Protective field 1 (innermost) <0.1 m/s

Protective field 2 0.1-0.3 m/s

Protective field 3

Protective field 4

Protective field 5

0.3-0.6 m/s

0.6-0.9 m/s

>0.9 m/s

Protective fields opposite the driving direction:

35 cm

40 cm

60 cm

85 cm

135 cm

Field size

6. Product presentation

Safety fields

Protective field

Speed range all speeds 35 cm

Field size

When the robot moves backwards, the protective fields switch, so that the largest protective fields are in the driving direction.

CAUTION

The speed/zone rate is configured to comply with the safety standards of

MiR500.

If they are changed, Mobile Industrial Robots takes no responsibility for any safety related incidents, and the warranty becomes void.

Muted personnel detection means

When docking to pallet rack or a charging station, the protective fields are muted to avoid unintended activation. Muted protective fields is part of the drive mode Muted personnel detection means where the robot also slows down the speed. For more information, see

Muting of the personnel detection means on page 58 .

3D cameras

Two 3D depth cameras positioned on the front of the robot detect objects in front of the robot while the robot’s local planner continuously adjusts its planned routes around such objects.

The 3D cameras detect objects:

• Vertically up to 1700 mm at a distance of 950 mm in front of the robot.

• Horizontally in an angle of 114° and 250 mm to the first view of ground.

The camera readouts are used as 3D point cloud data. They are not recording recognizable objects or people.

The following illustrations show the fields of view of the cameras.

6. Product presentation

The two 3D cameras can see objects up to 1700 mm above floor height.

6. Product presentation

The two 3D cameras have a horizontal field of view of 114°.

6. Product presentation

Proximity sensors

Proximity sensors placed in all four corners of the robot detect objects close to the floor that cannot be detected by the safety laser scanners.

Using infrared light, the proximity sensors point downwards and make sure that the robot does not run into low objects such as pallets and forklift forks.

The proximity sensors in the corners of the robot detect objects close to the floor.

Internal sensors

The internal sensor system of the robot consists of the following components:

• Gyroscope (IMU)

Measures the orientation and angular velocity of the robot.

• Motor encoder

Provides closed loop feedback to motor controllers for closed loop speed control. They also provide position feedback to the robot control system.

• Accelerometer

Measures non-gravitational acceleration.

6.8 Light indicators

The robot uses two types of light indicators to let people in the environment know what the robot is currently doing or planning to do.

• Status lights

An LED light band on all four sides of the robot uses colors and light motion patterns to signal the current status of the robot

6. Product presentation

• Signal lights

The signal lights at the front and back of the robot show people in the environment if the robot is about to turn a corner or go backwards.

The following illustration shows the light indicators.

1. Status lights 2. Signal lights

Status lights

The LED light band running all the way around the robot indicates the robot’s current operational state. Colors may also be used as part of missions, but as standard, the robot is delivered with the following setup.

NOTICE

When the robot's battery reaches a critically low level of power (0-1%) the corner LED lights flash red. You should immediately recharge your robot.

Signal lights

Signal lights are used to indicate the robot’s immediate motion plans, for example by signaling forwards-backwards-braking and left-right turns.

The signal lights work similarly to lights used on cars; white at the front, red at the back, and are used to indicate for example a left or right turn by blinking.

When the robot drives with muted personnel detection means, for example when docking to a pallet rack, all signal lights blink yellow. For more information, see

Muting of the personnel detection means on page 58

7. Applications

You can install top modules on top of MiR500 for specific applications. For more information about top modules, go to our website: http://www.mobile-industrial-robots.com

For instructions on how to mount top modules and accessories, contact your distributor.

7.1 Mounting a top module

MiR500 has four M10 holes for mounting top modules as shown in

Figure 7.1

. The tightening torque is 47 Nm.

7. Applications

See

MiR500 external parts on page 59

for more information on the mounting holes.

Figure 7.1. Mounting holes on the top of MiR500.

M12 lifting holes can also be used to mount top modules. If a top module is mounted using these holes, it is necessary to drill M12 lifting holes in the top application in order to lift the robot. Alternatively, the top module must be easily removed to access the M12 holes.

Certain top modules may require the installation of an extra emergency stop button.

Perform risk assessment according to standard ISO 12100, see

Risk assessment on page 12

7. Applications

CAUTION

Certain top modules may lead to new hazards and/or increased risks that cannot be eliminated or reduced by the risk reduction measures applied by

Mobile Industrial Robots. Perform risk assessment according to standard ISO

12100, see

Risk assessment on page 12

CAUTION

Stay within the specifications for weight and the total payload’s center of gravity, see

Payload specifications on page 90

7. Applications

7.2 Lift modifications

Additional holes can be added to the MiR500MiR500 Pallet Lift for custom applications.

However, it is important not to damage any vital parts of the lift when doing so.

Top plate of the lift

1. Material: Steel (S355)

Thickness: 3 mm

Treatment: Powder coating RAL

9005

2. Areas marked with red indicate where you are not allowed to make modifications, such as drilling holes or mounting accessories.

Bottom frame of the lift

7. Applications

1. Material: Steel (S355)

Thickness: 3 mm

Treatment: Powder coating RAL

7011

2. Areas marked with red indicate where you are not allowed to make modifications, such as drilling holes or mounting accessories.

NOTICE

The drawings above only show where you can make minor modifications without damaging the product. You should not use it for any other measurements or calculations.

NOTICE

It is only possible to modify the MiR500 Pallet Lift, not the

MiR500 EU Pallet Lift.

7. Applications

8. Maintenance

The following maintenance schedules give an overview of regular cleaning and parts replacement procedures.

The stated intervals are indicative and depend on the operating environment and frequency of usage of the robot.

NOTICE

Only use approved spare parts.

Mobile Industrial Robots disclaims any and all liability if unapproved spare parts are used. Mobile Industrial Robots can not be held responsible for any damages caused to the robot, accessories or any other equipment due to use of unapproved spare parts.

8.1 Regular weekly checks and maintenance tasks

Once a week carry out the following maintenance tasks:

Parts

Robot top plate and sides

Maintenance tasks

Clean the robot on the outside with a damp cloth.

Do not use compressed air.

8. Maintenance

Parts

Laser scanners

Maintenance tasks

Clean the optics covers of the scanners for optimum performance.

Avoid aggressive or abrasive cleaning agents.

NOTICE

Static charges cause dust particles to be attracted to the optics cover. You can diminish this effect by using the anti-static plastic cleaner (SICK part no. 5600006) and the SICK lens cloth (part no. 4003353). See the manufacturer’s own documentation.

Caster wheels (the four corner wheels)

Remove dirt with a damp cloth, and make sure nothing is entangled in the wheels

Drive wheels (the two middle wheels)

LED light band

Signal lights

Remove dirt with a damp cloth, and make sure nothing is entangled in the wheels.

Check if the LED light band is intact. Does the light show all the way around the robot.

Check if the signal lights on the four corners blink and show correctly all the way around the robot.

8.2 Regular checks and replacements

Before starting replacement tasks that involve removal of the top plate:

• Press the On/Off button to turn off the robot.

• Push the battery switch button to remove power from the battery.

• Turn off relays and unplug the battery.

The following table contains the parts that you should check and the intervals when you should do that:

Part

Robot top plate

Maintenance

Check mounting. Does it sit evenly on top of the robot with connections accessible.

Interval

Check monthly and replace as needed.

8. Maintenance

Part

Caster wheels

(the four corner wheels)

Drive wheels (the two middlewheels)

Maintenance

Check bearings and tighten.

Check wheel surfaces for wear.

Check weekly and replace as needed.

Interval

Check every six months and replace as needed.

NOTICE

The robot must be calibrated after replacement of the wheels.

Replace as needed.

Scanners Check for visual defects, e.g.

cracks and scratches.

NOTICE

The robot must be calibrated after replacement of the scanners.

Emergency stop To check that the emergency stop buttons work, push down the red button and check that the emergency reset button lights up.

ESD tail To check the ESD tail, open the left-hand side maintenance hatch and make sure that the tail has contact with the ground.

Every three to four months / according to EN/ISO 13850

Safety of machinery - Emergency stop function.

Check every six months and replace as needed.

8. Maintenance

Part

Broom (front of robot)

Maintenance

Open the front maintenance hatch and remove the three screws to get to the broom.

Interval

Check every six months if the broom is intact.

Replace as needed.

3D cameras

Proximity sensors

Manual brake release

Safety marking on the floor

Safety stickers

If the charger pads are dirty or dusty, check the broom.

Check for visual defects, e.g.

cracks and scratches.

Check for dust or dirt.

Check if the brakes can be deactivated. Activate the brakes and push the robot gently forward.

Remember to deactivate the brake after testing.

Check monthly and replace as needed.

Check if the safety markings made with e.g. tape around

MiR EU Pallet Rack or

MiR Lift Pallet Rack are intact and visible.

Check if the safety stickers on the robot are still intact and visible.

Check monthly and replace as needed.

Check weekly and clean with a swab.

Check every six months and replace as needed.

8.3 Packing for transportation

This section describes how to pack the robot for transportation.

Original packaging

Use the original packaging materials when transporting the robot.

8. Maintenance

The packaging materials are:

• The bottom of the box (the pallet)

• The lid of the box (the ramp)

• The walls of the box

• The wheel stop board

• Protective foam blocks: Side blocks and the top layer

• Protective corner braces. The braces prevent the robot from being damaged by the transport straps

• Screws

Packing the robot for transportation

To pack the robot for transportation:

Shut down the robot. See

Shutting down the robot on page 33

Open the rear maintenance hatch.

8. Maintenance

Turn the battery disconnect switch to position OFF .

Repeat the steps in section

Getting started on page 18

in the reverse order.

NOTICE

Pack and transport the robot in an upright position. Packing and transporting the robot in any other position voids the warranty.

Battery

The lithium battery is subject to transport regulations. Make sure that you follow the safety precautions in this section and the instructions in section

Packing for transportation on the previous page

. Different regulations apply depending on the mode of transportation.

8. Maintenance

Contact your distributor for more information.

CAUTION

Lithium batteries are subject to special transportation regulations according to

United Nations Regulation of Dangerous Goods, UN 3171. Special transport documentation is required to comply with these regulations. This may influence both transport time and costs.

9. Payload specifications

The following drawings illustrate the center of mass (CoM) specifications for safe operation at different payloads.

WARNING

If the load on the robot is not positioned or fastened correctly, the load may fall or the robot may overturn and cause injury to personnel and damage to equipment.

• A safe and secure fastening method must be determined during commissioning.

The specifications apply to total payloads of up to 500 kg.

Side view 500 kg

Front view 500 kg

9. Payload specifications

10. Interface specifications

This section describes the specifications of the top application interface.

NOTICE

Read

Safety on page 8

before using the electrical interface.

MiR500 has five electrical interfaces divided into two groups:

•

General purpose interfaces below :

• Power

• GPIO

• Ethernet

•

Safety interfaces on page 100

• Auxiliary Emergency Stop

• Auxiliary Safety Functions

To see the locations of the interfaces on the robot, see section

Top compartments on page 67

10.1 General purpose interfaces

This section describes the general purpose interfaces located in the left-hand side compartment on the top side of MiR500.

10. Interface specifications

Power

An auxiliary power connection for top applications is provided in the top left-hand side compartment. See

Connector list on page 103

for more information.

Figure 10.1. Pin numbers: female connector viewed from the front (left) and wiring diagram (right).

The following table contains the description of the pins of the Power interface.

The maximum current across pins 1 and 3 combined is 20A. You cannot receive 20A from both of them at the same time.

Pin number

Signal name

Max.

current

48V power 20A

GND

Description

Turns off in case of a protective or emergency stop, via a transistor in the power board.

There are no additional safety precautions taken with this power output. For this reason, it is recommended to use the power output from pin 3 instead.

Intended for high power loads like motors or actuators.

Ground.

10. Interface specifications

Pin number

Signal name

48V safe power

GND

24V

GND

Unassigned

Max.

current

20A

Description

Turns off in case of a protective or emergency stop.

This output is controlled by the internal safety PLC and the STO contactor to ensure that power is always disconnected from this pin in case of a protective or emergency stop. For this reason, it is always recommended to use this power output instead of the output from pin 1.

Intended for high power loads like motors or actuators.

Ground.

Always on when robot is on.

Intended for low power use, like powering an external PLC.

Ground.

Unassigned.

GPIO

A GPIO connection is in the top left-hand side compartment.

10. Interface specifications

Figure 10.2. Pin numbers: male connector viewed from the front (left) and wiring diagram (right).

A variety of top applications requires a general purpose and "simple-to-use" digital I/O

(GPIO).

10. Interface specifications

The GPIO supports low current/power devices like relays, contactors, lamps and/or separate

PLC units.

Figure 10.3. It is intended that outputs and RTNs are used to send signals to the top application, and inputs and

24V pins are used to receive signals from the top application.

The GPIO has the following features:

• Four inputs, for use with 24V, but robust against 48V.

• Four outputs, for use with 24V.

To use the GPIO for a top application of your own design, ensure that the Pallet lift feature is disabled. This setting is found under System > Settings > Features .

10. Interface specifications

This enables the GPIO interface to work as input and output to top applications that can be used in missions. The pallet lift feature uses a different kind of communication that is specific to the pallet lift top module.

Outputs (O0, O1, O2, O3) can be toggled on and off by the robot in a Set I/O module mission action or manually in Setup > I/O modules .

A top application can be connected to the output pins and monitor when they are high at

+24V. RTN is used as ground.

Inputs (I0, I1, I2, I3) can be used by the top application to send inputs to the robot. When

+24V is connected to the input pin, the robot registers the input as high.

Figure 10.4. Example of I2 registered as high by the robot.

10. Interface specifications

Output pins must be connected to RTN pins, and input pins must be connected to 24V pins.

The following table contains the description of the pins of the GPIO interface.

Pin number

Signal name

RTN

24V

Unassigned

Max. current

1A @ 24V

Description

Output 0.

Protected return.

Output 1.

Protected return.

Output 2.

Protected return.

Output 3.

Protected return.

PNP Input 0.

Protected output.

PNP Input 1.

Protected output.

PNP Input 2.

Protected output.

PNP Input 3.

Protected output.

Unassigned.

Ethernet

An Ethernet connection is in the top left-hand side compartment.

10. Interface specifications

Figure 10.5. Ethernet connection. Pin numbers (left) and wiring diagram (right).

The communication interface is 10/100 Mbit Ethernet using a M12 connector. See

Connector list on page 103 .

Various protocols are supported, such as Modbus. For more information on how to use

Modbus, refer to the how-to guide How to use Modbus with MiR robots found on the

Distributor site.

The following table contains the description of the pins of the Ethernet interface.

Pin number Signal name

TX+

RX+

TX-

RX-

10. Interface specifications

10.2 Safety interfaces

This section describes the safety interfaces located in the right-hand side compartment on the top side of MiR500.

Auxiliary emergency stop

An Auxiliary emergency stop connection is provided in the top right-hand side compartment.

Figure 10.6. Pin numbers: female connector viewed from the front (left) and wiring diagram (right).

Auxiliary emergency stop is designed to support emergency stop and other safety functions.

The emergency stop circuit in the robot runs through all four emergency stop buttons and through pins 1-4. If the circuit is broken, MiR500 enters protective stop. To complete the circuit, you must connect pins 1 and 3 together and pins 2 and 4. If you have any emergency stop buttons on your top application, they can be connected to the emergency stop circuit through these pins.

The following table contains the description of the pins of the Auxiliary emergency stop interface.

Pin number

Signal name

Test output

Description

2 Test output

Input signal 1 from safety PLC for emergency stop circuit. Should connect to pin 3.

Input signal 2 from safety PLC for emergency stop circuit. Should connect to pin 4.

100

10. Interface specifications

Pin number

Signal name

E-stop 1

E-stop 2

Reset

Safe RTN

Reset lamp

Description

Output signal 1 to safety PLC for emergency stop circuit. Should connect to pin 1.

Output signal 2 to safety PLC for emergency stop circuit. Should connect to pin 2.

When high, the robot restarts.

Safe return.

Only available in MiR500 U0277 and MiR1000 V0036 and higher.

Unassigned.

8 Unassigned

Auxiliary safety functions

An Auxiliary safety functions connection is provided in the top right-hand side compartment.

Figure 10.7. Pin numbers: female connector viewed from the front (left) and wiring diagram (right).

The Auxiliary safety functions interface is designed to support emergency stop and other safety functions.

101

10. Interface specifications

The following table contains the description of the pins of the Auxiliary safety functions interface.

Pin number

Signal name Description

Test output

Safeguarded stop

Locomotion 1

Locomotion 2

Shared E-stop out

Shared E-stop in

24V out.

Safeguard dual channel input. Set any or both pin(s) low to enter Emergency stop. If pins are unequally set for a period greater than 3 seconds, PLC will have to be reset by setting both pins LOW, then high.

Output - high when the robot is standing still.

Shared emergency stop out 1. Output - low when the robot is in protective stop.

Shared emergency stop out 2. Output - low when the robot is in protective stop.

Shared emergency stop in 1. Input - Low = robot goes to protective stop.

Shared E-stop in

Shared emergency stop in 2. Input - Low = robot goes to protective stop.

Reduced speed 1 Input - circuit broken will result in that the robot can not drive fast.

Reduced speed 2 Input - circuit broken will result in that the robot can not drive fast.

Unassigned Unassigned.

102

10. Interface specifications

Pin number

Signal name

Unassigned

Safe RTN

Unassigned

Unassigned.

Safe return - Ground.

Unassigned.

Description

10.3 Connector list

We recommend the following connectors for the five different interfaces.

Connector name

Power

GPIO

Ethernet

Auxiliary Emergency Stop

Auxiliary Safety

Functions

Connector type

M23 6p

M17 17p

M12 4p

M17 8p

M17 17p

Phoenix Contact

Dimension drawing

CA-06P1N8A8008S See

Figure 10.8

See

Figure 10.9

ST-17S1N8A8K03S

SACC-MSD-4PCT-SH

PN SCO

ST-08P1N8A8K03S See

Figure 10.9

ST-17P1N8A8K03S See

Figure 10.9

Figure 10.8. Connector dimensions for Power connector.

103

10. Interface specifications

Figure 10.9. Connector dimensions for GPIO, Auxiliary Emergency Stop, and Auxiliary Safety Functions connectors.

104

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User guide (en)

Copyright and disclaimer

Table of contents

1. About this document

1.1 Where to find more information

1.2 Version history

2. Safety

2.1 Safety message types

2.2 General safety precautions

2.3 Intended use

2.4 Users

Commissioners

Operators

Direct users

2.5 Foreseeable misuse

2.6 Risk assessment

2.7 Residual risks

2.8 Safety-related functions and interfaces

2.9 Limiting safety-related functions

2.10 Safety-related electrical interfaces

Safety-related electrical inputs

Safety-related electrical outputs

2.11 Lithium battery

3. Getting started

3.1 In the box

3.2 Unpacking MiR500

3. IT security

3.3 Managing users and passwords

3.4 Software security patches

Understanding MiR software versions

Security patch policy

4. Commissioning

4.1 Powering up

4.2 Connecting to the robot interface

4.3 Driving the robot in Manual mode

4.4 Checking the hardware status

4.5 Charging the robot

4.6 Shutting down the robot

4.7 Creating and configuring a map

5. Planning

5.1 Analysis of the work environment

What does the robot see?

5.2 MiR500 user roles

Types of users

Interface and dashboards

Training of the users

5.3 Creating an efficient map

Use zones on the map

5.4 Creating efficient missions

5.5 Create mission

5.6 Mission editor

Change mission settings

Save mission

Save mission as

5.7 Error handling

5.8 Handover testing

6. Product presentation

6.1 Main features of MiR500

Top modules

6.2 Identification label

6.3 MiR500 control panel

The Operating mode key

The control panel buttons

6.4 MiR500 operating modes

Manual mode

Autonomous mode

Muting of the personnel detection means

6.5 MiR500 external parts

6.6 MiR500 internal parts

Front compartment

Rear compartment

Side compartments

Top compartments

6.7 Sensor system

Safety laser scanners

3D cameras

Proximity sensors

Internal sensors

6.8 Light indicators

7. Applications