MOTOMAN XRCIndustrial Robot Controller

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NewA New DimensionNew

Controller

Robots

Tasks

Axes

Dimension

27 controlled servo axes

Synchronized operation of threerobots

Synchronized programming of threerobots including external axes

Multi-tasking – Simultaneous operationof six tasks

Simple programming and diagnosis dueto several software functions

Multi functional • User friendly • Compact

design • Expandable modular cabinet

Outlines of the XRC

Built-in transformerSimple installation and setup by plug-connections.Used for robot in UP-series and SK-X, SP-Xand SV-X-series.INFORM programming languageExpandable slots for optional boards -Sensor function by XSL-board -Welding interface MEW and XEW-board -I/O-interface MIO-board -Ethernet and Fieldbus boardXRC cabinets may be put on top of eachother or docked side by sideFulfils the EC-directive incl. EMC and LVDMade in Sweden

Advanced control system

Powerful 32-bit micro processor for rapiddata processing.PLC-programs for different applications, forexample: arc welding and handling.Advanced PLC-unit in the control systemwith expanded program capacity and newlogical functions e.g. for controlling pneumaticfunctions in fixtures.Multi tasking makes it possible to run severaljobs simultaneously.Digital servopacks with software controlledspeed and position feedback.

Programming pendant

All programming functions are in one unitwith clear and large 12-line screen. Optimalprogramming time is achieved while allfunctions are available during programming.The menu text can be switched betweenseveral different European languages by asimple key operation. The programmingpendant is equipped with a 3-position ”dead-man´s handle”.

Communication

XRC like the previous control system forMOTOMAN robots, is a technical datasolution that is PC-compatible allowingcommon computer tools to be used forcreating, reading and editing jobs in a PC.The flexibility of the control system makes itpossible to communicate with other systemssuch as PLC’s, host computers, visionsystems etc., through serial links, Ethernet,digital I/O’s and fieldbus.The controller memory is also accessiblethrough a PC-card.

Path control

The robots working path is controlled withconsistent precision and quality. Even at highspeeds the robot will not vary from theprogrammed path of travel.XRC improves high speed welding, cuttingand sealing applications better than ever.

Shock detection function

This function stops the robot when it comesinto contact with an object. Robot orperipherical devices can be protected in caseof accidental collision.

Maintenance functions

Remotely monitors maintenance function ofrobot status through Ethernet network.Production processing and quality controlmonitoring can be managed from a centralcontrol room. Maintains history of when andwho changed the robot job instructions.

ARM control

Advanced Robot Motion Control improvesthe quality and productivity by improvedservo response of the motion control.Optimised acceleration/deceleration andvibration control ensures the correct pathand cycle time. Speed is automaticallyoptimised for circles and corners. Collisionbetween robot, robot tool and other devicesis immediately detected to stop the robotand protect it from damage.

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The new programming pendant

Status menu

Dead-man’s handle(at the back)

Teach lock, forblocking the Play-back panel

Go to top menu

Switch menucursor area

Go to sub-menu

Enter selection

Switching ofcoordinatesystem type

Cursor, navigationkey Emergency stop

Serial interfaceRS-232C

Go topredefined menu

Command menu

Backlighted LCDscreen

Programming andtest-run keys

Axis keys, for robotand external axis

Programming keys

Go to next menu

Numerical andapplication functionkeys

Start playbackoperation

Hold playbackoperation

Emergency stop

Remote operation

Servo power ON

Mode selectionTeach / Play

Alarm signal

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Large LCD-display with back-lighting. High contrast for day-light operation.

Cross shape cursor button forinstruction basic operations.Operates by icons and pull-downmenues make operation as easyas using your personal computer.

Lightweight thermoplasticprogramming pendant reducesfatigue.

Key allocation is based onhuman engineering research.The number of keys areminimised for requiredfunctions only.

Top menu iconsOpen new jobs • Call up jobs •Copy job • Rename jobs • Deletejobs • Modify jobs • Set Master job

Application, e.g.Arc welding • Spot welding •Handling application or Generalapplication

Variable diagnosis • Positionvariables for robot, station andbase axes

Diagnosis of external I/Os • Dia-gnosis of universal I/Os • Diagno-sis of direct I/Os • Setting of I/Os

Tool data • User coordinates •Robot position coordinates •Setting of cubes and softwarelimits • Parameter setting • Systemdiagnosis functions

System diagnosis functions •Software version • Alarm history •System clock • Counters

The programming pendant hasbeen awarded for its good designand user friendly layout.

Ministry of International Trade andIndustry, Japan

Back-up functions • Load • Save •Verify • Delete

System settings • Date/Time •Speed settings • Setting groupcombinations • Operating/Teachingconditions • User ID

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Controller

ConfigurationDimensionsWeightCooling systemAmbienttemperatureRelative humidityPower supplyGroundingDigital I/O

CommunicationPositioning systemDrive unitsAccel / DecelProgrammingcapacity(standard)

Free-standing, Enclosed type800(W)x900(H)x650(D) mmApprox. 170 kgIndirect coolingDuring operation 0° to +45°During transport -10° to +60°Max. 90% (non-condensing)3 x 400/415/440V AC, 50/60 HzLess than 100 ohmGeneral signals (standard)40 inputs and 40 outputs of which24 inputs and 24 outputs are free4 direct inputsRS-232C and PC-cardAbsolute encoder / Serial interfaceServopacks for AC servo motorSoftware servo control5.000 steps and3.000 instructions1.500 ladder steps

Programming functions

CoordinatesystemRobot MotionControlSpeed setting

Program ControlInstructions

Modification ofteaching pointPosition control

Speed adjustmentI/O-function

ProgrammingLanguageDisplay text

Tool Centre Point

TCP-calibration

Joint, rectangular/cylindrical, tool,user coordinatesJoint coordinates, linear/circular,interpolation, tool coordinatesPercentage for joint coordinates,0.1 mm/s units for interpolations,angular velocity for T.C.P. fixedmotionJump, call, timer, robot stop,execution of some instructionsduring robot motionAdding, deleting, correcting (robotaxes and/or external axes)Manually forwards and backwards inthe job (even circular)Fine adjustment possibleDiscrete I/O control, patternI/O processingInteractive programmingRobot language: INFORM IIEnglish, Swedish, French, Spanish,Italian, Finnish, GermanMax. 24 and up to 24 externalTCP´sAutomatically calibrates parametersfor end effectors using master jigPersonal safety

Teach Lock Mode

Collision proofframesMachine lock

Self-diagnosis

User Alarm display

3-position ”dead-man´s handle”Low speed in teaching modeProhibits operation from operator´spanelDoughnut-sector frame, cubic frame

Test-run peripherial device withoutrobot motionAlarm and error messages displayedtogether with explanationPossible to display alarm messagesfor peripheral devices

Safety features

Maintenance functions

Software timeusage meters

Alarm display

I/O-diagnosis

Control power-ON time, servopower-ON time, playback time, worktime and operation time displayedAlarm messages and previous alarmrecordsSimulated enable/disabled outputpossible

Digital I/O

Analogue outputMemory expansion(up to...)

External axisEnclosureclassification

I/O-boards, total max. 256/256MIO02: 32 inputs and outputsMIO03: 16 inputs and outputsXO102: 40 inputs and outputs12 channel (MEW/XEW-board)Max 60.000 points for 6 axesand 20.000 instructions3.000 ladder stepsTotal max. 27 axesIP54, by add on kit

Options

Programming pendant

Material

DimensionsWeightDisplaySafety featureInterface

Reinforced thermoplasticenclosure200(W)x322(H)x65(D) mm1.2 kg5.7 inch, 40 characters x 12 lines3-position ”dead-man´s handle”RS-232C

Operator´s panel

Buttons provided Mode, Start, Hold, Emergency stopServo power ON

Technical specifications

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MOTOMANXRC

800 650

725

900

MOTOMANXRC

MOTOMANXRC

1600

1450

1800

Controller layoutBasic cabinet

Optional cabinets

XRC Controller cabinet is expandable byadding extra modules (XOC-1 and XOC-2).The extra cabinets are required for Twin andTriple robot mounting, external axisservopacks as well as optional functionssuch as PLC’s and safety systems.The optional cabinets are docked with thecontroller cabinet either on top or by theside providing a tidy cable installation.

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Indirect cooling by means of a set of fans atthe rear makes it possible to place thecabinet in confined places. The indirect

cooling also keeps pollution and dust out ofthe cabinet.

Optional units such asservopacks for external axes,optional I/O boards, weldinginterface boards and fieldbus

boards may be mounted on theback plate inside the cabinet.

Cables for safety circuits, external axesI/O’s and other communication optionsare easily connected at the bottom ofthe cabinet. The plugs are well protectedbehind a removable panel.

MOTOMAN XRC will be theIt is physically reduced to minimise space but is optimised

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premier robot controllerfor functions, simple operations and expandability

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

PC-card (PCMCIA)interface for highspeed backup or

robot jobtransferring.

Robot and systemsoftware upgrade.

Serial interface through RS-232Cconnector suitable for PC communicationi.g. backup of robot jobs remote controletc.

Serial interface through RS-232C connectorin the programming pendant is suitable forPC communications e.g. back-up of robotjobs.

Cables for robot motors and signal cableare easily connected by plugs at the back ofthe cabinet to increase flexibility.

Standard field networks are available:Ethernet, Profibus, Interbus-S, Device-NET, etc. Your manufacturing line can beintegrally controlled through yourexisting network.

Main power supply line isconnected by CEE plug.

Software functions

The Advanced Robot Motion functionimproves quality and productivity forapplications where correct path and highspeed is needed e.g. Laser cutting, water jetcutting, gluing and sealing application.

By integrated Collision Detection functionthe robot tool, fixtures and jigs as well as therobot arm itself are protected against damages.Moment limits may be individually set.

The XRC System gives possibility to control27 axes from one single CPU, three robotswith external axes could be used forsynchronuous motion or for individual jobs.

Using the Twin-Drive function, two externalservomotors may be used for synchronuousdrive of a heavy fixture or large track (e.g.welding application).

Endless Rotation of robot axis (T-axis) or anexternal axis. Normally a servo motor islimited to one or two turns in each direction.By this function wrapping/unwrapping proces-ses or painting applications are improved andno time consuming reset of the turning isneeded.

The XRC system can handle six tasks at thesame time ”Multi-Tasking” such as robotjobs, concurrent I/O master job. By means ofspecial commands programming and editing ismade easily.

Welding Parameters (welding current, wirespeed, weaving, etc.) for a special weldingpower source may be saved in a data file(charcteristics). Start conditions, endconditions are easily added to the robot jobby calling ARCON/ARCOF-command, whichreduces the programming time.Other parameters for welding may be set, suchas: Retry function and Restart function.Of course, it is possible to set individual valuesfor voltage, current wire feed, etc. for a singlewelding string.

Communication interface between XRCsystem and e.g. a PC may be handled inseveral ways. A PC-card (PCMCIA) slot isintegrated in the CPU-rack. This PC-card canbe used as backup of user memory (jobs) andalso for upgrading of system software. Foradvanced communication the RS-232C serialinterface or optional Ethernet board is used.This together with our PC software puts therobot into your network. Robot jobs may bedown- and uploaded to the system from acentral computer. The robot can be remote-controlled.

The Interrupt Job function is used when therobot serves e.g. one or several toolingmachines. A signal from the machine makesthe robot to interrupt its job for a moment toserve the machine and then returns tomaintain its main job, e.g. deburring.

The Search function is used when theworkpiece may vary in size or position e.g.picked up from a pallet or roughly cut piecesat welding application. The data from thesensor adjusts the robot job.

In arc welding applications the COMARCpackage (including: start point search function,seam tracking and multi layer) increase theproductivity by decreasing the demands of theaccuracy of the workpiece. It automaticallyadjusts the robot job due to the actualconditions. Multi layer function reduces theprogramming time in heavy weldingapplications.

When the robot is used together with amachine tool for placing the workpiece in thechuck, the Servo Float function allows therobot arm to float with torque control makingit flexible with external forces.

When using the External Reference ToolCentre Point function, it is possible todesignate a point in space as the tool controlpoint. This function may be used when therobot is holding the workpiece and the toolfixed e.g. pedestal spot welding machine orapplication nozzle for gluing or sealing.

PMT function can be used to correct positiondata easily and accurately when the robot toolinadvertently collides with periferial jigs orwalls and becomes deformed. The job positiondata will be corrected according to the ”newtool” data automatically.

The actual position of the robot is memorizedby pulse data. These data can be shifted intoanother coordinate system, Relative Jobfunction. This function is used to performexactly the same operation but in anotherlocation or direction.

The Parallel Shift function simplifiesprogramming. One operation is shifted(copied) a specified distance. A counter setsthe number of operations. The function is usedin e.g. palletising application. Any type ofcoordinate system can be used.

The PAM function is used for manualoperation. During playback the programmedposition or speed, can be corrected easily. It isnot necessary to stop the robot as thecorrection amount and speed is set from theprogramming pendant. This function is usedwhen the workpiece is only roughlypositioned in the fixture and the operatorchecks and corrects the position.

The TCP (Tool Centre Point) function, adjuststhe robot position according to the tool data.This function reduces the programming timee.g. it can be used in a painting applicationwhere the first nozzle applies the primer coatand after shifting the TCP, the second nozzleapplies the topcoat by running the job again.

The Analogue Output Corresponding toSpeed uses an optional analogue board tosupply a signal to control a glue or paint pump,or similar when the amount of sealant or paintmust be accurately controlled.

The Conveyor synchronisation functionsynchronises the robot motion to the speed ofthe conveyor. By connecting the optionalsensor board to an incremental encoder onthe conveyor drive motor, the speed isdetected and the robot can adjust its speed tosuite. This function is used both when pickingup as well as placing the workpiece onto theconveyor without stopping it.

The Press synchronises the robot motionwith the press machine, where an encodermounted on the press flywheel monitors theposition of the press. The robot motion ishalted when it may interfere with the pressmotion and starts again when the press risesand interference is avoided. I/O signals are notneeded and cycle time is optimised.

For Spot welding applications the ShortPitch function is used to suppress the rapidrobot arm movements during the short pitchtraverse of the spot welding gun.

A number of Optional Boards can be addedto the XRC system, such as; -Sensor board,-Ethernet board, -I/O board, -Analogue outputboard and COMARC board.

Complex I/O installations are easily solved byuse of the Fieldbus Interface Board whichis designed for well known market brandssuch as; Interbus-S, Device-NET and Profibusetc. Digital I/O optional boards of varioustypes are easily installed to customise yoursystem (16/16, 32/32, 40/40).

MOTOMAN

MOTOMAN

ROBIA SUOMI

ROBIA

ROBIA

MOTOMAN

MOTOMAN

MOTOMAN

MOTOMAN

MOTOMAN

MOTOMAN

MOTOMAN

MOTOMAN

KOUVALIAS INDUSTRIAL ROBOTS

RISTRO

MESSER SAG

GEIGER HANDLING

KNT ENGINEERING

REHM

MGM SPOL

ROBOTIC SYSTEMS

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 Robo-tics, 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,Torsås +46-486-48800 • MOTOMAN Mecatron Robotic Systems, Kalmar +46-480-444600Distributors: Czech Republic: MGM Spol, Tabor +420-361-254571, Denmark: Robia, Vejle +45-79428000, Finland: Robia Suomi, Turku +358-22145600, Greece: Kouvalias Industrial Robots, Kallithea +30-1-95892436, Hungary: REHM Hegesztéstechnika, Budapest +36-12562012,Israel: KNT Engineering, Kfar Azar +972-39231944, Norway: Robia, Hokksund +47-32252820, South Africa: Robotic Systems, Bertsham +27-114943604, Switzerland: Geiger Handling, Schwarzenburg +41-31-7343111 • Messer SAG, Dällikon +41-18471717

Reg 7P

-03-07-01INT

MOTOMAN ROBOTICS EUROPE ABBox 504 • SE-385 25 Torsås • SwedenTel: +46-486-48800 • Fax: +46-486-41410www.motoman.se

a YASKAWA company