Industrial Robot Controller

MOTOMAN XRC

New A New Dimension

Dimension New

1 Controller Robots 3 Tasks 6 27 Axes

27 controlled servo axes Synchronized operation of three robots Synchronized programming of three robots including external axes Multi-tasking Simultaneous operation of six tasks Simple programming and diagnosis due to several software functions

Multi functional User friendly Compact

Outlines of the XRC

Built-in transformer Simple installation and setup by plugconnections. Used for robot in UP-series and SK-X, SP-X and SV-X-series. INFORM programming language Expandable slots for optional boards -Sensor function by XSL-board -Welding interface MEW and XEW-board -I/O-interface MIO-board -Ethernet and Fieldbus board XRC cabinets may be put on top of each other or docked side by side Fulfils the EC-directive incl. EMC and LVD Made in Sweden

Programming pendant
All programming functions are in one unit with clear and large 12-line screen. Optimal programming time is achieved while all functions are available during programming. The menu text can be switched between several different European languages by a simple key operation. The programming pendant is equipped with a 3-position deadmans handle.

Communication
XRC like the previous control system for MOTOMAN robots, is a technical data solution that is PC-compatible allowing common computer tools to be used for creating, reading and editing jobs in a PC. The flexibility of the control system makes it possible to communicate with other systems such as PLCs, host computers, vision systems etc., through serial links, Ethernet, digital I/Os and fieldbus. The controller memory is also accessible through a PC-card.

Advanced control system

Powerful 32-bit micro processor for rapid data processing. PLC-programs for different applications, for example: arc welding and handling. Advanced PLC-unit in the control system with expanded program capacity and new logical functions e.g. for controlling pneumatic functions in fixtures. Multi tasking makes it possible to run several jobs simultaneously. Digital servopacks with software controlled speed and position feedback.

Path control
The robots working path is controlled with consistent precision and quality. Even at high speeds the robot will not vary from the programmed path of travel. XRC improves high speed welding, cutting and sealing applications better than ever.

Shock detection function

This function stops the robot when it comes into contact with an object. Robot or peripherical devices can be protected in case of accidental collision.

ARM control
Advanced Robot Motion Control improves the quality and productivity by improved servo response of the motion control. Optimised acceleration/deceleration and vibration control ensures the correct path and cycle time. Speed is automatically optimised for circles and corners. Collision between robot, robot tool and other devices is immediately detected to stop the robot and protect it from damage.

Maintenance functions
Remotely monitors maintenance function of robot status through Ethernet network. Production processing and quality control monitoring can be managed from a central control room. Maintains history of when and who changed the robot job instructions.

design Expandable modular cabinet

The new programming pendant

Command menu Backlighted LCD screen Go to sub-menu Go to predefined menu Go to top menu Cursor, navigation key Switching of coordinate system type Go to next menu Emergency stop Status menu

Dead-mans handle (at the back) Enter selection

Axis keys, for robot and external axis

Programming keys Serial interface RS-232C Numerical and application function keys

Mode selection Teach / Play Emergency stop Servo power ON Alarm signal Remote operation Start playback operation Hold playback operation

Switch menu cursor area Teach lock, for blocking the Playback panel Programming and test-run keys

Large LCD-display with backlighting. High contrast for daylight operation. Cross shape cursor button for instruction basic operations. Operates by icons and pull-down menues make operation as easy as using your personal computer. Lightweight thermoplastic programming pendant reduces fatigue. Key allocation is based on human engineering research. The number of keys are minimised for required functions only.

Top menu icons

Open new jobs Call up jobs Copy job Rename jobs Delete jobs Modify jobs Set Master job

Application, e.g. Arc welding Spot welding Handling application or General application Variable diagnosis Position variables for robot, station and base axes

Diagnosis of external I/Os Diagnosis of universal I/Os Diagnosis of direct I/Os Setting of I/Os

Tool data User coordinates Robot position coordinates Setting of cubes and software limits Parameter setting System diagnosis functions System diagnosis functions Software version Alarm history System clock Counters

Back-up functions Load Save Verify Delete

The programming pendant has been awarded for its good design and user friendly layout.

System settings Date/Time Speed settings Setting group combinations Operating/Teaching conditions User ID

Ministry of International Trade and Industry, Japan

Technical specifications
Controller
Configuration Dimensions Weight Cooling system Ambient temperature Relative humidity Power supply Grounding Digital I/O Free-standing, Enclosed type 800(W)x900(H)x650(D) mm Approx. 170 kg Indirect cooling During operation 0 to +45 During transport -10 to +60 Max. 90% (non-condensing) 3 x 400/415/440V AC, 50/60 Hz Less than 100 ohm General signals (standard) 40 inputs and 40 outputs of which 24 inputs and 24 outputs are free 4 direct inputs RS-232C and PC-card Absolute encoder / Serial interface Servopacks for AC servo motor Software servo control 5.000 steps and 3.000 instructions 1.500 ladder steps

Communication Positioning system Drive units Accel / Decel Programming capacity (standard)

Safety features
Personal safety Teach Lock Mode Collision proof frames Machine lock 3-position dead-mans handle Low speed in teaching mode Prohibits operation from operators panel Doughnut-sector frame, cubic frame

Test-run peripherial device without robot motion Self-diagnosis Alarm and error messages displayed together with explanation User Alarm display Possible to display alarm messages for peripheral devices

Operators panel
Buttons provided Mode, Start, Hold, Emergency stop Servo power ON

Programming pendant
Material Dimensions Weight Display Safety feature Interface Reinforced thermoplastic enclosure 200(W)x322(H)x65(D) mm 1.2 kg 5.7 inch, 40 characters x 12 lines 3-position dead-mans handle RS-232C

Programming functions
Coordinate system Robot Motion Control Speed setting Joint, rectangular/cylindrical, tool, user coordinates Joint coordinates, linear/circular, interpolation, tool coordinates Percentage for joint coordinates, 0.1 mm/s units for interpolations, angular velocity for T.C.P. fixed motion Jump, call, timer, robot stop, execution of some instructions during robot motion Adding, deleting, correcting (robot axes and/or external axes) Manually forwards and backwards in the job (even circular) Fine adjustment possible Discrete I/O control, pattern I/O processing Interactive programming Robot language: INFORM II English, Swedish, French, Spanish, Italian, Finnish, German Max. 24 and up to 24 external TCPs Automatically calibrates parameters for end effectors using master jig

Program Control Instructions Modification of teaching point Position control Speed adjustment I/O-function Programming Language Display text Tool Centre Point TCP-calibration

Maintenance functions
Software time usage meters Alarm display I/O-diagnosis Control power-ON time, servo power-ON time, playback time, work time and operation time displayed Alarm messages and previous alarm records Simulated enable/disabled output possible

Options
Digital I/O I/O-boards, total max. 256/256 MIO02: 32 inputs and outputs MIO03: 16 inputs and outputs XO102: 40 inputs and outputs Analogue output 12 channel (MEW/XEW-board) Memory expansion Max 60.000 points for 6 axes (up to...) and 20.000 instructions 3.000 ladder steps External axis Total max. 27 axes IP54, by add on kit Enclosure classification

Controller layout

Basic cabinet

MOTOMAN

XRC

900

800

650 725

Optional cabinets
XRC Controller cabinet is expandable by adding extra modules (XOC-1 and XOC-2). The extra cabinets are required for Twin and Triple robot mounting, external axis servopacks as well as optional functions such as PLCs and safety systems. The optional cabinets are docked with the controller cabinet either on top or by the side providing a tidy cable installation.

1800

MOTOMAN

MOTOMAN

XRC
1450

XRC

1600

MOTOMAN XRC will be the

It is physically reduced to minimise space but is optimised

Optional units such as servopacks for external axes, optional I/O boards, welding interface boards and fieldbus boards may be mounted on the back plate inside the cabinet.

Indirect cooling by means of a set of fans at the rear makes it possible to place the cabinet in confined places. The indirect cooling also keeps pollution and dust out of the cabinet.

Cables for safety circuits, external axes I/Os and other communication options are easily connected at the bottom of the cabinet. The plugs are well protected behind a removable panel.

premier robot controller

for functions, simple operations and expandability

Free slot in the CPU rack for optional boards e.g. Sensor or Ethernet board.

PC-card (PCMCIA) interface for high speed backup or robot job transferring. Robot and system software upgrade.

Serial interface through RS-232C connector suitable for PC communication i.g. backup of robot jobs remote control etc.

Cables for robot motors and signal cable are easily connected by plugs at the back of the cabinet to increase flexibility.

Standard field networks are available: Ethernet, Profibus, Interbus-S, DeviceNET, etc. Your manufacturing line can be integrally controlled through your existing network.

Main power supply line is connected by CEE plug.

Serial interface through RS-232C connector in the programming pendant is suitable for PC communications e.g. back-up of robot jobs.

Software functions
The Advanced Robot Motion function improves quality and productivity for applications where correct path and high speed is needed e.g. Laser cutting, water jet cutting, gluing and sealing application. By integrated Collision Detection function the robot tool, fixtures and jigs as well as the robot arm itself are protected against damages. Moment limits may be individually set. The XRC System gives possibility to control 27 axes from one single CPU, three robots with external axes could be used for synchronuous motion or for individual jobs. Using the Twin-Drive function, two external servomotors may be used for synchronuous drive of a heavy fixture or large track (e.g. welding application). Endless Rotation of robot axis (T-axis) or an external axis. Normally a servo motor is limited to one or two turns in each direction. By this function wrapping/unwrapping processes or painting applications are improved and no time consuming reset of the turning is needed. The XRC system can handle six tasks at the same time Multi-Tasking such as robot jobs, concurrent I/O master job. By means of special commands programming and editing is made easily. Welding Parameters (welding current, wire speed, weaving, etc.) for a special welding power source may be saved in a data file (charcteristics). Start conditions, end conditions are easily added to the robot job by calling ARCON/ARCOF-command, which reduces the programming time. Other parameters for welding may be set, such as: Retry function and Restart function. Of course, it is possible to set individual values for voltage, current wire feed, etc. for a single welding string. Communication interface between XRC system and e.g. a PC may be handled in several ways. A PC-card (PCMCIA) slot is integrated in the CPU-rack. This PC-card can be used as backup of user memory (jobs) and also for upgrading of system software. For advanced communication the RS-232C serial interface or optional Ethernet board is used. This together with our PC software puts the robot into your network. Robot jobs may be down- and uploaded to the system from a central computer. The robot can be remotecontrolled. The Interrupt Job function is used when the robot serves e.g. one or several tooling machines. A signal from the machine makes the robot to interrupt its job for a moment to serve the machine and then returns to maintain its main job, e.g. deburring. The Search function is used when the workpiece may vary in size or position e.g. picked up from a pallet or roughly cut pieces at welding application. The data from the sensor adjusts the robot job. In arc welding applications the COMARC package (including: start point search function, seam tracking and multi layer) increase the productivity by decreasing the demands of the accuracy of the workpiece. It automatically adjusts the robot job due to the actual conditions. Multi layer function reduces the programming time in heavy welding applications. When the robot is used together with a machine tool for placing the workpiece in the chuck, the Servo Float function allows the robot arm to float with torque control making it flexible with external forces.

When using the External Reference Tool Centre Point function, it is possible to designate a point in space as the tool control point. This function may be used when the robot is holding the workpiece and the tool fixed e.g. pedestal spot welding machine or application nozzle for gluing or sealing. PMT function can be used to correct position data easily and accurately when the robot tool inadvertently collides with periferial jigs or walls and becomes deformed. The job position data will be corrected according to the new tool data automatically. The actual position of the robot is memorized by pulse data. These data can be shifted into another coordinate system, Relative Job function. This function is used to perform exactly the same operation but in another location or direction. The Parallel Shift function simplifies programming. One operation is shifted (copied) a specified distance. A counter sets the number of operations. The function is used in e.g. palletising application. Any type of coordinate system can be used. The PAM function is used for manual operation. During playback the programmed position or speed, can be corrected easily. It is not necessary to stop the robot as the correction amount and speed is set from the programming pendant. This function is used when the workpiece is only roughly positioned in the fixture and the operator checks and corrects the position. The TCP (Tool Centre Point) function, adjusts the robot position according to the tool data. This function reduces the programming time e.g. it can be used in a painting application where the first nozzle applies the primer coat and after shifting the TCP, the second nozzle applies the topcoat by running the job again. The Analogue Output Corresponding to Speed uses an optional analogue board to supply a signal to control a glue or paint pump, or similar when the amount of sealant or paint must be accurately controlled. The Conveyor synchronisation function synchronises the robot motion to the speed of the conveyor. By connecting the optional sensor board to an incremental encoder on the conveyor drive motor, the speed is detected and the robot can adjust its speed to suite. This function is used both when picking up as well as placing the workpiece onto the conveyor without stopping it. The Press synchronises the robot motion with the press machine, where an encoder mounted on the press flywheel monitors the position of the press. The robot motion is halted when it may interfere with the press motion and starts again when the press rises and interference is avoided. I/O signals are not needed and cycle time is optimised. For Spot welding applications the Short Pitch function is used to suppress the rapid robot arm movements during the short pitch traverse of the spot welding gun. A number of Optional Boards can be added to the XRC system, such as; -Sensor board, -Ethernet board, -I/O board, -Analogue output board and COMARC board. Complex I/O installations are easily solved by use of the Fieldbus Interface Board which is designed for well known market brands such as; Interbus-S, Device-NET and Profibus etc. Digital I/O optional boards of various types are easily installed to customise your system (16/16, 32/32, 40/40).

KNT ENGINEERING

ROBOTIC SYSTEMS

ROBIA SUOMI

ROBIA

ROBIA

MOTOMAN MOTOMAN

MOTOMAN MOTOMAN MGM SPOL MOTOMAN MOTOMAN MOTOMAN MESSER SAG MOTOMAN RISTRO MOTOMAN MOTOMAN REHM

GEIGER HANDLING

KOUVALIAS INDUSTRIAL ROBOTS

MOTOMAN ROBOTICS EUROPE AB

Box 504 SE-385 25 Torss Sweden Tel: +46-486-48800 Fax: +46-486-41410 www.motoman.se

a YASKAWA company

Group Companies: France: MOTOMAN Robotics, Nantes +33-2-40131919, Germany: MOTOMAN Robotec, Allershausen +49-8166-90-0 MOTOMAN Robotec, Frankfurt +49-6173-6077-30, Great Britain: MOTOMAN Robotics, Banbury +44-1295-272755, Italy: MOTOMAN Robotics, Modena +39-059-280496, Netherlands: MOTOMAN Benelux, Breda +31-76-5424278, Portugal: MOTOMAN Robotics, Porto +351-14968160, Slovenia: RISTRO, Ribnica +386-61-861113, Spain: MOTOMAN Robotics, Barcelona +34-93-6303478, Sweden: MOTOMAN Robotics Europe, Torss +46-486-48800 MOTOMAN Mecatron Robotic Systems, Kalmar +46-480-444600 Distributors: Czech Republic: MGM Spol, Tabor +420-361-254571, Denmark: Robia, Vejle +45-79428000, Finland: Robia Suomi, Turku +35822145600, Greece: Kouvalias Industrial Robots, Kallithea +30-1-95892436, Hungary: REHM Hegesztstechnika, Budapest +36-12562012, Israel: KNT Engineering, Kfar Azar +972-39231944, Norway: Robia, Hokksund +47-32252820, South Africa: Robotic Systems, Bertsham +27114943604, Switzerland: Geiger Handling, Schwarzenburg +41-31-7343111 Messer SAG, Dllikon +41-18471717

Reg 7P-03-07-01INT