Bosch Rexroth R901508696 Robotics Trainings System WS502 Instruction manual
Annons
Annons
Robotics Trainings System
WS502
Instruction manual
R901508696
Version: 01-01 EN
The data stated is used for the product description.
If particulars are also furnished they are only examples and proposals. Catalogue specifications are not warranted characteristics. The information does not release the user from their obligation for their own assessments and tests. Our products are subject to natural wear and tear as well as the ageing process.
All rights reserved by Bosch Rexroth AG, also in case of registration of industrial property rights. We retain all powers of disposition such as the right to copy and forward.
The title page shows an example of a configuration.
The delivered product may therefore differ from the figure.
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Contents
Contents
Validity of the documentation ............................................................. 6
Required and supplementary documentation ..................................... 6
Presentation of information ................................................................ 6
Safety information .............................................................. 6
Symbols .............................................................................. 7
Abbreviations ...................................................................... 8
About this chapter .............................................................................. 8
Appropriate use .................................................................................. 8
Non-intended use ............................................................................... 8
Qualification of personnel ................................................................... 9
Teaching ............................................................................. 9
Transport, assembly, installation and commissioning....... 10
Troubleshooting, maintenance and repair ........................ 10
General safety information ............................................................... 10
Product and technology-specific safety information ......................... 11
Personal protection equipment ......................................................... 11
Obligations of the operating organisation ......................................... 12
User workstations ............................................................................. 14
3 General information on preventing property damage and damage to product 15
Agilus industrial robot ....................................................................... 19
Gripper on the Agilus robot ............................................... 20
Connections on the Agilus robot ....................................... 21
Control cabinet ................................................................................. 25
Connection and controls on the control cabinet ................ 26
Pneumatic maintenance unit ............................................................ 28
Technical data .................................................................................. 29
Identification of the WS502 training system ..................................... 30
7 Operating and display elements ................................................................ 31
EMERGENCY STOP button ............................................................ 31
Hand control VH2110 ....................................................................... 32
smartPAD hand control .................................................................... 33
Delivery and unpacking .................................................................... 34
Make the gripper ready for operation................................ 34
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Contents
Bosch Rexroth AG Robotics Trainings System WS502
Assembling the VH2110 hand control ............................... 35
Transport within a building ................................................ 36
Transportation between two buildings ............................... 36
9 Assembly, installation and commissioning ................................................. 38
Assembling the WS502 training system ........................................... 38
Check and connect the pneumatic supply ........................................ 39
Check and connect the electrical installation .................................... 39
Switching on the training system ...................................................... 40
Setting the robot speed ..................................................................... 40
Predefined robot programs ............................................................... 41
Adjustment of the zero position on the mounted mMS 4.0 ............... 41
Correction of the horizontal and vertical zero position....... 42
Save the new zero position ............................................... 42
Selecting the operating mode and program ...................................... 43
Start the program .............................................................................. 43
Program stop (stop cycle) ................................................................. 43
Stop movement ................................................................................. 43
Stop movement (immediate stop) ..................................................... 44
Perform home position run................................................................ 44
Move the robot in jog mode .............................................................. 45
Saving the current robot position ...................................................... 46
Open / close gripper ......................................................................... 47
Restore operational readiness after gripper collision ........................ 48
Reset the set position points to the as delivered condition ............... 49
Switch off the training system ........................................................... 49
Position data screen ......................................................................... 52
Structure of a position data record .................................... 52
Changing a position data record ....................................... 53
Description of the coordinate system ................................................ 55
mMS 4.0 attachment ......................................................................... 55
Connect the Bosch Rexroth mMS 4.0 with the WS502 training system
Connect the mMS 4.0 with the training system ................. 57
General information .......................................................................... 59
Service and inspection plan .............................................................. 60
General information .......................................................................... 61
Maintenance schedule ...................................................................... 61
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Contents
Replacing parts ................................................................ 62
EC – Declaration of Conformity ................................................................. 63
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About this documentation
Robotics Trainings System WS502
1 About this documentation
1.1
Validity of the documentation
This document describes the “Trainings System Robotics WS502 ”.
For the sake of simplification, in the further course of the operating instructions the term "WS502 training system” is used.
This documentation is aimed at fitters, operators, service engineers and plant operators.
This documentation contains important information on how to safely and properly assemble and transport the product along with how to put it into operation, use it, maintain it, dismantle it and how to correct simple faults.
Read this documentation in its entirety and in particular the "Safety
Information" chapter before you work with the product.
1.2
Required and supplementary documentation
In addition to these operating instructions for the (ready-to-use) WS502 training system the following additional documentation is also available:
• “Teachware" teacher and student manuals and software
– contains exercises in accordance with the recommendations
– Educational and information books on the topic of "robotics".
1.3
Presentation of information
To help you use this documentation to be able to quickly and safely use your product, uniform safety information, symbols, terminology and abbreviations are used. To improve understanding they are explained in the following sections.
1.3.1
Safety information
This documentation includes safety information before taking a sequence of actions that involve the risk of personal injury or property damage. The described measures for averting danger must be adhered to.
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About this documentation
Safety information are structured as follows:
SIGNAL WORD
Type and source of the hazard
Consequences of non-compliance
Measures for averting danger
• Warning symbol: Points out the hazard
• Signal word: Indicates the severity of the hazard
• Type and source of the hazard: Identifies the type and source of the hazard
• Consequences: Describes the consequences of non-compliance
• Protection: States how you can avoid the hazard
Warning symbol, signal word
Meaning
HAZARD
WARNING
Indicates a hazardous situation which will result in death or serious bodily injury if it is not avoided.
Indicates a hazardous situation which could result in bodily injuries if it is not avoided.
CAUTION
Indicates a hazardous situation which could result in minor or moderate bodily injuries if it is not avoided.
NOTE
Indicates property damage: The product or the environment can be damaged/harmed.
Tabelle 1:
Hazard classes according to ANSI Z535.6-2006
1.3.2
Symbols
The following symbols indicate instructions that are not safety-relevant but which enhance the clarity of the documentation.
Symbol Meaning
If this information is not observed, the product cannot be optimally used or operated.
1.
2.
3.
Individual, independent process steps
Numbered job instruction:
The digits indicate that the process steps follow one another.
Tabelle 2:
Meaning of the symbols
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Safety information
Robotics Trainings System WS502
1.3.3
Abbreviations
This documentation uses the following abbreviations:
Abbreviation
Agilus
Meaning
6-axis Agilus industrial robot, type KR Sixx, Manufacturer: KUKA
Roboter GmbH
WS502 training system
Robotics training system with WS502 robot
Tabelle 3:
Abbreviations
2 Safety information
2.1
About this chapter
The product was manufactured in accordance with the generally recognized rules of technology. However there remains the danger of personal injury and property damage if you do not adhere to the safety information in this documentation.
Read this documentation thoroughly and in its entirety before you work with the product.
Keep the documentation so that it is user-accessible at all times for all users.
Always pass the product on to third parties together with the required documentation.
2.2
Appropriate use
The WS502 training system is a mechanical and electrical system.
It may only be used to impart the technical training and development knowledge and skills in the sector of robotics as well as to control and feedback control systems technology.
For the development of complete systems and simulations use only devices and sets approved for the WS502 training system.
Operation is only permitted under the operating conditions stated in chapter 5.
The product is intended for professional use only and not for private use.
Proper use also includes that this documentation and in particular the "Safety
Information" chapter have fully read and understood.
2.3
Non-intended use
Any use other than the use described in intended use is not proper and therefore impermissible.
If unsuitable products are installed or used in safety-relevant applications, unintentional operating states can occur in the application which can cause injuries/damage to persons and/or property. For that reason use a product in safety-relevant applications only if such use is expressly stated and allowed in the documentation of the product. For example in explosion-protection areas or in safety-related parts of a control system (functional safety).
Bosch Rexroth AG assumes no liability for damage in the event of improper use.
The risks associated with non-intended use are the sole responsibility of the user.
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Safety information
Non-intended use of the product includes, in particular, that
• the WS502 training system is used playfully and not properly during the practical exercises or is used outside of the training session,
• the components are used in a different training system,
• devices or sets are used that are not approved for the WS502 training system,
• pneumatic pressure circuits are merged,
• the WS502 training system is operated with (even partially) deactivated or nonfunctional safeguards
• The WS502 training system is operated despite identified defects.
2.4
Qualification of personnel
Instructors
Trained staff
2.4.1
Teaching
Apprentices and trainees may work on the WS502 training system only
• under the direct supervision and
• with the appropriate instruction of an instructor or by trained personnel.
The instructors for the WS502 training system must be trained specialists who are qualified in the field of mechatronics and robotics.
The instructor must
• give clear instructions if apprentices or participants work on the WS502 training system,
• check the installation and functional impacts of the control circuit for safe operation,
• answer questions clearly and understandably.
Trained staff can also be used for the supervision of the WS502 training system during the exercises.
These are qualified persons who have been taught and instructed on:
• instructed tasks,
• possible hazards in the event of improper use,
• safeguards and protective measures.
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Safety information
Robotics Trainings System WS502
2.4.2
Transport, assembly, installation and commissioning
Work on the WS502 training system such as assembly, connection, maintenance and repair shall only be performed by authorised specialised personnel or persons with sufficient skills and authorization.
Persons charged with working on the WS502 training system must be capable of understanding the information in this documentation as well as independently performing any details necessary due a possible lack of information based on their own professional qualifications.
2.4.3
Troubleshooting, maintenance and repair
Maintenance, repair, troubleshooting and breakdown maintenance require special knowledge and may only be carried out by a qualified specialist!
• Only a qualified electrician is allowed to work on the electrical equipment.
A qualified electrician is a person who, based on his technical training and experience as well as his knowledge of the relevant provisions is able to assess, recognize possible dangers, and take suitable safety measures for the work assigned.
• Only qualified personnel with special knowledge and experience are permitted to work with the pneumatics. Special knowledge in pneumatics means that the personnel must
–
–
– be capable of reading and completely understanding pneumatic control circuit diagrams, completely comprehend in particular the correlations of the built in safeguards and have knowledge of the function and construction of pneumatic components.
2.5
General safety information
• Observe the valid regulations for the prevention of accidents and on the protection of the environment.
• Observe the safety rules and regulations of the country in which the product is used/is applied.
• Use Rexroth products only in technically perfect condition.
• Comply with the instructions on the product.
• Persons who install, operate, disassemble or maintain Rexroth products must not be under the influence of alcohol, other drugs or medication which could influence responsiveness.
• Use only manufacturer-approved accessories and spare parts to exclude personal injury hazards due to unsuitable replacement parts.
• Adhere to the technical data and environmental conditions stated in the product documentation.
• If unsuitable products are installed or used in safety-relevant applications, unintended operating states can occur in the application which can cause injuries/damage to persons and/or property. For that reason use a product in safety-relevant applications only if such use is expressly stated and allowed in the documentation of the product.
• You may start using the product only after it has been established that the end product (for example, a machine or plant) in which the Rexroth products are installed meets the country-specific regulations, safety regulations and standards of the application.
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Safety information
2.6
Product and technology-specific safety information
WARNING
High electrical voltage!
Risk of death or injury due to electric shock or serious injury!
Always deenergize the WS502 training system before you do any electrical work.
Secure the plant/system from reconnection.
Operate the WS502 training system only in a network with a functional RCD protective conductor or a protective ground.
Manipulated and/or non-functional safeguards and protection equipment!
Risk of serious injury!
Immediately stop the system!
The fault or manipulation must be immediately repaired by specialists.
Danger caused by incorrect assembly and installation!
Risk of serious injury in subsequent operation!
Installation work and commissioning may only be performed by employees of
Bosch Rexroth or instructed trained specialists. This also applies to restarting after repair work.
Have maintenance work performed by qualified personnel only.
2.7
Personal protection equipment
The personal protective equipment for users of the WS502 training system consists of:
• Safety footwear during the entire teaching activity
All constituent parts of the personal protective equipment must be intact.
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Safety information
Robotics Trainings System WS502
2.8
Obligations of the operating organisation
The operating organisation must ensure the necessary conditions for the assembly and the installation of the WS502 training system
• Ensures safe assembly of the WS502 training system by its staff and/or persons it has authorised; in this respect it makes sure above all that the undersurface
– has a sufficient load capacity and
– is flat and horizontal;
• Ensures that the accident prevention regulations (German: UVV), the safety regulations of the professional associations as well as other in-company, local conditions are adhered to.
It teaches its employees and/or those commissioned by third parties about the potential hazards at the installation site.
The operating organisation must provide sufficient lighting in the installation area of the training system.
It must regularly instruct its staff on the following topics:
• Compliance with and use of the operating instructions;
• Compliance with the legal provisions;
• Intended use of the WS502 training system;
• Observance of the instructions by works security and the operating instructions of the operating organisation;
• Behaviour in case of emergency.
EMERGENCY STOP button
2.9
Safeguards
For the protection of persons the WS502 training system is equipped with the following safeguards:
• 3 EMERGENCY-STOP buttons on the cell
• 1 EMERGENCY-STOP button on the VH2110 hand control
• 1 EMERGENCY STOP button on the KUKA smartPAD (if the smartPAD is connected to the training system)
• 2 EMERGENCY-STOP switches on the safety doors of the cell
• EMERGENCY-STOP circuit to connected Bosch Rexroth expansion modules
• Guard on the cell
The stated equipment is described in detail below.
On the front and on the left and right side of the WS502 training system there is an EMERGENCY-STOP button that must be easy to reach.
The EMERGENCY-STOP button must be pressed in order to prevent hazards to persons or the WS502 training system.
The actuation of the EMERGENCY-STOP button puts the robot in Safe Torque off, i.e it goes into safely reduced torque and brakes the motors/drives; the
WS502 training system is stopped. The control cabinet is still supplied with power.
The actuation of the EMERGENCY STOP button also activates the
EMERGENCY STOP on all Bosch Rexroth expansion modules (e.g. mMS 4.0) that are connected to the WS502 training system.
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Safety information
EMERGENCY-STOP switches on the doors
Pneumatic pressure control
Guard
There are two protective doors on the front of the WS502 training system. These are provided with EMERGENCY-STOP door switches, which safely shut down the system as soon as a door is opened.
There is a sliding door on the rear of the WS502 training system. It is provided with EMERGENCY-STOP door switches which safely shut down the system as soon as the sliding door is opened.
When operating the WS502 training system without a Bosch Rexroth expansion module the sliding door must be closed.
If the WS502 training system is operated together with a Bosch Rexroth expansion module, open the left sliding door (viewed from the rear) and mount the expansion module to the rear of the WS502 training system. The existing
EMERGENCY-STOP door switch is then actuated by the mounted expansion module.
The training system must only be operated with a maximum pneumatic operating pressure of 5-6 bar. The pressure of the system is adjustable.
The WS502 training system is equipped with a guard (Makrolon panes) which prevents contact of persons in the hazardous area of the system.
WARNING
Danger due to missing or incomplete guards!
Risk of injury when operating the WS502 training system with missing or incorrectly installed pane elements!
In case of missing or incorrectly installed pane elements, immediately take the WS502 training system out of service!
Install the protective panes supplied with the WS502 training system correctly.
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Safety information
Robotics Trainings System WS502
2.10
User workstations
Provide the following space for the WS502 training system to teach and learn the procedures on the WS502 training system:
Abb. 1: WS502 training system space requirements
Teaching stations The following teaching stations are provided depending on the usage of the
WS502 training system:
Process step Number of persons
Setup 3
Operation 2
Tabelle 4:
Teaching stations in an WS502 training system
During setup, a maximum of three people are allowed to work simultaneously on one WS502 training system. When operating, a maximum of two people plus the instructor are allowed to perform work.
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General information on preventing property damage and damage to product
3 General information on preventing property damage and damage to product
NOTE
The system stands under pressure and tension!
Property damage!
Do not loosen/remove any connected lines, connections and components while there is pressure in the system.
Do not loosen/remove any plug connectors as long as the system is energized.
Switch the system off on the main switch.
The robot controller is equipped with an uninterruptible power supply. Voltage can still be present here approximately 5 minutes after switching off.
Incorrect setting of pressure relief valves and pressure switches of pneumatic components!
Property damage!
Operate the pneumatic components only with the recommended pressure values.
Hazards for the electrical equipment due to high electrical currents!
Property damage!
Ensure the provision of an overcurrent protector.
Secure the power socket by pulling the mains plug.
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Scope of supply
Robotics Trainings System WS502
4 Scope of supply
Dimensions of the wooden crate
The WS502 training system is supplied packed as a turnkey system.
It stands on a sub-pallet and is held taut with non-metallic straps. It is packed in a foil and stands in a wooden crate which is closed on the front by a cover. The cover is fastened with nails or screws.
Designation
Dimensions Length
Width
Unit mm mm
Value
1580
940
Height
Tabelle 5:
Dimension of the wooden crate mm 2200
5
4
3
2
1
Abb. 2: Crate with marking
The following details are provided: on the crate:
1
Transport instructions or warnings as needed
2
3
Shipping number/barcode
Delivery note in plastic bag
4
Label: gross/if applicable net weight
5
Label: packaging in accordance with the IPPC Standard
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About this Product
Scope of supply The scope of delivery of the WS502 training system includes:
• 1 WS502 training system with Agilus industrial robot, mounted
function modules and control cabinet, stationary
• 1 Hand control Rexroth VH2110 with connecting cable
• 1 KUKA smartPAD with connecting cable
• 1 connecting cable for the connection of expansion modules (e.g. Bosch
Rexroth mMS 4.0)
• 2 EMERGENCY STOP jumper plugs to operate the system without attachments
(mounted)
• 1 Operating instructions (DE, EN, ES)
• 1 Circuit diagram (DE, EN, ES)
• 3 Mechanical expansion modules for attachments:
–
–
1 Actuator assembly for the door switch (for mounting on the Bosch Rexroth mMS 4.0)
2 Mounting bracket for fastening the attachment
• 3 Cube demo objects
5 About this Product
5.1
General
The following sections of these operating instructions show examples of a variant of the WS502 training system and its components.
There are a multitude of attachment units and sets available for the WS502 training system. These components make the WS502 training system a complete, customized and practice-oriented training and developmental education system.
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About this Product
Robotics Trainings System WS502
5
6
7
8
1
2
3
4
5.2
General plan
The WS502 training system consists of an aluminium profile frame with Makrolon panes, adjustable mounts for fixed assembly, a KUKA Agilus robot, hand control, control cabinet.
13
12
11
10
9
Abb. 3: Agilus training system
8
1
EMERGENCY STOP, door switch, no-contact
2
Signal tower
3
Aluminium profile frame with protective doors and Makrolon panes
4
Agilus robot
5
EMERGENCY STOP button
6
Control cabinet
7
KUKA robot controller
8
Adjustable machine mounts for fixed assembly
9
Controls and connectors on the control cabinet
10
Cube chute (concealed)
11
EMERGENCY STOP button
12
Cube racks with light barriers
13
Hand control VH2110 with bracket
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About this Product
5.3
Agilus industrial robot
The Agilus Sixx is an industrial robot with six axes.
The robot is equipped with a pneumatic gripper with an occupied control which is protected against damage by a collision coupling system.
Abb. 4: KR6R700 Agilus Sixx
NOTE
Agilus robot system manufacturer documentation
You can find information about the Agilus robot system in the manufacturer documentation.
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About this Product
Robotics Trainings System WS502
Pneumatics
Occupied control
Collision avoidance
6
5
5.3.1
Gripper on the Agilus robot
The Agilus robot is equipped with a pneumatic gripper with sensory occupied control. The pneumatic triggering of the gripper is made through the internal
Agilus pneumatic functions.
If a cube is picked up with the gripper, the occupied control sensor detects the object. The gripper assignment is displayed on the hand control.
A mechanical coupling system with sensory position monitoring prevents the gripper from being damaged in case of accidental collisions.
In the event of a collision, the collision clutch yields and releases out of the coupling mount. The collision is detected by a position sensor and the system is stopped. The signal tower flashes red and a message is displayed on the hand control.
3
1
4
5
2
Abb. 5: Gripper Agilus robot
1
1
Sensor for "Collision clutch engaged” signal
2
Collision clutch
3
Coupling mount with 4 springloaded ball tensioners
4
Pneumatic gripper with open/close connections
5
Gripper jaws
6
Light sensor for "Gripper occupied” signal
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About this Product
Pneumatics
5.3.2
Connections on the Agilus robot
The Agilus robot is equipped with a total of 3 pneumatic valves (3/2-way valves), i.e. with 6 connectors. Two of these connections are for the gripper function
(opening and closing). The remaining connections can be used according to customer request.
Abb. 6: Pneumatic connections on the Agilus robot
Sensor system The Agilus robot is equipped with a sensor system connection.
Abb. 7: Sensor system connections on the Agilus robot
The following signals are transmitted via the connection X41:
• Gripper: End position open
• Gripper: End position closed
• Gripper occupied status
• Collision clutch status
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About this Product
Robotics Trainings System WS502
Connections on the base
1
2
3
All external connections of the Agilus robot are connected with the robot on the base.
4
Abb. 8: Connections on the base of the Agilus robot
1
2
Grounding cable to the base
Pneumatic supply
3
Signal line
4
Connection of the robot motor cables
Please refer to the manufacturer documentation for a complete description of the connections.
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About this Product
5.4
Cube rack
The WS502 training system is equipped with a sensor-monitored cube rack system for the "4Block" program included in the scope of delivery.
The racks on which the cube can be positioned are located on the base plate in the working area of the Agilus robot.
1
2 3
2
3
4
1 4
Abb. 9: Cube rack
Storage positions
1
Rack opening to the cube chute
2
Fork light sensor with connection cable
3
Rack with guide pins
4
Base frame made of aluminium profile
The storage positions assigned to the cube racks are each stated in the program.
The position names are also displayed on the hand control.
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About this Product
Robotics Trainings System WS502
1
5.5
Cube chute
The training system comes standard with the predefined "Rack” program.
Here the robot removes a cube from the attached mMS 4.0 expansion module and places it in the available cube rack. After 3 cubes are stored the remaining cubes are taken out of the mMS 4.0, unloaded through a hole in the base plate and collected on a chute.
2
Abb. 10: Cube chute
1
Cube chute
2
Rack opening to the cube chute
NOTE
Cube chute
The cube chute is not equipped with filling level detection. The system does not report when the chute is fully occupied.
Remove the cubes from the chute from time to time during ongoing training practices.
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About this Product
9
8
7
6
5.6
Control cabinet
The control cabinet is equipped with see-through Makrolon doors for training practices. In the control cabinet are the electrical supply unit, XM2200 control with
PROFINET extension modules and I/O extension module, the safety devices and additional safety devices and switching elements.
1 2 3 4
5
Abb. 11: Control cabinet
1
Power supply infeed
2
XM2200 controller with PROFINET extension module and I/O assemblies
3
Fuses
4
Switch
5
Safety devices for protective door and EMERGENCY-STOP
6
Series terminals
7
Power switch control
8
Power switch Agilus robot
9
Mains 230VAC for Agilus robot
NOTE
Agilus robot system mains connection
The 230VAC socket-outlet in the control cabinet may only be used for the supply of the Agilus robot system. Use for other external components is not permitted.
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About this Product
Robotics Trainings System WS502
1
2
3
4
5.6.1
Connection and controls on the control cabinet
On both sides of the WS502 training system control cabinet there are various connection elements and controls.
Connection elements and controls on the right-hand side
5
Abb. 12: Connection and controls on the control cabinet
1
Connector box VAC31 for hand control
VH2110
2
Illuminated pushbutton RESET (blue)
3
Ethernet connection
4
5
Main switch
Type plate
1. VAC31 connection module
2. RESET illuminated pushbutton
3. Ethernet interface
4. Main switch
Use the VAC31 connection module to connect the hand control VH2110 to the controller via cable.
The RESET (blue) illuminated pushbutton is used to execute various acknowledgements on the system. Whenever a state has to be acknowledged by the user the illuminated RESET pushbutton flashes; otherwise it is off.
The connection to the control cabinet-internal XM2200 control or the robot can be made through the Ethernet interface (RJ45).
The main switch is used to switch the power supply for the entire WS502 training system on or off.
Individual elements in the control cabinet are energized even when the main switch is switched off!
The power supply to the connected extension modules are not switched off through the main switch.
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About this Product
Connection elements on the left-hand side
The following connections are on the left side of the control cabinet:
• XS1: Connection for EMERGENCY-STOP and protective door circuit to the subsequent module
• XS2: Connection for EMERGENCY-STOP and protective door circuit to the predecessor module
NOTE
EMERGENCY-STOP and protective door circuit
When operating the WS502 training system without predecessor module such as the Bosch Rexroth mMS module or without a subsequent module, the jumper plugs included in the scope of supply must be installed.
To connect an expansion module:
Remove the jumper plug
Connect the connection cable to the expansion module
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About this Product
5.7
Pneumatic maintenance unit
Type key:
RD AS1-ACC-G014/R480320321
Robotics Trainings System WS502
1
2
3
4
Abb. 13: Maintenance unit
1
Maintenance unit
2
Connection input side
3
Cut-off valve
4
Connection output side
Abb. 14: Maintenance unit; pneumatic circuit diagram
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Technical data, Type plate
6 Technical data, Type plate
6.1
Technical data
Designation
Total weight training system
Dimensions
*(varies depending on the equipment variant)
Length max.
Width max.
Height max.
Min. operating temperature
Max. operating temperature
Installation site
Ambient temperature
Max. relative humidity
Max. site altitude
Pneumatics
°C
% m
Max. operating pressure bar mm
°C
°C
Unit kg mm mm
Supply
Min. operating pressure
Connection and operating voltage bar
V
Control voltage
Frequency
Rated power
Security
Protective ground
V
Hz kW
A
A-weighted continuous sound level
(at the workstation of the operating personnel during conveying) dB (A)
Tabelle 6:
Technical data on the WS502 training system
Value
260
1350
800
2000
+ 20
+ 60
Closed room
+ 10 to +25
90 at 20°C
1000 above sea level
8
6
230 AC
24 (DC)
50-60
2.5
16
PE (multiple protective earthing or
RCD protective switch)
< 70
30/64 Bosch Rexroth AG
Technical data, Type plate
Robotics Trainings System WS502
6.2
Identification of the WS502 training system
The type plate of the WS502 training system is located on the control cabinet of the system. In addition, the specific characteristics of the WS502 training system are also stated here.
Abb. 15: Type plate
The following information is needed on the type plate to identify the WS502 training system (e.g. for ordering spare parts):
• MATERIAL NO.: R901443001
• Type: TS-WS502-KUKA
Robotics Trainings System WS502 Bosch Rexroth AG 31/64
Operating and display elements
7 Operating and display elements
7.1
EMERGENCY STOP button
On the front and on the left and right side of the training system an
EMERGENCY-STOP button is attached.
Abb. 16: EMERGENCY STOP button on the training system
Additional EMERGENCY STOP buttons are located on the Bosch Rexroth
VH2110 mobile panel and the KUKA smartPAD.
Abb. 17: EMERGENCY STOP button on the mobile panel
CAUTION
EMERGENCY STOP button function on the hand controls
The EMERGENCY STOP button on the hand controls is only effective if it is connected to the system with its cable connection!
Always connect the Bosch Rexroth VH2110 hand control to the training system.
Remove the KUKA smartPAD from the training system installation site when it is not connected.
In the event of danger to persons and the machine, you can shutdown the WS502 training system by pressing one of these buttons.
Triggering the EMERGENCY-STOP button stops the movement of the robot. All processes are stopped immediately and hazardous currents are switched off.
Pressing the EMERGENCY stop button also stops any connected expansion modules. However, the mains voltage is still applied in the control cabinet!
Do not use the EMERGENCY-STOP button for normal training system shutdown!
32/64 Bosch Rexroth AG
Operating and display elements
Robotics Trainings System WS502
Prerequisites
1
2
3
7.2
Hand control VH2110
All process and setup functions of the training system can be run with the help of the VH2110 hand control. All control functions, operating modes, setting parameters and operator messages are shown on the display. Operator inputs can be conveniently made on the membrane keyboard.
An EMERGENCY STOP can be made when the VH2110 with the EMERGENCY-
STOP button (1) is connected.
Please refer to the product documentation for a detailed description of the
VH2110 hand control.
To use it, the hand control must
• be connected through a VAC 31 connecting unit,
• have had the correct VI composer installed,
• be connected with the basic module.
Always connect the hand control to the WS502 training system!
Never remove the hand control during operation! As long as not in use, hang the hand control in its mount.
5
4
Abb. 18: Hand control VH2110
1
EMERGENCY STOP button
2
OVERRIDE speed controller
3
Display with touch function
4
5
Connection line connection
Confirm button
The confirm button (5) is not needed for the operation of the WS502 training system and has no function.
Robotics Trainings System WS502 Bosch Rexroth AG 33/64
Operating and display elements
7.3
smartPAD hand control
The scope of delivery of the WS502 training system includes the smartPAD hand control. With the help of the smartPAD, different operating and setup functions of the Agilus robot can be executed.
It is not required for standard operation of the WS502 training system.
CAUTION
EMERGENCY STOP button function on the hand controls
The EMERGENCY STOP button on the hand controls is only effective if it is connected to the system with its cable connection!
Always connect the Bosch Rexroth VH2110 hand control to the training system.
Remove the smartPAD from the training system installation site when it is not connected.
Please refer to the manufacturer documentation for a detailed description of the smartPAD.
7.4
Signal tower
The training system is equipped with a signal tower that displays the status of the system.
Display colours and their meaning
Green: System is ready for operation
Yellow: No function
Red: A component of the system is defective
34/64 Bosch Rexroth AG
Transport and storage
Robotics Trainings System WS502
8 Transport and storage
Required tools:
Procedure
8.1
Delivery and unpacking
Screwdriver/cordless screwdriver, knife
CAUTION
Tipping hazard of the WS502 training system! It is possible that the centre of gravity is off-centre; the centre of gravity shifts depending on the attachments!
Risk of injury when lifting and transporting!
Secure the training system when lifting and transporting in order to prevent tipping.
Lift the WS502 training system only with a forklift truck or lift truck.
Transport the wooden crate upright using a forklift truck or lift truck to the unpacking space.
Use a screwdriver/cordless screwdriver to unscrew the front side of the wooden crate and put it to the side.
Carefully open the plastic packing with the knife.
Lift the WS502 training system carefully off the pallet with a forklift and take it out of the box.
Remove cable ties and adhesive tape carefully and dispose of them properly.
Discard the pallet and the wooden crate properly or properly store them for later storage.
8.1.1
Make the gripper ready for operation
Secure the gripper against falling during transport.
Remove the packaging and transport locks from the gripper
Make sure that the gripper with the clutch is correctly mounted in the coupler
mechanism (for assembly instructions see chapter 10.14 on page 48).
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Transport and storage
1
2
8.1.2
Assembling the VH2110 hand control
The VH2110 hand control is supplied in a separate box with the connection cable and bracket. To mount the VH2110 manual control panel on the WS502 training system proceed as follows:
Install the bracket at operating height to the vertical frame construction of the cell.
Abb. 19: Mounting the holder for the VH2110 manual control panel
Hang the VH2110 manual control in the holder
Unscrew the cap from the VAC31 connector module
Connect the connection cable of the VH2110 manual operating panels to the connection module
Abb. 20: VAC31 connection module
The WS502 training system can now be brought to its deployment location.
Immediately note down any transport damage and defects and report them in writing with a damage report.
36/64 Bosch Rexroth AG
Transport and storage
Robotics Trainings System WS502
8.2
Transport
General
Transport
8.2.1
Transport within a building
Note during transport:
Make sure the doors and entrances are sufficiently wide.
Remove attachments and sets that are not required beforehand.
Transport the WS502 training system only with a pallet truck or forklift.
Do not transport any other objects or persons together with the WS502 training system.
Perform the following steps:
Turn the main switch on the control cabinet to the "OFF" position.
Remove the plug from the power socket and store the mains cable.
Disconnect the cables connected to the hand control on the connection module.
Remove the compressed air supply.
CAUTION
Tipping hazard of the WS502 training system! It is possible that the centre of gravity is off-centre; the centre of gravity shifts depending on the attachments!
Risk of injury when lifting and transporting!
Secure the training system when lifting and transporting in order to prevent tipping.
Lift the WS502 training system only with a forklift truck or lift truck.
Transport the WS502 training system to the new space.
General
Transport
8.2.2
Transportation between two buildings
Note during transport:
Make sure the doors and entrances are sufficiently wide.
Remove attachments and sets that are not required beforehand.
Transport the training system only with a pallet truck or forklift.
Do not transport any other objects or persons together with the WS502 training system.
Perform the following steps:
Turn the main switch on the control cabinet to the "OFF" position.
Remove the plug from the power socket and store the mains cable.
Disconnect the cables connected to the hand control on the connection module.
Remove the compressed air supply.
Robotics Trainings System WS502 Bosch Rexroth AG 37/64
Transport and storage
CAUTION
Tipping hazard of the WS502 training system! It is possible that the centre of gravity is off-centre; the centre of gravity shifts depending on the attachments!
Risk of injury when lifting and transporting!
Secure the training system when lifting and transporting in order to prevent tipping.
Lift the WS502 training system only with a forklift truck or lift truck.
To transport the WS502 training system:
Put the WS502 training system on a pallet with the forklift.
Secure the WS502 training system with belts or non-metallic straps against falling down; you may use the original shipping box.
Protect the WS502 training system against wetness (e.g. rain).
Use the forklift to transport the pallet together with the
WS502 training system.
Set the WS502 training system on a firm and level surface.
Carefully lift the WS502 training system at the intended location using the forklift out of the transport crate or down from the pallet.
Remove any packaging and restraints with the belts and non-metallic straps.
8.3
Storage
Designation
Floor space of the WS502 training system
Quality of the floor space
Min. storage temperature
Max. storage temperature
Relative humidity
Unit
M
°C
°C
%
Value
Approx. 0.70 x 1.50
Level, horizontal
-10
+50
25 - 70, noncondensing
Max. site altitude m 1000 above sea level
Tabelle 7:
Storage conditions
Requirements for the storage of the training system:
Make the training system is fit for transport as described above
Protect the WS502 training system against dust and moisture.
The WS502 training system can now be stored.
38/64 Bosch Rexroth AG
Assembly, installation and commissioning
Robotics Trainings System WS502
9 Assembly, installation and commissioning
Preparations for assembly
Assembly
9.1
Assembling the WS502 training system
CAUTION
Danger due to irregularities, deviations, faults, defects during assembly or testing!
Risk of damage!
Do not put the WS502 training system into operation, i.e. take it out of service immediately.
Investigate the cause and repair the defects.
Replace the defective component.
Proper assembly requires that:
• the delivery, transport and unpacking are done correctly in accordance with
• all the necessary components are within reach and are in good condition,
• required auxiliary equipment such as lifting equipment, ladders and steps as well as barriers are present.
Note the following points before final assembly:
Make sure there is sufficient space for the WS502 training system and that there are sufficient clearances to other permanent fixtures (for corresponding
specifications seeAbb. 1: WS502 training system ). Also take any possible
supplementary attachments into consideration.
Check the flatness of the floor space and if necessary rework the surface or choose a different installation location.
Make sure that an electrical connection is available.
Ensure sufficient lighting conditions at the installation location.
During assembly please note the following:
Adjust the legs of the training system so that it does not tip over.
Check the alignment of the WS502 training system at installation location
(water level)
If necessary correct the horizontal alignment by adjusting the legs.
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Assembly, installation and commissioning
Connection
9.2
Check and connect the pneumatic supply
The WS502 training system is shipped completely assembled and factory tested.
However, defects or damage to the WS502 training system could possibly be caused during transport.
For that reason, before commissioning the pneumatic system always check
• the hosing for damage;
• for the proper fit of the hose couplings;
• to see if any components are damaged;
• if all the parts are properly connected;
Connect the maintenance unit to the compressed air supply. For proper operation a pressure of at least 6 bar is required.
Prerequisites
9.3
Check and connect the electrical installation
The requirements for installing the WS502 training system are
•
• the mains voltage and fusing to the customer power supply is correct,
• only trained electricians perform the work on the electrical equipment of the training system,
• no cables are damaged,
• the connection cable is routed so that it cannot be crushed, overrun, bent, clamped or concealed.
Check for correct and sufficient electrical protection.
Connect the power plug to the customer’s supply voltage socket-outlet (230V
AC). Operate the training system WS502 only on an electrical grid with an operational residual current operated circuit breaker (RCCB) or protective grounding.
The electrical supply of the WS502 training system is established.
40/64 Bosch Rexroth AG
Operation of the training system
Robotics Trainings System WS502
10 Operation of the training system
Prerequisites:
How to proceed when switching on:
10.1
Switching on the training system
• The electrical supply and installation is correct.
• A function test has been performed.
• There are no tools, cleaning rags or other objects on the WS502 training system.
• Accessibility and the functioning of the EMERGENCY STOP button are guaranteed.
Assess every exercise setup:
–
–
Reliability,
Protection against injury.
Depending on the operating condition, before switching on check the following:
Ensure that the power plug for the power supply of the WS502 training system is plugged in.
If applicable, unlock all EMERGENCY-STOP buttons.
Turn the main switch of the training system to the ON position.
The control system starts. The illuminated RESET (blue) pushbutton on the control cabinet flashes.
Press the illuminated RESET pushbutton.
A message is displayed on the robot system’s hand control.
Press the Reset/Abort button on the display.
The message "Start Robot Auto External” is displayed.
Press the Start Auto External button
10.2
Setting the robot speed
In order to reduce the speed, turn the speed control override (1) counterclockwise.
In order to increase the speed, turn the speed control override clockwise.
Set to the lowest speed setting of the robot. Turn the speed override counterclockwise until it stops and then one stage in the clockwise direction.
1
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Operation of the training system
10.3
Predefined robot programs
The WS502 training system comes standard with two predefined robot programs.
“4Block”: transfers three cubes to 4 cube racks
“Rack”: removes a cube from the attached mMS 4.0 expansion module and places it in the available cube rack. After 3 cubes are stored, the remaining cubes are taken out of the mMS 4.0, unloaded through a hole in the base plate and collected on a chute.
10.4
Adjustment of the zero position on the mounted mMS
4.0
If you want to run the WS502 training system with the mMS 4.0, check first to see whether the set positions for operating the rack match the end customer’s existing system.
To check the conformity of the positions of the WS502 training system proceed as follows:
Install the mMS 4.0 on the WS502 training system (see chapter 11.6 on page
Press the Automatic button
Press the Rack button
Set the speed override to low speed (see chapter, 10.2 page 40).
Press the Automatic Start button
The robot program starts and the robot moves to the position before the first storage location in the rack.
Before the robot enters the rack:
Set the speed override to zero
Check the horizontal and vertical position of the gripper in relation to the cube in the storage space
42/64 Bosch Rexroth AG
Operation of the training system
Robotics Trainings System WS502
10.4.1
Correction of the horizontal and vertical zero position
Proceed as follows to correct the position:
Press the Manual button
Press the MoveTypJog button
Set the speed override to minimum speed
Select the X-axis in the desired direction (+ / -)
Press and hold the Jog Enable button until the gripper reaches the desired Xposition, if necessary correct in the reverse direction
Select the Z-axis in the desired direction (+ / -)
Press and hold the Jog Enable button until the gripper reaches the desired Zposition, if necessary correct in the reverse direction
10.4.2
Save the new zero position
Proceed as follows to save the position:
Tap in the “Index” section on the entered number
Enter the number “20”
Press the Touch Up button
The "Confirm?" dialogue box opens.
Click the "Yes" button to save the data.
The position data are stored under the index number.
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Operation of the training system
10.5
Selecting the operating mode and program
The message "Select Operation Mode" is displayed.
Press the Automatic button
Press the 4Block button to activate the "4Block” program.
Press the Rack button to activate the "Rack” program.
The “Rack” program can only be executed if the Bosch Rexroth mMS 4.0 is installed.
It is necessary that the mMS module of the first digital output is set to the WS502 training system. This is to prevent that the robot and handling of the mMS 4.0 intervene in the rack at the same time.
The Automatic Start button flashes.
10.6
Start the program
Proceed as follows to start the selected program:
Check the set speed and reduce it if necessary
Press the Automatic Start button.
The program starts.
After ensuring that during the program run no collisions or problems arise, the speed of the robot can be increased step by step.
10.7
Program stop (stop cycle)
Proceed as follows to stop the running program:
Press the Automatic Stop button
The current movement cycle will be completed. The program will then be stopped.
10.8
Stop movement
To stop the movement of the robot without stopping the current program proceed as follows:
Turn the speed override control counter-clockwise to the limit.
The movement of the robot stops. This message will appear on the display:
44/64 Bosch Rexroth AG
Operation of the training system
Robotics Trainings System WS502
10.9
Stop movement (immediate stop)
Proceed as follows to immediately stop the running program:
Press the Reset/Abort button
The program sequence is stopped immediately.
After a program abort the robot is typically not in the home position. This message will appear on the display:
10.10
Perform home position run
In the as delivered condition, the home position of the robot (home position) is stored in the position coordinate with the index number "0".
Proceed as follows to put the robot into home position:
Press the Manual button to switch to manual mode
Press the MoveTypPos button
Tap the number below the "Index” entry:
The input window opens.
Enter the number “0”
Press the button
Robotics Trainings System WS502 Bosch Rexroth AG 45/64
Operation of the training system
CAUTION
Obstacles in the area of movement of the robot!
Risk of damage to components!
First move the robot gripper manually to a position from which the desired position can be safely approached.
Before you perform an automatic movement of the robot ensure that the range of movement is free of obstruction.
Press the EXECUTE button
The robot moves to the coordinates stored in Position
Index "0" (as delivered condition: home position coordinates).
10.11
Move the robot in jog mode
CAUTION
Obstacles in the area of movement of the robot!
The robot has no range limit. In manual mode there is the risk of damage to components.
Before you perform a movement of the robot ensure that the range of movement is free of obstruction.
Make the movements carefully and at low speed.
Proceed as follows to move the robot in jog mode:
Press the Manual button to switch to manual mode
46/64 Bosch Rexroth AG
Operation of the training system
Robotics Trainings System WS502
Press the MoveTypJog button.
Press the World button to select the global coordinate system.
Select the desired direction (+ / -) for the movement directions X, Y, Z, A, B,
C.
Check the set speed and reduce it if necessary
Press and hold the Jog Enable button.
The robot moves the selected axes.
Let go of the Jog Enable button to stop the movement.
Optionally, you can also select the axis coordinate system:
Press the Axis button.
The further procedure is identical.
10.12
Saving the current robot position
The current position of the robot can be stored on a position index number.
Proceed as follows to save the current position of the robot:
Move the robot to the desired position
Tap the number below the "Index” entry
The input window opens.
Enter the index number under which the position will be stored
Press the button
Press the Touch Up button
The "Confirm?" dialogue box opens.
Click the "Yes" button to save the data.
The position data are stored under the index number.
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Operation of the training system
10.13
Open / close gripper
The gripper can only be opened or closed in manual mode.
To open the gripper of the robot manually, proceed as follows:
In the main screen:
Press the Manual button in the
OperationMode section
Press the “Open” button in the Gripper section
The gripper opens.
To manually close the gripper of the robot proceed as follows:
In the main screen:
Press the “Close” button in the Gripper section
The gripper closes.
48/64 Bosch Rexroth AG
Operation of the training system
Robotics Trainings System WS502
1
2
10.14
Restore operational readiness after gripper collision
During movements of the robot in manual mode there may be collisions of the gripper with attachments or the cell. This triggers the gripper coupling which holds the gripper in place with the help of 4 spring-actuated balls. The sensor on the gripper coupling signals to the control system that the gripper is not correctly mounted. The system is stopped. The red indicator light on the signal tower flashes.
To restart the system after a gripper collision proceed as follows:
Check the set speed and reduce it if necessary
Press and hold the illuminated RESET pushbutton on the control cabinet
Move the gripper free in jog mode (for jog mode description see above)
Install the gripper correctly again:
–
–
–
The control pin must point into the direction of the position sensor
The 4 spring-loaded ball tensioners must mesh in the groove of the coupling
The indicator light of the position sensor must be lit
3
Abb. 21: Gripper coupling
1
Coupling mount
2
Spring-loaded ball tensioner (total of 4 units)
3
Coupling slot
4 5 6
4
Control pin for sensor
5
Position sensor for "Collision clutch engaged” signal
6
Illuminated position sensor lamp
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Operation of the training system
10.15
Reset the set position points to the as delivered condition
To reset position points to the as delivered condition proceed as follows:
In the main screen:
Press the Position Screen button.
The position data screen opens.
Press the Setup Screen button.
The Setup screen opens.
Press the Restore button.
The data is displayed in the as delivered condition.
10.16
Switch off the training system
Proceed as follows to switch off the training system.
In the main screen:
Press the Automatic Stop button to stop the automatic program
Wait until the robot is at a standstill.
Turn the main switch to the "0 - Off" position.
The Bosch Rexroth control is immediately switched off.
The robot system is shut down through an uninterruptible power supply (UPS) and then turned off.
After the cooling fan on the robot control cabinet has been switched off wait approx. 30 seconds before switching on again.
50/64 Bosch Rexroth AG
Description of the user interface
Robotics Trainings System WS502
11 Description of the user interface
11.1
Main screen
The system user interface is displayed on the VH2110 control panel. After the system is started up the main menu of the training system appears on the display of the control panel.
Abb. 22: Main screen
Sections of the main screen
Gripper:
Open:
Close:
Opens the gripper in manual mode
Closes the gripper in manual mode
Button is grey: limit switch not reached yet
Button is green: limit switch reached
Part detected: indicates if a part is detected in the gripper
Robot:
Ready:
Run:
Override:
Operation Mode:
Green: robot is ready for operation
Red: robot is not ready for operation
Grey: robot is not in Run mode
Green: robot is in Run mode
StartAutoExternal: button to start the robot in the AutoExternal operating mode to
(normal automatic operating mode of the robot)
Display of the currently set speed value for the robot in %
Automatic:
Manual:
Button for selection of the automatic operating mode
Button for selection of the manual operating mode
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Description of the user interface
Automatic Mode:
4Block:
Rack:
Button for selection of the “4Block" program
Button for selection of the “Rack" program
Automatic Start: Button to start the automatic mode
Automatic Stop: Button to stop the automatic mode (cycle stop)
Part Pos1-4: Busy indicator for the 4 racks of the "4Block” program
Manual Mode:
MoveTypPos: Selects the “Move top position…” type of movement. During this, the position shown in the coordinates X, Y, Z, A, B, C (axis coordinates: 1 to 6) is approached
Index:
TouchUp:
S:
T:
Execute:
Shows the currently selected index number.
The coordinates of a location can be stored under this number.
Use "Execute" to move the robot to this position.
Button to save the currently displayed position in the currently displayed index number.
Status (for explanations see the KUKA manufacturer documentation)
Turn (for explanations see the KUKA manufacturer documentation)
Button to start the movement
CAUTION
Obstacles in the area of movement of the robot!
Risk of damage to components! The robot has no range limit. In manual mode there is the risk of damage to components.
Before you perform a movement of the robot ensure that the range of movement is free of obstruction.
Make the movements carefully and at low speed.
MoveTypJog: Selects the jog operating mode. Here, the axes selected by the operator are moved in the desired direction as long as the Jog
Enable button is pressed.
Axis:
World:
Button for selecting the axis coordinate system; display of the rotary axes 1 to 6 with position data
Button for selection of the global coordinate system; display for the axis coordinates X, Y, Z, A, B, C.
Jog Enable:
Reset/Abort:
Button to start the jog motion
Button with the following functions:
• Reset the robot system (e.g. after a restart of the training system)
• Abort the running program in automatic mode
Display box:
Position screen:
Text display for instructions and error messages
Main menu function buttons:
Opens the position data operating screen
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Description of the user interface
Robotics Trainings System WS502
11.2
Position data screen
Pressing the "position screen" button in the main screen opens the position data control screen. It shows a list of the stored position data.
Abb. 23: Position data screen
11.2.1
Structure of a position data record
Index:
X, Y, Z, A, B, C:
Name:
S:
T:
LIN:
Cont.:
Done:
InPos:
Reset/Abort:
Number of each stored position
Shows the current position of the robot in the global coordinate system
The name of the position (e.g. home position)
Status (for explanations see the KUKA manufacturer documentation)
Turn (for explanations see the KUKA manufacturer documentation)
1: The robot performs a linear movement
0: The robot moves as fast as possible to the specified target position
1: The robot rounds the individual points of a movement that has multiple points
0: The robot approaches each point, briefly stops and then continues
Green: Movement command to approach the position point was transmitted by the Bosch Rexroth control to the robot controller
Red: No movement command sent
Green: The robot has reached the position
Red: The robot is not at the position
Button with the following functions:
• Reset the robot system (e.g. after a restart of the training system)
• Abort the running program in automatic mode
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Description of the user interface
Display box: Text display for instructions and error messages
Main menu function buttons:
Main Screen:
Setup screen:
Displays the main screen
Opens the setup screen
11.2.2
Changing a position data record
A list with all existing position records is shown in the position data screen.
Abb. 24: Position data record (excerpt)
To change individual pieces of data in a position data record proceed as follows:
Example: You want to change the term "Rack Position Y0 Z0" of position index
20:
Tap the “Rack Position Y0 Z0” text entry
The following screen keyboard opens.
Abb. 25: Screen keyboard
Enter the desired name/value in the input box
Press the button
Press the entered values to adapt all data of the position data.
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Description of the user interface
Robotics Trainings System WS502
11.3
Setup screen
Press "position screen" button in the main screen and click on the "setup screen" button in the position data screen to open the setup screen.
Abb. 26: Setup screen
PositionData:
Save:
Load:
Restore: condition
Saves all position data in the system
Loads saved position data
Resets the position data and offsets to the as delivered
Rack Turn Overview:
The Rack Turn Overview section displays the storage locations of the Bosch
Rexroth mMS 4.0 (from 0/0 to 2/4). In order to service a location (position gripper in front of storage position, move into the storage position, close gripper, move out of the storage position), Positions 23, 24, 25, and 26 were stored in the system. The Turn value is displayed for each of these positions (for explanations on Turn see the KUKA manufacturer documentation).
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Description of the user interface
11.4
Description of the coordinate system
The X and Y direction coordinates are specified as follows:
X -
Y - Y +
X +
11.5
mMS 4.0 attachment
Additional stations can be attached to the WS502 training system and thus connected to the training system.
The back of the training system is equipped with two sliding doors where the
Bosch Rexroth training system mMS 4.0 (R901423235), which is not included in the scope of delivery, can be attached.
Abb. 27: mMS 4.0 training system
NOTE
Operation with mMS 4.0
The operation of the WS502 training system is possible either with an attached mMS 4.0 or with the sliding door closed.
The scope of delivery of the WS502 training system includes attachments for the detection and mounting of the mMS 4.0 to the training system.
Before operation:
Mount the door switch actuation attachment group to the mMS as described
Secure the mMS with the connection elements to the WS502 training system
as described in chapter 11.6 on page 56.
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Description of the user interface
Robotics Trainings System WS502
11.6
Connect the Bosch Rexroth mMS 4.0 with the WS502 training system
11.6.1
Modification of an existing mMS 4.0 for use with the WS502 training system
Mount the Bosch Rexroth mMS 4.0 on the rear of the training system. On the rear there is a sliding door for intervention into the storage module by the robot. For the operation of the training system either the sliding door is closed or the mMS
4.0 must be installed.
The query of the protective door or the mMS 4.0 is via an electrosensitive
EMERGENCY-STOP switch.
To be able to use an existing mMS 4.0, the actuator with bracket (1), which is included in the scope of the WS502 training system, must be retrofit to the mMS
4.0.
This is done as follows:
Install the bracket using the bolts and slide blocks on the right-hand vertical frame of the mMS system 4.0.
1
Abb. 28: Actuator on the training system mMS 4.0
2
Push the mMS 4.0 system and the WS502 training system together.
Make sure that the actuator is flush with the door switch on the WS502 training system.
3
Robotics Trainings System WS502 Bosch Rexroth AG 57/64
Description of the user interface
11.6.2
Connect the mMS 4.0 with the training system
Mount the Bosch Rexroth mMS 4.0 on the rear of the training system. On the rear there is a sliding door for intervention into the mMS 4.0 by the robot.
To attach the Bosch Rexroth mMS 4.0 to the training system proceed as follows:
Remove the mounting bolt from the left sliding door left (as viewed from the rear of the system)
Open the sliding door.
Place the mMS system 4.0 and the training system together so that the frame parts on the left side are flush.
Abb. 29: Locking of left side sliding door
Connect the frame elements to the left rear below the worktop and on the vertical frame of the training system with a retaining bracket (1)
Abb. 30: Connection left side
Connect the frame elements on upper rear right with a second retaining bracket.
Abb. 31: Connection right side
Connect the supplied connection cable for EMERGENCY-STOP and I/O signals to the XS2 interface on the control cabinet.
Connect the connecting cable to the mMS 4.0.
The release bit for intervention of the robot must be set by the mMS 4.0 in order to avoid collisions (see mMS documentation).
1
58/64 Bosch Rexroth AG
Description of the user interface
Robotics Trainings System WS502
Connect the frame elements on upper rear right with a second mounting bracket.
The WS502 training system can now be operated with the mMS 4.0.
Robotics Trainings System WS502 Bosch Rexroth AG 59/64
Help in case of faults
12 Help in case of faults
System fault messages are displayed in plain text on the VH2110 hand control.
During faults, the red lamp on the signal tower flashes continuously.
In case of faults in the Agilus robot system:
Connect the KUKA smartPAD hand control to the robot system.
Run the fault diagnostics with the aid of the manufacturer documentation.
If the causes of a fault cannot be detected and eliminated get in touch with the responsible Bosch Rexroth Customer Service. www.boschrexroth.com/training
13 Service and inspection
This chapter covers the service and inspection work that may be performed by personnel trained on the WS502 training system.
Maintenance and inspection work that can only be performed by specifically
trained and qualified personnel are described in chapter 14.
13.1
General information
• Report any defects immediately to the competent supervisors so that they can be repaired quickly. Please note that small defects can lead to major defects if they are not resolved in a timely manner.
• Clean the plastic components exclusively with a slightly damp cloth. Only use water and a mild detergent without chemical additives. Never use solvents or aggressive cleaning agents.
Before you use a cleaning agent find out about the usability and possible hazards based on the user notes and the DIN safety data sheet.
• Never blow out the training system with compressed air as the sensors and valves of the function modules can be damaged.
• Protect the training system against dust and humidity so that it does not get dirty and so that you can use it for a long time.
60/64 Bosch Rexroth AG
Service and inspection
Robotics Trainings System WS502
13.2
Service and inspection plan
The following table lists the jobs, first by the service intervals and then by assemblies/components. Maintaining the intervals is mandatory.
When?
Daily/ before each use
Weekly
What?
Total training system
Total training system
Total training system
Connection elements
Connection elements
Where?
Environment of the training system,
Work areas
Protective enclosure
Comments
Remove parts that are lying around
Check the electrical connection cables and lines for visible damage (chafing, cracks, cuts).
Check electrical devices, switchboxes and switches/buttons for visible damage
Visual inspection for damage and check for tight fit
Check for completeness, damage and correct assembly
Have the damages immediately repaired by the competent electrician
Have the damages immediately repaired by the competent electrician
Retighten loose screws, etc.
Have damages repaired immediately!
Inform Bosch
Rexroth Customer
Service.
Tabelle 8:
Maintenance and checking work on Agilus
Robotics Trainings System WS502 Bosch Rexroth AG 61/64
Maintenance work
14 Maintenance work
14.1
General information
Poor maintenance causes
• faults,
• possibly failure and
• high repair costs.
If during operation or testing irregularities, deviations, faults or wear is noted, adhere to the following in all cases:
Immediately take the training system out of operation.
Investigate the cause and repair the defects.
Replace the defective component.
Do not put the WS502 training system back into operation.
14.2
Maintenance schedule
Tabelle 9:
When?
Daily/ before each use
The following table lists the jobs, first by the maintenance intervals and then by assemblies/components. Maintain the intervals.
What? Where? Comments
EMERGENCY OFF button
Check functioning.
Check effect when pressing; no start-up during unlocking
In case of malfunction:
Put the system into standstill.
Inform a qualified electrician!
Weekly Control cabinet Check all functions: fuses, RCD protection socket-outlets buttons
If necessary, arrange for the replacement of defective parts.
Replacement only by qualified electricians!
Monthly or as necessary
Cleaning Light barriers, cube storage, control sensor robot gripper
Clean with a slightly damp cloth.
In line with the company rules
The entire electrical installation
Is the protective conductor test valid?
Is it marked?
Testing only by a trained electrician!
WS502 training system maintenance schedule
Auxiliary equipment
14.2.1
Operating materials, auxiliary materials, tools, measuring instruments
The following are required to work on the WS502 training system:
• Protective work clothing according to regulations
• Cleaning and care products: cleaning cloths
• Test and maintenance log, writing device
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Disposal
Robotics Trainings System WS502
Tools • 1 set of open-ended spanners
• 1 set of hex sockets
• 1 set of screwdrivers
14.2.2
Replacing parts
Use only genuine original spare parts.
When ordering spare parts always state the device type, material number, year of manufacture and part description.
Please contact Bosch Rexroth Customer Service.
The address and contact details can be found on the back of these operating instructions. www.boschrexroth.com/training
Immediately repair wear on the WS502 training system if
–
–
Work safety and functions do not exist
Consequential damages are to be expected
If elements are damaged, check to see if the wear limit is reached and decide if replacement is needed immediately or only during the next maintenance.
Repair wear only if
–
– the WS502 training system is located at a site that is safe for the personnel and there is no risk to health (falling down, slippery due to moisture, etc.).
After you have repaired the wear and before starting up, have a qualified specialist check that
–
– the job(s) was/were properly executed and the WS502 training system is fully operational.
15 Disposal
The training system consists of materials which can be recycled and re-used.
Specialized companies can recycle this training system to extract recyclable material and minimise the quantity of materials that need to be discarded.
Dispose of the training system according to the local and statutory provisions.
Water-polluting substances such as cleaning agents containing solvents must not get into the soil or the sewerage system.
Operating and auxiliary materials must be kept stored, transported, collected and disposed of in appropriate containers in accordance with the statutory provisions.
In case of doubt get information about the type of storage and disposal from the respective material manufacturer or material supplier.
Robotics Trainings System WS502 Bosch Rexroth AG 63/64
EC – Declaration of Conformity
16
EC – Declaration of Conformity
As per Machinery Directive 2006/42/EEC
As per Low Voltage Directive 2014/35/EC
As per EMC Directive 2014/30/EU
DOC no.: D16060101
The manufacturer herewith declares
Fritz Automation GmbH
Sägmühlstr. 1
76596 Forbach
Bosch Rexroth AG
Drive & Control Academy
Bahnhofplatz 2
D-97070 Würzburg, Germany
Fax: 09352 18 6882 [email protected] www.boschrexroth.com\training that the following product
Description:
Model:
Agilus Training System SM20
TS-WS-502-KUKA
Type:
Serial number:
Year built:
R901441001
AU15080301
2016 was developed, designed and manufactured in conformity with the above-mentioned EU directives.
Applied standards
DIN EN 349:2008-09
DIN EN 1037:2008-11
Safety of machinery - Minimum gaps to avoid crushing of parts of the human body; German version EN 349:1993+A1:2008
Safety of machinery - Prevention of unexpected start-up; German version EN
1037:1995+A1:2008
Safety of machinery - Electrical equipment of machines - Part 1: General requirements DIN EN 60204
DIN EN ISO 10218
EN ISO 12100
EN ISO 13849-1
Robots and robotic devices - Safety requirements for industrial robots
Safety of machinery - General principles for design
Safety of machinery - Safety-related parts of control systems
EN ISO 13849-2 Safety of machinery - Safety-related parts of control systems - Validation
DIN EN ISO 13850:2008-09 Safety of machinery - Emergency stop - Principles for design (ISO 13850:2006); German version EN ISO 13850:2008
ISO 14120:2002-02 Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards
DIN EN ISO 4414:2011-04 Pneumatic fluid power - General rules and safety requirements for systems and their components
The manufacturer undertakes to electronically transfer the special documentation for the machine to national authorities in response to a duly substantiated request. The technical documents belonging to the machine according to annex VII part A were created.
Name of the person responsible for documentation: Gunther Arntz
Address of the person authorised to compile the technical documentation: Sägmühlstraße 1, 76596 Forbach
Forbach, 01.06.16 Horst Fritz, Managing Director
Changes in the content of the declaration of conformity are reserved. The currently valid edition is available on request.
64/64 Bosch Rexroth AG
EC – Declaration of Conformity
Robotics Trainings System WS502
Bosch Rexroth AG
Drive & Control Academy
Bahnhofplatz 2
97070 Würzburg, Germany
Phone: +49 9352 18-1920
Fax: +49 9352 18-1040 eMail: [email protected]
www.boschrexroth.com/training
R901508696 (Version 01-01 EN)
© Bosch Rexroth AG 2019
Subject to change.
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