STE 58761 INSTRUCTION MANUAL INDUSTRIAL ROBOT SR SERIES OPERATING MANUAL Notice 1. Make sure that this Instruction Manual is delivered to the final user of the Toshiba Industrial Robot. 2. Please read this manual before installing or operating the Toshiba Industrial Robot, and keep the manual nearby for further reference during use of the robot. TOSHIBA MACHINE CO.,LTD.
STE 58761 Copyright 1997 by Toshiba Machine Co., Ltd. All rights reserved. No part of this document may be reproduced in any form without obtaining prior written permission from the Toshiba Machine Co., Ltd. The information contained in this manual is subject to change without notice.
STE 58761 PREFACE This Manual describes how to utilize various robot system functions in order to manually guide the robot with the teach pendant, edit programs, compile data and carry out automatic operation. This manual is directed at the robot operator. Before reading this manual, he or she should first read the Introductory Manual and the Start-up Manual.
STE 58761 NOTE! FOR EUROPEAN UNION (EU) In the European Union (EU), there are following limitations and notes to approve the CE Marking EMC Direction. In other countries and areas, it is not necessary to apply to these limitations and notes. (1) Setup conditions ◆ The following type of power line transformer must be used. Frequency: 50 or 60 Hz Secondary voltage: 3-phase, 200~230 VAC Power capacity: Min. 2.
STE 58761 (6) Limitation on the robot specifications ◆ Cable length from robot to controller: ◆ Cable length of teach pendant: ◆ Optional axis 5: ◆ Optional input/output signals (type; SR-5500IO): ◆ Optional relay output signals (type; SR-5500RO): ◆ Optional conveyer tracking system (type; SR-5500CV): ◆ Separated operation panel: - iv - Max. 8 m Max. 8 m Can not be used. Only one optional board can be used. Can not be used. Can not be used. Can not be used.
STE 58761 This Manual describes how to utilize various robot system functions in order to manually guide the robot with the teach pendant, edit programs, compile data and carry out automatic operation. This manual is directed at the robot operator. Before reading this manual, he or she should first read the Introductory Manual and the Start-up Manual.
STE 58761 Cautions on Safety This manual contains the important information on the robot and controller to prevent injury to the operators and persons nearby, to prevent damage to assets and to ensure correct use. Make sure that the following details (indications and symbols) are well understood before reading this manual. Always observe the information that is noted.
STE 58761 [Operation] ! Danger • During operation, NEVER enter the dangerous area of the robot. Otherwise, you will be injured seriously. • DO NOT leave in the working range any machinery or materials which will hinder the operation. If the equipment went wrong, a person nearby will be injured or involved in an accident. • Anyone other than the operator MUST NOT approach the equipment.
STE 58761 ! • DO NOT change the data of the system structure file. Otherwise, the robot will operate abnormally, resulting in damage or an accident. • In principle, teaching operation should be performed outside the dangerous area of the robot. If it should be performed inevitably within the dangerous area, strictly observe the following matters. Prohibited ! Mandatory Caution (1) The teaching operation should be always performed by two (2) persons.
STE 58761 ! • ! Caution Before operating the equipment, perform the following inspection. (1) Make sure that visual appearance of the robot, controller, peripheral equipment and cables is in good condition. (2) Make sure that no obstacle stands in or near the operating range of the robot and peripheral equipment. (3) Make sure that the emergency stop and other safety devices operate properly. (4) Make sure that no abnormal noise or vibration is involved in the robot operation.
STE 58761 TABLE OF CONTENTS CHAPTER 1 BEFORE OPERATING YOUR ROBOT 1.1 OVERVIEW OF CONTROL FUNCTIONS・・・・・・・・・・・・ 1.2 MODE STRUCTURE・・・・・・・・・・・・・・・・・・・・・ 1.2.1 External Automatic Mode・・・・・・・・・・・・・・・・・・ 1.2.2 Internal Automatic Mode・・・・・・・・・・・・・・・・・・ 1.2.3 Manual Mode・・・・・・・・・・・・・・・・・・・・・・・ 1.2.4 Edit・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.2.5 Test Operation・・・・・・・・・・・・・・・・・・・・・・ 1.3 PRECAUTIONS FOR USE・・・・・・・・・・・・・・・・・・・ 1.3.1 Handling Disks・・・・・・・・・・・・・・・・・・・・・・ 1.4 GENERAL OPERATION・・・・・・・・・・・・・・・・・・・・ 1.4.
STE 58761 CHAPTER 3 MANUAL OPERATION 3.1 SELECTING THE MANUAL MODE・・・・・・・・・・・・・・ 3.2 GUIDANCE COORDINATES・・・・・・・・・・・・・・・・・・ 3.3 GUIDE MOVEMENT・・・・・・・・・・・・・・・・・・・・・ 3.4 GUIDE SPEED・・・・・・・・・・・・・・・・・・・・・・・・ 3.5 GUIDANCE・・・・・・・・・・・・・・・・・・・・・・・・・ 3.6 SERVO FREE・・・・・・・・・・・・・・・・・・・・・・・・ 3-1 3-3 3-4 3-5 3-6 3-7 CHAPTER 4 AUXILIARY SIGNALS CHAPTER 5 PROGRAM EDITING 5.1 INVOKING THE SCREEN EDITOR・・・・・・・・・・・・・・・ 5.2 CHARACTER INPUT・・・・・・・・・・・・・・・・・・・・・ 5.2.1 Character Input Mode Selection・・・・・・・・・・・・・・・ 5.2.
STE 58761 5.5.10 5.5.11 5.5.12 5.5.13 5.5.14 5.5.15 5.5.16 5.5.17 5.5.18 5.5.19 5.5.
STE 58761 6.7 EDITING COORDINATE DATA・・・・・・・・・・・・・・・・ 6.7.1 Coordinate-data Edit-mode Selection・・・・・・・・・・・・・ 6.7.2 Teaching Coordinate Data・・・・・・・・・・・・・・・・・ 6.7.3 Numerical Input of Coordinate Data・・・・・・・・・・・・・ 6.7.4 Deleting Coordinate Data・・・・・・・・・・・・・・・・・・ 6.7.5 Base Coordinate Selection・・・・・・・・・・・・・・・・・ 6.7.6 Tool Coordinate Selection・・・・・・・・・・・・・・・・・・ 6.7.7 Work Coordinate Selection・・・・・・・・・・・・・・・・・ 6.8 EDITING LOAD DATA・・・・・・・・・・・・・・・・・・・・ 6.8.1 Load-data Edit-mode Selection・・・・・・・・・・・・・・・ 6.8.
STE 58761 CHAPTER 8 INTERNAL AUTOMATIC OPERATION 8.1 SELECTING THE INTERNAL AUTOMATIC MODE・・・・・・・ 8.2 PROGRAM SELECTION・・・・・・・・・・・・・・・・・・・ 8.3 OPERATION MODE SELECTION・・・・・・・・・・・・・・・ 8.4 SPEED OVERRIDE・・・・・・・・・・・・・・・・・・・・・・ 8.5 SPEED LIMIT・・・・・・・・・・・・・・・・・・・・・・・・ 8.6 START-UP・・・・・・・・・・・・・・・・・・・・・・・・・・ 8.7 STOP COMMANDS・・・・・・・・・・・・・・・・・・・・・・ 8.7.1 Cycle Stop・・・・・・・・・・・・・・・・・・・・・・・・ 8.7.2 STOP・・・・・・・・・・・・・・・・・・・・・・・・・・ 8.7.3 BREAK・・・・・・・・・・・・・・・・・・・・・・・・・・ 8.7.4 Feed Hold・・・・・・・・・・・・・・・・・・・・・・・・ 8.7.
STE 58761 CHAPTER 10 SYSTEM CONTROL 10.1 SETTING THE DATE・・・・・・・・・・・・・・・・・・・・ 10.2 SETTING THE TIME・・・・・・・・・・・・・・・・・・・・ 10.3 CHANNEL SELECTION・・・・・・・・・・・・・・・・・・ 10.4 RESET・・・・・・・・・・・・・・・・・・・・・・・・・・ 10.4.1 Program Reset・・・・・・・・・・・・・・・・・・・・・ 10.4.2 Step Reset・・・・・・・・・・・・・・・・・・・・・・・ 10.4.3 Cycle Reset・・・・・・・・・・・・・・・・・・・・・・ 10.4.4 Output Signal Reset・・・・・・・・・・・・・・・・・・・ 10-1 10-4 10-7 10-10 10-10 10-12 10-14 10-16 CHAPTER 11 FILE MANAGEMENT 11.1 INITIALIZATION・・・・・・・・・・・・・・・・・・・・・・ 11.
STE 58761 CHAPTER 14 JOINT LIMIT SETTING 14.1 SELECTING JOINT LIMIT SETTING MODE・・・・・・・・・・ 14.2 JOINT LIMIT TEACHING・・・・・・・・・・・・・・・・・・ 14.
STE 58761 CHAPTER 1 BEFORE OPERATING YOUR ROBOT 1.1 OVERVIEW OF CONTROL FUNCTIONS Function Description Main power ON/OFF Used to turn the main power on or off. Servo power ON/OFF Use to turn the power for the servo on or off.
STE 58761 Function Present position monitor External I/O signal monitor File selection Move Description External Control Teaching control Panel pendant signals Used to display the present position of the robot in terms of the various coordinate system. 〇 Used to display the status of digital I/O signals. 〇 Used to select a file for execution. Moves the robot to a point which has been taught.
STE 58761 1.2 MODE STRUCTURE Master Mode External Automatic Mode (EXT) The External Automatic Mode is used to automatically operate the robot by program. This operation is performed with external control signals or signals from a host computer. Internal Automatic Mode (INT) The Internal Automatic Mode is used to automatically operate the robot by program. This operation is carried out from either the control panel or the teach pendant.
STE 58761 1.2.1 External Automatic Mode External Operation Signal Mode (SIG) External Automatic Mode (EXT) Host Mode (HOST) This mode is used to perform the program automatic operation. This operation is carried out with external operation signals. For details, see the Interface Manual. This mode is used to perform the program automatic-operation, file uploading and file downloading. All operations are carried out by the host computer through serial communication channel(s).
STE 58761 1.2.3 Manual Mode Edit (EDIT) Manual Mode (MANU) Test Operation (TESTRUN) File Load (LOAD) File Save (SAVE) Disk Initialization (FORMAT) Directory Display (DIR) File Copy (COPY) File Comparison (VERIFY) File Renaming (REN) File Deletion (DEL) File Printing (PRINT) Date Setting (DATE) Time Setting (TIME) Channel Selection (CHANNEL) Reset (RESET) Guidance Edits programs and data (positional data, coordinate data and load data). Checks to see that programs run properly.
STE 58761 1.2.4 Edit Screen editor Program editing Programs and global data are created and edited by entering and deleting characters, by selecting command menus and by selecting SCOL menus. Positional data editing Positional data are created and edited by teaching and by entering numbers. Work coordinate systems are selected; work coordinates are edited. Editing Data editor Coordinate data editing Coordinate data are created and edited by teaching and by entering numbers.
STE 58761 1.2.5 Test Operation Test Operation (TESTRUN) Program Selection (SELECT) Operation Mode Selection (MODE) Speed Override (MSPEED) Speed Limit (LSPEED) Machine Lock (MACHINE) Step Execution (STEP) Start-up (RUN) Stop (STOP,BREAK) Direct Execution (DO) Reset (RESET) Selects a program for execution. Selects an operation mode. Selects the speed override. Sets the speed limit. Enables and disables the machine lock. Executes the program one step at a time.
STE 58761 1.3 PRECAUTIONS FOR USE For the connection of FDD unit (option), see the Interface Manual. 1.3.1 Handling Disks (1) General precautions (a) Don’t open the shutter section. The disk will be unusable should any dirt get on the magnetic surface. ' I~ (b) Keep away from speakers or other devices which create strong magnetic fields. If you don't, the contents of your disks may get erased. (c) Keep out of direct sunlight and away from hot objects.
STE 58761 (2) Inserting a disk (a) With the label up and the metal shutter forward, insert the disk straight and slowly into the slot until you hear it click into place. (3) Removing a disk (a) Push the push button. The floppy disk should pop out a little ways from the slot. (b) Grip the disk with your fingers at the label section and draw it straight out. ! Caution Do not try to remove the disk while the disk drive light is still lit.
STE 58761 1.4 GENERAL OPERATION Only one key can be input at a time with the teach pendant. 1.4.1 Use of the Shift Key When a key is pushed while the "shift" key is held down, the upper character on that key will be input. (1) Entering the lower character To enter the lower character on a key, simply push that key. Example) Entering the character "9". Key operation Display ( 9 9 (2) Entering the upper character To enter the upper character, push down that key while holding down the "shift" key.
STE 58761 1.4.2 Use of the Function Keys In order to make it easier to input data, the teach pendant is provided with six function keys, i.e., "F1" to "F6". The functions to which "F1" to "F5" correspond will change depending on the mode. The names of these functions will appear above the corresponding function key. By pushing the appropriate key, commands can be executed without having to type in each letter making up that command. The "F6" key is the NEXT key.
STE 58761 1.4.3 Repeating an Entry The repeat operation is available for the following keys. [Bs], [Esc], [Exec] Guide key [Move] Cursor keys [Coordinates], [Teach Speed], [Control] 1.4.4 Correcting Incorrect Entries Use the "Bs" key to erase any characters which were incorrectly entered. Example: (Correct) TIME 13:50:00 (Incorrect) TIME 13:60:__ Push the “Bs” key. TIME 13:6__ Push the “Bs” key. TIME 13:__ Keep on pushing the “Bs” key until the incorrect characters are erased. correct characters.
STE 58761 1.4.6 Use of Wild Cards You may use the wild cards * and ? when specifying files with the directory [DIR], delete [DEL], print [PRINT], file save [SAVE] or file load [LOAD] command. Wild cards are used to simultaneously specify multiple files. Using wild cards correctly can save time and increase efficiency when specifying files. (1) The asterisk wild card”*” The asterisk wild card (*) can take the place of a file name or an extension. For example, the specification “A*.
STE 58761 1.4.7 Format for Operating Instructions The following format is used in this manual to explain how to use commands. Title [command name] (1) Function Explains the purpose of the command and what it does. (2) Input format Explains the input format for operation. An input consists of a command and parameters. Listed below are notation used to describe the input format. [ ] Indicates an item (or items) that may be specified if necessary and omitted if not.
STE 58761 1.5 ASSIGNING NAMES 1.5.1 Assigning the Volume Name When a disk is initialized, you can assign a name to that disk. This is the volume name. In order to simplify disk handling, you should keep your files sorted by task and put related files on the same disk. Also, be sure to give the disk a descriptive, easy to understand name. The volume name can be checked by looking at the directory display. Volume names consist of a volume name proper, a period, and a volume name extension.
STE 58761 1.5.2 Assigning a File Name Every file in a disk or in the RAM drive has its own name. This is called the file name. File names consists of a file name proper, a period, and a file name extension. An example is shown below: CONSTRUC . SYS SYS is the file name extension. It may have up to three characters. A period is used to separate the file name and the file name extension. CONSTRUC is the file name. It may have up to eight characters.
STE 58761 1.5.3 Assigning a Point Name When entering positional data for a point, you have to assign a name to that point. This name will be used later in the program when telling the robot where to go. Point names generally have a format like that shown in the example below: PNT100 PNT100 is the point name (in this example). The point name may have up to ten characters. The following characters may be used in the point name. (The first letter of a point name must be an alphabetic character.
STE 58761 1.5.4 Assigning a Name to Coordinate Data When entering coordinate data for a work coordinate system, a tool coordinate system or the base coordinate system, you have to assign a coordinate name to that data. This name will be used later in the program when telling the robot which coordinate system to use. Coordinate names generally have a format like that shown in the example below: TABLE1 TABLE1 is the coordinate name (in this example). The name may have up to ten characters.
STE 58761 1.5.5 Assigning a Name to Load Data When entering load data, you have to assign a load name to that data. This name will be used later in the program when telling the robot which load value to use. Load names generally have a format like that shown in the example below: SAMPLE1 SAMPLE1 is the load name (in this example). The name may have up to ten characters. The following characters may be used in the load name. (The first letter must be an alphabetic character.
STE 58761 CHAPTER 2 BASIC OPERATION 2.1 BASIC OPERATING PROCEDURE The following flowchart shows the basic operating procedure for automatic operation. It covers all operations from turning on the power to turning off the power.
STE 58761 2.2 TURNING ON THE MAIN POWER There are two ways to start up the controller - cold starting and hot starting. Normally, only the hot starting is required. For details, see Para. 2.2.2. 2.2.1 Cold Starting ! Danger If an abnormality has generated or the POWER LED lamp on the control panel remains off after the main power switch of the equipment was turned on, turn off the main power immediately and confirm the wiring.
STE 58761 Files marked by an asterisk are not absolutely necessary to run the system. However, you will get an error if you try to execute a function dependent on a missing file. For more information on these files, see the Start-up Manual. (4) Procedure (a) Step 1: Insert the system disk Insert the system disk into the FDD unit (option). (b) Step 2: Turn on the main power. Turn on the main power switch located on the controller. The POWER lamp and SERVO POWER OFF lamp should light up.
STE 58761 2.2.2 Hot Starting ! Caution If an abnormality has generated or the POWER LED lamp on the control panel remains off after the main power switch of the equipment was turned on, turn off the main power immediately and confirm the wiring. Otherwise, you will be struck by an electric shock or a fire will break out. When hot starting has been done, the controller enters a program reset status. (1) Function Starts up the controller with files contained in the RAM drive.
STE 58761 (4) Procedure (a) Step 1: Turn on the main power First, make sure that the system disk is not in the FDD unit (option). Then, turn on the controller main power. The POWER lamp and the SERVO POWER OFF lamp on the control panel will light up. The lamp turns on SERVO POWER POWER POWER 10AT OFF ON STOP START EMERGENCY FAULT BATTERY ALARM EXT INT MANU CYCLE STOP The controller will start initializing the system. The disk drive light will blink for about 15 seconds.
STE 58761 2.3 TURNING ON THE SERVO POWER ! Caution ・ If the robot moves abnormally at the servo power ON, press the EMERGENCY STOP switch immediately to turn the servo power off. ・ If anyone enters the robot dangerous area, turn the servo power off beforehand. (1) Function Turns on the main power circuit for the servo drivers. Servo control axes will change over to the servo-lock state, and any brakes will be released.
STE 58761 2.4 TURNING OFF THE SERVO POWER (1) Function Turns off the main power circuit for the servo drivers. Servo control axes will change over to the servo-free state, and any brakes will be activated. (2) Input format: None (3) Comments Do not turn the servo power off while the robot is running. When you wish to stop the robot in a hurry, push an emergency stop switch instead.
STE 58761 2.5 TURNING OFF THE MAIN POWER (1) Function Turns off the main power and stops controller processing. (2) Input format: None (3) Comments Do not turn off the main power while the servo power is on or while the controller is either processing data or manipulating files. Before turning off the main power, make sure that the servo power is off and that the controller is not running.
STE 58761 CHAPTER 3 MANUAL OPERATION 3.1 SELECTING THE MANUAL MODE (1) Function Changes over to the Manual Mode in which the robot is manually guided, points are taught, files are managed and the system is controlled. All of these operations are performed with the teach pendant. (2) Input format None (3) Comments The Test Operation Mode is classified as a manual mode. However, the Test Operation Mode is treated as completely separate in this manual.
STE 58761 a) Display field for command input and messages b) Display field for function key menu EDIT Edit LOAD File load SAVE File save TESTRUN Test operation RESET Reset DIR Directory display COPY File copy DEL File deletion REN File renaming PRINT File printing FORMAT Disk initialization VERIFY File comparison ZEROP Zero point teaching JLMIT Soft limit teaching CHANNEL Channel selection DATE Date setting TIME Time setting - 3-2 -
STE 58761 3.2 GUIDANCE COORDINATES (1) Function Selects a coordinate system in which to guide the robot from among the joint coordinates, tool coordinates, work coordinates and world coordinates. (2) Input format None (3) Comments Refer to the Introductory Manual for information on robot coordinate systems. If a tool, base or work coordinate system has not been taught to the robot, the robot will assume: (a) The tool coordinate system coincides with the surface of the hand mounting flange.
STE 58761 3.3 GUIDE MOVEMENT There are three types of guide movement: jog, inching and free. In the jog mode, the robot will move in the specified direction at the specified speed in the specified coordinate system for as long as you hold down the corresponding guide key. The jog mode is useful for rough positioning of the robot to get it near the target position. In the inching mode, the robot will move in the specified direction at the specified displacement in the specified coordinate system.
STE 58761 3.4 GUIDE SPEED (1) Function Selects the guide speed or the guide displacement. Guide speed will be set if the guide movement mode is set to jog. Guide displacement will be set if the guide movement mode is set to inching. Set the guide speed or guide displacement in accordance with how far the robot is from the target position. (2) Input format: None (3) Comments: None (4) Procedure (a) Step 1: Select the guide speed mode Push the "Teach Speed" key on the teach pendant.
STE 58761 3.5 GUIDANCE ! Caution ・ If the guidance is performed manually, do not enter the robot dangerous area. ・ If the robot moves abnormally, immediately effect an emergency stop. ・ If the robot will not move in the specified direction, consult Toshiba Machine. (1) Function The robot can be moved in the desired direction by pushing the appropriate guide keys when the guide movement mode is set to inching or jog.
STE 58761 3.6 SERVO FREE (1) Function Servo locks can be released for axes as desired when the guide movement mode is set to free. Axes in the servo free (i.e., unlocked) state can be moved freely by hand. This is convenient when moving the robot near workpieces and other such objects. (2) Input format None (3) Comments If You change from the servo free state to either the Test Operation Mode, the Internal Automatic Mode or the External Automatic Mode, the servo lock will be set for all axes.
STE 58761 While pushing down on a deadman switch, push the guide keys on the plus (+) side for those axes in the servo free state. Such axes will then change over to the servo lock state.
STE 58761 CHAPTER 4 AUXILIARY SIGNALS (1) Function Manages auxiliary signals used to control the hand, the air control axes, etc. (2) Input format None (3) Comments The output signal port and solenoid type corresponding to each function key must be defined (specified) in the system configuration file. For more information, see the Start-up Manual. Press the "Esc" key to exit the Auxiliary Signal Operation Mode and return back to the original menu.
STE 58761 (4) Procedure (a) Step 1: Select the Manual Mode Turn the master mode switch on the control panel to "MANU". (b) Step 2: Select the Auxiliary Signal Operation Mode Push the "Aux. Signal" key on the teach pendant. The Auxiliary Signal Operation Mode menu should then appear. Auxiliary signal operation mode [208] Aux 1 [210] [209] Aux 2 [212] [211] Aux 3 [214] [213] Aux 4 Aux 5 Aux 6 The numbers on the screen correspond to the output signal ports.