FANUC R-30iB Plus CONTROLLER, iRVision 2D Camera Application. OPERATOR'S MANUAL

SAFETY PRECAUTIONS

This chapter describes the precautions which must be followed to ensure the safe use of the robot.

Before using the robot, be sure to read this chapter thoroughly.

For detailed functions of the robot operation, read the relevant operator's manual to understand fully its

specification.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its

peripheral equipment installed in a work cell.

In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.

1 DEFINITION OF USER

The user can be defined as follows.

Operator:

• Turns ON/OFF power to the robot

• Starts the robot program from the operator’s panel

Programmer:

• Operates the robot

• Teaches the robot inside the safety fence

Maintenance engineer:

• Operates the robot

• Teaches the robot inside the safety fence

• Performs maintenance (repair, adjustment, replacement)

Operator is not allowed to work in the safety fence.

Programmers and maintenance engineers are allowed to work in the safety fence. The work inside

the safety fence includes lifting, setting, teaching, adjustment, maintenance, etc.

To work inside the safety fence, the person must receive a professional training for the robot.

During the operation, programming, and maintenance of your robotic system, the programmer, operator,

and maintenance engineer should take additional care of their safety by wearing the following safety

items.

Adequate clothes for the operation

Safety shoes

A helmet

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2 DEFINITION OF SAFETY NOTATIONS

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on

safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is indicated

by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before using the robot.

Symbol

Definitions

Used if hazard resulting in the death or serious injury of the user will

WARNING

be expected to occur if he or she fails to follow the approved

procedure.

Used if a hazard resulting in the minor or moderate injury of the user,

CAUTION

or equipment damage may be expected to occur if he or she fails to

follow the approved procedure.

Used if a supplementary explanation not related to any of WARNING

NOTE

and CAUTION is to be indicated.

• Check this manual thoroughly, and keep it handy for the future reference.

3 SAFETY OF THE USER

User safety is the primary safety consideration. Because it is very dangerous to enter the operating

space of the robot during automatic operation, adequate safety precautions must be observed.

The following lists the general safety precautions. Careful consideration must be made to ensure user

safety.

(1) Have the robot system users attend the training courses held by FANUC.

FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is

waiting for a signal. In this state, the robot is regarded as still in motion. To ensure user safety,

provide the system with an alarm to indicate visually or aurally that the robot is in motion.

(3) Install a safety fence with a gate so that no user can enter the work area without passing through the

gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is

stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate

is opened and this signal received, the controller stops the robot (Please refer to "STOP

TYPE OF ROBOT" in "SAFETY PRECAUTIONS" for detail of stop type). For connection,

see Fig. 3 (b).

(4) Provide the peripheral equipment with appropriate earth (Class A, Class B, Class C, and Class D).

(5) Try to install the peripheral equipment outside the robot operating space.

(6) Draw an outline on the floor, clearly indicating the range of the robot operating space, including the

tools such as a hand.

(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm

that stops the robot when a user enters the work area.

(8) If necessary, install a safety lock so that no one except the user in charge can turn on the power of

the robot.

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The circuit breaker installed in the controller is designed to disable anyone from turning it on

when it is locked with a padlock.

(9) When adjusting each peripheral equipment independently, be sure to turn off the power of the robot.

(10) Operators should be ungloved while manipulating the operator panel or teach pendant. Operation

with gloved fingers could cause an operation error.

(11) Programs, system variables, and other information can be saved on memory card or USB memories.

Be sure to save the data periodically in case the data is lost in an accident. (refer to Controller

OPERATOR’S MANUAL.)

(12) The robot should be transported and installed by accurately following the procedures recommended

by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe

injury to workers.

(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.

Then, the speed should be gradually increased to check the operation of the robot.

(14) Before the robot is started, it should be checked that no one is inside the safety fence. At the same

time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a

situation should be eliminated before the operation.

(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and

peripheral equipment can be adversely affected, or workers can be severely injured.

- Avoid using the robot in a flammable environment.

- Avoid using the robot in an explosive environment.

- Avoid using the robot in an environment full of radiation.

- Avoid using the robot under water or at high humidity.

- Avoid using the robot to carry a person or animal.

- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)

- Outdoor

(16) When connecting the peripheral equipment related to stop (safety fence etc.) and each signal

(external emergency, fence etc.) of robot, be sure to confirm the stop movement and do not take the

wrong connection.

(17) When preparing footstep, please consider security for installation and maintenance work in high

place according to Fig. 3 (c). Please consider footstep and safety belt mounting position.

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㻾㻼㻝

㻼㼡㼘㼟㼑㼏㼛㼐㼑㼞

㻾㻵㻛㻾㻻㻘㼄㻴㻮㻷㻘㼄㻾㻻㼀

㻾㻹㻝

㻹㼛㼠㼛㼞㻌㼜㼛㼣㼑㼞㻛㼎㼞㼍㼗㼑

㻱㻭㻾㼀㻴

Safety fence

Interlocking device and safety plug that are activated if the gate is opened.

Fig. 3 (a) Safety fence and safety gate

WARNING

When you close a fence, please confirm that there is not a person from all

directions of the robot.

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㻔㻺㼛㼠㼑㻕㻌

㼛㼞㻌㻼㼍㼚㼑㼘㻌㼎㼛㼍㼞㼐㻌

㻌

㻌㻱㻭㻿㻝

㻌

㻲㼛㼞㻌㼠㼔㼑㻌㻾㻙㻟㻜i㻮㻘㻌㼠㼔㼑㻌㻾㻙㻟㻜i㻮㻌㻹㼍㼠㼑㻌㻘㻌

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㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼎㼛㼍㼞㼐㻚㻌

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㻾㻙㻟㻜i㻮㻛㻾㻙㻟㻜i㻮㻌㻼㼘㼡㼟㻌㻯㻻㻺㼀㻾㻻㻸㻸㻱㻾㻌㻹㻭㻵㻺㼀㻱㻺㻭㻺㻯㻱㻌㻹㻭㻺㼁㻭㻸㻌

㻔㻮㻙㻤㻟㻝㻥㻡㻱㻺㻕㻌㼛㼞㻌

㻾㻙㻟㻜i㻮㻌㻹㼍㼠㼑㻛㻾㻙㻟㻜i㻮㻌㻹㼍㼠㼑㻌㻼㼘㼡㼟㻌㻯㻻㻺㼀㻾㻻㻸㻸㻱㻾㻌㻹㻭㻵㻺㼀㻱㻺㻭㻺㻯㻱㻌

㻹㻭㻺㼁㻭㻸㻌㻔㻮㻙㻤㻟㻡㻞㻡㻱㻺㻕㻌㼒㼛㼞㻌㼐㼑㼠㼍㼕㼘㼟㻚㻌

㻿㼕㼚㼓㼘㼑㻌㼏㼔㼍㼕㼚

㻼㼍㼚㼑㼘㻌㼎㼛㼍㼞㼐

㻌

㻌㻲㻱㻺㻯㻱㻝

㻌㻲㻱㻺㻯㻱㻞

Fig. 3 (b) Connection diagram for the signal of safety fence

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㻴㼛㼛㼗㻌㼒㼛㼞㻌㼟㼍㼒㼑㼠㼥㻌㼎㼑㼘㼠

㻲㼑㼚㼏㼑

㻿㼠㼑㼜㼟

㼀㼞㼑㼟㼠㼘㼑

㻼㼑㼐㼑㼟㼠㼍㼘

㼒㼛㼞㻌㼙㼍㼕㼚㼠㼑㼚㼍㼚㼏㼑

Fig. 3 (c) Pedestal for maintenance

3.1

SAFETY OF THE OPERATOR

An operator refers to a person who turns on and off the robot system and starts a robot program from, for

example, the operator panel during daily operation.

Operators cannot work inside of the safety fence.

(1) If the robot does not need to be operated, turn off the robot controller power or press the

EMERGENCY STOP button during working.

(2) Operate the robot system outside the operating space of the robot.

(3) Install a safety fence or safety door to avoid the accidental entry of a person other than an operator in

charge or keep operator out from the hazardous place.

(4) Install one or more necessary quantity of EMERGENCY STOP button(s) within the operator’s reach

in appropriate location(s) based on the system layout.

The robot controller is designed to be connected to an external EMERGENCY STOP button.

With this connection, the controller stops the robot operation

(Please refer to "STOP TYPE

OF ROBOT" in "SAFETY PRECAUTIONS" for detail of stop type) when the external

EMERGENCY STOP button is pressed. See the diagram below for connection.

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SAFETY PRECAUTIONS

㻰㼡㼍㼘㻌㼏㼔㼍㼕㼚

㻱㼤㼠㼑㼞㼚㼍㼘㻌㼟㼠㼛㼜㻌㼎㼡㼠㼠㼛㼚

㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼎㼛㼍㼞㼐

㻔㻺㼛㼠㼑㻕㻌

㼛㼞㻌㻼㼍㼚㼑㼘㻌㼎㼛㼍㼞㼐㻌

㻯㼛㼚㼚㼑㼏㼠㻌㻱㻱㻿㻝㻌㼍㼚㼐㻌㻱㻱㻿㻝㻝㻘㻌㻱㻱㻿㻞㻌㼍㼚㼐㻌㻱㻱㻿㻞㻝㻚㻌㻌

㻌㻱㻱㻿㻝

㻌

㻲㼛㼞㻌㼠㼔㼑㻌㻾㻙㻟㻜i㻮㻘㻌㼠㼔㼑㻌㻾㻙㻟㻜i㻮㻌㻹㼍㼠㼑㻘㻌

㻌㻱㻱㻿㻝㻝

㼠㼔㼑㻌㻾㻙㻟㻜i㻮㻌㻼㼘㼡㼟㻘㻌㼠㼔㼑㻌㻾㻙㻟㻜i㻮㻌㻹㼍㼠㼑㻌㻼㼘㼡㼟㻌

㻌㻱㻱㻿㻞

㻌

㻱㻱㻿㻝㻘㻌㻱㻱㻿㻝㻝㻘㻌㻱㻱㻿㻞㻘㻌㻱㻱㻿㻞㻝㻌㼍㼞㼑㻌㼛㼚㻌㼠㼔㼑㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼎㼛㼍㼞㼐㻚㻌

㻌㻱㻱㻿㻞㻝

㻌

㻾㼑㼒㼑㼞㻌㼠㼛㻌㼠㼔㼑㻌㻟㻚㻌㻱㻸㻱㻯㼀㻾㻵㻯㻭㻸㻌㻯㻻㻺㻺㻯㻱㼀㻵㻻㻺㻿㻌㼛㼒㻌㻵㻵㻚㻌㻯㻻㻺㻺㻱㻯㼀㻵㻻㻺㻌㼕㼚㻌

㻾㻙㻟㻜i㻮㻛㻾㻙㻟㻜i㻮㻌㻼㼘㼡㼟㻌㻯㻻㻺㼀㻾㻻㻸㻸㻱㻾㻌㻹㻭㻵㻺㼀㻱㻺㻭㻺㻯㻱㻌㻹㻭㻺㼁㻭㻸㻌

㻿㼕㼚㼓㼘㼑㻌㼏㼔㼍㼕㼚

㻔㻮㻙㻤㻟㻝㻥㻡㻱㻺㻕㻌㼛㼞㻌

㻱㼤㼠㼑㼞㼚㼍㼘㻌㼟㼠㼛㼜㻌㼎㼡㼠㼠㼛㼚

㻾㻙㻟㻜i㻮㻌㻹㼍㼠㼑㻛㻾㻙㻟㻜i㻮㻌㻹㼍㼠㼑㻌㻼㼘㼡㼟㻌㻯㻻㻺㼀㻾㻻㻸㻸㻱㻾㻌㻹㻭㻵㻺㼀㻱㻺㻭㻺㻯㻱㻌

㻼㼍㼚㼑㼘㻌㼎㼛㼍㼞㼐㻌

㻹㻭㻺㼁㻭㻸㻌㻔㻮㻙㻤㻟㻡㻞㻡㻱㻺㻕㻌㼒㼛㼞㻌㼐㼑㼠㼍㼕㼘㼟㻚㻌

㻌

㻌㻱㻹㻳㻵㻺㻝

㻌㻱㻹㻳㻵㻺㻞

Fig. 3.1 Connection diagram for external emergency stop button

3.2

SAFETY OF THE PROGRAMMER

While teaching the robot, the operator may need to enter the robot operation area. The programmer

must ensure the safety especially.

(1) Unless it is specifically necessary to enter the robot operating space, carry out all tasks outside the

operating space.

(2) Before teaching the robot, check that the robot and its peripheral equipment are all in the normal

operating condition.

(3) If it is inevitable to enter the robot operating space to teach the robot, check the locations, settings,

and other conditions of the safety devices

(such as the EMERGENCY STOP button, the

DEADMAN switch on the teach pendant) before entering the area.

(4) The programmer must be extremely careful not to let anyone else enter the robot operating space.

(5) Programming should be done outside the area of the safety fence as far as possible. If programming

needs to be done inside the safety fence, the programmer should take the following precautions:

- Before entering the area of the safety fence, ensure that there is no risk of dangerous situations

in the area.

- Be prepared to press the emergency stop button whenever necessary.

- Robot motions should be made at low speeds.

- Before starting programming, check the whole robot system status to ensure that no remote

instruction to the peripheral equipment or motion would be dangerous to the user.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the

automatic operation (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for

the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other

people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with

the automatic operation set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in "SAFETY

PRECAUTIONS" for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The

programmer should understand that the safety gate is disabled and is responsible for keeping other people from

entering the inside of the safety fence.

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Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and

switch function as follows:

(1) Emergency stop button: Causes the stop of the robot (Please refer to "STOP TYPE OF ROBOT" in

"SAFETY PRECAUTIONS" for detail of stop type) when pressed.

(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting

status.

(a)

Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the

operator presses the switch strongly.

(b)

Disable: The DEADMAN switch is disabled.

(Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or

presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate/R-30iB Plus/R-30iB

Mate Plus employs a 3-position DEADMAN switch, which allows the robot to operate when the

3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the

DEADMAN switch or presses the switch strongly, the robot stops immediately.

The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the

teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator

should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000

times per year.

The teach pendant, operator panel, and peripheral equipment interface send each robot start signal. However the

validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator

panel, the teach pendant enable switch and the remote condition on the software.

Software

Teach pendant

Peripheral

Mode

remote

Teach pendant

Operator panel

enable switch

equipment

condition

Local

Not allowed

AUTO

Remote

Not allowed

mode

Local

Not allowed

Allowed to start

Not allowed

Off

Remote

Not allowed

Allowed to start

Local

Allowed to start

Not allowed

T1, T2

Remote

Allowed to start

Not allowed

mode

Local

Not allowed

Off

Remote

Not allowed

T1,T2 mode: DEADMAN switch is effective.

(6) To start the system using the operator box or operator panel, make certain that nobody is the robot

operating space area and that there are no abnormalities in the robot operating space.

(7) When a program is completed, be sure to carry out a test operation according to the following

procedure.

(a) Run the program for at least one operation cycle in the single step mode at low speed.

(b) Run the program for at least one operation cycle in continuous operation at low speed.

check that no abnormalities occur due to a delay in timing.

(d) Run the program for one operation cycle in continuous operation at the normal operating speed

and check that the system operates automatically without trouble.

(e) After checking the completeness of the program through the test operation above, execute it in

the automatic operation.

(8) While operating the system in the automatic operation, the programmer should leave the safety

fence.

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3.3

SAFETY OF THE MAINTENANCE ENGINEER

For the safety of maintenance engineer personnel, pay utmost attention to the following.

(1) During operation, never enter the robot operating space.

(2) A hazardous situation may arise when the robot or the system, are kept with their power-on during

maintenance operations. Therefore, for any maintenance operation, the robot and the system should

be put into the power-off state. If necessary, a lock should be in place in order to prevent any other

person from turning on the robot and/or the system. In case maintenance needs to be executed in the

power-on state, the emergency stop button must be pressed as far as possible.

(3) If it becomes necessary to enter the robot operating space while the power is on, press the emergency

stop button on the operator box or operator panel, or the teach pendant before entering the range.

The maintenance worker must indicate that maintenance work is in progress and be careful not to

allow other people to operate the robot carelessly.

(4) When entering the area enclosed by the safety fence, the worker must check the whole robot system

in order to make sure no dangerous situations exist. In case the worker needs to enter the safety area

whilst a dangerous situation exists, extreme care must be taken, and whole robot system status must

be carefully monitored.

(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off

and the pressure in the piping should be reduced to zero.

(6) Before the start of maintenance work, check that the robot and its peripheral equipment are all in the

normal operating condition.

(7) Do not operate the robot in the automatic operation while anybody is in the robot operating space.

(8) When you maintain the robot alongside a wall or instrument, or when multiple users are working

nearby, make certain that their escape path is not obstructed.

(9) When a tool is mounted on the robot, or when any movable device other than the robot is installed,

such as belt conveyor, pay careful attention to its motion.

(10) If necessary, have a user who is familiar with the robot system stand beside the operator panel and

observe the work being performed. If any danger arises, the user should be ready to press the

EMERGENCY STOP button at any time.

(11) When replacing a part, please contact your local FANUC representative. If a wrong procedure is

followed, an accident may occur, causing damage to the robot and injury to the user.

(12) When replacing or reinstalling components, take care to prevent foreign material from entering the

system.

(13) When handling each unit or printed circuit board in the controller during inspection, turn off the

circuit breaker to protect against electric shock.

If there are two cabinets, turn off the both circuit breaker.

(14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction

or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used.

Such a fuse may cause a fire.

(15) When restarting the robot system after completing maintenance work, make sure in advance that

there is no person in the operating space and that the robot and the peripheral equipment are not

abnormal.

(16) When a motor or brake is removed, the robot arm should be supported with a crane or other

equipment beforehand so that the arm would not fall during the removal.

(17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent

dangerous falls.

(18) The following parts are heated. If a maintenance user needs to touch such a part in the heated state,

the user should wear heat-resistant gloves or use other protective tools.

－ Servo motor

－ Inside the controller

－ Reducer

－ Gearbox

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－ Wrist unit

(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause

any danger.

(20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to

protect maintenance workers from excessive load. Otherwise, the maintenance workers would be

severely injured.

(21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot

would be adversely affected. In addition, a misstep can cause injury to the worker.

(22) When performing maintenance work in high place, secure a footstep and wear safety belt.

(23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the

floor around the robot and within the safety fence.

(24) When a part is replaced, all bolts and other related components should put back into their original

places. A careful check must be given to ensure that no components are missing or left not mounted.

(25) In case robot motion is required during maintenance, the following precautions should be taken :

- Foresee an escape route. And during the maintenance motion itself, monitor continuously the

whole robot system so that your escape route will not become blocked by the robot, or by peripheral

equipment.

- Always pay attention to potentially dangerous situations, and be prepared to press the emergency

stop button whenever necessary.

(26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller

maintenance manual.) A failure to do the periodical inspection can adversely affect the performance

or service life of the robot and may cause an accident

(27) After a part is replaced, a test execution should be given for the robot according to a predetermined

method. (See TESTING section of “Controller operator’s manual”.) During the test execution, the

maintenance worker should work outside the safety fence.

4 SAFETY OF THE TOOLS AND

PERIPHERAL EQUIPMENT

4.1

PRECAUTIONS IN PROGRAMMING

(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the

program to stop the robot when the sensor signal is received.

(2) Design the program to stop the robot when an abnormality occurs in any other robots or peripheral

equipment, even though the robot itself is normal.

(3) For a system in which the robot and its peripheral equipment are in synchronous motion, particular

care must be taken in programming so that they do not interfere with each other.

(4) Provide a suitable interface between the robot and its peripheral equipment so that the robot can

detect the states of all devices in the system and can be stopped according to the states.

4.2

PRECAUTIONS FOR MECHANISM

(1) Keep the component cells of the robot system clean, operate the robot where insulated from the

influence of oil, water, and dust.

(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.

(3) Adopt limit switches or mechanical stoppers to limit the robot motion, and avoid the robot from

collisions against peripheral equipment or tools.

(4) Observe the following precautions about the mechanical unit cables. Failure to follow precautions

may cause problems.

•

Use mechanical unit cable that have required user interface.

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SAFETY PRECAUTIONS

•

Do not add user cable or hose to inside of the mechanical unit.

•

Please do not obstruct the movement of the mechanical unit when cables are added to outside

of mechanical unit.

•

In the case of the model that a cable is exposed, please do not perform remodeling (Adding a

protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the

cable.

•

When installing user peripheral equipment on the robot mechanical unit, please pay attention

that the device does not interfere with the robot itself.

(5)

The frequent power-off stop for the robot during operation causes the trouble of the robot. Please

avoid the system construction that power-off stop would be operated routinely. (Refer to bad case

example.) Please perform power-off stop after reducing the speed of the robot and stopping it by

hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in

"SAFETY PRECAUTIONS" for detail of stop type.)

(Bad case example)

•

Whenever poor product is generated, a line stops by emergency stop and power-off of the robot

is incurred.

•

When alteration is necessary, safety switch is operated by opening safety fence and power-off

stop is incurred for the robot during operation.

•

An operator pushes the emergency stop button frequently, and a line stops.

•

An area sensor or a mat switch connected to safety signal operates routinely and power-off stop

is incurred for the robot.

•

Power-off stop is regularly incurred due to an inappropriate setting for Dual Check Safety

(DCS).

(6)

Power-off stop of Robot is executed when collision detection alarm (SRVO-050) etc. occurs. Please

try to avoid unnecessary power-off stops. It may cause the trouble of the robot, too. So remove the

causes of the alarm.

5 SAFETY OF THE ROBOT MECHANICAL

UNIT

5.1

PRECAUTIONS IN OPERATION

(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can

manage the robot in any eventuality.

(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the

jog mode.

5.2

PRECAUTIONS IN PROGRAMMING

(1) When the operating spaces of robots overlap, make certain that the motions of the robots do not

interfere with each other.

(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the

motion so that it starts from the origin and terminates at the origin. Make it possible for the operator

to easily distinguish at a glance that the robot motion has terminated.

5.3

PRECAUTIONS FOR MECHANISMS

(1)

Keep the robot operation area clean, and operate the robot in an environment free of grease, water,

and dust.

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5.4

PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER

IN EMERGENCY OR ABNORMAL SITUATIONS

For emergency or abnormal situations (e.g. persons trapped in or pinched by the robot), brake release unit

can be used to move the robot axes without drive power.

Please refer to controller maintenance manual and mechanical unit operator’s manual for using method of

brake release unit and method of supporting robot.

6 SAFETY OF THE END EFFECTOR

6.1

PRECAUTIONS IN PROGRAMMING

(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time

delay after issuing each control command up to actual motion and ensure safe control.

(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of

the end effector.

7 STOP TYPE OF ROBOT (R-30iB, R-30iB

Mate)

There are following four types of Stopping Robot.

Power-Off Stop (Category 0 following IEC 60204-1)

Servo power is turned off, and the robot stops immediately. Servo power is turned off when the robot is

moving, and the motion path of the deceleration is uncontrolled.

“Power-Off stop” performs following processing.

• An alarm is generated, and then the servo power turns off. Instantly the robot stops.

• Execution of the program is paused.

Frequent Power-Off stop of the robot during operation can cause mechanical problems of the robot.

Avoid system designs that require routine or frequent Power-Off stop conditions.

Controlled stop (Category 1 following IEC 60204-1)

The robot is decelerated until it stops, and servo power is turned off.

“Controlled stop” performs following processing.

• The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. The program

execution is paused.

• An alarm is generated, and then the servo power turns off.

Smooth stop (Category 1 following IEC 60204-1)

The robot is decelerated until it stops, and servo power is turned off.

“Smooth stop” performs following processing.

• The alarm "SRVO-289 Smooth Stop" occurs along with a decelerated stop. The program

execution is paused.

• An alarm is generated, and then the servo power turns off.

• In Smooth stop, the robot decelerates until it stops with the deceleration time shorter than Controlled

stop.

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SAFETY PRECAUTIONS

Hold (Category 2 following IEC 60204-1)

The robot is decelerated until it stops, and servo power remains on.

“Hold” performs following processing.

• The robot operation is decelerated until it stops. Execution of the program is paused.

WARNING

The stopping distance and time of Controlled stop and Smooth stop are longer

than those of Power-Off stop. A risk assessment for the whole robot system

which takes into consideration the increased stopping distance and stopping

time is necessary when Controlled stop or Smooth Stop is used. Please refer to

the operator's manual of a particular robot model for the data of stopping

distance and time.

In multi arm system, the longest stopping distance and time of Controlled Stop

or Smooth Stop among each robot are adopted as those for the system. A risk

assessment for the whole robot system which takes into consideration a

possibility that the stopping distance and time increase, is necessary on the

multi arm system.

In the system which has extended axis, the longer stopping distance and time of

Controlled Stop or Smooth Stop among robot and extended axis are adopted as

those for the system. A risk assessment for the whole robot system which takes

into consideration a possibility that the stopping distance and time increase, is

necessary on the system which has extended axis. Please refer to the extended

axis setup procedure of the controller operator’s manual for considering the

stopping distance and time of the extended axis.

When Smooth stop occurs during deceleration by Controlled stop, the stop type

of robot is changed to Power-Off Stop.

When Smooth stop occurs during deceleration by Hold, the stop type of robot is

changed to Power-Off Stop.

In case of Controlled stop or Smooth Stop, motor power shutdown is delayed for

a maximum of 2 seconds. In this case, a risk assessment for the whole robot

system is necessary, including the 2 seconds delay.

When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off

stop, Controlled stop, or Smooth stop. The configuration of stop type for each situation is called stop

pattern. The stop pattern is different according to the option configuration.

There are the following 3 Stop patterns.

Emergency

External

Stop

Deadman

Mode

stop

Emergency

FENCE open

SVOFF input

pattern

switch (*)

button

stop

AUTO

P-Stop

C-Stop

P-Stop

C-Stop

P-Stop

C-Stop

P-Stop

AUTO

C-Stop

P-Stop

C-Stop

P-Stop

C-Stop

P-Stop

AUTO

S-Stop

C-Stop

S-Stop

C-Stop

S-Stop

C-Stop

S-Stop

P-Stop: Power-Off stop

C-Stop: Controlled stop

S-Stop: Smooth stop

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Disable

(*) The stop pattern of NTED input is same as Deadman switch.

The following table indicates the Stop pattern according to the controller type or option configuration.

Option

R-30iB/ R-30iB Mate

Standard

A(**)

Controlled stop by E-Stop (A05B-2600-J570)

C(**)

Smooth E-Stop (A05B-2600-J651)

D(**)

(**) R-30iB Mate does not have SVOFF input.

The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please

refer to "Software version" in operator's manual of controller for the detail of software version screen.

"Controlled stop by E-Stop" option

When "Controlled stop by E-Stop" (A05B-2600-J570) option is specified, the stop type of the following

alarms become Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off

stop which is the normal operation of the system.

Alarm

Condition

SRVO-001 Operator panel E-stop

Operator panel emergency stop is pressed.

SRVO-002 Teach pendant E-stop

Teach pendant emergency stop is pressed.

SRVO-007 External emergency stops

External emergency stop input (EES1-EES11, EES2-EES21) is open.

SRVO-408 DCS SSO Ext Emergency Stop

In DCS Safe I/O connect function, SSO[3] is OFF.

SRVO-409 DCS SSO Servo Disconnect

In DCS Safe I/O connect function, SSO[4] is OFF.

Controlled stop is different from Power-Off stop as follows:

• In Controlled stop, the robot is stopped on the program path. This function is effective for a system

where the robot can interfere with other devices if it deviates from the program path.

• In Controlled stop, physical impact is less than Power-Off stop. This function is effective for

systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be

minimized.

• The stopping distance and time of Controlled stop is longer than those of Power-Off stop, depending

on the robot model and axis.

When this option is loaded, this function cannot be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING

The stopping distance and time of Controlled stop are longer than those of

Power-Off stop. A risk assessment for the whole robot system which takes into

consideration the increased stopping distance and stopping time, is necessary

when this option is loaded.

"Smooth E-Stop Function" option

When "Smooth E-Stop Function" (A05B-2600-J651) option is specified, the stop type of the following

alarms becomes Smooth stop in all operation modes (AUTO, T1 and T2 mode).

Alarm

Condition

SRVO-001 Operator panel E-stop

Operator panel emergency stop is pressed.

SRVO-002 Teach pendant E-stop

Teach pendant emergency stop is pressed.

SRVO-003 Deadman switch released

Both deadman switches on Teach pendant are released.

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SAFETY PRECAUTIONS

Alarm

Condition

SRVO-007 External emergency stops

External emergency stop input (EES1-EES11, EES2-EES21) is

open.

SRVO-037 IMSTP input (Group: %d)

IMSTP input (*IMSTP signal for a peripheral device interface) is

OFF.

SRVO-232 NTED input

NTED input (NTED1-NTED11, NTED2-NTED21) is open.

SRVO-408 DCS SSO Ext Emergency Stop

In DCS Safe I/O connect function, SSO[3] is OFF.

SRVO-409 DCS SSO Servo Disconnect

In DCS Safe I/O connect function, SSO[4] is OFF.

SRVO-410 DCS SSO NTED input

In DCS Safe I/O connect function, SSO[5] is OFF.

SRVO-419 DCS PROFIsafe comm. error

PROFINET Safety communication error occurs.

Smooth stop is different from Power-Off stop as follows:

• In Smooth stop, the robot is stopped along the program path. This function is effective for a system

where the robot can interfere with other devices if it deviates from the program path.

• In Smooth stop, physical impact is less than Power-Off stop. This function is effective for systems

where the physical impact to the mechanical unit or EOAT

(End Of Arm Tool) should be

minimized.

• The stopping distance and time of Smooth stop is longer than those of Power-Off stop, depending on

the robot model and axis.

Smooth stop is different from Controlled stop as follows:

• The stopping distance and time of Smooth stop is normally shorter than those of Controlled stop,

depending on the robot model and axis.

When this option is loaded, this function cannot be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING

The stopping distance and time of Smooth stop are longer than those of

Power-Off stop. A risk assessment for the whole robot system which takes into

consideration the increased stopping distance and stopping time, is necessary

when this option is loaded.

8 STOP TYPE OF ROBOT (R-30iB Plus,

R-30iB Mate Plus)

There are following three types of Stop Category.

Stop Category 0 following IEC 60204-1 (Power-off Stop)

Servo power is turned off, and the robot stops immediately. Servo power is turned off when the robot is

moving, and the motion path of the deceleration is uncontrolled.

“Stop Category 0” performs following processing.

• An alarm is generated, and then the servo power turns off. Instantly the robot stops.

• Execution of the program is paused.

Frequent Category 0 Stop of the robot during operation can cause mechanical problems of the robot.

Avoid system designs that require routine or frequent Category 0 Stop conditions.

Stop Category 1 following IEC 60204-1 (Controlled Stop, Smooth Stop)

The robot is decelerated until it stops, and servo power is turned off.

“Stop Category 1” performs following processing.

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• The alarm "SRVO-199 Controlled stop" or "SRVO-289 Smooth Stop" occurs along with a

decelerated stop. The program execution is paused.

• An alarm is generated, and then the servo power turns off.

In Smooth stop, the robot decelerates until it stops with the deceleration time shorter than Controlled stop.

The stop type of Stop Category 1 is different according to the robot model or option configuration. Please

refer to the operator's manual of a particular robot model.

Stop Category 2 following IEC 60204-1 (Hold)

The robot is decelerated until it stops, and servo power remains on.

“Stop Category 2” performs following processing.

• The robot operation is decelerated until it stops. Execution of the program is paused.

WARNING

1 The stopping distance and time of Stop Category 1 are longer than those of

Stop Category 0. A risk assessment for the whole robot system which takes into

consideration the increased stopping distance and stopping time is necessary

when Stop Category 1 is used. Please refer to the operator's manual of a

particular robot model for the data of stopping distance and time.

2 In multi arm system, the longest stopping distance and time of Stop Category 1

among each robot are adopted as those for the system. A risk assessment for

the whole robot system which takes into consideration a possibility that the

stopping distance and time increase, is necessary on the multi arm system.

3 In the system which has extended axis, the longer stopping distance and time of

Stop Category 1 among robot and extended axis are adopted as those for the

system. A risk assessment for the whole robot system which takes into

consideration a possibility that the stopping distance and time increase, is

necessary on the system which has extended axis. Please refer to the extended

axis setup procedure of the controller operator’s manual for considering the

stopping distance and time of the extended axis.

4 When Stop Category 1 occurs during deceleration by Stop Category 2, the stop

type of robot is changed to Stop Category 0.

5 In case of Stop Category 1, motor power shutdown is delayed for a maximum of

2 seconds. In this case, a risk assessment for the whole robot system is

necessary, including the 2 seconds delay.

When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Stop Category

0 or Stop Category 1. The configuration of stop type for each situation is called stop pattern. The stop

pattern is different according to the option configuration.

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SAFETY PRECAUTIONS

There are the following 3 Stop patterns.

Emergency

External

Stop

Deadman

Mode

stop

Emergency

FENCE open

SVOFF input

pattern

switch (*)

button

stop

AUTO

Category 0

Category 1

Category 0

Category 1

Category 0

Category 1

Category 0

AUTO

Category 1

Category 0

Category 1

Category 0

Category 1

Category 0

AUTO

Category 1

Category 0: Stop Category 0

Category 1: Stop Category 1

Disable

(*) The stop pattern of NTED input is same as Deadman switch.

The following table indicates the Stop pattern according to the controller type or option configuration.

The case R651 is specified.

Option

R-30iB Plus/ R-30iB Mate Plus

Standard

C(**)

Old Stop Function (A05B-2670-J680)

A(**)

All Smooth Stop Function (A05B-2670-J651)

D(**)

The case R650 is specified.

Option

R-30iB Plus/ R-30iB Mate Plus

Standard

A(**)

Stop Category 1 by E-Stop (A05B-2670-J521)

C(**)

All Smooth Stop Function (A05B-2670-J651)

D(**)

(**) R-30iB Mate Plus does not have SVOFF input.

The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please

refer to "Software version" in operator's manual of controller for the detail of software version screen.

"Old Stop Function" option

When "Old Stop Function" (A05B-2670-J680) option is specified, the stop type of the following alarms

becomes Stop Category 0 in AUTO mode.

Alarm

Condition

SRVO-001 Operator panel E-stop

Operator panel emergency stop is pressed.

SRVO-002 Teach pendant E-stop

Teach pendant emergency stop is pressed.

SRVO-007 External emergency stops

External emergency stop input (EES1-EES11, EES2-EES21) is open.

SRVO-408 DCS SSO Ext Emergency Stop

In DCS Safe I/O connect function, SSO[3] is OFF.

SRVO-409 DCS SSO Servo Disconnect

In DCS Safe I/O connect function, SSO[4] is OFF.

Stop Category 0 is different from Stop Category 1 as follows:

• In Stop Category 0, servo power is turned off, and the robot stops immediately. Servo power is

turned off when the robot is moving, and the motion path of the deceleration is uncontrolled.

• The stopping distance and time of Stop Category 0 is shorter than those of Stop Category 1,

depending on the robot model and axis.

When this option is loaded, this function cannot be disabled.

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SAFETY PRECAUTIONS

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

"All Smooth Stop Function" option

When "All Smooth Stop Function" (A05B-2670-J651) option is specified, the stop type of the following

alarms becomes Stop Category 1 in all operation modes (AUTO, T1 and T2 mode).

Alarm

Condition

SRVO-001 Operator panel E-stop

Operator panel emergency stop is pressed.

SRVO-002 Teach pendant E-stop

Teach pendant emergency stop is pressed.

SRVO-003 Deadman switch released

Both deadman switches on Teach pendant are released.

SRVO-007 External emergency stops

External emergency stop input (EES1-EES11, EES2-EES21) is

open.

SRVO-037 IMSTP input (Group: %d)

IMSTP input (*IMSTP signal for a peripheral device interface) is ON.

SRVO-232 NTED input

NTED input (NTED1-NTED11, NTED2-NTED21) is open.

SRVO-408 DCS SSO Ext Emergency Stop

In DCS Safe I/O connect function, SSO[3] is OFF.

SRVO-409 DCS SSO Servo Disconnect

In DCS Safe I/O connect function, SSO[4] is OFF.

SRVO-410 DCS SSO Ext Emergency Stop

In DCS Safe I/O connect function, SSO[5] is OFF.

SRVO-419 DCS PROFIsafe comm. error

PROFINET Safety communication error occurs.

Stop Category 1 is different from Stop Category 0 as follows:

• In Stop Category 1, the robot is stopped along the program path. This function is effective for a

system where the robot can interfere with other devices if it deviates from the program path.

• In Stop Category 1, physical impact is less than Stop Category 0. This function is effective for

systems where the physical impact to the mechanical unit or EOAT (End of Arm Tool) should be

minimized.

• The stopping distance and time of Stop Category 1 is longer than those of Stop Category 0,

depending on the robot model and axis.

When this option is loaded, this function cannot be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING

The stopping distance and time of Stop Category 1 are longer than those of Stop

Category 0. A risk assessment for the whole robot system which takes into

consideration the increased stopping distance and stopping time, is necessary

when this option is loaded.

"Stop Category 1 by E-Stop" option

When "Stop Category 1 by E-Stop" (A05B-2670-J521) option is specified, the stop type of the

following alarms become Category 1 Stop but only in AUTO mode. In T1 or T2 mode, the stop type is

Category 0 Stop which is the normal operation of the system.

Alarm

Condition

SRVO-001 Operator panel E-stop

Operator panel emergency stop is pressed.

SRVO-002 Teach pendant E-stop

Teach pendant emergency stop is pressed.

SRVO-007 External emergency stops

External emergency stop input (EES1-EES11, EES2-EES21) is open.

SRVO-408 DCS SSO Ext Emergency Stop

In DCS Safe I/O connect function, SSO[3] is OFF.

SRVO-409 DCS SSO Servo Disconnect

In DCS Safe I/O connect function, SSO[4] is OFF.

Stop Category 1 is different from Stop Category 0 as follows:

• In Stop Category 1, the robot is stopped along the program path. This function is effective for a

system where the robot can interfere with other devices if it deviates from the program path.

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SAFETY PRECAUTIONS

• In Stop Category 1, physical impact is less than Stop Category 0. This function is effective for

systems where the physical impact to the mechanical unit or EOAT (End of Arm Tool) should be

minimized.

• The stopping distance and time of Stop Category 1 is longer than those of Stop Category 0,

depending on the robot model and axis.

When this option is loaded, this function cannot be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING

The stopping distance and time of Stop Category 1 are longer than those of Stop

Category 0. A risk assessment for the whole robot system which takes into

consideration the increased stopping distance and stopping time, is necessary

when this option is loaded.

170406

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TABLE OF CONTENTS

SAFETY PRECAUTIONS

s-1

Introduction

1 PREFACE

1.1

OVERVIEW OF THE MANUAL

1.2

RELATED MANUALS

2 ABOUT VISION SYSTEM

2.1

BASIC CONFIGURATION

2.2

FIXED CAMERA AND ROBOT-MOUNTED CAMERA

2.3

SIZE OF A CAMERA’S FIELD OF VIEW

2.4

FIXED FRAME OFFSET AND TOOL OFFSET

2.5

CALCULATION OF THE OFFSET DATA

2.6

PART Z HEIGHT

2.7

MEMORY CARD PREPARATION

2.8

CALIBRATION GRID

3 FEATURES

3.1

OVERVIEW OF 2D SINGLE VIEW VISION PROCESS

3.2

OVERVIEW OF 2D MULTI-VIEW VISION PROCESS

3.3

OVERVIEW OF DEPALLETIZING VISION PROCESS

3.4

OVERVIEW OF 3D TRI-VIEW VISION PROCESS

Setup

2D SINGLE VIEW VISION PROCESS

1.1

FEATURES AND NOTES

1.2

SETUP FOR FIXED FRAME OFFSET WITH FIXED CAMERA

1.2.1

Camera Data Creation and Teaching

1.2.2

Offset Frame Setting

1.2.3

Vision Process Creation and Teaching

1.2.3.1

Vision process creation

1.2.3.2

Command tool teaching

1.2.3.3

Reference position setting

1.2.4

Robot Program Creation and Teaching

1.2.5

Robot Compensation Operation Check

1.3

SETUP FOR FIXED FRAME OFFSET WITH ROBOT MOUNTED CAMERA

.....................................................................................................................32

1.3.1

Camera Data Creation and Teaching

1.3.2

Offset Frame Setting

1.3.3

Vision Process Creation and Teaching

1.3.3.1

Vision process creation

1.3.3.2

Command tool teaching

1.3.3.3

Reference position setting

1.3.4

Robot Program Creation and Teaching

1.3.5

Robot Compensation Operation Check

1.4

SETUP FOR TOOL OFFSET WITH FIXED CAMERA

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TABLE OF CONTENTS

1.4.1

Camera Data Creation and Teaching

1.4.2

Offset Frame Setting

1.4.3

Vision Process Creation and Teaching

1.4.3.1

Vision process creation

1.4.3.2

Command tool teaching

1.4.3.3

Reference position setting

1.4.4

Robot Program Creation and Teaching

1.4.5

Robot Compensation Operation Check

2D MULTI VIEW VISION PROCESS

2.1

FEATURES AND NOTES

2.2

SETUP FOR FIXED FRAME OFFSET WITH FIXED CAMERA

2.2.1

Camera Data Creation and Teaching

2.2.2

Offset Frame Setting

2.2.3

Vision Process Creation and Teaching

2.2.3.1

Vision process creation

2.2.3.2

Camera view teaching

2.2.3.3

Reference position setting

2.2.4

Robot Program Creation and Teaching

2.2.5

Robot Compensation Operation Check

2.3

SETUP FOR FIXED FRAME OFFSET WITH ROBOT-MOUNTED CAMERA

.....................................................................................................................59

2.3.1

Camera Data Creation and Teaching

2.3.2

Offset Frame Setting

2.3.3

Vision Process Creation and Teaching

2.3.3.1

Vision process creation

2.3.3.2

Camera view teaching

2.3.3.3

Reference position setting

2.3.4

Robot Program Creation and Teaching

2.3.5

Robot Compensation Operation Check

2.4

SETUP FOR TOOL OFFSET WITH FIXED CAMERA

2.4.1

Camera Data Creation and Teaching

2.4.2

Offset frame Setting

2.4.3

Vision Process Creation and Teaching

2.4.3.1

Vision process creation

2.4.3.2

Camera view teaching

2.4.3.3

Reference position setting

2.4.4

Robot Program Creation and Teaching

2.4.5

Robot Compensation Operation Check

DEPALLETIZING VISION PROCESS

3.1

FEATURES AND NOTES

3.2

SETUP FOR FIXED FRAME OFFSET WITH FIXED CAMERA

3.2.1

Camera Data Creation and Teaching

3.2.2

Offset Frame Setting

3.2.3

Vision Program Creation and Teaching

3.2.3.1

Vision Process Creation

3.2.3.2

Command tool teaching

3.2.3.3

Reference position setting

3.2.4

Robot Program Creation and Teaching

3.2.5

Robot Compensation Operation Check

3.3

SETUP FOR FIXED FRAME OFFSET WITH ROBOT-MOUNTED CAMERA

.....................................................................................................................90

3.3.1

Camera Data Creation and Teaching

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3.3.2

Offset Frame Setting

3.3.3

Vision Process Creation and Teaching

3.3.3.1

Vision Process Creation

3.3.3.2

Command tool teaching

3.3.3.3

Reference position setting

3.3.4

Robot Program Creation and Teaching

3.3.5

Robot Compensation Operation Check

3D TRI-VIEW VISION PROCESS

100

4.1

FEATURES AND NOTES

101

4.2

SETUP FOR FIXED FRAME OFFSET WITH FIXED CAMERA

103

4.2.1

Camera Data Creation and Teaching

103

4.2.2

Vision Process Creation and Teaching

106

4.2.2.1

Vision process creation

107

4.2.2.2

Camera View Teaching

107

4.2.2.3

Reference position setting

109

4.2.3

Robot Program Creation and Teaching

110

4.2.4

Robot Compensation Operation Check

110

4.3

SETUP FOR FIXED FRAME OFFSET WITH ROBOT-MOUNTED CAMERA

...................................................................................................................111

4.3.1

Camera Data Creation and Teaching

112

4.3.2

Vision Process Creation and Teaching

112

4.3.2.1

Vision process creation

113

4.3.2.2

Camera View Teaching

114

4.3.2.3

Reference position setting

116

4.3.3

Robot Program Creation and Teaching

117

4.3.4

Robot Compensation Operation Check

117

Know-How

1 FRAME SETTING

121

1.1

FRAME SETTING WITH A POINTER TOOL

121

1.1.1

User Frame Setting

121

1.1.1.1

TCP set up

122

1.1.1.2

Setting method types and procedures

128

1.1.2

Tool Frame Setting

140

1.2

FRAME SETTING WITH THE GRDI FRAME SSETTING FUNCTION

150

1.2.1

Setting procedure

151

1.2.1.1

Mounting the calibration grid

152

1.2.1.2

Setting the parameters

154

1.2.1.3

Teaching start position

157

1.2.1.4

Run measurement

158

2 CAMERA DATA SETTING

160

2.1

GRID PATTERN CALIBRATION WITH A FIXED CAMERA

160

2.1.1

Application Frame Setting

161

2.1.2

Camera Data Creation

163

2.1.3

Camera Setup

163

2.1.4

Calibration

164

2.1.4.1

For fixed installation

164

2.1.4.2

For robot-mounted installation

167

2.1.4.3

When two or more robots are used

170

2.1.5

Checking Calibration Point

171

2.1.6

Checking Calibration Result

171

B-83914EN-2/01

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TABLE OF CONTENTS

2.2

GRID PATTERN CALIBRATION WITH A ROBOT-MOUNTED CAMERA. 172

2.2.1

Application Frame Setting

173

2.2.2

Camera Data Creation

173

2.2.3

Camera Setup

174

2.2.4

Calibration

175

2.2.5

Checking Calibration Point

177

2.2.6

Checking Calibration Result

177

2.3

ROBOT-GENERATED GRID CALIBRATION

179

2.3.1

Application Frame Setting

181

2.3.2

Selecting and Mounting the Target

183

2.3.3

Camera Data Creation

184

2.3.4

Camera Setup

184

2.3.5

Calibration Setup

185

2.3.6

Teaching Model

186

2.3.7

Camera Data Selection

188

2.3.8

Measuring Target Position

190

2.3.8.1

6-axis robot

190

2.3.8.2

4- or 5-axis robot

193

2.3.9

Generating Calibration Program

194

2.3.10

Executing Calibration Program

198

2.3.11

Checking Calibration Point

199

2.3.12

Checking Calibration Result

200

SETUP OF SNAP IN MOTION

201

3.1

OVERVIEW OF SNAP IN MOTION

201

3.1.1

Features

201

3.1.2

Using Snap in Motion

202

3.1.3

Checking Position and Speed at Snap

202

3.1.4

Robot Program for Snap in Motion

202

3.1.5

Notes

203

3.2

STUDY FOR APPLICATION

203

3.2.1

Light and Exposure Time

203

3.2.2

Image Processing Time and Motion Time

204

3.2.3

Shift of Snap Position

204

3.3

SAMPLE APPLICATIONS

205

3.3.1

Tool Offset with a Fixed Camera (2D single-view vision process)

205

3.3.1.1

Robot program creation and teaching

206

3.3.2

Tool Offset with a Fixed Camera (2D multi-view vision process)

207

3.3.2.1

Robot program creation and teaching

207

3.3.3

Fixed Frame Offset with a Robot Mounted Camera (3D Tri-view vision process)

..............................................................................................................................209

3.3.3.1

Robot program creation and teaching

209

FAQS FOR TROUBLESHOOTING

211

4.1

METHOD FOR ADJUSTMENTS AFTER CAMERA REPLACEMENT

211

4.2

VISION DATA RECOVERY

211

4.3

DETECTION PROBLEMS

212

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B-83914EN-2/01

Introduction

1. PREFACE

1 PREFACE

This chapter describes an overview of this manual which should be noted before operating the iRVision

function.

1.1

OVERVIEW OF THE MANUAL

This manual describes how to operate iRVision controlled by the R-30iB Plus controller. This manual

is directed to users who are reasonably familiar with the FANUC two-dimensional vision.

In this manual, only the operation and the technique of programming for the dedicated sensor functions

are explained, assuming that the installation and the setup of the robot are completed. Refer to the

"R-30iB/R-30iB Mate CONTROLLER OPERATOR’S MANUAL (Basic Operation)B-83284EN" about

other operations of FANUC Robots.

CAUTION

This manual is based on R-30iB Plus system software version 7DF0/03. Note

that the functions and settings not described in this manual may be available,

and some notation differences are present, depending on the software version.

Volume

Chapter

Chapter Title

Description

Introduction

Chapter 1

PREFACE

Gives an overview of and a guide to using this

manual and related manuals.

Chapter 2

ABOUT VISION SYSTEM

Gives an overview of the functions of iRVision

and the basic knowledge required to use the

functions.

Chapter 3

FEATURES

Gives an overview of the four types of Vision

Processes.

Setup

Chapter 1

2-D SINGLE-VIEW VISION

Explains the 2-D Single-View Vision Process

PROCESS

start-up procedures.

Chapter 2

2-D MULTI-VIEW VISION

Explains the 2-D Multi-View Vision Process

PROCESS

start-up procedures.

Chapter 3

DEPALLETIZING VISION

Explains the Depalletizing Vision Process

PROCESS

start-up procedures.

Chapter 4

3-D TRI-VIEW VISION

Explains the 3-D Tri-View Vision Process

PROCESS

start-up procedures.

Know-How

Chapter 1

FRAME SETTING

Explains the methods for frame setting with a

pointer tool and frame setting with the Automatic

Grid Frame Setting function.

Chapter 2

CAMERA DATA SETTING

Explains the method for camera data setting.

Chapter 3

SETUP OF SNAP IN MOTION

Explains the method for snapping without

stopping the motion of the robot.

Chapter 4

FAQS FOR

Explains the causes and actions to take

TROUBLESHOOTING

regarding a variety of problems.

Indications in this Manual

The symbol below is used in this manual. Please refer to it when looking for information.

Symbol

Description

Gives information that will provide hints for performing screen operations, and information

MEMO

that will provide a reference for function explanations and setting details.

B-83914EN-2/01

1. PREFACE

Introduction

Explanation of teach pendant operation

This manual explains each procedure on the assumption that teaching is performed using a teaching PC. However, some

procedures include a description of operation of the teach pendant. The teach pendant can be operated through touch panel

operation, but the procedures using key input, for which the operations are more complex, are described in this manual.

1.2

RELATED MANUALS

This section introduces related manual.

Manual

Spec. No.

Description

OPERATOR’S MANUAL

B-83284EN

This is the main manual of the controller.

(Basic Operation)

This manual describes the following items for manipulating

workpieces with the robot:

• Setting the system for manipulating workpieces

• Operating the robot

• Creating and changing a program

• Executing a program

• Status indications

• Backup and restore robot programs.

This manual is used on an applicable design, robot

installation, robot teaching.

MAINTENANCE MANUAL

B-83195EN

This manual describes the maintenance and connection of

R-30iB/R-30iB Plus Controller.

OPERATOR’S MANUAL

B-83284EN-1

This manual describes the error code listings, causes, and

(Alarm Code List)

remedies.

Optional Function

B-83284EN-2

This manual describes the software optional functions

OPERATOR’S MANUAL

Sensor Mechanical Unit /

B-83434EN

This manual describes the connection between sensors which

Control Unit

is a camera or 3D Laser Sensor and R-30iB/R-30iB Mate

OPERATOR’S MANUAL

Controller, and maintenance of sensors.

iRVision

B-83914EN

This manual is the reference manual. This manual describes

OPERATOR’S MANUAL

each functions which are provided by iRVision. This manual

(Reference)

describes the meanings (e.g. the items on iRVision setup

screen, the arguments of the instruction, and so on.

iRVision Inspection Application

B-83914EN-5

This manual is desired to first refer to when you start up

OPERATOR'S MANUAL

systems of inspection which uses iRVision. This manual

describes startup procedures of inspection system which uses

iRVision, creating programs, caution, technical know-how,

response to several cases, and so on.

iRPickTool

B-83924EN

This manual is desired to first refer to when you start up

OPERATOR'S MANUAL

systems of iRVision Visual Tracking. This manual describes

startup procedures of iRVision Visual Tracking system,

creating programs, caution, technical know-how, response to

several cases, and so on.

Ethernet Function

B-82974EN

This manual describes the robot networking options such as

OPERATOR’S MANUAL

FTP, RIPE, PC Share, and so on.

B-83914EN-2/01

Introduction

2. ABOUT VISION SYSTEM

2 ABOUT VISION SYSTEM

This chapter explains the fundamental items of the vision system.

The following eight items are explained.

Basic configuration

Fixed camera and robot-mounted camera

Size of a camera’s field of view

Fixed frame offset and tool offset

Calculation of the offset data

Part Z height

Memory card preparation

Calibration Grid

2.1

BASIC CONFIGURATION

iRVision consists of the following components:

• Camera and lens

• Camera cable

• Lighting Equipment

• Camera multiplexer (used if needed)

Camera Cable

Robot Controller

Camera and Lens

Lighting Equipment

Workpiece

Basic configuration of iRVision

For detailed information about the connection method between the Robot Controller and a camera, please

refer to “R-30iB/ R-30iB Mate CONTROLLER Sensor Mechanical Unit/ Control unit OPERATOR’S

MANUAL B-83434EN”.

The camera and lens of 3D Laser Vision Sensor are sane as the two-dimensional camera, so the 3D Laser

Vision Sensor can also be used for the two-dimensional applications.

2.2

FIXED CAMERA AND ROBOT-MOUNTED CAMERA

Decide where to place the camera according to the workpieces size and location.

Fixed camera

• Detect workpieces using the camera installed on the stand.

• A fixed camera will always snap the same place from the same distance.

• While the robot transfers the workpieces, iRVision can detect the other workpieces, so the cycle time

can be shortened.

• Use a sufficient strength camera stand so that the camera doesn’t vibrate.

B-83914EN-2/01

Introduction

2. ABOUT VISION SYSTEM

2.3

SIZE OF A CAMERA’S FIELD OF VIEW

Depending on the size and location of the workpiece, determine the size of the field of view of the

camera.

The size of the field of view of the camera is determined by three factors: The size of the image sensor,

the focal distance of the lens, and the distance from the camera to the workpiece.

The size of the image sensor (Lc) is calculated by the following formula.

Lc  Cell size  Image size (pixels)

The rough value of the field of view of the camera (L) is calculated by the following formula.

L  (D  f)  f  Lc

When the distance D from a camera to a workpiece is 700mm and the monochrome camera (SC130EF2)

is used, the view size is shown below table.

Focal distance of the lens

Size of the field of view

8 mm

587 mm  469 mm

12 mm

389 mm  311 mm

16 mm

290 mm  232 mm

25 mm

183 mm  147 mm

The calculation result is an approximate value. Some difference may occur between the calculated value

and the actual measurement value. When an accurate value is required, please confirm by the actual

measurement.

B-83914EN-2/01

FANUC R-30iB Plus CONTROLLER, iRVision 2D Camera Application. OPERATOR'S MANUAL - page 1