.

We need to be able to understand what the customers are receiving in terms of education so that we
can understand things from their point of view should anything happen.

. When we receive a complaint/ request from customer, which documents should you reference? And
what steps should you take?

. Operation of a robot is just like obtaining a driers license. Theory and practical tests must be done
before operation of a robot.

. Safety-> Theory -> Practice (None of these must be left out, they are also done in this order)

. Safety is extremely important. We will spend 2 hours on safety. Rest on theory and practice. (Safety is
enshrined in Japanese Law)

. This textbook is prepared for training on robots. It only describes general principles. It is not necessarily
enough in terms of technicality.

. Therefore one must refer to the manual of the specific robot or controller that you are using.

. Safety, refer to the safety booklet

. There are two circumstances where the robot is not moving 1. No power 2. Software is commanding
the robot to pause/ be dormant for the itme being.

. 教示作業 Teaching Work

. 検査 Diagnostics and investigation into the robot

. Robots were born in an industrial era where things that are made can be sold. The creation of
machines were already finished. They needed robots to fill the spaces between robots.

. Robots were needed to be multifunctional. Able to be used in a variety of situations. They are needed
to be able to receive various commands and act accordingly. But that also means that robots are things
that users need to program and teach in order to use.

. There are hundreds of things we need to teach robots, therefore abnormalities may arise.

. A product that doesn’t break doesn’t exist. And since the robot moves rapidly, it breaks down easily.

. Dependent on the environment, the robot may deteriorate rapidly. E.g. cleaning machine requires
water which means rust. An oven implies heat, this means that the grease may dry up rapidly or
structures may warp.

. The robot’s power is separated into main power and servo power which is the motor power. This is so
that the majority of the work can be done without giving the robot the ability to move.

. We use three types of teaching, 1. Manual position setting and registration of co ordinates 2. Jog keys
positioning and registration of co ordinates 3. Completely using program.

. The first thing to check in a pre-operation checklist is whether the EMS functions are working properly.

. This means all EMS switches including those in other machinery.

. Make sure all exits are open. Position yourself next to the exit. Never have your back facing the robot.

. Make sure you don’t do things by yourself. Ask if you’re finished on a job.

. If there is anything that seems wrong, make sure to stop the robot straight away because there may be
something wrong. It is possible that it can do anything.

. We have to remember that robots can break down. The best way to stop a robot is through humans.
Not by using sensors etc.

. Safety measures must be extended to all peripheral equipment. E.g. peripheral equipment’s controller
must be off so that a servo on signal doesn’t go to the manipulator.

. Diagnostics is an extremely complex job.

. When the robot is broken down, it is in an abnormal state so anything can happen.

. Make sure one EMS is depressed and close to you as so other people can’t accidentally turn it on.

. When troubleshooting make sure to keep narrowing down what the issues are until you find out the
root problem.

. We also need to make sure that there is no potential energy left inside either the manipulator
controller before working. For example if a robot is raised high, lower before doing work. If you can’t
lower it, put a mechanical stopper in place.

. Diagnostics is very complex. There may be pressure from customers to just fix the robot. However it is
for safety reasons to why we need to create work outlines.

System structure

. There is one more thing that allows the manipulator to move and is inside the system. Peripheral
manipulator.

. We cannot prepare a machine inside the training room and there for the signal from external machines
is given by the small machine on the side of the controller.

. The controller can support a maximum of 8 axis.

. One axis is equivalent to one power source, one direction of movement.

. SSLE is the name of the program used to create programs for the manipulator. (It is derived from C
programming language)

. Programs are firstly made inside the computer and then uploaded to the controller.

. We cannot directly edit programs that are inside a controller. Programs must first be edited in the
computer and then updated into the controller.

. There are many models of manipulators and controllers and you must understand them all.
SC1000 1980

SC2000

SC3000 1990

SC3150

SC3300

SC3400

SC5000 2005 (C1 System)

SC5000 2010 (C2 System)

Currently, only SC5000 is on sale. However older systems are still supported by Nidec

SC5000:

STD - Standard

EX2 – Extended

HP HP2 HP3 HP4 - High Power (HP2 is designed to repel EM interference due to the large amount of
electricity used in the machine.

UHP UHP2 - Ultra High Power

HHP – Huge High Power

These controllers are rated by power. They serve the exact function.

. The CD contains manuals which also acts as a contract between Sankyo and the customers.

. The customer is responsible for creating the program, teaching the manipulator.

. The program is created using the BUZZ5000 program.

. Teaching is done by the pendant. You cannot teach using a computer and you cannot create programs
by using the pendant.

. The program must have a name and this can be anything. The file must also have an extension. This is
TEXT.SSL which means Sankyo Structured Language. However everyone must be able to edit this fil
freely hence it can also be opened as a .TXT file. This original program file contains text and is the source
file for the program.

. We must receive the signal for P1 before we can continue to the next command and go to P2

. Just like the encoder we need to make sure that the robot is holding the substrate.

. But also if we are using the robot with an oven, the WIN (10,1) command would mean that the hand is
in the oven and will melt.
. Therefor you need to use the IF command. If we don’t get a positive command, we need to retract the
arm.

. The end effector is not part of the robot. The hand is an option that the customer chooses and
specifies. Its function is decided by the customer. Therefore there must be a freedom of programing in
order to facilitate a variety of end effectors.

. As long the hand is within the general parameters specified by Sankyo, the customer is free to use any
kind of hand.

. Even if customers order the hand form Sankyo, it is the customers responsibility as the hands
specifications are decided by the customers.

. Do not touch the teaching data, it is in binary.

. The source file must be compiled into an object filed in order to have the controller use the data. This is
a task filed with the extension .TSK

. When the program uploads the program to the controller the source file is also uploaded as backup.

. There are times where the source file is not uploaded. This is when the program is too large.

Memory

. RAM memory is needed as read write is faster. In the case of a blackout or sudden defect, information
about the status of the robot can be stored inside the RAM. A battery keeps this RAM alive.

. To move program to RAM, the controller needs to be turned off and on once.

. One reason why the program hasn’t changed is because the updated source file has not been
compiled. The other is that the controller hasn’t been turned off and on once.

. We need to make sure that the data in RAM doesn’t disappear so we use a battery to keep the RAM
alive. The number of cycles that the robot has operated is stored into the RAM. If this data is lost then it
can be dangerous to operations.

. For controllers to copy new data into RAM, a program must not already exist in RAM unless time
stamps do not match.

. If pendant is used to edit data, both programs in RAM and flash memory will sync.

Controller Back panel

. The controller back panel is split into three main sections.

. The power is 200v to 230v. We can’t surely say the current that flows through the wire. It is dependent
on the manipulator used. This is written usually on the manual and therefore the people using the
system can guess how much energy is used in a year.

. It takes a few seconds for the capacitors to store enough electrical energy to move the servos.
Therefore this can cause error if the customers link the switches IN with other machines OUT.
Co ordinates

. 0 for RR and RL is from when the arms are all stacked together.

. When teaching, a home position must be taught. 作業原点 Home position.

. This home position is when the robot is the most compact. Therefore the home position is different for
different robots as the end effector has different lengths. RL and LL may also vary.

. Vacuum chucks are designed to be flexible. However this is not to combat warping but to combat
flapping of glass during high speed movement.

. Understand that the positions can be named freely.

. HOME IS DIFFERENT FROM THE POINT IN ABS HOMING

E.g.

In mm

RR, RL, Z, 𝜃

P1 = -400, -400, 30, 0 ( We can also call this HOME instead of P1)

P2 = -400, -400, 30, -90

P3 = 600, -400, 30, -90

P4 = 600, -400, 40, -90

P5 = 600, -400, 50, -90

P6 = -400, -400, 50, -90

P7 = -400, -400, 50, 0

. Before the robot is commanded to move, we need to tell the robot how to move from one point to
another.
. SR’s usually use PTP control. Pose to pose or point to point control. Only the axis that change will
move. It is the easiest way for the robot to move.

. If multiple axis move, then all axis that change in parameters will start moving at the same time. All axis
that change in parameters will also stop moving at the same time.

. Robots are devices that will move only until the robot knows where it is moving. Therefore the robot
will make sure that speed is set with the axis that needs to move the most.

. PTP command is included in the SPEED (60) function.

. Cycle time is calculated by the sum of the time it takes to move the longest distance between two
different positions.

. Cycle times is also affected by the weight of the load. (Slower acceleration/ deceleration )

. To move from one physical coordinate to another through a complete straight line you need to use the
LINEAR command. Speed setting in this case is inputted in mm/sec

. A CIRCULAR command can also be used to travel between three points in a circular shape.

. HOWEVER the command of LINEAR and CIRCULAR is not recommended. This is because in order to
move in a straight line the robot needs to decelerate and move in the opposite direction without
stopping. This means a surge and peak in electrical output which causes stress in the controller.

Co ordinate

. There are different kinds of layouts when it comes to co ordinates.

. Robot is standard. Joint co ordinates are measured by degrees of motion.

. It is easier for the robots to use angular co ordinates as the robot uses circular motion to translate to
linear motion.

. Robot co ordinates are used by humans (Teaching and programming) and Joint co ordinates are used
by the robots. (For maintenance and repairs).

. There is one last co ordinate and it is called the Pulse co ordinates.

. The kind of movement will change depending on which co ordinates you use. XY uses straight direction.
Angular co ordinates uses round movements.

C CODE

. The C code label is on both manipulator and the controller. So only one controller can control one
specific robot.

. When the controller is turned on for SC3000 and the robot is moved then the homing operation need
to be done again. When the controller is being turned on, neither the battery or main power is supplied
to monitor servo status.

Pendant
. Area over warning - Servo stays on (Software)

. Over Run error – Servo turns off as it is in a broken state. (Relies on hardware data)

Practical

. The person who is installing the robot also needs to know the full contents of the program being
loaded.

There must be a teaching map, a list of all the teaching positions.

. Some robots have batteries that are located next to the servo so that it’s harder for ABS loss.

. We need to use maintenance level to cause ABS loss.

. SETPRMS5.DEF is a file that can add different functions to the controller.

. For operator level a password is needed. After some time, the pendant will automatically switch back
to maintenance level.

. If password is changed, a file is created in the controller. It’s called the PENDANT.PRM and this is where
the password is changed. If the file is deleted the default password is restored.

Operation of robot

. STBY - Servo On

. Error Reset – Resets errors just like in teach mode/pendant

. Start – Start function, starts program form the start

. Restart – Resume function

. Step – Step stop

. Cycle – Cycle stop

. Hold - Hold stop

.You are not allowed to press Start after stopping. This may cause an accident.

. We need to ask the person who set the bottoms of operation in order to fix the robot completely.

. If BIN file is deleted, we cannot connect to the controller.

. Pitch setting is stored inside the controllers.

. Transfer the BAK file to PC and manually change extension of the file to DAT and return to controller.

. Back up all files except for the BIN file.

. The relationship between the pulse co ordinates and the physical robot co ordinates is written inside
the HWDEF.CFG file.

. Reason why we cannot store HWDEF in the same folder is because it can cause damage. As the co
ordinates are skewed.

. 工場原点復帰 This is when belts or servo motors are replaced. Do not use this in any other
circumstances. Normal encoder info loss = Normal ABS homing operation.

. Axis layout in the ERROR list is different from actual axis. Axis in error list refers to the servo drivers
inside the controller.

. For the SC3000 there are four servo driver ports for small powers supply. There are two driver ports for
large power supply. You can use two axis for every small power supply port and one axis for every large
driver port.

. Axis number for servo drivers are different from axis number for physical servos.

Things we need from customers:

C. Code ( We can see repair history)

What happened before the defect? (Did it break down after maintenance? Etc)

Error History List

Sankyo Program

STR1 Upper hand

STR2 Lower hand

STAGE NUMBER

Position number

STR1_2[2] =700, -420, 300, -90; Not actually used

Then we can set where we want the hand to move in and move out by using parameters

ST2_PRM[1]= 20, -30, 0, 0;

20 is above and -30 is below

CST_UR1_1[2]= 700, 420, 650, 90;

CST_LR1_1[2]=700, -420, 100, 90;

Upper and lower bounds for cassette

CS1_PRM[1] = 15, -20, 0, 0

CSST_PRM[1]= 10, 0, 0, 0; (Number of rows)

These are the parameters needed to set for cassette loading.

We also need to set a P_HOME which is for safety reasons

Eg P_HOME = -420, -420, 200, 0;

The RR and RL in P_HOME is used for returning position after retrieving the wafer.

Name of the program will display on the pendant. Make sure to provide information.

PM system is usually the same. Only one file is increased, It is called index.tsk